Hoist, Sub-Frame, and Flatbed

Proudly built in the USA
Owner’sManual TC-515
Hoist, Sub-Frame,
and Flatbed
TruckCraft Corporation
Chambersburg, PA
www.TruckCraft.com
1-800-755-3867
Copyright c 2008
TruckCraft Corporation
Rev. - - 12/9/08
TRUCKCRAFT CORPORATION
5751 Molly Pitcher Hwy. S.
Chambersburg, Pa. 17201
Tel. 800.375.3867
Phone 717.375.2900
Fax
717.375.2975
www.truckcraft.com
I5-04953
"WHERE WORKMANSHIP IS EVERYTHING"
Table of Contents
Preface……………………………………………………..1
Ordering Repair Parts……………………………………1
Safety Information………………………………………...2
Mounting Instructions…………………………………….3
Maintenance…………………………………………….....6
Parts List…………………………………………………..7
Warranty…………………………………………………..9
This hoist is designed for use on single-axle trucks with a cab-to-axle,
CA, dimension of 56 inches. It is designed to be used in conjunction
with the TruckCraft 100” long flatbed.
TruckCraft Corporation
Rev. - - 12/9/08
I5-04953
Preface
Read and understand all sections of this manual prior
to installing or operating the TruckCraft hoist. This manual
contains information for the installation, operation, and maintenance of a TC515 Hoist, Subframe and Deck. Proper care and operation of the unit will assure
years of dependable service. Your local TruckCraft Dealer will instruct you in its
general operation. TruckCraft Corporation will be glad to answer any questions
that may arise regarding the operation of your unit.
Ordering Repair Parts
When service is necessary, your local TruckCraft dealer can provide assistance.
Always obtain original TruckCraft replacement parts from your dealer. Substitute
items could affect the performance and warranty of the unit. Dealers in your
area can be found on the web at www.TruckCraft.com.
When ordering parts the hoist assembly serial number, pump serial number and
description or part number of parts needed are required. The hoist assembly
serial number is located on the front rub rail-drivers side-of the deck.
On units without a deck, the serial number will be on the drivers side
subframe long sill near the decal. The pump serial number is located
on the top of the valve block.
Hoist Serial Number: ___________________________
Pump Serial Number: ___________________________
Date of Purchase: _____________________________
Purchased From: _____________________________
TruckCraft Telephone #800.375.3867 or 717.375.2900
TruckCraft Fax #717.375.2975
Method of shipping parts to be specified such as customer pickup, UPS, Common Carrier, Parcel Post or Air Freight. All orders to be confirmed in writing, or
faxed, to insure proper understanding of request.
Having preventative maintenance parts on hand could save valuable time.
Improvements and Changes
Because TruckCraft strives to continually improve our products, we reserve the right to make changes and improvements wherever practical,
without obligation to make those same changes or improvements to the
equipment already sold. Photographs used in this manual may not be upto-date with current design changes.
1
TruckCraft Corporation
Rev. - - 12/9/08
I5-04953
Safety Information
Observe the following safety procedures during the use of the hoist and deck:
Before operating read and understand all information furnished with your hoist
and in this manual.
Keep hands, feet and clothing away
from moving parts.
Keep hinge pins and bushings well
greased-inspect regularly for proper
operation during rotation.
Never exceed the rating of the hoist ,
truck, axles, or tires. Make certain
FIGURE 1
the load is evenly distributed.
Never work under a raised body unless the body is supported by blocking
or propped in the raised
position. Always unload the
body prior to using the
prop.
Operate the hoist only
when the truck is on a firm,
level surface.
Always inspect the area
FIGURE 2
around the truck for safe dumping prior to operating the hoist.
Do not move the truck with the deck in a raised position.
Store the remote control in a location that assures that no object can come
in contact with the raise button unintentionally.
Before raising the dumper, check for adequate overhead clearance. Be
alert for overhead electrical wires.
Always ensure that the red warning light is off, indicating that the deck is all
the way down, before operating the truck.
Regularly check and tighten all fasteners to the recommended torque values in the Torque Chart shown below.
Maximum hydraulic pressure is factory set at 3200 PSI. Tampering with
this setting can damage hydraulic components and result in system failure.
Use automatic transmission fluid in the hydraulic reservoir. Check regularly
and keep clean.
FIGURE 3
Torque Chart - Steel Fasteners
Size Grade 5 (Lb-Ft) Grade 8 (Lb-Ft)
1/4-20
6-7
10-11
1/4-28
8-9
11-12
5/16-18
14-15
21-22
3/8-16
24-26
37-40
1/2-13
60-65
90-100
5/8-11
122-130
180-190
3/4-10
220-230
315-330
2
TruckCraft Corporation
Rev. - - 12/9/08
I5-04953
Mounting Instructions
CAUTION: Verify lifting and support devices can support the hoist, sub frame,
and flatbed combined weight before picking up the assembly.
The hoist, sub-frame and flatbed are normally shipped assembled and ready to
install on a truck frame-see Figure 4. Solid connections between the truck frame and the
sub-frame are required at the rear of the sub-frame and at the location where the hoist
pins to the sub-frame. The solid connections are accomplished by rigidly mounting the
56
100
3 Min.
Relocate frame
mount crossmember
as required.
Figure 4
1.12
2.25
2.25
35.2
70.18
two cross members supplied to
the truck frame approximately in
the areas shown in figure 4. If
possible, the cross members
should align with the holes in the
subframe. However, additional
holes can be drilled in the subframe as required. The front
mount should be located as close
as possible to the hoist cylinder
mount on the subframe-see Detail A.
Center of
Hoist Mount
Locate this Frame Crossmember
as close to center of hoist mount
as possible.
2.25
DETAIL A
Mounting Angle
1. Set the assembly on top of the frame cross members and position it a minimum of
3.0” from the cab as shown above in Figure 4.
3
TruckCraft Corporation
Rev. - - 12/9/08
I5-04953
2. Position the mounting angles
along the sides of the frame
in an area where the brackets
do not interfere with existing
frame bolts or hardware.
Bolt cross member to the
subframe and the angles to
frame. Attach cross members to angles with bolts
supplied—see Figure 5. Additional holes can be drilled in the sub-frame as required. . Caution: Be careful of wiring, brake lines, etc. inside frame when drilling. Install 5/8”, grade 8 bolts and nuts supplied at all mounting locations and
torque to 180 FT-LBS.
3. Route control cable into cab and install remote control box in an area where the
up button will not be unintentionally bumped.
CAUTION:
The TruckCraft assembly is designed to bolt to the truck frame. No welding is
required. Do not weld any part of this assembly to the truck frame.
Never cut or drill any openings on the top or bottom flanges of the sub-frame.
4. Route power supply cable to battery and hook up leads to battery.
5. Make sure all blocking and tie-downs used for shipping are removed. Activated
the remote control up button and carefully raise the bed. Do not reach under or
place any body parts under the bed. Raise the bed up about half way to about 30
degrees from horizontal. Rotate the safety prop counterclockwise until it rests on
the angle stop on the hoistsee figure 6. Carefully
Safety prop shown resting on hoist
cross shaft - proper position for prop
lower the hoist until the
when working under deck.
cross shaft of the hoist rests
on the prop. Do not power
down the hoist after the
shaft rests on the prop.
With the prop in this position it is now safe to work
under the deck.
6. With the safety prop supporting the deck and the
truck level, check the depth Figure 6
of the oil in the hydraulic
reservoir. The depth of the
fluid in the tank at this position should be 3”. Use automatic transmission fluid only to fill the reservoir to
this level.
4
TruckCraft Corporation
Rev. - - 12/9/08
I5-04953
7. Apply grease at nine grease zerks:
One on rod end of cylinder
One on barrel end of cylinder
Two on the cross shaft at the deck
Two on the hoist cross shaft at the sub-frame mount
One on each deck pivot hinge at rear of sub-frame
One on the hoist link arm cross shaft
Warning:
Never use the safety prop to support a loaded deck. Never position yourself under a loaded deck.
8.
Install the light, mount bracket and decal shown in figure 7 on the dash inside the
cab of the truck. Using the fuse
holder, wire the light to the dump
switch mounted on the front of
the sub-frame across from the
hydraulic reservoir. Use the schematic shown in figure 8 to connect the wiring. Note: Wire not
supplied by TruckCraft.
9. Place the two decals A4-04684
and A4-04685 inside the cab on
the dash in an easy to read location.
10. Connect the marker light wiring
harness to the truck wiring.
11. Push the remote control up button.
Raise the hoist high enough to
drop the safety prop back into its
storage position. Cycle the hoist
through the complete stroke of the
telescope cylinder a couple times
to make sure everything works
properly.
5
TruckCraft Corporation
Rev. - - 12/9/08
I5-04953
Maintenance
1. Depending on frequency of use, check hydraulic reservoir level and add
oil. Periodically drain system and replace with clean oil. Use automatic
transmission fluid only.
2. Depending on frequency of use, apply grease to all rotating parts at nine
grease zerks.
3. Check to make sure that the bed up warning light illuminates when the
bed begins to raise. Adjust switch or replace bulb as required.
4. Depending on frequency of use, check all bolts for proper tightness and
torque.
6
F
C
C
17
1
18
1
27
9
A
24
2
27
9
A
0.096 lbm
0.129 lbm
6.134 lbm
0.000 lbm
0.273 lbm
7.539 lbm
197.410 lbm
11.569 lbm
356.680 lbm
149.080 lbm
34.045 lbm
17.684 lbm
2.400 lbm
1.612 lbm
2.400 lbm
0.251 lbm
0.546 lbm
Weight
0.203 lbm
0.001 lbm
1.437 lbm
0.036 lbm
0.002 lbm
0.004 lbm
0.029 lbm
7.034 lbm
46
3
15
1
47
3
Rev Qty
1
9
2
16
2
2
24
10
4
18
1
2
1
8
1
4
16
4
8
32
3
3
7
1
10
2
3
5
1
Name
Manual, TC-515
Lube Fitting
Hex Head Cap Screw
Hex Head Cap Screw
Hex Flange Nut
Lock Washer
Nyl. Insert Lock Nut
Flat Washer
Nyl. Insert Lock Nut
Hex Head Cap Screw
Hyd. Power Supply
Hyd. Ftg.-Straight
Roll Pin - .19 X 2.00 SS
Hex Hd Cap Screw
Cylinder
Washer, Shim
Nyl. Insert Lock Nut/GR 8
Hex Head Cap Screw Gr 8
Flat Washer-Hardened-3/4
Flat Washer-Hardened-5/8
Hex Head Cap Screw
Nyl. Insert Lock Nut
40
1
26
1
E
E
G
H
Mount Decals shipped
loose in truck cab. 9
12
2
Item Part #
26 I5-04953
27 P4-00375
28 P4-00466
29 P4-00468
30 P4-00482
31 P4-00568
32 P4-00590
33 P4-00592
34 P4-01261
35 P4-04453
36 P4-04480
37 P4-04595
38 P4-04629
39 P4-04709
40 P4-04731
41 P5-04952
42 P5-05010
43 P5-05011
44 P5-05012
45 P5-05013
46 P5-06418
47 P5-06419
100" Deck Shown in assembly.
9
3
Mount decals approx. in area shown on
both sides of deck or dump body
Item Part # Rev Qty
Name
1 A4-00092
1 Body Switch
2 A4-00107
1 Warning Light
3 A4-01123
2 Hydraulic Hose .38x50"
4 A4-01292
2 Bumper, Stick-on
5 A4-01296
1 Mounting Bracket
6 A4-01297
1 Light Decal
7 A4-01304
1 Fuse Holder
8 A4-03313 A
1 Braided Duplex Cord/4
GAX16'-4"/Bl-Rd
9 A4-04684 3 Decal / Danger Crush. Hazard
10 A4-04685 2 Decal / Caution/Safety Prop
11 B3-01288
2 Hinge Pin Weldment
12 B4-04077
2 Medium LOGO / Plastic
13 B4-04135 2 Hyd. Ftg.-Elbow 90
14 C3-04574 A
1 Prop Weldment
15 D3-04734 1 Hoist Weldment
16 D3-04773 B
2 Pin Weldment, Deck Mount
17 D3-04775 1 Flatbead w/6" stringers - TC-515
18 D3-04783 D
1 Sub-Frame Weldment - Pick-up
19 D3-05019 2 Crossmember, Subframe
20 D3-05022 4 Weld., Frame Mount
21 D4-04737 B
1 Pivot Hinge - L.H.
22 D4-04738 2 Clamping Bar
23 D4-04749 B
1 Pivot Hinge - R.H.
24 D4-04759 2 Decal, "Starlifter"
25 D4-04772 2 Tube, Spacer
Page 7
6
1
F
8
1
Installer to hook
power supply cord
to battery
DETAIL H
2
1
27
9
Installer to mount items shown
in Detail H inside cab of truck.
0.055 lbm
0.098 lbm
3.718 lbm
0.128 lbm
0.012 lbm
1.234 lbm
0.374 lbm
0.600 lbm
2.253 lbm
20.000 lbm
0.158 lbm
0.010 lbm
1.224 lbm
27.291 lbm
0.357 lbm
1.469 lbm
2.798 lbm
0.333 lbm
1.103 lbm
0.778 lbm
0.242 lbm
Weight
J
J
29
16
Subframe mounting
hardware to ship
loose.
See sheet #2 for
mounting note.
Flatbed Removed
from This View.
"C1" hoist raise port
3
2
3
2
20
4
45
32
28
2
31
2
37
2
SHEET
None
SCALE:
TITLE:
1
43
4
34
4
19
2
OF
2
4/22/2008
DATE:
APPR. BY:
MATERIAL:
GerryL
DRAWN BY:
DWG. NO.
36
1
D1-04782
D
REV.
909.397 lbm
WEIGHT
FAX 717-375-2975
717-375-2900
Chambersburg, PA. 17201
5751 Molly Pitcher Highway
VIEW J-J
44
8
10
2
DATE
11/14/2011
Locate decal on side of
sub-frame in area shown.
Hoist & Subframe Ass'y - 100" TC-515
19
2
DETAIL G
13
2
"C2" hoist
lower port
See view F-F for attachment
location of hoses on cylinder.
1. REMOVE ALL BURRS, CHAMFER, OR
RADIUS CORNERS.
2. TOLERANCES UNLESS OTHERWISE
SHOWN:
DECIMALS
TWO PLACES
.00 ±.030
THREE PLACES .000 ±.005
ANGLES ±1°
3. DO NOT SCALE DRAWING.
42
16
DESCRIPTION
D Changed cyl. mount bolts from .50 to .56 dia.
REV.
Page 8
19
2
20
4
44
8
43
4
32
24
33
10
39
8
42
16
45
32
16
2
C
29
16
DETAIL B
32
24
35
18
45
32
27
9
42
16
45
32
DETAIL C
29
16
25
2
SECTION E-E
47
3
46
3
B
37
2
Attach 50" long hose to this
end of cylinder and to "C2"
hoist lower port on pump.
27
9
D
4
2
VIEW F-F
SECTION A-A
14
1
21
1
13
2
I
37
2
38
1
I
Attach36" long hose to this
end of cylinder and to "C1"
hoist raise port on pump.
36
1
13
2
35
18
33
10
30
2
35
18
DESCRIPTION
SHEET
None
SCALE:
TITLE:
2 OF 2
4/22/2008
DATE:
APPR. BY:
MATERIAL:
GerryL
DRAWN BY:
DWG. NO.
1
1
D1-04782
D
REV.
909.397 lbm
WEIGHT
FAX 717-375-2975
717-375-2900
Chambersburg, PA. 17201
5751 Molly Pitcher Highway
SECTION I-I
27
9
Hoist & Subframe Ass'y - 100" TC-515
1. REMOVE ALL BURRS, CHAMFER, OR
RADIUS CORNERS.
2. TOLERANCES UNLESS OTHERWISE
SHOWN:
DECIMALS
TWO PLACES
.00 ±.030
THREE PLACES .000 ±.005
ANGLES ±1°
3. DO NOT SCALE DRAWING.
41
4
22
2
Dump Bed Raised Lamp
Wiring Diagram
32
24
DATE
11/14/2011
Connecting wiring
by installer.
Ground
Dump
Switch
D Changed cyl. mount bolts from .50 to .56 dia.
REV.
Adjust lock nuts to open
switch contacts when deck
begins to rise off subframe.
DETAIL D
11
2
Hot Wire
From Truck
Electrical
System
The frame mount angles can be deleted from installation
if existing bed mount holes in the truck frame can be
used to bolt the 2 X 2 crossmember tube to the frame.
Do not drill any new holes in the top flange of the truck
frame-instead use the frame mount angles and drill
through the sides of the truck frame to align with holes in
mounting angles..
SECTION C-C
Deck not shown on this view for clarity
Dash
Pilot
Lamp
Fuse
9
Page 13
TruckCraft Corporation
5751 Molly Pitcher Hwy. S., Chambersburg, PA 17202
PRINTED IN U.S.A.
©2007 TRUCKCRAFT CORP.
LABOR SHALL BE CONSIDERED UNLESS AUTHORIZED BY THE MANUFACTURER.
CONSIDERED DEFECTS WITHIN THE SCOPE OF THE FOREGOING WARRANTY. NO CLAIMS FOR
RATED CAPACITY OR THE IMPROPER USE OR APPLICATION OF ANY PRODUCTS SHALL NOT BE
REASONABLE TIME TO CORRECT THE DEFECT. DEFECTS FOLLOWING OPERATION BEYOND
SUCH DEFECT OR DEFECTS WITHIN THE TWO YEAR WARRANTY PERIOD AND GIVEN A
TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP, PROVIDED MANUFACTURER IS NOTIFIED OF
MANUFACTURE, AT MANUFACTURER’S OPTION, ANY PART OR PARTS OF THE PRODUCT FOUND
REPAIR OR REPLACE AT ITS OWN EXPENSE, F.O.B. THE PLACE OR PLACES OF
SALE , LEASE, RENTAL, OR OTHER DISPOSITION OF SUCH PRODUCT, AND AGREES ONLY TO
IN MATERIAL AND WORKMANSHIP FOR A PERIOD OF TWO YEARS FROM THE DATE OF INITIAL
TRUCKCRAFT CORPORATION WARRANTS EACH STARLIFTER
D-ICER
TO BE FREE FROM DEFECTS
WARRANTY