TruckCraft TC-515 User manual
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.
1
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
2
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
3
56
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.
4
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
5
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
6
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
D
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
1.
2.
3.
None
Hoist & Subframe Ass'y - 100" TC-515 909.397 lbm
D1-04782
GerryL2
1
4/22/2008
REV.
WEIGHT
D
G
DETAIL G
28
2
E
E
27
9
Flatbed Removed
from This View.
27
946
347
3
27
9
40
1
18
1
A
A
C
C
F F
See view F-F for attachment
location of hoses on cylinder.
100" Deck Shown in assembly.
H
DETAIL H
8
1
Installer to hook
power supply cord
to battery
Installer to mount items shown
in Detail H inside cab of truck.
10
2
Mount Decals shipped
loose in truck cab.
Mount decals approx. in area shown on
both sides of deck or dump body
J
J
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.
12
2
24
2
9
3
17
1
7
1
5
1
2
1
6
1
15
1
10
2
19
2
"C1" hoist raise port
"C2" hoist
lower port
36
1
31
2
13
2
45
32
42
16
29
16
43
434
444
8
20
4
19
2
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
3
2
3
237
2
9
3
26
1
Page 7
DATE
DESCRIPTION
REV.
Changed cyl. mount bolts from .50 to .56 dia. 11/14/2011
D
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
1.
2.
3.
None
Hoist & Subframe Ass'y - 100" TC-515 909.397 lbm
D1-04782
GerryL2
2
4/22/2008
REV.
WEIGHT
D
SECTION E-E
C
DETAIL C
27
9
SECTION A-A
B
DETAIL B
SECTION C-C
D
DETAIL D
VIEW F-F
37
2
13
2
37
2
36
1
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.
14
1
38
1
4
2
Fuse
Pilot
Hot Wire
From Truck
Electrical
System
Dash
Dump
Switch
Ground
Wiring Diagram
Dump Bed Raised Lamp
Lamp
Connecting wiring
by installer.
I
I
SECTION I-I
Adjust lock nuts to open
switch contacts when deck
begins to rise off subframe.
1
1
25
2
16
2
Deck not shown on this view for clarity
22
2
27
9
35
18
35
18
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
2
35
18
30
2
33
10
27
9
41
4
39
8
32
24
33
10
21
1
32
24
19
2
20
4
32
24
29
16 45
32
42
16
13
2
43
4
44
8
29
16 45
32
45
32
42
16
46
3
47
3
Page 8
WARRANTY
TRUCKCRAFT CORPORATION WARRANTS EACH D-ICER TO BE FREE FROM DEFECTS
IN MATERIAL AND WORKMANSHIP FOR A PERIOD OF TWO YEARS FROM THE DATE OF INITIAL
SALE , LEASE, RENTAL, OR OTHER DISPOSITION OF SUCH PRODUCT, AND AGREES ONLY TO
REPAIR OR REPLACE AT ITS OWN EXPENSE, F.O.B. THE PLACE OR PLACES OF
MANUFACTURE, AT MANUFACTURER’S OPTION, ANY PART OR PARTS OF THE PRODUCT FOUND
TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP, PROVIDED MANUFACTURER IS NOTIFIED OF
SUCH DEFECT OR DEFECTS WITHIN THE TWO YEAR WARRANTY PERIOD AND GIVEN A
REASONABLE TIME TO CORRECT THE DEFECT. DEFECTS FOLLOWING OPERATION BEYOND
RATED CAPACITY OR THE IMPROPER USE OR APPLICATION OF ANY PRODUCTS SHALL NOT BE
CONSIDERED DEFECTS WITHIN THE SCOPE OF THE FOREGOING WARRANTY. NO CLAIMS FOR
LABOR SHALL BE CONSIDERED UNLESS AUTHORIZED BY THE MANUFACTURER.
TruckCraft Corporation
5751 Molly Pitcher Hwy. S., Chambersburg, PA 17202
PRINTED IN U.S.A.
©2007 TRUCKCRAFT CORP.
Page 13
STARLIFTER
9
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