DUMP BODY SPREADERS INSTALLATION INSTRUCTIONS

 
 
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                                                                                                                                            DUMP BODIES
                                                                                    Tableheader
                                                                                          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




                     Dump Body Install-A
                     Page Rev. A                                                                          2
Hi-Way                                                                                            DUMP BODIES
                                      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		             20 GPM (76 LPM)

PUMP TYPE			                    Gear or load sense




                                                                                                                     I nstallation
PUMP PRESSURE		                 2200-2500 PSI (151.8-172.5 Bar) operating

CONTROL TYPE			                 Manual
				                            Electric solenoid

FILTRATION			                   Return line filter, 10 Micron

RESERVOIR			                    30 gallon (113.5 liter) frame mount with sight gauge




                                                                                                                             installation
RELIEF VALVE			                 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




                                                                                                                                   I nstructions
							                                                     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
      NOTICE!
                      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.




                                                                                               Dump Body Install-A
                                                                3                                     Page Rev. A
HI-WAY                                                                                             DUMP BODIES
                                                           Installation Instructions Continued

                               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




                                                                                                                       DANGER
                                                                               A
                                                                55°
                                                                    X                              Tailgate must be closed and latch locked before
                                                                 MA
                                                                                                   lifting with rear tailgate bolsters. Serious injury
                                                                                                   or death could occur if tailgate swings open and
I nstallation I nstructions




                                                                                                   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
                                                    Figure 1 – Lifting                             unit.

                                                  Maximum Angle             A (Figure 6)
                                  Unit Length
                                                   from Vertical         Sling Leg Length
                                  10’ (31 mm)                              99” (25 mm)
                                                                                                                       CAUTION
                                  12’ (37 mm)                             113” (29 mm)
                                  13’ (40 mm)                             120” (30 mm)             Do not remove lifting device until dump body is
                                                         55°                                       secured to truck.
                                  14’ (43 mm)                             126” (32 mm)
                                  15’ (46 mm)                             132” (34 mm)
                                                                                                                 Lift with a maximum 55° angle
                                  16’ (49 mm)                             138” (35 mm)                           from vertical to prevent damage
                                                                                                    NOTICE!
                                                                                                                 to the unit (35° minimum angle
                                Attach a 4-point harness to the front lift hooks and rear corner                 from horizontal).
                                bolsters as shown in Figure 1




                              Dump Body Install-A
                              Page Rev. A                                                   4
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
1. Measure from front of unit to rear
   of hinge and add three inches. This                                                    11 5/8"
   is the distance from the cab to the                                                    CENTER OF HINGE PIN
                                                                                          TO REAR OF PS FLOOR




                                                                                                                I nstallation I nstructions
   rear of truck frame.
2. Mark this distance on truck frame
   rail.                                                                 41 31/64"

3. Test fit hoist sub-frame and dump
   body to check mark.                                    Figure 2 – Truck Modification
4. Remove hoist/unit and cut off
   excess truck frame.




                                                                                     Dump Body Install-A
                                                  5                                         Page Rev. A
HI-WAY                                                                                                 DUMP BODIES
                                                                       Installation Instructions Continued

                               Hoist


                                                              Do not install hoist cylinder at an angle. If the dump body is raised with the cylinder
                                               DANGER
                                                              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.


                                                              Do not leave raised body unattended. Do not raise body on unlevel ground. Check for
                                               CAUTION
                                                              overhead power lines and other obstructions before raising body.


                                                                                                                                Make sure hoist sub-
                                                                                                                                frame is square with
                                                                                                                                the truck cab and rails
                                               3.00 MINIMUM                                                         NOTICE!     and that the hoist
                                                                                                                                cylinder is centered
I nstallation I nstructions




                                                                                                         90°                    from side-to-side on
                                                                                           90°
                                                                                                                                the truck chassis.
                                 CAB




                                                                                                                                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
                                                                                                                    NOTICE!     warranty. Drill only
                                                                                                                                through vertical web
                                                                                                                                portions of truck frame,
                                                                  Figure 3 – Hoist Position                                     a minimum of 2.00”
                                                                                                                                (5.08 cm) from the top
                                                                                                                                or bottom flanges.

                                                                                                                                Do not weld directly
                                                                                                                                to truck frame. Such
                                  LOCATE MOUNT
                                  PLATES AT HOIST                                                                   NOTICE!     welding could lead to
                                  CROSS SUPPORTS
                                                                                                                                fatigue cracking and
                                                                           LOCATE REAR
                                                                           MOUNT PLATES
                                                                                                                                must be avoided.
                                                                           UNDER HINGE


                                                                                                                                Connect arc welder’s
                                                                                             BOTH
                                                                                                                                ground directly to one
                                                        2.00 MINIMUM                         SIDES                              of the two items being
                                  TRUCK RAIL                                                                        NOTICE!     welded before using
                                                        2.00 MINIMUM
                                                                                                                                welder on anything
                                                                                                                                connected to the
                                                                                                                                vehicle.
                                                                                       .656-10X
                                                                                    FIELD DRILL

                                                                 Figure 4 – Hoist Mounting




                              Dump Body Install-A
                              Page Rev. A                                                            6
Hi-Way                                                                                             DUMP BODIES
                              Installation Instructions Continued

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 &




                                                                                                                         I nstallation I nstructions
                                                                   INSTALL PINS




          2X



                                         Figure 5 – Dump Body Mounting

                      Do not remove lifting device until dump body is completely welded and body props are
          CAUTION
                      operational.


                      Make sure the dump body is securely anchored and will not shift or slide off truck. Periodically
          CAUTION
                      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.




                                                                                               Dump Body Install-A
                                                             7                                        Page Rev. A
HI-WAY                                                                                             DUMP BODIES
                                                          Installation Instructions Continued

                               Body Props


                                                     Do not work beneath dump body without body props in place. Serious injury or death could
                                           DANGER
                                                     occur from crushing.


                                                     Make sure dump body is securely anchored and will not shift or slide off truck. Periodically
                                           CAUTION
                                                     check welds and mounting hardware to make sure it is secure.




                                                                              BODY
                                                                              PROP
I nstallation I nstructions




                                                                        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
                                        NOTICE!
                                                     clear view. Install “Caution, Operation Safety” (PN 96716) and “Caution, Raised Body” (PN
                                                     96715) decals in clear view in truck cab.




                              Dump Body Install-A
                              Page Rev. A                                               8
Hi-Way                                                                                             DUMP BODIES
                                Installation Instructions Continued

MOUNTING OF BODY WITH TELESCOPIC HOIST

Hinge

                        Connect arc welder’s ground directly to one of the two items being welded before using
        NOTICE!
                        welder on anything connected to the vehicle.

                        Do not exceed 300° F (148° C) at Greaseless Hinge Bushings (optional). Heat can distort
        NOTICE!         Hinge Bushings. Contact Hi-Way Genuine Parts dealer for replacements if Bushings are
                        damaged.

                            EVEN WITH                                                1. Measure from front of unit
                                                              HINGE BLOCK
                          MOUNT SURFACE                                                 to rear of bottom sill and
                                                                                        add 4” (10.16 cm). This is
                                                                                        the distance from the cab
                                                                                        to the rear of the hinge.
                    4.50 W/ PADS                                             5.00
                   5.00 W/O PADS                                                     2. Mark this distance on truck




                                                                                                                       I nstallation I nstructions
                                                                                        frame rail.
                                                                                     3. Test fit unit to make sure
                                                                     HINGE BUSHING      there is a minimum of
                  BOTH TRUCK                                  HINGE ANGLE               4” (10.16 cm) clearance
                  FRAME RAILS                                                           between dump body and
                                                                                        truck cab as shown in
   DO NOT WELD TO                                   4.00                                Figure 10. Figure 13 shows
    TRUCK FRAME!                                                                        position of dump body
                                                                                        in respect to hinge/truck
                       Figure 7A – PS350 Hinge Installation                             frame.
                                                                                     4. Cut truck frame so Hinge
                                                                                        Block will be even with rear
                  EVEN WITH                                                             and level with mounting
                  MOUNT SURFACE
                                                       HINGE BLOCK                      surface as shown in Figures
                                                                                        7A-7B.
                                                                                     5. Place Hinge Angle in cutout
                                                                                        and center from side-to-
                   6.00 W/ PADS                               6.50                      side.
                  6.50 W/O PADS                                                      6. Make sure top of Hinge
                                                                                        Block will be level with top
                                                                   HINGE BUSHING
                                                                                        of Mount Pads (1, Figure 8),
   BOTH TRUCK                                                                           or truck frame if mounting
   FRAME RAILS
                                                           HINGE ANGLE                  directly to frame.
                                                                                     7. Tack weld Hinge Angle to
   DO NOT WELD TO
                                            8.00                                        both truck frame rails.
    TRUCK FRAME!
                       Figure 7B – PS400 Hinge Installation




                                                                                              Dump Body Install-A
                                                               9                                     Page Rev. A
HI-WAY                                                                                                      DUMP BODIES
                                                           Installation Instructions Continued

                               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
                                     NOTICE!
                                                     and must be avoided.




                                            5" MAX                                         28              .438 - TYP                        5" MAX
                                                                                              - TYP
                                             FROM                                          22           FIELD DRILL                          FROM
                                                                       2    3 4 5
                                           CRADLE                                                                                            HINGE


                                                                                                                        1
                                                                                    TYP.
                                                                                                 .125
I nstallation I nstructions




                                                          2" MIN




                                                                                                                            TRIM RUBBER TO WELD
                                                                                                                            MOUNT ANGLES TO
                                                                                                                            MOUNT PAD'S METAL BASE



                                                 SECTION VIEW



                                                                           Figure 8 – Mounting Pads

                                Parts needed:                              3. Trim rubber from Mount Pads (1) so Mount Angles (2) can be
                                 ITEM DESCRIPTION                  QTY        welded on without damaging rubber.
                                                                           4. Position Mount Angles (2) on Mount Pads (1) as shown in Figure 8
                                   1    Mount Pad                  AR         and mark hole locations on truck frame.
                                   2    Mount Angle                AR
                                   3    Cap Screw – 3/8 x 1-1/4    AR      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
                                   4    Lock Washer – 3/8          AR      than 5” (12.7 cm) from the cradle.
                                   5    Hex Nut – 3/8              AR
                                   AR – As Required

                                                     DO NOT PUT HOLES IN TOP OR BOTTOM FLANGES—to do so may void truck manufacturer’s
                                     NOTICE!         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.




                              Dump Body Install-A
                              Page Rev. A                                                  10
Hi-Way                                                                                     DUMP BODIES
                                Installation Instructions Continued

Cradle & Hoist Cylinder to Truck


                    A (Figure 9) (CRADLE                                HINGE
    BODY SIZE         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)
                                                                         A    B

Parts needed:
 ITEM DESCRIPTION                    QTY
   1    Cradle                        1




                                                                                                              I nstallation I nstructions
   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                        C                        D
   9    Grease Zerk                   4
   10 Cap Screw – 1/2 x 3-3/4         8
   11 Lock Washer – 1/2               8

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).




                                                                                     Dump Body Install-A
                                                      11                                    Page Rev. A
HI-WAY                                                                                        DUMP BODIES
                                                       Installation Instructions Continued


                                                    DO NOT PUT HOLES IN TOP OR BOTTOM FLANGES—to do so may void truck manufacturer’s
                                     NOTICE!        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
                                     NOTICE!        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
                                     NOTICE!
                                                    be avoided.

                                                    Connect arc welder’s ground directly to one of the two items being welded before using
                                     NOTICE!
                                                    welder on anything connected to the vehicle.

                               6. Tack weld Cradle to Angles as shown in Figure 10.
I nstallation I nstructions




                                                                      2X                                          2X


                                                               4" MINIMUM


                                                                                                             2X




                                                                            SECTION CUT AWAY
                                                  HOIST                     TO SHOW UPPER
                                                 CYLINDER                   CYLINDER MOUNT
                                                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                                                                                              DUMP BODIES
                               Installation Instructions Continued


                             SECTION
                               VIEW                                                                   90°




                                                                                             TOP VIEW
        6
                             90°
        8                                                                                             90°
     11 10

         9


                       7
                                                                                            FRONT VIEW

                                       Figure 11 – Hoist Cylinder Installation




                                                                                                                          I nstallation I nstructions
                       Do not install hoist cylinder at an angle. If dump body is raised with the cylinder improperly
             DANGER
                       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
             CAUTION
                       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
             CAUTION
                       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.




                                                                                               Dump Body Install-A
                                                             13                                       Page Rev. A
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    .313
                                                                                                                   CAUTION
                                                                                              Do not remove lifting device until hoist cylinder is
                                                                                              secured to dump body.

                                                                                 7.0


                                            Figure 12 – Mounting Dump Body
I nstallation I nstructions




                               Body Props


                                                      Do not remove lifting device until dump body is completely welded and body props are
                                         CAUTION
                                                      operational.


                                                      Make sure dump body is securely anchored and will not shift or slide off truck. Periodically
                                         CAUTION
                                                      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
                                          DANGER
                                                      occur from crushing.

                                                              Parts needed:
                                Figure 13 – Install Body      ITEM DESCRIPTION                       QTY
                                Props (1) on cradle with
                                3/4” hardware (2 & 3).          1    Body Prop                        2
                                Insert non-threaded end         2    Cap Screw – 3/4 x 5              2
                                of Latch Pins (5) through       3    Lock Nut – 3/4                   2           5          1
                                Body Props, with bend                                                         4
                                to inside, and secure           4    Flange Nut – 1/4                 2                      6
                                with Cotter Pins (6).           5    Latch Pin                        2
                                Place Flange Nut (4) on         6    Cotter Pin                       2
                                threaded end of Latch                                                                       2 3
                                Pin.
                                                                                                                      Figure 13 – Body Prop




                              Dump Body Install-A
                              Page Rev. A                                                14
Hi-Way                                                                                               DUMP BODIES
                              Installation Instructions Continued

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




                                                                                                                           I nstallation I nstructions
   necessary.

                      Do not exceed 300° F at the Hinge Bushings. Heat can distort the Hinge Bushings. Contact
         NOTICE!
                      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
         NOTICE!
                      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.




                                                                                                Dump Body Install-A
                                                             15                                        Page Rev. A
HI-WAY                                                                                                    DUMP BODIES
                                                         Installation Instructions Continued

                               CAB SHIELD (Optional)


                                                    Never lift equipment over people. Use a suitable lifting device to lift the cab shield. Loads
                                        CAUTION
                                                    may shift or fall if improperly supported, causing injury.


                               PS350 with Underbody Hoist Option


                                                               CAB SHIELD CL
                                                                                                                            TOP OF CAB SHIELD
                                              C                   TRUCK CL                                                  SHOULD BE ABOVE
                                                                                MIN. CAB                                    TOP OF HEADSHEET
                                                                               CLEARANCE




                                                                                                     TOP OF
                                                                                                     CAB
                                                                                        B    CAB
I nstallation I nstructions




                                                                                            HEIGHT
                                                                               A




                                                                                304
                                                                                UNITS                         Hoist - 4.0                  TRUCK FRAME
                                                                       2-8      ONLY


                                                          Figure 14 – Cab Shield Installation with Underbody Hoist


                                                    A                    B                  1. Measure cab clearance (cab height + minimum cab
                                                                                               clearance) as shown in Figure 14 and match to “B”
                                      16”/22”/30”        40”                                   in chart to find corresponding “A” dimension.
                                          16             22           62.125                2. Determine offset of cab shield to truck centerline
                                          18             24           64.125                   “C” (to clear obstructions such as exhaust stack).
                                                                                               NOTE: Side of cab shield should not extend past
                                          20             26           66.125                   bolster edge.
                                          22             28           68.125                3. Lift cab shield by its lift hook, using a crane that
                                                                                               meets or exceeds OSHA standards. Test fit by
                                          24             30           70.125
                                                                                               dimension “A”. Make any necessary modifications
                                          26             32           72.125                   for proper fit.
                                          28              -           74.125                4. Clamp cab shield in place, keeping it attached to
                                                                                               the crane, and solid fillet weld all seams.
                                          30              -           76.125
                                          32              -           78.125
                                          34              -           80.125




                              Dump Body Install-A
                              Page Rev. A                                                   16
Hi-Way                                                                                             DUMP BODIES
                                Installation Instructions Continued

Body with Telescopic Hoist Option


                        15.00                                  MIN. CAB
                                    CAB SHIELD CL
                    D                                          CLEARANCE
                                      TRUCK CL
                                                                                   TOP OF CAB SHIELD
                                                                                   SHOULD BE ABOVE
                                                                                   TOP OF HEADSHEET


                                               B

                                                      A     CAB
                                                           HEIGHT
                                               C




                                                   Mount pads - .50                 TRUCK FRAME




                                                                                                                         I nstallation I nstructions
                             Figure 15 – Cab Shield Installation with Telescopic Hoist

                         PS350                                                       PS400
                  B                       C                    A               B                       C
   A       CAB SHIELD SIZE         CAB SHIELD SIZE                    36 “/ 44”     52”    16” / 22” / 30”    40”
         16”/22”/30” 40”         16”/22”/30”    40”           66.0     32.13       40.13       25.88         31.88
  56.0      22.37       16.37        15.88         21.88      68.0     30.13       38.13       27.88         33.88
  58.0      20.37       14.37        17.88         23.88      70.0     28.13       36.13       29.88         35.88
  60.0      18.37       12.37        19.88         25.88      72.0     26.13       34.13       31.88         37.88
  62.0      16.37       10.37        21.88         27.88      74.0     24.13       32.13        33.88        39.88
  64.0      14.37       8.37         23.88         29.88      76.0     22.13       30.13        35.88        41.88
  66.0      12.37       6.37         25.88         31.88      78.0     20.13       28.13        37.88        43.88
  68.0      10.37       4.37         27.88         33.88      80.0     18.13       26.13        39.88        45.88
  70.0      8.37        2.37         29.88         35.88
  72.0      6.37        0.37         31.88         37.88    1. Measure cab clearance (cab height + minimum cab
  74.0      4.37          --         33.88           --        clearance) as shown in Figure 15 and match to “A” in
                                                               chart to find corresponding “B” dimension.
  76.0      2.37          --         35.88           --     2. Determine offset of cab shield to truck centerline “D”
  78.0      0.37          --         37.88           --        (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.




                                                                                               Dump Body Install-A
                                                              17                                      Page Rev. A
HI-WAY                                                                                         DUMP BODIES
                                                             Installation Instructions Continued

                               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.

                                                                                                                        1. Position ladder on
                                                                                            16.00                          side of PS as shown
                                                                                                                           in Figure 16.
                                                                                                            1.24-2X
                                                                                                                        2. Fillet   weld    all
                                                                                                                           around the four
                                                                                                                           ladder brackets.

                                                                                                                        If ladders are being
                                                                                                                        installed on both sides,
I nstallation I nstructions




                                                                                                                        they must be offset
                                                                                                                        to comply with 102”
                                                                                                                        max vehicle width
                                                                                                                        regulations      (FHWA
                                                                                                              .50-2X    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     7.00
                                                                                 14.00                       2X


                                                                        3.00          7.00
                                                                                         14.00                     2X

NOTE:      A tailgate with vertical
supports is required for the coal chute
modification.




                                                                                                                                 I nstallation I nstructions
1. Cut opening in tailgate and through
   horizontal rails as shown in Figure                          3.01
                                                                                    +.12
   17.                                                                         14.00
                                                                                     - .00
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                                 Mount Tailgate Air Valve with knob in truck cab.
•     All ports are 0.250-NPTF                                     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
                                          .625 MOUNTING            to air chamber.
                                         HOLE REQUIRED

 PORT #4 EXHAUST PORT
                                                                   Install an air safety control valve, if necessary, into the
    SHALL BE PLUGGED                     OUTLET PRESSURE PORT      supply port and connect the line to the valve inlet.
                                         WHEN KNOB IS DOWN
                                         SHALL BE PLUGGED
    INLET PRESSURE PORT                                            Place cable ties as needed to keep air lines away from
                                         OUTLET PRESSURE PORT
                                                                   hot or moving parts. Check for leaks and proper
 PORT #2 EXHAUST PORT
                                         WHEN KNOB IS UP           operation.

                 Figure 18 – Tailgate Air Valve




                                                                                                     Dump Body Install-A
                                                                  19                                        Page Rev. A
HI-WAY                                                                                               DUMP BODIES
                                                         Installation Instructions Continued

                               LIGHTS (Optional)

                                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
                                                                            Mount 3-Light Bar (15) on rear of truck frame as required.
                                    5   Round Grommet              5
                                    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.
I nstallation I nstructions




                                   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
                                        CAUTION     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
                                        CAUTION
                                                    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!
                                                                                            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
                                       Figure 19 - Hydraulic Pump Installation              damage the system.




                              Dump Body Install-A
                              Page Rev. A                                              20
Hi-Way                                                                                         DUMP BODIES
                            Installation Instructions Continued

HOSE Installation Guide




                                                                WRONG                     RIGHT


                  WRONG               RIGHT
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




                                                                                                                   I nstallation I nstructions
   of the assembly.                                          in the clamp causing abrasion at this point.


                    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

                                          RIGHT                 WRONG                 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.)



                                                                                          Dump Body Install-A
                                                         21                                      Page Rev. A
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
                                           MOUNT RESERVOIR                                                                REAR VIEW
                                          AS HIGH AS POSSIBLE.        SIDE VIEW
I nstallation I nstructions




                                                                         Figure 20 – Frame Mount Reservoir

                                Parts needed:                                        The 30-gallon (113.5-liter) Frame Mount Reservoir (1) mounts on
                                 ITEM DESCRIPTION                       QTY          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
                                   1    Reservoir                        1           of three inches above the cap. Mark hole locations, making sure
                                   2    Cap Screw – 1/2x 1-1/2           4           they’re at least two inches from the top and bottom of the truck
                                   3    Washer – 1/2                     4           frame rail. Drill 0.562” (9/16”) holes and attach with 1/2” hardware
                                                                                     (2, 3 & 4).
                                   4    Lock Nut – 1/2                   4

                               Filling the Hydraulic System


                                                       Do not attempt to run pump without first filling hydraulic reservoir with oil and opening
                                      NOTICE!
                                                       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.




                              Dump Body Install-A
                              Page Rev. A                                                    22
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