DURACLASS 1715 Owner's manual

1715, 1715 DA,1721, 1721 DA,1821, 1821 DA
1824 HD, 1824 DA-HD OWNER’S & OPERATOR’S MANUAL

IMPORTANT SAFETY NOTICE
Proper service and repair are important to the safe, reliable operation of the DURACLASS
products. Service procedures recommended by DURACLASS are described in this service
manual and are effective for performing service operations. Some of these service operations
may require the use of tools or blocking devices specialty designed for the purpose. Special
tools should be used when and as recommended. It is important to note that some warnings
against the use of specic methods that can damage the product or render it unsafe are stated
in the service manual. It is as important to understand these warnings are not exhaustive.
DURACLASS could not possibly know, evaluate and advise the service trade of all conse-
quence of each way. Consequently, DURACLASS has not undertaken any such broad evalua-
tions. Accordingly, anyone who uses service procedures or tools which are not recommended
by DURACLASS must rst satisfy himself thoroughly that neither his safely nor the products
safety will be jeopardized by the method he selects.
"DURACLASS as manufacturer of the equipment that is covered by this manual, is providing
a product to the user who has acknowledged to have superior knowledge of the conditions
of the use to which the product will be put DURACLASS relies upon the user's superior
knowledge in specifying any changes or modications including but not limited to the inclu-
sion or non inclusion of options that are required by the user and the DURACLASS product,
and for the particular application of the user relative to the DURACLASS product."
WARRANTY
DURACLASS warrants this unit to be free from defects in material and workmanship, under normal
use and service, for a period of 1 year, said period to run from the date when rst placed into opera-
tion.
This warranty is expressedly limited to the replacement or repair at such place as DURACLASS may
designate, of such parts of such products as shall be returned to it with transportation charges prepaid
(all collect shipments will be refused) and which shall appear to its satisfaction, upon inspection at
such place designated by it, to have defective in material or workmanship. In lieu of such repair or
replacement. DURACLASS may elect to issue a credit or refund for such products.
This warranty does not apply to any unit of DURACLASS equipment which shall have been repaired
or altered outside of the DURACLASS so as to affect its stability or which has been subject to mis-
use, negligence or accident or which shall have been installed or operated other than in accordance
with the printed instructions of DURACLASS.
This warranty does not obligate DURACLASS to bear the cost of labor in replacing defective parts.
No other obligation is assumed or authorized to be assumed with respect to products of DURA-
CLASS other than herein set forth.
DURACLASS DOES NOT ASSUME ANY LIABILITY FOR SECONDARY CHARGES, EX-
PENSES FOR ERECTING OR DISCONNECTING, OR ANY OTHER CONSEQUENTIAL LOSS-
ES OR DAMAGES.
"WE MAKE NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND MAKE NO WARRANTY
OF MERCHANTABILITY OF FITNESS FOR ANY PARTICULAR PURPOSE."
"NO EMPLOYEE CAN CHANGE THIS WARRANTY, UNLESS APPROVED IN WRITING BY
THE GENERAL SALES MANAGER OR THE PRODUCT MANAGER."
DURACLASS

TABLE OF CONTENTS
SAFETY NOTICE
WARRANTY
SECTION I — INTRODUCTION .......................................................................1
Introduction............................................................................................1
Hoist Description...................................................................................1
SECTION II — OPERATING PROCEDURES................................................... 3
Safety Precautions................................................................................ .3
Hoist Capacity....................................................................................... 3
Caution Decal Index..............................................................................4
Storage Caution.....................................................................................7
Lowering A Raised Dump Body............................................................8
Operating Instructions .........................................................................
Power Take-Off Operation With
Manual Transmission.......................................................................11
Power Take-Off Operation With
Allison Transmission........................................................................12
Hoist Operation.....................................................................................13
Traveling Instructions...........................................................................14
SECTION III — MAINTENANCE INSTRUCTIONS .... .................................15
General...................................................................................................15
Maintenance Safety................................................................................15
Preventive Maintenance Instructions.....................................................17
Daily Maintenance.................................................................................17
Weekly Maintenance— Lubrication......................................................18
Monthly Maintenance Checks...............................................................19
6-Months Maintenance — Hydraulic Oil Change.................................20
Corrective Maintenance (Troubleshooting)...........................................20
Trouble Chart ........................................................................................21
Cylinder Repair......................................................................................24
Pump Repair...........................................................................................25
Control Valve Repair..............................................................................25
TED 73708-684
Page

WARNING
IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE
SEVERE INJURY. THOSE WHO USE AND MAINTAIN
THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER
USE, WARNED OF ITS DANGERS, AND SHOULD READ
THE INSTALLATION INSTRUCTIONS AND THE OPERA-
TOR'S MANUAL BEFORE ATTEMPTING TO SET UP, OP-
ERATE, ADJUST OR SERVICE THE EQUIPMENT.
The information and specications included in this
publication were in effect at the time of approval for
printing. DuraClass, Tishomingo, MS. reserves the
right, however, to discontinue or change specications
or design at any time without notice and without incur-
ring any obligation whatsoever.

1
SECTION I
INTRODUCTION
INTRODUCTION
This instruction manual has operation and maintenance information for DuraClass
Model 1715, 1721, 1821 and 1824 HD single-acting and 1715 DA, 1721 DA, 1821
DA and 1824 DA-HD double-acting, twin-arm type hydraulic hoists.
It's been prepared to acquaint you with the design features of the unit, and to instruct
you in its proper operation and maintenance.
Read this manual carefully before you operate or service one of the arm type hoists.
Remember that you're working with heavy equipment that can injure you or some-
one else. You can lessen the chance of injury by following the procedures in this
manual, carefully.
All Operator/Service people should review it carefully and become familiar with the
contents. This manual is to be retained in the glove box of the vehicle equipped with
this hoist for future reference for Operator and Maintenance Personnel. If anyone
else besides yourself operates or services this equipment, make sure they read this
manual and are instructed with all the safety procedures related to this equipment.
HOIST DESCRIPTION
DuraClass Model 1715, 1721, 1821 and 1824 HD hoists are single-acting, single
cylinder, twin-arm type hydraulic hoists (see Figure 1) whereas the Model 1715
DA, 1721 DA, 1821 DA and 1824 DA-HD hoists are double-acting, single cylin-
der, twin-arm type hydraulic hoists (see Figure 2). These hoists are designed for
use with DuraClass steel dump bodies on single or tandem axled chassis. Dumping
angle is 50 ° for all hoist models.

2
Figure 1. Typical Single-Acting, Twin-Arm Hoist
Figure 2. Typical Double-Acting, Twin-Arm Hoist

3
SECTION II
OPERATING PROCEDURES
SAFETY PRECAUTIONS
Before you start operating the hoist, familiarize yourself with the following
safety precautions.
HOIST CAPACITY
CAUTION
!
Do not exceed hoist capacities shown. Excessive loads will result in dan-
gerous operating conditions.
HOIST LIFTING CAPACITY*
HOIST
MODEL
BODY LENGTH MOUNTING
HEIGHT
CAPACITY BODY
& PAYLOAD
ft. m. in. mm
tons
U.S. Metric
1715 8 2.438 13-3/8 340 12.0 109
9 2.743 14-3/8 365 10.5 9.5
10 3.048 14-3/8 365 9.0 8.2
1721 9 2.743 14-3/8 365 13.5 12.2
10 3.048 14-3/8 365 12.0 10.9
1821 9 2.743 15-3/8 391 17.0 15.4
10 3.048 15-3/8 391 15.0 13.6
11 3.353 15-3/8 391 13.0 11.8
12 3.658 15-3/8 391 12.0 10.9
1824 HD 10 3.048 16-3/8 416 21.0 19.0
11 3.353 16-3/8 416 19.0 17.2
12 3658 16-3/8 416 17.0 15A
13 3.962 16-3/8 416 15.0 13.6
14 4267 16-3/8 416 14.0 12.7
(Cont)

4
HOIST
MODEL
BODY
LENGTH
MOUNTING
HEIGHT
CAPACITY
BODY
& PAYLOAD
ft. m. in. mm
tons
U.S. Metric
1715 DA 8 2.438 13-3/8 340 12.0 10.9
9 2.743 14-3/8 365 10.5 9.5
10 3.048 14-3/8 365 9.0 8.2
1721 DA 9 2.743 14-3/8 365 13.5 12.2
10 3.048 14-3/8 365 12.0 10.9
1821 DA 9 2.743 15-3/8 390 17.0 15.4
10 3.048 15-3/8 390 15.0 13.6
11 3.353 15-3/8 390 13.0 11.8
1824 DA-
HD
10 3.048 16-3/8 416 21.0 19.0
11 3.353 16-3/8 416 19.0 17.2
12 3.658 16-3/8 416 17.0 15.4
13 3.962 16-3/8 416 15.0 13.6
14 4.267 16-3/8 416 14.0 12.7
*Above capacities based on mounting body with 12 in. (305 mm) overhang from
hinge to end of body. Also assumes level loading, with center of gravity at mid-
point of body.
CAUTION DECAL INDEX
The following illustration shows the location of all caution and warning
decals. Following the illustration you will nd a listing of the cautions
contained on the decals. Familiarize yourself with all of the operating cau-
tions before you operate the hoist.
All decals must be kept clean and complete. Replace any decals which
are unreadable. Decals may be procured from your authorized DuraClass
Distributor.

5
Figure 3. Caution and Warning Decal Location

6
WARNING
DO NOT OPERATE OR SERVICE THIS MACHINE UNTIL
YOU HAVE READ AND UNDERSTAND THE OPERATION
AND MAINTENANCE MANUAL SUPPLIED WITH THIS
EQUIPMENT. MANUALS CAN ALSO BE OBTAINED FROM A
DURACLASS DISTRIBUTOR.
CAUTION
!
THIS VEHICLE EQUIPPED WITH HOIST OPERATING LEVER
LOCKOUT. HOIST CONTROL LEVER MUST BE ENGAGED IN
NEUTRAL POSITION WITH LEVER LOCK. OUT ENGAGED
IN LOCK POSITION WHENEVER HOIST IS NOT BEING OP-
ERATED.
CAUTION
!
WHENEVER THE BODY IS IN ANY ELEVATED OR RAISED
POSITION IT MUST BE SECURELY PROPPED OR BLOCKED
SO IT CANNOT FALL ON ANYONE.
CAUTION
!
For detailed PTO and HOIST operating and maintenance instruc-
tions, see manual. Whenever vehicle is in motion the HOIST con-
trol must be in the neutral position with lever lockout engaged in the
"lock" position and the PTO control in the OUT position.
CAUTION
!
1. DO NOT operate this equipment until you have read and understand
the "Operations Manual" or have been properly trained in its operation.
2. Whenever vehicle is in transit, the hoist control lever MUST BE in
neutral with lever lockout engaged in the "lock" position and the PTO
disengaged.
3. Tailgate controls MUST BE locked when the vehicle is in transit.
4. The vehicle MUST BE on level ground before dumping.

7
5. DO NOT dump on ground that has been recently excavated or lled with-
out being properly compacted.
6. Operator MUST REMAIN at the controls during the dumping cycle.
7. Tailgate controls MUST BE released before the front of the body is 2 feet
(0.6 m) above the chassis frame.
8. When operating, DO NOT allow anyone to stand in or move through the
area where the hoist operates, or into an area where an upset load might
fall.
9. When the truck is stored or not in use, the body MUST BE in the full
lowered position, and resting on the chassis or hoist frame. Ignition key
SHOULD BE removed from the ignition switch and the cab locked to
prevent tampering by unauthorized personnel.
10. Whenever the body is in any elevated or raised position for any repairs or
adjustments, it MUST BE securely propped or blocked so it can not fall
on anyone.
CAUTION
!
Whenever the body is in any elevated or raised position it must be securely
propped or blocked so it can not fall on anyone.
Be sure that body is unloaded before using body props.
CAUTION
!
BOTH BODY PROPS MUST ALWAYS BE USED.
STORAGE CAUTION
CAUTION
!
In all cases, when truck is stored or not in use, the body must be in the
fully lowered position and resting on the truck chassis or hoist frame. Key
should be removed from ignition and the cab locked to prevent tampering
by unauthorized people.

8
LOWERING A RAISED DUMP BODY
PROCEDURE FOR LOWERING A RAISED DUMP BODY
WHEN THE IN-CAB OPERATING CONTROLS BECOME IN-
OPERATIVE OR IF RAISED DUMP BODY WILL NOT LOWER
BECAUSE OF ANY OTHER REASON.
NEVER ENTER BETWEEN A RAISED DUMP BODY AND CHASSIS
FRAME AS IT MAY DESCEND AND CAUSE INJURY OR DEATH. READ
AND UNDERSTAND THE FOLLOWING INSTRUCTIONS BEFORE PRO-
CEEDING. RETAIN THIS BULLETIN WITH OWNERS, OPERATOR'S
AND MAINTENANCE MANUAL IN THE CHASSIS CAB FOR FUTURE
REFERENCE.
1. Make sure all persons are cleared at least 30' away from the vehicle
to avoid potential injury or death while performing the following
steps, unless otherwise indicated herein.
2. Set vehicle parking break and chock or block wheels securely so the
vehicle cannot move.
3. Either allow the load to nish dumping, or if part of load is stuck
in body, use a backhoe orfront end loaderto remove balance of load.
NOTE! Use extreme caution not to overturn vehicle.
4. Block the raised body with three (3) 6"x6" timbers of sufcient
length or railroad ties as shown to support body (and load if unable
to remove load).

9
Figure 4. Blocking the Body.
5. Connect a chain or cable sling to an overhead crane, truck crane,
large front end loader or other lifting device having adequate ca-
pacity to safely hold and lower the body and load.
6. Attach the chain or cable device with hooks, all of adequate lift
rating, to the body rubrail just behind the front crossmember as
shown. Snug up the tension on the sling with the crane, without
relieving the pressure from the body supporting timbers.
Figure 5. Lifting the Body

10
7. With the chocking and timber blocking still in place, from a posi-
tion on the ground, under the chassis frame, shift the control valve,
at the valve location, into the "Lower" position. If the valve is
spring centered, wire or lock the valve in the "Lower" position.
8. To prevent injury or death, move out from under the truck chas-
sis and clear all people from the area where the raised body could
potentially overturn. Use the crane mechanism to slightly raise
the dump body to relieve the pressure from the body supporting
timbers. Be sure the crane lifting device is securely attached to the
body and that both the crane and body are stable before removing
the body supporting timbers. Remove body supporting timbers,
being sure not to place your body or limb between the dump body
and chassis frame.
9. Using the crane, slowly lower the body in a controlled manner until
it is resting on the chassis frame.
10. Proceed to perform the repairs or replacement necessary to correct
the control mechanism failure, or other malfunction, by qualied
and trained personnel, such as your authorized DuraClass Distribu-
tor.
IF PROPER EQUIPMENT IS NOT AVAILABLE OR IF
YOU ARE INEXPERIENCED IN PERFORMING THE
ABOVE, DO NOT ATTEMPT TO LOWER THE BODY
OR ATTEMPT REPAIRS. IN EITHER CASE GET EX-
PERIENCED HELP AND PROPER EQUIPMENT BE-
FORE PROCEEDING. IF YOU SHOULD HAVE ANY
QUESTIONS CONCERNING ANYTHING CONTAINED
IN THESE INSTRUCTIONS, PLEASE CONTACT
DURACLASS FIELD SERVICE DEPT. [phone].

11
OPERATING INSTRUCTIONS
POWER TAKE-OFF OPERATION WITH MANUAL TRANSMISSION
CAUTION
!
Disengage PTO when hoist is not in use or when traveling on the
highway.
Figure 6. Standard Hoist Controls
To Engage Power Take-Off (PTO)
1. Place transmission shift lever in NEUTRAL.
2. Set hand brake.
3. Depress clutch pedal.
4. Shift PTO into gear.
5. Release clutch pedal.
Equipment is now ready to operate.
To Disengage PTO
1. Depress clutch pedal.
2. Shift PTO out of gear.
3. Release clutch pedal.
Truck is now ready to move.

12
POWER TAKE-OFF OPERATION WITH ALLISON TRANSMISSION
CAUTION
!
Disengage PTO when hoist is not in use or when traveling on
highway.
Figure 7. Optional Flat Controls
To engage Power Take-Off (PTO)
1. Stop the truck and set the hand brake.
2. With the Allison transmission in a gear position to provide a PTO
output at 45 to 60% of engine speed, engage PTO.
NOTE: Do not exceed RPM on the pump.
NOTE: If gears do not mesh, it may be necessary to let the truck
creep slightly in gear while putting slight pull on the PTO
control.
3. After PTO is engaged, move transmission shift lever to
NEUTRAL.Equipment is now ready to operate.
To disengage PTO
1. Move transmission shift lever into any gear position and shift
PTO
out of gear.
2. Move transmission shift lever to NEUTRAL.
Truck is now ready to move.

13
HOIST OPERATION
CAUTION
!
Whenever traveling on the highway, the hoist control in cab must
be in the neutral position with the hoist lever lockout engaged in the
"lock" position and the PTO disengaged
Figure 8. Optional Cable Control
To Raise Body — With PTO engaged and truck engine running at a
speed slightly faster than idle, release lever lock and move valve control
in cab to RAISE position (rearward).
To Hold Body — To hold in any position, move valve control in cab to
HOLD position. If body will be held in position any length of time, shift
PTO out of gear, and reengage lever lock.
To Lower Body — If lever lock is engaged, release and move valve con-
trol in cab to LOWER rosition (forward). When body is rmly resting
on chassis frame, disengage PTO and reengage hoist control lever lock.

14
TRAVELING INSTRUCTIONS
Observe the following cautions when traveling with your truck.
CAUTION
!
Disengage PTO when hoist is not in use or when traveling on the
highway. Do not move truck (loaded or unloaded) unless the body is
lowered and resting on truck frame.
CAUTION
!
Whenever traveling on the highway, the hoist control in cab must
be in the neutral position with the hoist lever lockout engaged in the
"lock" position and the PTO disengaged.

15
SECTION III
MAINTENANCE INSTRUCTIONS
GENERAL
Maintenance people whose job is to service and maintain this equipment
should have a basic understanding of the equipment and normal sequence
of operation. Refer to Sections I and II of this manual.
Maintenance in this section is divided into two parts — Preventive Mainte-
nance and Corrective Maintenance (Troubleshooting).
Preventive maintenance routines keep the equipment in proper working
condition. Preventive maintenance is not only desirable, but is necessary,
since scheduled inspection ensures continued trouble-free operation of the
equipment. It also prevents or at least detects at an early stage, mechanical
or hydraulic troubles that might otherwise develop into equipment mal-
function.
Corrective Maintenance (Troubleshooting) is the examination and repair or
replacement of the part or parts of the equipment that resulted in equipment
malfunction.
MAINTENANCE SAFETY
CAUTION
!
When any repairs or adjustments are made and body is fully or partly
raised, body must have props securely set or be blocked securely so it can-
not fall. In addition, the HOIST control lever must be in neutral with the
lever lockout engaged in the "lock" position and the PTO disengaged.
The following illustrations show how to correctly block the body when it
is in a raised position.

16
Figure 9. Blocking the Body with Factory Installed Props
CAUTION
!
Whenever the body is in any elevated or raised position it must be
securely propped or blocked so it cannot fall on anyone.
The illustration above shows how to block the body using the props sup-
plied with the hoist. Alternate methods for blocking are shown in follow-
ing illustrations.
Railroad tie or wood piece of approxi-
mate size 6" x 6" x 5 ft. (14 x 14 x 150
cm) to extend approximately 1 ft. (30
cm) each side of frame.
Place two 4" x 4"'s (9 x 9 cm) approxi-
mately 5 ft. (150 cm) long between tan-
dem tires and block securely against body
understructure.
Figure l0. Alternate Blocking Meathods