VENCO VC-416 ES Operating instructions

6245
-
6-13-00C
8-18-00D
TABLE OF CONTENTS
VP / VC - 6D SUPERCEDES
TITLE DATE SECTION
TABLE OF CONTENTS
VP / VC - 6D MANUAL
PAGE DESCRIPTION REF.NO.
1 GENERALINFORMATION ...................................................... 6246
2 PREPARATION-MOUNTINGHOIST ........................................ 6241
3 UPPERNEST& REARHINGES .............................................. 6248
4 HOISTFRAMEONCHASSIS .................................................. 6242
5 LONGITUDINALSUPPORTS-OPTION .................................... 6244
6 HYDRAULICS ......................................................................... 6122
7 EDHOISTPOWERUNIT(BI-ROT) ........................................... 6096
8 6425 ED POWER UNIT PLUMBING & WIRING ......................... 6493
9 6425EDPOWERUNITW/PUSHBUTTONINSTALLATION........ 6500
10 6426 ES POWER UNIT ............................................................ 6506
11 6426 ES POWER UNIT W/ PUSH BUTTON CONTOL ................. 6507
12 RESERVOIRFILLING ............................................................. 416140
13 ESHOISTPOWERUNIT ......................................................... 6133B
14 DASH CONTROL SWITCH ....................................................... 6123
15 DASHCONTROLDRAWING ................................................... 40124
16 UPPERNEST PIVOTS- BODY ............................................... 6243
17 UPPERNEST PIVOTS-UPPER NEST .................................... 6251
18 FUELFILLERTUBE-SUPPORT ............................................. 6252
19 BUMPERBRACKETS ............................................................ 6072
20 LUBRICATION/SERVICECHART ........................................... 40260
21 BUMPER,GREASEFITTINGS,DECALS ................................. 6118
22 CONTRACTORREARHINGE&UPPERPIVOTS ..................... 6250
23 HOISTREPLACEMENTPARTSDRAWING .............................. 6255
24 HOISTREPLACEMENTPARTSLIST ....................................... 6256
25 FENNERESPARTSLIST ....................................................... 40058-2
26 MTEED(BI-ROT)6136POWERUNIT .................................... 6097
27 REPLACEMENT PARTS DWG - ED POWER UNIT .................... 6486
28 REPLACEMENT PARTS LIST - ED POWER UNIT .................... 6487
29 REPLACEMENT PARTS DRAWING ES POWER UNIT .............. 6508
30 REPLACEMENT PARTS LIST ES POWER UNIT ....................... 6509
31 WARRANTYPAGE ................................................................ 12-00073
-PDECALSANDPACKAGEINCLUDES:
12524 CAUTIONSTANDCLEAR 2 PCS.
416052 CAUTIONDECAL 2 PCS.
6066 PLASTICBAG 1 PC.
12-00075 ENVELOPE 1 PC.
MANUFACTURING,INC.
BOOKMARKS
THUMBNAILS

VP/VC-6D HOIST SPECIFICATIONS OVERVIEW
VP - PICK-UP PowerSource:
VC-CONTRACTOR ES - Electric Single Acting
6-*6000lbs.CAPACITY ED - Electric Double Acting
Designed for: '94 - Current Dodge 1/2 & 3/4 ton pickup trucks and club cabs
NOTE: Foroptional longitudinal body supports-add30lbs.
Recommended if payload is in excess of 1000 lbs.
1/2ton&some3/4tontrucksmayrequireoverload/helperspringstokeephoistfrombeing
toolow.
Suggestedmaximum capacityforpick-up bed
Specifications:
Weight - 265 lbs (ES/ED)
Cylinder - 3-1/2" dia, 12-7/8" stroke
Operating Pressure - 2400 psi "up" (ES/ED) and 650 psi "down" (ED only)
12-VoltElectricHydraulicSingleActingPump(Option-DoubleActingPump)
Factoryassembledscissorswithbasemountingfasteningtochassisframecrossmember-bolt
on& no welding. Welding onlyrequiredonUpperNest Pivot Assemblies.
IMPORTANT: Toavoidcostlydelaysininstallationandimproperoperation,readandunderstandthis
manualinitsentiretybeforeproceeding.
WARNING: Wheneverworkormaintenanceisperformedonatruckunderaraisedbody,always
remembertopropthebodyupwiththeoptionalsafetyprop(40042)oranothersafe
methodtoavoidinjuryfromthebodyinadvertentlyfalling.
6246
H200
7-6-98A
1-19-99B
SPECIFICATIONS
VP/VC-6D SUPERCEDES
TITLE DATE SECTION
HTGNELACGNAHREVO°04TAYTICAPAC
'7"65"0snot34.3
'8"65"01snot97.3
'9"65"22snot05.4
•Cab to axle dimensions may differ
resulting in a change in capacities
shown.
•Capacities include weight of body
which must be deducted to
determinepayload.
Caution - Weight of chassis
combinedwithweightofbody,hoist
andpayloadcannotexceedGVWR
orGAWRoftruck.
PLATFORM AND DUMP APPLICATIONS
*
MANUFACTURING,INC.

6241
H200
10-24-94
7-6-98A
INST INSTRUCTIONS
VP/VC-6D SUPERCEDES
TITLE DATE SECTION
VP-6D DODGE PICKUP HOIST INSTALLATION INSTRUCTIONS
1. Removepick-upbumperandpickupbodyandremovesparetirewinchextensionatrightof
licenseplate bracket. Keeptheextension and brackettobe reinstalledlater. Disconnect
taillightsoranyotherelectricalitemsattachedtothebed(pickupbody). Savethebedbolts.
2B. Afterremovingthepickupbody,cutthetaperedpartattherearofthechassisframeasshown
inFIGURE2B.
2C. See FIGURE 2C. Cut 4-5/8 inches off the driver side (left side) of the Hoist Frame Upper
PivotShaft (1-1/2" dia. x21" - ref.)
3. RearHinge:
6248 - SeeFigure3A. Fastenthelowerrearhingetotherearofthetruckframerailcut-out
in step 2B with the 1/2"-13 x 1" bolts, nuts and lock washers (3 each required per
lowerrearhinge). Iftheholesinthelowerrearhingedon'talignwiththeholesinthe
framematchdrilltheholesusingthelowerrearhingeasaguide. Fastentheupper
rearhinge(withthecollarstowardinside)totherearbedcrossmembersusingthe
bed bolts - see Figure 3B.
4. UpperNest:
6248 - See Figure 4. Offset theUpperNest2-1/2"towardtherightside(curb side). Use
5/16"-18x 3" bolts to fastenthe Upper Nest tothe under side of thepickup bed.
MANUFACTURING,INC.

TITLE SECTION
SUPERCEDES
DATE
6248
H200
1-31-95
7-6-98AINSTALLATION DRAWING
VP/VC-6D
MANUFACTURING,INC.

6242
H200
10-24-94
7-6-98A
INST INSTRUCTIONS
VP/VC-6D SUPERCEDES
TITLE DATE SECTION
5&6.LongitudinalSupports (optional)&Plastic Pads:
- See instructions on page 6244
7. HoistMainframe:
TheHoistMainframeisoffset2-1/2inchestowardthecurbside(rightside). Put3/8"-16x3"
bolts with flat washer up through the inside of the chassis frame rails on each side of the
crossmemberandupthroughthe2inchsquaretube-7/16"holethrougheachendoftubeand
put3/8"lockwasherandhexnutonthetopsideofthetube. Usethe4holesinthe1/4"thick
Base Plate as a guide to drill four 5/16" dia. holes through the front flange of the chassis
crossmember- seeFIGURE7Dbelow.
8. Hydraulics:
Powerunitcanbe mounted under the hood at the auxiliary batterylocation-rightside, but
longerhosesarerequiredone13FT.andone14FT. Otherwise,mountPowerUnitsameas
specified in the instructions - See instructions on pages 6122, 6096, and 6133B.
9. Electrical:
Connectthebatterycabletothepositiveleadinthefuseboxnexttothebatteryunderthehood.
10. DashControlSwitch:
- See instructions on page 6123
MANUFACTURING,INC.

TITLE SECTION
SUPERCEDES
DATE
6244
H200
1-30-95
7-6-98INSTALLATION DRAWING
VP/VC-6D
MANUFACTURING,INC.

6122
H200
11-6-95
7-6-98
INST INSTRUCTIONS
VP/VC-6D, VP/VC-6R SUPERCEDES
TITLE DATE SECTION
8. InstallingHydraulics:
Important- Besuretoblowdirtandothermaterialoutofthehose(s)withcompressedair
topreventthehydraulicsystemfrombeingcontaminated.
A. ED(Electric Double Acting) Power Unit:See Dwg. 6096 (Bi-rotationalpower unit)
1. Installtheshorthydraulichosetothefull/baseendofthecylinder. Connectthelong
hydraulichosetotherodendofthecylinder. Directhosestotherightoftheframe.
2. Install the ED (Electric Double Acting) Power Unit (6136 Bi-Rotational) on the
outsideoftheframejustforwardoftherightrearfrontspringhanger. Put1/2"pipe
spacers1-1/4"longbetweenframeandpowerunit,ifrequired. Boltthroughframe
andpipeintosideofpowerunit-use3/8"-16bolts,3/8"washersandlockwashers
(2 each required). Be sure not to drill through cables running on inside of truck
longsills. Connecttheshort(pressure)hoseandlong(return)hoseasshownon
Dwg. 6096.
B. ES (Electric Single Acting) Power Unit: See Dwg. 6133B
Installbreather#40226intorod-endportofcylinder. Installhosetothefull/baseend
ofcylinder. Mountpowerunittotruckframewith3/8"-16bolts,3/8"lockwashersand
washersoninsideoftruckframetopreventinterferencewithsideoftruckbed.
NOTE: Be sure hoses are not crimped and use cable ties to secure hoses in a safe
mannerbetweencylinderandpowerunit.
NOTE: Checkhydraulicfluidlevelinpowerunitreservoir. Iffluidisrequired,useDextron
II- ATF,mobileDTE 13 orequivilent. Fill3/4" fromthetop of thereservoir.
MANUFACTURING,INC.

6493 -
2-8-00 10-27-00A
6425 ED POWER UNIT VP6S SUPERCEDES
TITLE DATE SECTION
MANUFACTURING,INC.
6425 ED (DOUBLE ACTING)
POWER UNIT

6500 -
10-27-00A 8-24-01B
6425 ED POWER UNIT VP6S SUPERCEDES
TITLE DATE SECTION
MANUFACTURING,INC.
6425 ED WITH MONARCH PUSH BUTTON CONTROL
416533 MONARCH PUSH BUTTON CONTROL
NOTE: ENERGIZING 'G' COIL SENDS FLOW TO 'C1' PORT (HOIST UP) ENERGIZING 'R' COIL SENDS FLOW TO 'C2' PORT (HOIST DOWN)
BLKWHT
RED GRN
C2PORT

6506 -
6-9-00A 8-2-01B
6426 ES POWER UNIT VP6S SUPERCEDES
TITLE DATE SECTION
MANUFACTURING,INC.
6426 ES (SINGLE ACTING) POWER UNIT
NOTE: ENERGIZING'B'COIL RELEASES 'C1' PORT ENERGIZING SOLENOID COIL SENDS FLOW TO 'C1' PORT
B
WGTO BAT.
POST 416527
WIRINGHARNESS
SWITCH
BREATHER PLUG
B
W

6507 -
5-30-00 6-9-00A6426 ES PWR UNIT W/ PUSHBUTTON INST.
VP6S
MANUFACTURING, INC.
6426 ES (SINGLE ACTING) POWER UNIT
NOTE: ENERGIZING 'B' COIL RELEASES 'C1' PORT ENERGIZING SOLENOID COIL SENDS FLOW TO 'C1' PORT
B
WGTO BAT.
POST
BREATHER PLUG
6501 MONARCH PUSH BUTTON CONTROL

TITLE SECTION
SUPERCEDES
DATE
416140
H300
2-1-94
9-15-97
FILLING HYD. RESERV.
VP/VC6(R) - VC520
INSTRUCTIONS FOR FILLING THE RESERVOIR OF
ELECTRIC HYDRAULIC POWER UNITS
THEFOLLOWINGHOISTMODELSAREINCLUDED:
VP/VC-6(R), VC-416/516, VC-520 - ES & ED
PROCEDURE
STEP 1 - On 416, 516, 520 ES models only, do not attach rod
end hose to the cylinder until after completing Steps 2
thru 6.
STEP 2 - Removethe reservoirbreather. Withthe hoistinthe
downposition,fillthereservoirwithATF-DextronII
(MobileDTE 13or equivalent)- 3.5qts. for416, 516,
520 and 2 qts. for VP-6(R).
STEP3- Raisethehoisthalfway(22-25°dumpangle,
approx. 8" of cylinder stroke).
STEP 4 - Fillthe reservoirwith anadditional 2qts.for VP-6(R),
416, 516 and 3 qts. for 520.
STEP 5 - Raise the hoist completely.
STEP 6 - Refillthereservoirwiththeremainingfluidrequired.
STEP 7 - Attach hose to rod end of cylinder on the 416, 516,
520 ES models.
MODELNO. RESERVOIRCAPACITY TOTAL
FLUIDREQ'D
VP/VC-6(R)ED 2QTS. 3.5QTS
VC-416ES/ED 4QTS. 5.5QTS
VC-516ES/ED 4QTS. 7.5QTS
VC-520ES/ED 4QTS. 9.0QTS.
Example: VC-416ES/EDHoist
Step 2 - Add 3.5 qts.
Step 3 - Add 2.0 qts.
Step 4 - Add0.0qts(nonereq'd)
= 5.5 qts. total
MANUFACTURING,INC.

6123
H200
7-7-98A
1-16-02B
INST INSTRUCTIONS
VP/VC-6D, VP/VC-6R SUPERCEDES
TITLE DATE SECTION
10. DashControlSwitchInstallation: SeeDwg.40124
- Installdashmountingplateunderthedashinaconvenientlocationforoperatorcontrol.
Usethe#12panheadslottedscrews, 1/2"long, furnishedin kit.
- Installswitchextensionontotoggleswitch.
- Connectcenterpostofswitchtothe20ampin-linefuse.
Connectfusetohotleadunderdash.
- Connectthe16/2SJOcableinthefollowingmanner:
Connectonewireleadtotoppole,andtheotherleadtothelowerpoleofswitch. Runcable
tothepowerunit.
Single Acting: See Dwg. 6133B, 6506, 6507.
Double Acting: See Dwg. 6096, 6493, 6500.
MANUFACTURING,INC.

40124 H200
1-22-90A 5-15-98B
DASH CONTROL INSTALLATION VP/VC-6 SERIES SUPERCEDES
TITLE DATE SECTION
MANUFACTURING,INC.

6243
H200
7-7-98
2-22-01A
INST INSTRUCTIONS
VP/VC-6D SUPERCEDES
TITLE DATE SECTION
11. UpperNestPivotAssemblies:
BesuretheshortUpperPivotAssemblyisontheleftsideandnothittingtheFuelTank.
BesurethattheverticalflangeontheUpperPivotAssemblyistowardthecab. SeeFigure
7D on page 6242 and Figure 11 below.
12. InstallingBodyonTruck:
BesurethePowerUnitandHoistareoperatingproperly. CycletheHoistupanddown
2-3timesbeforeinstallingthebodyonthetruckframe-chassis. Placethebodybackon
thepickupchassisandinstalltherearhingepivotpins(1"dia.x5-1/16"-2required). The
headonthe hingepinshouldbeontheoutsideofthehinge. Usea 1/4"x1-3/4"rollpin
throughthecollarontheinsideofthehingeandthroughtheholeinthehingepinonboth
hinges. Loosenthebedboltsontherearhingetopositionthebodysquare(lefttoright)
with the truck cab. Tighten all the fasteners on the rear hinges (left and right) before
continuing.
MANUFACTURING,INC.

6251
H200
7-7-98A
10-1-99B
INST INSTRUCTIONS
VP/VC-6D SUPERCEDES
TITLE DATE SECTION
13A.Attaching Upper Nest Pivots to Upper Nest: See Figure 13A
BesuretheflangesontheUpperPivotarepositionedasspecifiedinStep11,withthe
vertical flange toward the cab. Power the hoist upward so the Upper Pivots make
contactwiththeUpperNest. Theknuckleofthehoistscissorsshouldbepushed(with
abottlejackora2x4)upwardasfaraspossibletomisstheAxle/RearEndHousing.
Besurethebodyisnotliftedbypushinguptheknuckleofthescissors. Ifrequired,shim
betweenthe Lower Arm and theBasePlateAssemblyto keep the scissors knuckle
frombeingtoolow. ChecktoseeiftheUpperPivotsarestillagainsttheUpperNest
-Ifnot,thenactivatehoistupslowlyuntilUpperPivotsmakecontactwiththeUppernest.
checktosee if the body is stillsquarewithcab.
WARNING: CovertheFueltankwithwatersoakedtowelsornon-flammablematerialbefore
weldingtheUpperNestPivots.
Fromunderthetruck,weldtheUpperNestPivotstotheUpperNestwith1/4"filletwelds
2"longtwoplacesoneachUpperPivot. Pushthecollarontheuppershaftagainstthe
UpperPivot(1perpivot). Weldtheinsideedgeofthecollarstotheupperpivotshaft.
Raisethehoistandsafelypropthebodyintheupposition. Completeweldingofthe
Upper Pivots to the Upper Nest - 1/4" continuous fillet weld all around. Add 1-1/2"
channel forward (toward cab) of LEFT Upper Pivot - weld to Upper Nest and Upper
Pivot. BesureLEFT Pivotclears -doesnothit-thefueltankorfuelfiller.
13B.Fastenthesparetirewinchextensionpipetothewinch. Slidethebracket(1/8"plate
1-1/2"x2"with7/8"dia.hole)overtheendofthewinchextensionpipe. Puttheoriginal
plasticgrommetforthewinchextensionpipeintheoriginallocationintherearofthe
bodytotherightsideofthelicenseplate. Removethebodypropandstandclearofthe
body. Lowerthebody. Centertheendoftheextensionpipewiththeplasticgrommet
attherearofthetruck. Fromunderthetruck,weldthebrackettothecrossmemberas
showninFigure13Babove.
MANUFACTURING,INC.