Proudly Built In The USA Owner’s Manual TC-503 With .

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Proudly built in the USAOwner’sManual TC-503withTailgateorBarnDoorsHoist, Sub-Frame,Dump Body and OptionsTruckCraft CorporationChambersburg, PAwww.TruckCraft.com1-800-755-3867Copyright c 2012

TruckCraft CorporationRev. - - 4/20/12TRUCKCRAFT CORPORATION5751 Molly Pitcher Hwy. S.Chambersburg, Pa. 17201Tel. 800.375.3867Phone 699"WHERE WORKMANSHIP IS EVERYTHING"Table of ContentsPreface . 1Ordering Repair Parts 1Safety Information . 2Certifying and Labeling Chassis-Cabs . 3Mounting Instructions . 5Maintenance . 8Parts Lists:Hoist & Sub-frame . 9Dump Body Installation . 11Body with side door & rear barn doors-50” Sides 12Body without side door & rear barn doors-50” Sides. . 14Body with side door & rear barn doors-40” Sides 16Parts List: Tailgate with Coal Chute & Barn Doors (Option) . 18Parts List: Tarp Installation (Option). . 19Parts List: 40” long Cabguard (Option). . 20Parts List: Hitch Plate Installation (Option) . . 21Warranty . 22The TruckCraft hoists are designed for use with TruckCraft’s 9’-9” and11’-5” aluminum dump bodies.

TruckCraft CorporationRev. - - 4/20/12I5-06699PrefaceRead and understand all sections of this manual priorto installing or operating the TruckCraft hoist. This manualcontains information for the installation, operation, and maintenance of theTruckCraft TC-503 Hoist, Sub-Frame and Dump Body. Proper care and operation of the unit will assure years of dependable service. Your local TruckCraftDealer will instruct you in its general operation. TruckCraft Corporation will beglad to answer any questions that may arise regarding the operation of yourunit.Ordering Repair PartsWhen service is necessary, your local TruckCraft dealer can provide assistance.Always obtain original TruckCraft replacement parts from your dealer. Substituteitems could affect the performance and warranty of the unit. Dealers in yourarea can be found on the web at www.TruckCraft.com.When ordering parts the dumper assembly serial number, pump serial numberand description or part number of parts needed are required. The dumper se-rial number is located on the drivers side of the front face (behindtruck cab) of the dumper body. The pump serial number is locatedon the top of the valve block.Dumper Serial Number:Pump Serial Number:Date of Purchase:Purchased From:TruckCraft Telephone #800.375.3867 or 717.375.2900TruckCraft Fax #717.375.2975Method 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, orfaxed, to insure proper understanding of request.Having preventative maintenance parts on hand could save valuable time.Improvements and ChangesBecause 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 theequipment already sold. Photographs used in this manual may not be upto-date with current design changes.1

TruckCraft CorporationRev. A - 4/20/12I5-06699Safety InformationObserve the following safety procedures during the use of the hoist and dumpbody: Before operating read and understand all information furnished withyour hoist and in this manual.Keep hands, feet and clothing awayfrom moving parts.Keep hinge pins and bushings wellgreased-inspect regularly for properoperation during rotation.Never exceed the rating of the hoist ,truck, axles, or tires. Make certainFIGURE 1the load is evenly distributed.Never work under a raised body unless the body is supported by blockingor propped in the raisedposition. Always unload thebody prior to using theprop.Operate the hoist onlywhen the truck is on a firm,level surface.Always inspect the areaFIGURE 2around the truck for safe dumping prior to operating the hoist.Do not move the truck with the body in a raised position.Always release the tailgate pins prior to raising the dump body when it isloaded. The tailgate pins should not be released with a load against thetailgate.Store the remote control in a location that assures that no object can comein contact with the raise button unintentionally.Before raising the dumper, check for adequate overhead clearance. Bealert for overhead electrical wires.Always ensure that the red warning light is off, indicating that the body is allthe way down, before operating the truck.Regularly check and tighten all fasteners to the recommended torque values in the Torque Chart shown below.Maximum hydraulic pressure isfactory set at 3200 PSI. TamperingTorque Chart - Steel Fastenerswith this setting can damage hySize Grade 5 (Lb-Ft) Grade 8 (Lb-Ft)draulic components and result in1/4-206-710-11system failure.1/4-288-911-12Use automatic transmission fluid in5/16-1814-1521-22the hydraulic reservoir. Check3/8-1624-2637-40regularly and keep clean.FIGURE 0315-3302

TruckCraft CorporationRev. - - 4/20/12I5-06699Certifying and Labeling Chassis-Cabs aftermounting TruckCraft dump bodyNew chassis-cabs are supplied by the manufacturer with incomplete vehicledocumentation (IVD). According to the National Highway Traffic Administration,”NHTSA”, regulations a “manufacturer” is a person who performs a manufacturingoperation on a new incomplete vehicle. A Final Stage Manufacturer is a person whoperforms such manufacturing operations on an incomplete vehicle that it becomes acomplete 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. Regulations also require certification in many instanceswhen mounting a dump body on a used chassis-cab.It is strongly recommended that anyone contemplating mounting a TruckCraftdump body and not familiar with the regulations obtain a copy of the National TruckEquipment Association’s, “NTEA’s”, “Vehicle Certification Guide”. Thoroughly readand understanding all sections of this guide before attempting to certify a completedvehicle. The “Guide”, free to NTEA members, can be purchased on the NTEA website, www.NTEA.com.Below are answers/recommendations to key certification questions:1) If the end-user purchases a new cab-chassis and mounts the dump body, does thecompleted vehicle need to be certified?Per the NTEA “Guide” page 9B, “When the ultimate customer purchases an incomplete vehicle and installs additional equipment, he becomes, in effect, a manufacturerand thus is subject to the certification and registration requirements of the Act.”2) What must an end-user/manufacturer do in order to be able to certify a completedvehicle?Per the NTEA “Guide” pages 1C and 2C, Chapter 1, all manufacturers need to registerwith the NHTSA on form (49 CFR 566) - a copy of which is included in the book.3) Will the chassis-cab safely handle the weight of the dump body 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 notsupplied with the chassis-cab, this information should be obtained from the truckdealer and calculations need to be performed to make sure 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.3

TruckCraft CorporationRev. - - 4/20/12I5-066994) What are the steps to certifying and labeling the completed vehicle?Chapter 5, pages 1F through 4F, of the NTEA “Guide” outline this procedure whencertification is within the guidelines of the Incomplete Vehicle Manual. Certificationlabels, item #2159, can be purchased from the NTEA in quantities of 100 labels perorder.5) What are the Tire and Loading label requirements?Vehicles with a gross vehicle weight rating (GVWR) of 10,000# or less are requiredto have a Tire and Loading label. Chapter 7, 1H through 4H, of the NTEA “Guide”outlines the procedure for calculating the data on this label. This label, item #1220,can also be purchased in quantities of 60 from the NTEA.4

TruckCraft CorporationRev. - - 4/20/12I5-06699Mounting InstructionsCAUTION: 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 readyto install on a truck frame-see Figure 4. Truck manufacturers recommend that the subframe does not contact the top of the frame. A gap can be established by attaching 1/4”Make sure there is solid contact between the frame and sub-frame at the rear mount.thick wooden strips on top of the frame or installing a spacer layer of adhesive backed,high strength neoprene rubber on top of the frame. However, solid connections betweenthe truck frame and the sub-frame are required at the location where the hoist pins to thesub-frame and at therear of the frame.When mountingwith a 1/4” gap, thesteel spacers supplied with the kitneed to be installedbetween the truckframe and the subframe at the hoist mount location-see Detail A. This spacer can be eliminated if the subframe is mounted directly on top of the truck frame with no space between the two.1. Set the assembly on top of the frame or spacer and position it a minimum of 3.5”from the cab as shown above in Figure 4. Always make sure there is a solid connection between the sub-frame and the truck frame at the rear in the dump body pivotarea and the hoist mount area shown in detail “A”. If the rear pivot centerline extends beyond the rear of the frame, an angle iron brace or similar structure can bewelded across the back of the frame to support the pivot.2. Position the sub-frame mounting brackets along the sides of the frame in an areawhere the brackets do not interfere with existing frame bolts or hardware-see Figure5. Flipping the brackets or moving to alternate holes drilled in the sub-frame usually5

TruckCraft CorporationRev. - - 4/20/12I5-06699eliminates interference. However, additional holes can bedrilled in the sub-frame as required. Use shims supplied tofill any gaps between themounting brackets and theframe or sub-frame. Mark thelocation for mounting holes inthe frame and drill 8 holes (12on TC-430) 21/32” diameterfor 5/8” grade 8 bolts supplied.Caution: Be careful of wiring, brake lines, etc. inside frame when drilling. Installbolts, nuts and 2 washers per hole and torque to 180 FT-LBS.3. Route control cable into cab and install remote control box in an area where theup 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. Activatedthe remote control up button and carefully raise the body. Do not reach under orplace any body parts under the dump body. Raise the body up about half way toCAUTION:The TruckCraft assembly is designed to bolt to the truck frame. No welding isrequired. Do not weld any part of this assembly to the truck frame.Openings have been provided in the side of the sub-frame for fuel tank fillspouts. If additional holes are required in the sub-frame, the holes must be amaximum of 2.5” in diameter and centered in the web. Never cut the top or bottom flanges of the sub-frame.about 30 degrees fromhorizontal. Rotate thesafety prop counterclockwise until it restson the angle stop onthe hoist-see figure 6.Carefully lower thehoist until the crossshaft of the hoist restson the prop. Do notpower down thehoist after the shaftrests on the prop.With the prop in thisposition it is now safeto work under thedump body.6

TruckCraft CorporationRev. - - 4/20/12I5-066996. With the safety prop supporting the dump body and the truck level, check thedepth of the oil in the hydraulic reservoir. The depth of the fluid in the tank at thisposition should be 3”. Use automatic transmission fluid only to fill the reservoirto this level.7. Apply grease at nine grease zerks:One on rod end of cylinderOne on barrel end of cylinderWarning:Never use the safety prop to support a loaded deck. Never position yourself under a loaded deck.FuseTwo on the cross shaft at thedeckTwo on the hoist cross shaft atthe sub-frame mountOne on each deck pivot hinge atrear of sub-frameOne on the hoist link arm crossshaft8. Install the light, mount bracketand decal shown in figure 7 onthe dash inside the cab of thetruck. Using the fuse holder, wirethe light to the dump switch mounted on the front of the sub-frame across fromthe hydraulic reservoir. Use the schematic shown in figure 8 to connect the wiring. Note: Wire not supplied by TruckCraft.9. Place the two decals A4-04684Dashand A4-04685 inside the cab onPilotLampthe dash in an easy to read location.Dump10. Connect the marker light wiringSwitchharness to the truck wiring.11. Push the remote control up button. Raise the hoist high enough Hot WireTruckto drop the safety prop back into FromElectricalGroundSystemits storage position. Cycle thehoist through the complete strokeConnecting wiringof the telescope cylinder a coupleby installer.times to make sure everythingworks properly.Figure 8: Dump Bed RaisedLamp Wiring Diagram7

TruckCraft CorporationRev. - - 4/20/12I5-06699Maintenance1. Depending on frequency of use, check hydraulic reservoir level and addoil. Periodically drain system and replace with clean oil. Use automatictransmission fluid only.2. Depending on frequency of use, apply grease to all rotating parts at ninegrease zerks.3. Check to make sure that the bed up warning light illuminates when thebed begins to raise. Adjust switch or replace bulb as required.4. Depending on frequency of use, check all bolts for proper tightness andtorque.8

Page 9FCCSECTION I-I34.125191279A103279132A431201Ship switch loose. Installerto mount to deck.Ship Decals Loose.Installer to mount on deck.113Attach 50" hose to this endof cylider and to "C2" hoistlower port on pump.3845352EE361261II351DETAIL H61G10321171112F91236246Installer to hookItem #9 to batteryHMount decals shippedloose in truck cab.21Installer to mount items shownin Detail H inside cab of truck.383391Attach 36" hose to this end ofcylinder and to "C1" hoist raiseport on pump.Note Manual P/N;I6-04686 TC-520, TC-530 & TC-540I5-06301 TC-420, TC-430 & TC-43581VIEW F-F171141279JJ424824629282364128424829284128"C1" hoist raise port31See view F-F for attachmentlocation of hoses on cylinder.312Hot WireFrom EETNoneSCALE:25225241281OF22/15/2008DATE:APPR. BY:MATERIAL:GerryLDRAWN BY:DWG. NO.LREV.620.77 lbmWEIGHTFAX 717-375-2975717-375-2900Chambersburg, PA. 172015751 Molly Pitcher Highway292811232343424D1-04829Hoist & Subframe-6" Cyl.1. REMOVE ALL BURRS, CHAMFER, ORRADIUS CORNERS.2. TOLERANCES UNLESS OTHERWISESHOWN:DECIMALSTWO PLACES.00 .030THREE PLACES .000 .005ANGLES 1 3. DO NOT SCALE DRAWING.TITLE:351DETAIL GVIEW J-J41"C2" hoist lower portDATE2/8/2012Connecting wiringby installer.GroundDumpSwitchDeck Mount Plates Changed,Charted BillsDump Bed Raised LampWiring DiagramLREV.Fuse

1-04829 6" Cylinder/84" CATC-530/135, 140, & 145" DecksTC-430/11'-0" BodyTC-435/11'-5" BodyTC-503/11'-5" BodyItem 223422411123142848123D1-06517 6" Cylinder/120 " CATC-540/170" DeckItem 12111132221421211Hoist Ass'y P/ND1‐04828D1‐04829D1‐06517WeightBody Switch0.20 lbmWarning Light0.00 lbmHyd. Hose .38 JIC Swivelx36"0.72 lbmHyd. Hose .38 JIC Swivelx50"0.72 lbmBumper, Stick-on0.04 lbmMounting Bracket0.00 lbmLight Decal0.00 lbmFuse Holder0.03 lbmBraided Duplex Cord/4 GAX16'-4"/Bl-Rd 7.03 lbmDecal / Danger Crush. Hazard0.10 lbmDecal / Caution/Safety Prop0.13 lbmHinge Pin Weldment6.13 lbmMedium LOGO / Plastic0.00 lbmHyd. Ftg.-Elbow 900.14 lbmClamping Bar1.42 lbmWeld., Mounting Spacer7.44 lbmProp Weldment7.54 lbmPlate, Mounting3.19 lbmSub-Frame Weldment154.64 lbmHoist Weldment264.57 lbmFrame Extension Weldment36.93 lbmPivot Hinge4.80 lbmSpacer, Frame Mount0.68 lbmMount Plate11.26 lbmAngle, Frame Spacer2.82 lbmManualLube Fitting0.06 lbmHex Head Cap Screw0.10 lbmHex Head Cap Screw6.51 lbmHex Flange Nut0.13 lbmLock Washer0.01 lbmNyl. Insert Lock Nut1.75 lbmFlat Washer0.07 lbmHex Head Cap Screw3.00 lbmHyd. Power Supply20.00 lbmCylinder39.99 lbmHex Head Cap Screw2.84 lbmHyd. Ftg.-Straight0.24 lbmRoll Pin - .19 X 2.00 SS0.01 lbmWasher, Shim0.36 lbmNyl. Insert Lock Nut/GR 82.57 lbmFlat Washer-Hardened-5/81.65 lbmHex Head Cap Screw0.30 lbmHex Head Cap Screw0.52 lbmNyl. Insert Lock Nut0.24 lbmNameD1-04828 6" Cylinder/60 " CATC-520/110 & 115" DecksTC-420/9'-4" BodyTC-503/9'-9" BodyPart 4-04774I6-04686See -06419Page 10"B"D3‐04549D3‐04549D3‐05558DETAIL C1823424323429284248CDDETAIL B1624128424837123234BSlide Spacer, Item #16 betweenhoist and flatbed stringer.3234SHEETNoneSCALE:TITLE:2224042 OF 22/15/2008DATE:APPR. BY:MATERIAL:GerryLDRAWN BY:DWG. NO.DATE2/8/2012D1-04829LREV.620.77 lbmWEIGHTFAX 717-375-2975717-375-2900Chambersburg, PA. 172015751 Molly Pitcher Highway279DESCRIPTIONHoist & Subframe-6" Cyl.1. REMOVE ALL BURRS, CHAMFER, ORRADIUS CORNERS.2. TOLERANCES UNLESS OTHERWISESHOWN:DECIMALSTWO PLACES.00 .030THREE PLACES .000 .005ANGLES 1 3. DO NOT SCALE DRAWING.279361DETAIL DSECTION C-C1221543424SECTION E-E4423023323424Deck Mount Plates Changed,Charted BillsSECTION A-ALREV.

6"A"L7-01422Rev 00TC‐50311'‐5"TC‐503SideModel Length Ass'y P/N HeightTC‐503 9'‐9" D1‐0663150"#1234567Page 11GM & RamGM & RamFordFordGM & RamGM & RamFordFordGM & RamGM & RamFordTruckFordATypeBody without Side Door & Full RearBarn DoorsBody without Side Door & Full RearBarn DoorsBody without Side Door & Full RearBarn DoorsBody without Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsBody with Side Door & Full RearBarn DoorsNameLarge LOGO Decal - 3D EffectsDecal Strips / Drivers SideDecal Strips / Passengers SideHoist & Subframe Ass'yHoist & Subframe Ass'y w/ ExtensionLandscaper Body Body-9'-9" & 11'-5"Mud Flap Kit / Dual Rear 06627Body P/N"A"D1‐06627Weight0.00 lbm0.07 lbm0.07 lbm585.00 lbm620.00 lbm1255.40 lbm11.04 lbmB5141CInstaller to hook power supplycable to pump motor and battery.Mount Decals A4-04684 & B4-04077 calledout on B/M D1-04828 & D1-04829 approx.in the area shown on both sides of deck.Mount additional A4-04684 & A4-04685decal in truck cab.Place serial number decalon driver's side of front faceof dump body.Unit Shown is D1-06527 wit

high strength neoprene rubber on top of the frame. However, solid connections between the truck frame and the sub-frame are required at the location where the hoist pins to the sub-frame and at the rear of the frame. When mounting with a 1/4” gap, the steel spacers sup-plied with the kit

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