Proudly built in the USA. Owner s Manual TC-502 Metro Hoist, Sub-Frame, and Dump Body

Transcription

1 Proudly built in the USA Owner s Manual TC-50 Metro Hoist, Sub-Frame, and Dump Body TruckCraft Corporation Chambersburg, PA Copyright c 009

2 TruckCraft Corporation Rev. - - /7/09 I5-059 TRUCKCRAFT CORPORATION 575 Molly Pitcher Hwy. S. Chambersburg, Pa. 70 Tel Phone Fax "WHERE WORKMANSHIP IS EVERYTHING" Table of Contents Preface.. Ordering Repair Parts Safety Information.. Certifying and Labeling Truck. Mounting Instructions 5 Maintenance... Parts List..9 Warranty.

3 TruckCraft Corporation Rev. - - /7/09 I5-059 Preface Read and understand all sections of this manual prior to installing or operating the TruckCraft Metro. This manual contains information for the installation, operation, and maintenance of the TruckCraft Metro Dump Body, Hoist and Sub-Frame. 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. If you cannot locate a dealer near you, contact TruckCraft Corporation. When ordering parts the dumper assembly serial number, pump serial number and description or part number of parts needed are required. The dumper serial number is located on the drivers side of the front face (behind truck cab) of the dumper body. The pump serial number is located on the top of the valve block. Dumper Serial Number: Pump Serial Number: Date of Purchase: Purchased From: TruckCraft Telephone # or TruckCraft Fax # 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.

4 Safety Information Observe the following safety procedures during the use of the hoist and dump body: 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. TruckCraft Corporation Rev. - - /7/09 I5-059 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 FIGURE body in a raised position. Always release the tailgate or side latches prior to raising the dump body when it is loaded. The latches should not be released with a load against the tailgate or side. 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 pivot pins are installed at the rear of the truck and the red warning light is off, indicating that the body is all the way down, before operating the truck. Regularly check and tighten all mounting fasteners to the recommended torque values in the Torque Chart shown below. Maximum hydraulic pressure is factory set at 00 PSI. Tampering Torque Chart - Steel Fasteners 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 FIGURE Size Grade 5 (Lb-Ft) Grade (Lb-Ft) / /- -9-5/ / / / /

5 TruckCraft Corporation Rev. - - /7/09 I5-059 Certifying and Labeling Truck after mounting a TruckCraft Metro body According to the National Highway Traffic Administration, NHTSA, regulations a manufacturer is a person who performs a manufacturing operation on a new incomplete vehicle. A Final Stage Manufacturer is a person who performs such manufacturing operations on an incomplete vehicle that it becomes a complete vehicle. It is the responsibility of this Final Manufacturer to affix an approved label to the vehicle certifying that the vehicle meets all applicable Federal Motor Vehicle Safety Standards. Pickup trucks ordered with the box delete option are incomplete vehicles and must be labeled as noted above when installing a Metro body or dump assembly. Removal of a pickup box to install a Metro body or dump assembly on a truck before the first purchase of the vehicle is considered an alteration and requires the one performing the alteration affix an altered certification label in an approved location. The label must state that, as altered, the vehicle conforms to all applicable Safety Standards affected by the alteration. Note: The original certification label must not be removed from the vehicle. It is strongly recommended that anyone contemplating mounting a TruckCraft Metro body and not familiar with the regulations obtain a copy of the National Truck Equipment Association s, NTEA s, Vehicle Certification Guide. Thoroughly read and understanding all sections of this guide before attempting to certify a completed vehicle. The Guide, free to NTEA members, costs $9 and can be purchased on the NTEA website, Below are answers/recommendations to key certification questions:. What must an end-user/manufacturer do in order to be able to certify a completed vehicle? Per the NTEA Guide pages C and C, Chapter, all manufacturers need to register with the NHTSA on form (9 CFR 566) - a copy of which is included in the book.. Will the pickup safely handle the weight of the Metro and payload? The Incomplete Vehicle Manual usually contains information on calculating maximum completed vehicle weights and acceptable horizontal and vertical combined centers of gravity for compliance to the Federal Motor Vehicle Safety Standards. If the box is removed from a pickup or the above information is not supplied, this information should be obtained from the truck dealer and calculations need to be performed to make sure weight limits are not exceeded. Based on the maximum axle weight limitations, calculations should also be run to determine the maximum payload capacity of the dump body.

6 TruckCraft Corporation Rev. - - /7/09 I What are the steps to certifying and labeling the completed vehicle? Chapter 5, pages F through F, of the NTEA Guide outline this procedure when certification is within the guidelines of the Incomplete Vehicle Certification. Incomplete Vehicle Certification labels, item #59, can be purchased from the NTEA in quantities of 00 labels per order. Chapter 6, pages G through 5G, of the NTEA Guide outline this procedure when certification is within the guidelines of an Altered Vehicle Certification. Altered Vehicle Certification labels, item #00, can be purchased from the NTEA in quantities of 50 labels per order.. What are the Tire and Loading label requirements? Vehicles with a gross vehicle weight rating (GVWR) of 0,000# or less are required to have a Tire and Loading label. Chapter 7, H through H, of the NTEA Guide outlines the procedure for calculating the data on this label. This label, item #0, can also be purchased in quantities of 60 from the NTEA.

7 TruckCraft Corporation Rev. - - /7/09 I5-059 Mounting Instructions CAUTION: Verify lifting and support devices can support the hoist, sub frame, and dump body combined weight before picking up the assembly. The hoist, sub-frame and dump body are normally shipped assembled and ready to install on a truck frame-see Figure. Solid connections between the truck frame and the sub-frame are required at the front and rear of the sub-frame. For recent Ford and GM trucks, bolt on mounting brackets are available from TruckCraft. " '-6" " A Figure 56" Figure 5 Showing typical mounting of the Metro on a Ford Pickup frame. Section A-A, shown below, depicts the typical front mounting and Figure 5, on the next page, depicts the rear mounting with a Ford mounting bracket.. Set the assembly on top of the frame Metro subframe and position it from the cab as shown above in Figure.. Position the sub-frame mounting brackets as shown in Section A-A and Figure (Ford Frame) Front Mounting bracket 5. Attach the Sub-frame with bolts provided and torque all mounting bolts per SECTION A-A Truck frame Figure on page (0-90 Lb-Ft). Caution: Never drill holes in the top flange of the truck frame. If mounting on trucks by other manufacturers requires drilling through the sides of the frame, be careful of wiring, brake lines, etc. inside frame when drilling. Always follow the truck manufacturer s guidelines for location and size if adding holes to the frame.. Mount cab guard, light bar, bumper hitch, and fenders if supplied.. 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. A 5

8 TruckCraft Corporation Rev. - - /7/09 I Plug in two wiring harnesses (Ford) or splice into existing wiring as required. 6. Route power supply cable to battery and hook up leads to battery. 7. Make sure all blocking and tiedowns used for shipping are removed. Make sure the two pivot locking pins are on the rear pivots-see decal on the deck rub rail. Activate the remote control up button and carefully raise the body toward the rear. Do not reach under or place any body parts under the dump body. Raise the body up completely. Pull the hair cotter pin on the safety prop and slide the prop off the stow pin. With the prop hanging freely on the support shaft, replace the cotter pin. Slowly lower the hoist until the saddle on the prop rests on the pin on the sub-frame see Figure 6. Do not power down the hoist after the prop rests on the pin. With the prop in this position it is now safe to work under the dump body.. With the safety prop supporting the dump body and the truck level, check the depth of the oil in the hydraulic reservoir. The depth of the fluid in the tank at this position should be. Use automatic transmission fluid only to fill the reservoir to this level. 9. Apply grease at six grease zerks, see Figure 7: ) One on the hoist/sub frame pivot pin ) One on the hoist/deck pivot pin ) One on the upper hoist attach pin ) One on the lower hoist attach pin 5) One on the cylinder Rod end/hoist attach pin. 6) One on the hoist link arm cross shaft Metro subframe Rear Mounting Bracket (Ford Frame) Truck Frame FIGURE 5 Safety prop show resting on pin on sub-frame-proper position for prop when working under dump body. Figure 7 Figure

9 TruckCraft Corporation Rev. - - /7/09 I Install the light, mount bracket and decal shown in figure 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 9 to connect the wiring. Note: Wire not supplied by Truck- Craft. 0. Place the two decals A-06 and D-0509 inside the cab on the dash in an easy to read location.. Connect the marker light wiring harness to the truck wiring.. Push the remote control up button. Raise the hoist high enough to swing 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. Figure Warning: Never use the safety prop to support a loaded deck. Never position yourself under a loaded deck. Figure 9-Dump Bed Raised Lamp Wiring Diagram 7

10 TruckCraft Corporation Rev. - - /7/09 I5-059 Maintenance. 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.. Depending on frequency of use, apply grease to all rotating parts at six grease zerks.. Check to make sure that the bed up warning light illuminates when the bed begins to raise. Adjust switch or replace bulb as required.. Check maximum side tip angle. Adjust the two switches at the hoist pivot as required to assure that the side tip angle does not exceed 5 degrees to either side. 5. Depending on frequency of use, check all bolts for proper tightness and torque.

11 # P/N Rev Qty Description Material Mass D Weldment, Deck 5.6 lbm D Post, Left/Use P lbm D Post, Right/Use P lbm D Drop Down Side Ass'y 0.76 lbm 5 D Tailgate Ass'y.5 lbm 6 D U-Bolt, Tie Down Make from P lbm 7 D Pin, Hinge 0 S.S.,.75 Dia. x. Lg. 0. lbm P-006 Hex Head Cap Screw.6 - x.75, Zinc Plated, Grade.79 lbm 9 P Nyl. Insert Lock Nut/GR.6- ZP Steel/Gr.69 lbm 0 D Sub-Frame Weldment 7.06 lbm D Weld., Hitch Ball Socket 7. lbm P Thrust Washer Iglide #5-05,.5x.5x.059 Thk. 0.0 lbm P Flat Washer ZP Stl,.5 ID X.5 OD X.075 Thk. 0.5 lbm D-0505 Weld., Hoist Pivot.005 lbm 5 P-0057 Flat Washer / MS SS Stainless Steel, 0,.75" 0.06 lbm 6 P5-06 Nyl. Insert Lock Nut.75-0 ZP-Gr lbm 7 D Weldment, Hoist 0.0 lbm D Cylinder.0 Bore x.5 Rod x 6.0 Stoke 9.9 lbm 9 D Weld., Cyl Mount.9 lbm 0 D Weldment, Link Arm.7 lbm D Link Arm, Hoist A6 Stl,.5 x. x.56. lbm P Flat Washer -. SS. - SS 0.5 lbm P-0096 Hex Head Cap Screw.-6 X.5 - SS All Thd 0.75 lbm D-090 A Socket Nylatron or approved equal 0.7 lbm 5 P Hitch Ball-" 9.50 lbm 6 D Weld., Deck Hinge.66 lbm 7 D Weld., Cab Gaurd.77 lbm D-096 Sheet/ Cab Gaurd Side Alum. 505-H.5"x.5"x.0".99 lbm 9 D-097 Sheet / Cab Gaurd Center Alum. 505-H.5"x.5" x 9.5".5 lbm 0 B-079 Bent Pin Assembly 0.66 lbm P-0065 Hex Head Cap Screw.-6 X.5 - SS.7 lbm P Nyl. Insert Lock Nut -.-6 SS.-6 - S.S..07 lbm P Rubber cushioned pipe strap S.S.-McMaster #5T 0.6 lbm P Hex Hd Cap Screw X.75 SS.5-0 X.75 - SS 0.6 lbm 5 P-099 Hex Serrated-Flange Nut S.S lbm 6 P-057 Roll Pin -.9 X.75 SS.9 Ø X.75 0 S.S. 0.0 lbm 7 P-006 Hex Hd Cap Screw, /-6 x.5lg /-6nc, Grade, Zinc plated 0.0 lbm P-007 Nyl. Insert Lock Nut.-6 Zinc Plated 0.50 lbm 9 P-0056 Hex Head Cap Screw.-6 X.5 - SS 0.7 lbm 0 P-0 - Roll Pin.09 Ø X. Lg. - S.S lbm P-09 6 Pin -# Hairpin Cotter Steel-ZP.77" Rd. 0.0 lbm P Flat Washer -.5 SS.5 - S.S lbm P Screw-Button Hd. Hex Socket Screw SS -/-0 x.50"lg,hex Socket 0.6 lbm P Rivet,.9 SS/Magna-Lok (Short).9 Ø Grip/ S.S lbm 5 A Grommet,.5" Purchased 0.0 lbm 6 A Light, Clearance.50 Dia. LED Yellow Light 0.09 lbm 7 A Light, Clearance.50 Dia. LED Red Light.00 lbm P Grommet TruckLite #60700-Rubber 0.5 lbm 9 P Stop/Turn/Tail LED Light Trucklite #6650R 0.6 lbm 50 P Light-Back-up Trucklite #60C.09 lbm 5 P Hex Head Cap Screw /-6nc X.5, Grade, Zinc plated.6 lbm REV. DESCRIPTION - /7/009 # P/N Rev Qty Description Material Mass 5 P-007 Flat Washer. Zinc Plated 0. lbm 5 D Weld., Light Bar 9.55 lbm 5 A-06 License Plate Light Purchased 0.07 lbm 55 P-005 Flat Washer #0 - S.S lbm 56 P-0 Combo Pan Head Screw #-/" # x /" lg S.S. 0.0 lbm 57 P-0056 Hex Hd Cap Screw -.-6 X.00 SS.-6 X.00 - SS 0. lbm 5 P Flat Washer-Hardened ZP Steel/.69 ID x. OD x. Thk 0.90 lbm 59 D Weld., Fender Mount/Front.6 lbm 60 D Weldment, Fender 6.96 lbm 6 D Weld., Fender Mount/Rear.6 lbm 6 A-0009 Body Switch Purchased 0.60 lbm 6 D Plate, Switch A6 Steel,. x. x lbm 6 P-00 - Hyd. Power Supply Monach Model #M lbm 65 P-0056 Lock Washer. - S.S. 0.0 lbm 66 P-0066 Hex Head Cap Screw /-6nc X.00, Grade, Zinc plated 0.09 lbm 67 D Safety Prop 7. lbm 6 A-00 Hairpin Purchased Part 0.09 lbm 69 P Nyl. Insert Lock Nut.50- ZP 0.0 lbm 70 P-0059 Flat Washer.50 ZP 0.50 lbm 7 P-0067 Hex Head Cap Screw.50- X.00 Gr 5 ZP 0.5 lbm 7 B-05 - Hyd. Ftg.-Elbow 90 Steel -. JIC X #6 SAE 0.7 lbm 7 P-000 Pin, Slotted Spring, /6" x.00 - Stainless Steel 0.0 lbm 7 P Lube Fitting Straight Drive,.9" 0.07 lbm 75 P Hyd. Ftg.-Straight Steel -. JIC X #6 SAE 0.5 lbm 76 A-006 _ Hyd. Hose. JIC Swivel x 6" 0.7 lbm 77 A-0 Hydraulic Hose.x50" 0.7 lbm 7 A-06 - Decal / Danger Crush. Hazard Purchased Part lbm 79 D Decal, Dumping Instructions Polyethylene, low density 0. lbm 0 A-0 A Braided Duplex Power Cord / GA. / Black-Red / 6'-" lg. 7.0 lbm D Weld. Front Mount/RH/Ford 6.0 lbm * D Wiring Harness, Stop/Turn/Tail ABS Plastic lbm * D Wiring Harness, Bed (None) lbm D Weld. Rear Mount/LH/Ford.9 lbm 5 D Weld. Front Mount/LH/Ford 6.0 lbm 6 P5-050 Hex Head Cap Screw.6 - x.50", Zinc Plated, Grade.5 lbm 7 B-0077 Medium LOGO / Plastic Purchased lbm A-097 Light Decal Aluminum, 606-T lbm 9 A-00 Fuse Holder Purchased 0.09 lbm 90 D Decal / Caution/Safety Prop 0. lbm 9 A-096 Mounting Bracket Purchased 0.00 lbm 9 A-0007 Warning Light Purchased 0.00 lbm 9 D Weld. Rear Mount/RH/Ford 5.57 lbm 9 D-05 - Step Weld., Side 6.6 lbm 95 D Hitch, Frame Mount 60.0 lbm 96 D Decal / Caution/Tailgate 0.06 lbm REMOVE ALL BURRS, CHAMFER, OR RADIUS CORNERS. TOLERANCES UNLESS OTHERWISE SHOWN: 575 Molly Pitcher Highway DECIMALS Chambersburg, PA. 70 TWO PLACES.00 ±.00 THREE PLACES.000 ± ANGLES ± DO NOT SCALE DRAWING. FAX TITLE: WEIGHT Metro TC-50.5 lbm SCALE: DATE: MATERIAL: None SHEET OF /0/009 APPR. BY: DRAWN BY: DWG. NO. GerryL D REV DATE

12 K K 6 6 SECTION H-H F F I I SECTION D-D D D E E A A B REV. DESCRIPTION - /7/009 C C B H SECT. C-C H G G REMOVE ALL BURRS, CHAMFER, OR RADIUS CORNERS. TOLERANCES UNLESS OTHERWISE SHOWN: DECIMALS TWO PLACES.00 ±.00 THREE PLACES.000 ±.005 ANGLES ± DO NOT SCALE DRAWING. TITLE: Molly Pitcher Highway Chambersburg, PA FAX WEIGHT Metro TC-50.5 lbm SCALE: DATE: MATERIAL: None SHEET OF /0/009 APPR. BY: DRAWN BY: DWG. NO. GerryL D REV DATE

13 SECTION J-J REV. DESCRIPTION - /7/ SECTION I-I SECTION B-B 9 SECTION A-A 50 SECTION E-E SECTION G-G J J VIEW K-K 6 REMOVE ALL BURRS, CHAMFER, OR RADIUS CORNERS. TOLERANCES UNLESS OTHERWISE SHOWN: DECIMALS TWO PLACES.00 ±.00 THREE PLACES.000 ±.005 ANGLES ± DO NOT SCALE DRAWING. TITLE: 0 SCALE: DATE: MATERIAL: None SHEET OF APPR. BY: DRAWN BY: DWG. NO. 575 Molly Pitcher Highway Chambersburg, PA FAX WEIGHT Metro TC-50.5 lbm /0/ SECTION F-F GerryL 79 D REV DATE

14 Page Page TO BE FREE FROM DEFECTS TruckCraft Corporation 575 Molly Pitcher Hwy. S., Chambersburg, PA 70 PRINTED IN U.S.A. 007 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 Metro TRUCKCRAFT CORPORATION WARRANTS EACH D-ICER WARRANTY