DUMP BODY SPREADERS INSTALLATION INSTRUCTIONS
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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 2Hi-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. AHI-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 4Hi-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. AHI-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 6Hi-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. AHI-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 8Hi-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. AHI-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 10Hi-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. AHI-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 12Hi-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. AHI-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 14Hi-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. AHI-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 16Hi-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. AHI-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 18Hi-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. AHI-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 20Hi-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. AHI-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
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