B300RMANUAL # 123629
INSTRUCTIONS FOR ORDERING PARTS Order parts from the authorized dealer covering your area. DEALER: Phone #: ALWAYS GIVE THE MODEL AND SERIAL NUMBER. To obtain parts promptly, give part name and part number. Give post office address, town, and state where the parts are to be shipped. UPS (United Parcel Service) and other carriers will not ship to a post office box. You must use a street address. Also be sure to specify whether material is to be shipped by freight, express, parcel post, or UPS. All UPS shipments will be normal surface routing unless specified otherwise. Confirm all telephone or FAX orders in writing. Credit for new parts not needed must be obtained from the dealer from whom they were purchased. Unless claims for shortages or errors are made immediately upon receipt of goods, they will not be considered. Inspect all goods received immediately upon receipt. When damaged goods are received, insist that a full description of the damage be made by the carrier agent on the freight bill. If this description is insisted upon, full damage can be collected from the transportation company. No responsibility is assumed for delay or damage to merchandise while in transit. Dealer’s responsibility ceases upon delivery of shipment to the transportation company from whom a receipt is received showing that shipment was in good condition when delivered to them; therefore, claims (if any) should be filed with the transportation company and not with the dealer. SNOWFOE is a registered trademark of Henderson Products, Inc.
03/14
1085 S. Third St. PO Box 40 Manchester, IA 52057
PH: (563) 927-2828 TF: (800) 359-4970 FX: (563) 927-2521
Email Sales: sales@hendersonproducts.com Email Parts: parts@hendersonproducts.com
Email Service: service@hendersonproducts.com Website: www.hendersonproducts.com
COMPLETE WARRANTY POLICY A. PARTS REPLACEMENT AND REPAIR:
Henderson Products, Inc. warrants its manufactured products to be free from defects in material or workmanship for a period of one year after delivery to the original user, or 18 months after factory invoice, whichever occurs first. This warranty of our products under normal use and service is limited to replacement or repair at the company's factory of any parts which are returned to the factory freight prepaid, and upon examination found to be defective.
B. EXCLUSIONS:
1. This warranty is expressly limited to parts replacement and repair, and is not transferable. Any expressed warranty not herein provided, and any remedy for breach of contract is excluded and disclaimed. The implied warranties of merchantability and of fitness for any particular purpose are limited to one year from delivery to the original user, or 18 months from factory invoice, whichever occurs first.
2. Any component or part manufactured by others will carry that manufacturer’s warranty, and in no
case will Henderson Products, Inc. be liable, either expressed or implied, for warranties in excess of those made by the original manufacturer.
3. Henderson Products, Inc. shall not be liable for loss of time, manufacturing costs, labor,
material, loss of profits, incidental, special or consequential damages, direct or indirect, because of defective products, whether due to claims arising under the contract of sale or independently thereof, and whether or not such claim is based on contract, tort or warranty.
4. Repairs or modifications done by others, or parts from other sources outside the company's factory are not covered by this warranty.
5. No agent, employee, or representative of Henderson Products, Inc. has any authority to make any
affirmation, representation, or warranty concerning Henderson Products, Inc. products, except as specifically stated above.
WARRANTY PROCEDURE
1. Prior authorization by Henderson Products, Inc. must be obtained for all warranty work. 2. Contact our distributor or Henderson Products, Inc. giving complete details of your request, the unit
involved, including serial number, date purchased, who purchased from, and the nature of or reason for the claim.
3. A Claim number will be assigned, and is required, whenever any warranty is to be paid either in the
form of credit, replacement of parts, or service work. The assignment of this does not guarantee warranty will be allowed. This number is to identify the request and track parts that may need to be returned.
4. When warranty replacement parts are shipped, you may be required to return defective part(s) for inspection by Henderson Products, Inc. or the original manufacturer. In this case, you will be invoiced for shipment of new components until the old unit is returned.
STD Warranty Card 10/2012
HENDERSON PRODUCTS, INC. WARRANTY CARD
Warranty card must be in the files of HENDERSON PRODUCTS, INC. within 14 days after delivery to the initial user. The Dealer is responsible to see that the card is completed with information required and returned. HENDERSON PRODUCTS, INC. will not be obligated to warranty machines unless this registration is on file. For future reference and records, please record the model and serial number of your unit. MODEL NUMBER _____________________
SERIAL NUMBER _____________________
PLEASE PRINT INFORMATION BELOW AND RETURN TO: Henderson Products, Inc. Attention: Customer Service P.O. Box 40 Manchester, Iowa 52057
SERIAL NO. ________________________ MODEL NO. ________________________ CUSTOMER NAME OR FIRM: ______________________________________________ CUSTOMER ADDRESS: ___________________________________________________ _______________________________________________________________________ DATE OF DELIVERY TO CUSTOMER: _______________________________________ DEALER: _______________________________________________________________ LOCATION: _____________________________________________________________ _______________________________________________________________________
MAIL WITHN 14 DAYS AFTER DELIVERY OF UNIT TO HENDERSON PRODUCTS, INC.
HENDERSON WING SYSTEM Manual #123629
TABLE OF CONTENTS Page Number
Title Page
Table of Contents
a. Features and Options .......................................................................... 1-01 - 1-08
2. Safety Information ................................................................................................ 2-00
b. Safety Decals ................................................................................................. 2-02
e. Dealer Installed Decal ..................................................................................... 2-03
f. Installation & Removal of Equipment Safety ................................................... 2-05
g. Operation Safety ............................................................................................. 2-06
i. Procedure for Lowering Wing From Transport Position ................................... 2-08
j. Maintenance & Service Safety ........................................................................ 2-09
k. Hydraulic Extendable Brace With Nitrogen Accumulator ................................. 2-10
l. Mast Safety Bolt ............................................................................................. 2-11
3. Installation & Operating Information ...................................................................... 3-00
a. Hydraulic System Requirements ................................................................... 3-00a
b. Rear Mount Wing with Brace Ahead of Rear Axle (Mid-Mount) ............. 3-01 - 3-02
c. Cheekplate Mounting Instructions ................................................................... 3-03
d. Mast and Rear Cross Tube Installation ................................................. 3-04 - 3-05
e. Mast and Cross Tube Bracing ........................................................................ 3-06
f. Mast and Cross Tube Installation Parts List .................................................... 3-07
g. Front Mast – Power Tilt Hitch
1. Front Mast Installation – Hitch Mount ........................................................ 3-08
2. Hitch Mounting Heights ............................................................................. 3-09
1/31/2018
c. Power Tilt Hitch – Tilt Instructions ..................................................... 3-10c
d. Power Tilt Hitch – Self Storing Lift Arm .............................................. 3-10d
e. Power Tilt Hitch Parts List ..................................................... 3-10e – 3-10f
f. Lift Cylinder Shut-Off Valve (Optional Equipment) ............................. 3-10g
4. Front Mast Mounting Instructions – Hitch Mount ....................................... 3-11
5. Front Mast Installation – Power Tilt Hitch .................................................. 3-13
h. Front Mast – Cheek Plate/Cross Tube
1. Cheek Plate/Cross Tube Installation (Mast Ahead of Cab) .............. 3-14 - 3-15
2. Cheek Plate/Cross Tube Mounting Diagram ............................................. 3-16
3. Cheek Plate/Cross Tube & Mast Installation Parts List ............................. 3-17
i. Cheek Plate to Frame Brace Kit Installation .................................................... 3-18
j. Cheek Plate or Hitch to Frame Brace Kit ........................................................ 3-19
k. Rear Support Installation Instructions – Above, Below, Cradle Mounting ........ 3-20
l. Patrol Wing Brace Installation Guidelines ....................................................... 3-21
m. Above Frame Rear Support Diagram .............................................................. 3-22
n. Above Frame & Cradle to Frame Rear Support Parts List ............................... 3-23
o. Below Frame Rear Support Diagram .............................................................. 3-24
p. Below Frame Rear Support Parts List ............................................................. 3-25
q. Rear Support Installation Instructions – Cheek Plate and Cross Tube ............ 3-26
r. Cheek Plate/Cross Tube Rear Support Diagram ............................................ 3-27
s. Cheek Plate & Cross Tube Rear Support ....................................................... 3-29
t. Wing Installation & Set-Up .............................................................................. 3-30
u. Installation & Set-Up (Front Heel Lift).............................................................. 3-31
v. HWS 18” Lift Mast With Front Heel Lift ........................................................ 3-31B
w. Brace Applications .......................................................................................... 3-32
z. Set-up Installation (Brace & Stop for Rear Mount Wing) ................................. 3-35
aa. Wing Installation & Set-Up (Brace Heel Lift).................................................... 3-36
bb. Push Arm Installation (Brace Heel Lift) ........................................................... 3-37
cc. Push Arm Stop Installation (Brace Heel Lift) .................................................. 3-38
1/31/2018
dd. Stowage Chain Lug & Stop Installation (Brace Heel Lift) ................................ 3-39
ee. Trip Dee & Wing Brace Lock Out Instructions ................................................. 3-40
ff. Trip Edge Adjustments ................................................................................... 3-41
gg. Mast Float Adjustment .................................................................................... 3-42
hh. Stowage Chain Hook Installation (Mast) ......................................................... 3-43
ii. Wing Operation .................................................................................... 3-44 – 3-45
4. Service and Maintenance ................................................................................... 4-00
a. Service and Maintenance .................................................................... 4-01 – 4-03
b. Lubrication Points ........................................................................................... 4-04
5. Parts Lists .......................................................................................................... 5-00
c. Moldboard Assembly, Trip Edge ..................................................................... 5-03
d. Cutting Edges Parts List ................................................................................. 5-05
e. Wing Mast Assembly ........................................................................... 5-06 – 5-07
f. Wing Braces ................................................................................................... 5-08
h. Push Arm (Mid-mount) .................................................................................... 5-10
i. Trip Dee For Full Trip Wing ............................................................................. 5-11
j. Accessories .................................................................................................... 5-12
b. Hydraulic Extendable Brace with Nitrogen Accumulator.................................. 6-02
c. Above Frame Rear Support for Hydraulic Brace ............................................. 6-03
d. Cradle to Frame Rear Support for Hydraulic Brace ......................................... 6-04
e. Below Frame Rear Support for Hydraulic Brace ............................................. 6-05
7. Hydraulic Diagrams and Schematics .................................................................. 7-00
a. Wing (Brace) Heel or Front Plow Lift Holding Valve ........................................ 7-01
b. Hydraulic Single Function Wing ..................................................................... 7-02
c. Smartlink Toe Lift Holding Valve ..................................................................... 7-03
8. Extendable Mid Mount Wing ............................................................................... 8-00
1/31/2018
b. Smart Link Mast Assembly .................................................................. 9-04 – 9-07
c. Smart Link Moldboard Assembly ......................................................... 9-08 – 9-09
d. Smart Link FHL Adjustable Float Instructions .............................................. 9-09A
e. Smart Link Moldboard Assembly (Mid Mount) .............................................. 9-09B
f. Smart Link Mast Installation – Front Cheek Plate & Cross Tube .......... 9-10 – 9-11
g. Smart Link Rear Supports for Brace Heel Lift ................................................. 9-12
h. Smart Link Brace Options .................................................................... 9-13 – 9-15
i. Brace Stop Installation .................................................................................... 9-16
j. Brace Lift Spacer Installation ....................................................................... 9-16A
k. Smart Link Transport Pin ................................................................................ 9-17
l. Procedure for Lowering Wing from Transport Position .................................... 9-18
m. Lubrication ...................................................................................................... 9-19
c. Dimension Chart ........................................................................................... 10-03
1/31/2018
02/11 Page 1-00
MAN201.DWG
04/11
Page 1-02
NON-TRIP (NTRP)
MAN203.DWG
04/11
Page 1-04
GENERAL INFORMATION - FEATURES AND OPTIONS
e. Moldboard Material: i. 10 GA, Grade 50 (10GA). ii. 10 GA, 304 stainless steel (10S3). iii. 10 GA, 201 stainless steel (10S2). iv. 7 GA, Grade 50 (7GA). v. 7 GA, 304 stainless steel (7SS3). vi. 7 GA, 201 stainless steel (7SS2).
f. Moldboard Height, Length, Shape, and Discharge: i. Height: Full trip and Non-trip have two height options and measured at the toe
(Inlet) end when used with an Top Punch cutting edge. Trip Edge option has one height, which is at the toe (Inlet) end. Heights are reduced by when used with a
ii. Length determines which heights are available for Full Trip and Non-trip options. 6' and 7' are only available in height. 8' is available in and 9' through 13' are only
1. 6', 7', and 8' lengths which are high are designed for a front mast to be mounted behind the cab and the rear brace to be ahead of the rear axle and
2. 8' through 13' lengths which are high are designed to be mounted to the truck so that the brace will be located closer to the heel of the moldboard
iii. Shape: 1. Straight (ST): Discharge height is the same as the inlet height. Top edge of
moldboard is parallel to the cutting edge. 2. Tapered (T): Discharge height is higher than the inlet height. Top edge of
moldboard tapers upward from the toe end to the heel end at approximately angle from the cutting edge.
iv. Discharge: Flare is the distance the moldboard sheet extends rearward beyond the cutting edge. Available with or without a bead.
1. 2. 3. No Flare - mailbox cut (NFL). 4. Bead (6FLB, 12FB): round bar welded to the discharge end of the
moldboard sheet. g. Moldboard Bottom Angle:
ii. 6' and 7' Length Options have 4" x 4" x angle (44AN) and 8' Length, high
h. Moldboard Bottom Angle Gussets (BAG): triangular-shaped gussets are thick welded between the cutting edge mounting holes. Not available on Trip Edge Option.
MAN205.DWG
04/11 Page 1-06
I. Moldboard Stiffeners: Provide strength along the length of the moldboard and are located between ribs.
ii. Two horizontal stiffeners (2MBS top and bottom): same as above with a bottom stiffener added which is aligned with the bottom rear brace angle.
j. Moldboard Offset: Distance between the moldboard toe edge and the dee pivot hole on the moldboard. More offset increases the overlap with the front plow.
i. Adjustable on 9' to 13' lengths and some 8' lengths via 2 holes in the moldboard. 1. Non-trip and Trip Edge: and offsets (also available with Front Heel Lift
Option since the pivot link location on moldboard is adjustable (see Page 3-27). 2.
ii. Std. offset is on 6' and 7' lengths and 8' Rear Mount wings with brace location Ahead of Rear Axle.
k. Moldboard Top Flange. i. J-Break Top Flange (JTF std.): Two 90 degree bends are formed into the top edge of the
ii. Boxed-in Top Flange (BTF): Formed 7 gauge angles are welded to the J-break between the ribs to enclose the top flange.
l. Moldboard Heel Lift: mechanism by which the heel of the moldboard is raised (see page 1-03). i. Front heel lift (FHL): Cylinder is connected between the dee at the toe end of the moldboard
and a pivot link on the back side of the moldboard. Available on mast lift height options of and Cylinder options are bore, bore, and bore with cushion on retract for any
moldboard length. Typically used with single brace applications. ii. Brace heel lift (BHL): Cylinder is located between the rear support and one of the braces,
typically the top one.
MAN206.DWG
MAN208.DWG
04/11 Page 1-08
i. ii. Float: adjustable cylinder positions in increments to allow for different cutting edge
heights. Bottom pin hole location is standard for and center-punch cutting edges. Center hole is for top-punch cutting edge. Top hole is for reducing the amount of float downward (see Page 3-42).
iii. iv. v. vi. vii.
GENERAL INFORMATION - FEATURES AND OPTIONS
8", 12" LIFT
SAFETY The Safety-Alert Symbol.
This symbol is on safety signs on the equipment and in the manual. This symbol indicates to you the potential for personal injury and/or property damage.
Hazard Seriousness Levels.
The DANGER signal word indicates - immediate hazards which WILL result in severe personal injury or death.
DANGER
The WARNING signal word indicates - hazards or unsafe practices which COULD result in severe personal injury or death.
WARNING
The CAUTION signal word indicates - hazards or unsafe practices which COULD result in minor personal injury or product or property damage.
CAUTION
Persons who install, mount, operate, or service this equipment must be properly instructed and warned. Do not let anyone operate equipment without instruction.
Read operator manuals completely before operating equipment. Learn how to operate controls properly.
Read decal instructions, cautions, and warnings. Read the safety messages in this manual and on safety decals on the snowplow unit. Replace missing or damaged safety decals.
Unauthorized modifications to the snowplow and related components may impair the function and/or safety.
1. Safety decals are installed on the equipment at the factory. Additional safety decals are shipped loose for applying by the dealer in the operator's cab. These decals MUST be installed by the dealer prior to passing possession of the equipment to the end user.
2. Safety decals are provided with an overlay that can be peeled off after painting.
3. Check to make certain all safety decals are in place and the overlays are removed.
4. Keep safety decals clean and in good condition.
5. Replace damaged or missing safety decals at once. Order replacements through your dealer, or from:
Henderson Products, Inc. Parts Department 1085 South Third Street P.O. Box 40 Manchester, IA 52057
Telephone: (563) 927-2828
95593
81555
NOTE: THIS SAFETY DECAL IS PROVIDED WITH THE POWER TILT HITCH. IT SHOULD BE MOUNTED ON THE TILT SECTION SIDE PLATE DRIVER'S SIDE OF THE HITCH.
NOTE: THIS DECAL SHOULD BE INSTALLED IN THE CAB OF THE TRUCK IN THE SIGHT OF THE OPERATOR.
Safety decals
DANGER_WING_DROP_ZONE
01/17
HEEL
TOE MUST BE CLIPPED (3" X 45 DEGREES) ON ALL CUTTING EDGES TO PREVENT DAMAGE TO WING.
A 81555
PART NO.ITEM
Safety Installation and Removal of Equipment Safety
NOTE: Any additional hardware used in assembly or repair must be a minimum of Grade 8. Failure to use proper hardware may result in equipment failure and possibly cause serious bodily injury.
NOTE: Do not weld to truck chassis frame at any time when mounting a wing system or hitch. Use a minimum of Grade 8 hardware for mounting a wing system or hitch to the truck chassis.
Do not weld stowage chains to masts, supports, or braces. Welding the chain may weaken it, causing it to break under some circumstances which could result in injury or death.
NOTE: During the installation or removal of any equipment which requires to be lifted, use a suitable lifting device that is properly rated for the weight of the equipment to be lifted. Failure to do so could cause serious injury or death.
Chassis frame rail Resisting Bending Moment (RBM): It is recommended that any chassis being equipped with Henderson front mounted HWS (and/or plow hitch, RSP, OWP, etc.) have a minimum frame rail RBM of 2,000,000 in-lbs. Some equipment combinations and truck chassis configurations could require a higher RBM value. Contact Henderson Products Inc. for assistance.
08/17 Page 2-05
Operation Safety
Always raise the front (toe) of the wing off the ground first, then the rear (heel). Always lower the rear (heel) of the wing to the ground first then the front. Severe equipment and road damage will occur with the possibility of personal injury if this procedure is not followed.
Do not tilt hitch with plow or wing attached to truck. Damage or injury can occur. Carry or Transport Position: The toe of the wing should be 10”-12” from the ground and the
heel should be at its highest position to prevent damage or injury. NOTE: The stowage chain and/or stowage devices should be installed and engaged whenever
the wing is not in use or is unattended with the wing in the raised position to prevent the wing from falling and causing damage, injury or death (see “Wing Drop Zone”).
Road Plowing Mode: The toe and heel of the wing should be on the ground. The full trip wing brace and dee (if equipped) may be either locked in or out of trip mode. Truck speeds in this mode should be between 25-40 MPH. Some conditions may require slower speeds. It is very important not to overdrive the equipment given the plowing conditions. Doing so will shorten the life cycle of the equipment.
Full Trip Dee and Wing Brace Lockout: Do not run the wing at ground level (shouldering) with the lock pins inserted in either the trip dee or wing brace. Damage to the wing components and/or chassis may result if the lock pins are used while plowing at ground level. Never insert one lock pin and not the other. Winging with one pin in and one pin out can cause wing component and/or chassis damage as well as unsafe travel conditions.
Leveling (benching) Mode: The front of the wing should be slightly lower than the rear of the wing. The full trip wing brace and dee (if equipped) should be locked into the non-trip mode. Truck speeds should be very slow in this mode. Extra care should be taken to avoid hitting objects hidden under the snow banks. These objects can cause substantial equipment damage and may cause injuries. The operator should also be aware of the surfaces being driven on. Keep the truck on hard, level ground.
Page 2-06 01/17
SMART LINK CYLINDER STOP- TRANSPORT POSITION
SMART LINK CYLINDER STOP- PLOWING POSITION
Maintenance and Service Safety
NOTE: The hydraulic system is under extreme pressure and can cause serious personal injury if released. Never use your hands to check for leaks with the system under pressure. Always wear safety glasses. Never let any part of your body be under the wing if the stowage devices are not engaged. Serious personal injury can occur.
The Henderson Wing System was designed to reduce maintenance and to make required maintenance easier. OBSERVE CAUTION/SAFETY LABELS AND INSTRUCTIONS BEFORE AND DURING ANY MAINTENANCE PROCEDURES.
WARNING: Shut off all power, allow all moving parts to come to rest, and lower the wing to the ground before performing any maintenance operations.
Snow removal equipment must be cared for and maintained regularly. Daily or pre-route inspection and maintenance are necessary. Failure to do so may affect efficiency, equipment life, or safety.
A visual inspection must be carried out after every eight hours of operation. See Page 10-01 in the General Information Section for a recommended practice for checking for loose hardware. Look for damaged components, bends, cracked welds or hydraulic leaks. Repair immediately. It is recommended to re-torque all bolts after the first eight hours of use and to regularly check for loosened or missing fasteners. Replace any damaged fasteners immediately.
Because of the environment in which snow equipment is expected to operate, hydraulic lines, fasteners, wearable or replaceable items and warning decals may become damaged by snow, ice and road debris. These items must be inspected daily and replaced if necessary to avoid equipment damage or personal injury.
Equipment with Cables: Inspect all cables for signs of wear daily with a thorough inspection weekly during the plowing season. If any broken strands are found, “bird caging” is evident, or kinking is found, replace the cable immediately. NOTE: A broken cable could result in severe injury or death. Lubrication is very important to the life of the cable. While the cable is lubricated at the factory, it should be cleaned and re-lubricated with a light bodied oil periodically. Oil is applied most effectively on the radius of a sheave. The movement of the cable over the sheave allows the oil to penetrate the cable.
Mounting bolts are Grade 8 cap screws with hardened flat washers. Care should be taken not to mix or misplace them when the snowplow is removed during the off-season. Be sure to replace any fasteners with damaged threads.
09/17 Page 2-09
Page 2-10
PARTS LIST
1 1 106807 CYLINDER, 4.0-28, 3.00, DA, ACCUM * 2 105418 JOINT,UNIVERSAL,WLDT,MALE
This cylinder is pre-charged with nitrogen gas under pressure. Do not attempt to disassemble or service this part without first contacting Henderson Products, Inc.
* 2 83310 SCREW,CP,HX,3/4NC X 3 1/2 G8 * 2 11483 NUT,LOCK,NYLON INSERT,3/4NC
CAUTION: To avoid damage to equipment, set relief pressure on the brace extend/retract circuit to 600-700 psi.
MAST SAFETY BOLT
01/18 Page 2-11
MAST SAFETY BOLT
**IMPORTANT!!
REMOVE SAFETY BOLT & WASHER AFTER INSTALLATION & BEFORE OPERATING. FAILURE TO DO SO WILL RESULT IN DAMAGE TO MAST.
THIS PAGE
Page 3-00a 01/12
HYDRAULIC SYSTEM REQUIREMENTS PUMP SIZE 20 gpm CONTROL VALVES Toe lift function 7-10 gpm – double acting Heel lift function 7-10 gpm – double acting Brace extend/retract (opt.) 7-10 gpm – double acting RELIEF PRESSURE 2000 psi FILTRATION 10 micron rating HOSE 0.50 dia. SAE 100R2 minimum
06/12 Page 3-01
INSTALLATION INSTRUCTIONS – REAR MOUNT WITH BRACE AHEAD OF REAR AXLE (MID-MOUNT WING)
NOTE: Any additional hardware used in assembly or repair must be a minimum of Grade 8. Failure to use proper hardware may result in equipment failure and possibly cause serious bodily injury.
NOTE: Do not weld to truck chassis frame at any time when mounting a wing system or hitch. Use a minimum of Grade 8 hardware for mounting a wing system or hitch to the truck chassis. This section applies to a wing which has the front mast located behind the cab and the brace located ahead of the rear axle (also known as a mid-mount wing). For other configurations, refer to later sections in the manual. These installation instructions and diagrams are written for a standard right hand (RH) or passenger side wing system. The same process applies for a wing system mounted on the left hand (LH) or driver side. WING-SIDE CHEEK PLATES Refer to the diagrams on pages 3-03. Starting with the wing-side front cheek plate (P/N 122233 – 16” x 35” w/4 holes), find the most suitable frame location for mounting, working around the exhaust system and fuel tank. Modification to cheek plate and/or use of spacers (not supplied) may be necessary to assure solid mounting. Locate the front cheek plate so that the bottom edge of the 4” x 7” cutout will be 13” above ground level with all equipment (wing, dump body, etc.) installed on the chassis. Variations in the truck suspension must be accounted for by the installer. In cases where the suspension has already been modified for the additional weight of the wing, body, etc., the cheek plates will need to be mounted higher than 13” to allow for sag downward. If the suspension will be modified later to adjust for sag, the cheek plates can be installed to the dimensions provided in these instructions. When determining the best location for the front cheek plate, keep in mind that the rear cheek plate cutout (P/N 122233) must be located 39½” from rear of the front cheek plate cutout. Once the best location has been determined, clamp the cheek plate to the frame at the specified height, mark and drill a minimum of six (6) 41/64” diameter holes to allow for 5/8” bolts. Existing frame holes may be used if hole sizing is appropriate. Bolt the cheek plate to the frame. Arrange the reinforcing bars (P/N 81777) as suggested in drawing (trim as necessary) leaving sufficient clearance around cutouts for tube support angles. Skip weld the bars in place with ¼” fillet welds 2” long spaced 4-5” on both sides of the bars. Trim the top of cheek plates even with the top of the truck frame. Locate the rear cheek plate (P/N 122233 – 16” x 35” w/4 holes) so the front edge of the 4” x 7” cutout is located 39½” from the rear edge of front cheek plate cutout and the bottom edge of the cutout is 13” above ground level. Mark and cut the cheek plate as necessary to fit around the truck spring hanger. IMPORTANT: An absolute minimum of 10” of cheek plate width must remain at the top after modification for proper mounting and strength. Henderson Products Inc. strongly recommends adding the same amount of material that was notched out to the opposite side of the notch. This provides a full-width cheek plate to maximize the distance between the mounting bolts for a stronger connection to the truck frame. Complete the rear cheek plate mounting using the same steps as above.
Page 3-02 04/11
INSTALLATION INSTRUCTIONS – REAR MOUNT WITH BRACE AHEAD OF REAR AXLE (CONTINUED)
NON-WING-SIDE CHEEK PLATES (DRIVER’S SIDE FOR RH WING) Use the steps outlined on the previous page to mount the non-wing-side cheek plates. The cut-outs on the non-wing-side cheek plates (P/N 122232 – 16” x 35”, no holes) must be located directly across from the cut-outs on the wing-side cheek plates. Note that the cut-outs are offset in the plates. Weld one (1) tube support angle (P/N 81770 – 3 x 4 angle w/hole) flush with the top edge of cutout on both the front and rear cheek plates. Weld a continuous ¼” fillet around the 3” leg, leaving the cutout edge free of weld. Do not weld bottom tube support angles in place at this time. Return to the wing side.
GROUND
FOR CLEARANCE
IMPORTANT NOTE: DIMENSIONS IN DIAGRAM #1 ARE REQUIRED VERTICAL DIMENSIONS FOR COMPLETED TRUCK. ADJUSTMENTS MUST BE MADE AT INSTALLATION DEPENDING ON THE TRUCK SUSPENSION AND THE WEIGHT OF THE DUMP BODY TO ALLOW FOR THE DIMENSIONS SHOWN TO BE ACHIEVED.
BOTTOM OF DUMP BODY
39 1/2"
DIAGRAM #1
P/N 122232 (16 X 35, NO HOLES) TRIM EVEN WITH TRUCK FRAME, TYP
GROUND
TRIM AS REQ'D
13"
CHEEKPLATE MOUNTING INSTRUCTIONS - REAR MOUNT WITH BRACE AHEAD OF AXLE
10"
SIDE WING
NOTE: DIAGRAMS BELOW ARE FOR A RH (PASSENGER SIDE) MOUNTED WING SYSTEM
NON-WING
Page 3-03
10 MIN
ADD PLATE
(CHEEKPLATE TO TUBE ENDPLATE)
Insert front tube weldment (P/N 122227) through the wing-side front cheek plate and pass through to non-wing-side plate. See diagram below and on the following page. Push the tube against the rear of the cutout. Set wing-side distance from face of front cheek plate to
w/2 holes) loosely to cheek plate. Clamp angles tight against top and bottom of tube and weld with a 1/4" continuous weld. Tighten bolts to cheek plate. Bolt mast to cross tube so the bottom of the mast frame is 10" above the ground.
From wing side, insert 4" x 7" rear tube weldment (P/N 122230) through cutout in rear cheek plate and pass through to driver side rear cheek plate. Push the tube against the rear of the cutout. Set wing-side tube distance from face of rear cheek plate to end of tube endplate at
plate. Temporarily clamp or tack weld the tube to the angles to hold it in place.
Before the rear tube is permanently fastened into place, install the moldboard assembly to the mast and bolt the brace to the rear tube. Refer to the Wing Installation & Set-up instructions beginning on Page 3-30. Check for proper brace length, folding, and clearance to the dump body. Adjust the rear cross tube inward or outward per the instructions on pages 3-34 and 3-35 if necessary. Clamp and weld the angles to the tube as done on the front cross tube.
Return to non-wing-side and locate bottom tube support angle (P/N 81770 - 3 x 4 angle w/hole) flush to bottom of tube and in line with top support angle. Weld same as upper angle. Drill 41/64" diameter hole in top and bottom of rear tube assembly, using holes in tube support angles as guides. Bolt securely using 5/8" x 6" bolt (P/N 82821).
mm09
10/11
Page 3-04
MAST AND REAR CROSS TUBE INSTALLATION (CONT'D)
PUSH TUBES AGAINST REAR SIDE OF CUTOUTS BEFORE WELDING TO ANGLES
BOTTOM OF MAST FRAME ABOVE GROUND
9 1/4"
Refer to the diagram below and the installation parts list on page 3-07. Loosely bolt two (2) brace ears (P/N
face of rear tube end cap on front side of rear tube. Locate one brace ear centered on both the vertical side
between and tack weld. Loosely bolt one cast ball joint to the mast flange and another one in a convenient location on the front cheek plate. Rotate the ball joints so they point toward their respective opposite and so the centerline of the brace when installed will align with the ball joint mounting hole. Measure between the balls (Dim X) and add 1" to determine the cut length of the pipe braces (Dim X + 1). Cut, install, and weld the pipe braces to the ball joints. Weld the brace ears to the rear cross tube. Bolt braces securely into place.
Install top pipe braces between the mast and truck frame in similar fashion (see page 3-07).
BRACE CUTTING LENGTH MM10
Page 3-06
Dim X + 1
Page 3-08 10/11
Front Mast Installation-Hitch Mount
The front mast can be mounted to a power tilt hitch or to a cheek plate and cross tube. The cheek plate and cross tube can be mounted either ahead of or behind the truck cab. Each installation is similar in concept and outlined below. Power tilt hitch front mast installation: Refer to the diagram on page 3-09 for the correct heights for the various types of hitches and plows. Variations in the truck suspension must be accounted for by the installer. In cases where the suspension has already been modified for the additional weight of the wing, body, etc., the hitch will need to be mounted higher than the dimensions shown to allow for sag downward. If the suspension will be modified later to adjust for sag, the hitch can be installed to the dimensions provided in these instructions. Install the hitch on the truck frame per the plow hitch installation instructions on pages 3-10a and 3-10b. After the hitch is installed, position the front mast mounting plates on the ends of the cross tubes on the hitch so the bottom of the mast will be 10” above the ground when installed. Note the mounting plates have additional holes to allow for height adjustment of the front mast after installation. The mounting plates can be installed to allow for adjustment upward or downward. The front mast can be installed vertically or canted rearward 8° (see page 3-11 for canted installation). After mounting plates are welded to the cross tubes, bolt the mast to the mounting plates by using the closest set of holes which locates the mast 10” above the ground by using the eight fasteners provided (see page 3-13).
PIN HEIGHT FOR REVERSIBLE PLOW - 13" PIN HEIGHT FOR OUTBOARD CYLINDER RSP - 14 1/2"
PIN HEIGHT FOR FULL TRIP ONE-WAY PLOW - 13" PIN HEIGHT FOR SLOTTED TRIP ONE-WAY PLOW - 17 3/8"
CENTER PIN HEIGHT FOR REVERSIBLE PLOW - 14 5/8" CENTER PIN HEIGHT FOR OUTBOARD CYLINDER RSP - 16 1/4" CENTER PIN HEIGHT FOR FULL TRIP ONE-WAY PLOW - 14 5/8"
CENTER PIN HEIGHT FOR SLOTTED TRIP ONE-WAY - 19"
HEIGHTS FOR POWER TILT PIN HITCH
HEIGHTS FOR POWER TILT QUICK-HITCH
HEIGHTS FOR FLAT PLATE HITCH WITH WING
SEE DIAGRAMS ABOVE FOR PIN HEIGHTS FOR VARIOUS PLOWS
BUMPER TO FRAME KIT
10.0
2.00
10.0
Page 3-10a
POWER TILT HITCH INSTALLATION - 34" INSIDE FRAME
CAUTION!! FRONT PLOW AND WING MUST BE LOWERED TO THE GROUND BEFORE TILTING HITCH.
HCH_NY_1
3. PIN LIFT ARM AS SHOWN.
STORING LIFT ARM WHEN PLOW IS NOT ATTACHED
AND LIFT ARM DOWN OVER CYLINDER.
FOLD CYLINDER UP INTO VERTICAL POSITION CAREFUL TO SUPPORT BOTH LIFT ARM AND CYLINDER.
2. REMOVE PIN ON ROD END OF CYLINDER, BEING
1. REPOSITION INNER LIFT ARM TO SHORTEST POSITION.
INNER LIFT ARM
REMOVE THIS PIN TO FOLD
LIFT ARM
Page 3-10d
Page 3-10e
B
PULL LEVER FORWARD. REPIN CYLINDER TO LIFT ARM AND
AND IS PRESSED INTO THE DEACTIVATED
6. TO REACTIVATE CYLINDER HYDRAULICS 5. COMPLETE VALVE ASSEMBLY AS SHOWN. 4. WELD VALVE ASSY BRACKET TO ANGLE.
REAR VIEW
INSTALLATION INSTRUCTIONS:
ANGLE, SO THAT VALVE LEVER 3. LOCATE VALVE ASSY ON FRAME MOUNT
AND PIN EXTENDABLE LIFT ARM TO HITCH. 2. FOLD CYLINDER INTO STORED POSTION 1. MOUNT HITCH TO TRUCK FRAME.
DESCRIPTIONPART NO.QTY.ITEM
PARTS LIST
VALVE SHUT-OFF SELECTOR
SCREW CP HX 3/8nc X 2 1/482373 76127 50416
82936 96567 108320
2 2 2
1 1 1F
D
Page 3-10h 10/11
Hood
PLATE, MAST MOUNT21222361
TRUCK CENTERLINE
SHOWN WITH SLOPED MAST
GUSSET2 951802
Page 3-13
Front Mast Installation – Cheek Plate and Cross Tube (Ahead of Cab)
Page 3-14 03/12
The front mast can be mounted to a power tilt hitch or to a cheek plate and cross tube mounting kit. The cheek plate and cross tube can be mounted either ahead of or behind the truck cab. The installation with the mast ahead of the cab is described below. These installation instructions and diagrams are written for a standard right hand (RH) or passenger side wing system. The same process applies for a wing system mounted on the left hand (LH) or driver side. Installations with the front mast behind the cab and brace behind the rear axle require considerations for body and scraper clearances and are not described here. Contact your dealer or Henderson Products, Inc. for these installations. See the diagrams on pages 3-16 and 3-17. The cheek plate with the 4-hole pattern should be on the side next to the mast. Position the cheek plates on the truck frame as close to the hood as possible allowing a minimum of 2” between the mast and the hood/fender. Measure from the ground to the bottom of the tube cutout. This dimension should not exceed 16”-17”. Note that the cheek plates can be installed to allow for mast adjustment upward or downward. Variations in the truck suspension must be accounted for by the installer. In cases where the suspension has already been modified for the additional weight of the wing, body, etc., the cheek plates will need to be mounted higher than 16”-17” to allow for sag downward. If the suspension will be modified later to adjust for sag, the cheek plates can be installed to the dimensions provided in these instructions. Clamp the cheek plates in position. Slide the cross tube weldment through the tube cutouts in the cheek plates. Locate and position the tube support angles (P/N 81775 with two-hole pattern) on the cheek plate closest to the mast. Bolt the angles in place. Bolt the mast onto the cross tube so the bottom of the mast is 10” above the ground. Locate the dee and install it on the mast slide with the pin provided. Position the face of the dee parallel to the centerline of the truck. Measure from the face of the dee to the centerline of the truck. This dimension should be approximately 54”. Check that there will be sufficient clearance between the back of the wing and the steering tire when the wheels are turned to the extreme right. Also check that the wing will have sufficient overlap the front plow. If necessary the cross tube can be adjusted inward or outward. For the taller masts, check that the top of the mast clears the truck hood when opened. The hood rotation forward may need to be restricted and/or the top flanges of the mast frame trimmed off to allow the hood to open. Drill a minimum of six 41/64” diameter holes per side thru the cheek plate and frame. Trim the excess cheek plate that protrudes above the truck frame. Weld the tube support angles installed earlier to the cross tube. On the non-wing (driver’s) side, install the angles with a single hole (P/N 81770). Position these angles on the cheek plate opposite the mast facing away from the mast. The leg of the angle with the hole should be on the cross tube. Weld these angles to the cheek plate with the holes in line. Drill a hole thru the cross tube aligning with the holes in the cross tube support angle. Install the 5/8” x 6” bolt provided.
Front Mast Installation – Cheek Plate and Cross Tube (Ahead of Cab)
04/11 Page 3-15
Locate the four cast ball joints (P/N 81754) and two pieces of 1-1/2” Schedule 80 pipe (P/N 85348). Install two of the ball joints on the top of the mast and 2 on a convenient location on the frame (see page 3-13). Note that to provide the strongest support for the top of the mast, the braces should be mounted to the truck frame as high as possible and should not be parallel to each other. Position the ball joints so they point toward their respective opposite and so the centerline of the brace, when installed, will align with the ball joint mounting hole. Measure between the balls (Dim X) and add 1” to determine the cut length of the pipe braces (Dim X +1). Cut the provided 1-1/2” schedule 80 pipe to the required lengths, install, and weld as shown on page 3-17. Also included in the kit are six ½” x 1” reinforcing bars. Position them on the cheek plates and weld as shown on page 3-17.
Dim X Dim X + 1
ALIGN BRACE WITH HOLE IN BALL JOINT (BOTH ENDS)
BRACES SHOULD NOT BE PARALLEL
NOTE: SHOWN WITH NON-TRIP DEE.
ALLOW CLEARANCE BETWEEN WING, BODY, MIRRORS, AND STEERING TIRE
37.0 NON-TRIP OR TRIP EDGE 31.0 FULL TRIP
TRUCK CENTERLINE
man21b
03/12
FRONT MAST MOUNTING INSTRUCTIONS - CHEEK PLATE & CROSS TUBE (AHEAD OF CAB)
Page 3-16
(ADJUST FOR HOOD CLEARANCE OR FRONT PLOW OVERLAP IF NECESSARY)
man15
FRONT MAST INSTALLATION - CHEEK PLATE & CROSS TUBE MOUNT
Cheek Plate to Frame Brace Kit Installation (Refer to drawing on Page 3-19)
CAUTION NOTE: This kit (otherwise known as ‘bumper to frame kit’) is required for all chassis that DO NOT have full C-channel frame extensions. Damage to chassis frames could result if this kit is not installed. The installer is responsible for determining if this kit is required. Contact Henderson Products Inc. for assistance. See page 3-19 for a typical installation. Locate the four frame mounting angles provided with the kit. Notice that two of the angles have holes (P/N 82146) and two don’t have holes (P/N 82145). The angles with the holes are the bottom angles. Position the top angles (no holes) on the frame near and in front of the front axle. Clamp them in place. Clamp the bottom angle under the installed angles with the hole in the lower leg as shown. Locate the two brace arm stabilizer bars (P/N 82143). Install the stabilizer bars to the holes in the bottom angles with the fasteners provided. At this point, the stabilizer brace and angle assembly can be adjusted in and out, forward and back. It is very critical that these parts have proper clearance between all moving parts on the chassis, including axle travel, suspension parts, steering mechanisms, etc. Temporarily fasten the stabilizer brace up to the bottom of the truck frame. Once it is felt that these assemblies are in the proper location, locate the bottom frame angle. Position the angle on the backside of the cheek plates roughly at the height of the center of the cross tube. Center the angle left to right on the cheek plates and tack in place. Swing the stabilizer bars down onto the bottom frame angle (note that the stabilizer bar will have to be trimmed to length). Position the provided stabilizer arm mounting ear on either side of both stabilizers and weld in place. Mark the stabilizer bar for the mounting ear hole. Remove the stabilizer bar and drill thru with a 13/16” drill. Reinstall the stabilizer bar. Locate the stabilizer bar reinforcement (P/N 82144). This reinforcement should be mounted on the centerline of the stabilizer bar, either inside or outside, which ever fits the application. Note that the reinforcement will need to be cut to length. Tack the reinforcement to the stabilizer bar. With all of the components now in position, go back to the top frame mounting angles. Mark each angle for four 41/64” diameter holes through the frame. Keep in mind that no hole should ever be closer than 2-1/4” from the bottom (or top) flange of the frame. Drill these holes thru the angles and frame. Remove all components and finish welding as shown on page 3-19. Reinstall the angles to the truck frame using (4) 5/8” Grade 8 bolts on each side. Torque all bolts to the recommended torques outlined in the chart in Section 9 of this manual. Once installation is complete, again verify proper clearance between all moving parts of the chassis and hitch components.
Page 3-18 05/15
NUT, TOPLOCK, 5/8-11NC, G8
SCREW, CP, HX, 3/4NC X 3 1/4, G8
SCREW, CP, HX, 3/4NC X 2 1/4, G8
NUT, TOPLOCK, 3/4-10NC, G8
06/12 Page 3-19
A
3/8 TYP
1/4 TYP
Rear Support Installation – Above, Below, and Cradle To Frame
The location of the rear support is extremely important for keeping the forces through the support, braces, and joints to a minimum and maximizing the life of the equipment. Refer to the diagram on page 3-21, which shows that the angle between the brace and the moldboard should be as close as possible to 90° when plowing. After the front mast is mounted, the distance the rear support should be located behind the mast can be determined from the chart for a given moldboard and brace length combination. For example, an 11’ moldboard with a 71.5” brace length located in Position “A” (closest position to the toe end) requires the rear support to be located 130” behind the mast. This configuration has a 74” cutting path width.
The Henderson wing rear support is available in four basic configurations (see pages 3-22 to 3-28). They are above the frame mounting, below the frame mounting, cradle to frame, and cross tube/cheek plate mounting. The cross tube/cheek plate mounting is only available for a non-trip or trip edge wing. These installation instructions and diagrams are written for a standard right hand (RH) or passenger side wing system. The same process applies for a wing system mounted on the left hand (LH) or driver side.
Above the frame mounting: See pages 3-22 and 3-23 for illustration. Place the rear support weldment on top of the truck frame
facing the right side of the truck. Slide the weldment forward as far as possible allowing 2” of clearance between the structure and the exhaust system, fuel tanks, cab, etc. Be sure the area where the push arms attach is clear of all obstacles. Clamp the structure in place. Drill a minimum of six 41/64” holes through the mounting structure and the frame. No hole should be within 2-1/4” of the flanges of the frame. Insert six 5/8” Grade 8 fasteners and tighten per the torque chart in Section 9. Locate the mounting angle provided and position under the cross tube on the non-wing (driver’s) side of the truck. Clamp the angle in place under the tube and to the frame. Drill four 41/64” diameter holes through the provided holes into the truck frame. Install four 5/8” Grade 8 fasteners and torque. Weld the angle to the tube on both sides and across the end of the tube with a ¼” fillet.
Below the frame mounting: See pages 3-24 and 3-25 for illustration. Place the rear support weldment under the truck frame
facing the wing side of the truck. Slide the weldment forward as far as possible allowing 2” of clearance between the structure and the exhaust system, fuel tanks, cab, etc. Be sure the area where the push arms attach is clear of all obstacles. Raise the structure until the bottom of the cross tube is 14”-16” above the ground. Clamp the structure in place. Drill a minimum of six 41/64” holes thru the mounting structure and the frame. No hole should be within 2-1/4” of the flanges of the frame. Insert six 5/8” Grade 8 fasteners and tighten per the torque chart in Section 9.
Position the cheek plate provided on the non-wing (driver’s) side frame rail with the rectangular opening centered on the cross tube. Clamp it to the frame rail. Drill six 41/64” holes thru the cheek plate and the frame rail. Insert six 5/8” Grade 8 fasteners and tighten per the torque chart in Section 9. Position the two tube support angles on top and bottom of the tube up against the outside of the cheek plate. Align the centerline of the hole in each angle with the other. Clamp the angles in place. Drill through the provided holes in the angles through both walls of the tube. Install and tighten the 5/8” x 6” long bolt provided. Weld the angles to the cheek plate with a ¼” fillet on three sides (no weld on the side next to the cutout in the cheek plate). Locate the provided reinforcing bars (3). Position them on the cheek plate as shown on page 3-25. These may need to be trimmed to fit. Weld them in place with ¼” fillet welds spaced 4”-5” apart on both sides.
Cradle to frame mounting: The cradle to frame rear support is similar to an above the frame support but does not include the top
cross tube to tie it to both frame rails. Instead it is fastened to an existing structure, like the hoist cradle for the dump body. See pages 3-23, 3-37, and 6-04 for illustrations. Due to the variability of these structures, the installation of this option is not provided in this manual. Contact your dealer or Henderson Products, Inc. for this installation.
DIM "X" (MAST PIVOT PIN TO REAR BRACE PIVOT)
CUTTING PATH WIDTH
BRACE LENGTH
PWNG GUIDELINES
SEE PAGE 3-21
LOCATE WITH 2" MINIMUM CLEARANCE BETWEEN SUPPORT AND EXHAUST, TANKS, CAB, ETC.
SHOWN WITH FRONT CHEEK PLATE AND CROSS TUBE man20
04/11
Page 3-22
20" MAX *
* ON TRUCK FRAMES HIGHER THAN 44" THIS DIMENSION WILL EXCEED 20". USE A BELOW FRAME REAR SUPPORT INSTEAD.
NUT, CENTERLOCK, 5/8-11NC, G8 SCREW, CP, HX, 5/8NC x 2, G8 ANGLE, MOUNT, W/HOLES
SUPPORT, REAR, WLDT, ABOVE FRAME
D C
10 10
B
man02
ABOVE FRAME AND CRADLE TO FRAME REAR SUPPORT PARTS LIST
CRADLE TO FRAME REAR SUPPORT P/N 105589 (SIMILAR TO 82652 BUT DOES NOT INCLUDE A TOP CROSS TUBE)
SUPPORT, REAR, WLDT, CRADLE/FRAME105589
TO GROUND
7.50
LOCATE WITH 2" MINIMUM CLEARANCE BETWEEN SUPPORT AND EXHAUST, TANKS, CAB, ETC.
SHOWN WITH FRONT CHEEK PLATE AND CROSS TUBE
man20a
04/11
Page 3-24
SCREW, CP, HX, 5/8NC x 5, G5 ANGLE, TUBE SUPPORT, 3 x 4 BAR, REINFORCING, 29" NUT, CENTERLOCK, 5/8-11NC, G8 SCREW, CP, HX, 5/8NC x 2, G8 CHEEK PLATE, REAR SUPPORT SUPPORT, REAR, WLDT, BELOW FRAME
E
PART NO. DESCRIPTION PARTS LIST
A
B
DC
NON-WING (DRIVER'S) SIDE
Page 3-26 04/11
Rear Support Installation – Cheek Plate and Cross Tube
The location of the rear support is extremely important for keeping the forces through the support, braces, and joints to a minimum and maximizing the life of the equipment. Refer to the diagram on page 3-21, which shows that the angle between the brace and the moldboard should be as close as possible to 90° when plowing. After the front mast is mounted, the distance the rear support should be located behind the mast can be determined from the chart for a given moldboard and brace length combination. For example, an 11’ moldboard with a 71.5” brace length located in Position “A” (closest position to the toe end) requires the rear support to be located 130” behind the mast. This configuration has a 74” cutting path width.
See pages 3-27 and 3-28 for illustration. These installation instructions and diagrams are written for a standard right hand (RH) or passenger side wing system. The same process applies for a wing system mounted on the left hand (LH) or driver side. The cross tube/cheek plate support is only used with a single rear brace. Locate the wing (passenger) side cheek plate (the one with the 4-hole pattern) and position it on the truck frame. Position it as far forward as possible and with the bottom of the cut out 14”-16” above the ground. Clamp it in place. Locate the non-wing (driver’s) side cheek plate, positioning it on the driver’s side frame rail 7”- 10” behind (toward the rear of the truck) the passenger side cheek plate and at the same 14”-16” from the ground to the bottom of the cut out (same as on wing side). Clamp it in place. Slide the brace arm mounting tube weldment through the slots in the cheek plates from the passenger side. Align the centerline of the brace mounting hole with the face of the dee on the front mast, parallel with the centerline of the truck. Verify a minimum of 2” of clearance between the chassis components and the mounting structure. Be sure the area where the push arms attach is clear of all obstacles. Adjust as necessary.
Once satisfied with the location, drill six 41/64” holes thru each cheek plate and frame. No hole should be within 2-1/4” of the flanges of the frame. Insert six 5/8” Grade 8 fasteners (each side) and tighten per the torque chart in Section 9. Locate the two tube support angles provided (P/N 81775 with two holes) and install them on the wing side cheek plate on the top and bottom of the tube with the fasteners provided. Temporarily tack weld or clamp the angles to the tube. Locate the two tube support angles provided (P/N 81770 with one hole) and temporarily clamp them to the driver’s side cheek plate. Make sure the holes are aligned.
After the clearances between the moldboard and truck are confirmed in the set-up procedure (see Pages 3-30 to 3-35), drill through the tube using the holes in the angles as a guide. Install and tighten the 5/8” x 6” long bolt provided. Weld the angles to the cheek plate with a ¼” fillet on three sides (no weld on the side next to the cutout in the cheek plate. Locate the six reinforcing bars provided. Position them on the cheek plates as shown on page 3-28. These may need to be trimmed to fit. Weld them in place with ¼” fillet welds spaced 4”-5” apart on both sides. On the wing side finish welding with a ¼” fillet the angles to the tube that were temporarily clamped or tack welded.
Locate the two ball cast joints (P/N 81754) and the pipe (P/N 85348) provided. Position one of the ball joints on the backside of the tube (toward rear of the truck) as close to the wing brace mount as possible. Clamp it in place. Locate the other ball joint on the truck frame on or near a cross member. Align the balls so they point toward their respective opposite and so the centerline of the brace, when installed, will align with the ball joint mounting hole. Measure between the balls. Cut the pipe provided to 1” more than the ball to ball measurement (see page 3-06). Install the pipe between the balls and tack in place. Remove the assembly and weld all around the ball to pipe joint with a 3/16” fillet. Reinstall the assembly, bolting the ball joints to the frame and the cross tube.
SHOWN WITH FRONT MAST CHEEK PLATE AND CROSS TUBE AND BRACE AHEAD OF REAR AXLE
SEE PAGE 3-21
14" - 16"
LOCATE WITH 2" MINIMUM CLEARANCE BETWEEN CROSS TUBE, BRACE AND EXHAUST, TANKS, CAB, ETC.
man21
ALIGN HOLE WITH VERTICAL PIN ON FRONT DEE
Page 3-28 04/11
R
1
Q
81781
122233
Q
ANGLE, TUBE SUPPORT, 3 X 4
BALL, JOINT, CAST
GUSSET, STOP PLATE
BAR, REINFORCING, 29"
PIPE, BRACE, 48"
TUBE, WLDT, REAR SUPPORT,80"
WASHER, FLAT, .69 I.D.105343O 5
HARDWARE THROUGH TRUCK FRAME SUPPLIED BY INSTALLER. USE A MINIMUM OF (6) 5/8" GRADE 8 BOLTS PER SIDE
NOTE: INSTALLER TO DRILL & BOLT COMPONENTS TO FRAME. DO NOT WELD ANY COMPONENTS TO TRUCK FRAME.
4 O
Page 3-29
*INCLUDES RUBBER PAD & CHAIN HOOK
INSTALL NOTE: 81776 GUSSETS & 81781 STOP PLATE ARE MODIFIED AT INSTALL FOR PROPER ALIGNMENT WITH WING BRACE
Page 3-30 04/11
Wing Installation & Set-up
Attach the front of the wing to the dee bolt on the front post. There must be clearance between the wing and the plow in the plowing position, the carry position and when both the plow and wing trip. The wing and the plow must be able to travel though all of its travel without interfering with each other. The plow must also overlap the toe of the wing. Too little overlap will allow snow to “dribble” between the plow and wing. The dee nut should be tightened then loosened ½ - 1 turn to allow the moldboard to pivot freely. Make sure that the cotter pin is installed properly through the dee nut and bolt to keep the nut in place.
Note: For Front Heel Lift Option see Page 3-31 when attaching the moldboard to the dee.
Attach the wing braces to the rear support or mast with the fasteners provided. Attach the rear of the wing to the wing braces. The angle between the wing brace and wing should be as close as possible to 90° (see pages 3-21 and page 3-32). The closer this measurement is to 90°, the stronger the connection will be. It will also provide for a much smoother operating wing. Exception: For a rear mount wing with the brace ahead of the rear axle (mid mount…see illustration at bottom of page 3-04), this angle will be less than 90° due to short the space between the mast and rear cross tube.
Grease between slide and beam Slide must be free to move length
of stroke of cylinder
Grease between wing header and dee face Wing must be free to rotate on dee bolt
Allow 1/8 min gap between wing and nut Install cotter pin to secure nut
TOE MUST BE CLIPPED 3” X 45° ON ALL CUTTING EDGES TO PREVENT DAMAGE TO EQUIPMENT.
FOR FRONT HEEL LIFT MOLDBOARDS WITH (2) MOUNTING HOLES AT THE TOE END: THE PIVOT LINK AND BRACKET MUST BE MOUNTED TO THE MOLDBOARD WITH 44.50" BETWEEN THE PINS AS SHOWN BELOW. IF THE MOLDBOARD IS PINNED TROUGH THE FRONT HOLE, THE BRACKET MUST BE MOUNTED IN THE FORWARD POSITION. IF IT IS PINNED THROUGH THE REAR HOLE, IT MUST BE MOUNTED IN THE REARWARD POSITION.
PINNING THROUGH THIS HOLE SHIFTS THE MOLDBOARD REARWARD, DECREASING OVERLAP WITH FRONT PLOW OR SCRAPER
PINNING THROUGH THIS HOLE SHIFTS THE MOLDBOARD FORWARD, INCREASING OVERLAP WITH THE FRONT PLOW OR SCRAPER
DEE
PIVOT LINK AND BRACKET
THIS DIMENSION MUST BE HELD WHEN FASTENING THE DEE AND PIVOT LINK AND BRACKET TO THE MOLDBOARD.
MAN106
THIS PAGE
01/17 Page 3-31B
Page 3-32 04/11
Dual Brace Applications:
Refer to the wing brace parts pages 5-08 to 5-10 for proper orientation of the wing braces. Special care needs to be taken that the braces are adjusted to the same length. If the braces are of unequal length, equipment damage can occur or the wing will not operate or fold properly. The full trip wing brace should be used as a top wing brace only. This brace has an extension spring, which allows the wing to trip when an obstacle is encountered. Note: The spring should face the rear of the truck for maximum clearance with exhausts, etc. Note: On full trip applications, both the trip brace and the trip dee must be in the same mode, either both locked out of trip mode or unlocked and free to trip (see page 3-36). A standard wing brace is used as a bottom brace for tripping applications. See parts page for proper identification. Single Brace Applications:
Non-trip and trip edge applications require only one wing brace. This brace has a compression spring to handle shock loads. Refer to the installation instructions beginning on page 3-34 for proper length adjustment of a single brace.
65.5" AS SHOWN 71.5" 1 HOLE EXPOSED
77.5" 2 HOLES EXPOSED 83.5" 3 HOLES EXPOSED
65.5" 1 HOLE EXPOSED 71.5" 2 HOLES EXPOSED 77.5" 3 HOLES EXPOSED 83.5" 4 HOLES EXPOSED
65.5" AS SHOWN 71.5" 1 HOLE EXPOSED
77.5" 2 HOLES EXPOSED 83.5" 3 HOLES EXPOSED
116038 - SHOCK BRACE
116036 - STANDARD BRACE
116033 - TRIP BRACE (TOP)
IMPORTANT: FOR WINGS USING DUAL PUSH ARMS, BOTH PUSH ARMS MUST BE ADJUSTED TO THE SAME LENGTH FOR WING TO FOLD PROPERLY.
PIN HERE TO ALLOW WING TO TRIP
PIN HERE TO LOCK OUT TRIP
ON WING
Wing Installation & Set-up (continued)
Before the remainder of the installation can be completed, install the hydraulic lines and controls to the wing heel and toe cylinders and make any necessary adjustments to flow control valves and pressure relief valves for smooth operation. Front Heel Lift:
Most non-trip and trip edge applications have a cylinder mounted between the front mast dee and the back side of the moldboard. This cylinder raises and lowers the heel (rear) of the wing. See page 3-35 for illustration. NOTE: Correct brace length is critical for proper folding of a moldboard with a front heel lift. If the brace length is too short, damage to the front mast can occur while raising the heel. The top of the mast will appear to be pulled rearward as the heel nears the top.
Using the truck hydraulics raise the front of the moldboard (toe) to transport position (~10” above ground level).
1. Slowly raise the heel to the preferred transport position allowing sufficient clearances (approximately 4”) to mirrors, exhaust, and truck body. Caution should be taken to avoid trying to lift the heel beyond the height that the brace allows. If the brace length is too short, excessive forces can be applied, resulting in damage to the mast or moldboard. The cylinder rod should be within 1” of its completely retracted length when the heel is raised to the transport position.
2. If the cylinder is not retracting to within 1” of its completely retracted length, the brace should be lengthened as follows:
a. For Rear Mount wing with Brace Ahead of Rear Axle (mid-mount) with single non- adjustable brace: Lower the moldboard, remove pin from push arm. Slowly raise the heel with the truck hydraulics and, by using a forklift, push the heel toward the truck as it is raised until it reaches the desired folded position. Mark and re-drill hole in push arm (see Page 3-35).
b. For Above Frame, Below Frame, Cradle to Frame rear supports, or Rear Mast with single adjustable brace or dual adjustable braces:
i. Single brace: Lengthen brace by removing pin and adjusting outward to the next set of holes (~6”).
ii. Dual braces: Lengthen both top and bottom braces the same amount so they are the same length. Note: Both braces must be the same length for proper folding.
3. If the moldboard does not fold close enough to the side of the truck, with a cheek plate and cross tube rear support the cross tube can be adjusted inward toward the truck. Lower the heel to ground, remove clamps or tack welds holding cross tube in place (see page 3-26), adjust tube inward and re-clamp or tack weld, raise heel again. Making this adjustment will also narrow the cutting path of the wing in the plowing position.
4. Check for smooth operation by alternately raising the toe then the heel and then lowering the heel then the toe several times to make sure there is no binding. Finish welding the cross tube in place (see page 3-26).
5. Install stops on the cross tube. See instructions on Page 3-35.
MM12
01/17 Page 3-35
SETUP - BRACE AND STOP FOR REAR MOUNT WING, BRACE AHEAD OF REAR AXLE
Wing Installation & Set-up (continued) Brace Heel Lift:
Most full trip applications have a cylinder located between the braces to raise and lower the heel (rear) of the wing. Refer to pages 3-37 and 3-38 for illustrations of the following procedures.
After attaching the braces to the rear support, position the base of the cylinder and the pivot ear weldment on the rear support and attach with the fasteners provided. Attach the rod end of the cylinder to the sliding collar on the top wing brace. Raise the toe of the wing to the transport position, approximately 6” – 12” off the ground. Using an overhead crane, raise the heel of the wing not closer than 4” from the passenger side mirror, exhaust stack, front fender etc. Extend the wing brace cylinder fully. Mark the location of the outer side of the sliding collar on the top wing brace. Lower the heel and toe to the ground and fully retract the wing brace cylinder. Position two split collar stops (P/N 88429) ½” – ¾” inside (truck side) of the extended mark made earlier when the cylinder was extended. Weld all around the outside of the collar and the seam with a ¼” fillet. Install the other two split collar stops 9” (inside to inside) from the first collar stops on the opposite side of the sliding collar. Weld all around on the side opposite the sliding collar and at the seams between the collars. Locate strap (P/N 115166) between the cylinder lugs on the sliding collar. With a 1/16” gap between the strap and the split collars to allow the sliding collar to slide, weld the strap to the split collars on both ends all around with a ¼” fillet.
Install stowage chain lug and stop. See page 3-39 for instructions and illustrations.
Page 3-36 01/17
82470N
116036
1
1
C
B
SCREW,CP,HX,1NC X 4, G8
06/12 Page 3-37 MAN03
J 3
K SCREW, CP, HX, 1 NC X 3 1/2, G8952631
K F
BRACE CAN BE INSTALLED WITH SPRING ON OPPOSITE SIDE TO INCREASE CLEARANCE TO TRUCK EXHAUST, ETC.
DESCRIPTIONPART NO.QTY.ITEM
PARTS LIST
C
1
1 2" TO 34"
STEP 1. COMPLETE THE ENTIRE INSTALLATION INCLUDING HYDRAULIC SYSTEM AND CONTROLS. CONNECT CYLINDER (ITEM "C") AS SHOWN IN FIG. 2.
STEP 2. RAISE THE FRONT OF THE WING (TOE) TO THE TRANSPORT POSITION. USING AN OVERHEAD HOIST OR OTHER SUITABLE AND SAFE LIFTING DEVICE, RAISE THE HEEL OF THE WING TO ITS FOLDED POSITION.
STEP 3. OPERATE THE HEEL LIFT CYLINDER TO EXTEND IT TO ITS MAXIMUM LENGTH. WITH A WELDERS PENCIL OR PAINT, MARK THE UPPER ARM (ITEM "A") AT THE OUTER END OF THE SLIDING COLLAR. FIG. 1
STEP 4. RETRACT THE HEEL LIFT CYLINDER COMPLETELY. LOWER THE WING (TOE AND HEEL) TO THE FLOOR. THE SPLIT COLLAR (ITEM "D") SHOULD BE POSITIONED ONE-HALF (1/2) TO THREE QUARTERS (3/4) OF AN INCH INSIDE THE MARK (TOWARDS TRUCK) MADE IN STEP 3. WELD THE COLLAR ALL AROUND ONLY ON SIDE AWAY FROM THE SLIDING COLLAR. WELD SEAMS ALSO.
FIG. 1 FIG. 2
FIG. 3
STEP 5. LOCATE SECOND SPLIT COLLAR 9" (INSIDE TO INSIDE) FROM FIRST SPLIT COLLAR ON OPPOSITE SIDE OF SLIDING COLLAR. FIG. 3. WELD ALL AROUND SPLIT COLLAR ON SIDE AWAY FROM SLIDING COLLAR. WELD SEAMS ALSO.
STEP 6. LOCATE COLLAR STRAP (ITEM "E") BETWEEN CYLINDER COLLAR LUGS TO PREVENT SLIDING COLLAR FROM ROTATING. WELD BOTH ENDS OF STRAP TO SPLIT COLLARS.
E
D
1
4
115166
88429
WELD ALL AROUND THIS
9"
man09
04/11
Page 3-38
STOWAGE CHAIN LUG AND STOP INSTALLATION - BRACE HEEL LIFT
FULL TRIP TOP WING BRACE LOCK PIN When the wing is being used to plow at ground level (shouldering), the lock pin for the top wing brace should be inserted through the spring collar. This allows shock loads encountered at the wing to be transmitted to the tension spring attached to the brace. When winging back (benching) banks, this pin should be inserted through the slot in the tube. When in place, the lock pin makes a rigid structure of the top brace and locks out the tension spring.
FULL TRIP DEE LOCK PIN When the wing is being used to plow at ground level (shouldering), the lock pin should not be inserted in the trip dee to prevent the dee from tripping. In this way, shock loads, caused by obstructions encountered at the wing, will be absorbed by the torsion spring within the trip dee. When winging back (benching) banks, the lock pin should be inserted in the trip dee. When in place, the lock pin makes a rigid structure of the trip dee and locks out the torsion spring. This allows the wing to "cut" without tripping.
IMPORTANT *Do not run the wing at ground level (shouldering) with the lock pins inserted in either the trip dee or wing brace. Damage to wing components and/or chassis may result if the lock pins are used while plowing at ground level. *When winging back (benching), both pins should be used to avoid tripping. *Never insert one lock pin and not the other . Winging with one pin in and one pin out can cause wing component and/or chassis damage as well as unsafe travel conditions.
SPRING LOAD ADJUSTMENT In the event the wing may be tripping too hard (or too light), there is provisions for spring load adjustment at the top brace and on the trip dee. The wing brace has a threaded eyebolt with nut (see drawing). Turning the bolt clockwise preloads the spring and makes the wing trip harder. Turning the bolt counter-clockwise unloads the spring and allows the wing to trip easier. The trip dee has an adjusting u-bolt with lock nuts on the back side. Tightening the lock nuts preloads the trip spring and makes the wing trip harder. Loosening the lock nuts unloads the tension on the trip spring and allow the wing to trip easier.
SPRING COLLAR
TRUCK END
LOCK PIN POSITION FOR BENCHING - REMOVE FOR SHOULDERING
A 5" x 8" laminated card (part# 95589) of the above instructions are provided with each wing. We recommended installing the card in the cab of the truck in plain view for easy reference by the driver/operator. The card has an adhesive backing for ease in installation.
man27
04/11
Page 3-40
SPRING ADJUSTMENT U-BOLT
TENSION WRENCH (88567)
TO SET TENSION IN LOWEST SETTING: 1) USING BOX END OF TENSION WRENCH AS SHOWN IN DIAGRAM 1, LOWER END OF SPRING BELOW FIRST HOLE IN TENSION PLATE. INSERT 3/4 X 2 1/2 CLEVIS PIN (88571) IN FIRST HOLE. SLOWLY RELEASE PRESSURE ON SPRING. SECURE CLEVIS PIN WITH HAIR PIN (87430).
DIAGRAM 1
TENSION PLATE
TENSION ADJUSTMENT HOLES
TO SET TENSION IN MIDDLE SETTING: 2) USING OPPOSITE END AS IN STEP 1, ALIGN HOLE IN TENSION WRENCH WITH TOP PIVOT HOLE IN TENSION PLATE (SEE DIAGRAM 2). INSERT 1/2 X 2 3/4 BOLT THROUGH TENSION PLATES AND WRENCH. LOWER END OF SPRING BELOW MIDDLE HOLE IN TENSION PLATE AND INSERT CLEVIS PIN. SLOWLY RELEASE SPRING TENSION AND SECURE CLEVIS PIN WITH HAIR PIN.
DIAGRAM 2
DIAGRAM 3
TO SET TENSION IN HIGHEST SETTING: 3) USING SAME END AS IN STEP 2, ALIGN HOLE IN TENSION WRENCH WITH BOTTOM PIVOT HOLE IN TENSION PLATE (SEE DIAGRAM 3). INSERT 1/2 X 2 3/4 BOLT THROUGH TENSION PLATES AND WRENCH. LOWER END OF SPRING BELOW BOTTOM HOLE IN TENSION PLATE AND INSERT CLEVIS PIN. SLOWLY RELEASE SPRING TENSION AND SECURE CLEVIS PIN WITH HAIR PIN.
BOTTOM PIVOT HOLE
STANDARD PIN LOCATION FOR 6" CUTTING EDGE
STANDARD PIN LOCATION FOR 8" CUTTING EDGE
THIS PART CAN REVERSED (FLANGE INWARD) TO LIMIT SLIDE FROM FLOATING ABOVE MAST FRAME FOR MASTS MOUNTED UNDER DUMP BODY
There are 3 holes in the mast frame for locating the base end of the cylinder. The "standard" setting is to provide equal float upward and downward. With the mast mounted 10" above the ground, the standard setting for a 6" cutting edge or an 8" center punched cutting edge is the bottom hole. The standard setting for an 8" top punched cutting edge is the center hole. The top hole can be used to limit the amount of downward float, if desired.
The 8" lift and 12" lifts have an angle bracket (P/N 122088) at the top of the mast. The standard position is with the flange outward which allows the slide to float upward beyond the top of the mast frame. For masts mounted under the dump body with limited clearance, this part can be reversed to limit the slide from floating upward beyond the top of the mast frame and hitting the underside of the body.
NOTE: If the truck suspension is modified after wing installation to compensate for wing and equipment weight, the 10" mast height should be checked. The mast may need to be unbolted from the hitch or cross tube and raised or lowered to the 10" dimension to maintain proper float.
10.0
NOTE: A STOP BLOCK CAN BE WELDED TO THE MAST FRAME BELOW THE SLIDE TO HOLD THE CUTTING EDGE SLIGHTLY ABOVE GROUND LEVEL OR LIMIT THE AMOUNT OF DOWNWARD FLOAT
STOWAGE CHAIN INSTALLATION
01/17 Page 3-43
Wing Operation
Be sure to adhere to all safety and caution information while operating the equipment. Initial Start-up:
The initial start-up of the equipment should be done with a partner that can watch the operation of the wing at a safe distance. Be sure the hydraulic reservoir is filled with oil and all fasteners are tightened. Start the truck and raise the front of the wing 6” - 12”. Raise the rear of the wing off the ground. Have your partner verify that there are no hydraulic leaks and that there are no interferences with all moving parts. Note: The hydraulic system is under extreme pressure and can cause serious personal injury if released. Never use your hands to check for leaks with the system under pressure. Always wear safety glasses. Never let any part of your body be under the wing at any time, even if the stowage chain is attached. Serious personal injury can occur.
Slowly raise the rear of the wing full stroke. Watch for clearance between the wing braces and the exhaust stack, fuel tank and the passenger side mirror. Also watch for clearance between the wing and the fender of the truck. With the rear of the wing at full stroke, connect the stowage chain to the wing. Note: The stowage chain should be installed whenever the wing is not in use or is unattended with the wing in the raised position. The position of the wing now is considered in the carry position. Turn the front tires fully to the right and then the left. Have your partner verify clearance between the front tire and the wing. If the tire hits the wing, return the unit to your installer for adjustment.
Unhook the stowage chain and lower the rear of the wing half way. Raise the front of the wing full stroke and verify no interferences. Lower the front of the wing to 6” - 12” from the ground. Lower the rear of the wing to the ground and then the front of the wing to the ground. All operations should be smooth without any hang-ups. General Operation:
At the beginning of the shift, the operator should walk around the equipment and do a visual inspection. The operator should make sure all bolts are in place and not loose. See page 9-01 in the General Information Section for a recommended practice for checking for loose hardware. Loose bolts should be re-torqued to SAE standards (see chart in Section 9). The operator should inspect the wing and wing braces for bent, broken and missing parts. The cutting edge should be inspected for wear. Never let the cutting edge wear to the backer angle. The full trip wing brace should be inspected for broken or weak springs. Inspect the front slide for wear or damage. Inspect the dee for wear and damage. On full trip dee’s, inspect the spring and retainers for damage. Quickly inspect the hydraulic system for leaks and damage. Hoses and fittings should be inspected for cuts, damage, or corrosion. The hydraulic reservoir should be inspected for leaks. The hydraulic oil level and condition should be checked. The oil filter condition should be checked. The hydraulic pump and drive line should be checked for leaks, wear, and damage. If any deficiencies are discovered, they must be repaired before the equipment goes into service.
Once the visual inspection is complete and the equipment is in satisfactory condition, start and warm up the truck and the hydraulic system. Try all functions of the wing. The wing should move smoothly without any binding or hesitation. Make sure all other safety equipment on the truck is operational (ie: Lights, reflectors, horns, etc.).
Page 3-44 01/17
Now the equipment is ready for use. During the operation of the equipment, several items must be kept in mind:
Always raise the front of the wing off the ground first, then the rear. Always lower the rear of the wing to the ground first, then the front. Severe equipment and road damage will occur with the possibility of personal injury if this procedure is not followed.
The full trip wing brace and full trip dee have a trip lock out position. It is extremely important that both items are either locked in or out together. Equipment damage will occur.
The wing braces (when two are present) must be of equal length. Each wing brace is adjustable to allow more or less cleared path. Both braces must be adjusted to the same length or equipment damage will occur. Carry Position: The toe of the wing should be 10”-12” from the ground and the heel of the wing should be at its highest position. A marker kit (P/N 81665) can be installed to the toe end of the moldboard or mast slide as a visual indicator for the driver to easily determine the position of the toe. If the truck will be unattended or the wing not operated, the stowage chain should be attached to the rear of the wing. Road plowing mode: The front and rear of the wing should be on the ground. The full trip wing brace and dee (if equipped) may be either locked in or out of trip mode. Truck speeds in this mode should be between 25 – 40 MPH. Some conditions may require slower speeds. It is very important not to overdrive the equipment given the plowing conditions. Doing so will shorten the life cycle of the equipment. Leveling (benching) mode: The front of the wing should be slightly lower than the rear of the wing. The full trip wing brace and dee should be locked into the non-trip mode. Truck speeds should be very slow in this mode. Extra care should be taken to avoid hitting objects hidden in the snow banks. These objects can cause substantial equipment damage. The operator should also be aware of the surface being driven on. Keep the truck on hard, level ground.
01/17 Page 3-45
Page 3-46 04/11
The Henderson Wing System was designed to reduce maintenance and to make required maintenance easier. OBSERVE CAUTION/SAFETY LABELS AND INSTRUCTIONS BEFORE AND DURING ANY MAINTENANCE PROCEDURES.
WARNING: Shut off all power, allow all moving parts to come to rest, and lower the wing to the ground before performing any maintenance operations.
HYDRAULIC SYSTEM:
The use of proper oil in the hydraulic system is one of the most important factors for satisfactory operation. Utmost cleanliness in handling the oil can not be stressed enough. Keep the hydraulic oil in original closed containers, clean top of container before opening and pouring, and handle in thoroughly clean measures and funnels. Clean tank opening thoroughly before removing cover and use care to avoid dropping debris into opened tank.
Refer to the Lubricant and Hydraulic Oil Specifications section of the manual (page 4-03) as a general guide for the selection of the proper fluid viscosity for a given oil operating temperature. Refer to the manual supplied by the hydraulic system supplier for more specific recommendations on hydraulic oil and system requirements.
All parts are lubricated by the hydraulic oil in the circuit. Particular attention must be paid to keep the oil in the system clean. Whenever there is a pump failure or any reason that metal particles may be in the system, the oil must be drained, the entire system flushed clean, and any filters or screens thoroughly cleaned or replaced. New oil should be supplied for the entire system. Particular care must also be observed when washing the equipment. High pressure water sprayed at or near the fill cap and breather may contaminate the hydraulic oil with water. COLD WEATHER OPERATIONS:
Hydraulic oils for use in cold weather should have a viscosity not exceeding 7500 SSU at the minimum start-up temperature. A pour point of at least 20°F below start-up temperature is recommended. Start-up procedures should allow for a gradual warm-up until the oil reaches a reasonably fluid state. SERVICE SCHEDULE: 1. Check the hydraulic reservoir oil level daily during use to assure adequate oil to operate
the hydraulic system. Add oil when required. Inspect the breather to be sure it is clean and operational. Before filling, clean the filler - breather cap and surrounding area of dirt and dust to keep the oil and reservoir clean. Oil poured into the reservoir should pass through a 100-mesh screen. Pour only clean oil, from clean containers, into the reservoir. System oil should be changed at least twice a year.
Page 4-02 04/11
2. CHANGE THE HYDRAULIC OIL FILTER AFTER THE FIRST WEEK (OR NOT MORE THAN 50 HOURS) OF OPERATION ON A NEW UNIT. After first filter change, replace filter when indicator reaches Red Zone or minimum of twice a year.
3. Check the hydraulic system daily for any leaks or damaged hoses, lines, or fittings.
Replace any worn or damaged parts immediately. Oil temperature in reservoir must not exceed 200°F (93.3°C), with a maximum temperature of 180°F (82.2°C) recommended. Higher temperatures will result in rapid oil deterioration.
4. The reservoir should be drained through drain plug (not through suction outlet), flushed, and
refilled annually, or the oil should be changed if it shows any signs of contamination or breaking down under continued high-pressure operation. Discoloration of oil is one sign of breakdown.
5. Hydraulic pump controls vary greatly from installation to installation. Have the system
checked annually by a qualified hydraulic mechanic. Check and lubricate drive line components to remote mounted pump units monthly.
GREASE GUN LUBRICATION: See chart on page 4-04 for lubrication points.
Use a ball and roller bearing lithium base lubricant with a minimum melting point of 300°F. This lubricant should have a viscosity that assures easy handling in the pressure gun at prevailing atmospheric temperatures. The lubricant must be waterproof.
Be sure that all fittings are thoroughly cleaned before grease is injected. Points to be lubricated by means of a grease gun have standard grease fittings. CRANKSHAFT PTO GEAR BOX LUBRICANT: Use a SAE 50 petroleum base oil. LUBRICANT AND HYDRAULIC OIL SPECIFICATIONS: IMPORTANT: The lubricant distributor and/or supplier is responsible for the results obtained from their products. Procure lubricants from reputable distributors and/or suppliers who are supplying known and tested products. Do not jeopardize your equipment with inferior lubricants. No specific brands of oil are recommended. Use only products qualified under the following oil viscosity specifications and classifications and recommended by reputable oil companies.
04/11 Page 4-03
The following are general guidelines for the selection of the proper fluid viscosity for a given oil operating temperature. Refer to the manual supplied by the hydraulic system supplier for more specific recommendations on hydraulic oil requirements. Select a major brand industrial PREMIUM QUALITY (anti-wear type) hydraulic oil with viscosity between 100 - 200 SSU at operating temperature. Premium hydraulic oils will provide the following temperature ranges:
INDUSTRY IDENTIFICATION
VISCOSITY GRADE
OPERATING TEMPERATURE
100 SSU 200 SSU
100