TruckCraft TC-515 Manual de usuario

Proudly built in the USA

Owner’sManual TC-515

Hoist,Sub-Frame,

and Flatbed

TruckCraft Corporation Chambersburg, PA 1-800-755-3867 Copyright c 2008

www.TruckCraft.com

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

"WHERE WORKMANSHIP IS EVERYTHING"

TruckCraft Corporation Rev. - - 12/9/08 I5-04953

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 TC-

515 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, Com-

mon 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 re-

serve 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 up-

to-date with current design changes.

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

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

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 val-

ues 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.

TruckCraft Corporation Rev. - - 12/9/08 I5-04953

FIGURE 1

FIGURE 2

FIGURE 3

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

Torque Chart - Steel Fasteners

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

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 sub-

frame as required. The front

mount should be located as close

as possible to the hoist cylinder

mount on the subframe-see Detail A.

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.

TruckCraft Corporation Rev. - - 12/9/08 I5-04953

100

3 Min.

Figure 4

Relocate frame

mount crossmember

as required.

35.2

1.12

2.25

70.18

2.25

DETAIL A

Locate this Frame Crossmember

as close to center of hoist mount

as possible.

Mounting Angle

Center of

Hoist Mount

2.25

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 mem-

bers to angles with bolts

supplied—see Figure 5. Additional holes can be drilled in the sub-frame as re-

quired. . Caution: Be careful of wiring, brake lines, etc. inside frame when drill-

ing. 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.

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 hoist-

see figure 6. Carefully

lower the hoist until the

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 posi-

tion it is now safe to work

under the deck.

6. With the safety prop sup-

porting the deck and the

truck level, check the depth

of the oil in the hydraulic

reservoir. The depth of the

fluid in the tank at this posi-

tion should be 3”. Use automatic transmission fluid only to fill the reservoir to

this level.

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.

Figure 6

Safety prop shown resting on hoist

cross shaft - proper position for prop

when working under deck.

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

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 sche-

matic shown in figure 8 to con-

nect 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 loca-

tion.

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.

TruckCraft Corporation Rev. - - 12/9/08 I5-04953

Warning:

Never use the safety prop to support a loaded deck. Never position yourself un-

der a loaded deck.

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.

DATE

DESCRIPTION

REV.

Changed cyl. mount bolts from .50 to .56 dia. 11/14/2011

SHEET OF DRAWN BY: DWG. NO.

TITLE:

SCALE: DATE: MATERIAL:

APPR. BY:

REMOVE ALL BURRS, CHAMFER, OR

RADIUS CORNERS.

TOLERANCES UNLESS OTHERWISE

SHOWN:

DECIMALS

TWO PLACES .00 ±.030

THREE PLACES .000 ±.005

ANGLES ±1°

DO NOT SCALE DRAWIN G.

5751 Molly Pitcher Highway

Chambersburg, PA. 17201

717-375-2900

FAX 717-375-2975

None

Hoist & Subframe Ass'y - 100" TC-515 909.397 lbm

D1-04782

GerryL2

4/22/2008

REV.

WEIGHT

DETAIL G

Flatbed Removed

from This View.

946

347

F F

See view F-F for attachment

location of hoses on cylinder.

100" Deck Shown in assembly.

DETAIL H

Installer to hook

power supply cord

to battery

Installer to mount items shown

in Detail H inside cab of truck.

Mount Decals shipped

loose in truck cab.

Mount decals approx. in area shown on

both sides of deck or dump body

VIEW J-J

Locate decal on side of

sub-frame in area shown.

Subframe mounting

hardware to ship

loose.

See sheet #2 for

mounting note.

"C1" hoist raise port

"C2" hoist

lower port

434

444

Item Part # Rev Qty Name Weight

1 A4-00092 1 Body Switch 0.203 lbm

2 A4-00107 1 Warning Light 0.001 lbm

3 A4-01123 2 Hydraulic Hose .38x50" 1.437 lbm

4A4-01292 2Bumper, Stick-on 0.036 lbm

5A4-01296 1Mounting Bracket 0.002 lbm

6A4-01297 1Light Decal 0.004 lbm

7 A4-01304 1 Fuse Holder 0.029 lbm

8 A4-03313 A 1 Braided Duplex Cord/4

GAX16'-4"/Bl-Rd

7.034 lbm

9 A4-04684 - 3 Decal / Danger Crush. Hazard 0.096 lbm

10 A4-04685 - 2 Decal / Caution/Safety Prop 0.129 lbm

11 B3-01288 2 Hinge Pin Weldment 6.134 lbm

12 B4-04077 2Medium LOGO / Plastic 0.000 lbm

13 B4-04135 - 2 Hyd. Ftg.-Elbow 90 0.273 lbm

14 C3-04574 A 1 Prop Weldment 7.539 lbm

15 D3-04734 - 1 Hoist Weldment 197.410 lbm

16 D3-04773 B 2 Pin Weldment, Deck Mount 11.569 lbm

17 D3-04775 - 1 Flatbead w/6" stringers - TC-515 356.680 lbm

18 D3-04783 D 1 Sub-Frame Weldment - Pick-up 149.080 lbm

19 D3-05019 - 2 Crossmember, Subframe 34.045 lbm

20 D3-05022 - 4 Weld., Frame Mount 17.684 lbm

21 D4-04737 B 1 Pivot Hinge - L.H. 2.400 lbm

22 D4-04738 - 2 Clamping Bar 1.612 lbm

23 D4-04749 B 1 Pivot Hinge - R.H. 2.400 lbm

24 D4-04759 - 2 Decal, "Starlifter" 0.251 lbm

25 D4-04772 - 2 Tube, Spacer 0.546 lbm

Item Part # Rev Qty Name Weight

26 I5-04953 1Manual, TC-515

27 P4-00375 9 Lube Fitting 0.055 lbm

28 P4-00466 2 Hex Head Cap Screw 0.098 lbm

29 P4-00468 16 Hex Head Cap Screw 3.718 lbm

30 P4-00482 2 Hex Flange Nut 0.128 lbm

31 P4-00568 2 Lock Washer 0.012 lbm

32 P4-00590 24 Nyl. Insert Lock Nut 1.234 lbm

33 P4-00592 10 Flat Washer 0.374 lbm

34 P4-01261 4 Nyl. Insert Lock Nut 0.600 lbm

35 P4-04453 18 Hex Head Cap Screw 2.253 lbm

36 P4-04480 - 1 Hyd. Power Supply 20.000 lbm

37 P4-04595 - 2 Hyd. Ftg.-Straight 0.158 lbm

38 P4-04629 - 1 Roll Pin - .19 X 2.00 SS 0.010 lbm

39 P4-04709 - 8 Hex Hd Cap Screw 1.224 lbm

40 P4-04731 - 1 Cylinder 27.291 lbm

41 P5-04952 - 4 Washer, Shim 0.357 lbm

42 P5-05010 16 Nyl. Insert Lock Nut/GR 8 1.469 lbm

43 P5-05011 4 Hex Head Cap Screw Gr 8 2.798 lbm

44 P5-05012 8 Flat Washer-Hardened-3/4 0.333 lbm

45 P5-05013 32 Flat Washer-Hardened-5/8 1.103 lbm

46 P5-06418 - 3 Hex Head Cap Screw 0.778 lbm

47 P5-06419 - 3 Nyl. Insert Lock Nut 0.242 lbm

237

Page 7

DATE

DESCRIPTION

REV.

Changed cyl. mount bolts from .50 to .56 dia. 11/14/2011

SHEET OF DRAWN BY: DWG. NO.

TITLE:

SCALE: DATE: MATERIAL:

APPR. BY:

REMOVE ALL BURRS, CHAMFER, OR

RADIUS CORNERS.

TOLERANCES UNLESS OTHERWISE

SHOWN:

DECIMALS

TWO PLACES .00 ±.030

THREE PLACES .000 ±.005

ANGLES ±1°

DO NOT SCALE DRAWIN G.

5751 Molly Pitcher Highway

Chambersburg, PA. 17201

717-375-2900

FAX 717-375-2975

None

Hoist & Subframe Ass'y - 100" TC-515 909.397 lbm

D1-04782

GerryL2

4/22/2008

REV.

WEIGHT

SECTION E-E

DETAIL C

SECTION A-A

DETAIL B

SECTION C-C

DETAIL D

VIEW F-F

Attach 50" long hose to this

end of cylinder and to "C2"

hoist lower port on pump.

Attach36" long hose to this

end of cylinder and to "C1"

hoist raise port on pump.

Fuse

Pilot

Hot Wire

From Truck

Electrical

System

Dash

Dump

Switch

Ground

Wiring Diagram

Dump Bed Raised Lamp

Lamp

Connecting wiring

by installer.

SECTION I-I

Adjust lock nuts to open

switch contacts when deck

begins to rise off subframe.

Deck not shown on this view for clarity

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.. 11

16 45

Page 8

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