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Proudly built in the USA
Owner’s Manual
TC-121 ULTRA
TruckCraft Corporation Chambersburg, PA 1-800-755-3867 Copyright 2010
www.truckcraft.com
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy. S.
Chambersburg, Pa. 17202 Tel. 800.375.3867 Phone 717.375.2900 Fax 717.375.2975 www.truckcraft.com
"WHERE WORKMANSHIP IS EVERYTHING"
TruckCraft Corporation Rev. – 1/26/2010 I5-05579
Table of Contents Preface……………………………………………………..1 Ordering Repair Parts……………………………………1 Safety Information………………………………………...2 Mounting and operating Instructions……...…………….3 Maintenance…………………………………………….....7 Parts List…………………………………………………...8 D2-05343 Tailgate Parts List ……………………………..9 L7-00614 Mounting Kit Parts List ...………………...….10 D2-05357 Slipstream Cab Guard (Option)………….......11 D1-05581 Orion Bulkhead (Option) ………….………….12 B2-00636 Tarp Kit (Option) ……………………………...13 C2-00599 Side Board Kit-Rigid (Option) ….……………16 C2-01803 Side Board Kit-Swingaway (Option) …...……18 D1-05387 TC-131 D-ICER (Option) …………………….19 Warranty ………………………………………...………..20
TruckCraft Corporation Rev. - 1/26/2010 I5-05579
Preface Read and understand all sections of this manual prior to installing or operating the TruckCraft dump bed. This manual contains information for the installation, operation, and maintenance of the TruckCraft TC-121 dump bed. Proper care and operation of the unit will as-sure years of dependable service. Your local TruckCraft Dealer will instruct you in its general operation. TruckCraft Corporation will be glad to answer any ques-tions that may arise regarding the operation of your dump bed.
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 dump bed serial number and description or part num-ber of parts needed are required. The serial number is located on front plate (behind the cab) of the dumper weldment on the drivers side. Dumper 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 dumper: Before operating read and understand all information furnished with your dumper and in this manual. Keep hands, feet and clothing away from moving parts. Never exceed the structural capacity (7,000 lbs.) of the dumper. Structural
capacity means the maximum weight the dumper will carry and dump with an acceptable margin of safety. This does not mean that your truck can carry 7,000 lbs.
Never exceed the manufacturer’s GVWR (Gross Vehicle Weight Rating) of your truck. This rating can usually be found on the end of the driver’s door just above or below the latch.
Never exceed the truck axle and tire ratings. Always keep as much of the load as possible forward of the rear axle and
evenly distributed from side to side. 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 dumper only when the truck is on a firm, level surface. Always inspect the area around the truck for safe dumping prior to operat-
ing. Do not move the truck with the deck in a raised position. Never let the dumper sit with the bed raised when not in use. Always open the tailgate prior to raising the dumper when it is loaded. 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. Regularly check and tighten all fasteners to the recommended torque val-
ues in the Torque Chart shown below. Maximum hydraulic pressure is factory set . Tampering with this setting will
void the warranty and can damage hydraulic components and result in sys-tem failure.
Do not attempt to repair this dumper yourself unless you have experience working on dump beds and are familiar with the hazards involved. For safety, take your dumper to the dealer from which it was purchased for all repairs and service.
TruckCraft Corporation Rev. - 1/26/2010 I5-05579
2 FIGURE 1
Size 18‐8 S. S. Bolts Gr.5 Steel/Zinc PlatedTorque Ft.‐Lb. Torque ‐ Ft.‐Lb.
3/8‐16 8 241/2‐13 18 605/8‐11 36 1253/4‐10 63 225
Torque Chart
Mounting & Operation Instructions CAUTION: Verify any lifting and support devices used can support the Dumper before picking up the assembly. 1. WARNING: Do not install the dump bed on a pickup bed liner. Bed liners have cor-
rugated floors and prevent a solid installation. 2. Make sure the pickup truck is on level ground. 3. Remove the tailgate from the pickup truck. 4. Drill a 5/8” Diameter hole down through the pickup bed floor 1-1/2” forward of the
rear edge and on the center line of the bed. See hole “A” on Figure #2 on page 4. 5. Insert the dumper into the pickup bed allowing approximately 18” of space at the
front.. 6. Attach a jumper cable to the dumper and to the frame of the truck for a temporary
ground. 7. Cut and remove the shipping strap (if any) at the front of the dumper and temporar-
ily hook the loose end of the power cable to the positive terminal of the truck bat-tery.
8. Slide the dumper into the approximate mounting location. 9. While making sure everybody is standing clear, raise
the dumper high enough to engage the safety prop. Use the up and down buttons on the remote control to raise and lower the dumper (See figure #3). Lower the dumper while holding the prop in a vertical position so that it engages a slot in the bottom of one of the floor planks and is supporting the full weight of the dumper.
CAUTION: Do not work under the dumper without having the safety prop properly positioned (See figure #4).
TruckCraft Corporation Rev. - 1/26/2010 I5-05579
3
Figure 3
Figure 4
Safety prop raised and shown engaged in slot in floor plank.
TruckCraft Corporation Rev. - 1/26/2010 I5-05579
4
Plan View of Pickup Bed Figure 2
10. Align mounting hole “A” at the rear of the truck with the hole in the dumper base frame. From mount-ing kit L5-05329 insert the 5/8 diameter x 4” long bolt through the hole (See fig-ure #5). Install the 2” x 4” plate with 5/8” nut and washer provided under the pickup and fasten lightly.
11. Center the bed from side to side at the front.
12. From under the truck de-termine an accessible loca-tion on the centerline of the pickup bed for hole “B” on figure 2.
13. Drill a 5/8” hole through the pickup bed floor and through the cross member on the under side at the location determined in step #12. This hole must align with the slot between the angles on the dumper base frame. On some trucks there will already be a hole in the cross member. Slide the 4” x 4” plate provided between the angles at the front of the dumper base frame. Install the 5/8” dia. X 5.5” Long bolt through the plate, dumper base and truck bed and frame. Install the 2/1/2” x 4” plate, 5/8” nut and washer under-neath the truck bed and tighten the nut (See figure #6).
14. If the bolts provided are not the correct length for your par-ticular pickup, you can purchase the correct bolts at most hardware and farm equipment stores.
CAUTION: Use grade 5 bolts minimum.
TruckCraft Corporation Rev. - 1/26/2010 I5-05579
5
Figure 6
Install 4” x 4” plate and 5/8” bolt in this slot.
Install 5/8” dia. Bolt through base frame hole and hole “A”.
Figure 5
TruckCraft Corporation Rev. - 1/26/2010 I5-05579
6
15. With the correct bolts, washers, nuts and plates in plate, tighten to the torques speci-fied in figure 1.
16. Route the pump power cables to the battery in such a way as to avoid sharp edges and maintain a minimum distance of 8” from any portion of the exhaust system. By routing the power cable along the side of the truck frame, you will give the cable maximum protection. Fasten the cable to the truck frame using the stay straps pro-vided. These stay straps should be inserted through holes in the truck frame to secure the cable. Do not cross under of over the truck frame where the cable could get pinched or frayed due to rubbing.
17. The hydraulic pump reservoir has been filled at the factory. If more fluid is neces-sary use only Dextron Automatic Transmission Fluid. CAUTION: Do not overfill. Adding too much fluid will cause the reservoir to overflow when the bed is lowered The best method of refilling the reservoir is to place the dumper on the safety prop, with the prop being as straight up and down as possible under the dumper. Insert a clean ruler or measuring stick into the reservoir making sure it touches the bottom of the reservoir, not the pickup tube. Add fluid until the depth of fluid in the reservoir is 4”. If you have no way to measure 4”, an alternate method of filling is to add 2-3 oz. of fluid at a time and raise the bed. Repeat this procedure until the pump does not change sound (from pumping air) at the end of its stroke. Leave the breather off and fully lower the bed to the down position. The bed can then be raised and the breather reinstalled. The reason for leaving the breather off during the first cycle after filling is to guard against pressurizing the reservoir in the event that it has been overfilled. Back pressure due to overfilling may dislodge the reservoir from the pump. Adding too much fluid will result in the reservoir overflowing when the bed is lowered. The hydraulic cylinder will require bleeding of all air each time you replenish fluid.
CAUTION: An accumulation of air in the lifting cylinder will cause the bed to
bounce and possibly raise when the vehicle is moving. BLEEDING THE CYLINDER: After filling the hydraulic reservoir to the proper level, locate and remove the plug on the top of the hydraulic cylinder. Place a clean rag over the plug opening and jog the “UP” button until a small amount of fluid comes out the opening. Replace the plug and re-check the reservoir fluid level as described above. If the fluid level is low, repeat all steps listed above. 18. Install the remote control in the cab by making note of the wire colors and connec-
tion locations prior to disconnecting the remote cable from the power unit. Then route the end of the cable through the floor of the pickup cab behind the driver’s seat (preferably through a rubber plug in the floor). The cable should then be routed up the back of the cab, over the top front edge of the pickup box, and down to the power unit where it should be reconnected. Use a stay strap to secure the cable to the front of the dumper bottom frame to assure clearance when the dumper is raised and lowered.
TruckCraft Corporation Rev. - 1/26/2010 I5-05579
7
Maintenance 1. Check the hydraulic fluid level and bleed the cylinder every 6 months. If ad-
ditional fluid is required add Dextron Automatic Transmission Fluid. The fluid should not need to be changed unless it becomes contaminated from an outside source. To check the fluid level and bleed the cylinder follow step #16 in the “Mounting and Operating Instructions”.
2. Never operate the vehicle if any “bounciness” or “springiness” is noted in the empty dumper when fully down. The cylinder may have air trapped inside that could cause the empty dumper to bounce up into oncoming high wind, thus raising the dumper while moving. BLEED THE CYLINDER IMMEDI-ATELY. Follow the directions in step #17 in the “Mounting and Operating Instructions”.
3. Never close off the cab guard window screen when the bed is empty if your dumper is so equipped. High winds and high driving speed may cause the bed to raise.
4. Lubricate the stainless steel tailgate pins periodically with WD-40. 5. Depending on frequency of use, check all bolts for proper tightness and
torque.
19. The Insert Dumper has been designed for use with most pickup trucks with an 8’ bed. Never exceed the manufacturer’s gross vehicle rating of the truck. These ratings can usually be found on the end of door just above or below the latch on the driver’s side. Filling the bed with materials such as sand, stone, scrap steel, etc. could exceed the rating of the Dumper and would extremely overload the truck. Fill-ing the bed without regard to the weight of the material being loaded can result in structural failure and injury. Never exceed the dumper and trucks maximum ratings.
Have questions? Call Toll Free 1-800-375-3867
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Page 8
DETA
IL A
DETA
IL B
DETA
IL C
4 2
7 4
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4 2A
BC
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8 1
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13 1
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in A
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bly
9
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy. S. "WHERE WORKMANSHIP IS EVERYTHING" Chambersburg, Pa. 17202 Tel. 800 - 755 - 3867 Fax. 717 - 375 - 2975 WWW.TruckCraft.COM
L5-05329 TC-101 Magnum/TC-121 Ultra
Mounting kit Parts List
(1) Battery Insulator Boot - P4-00681
(10) Tie Straps - P4-00394 (for attaching battery cable to truck frame).
(1) 2" x 4" Mounting Plate - B4-00331
(for under the pickup bed at hole "A").
(1) 2-1/2" x 4" Mounting Plate - B4-00330 (for under the pickup bed at hole "B").
(1) 4" x 4" Mounting Plate - B4-00329
(for top side over slot in aluminum base frame, hole "B").
(1) 5/8" x 4" Grade 5 Hex Head Cap Screw, P4-00588, with Washers, P4-00593, and Nut, P4-00591 (for hole "A" at rear of body).
(1) 5/8" x 5-1/2" Grade 5 Hex Head Cap Screw, P4-00589, with Washers, P4-00593, and Nut, P4-00591 (for hole "B" at front center of body). Page 10
11 1
7 1
5 4 9 6
5 4 9 6
6 2 9 6 3 12
8 2
8 2
2 1
Top
View
-Roa
d Si
de
3 12
11 1
12 1
3 12
1 2
4 1
10 17
D4-0
5352
Top
-Cab
guar
dNo
t sh
own
for
clar
ity
1 2
4 110 17
7 1
Item
P/N
Qty
Nam
eW
eigh
t
1D4
-053
562
Brac
ket /
Sid
e Bo
ard
/ TC-
121
/ Cab
guar
d2.
023
lbm
2A4
-022
541
Deca
l / W
arni
ng /
Caut
ion
0.02
9 lb
m
3P4
-005
7012
Flat
Was
her
- .3
8 SS
0.08
0 lb
m
4D4
-053
531
Fron
t She
et/C
abgu
ard/
TC-1
2110
.376
lbm
5P4
-005
624
Hex
Hd C
ap S
crew
- .3
8-16
X1.0
SS
0.19
2 lb
m
6P4
-005
632
Hex
Head
Cap
Scr
ew0.
237
lbm
7D4
-053
541
LH S
ide
- Ca
bgua
rd -
TC-
121
4.05
8 lb
m
8B4
-040
772
Med
ium
LOG
O / P
last
ic0.
000
lbm
9P4
-005
676
Nyl.
Inse
rt L
ock
Nut
- .3
8-16
SS
0.14
3 lb
m
10P5
-054
0917
Pop
Rive
t/Lar
ge H
ead
0.08
9 lb
m
11D4
-053
551
RH S
ide,
Cab
guar
d/TC
-121
3.93
5 lb
m
12D4
-053
521
Top
Cabg
uard
/ TC
-121
19.9
95 lb
m
A
DETA
IL A
10 1712 1
11 1
1 2
B
DETA
IL B
10 17
12 1
11 1
D2-0
5357
Cab
Prot
ecto
r
11
14 2
15 1
12 410 6
11 6
5 1
A
DETA
IL A
9 6
2 6
7 6
B
DETA
IL B
4 1
3 16 2
Plac
e Sp
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em #
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etal
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es -
Typ
.
Item
Part
#Qt
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me
Wei
ght
1D4
-055
861
Chan
nel
3.26
0 lb
m
2P4
-005
666
Nyl.
Inse
rt L
ock
Nut -
.25-
20 S
S0.
062
lbm
3D4
-053
531
Fron
t She
et/C
abgu
ard/
TC-1
2110
.376
lbm
4D3
-055
831
LH S
ide
Wel
dmen
t4.
424
lbm
5D3
-056
001
Tube
Wel
dmen
t9.
739
lbm
6D4
-053
562
Brac
ket /
Sid
e Bo
ard
/ TC-
121
/ Ca
bgua
rd2.
023
lbm
7P4
-042
446
Spac
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/4"
ID a
nd .7
5"OD
0.00
6 lb
m
8D3
-055
821
RH S
ide
Wel
dmen
t4.
348
lbm
9P4
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926
Carr
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Bol
t - .
25-2
0 x
.75"
SS
0.10
1 lb
m
10P4
-005
676
Nyl.
Inse
rt L
ock
Nut -
.38-
16 S
S0.
143
lbm
11P4
-005
706
Flat
Was
her
- .3
8 SS
0.04
0 lb
m
12P4
-005
624
Hex
Hd C
ap S
crew
- .3
8-16
X1.0
SS
0.19
2 lb
m
13P4
-005
632
Hex
Head
Cap
Scr
ew0.
237
lbm
14B4
-040
772
Med
ium
LOG
O / P
last
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000
lbm
15A4
-022
541
Deca
l / W
arni
ng /
Caut
ion
0.02
9 lb
m
16P5
-054
0911
Pop
Rive
t/Lar
ge H
ead
0.05
8 lb
m
4 1
13 2 10 6 11 6
16 11
C
DETA
IL C
9 6
2 6
7 6
16 11
Asse
mbl
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rts
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ms
2, 7
, & 9
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inst
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ide
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k
12
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy S. "WHERE WORKMANSHIP IS EVERYTHING" Chambersburg PA 17202 Tel. 800 - 755 - 3867 Fax. 717 –375-2975 WWW.TruckCraft.COM
B2-00636 TC-101 Magnum/TC-121 Ultra
Tarp Kit (Option)
INSTALLATION INSTRUCTIONS
1. Slide 1 nylon bearing onto tarp crank, bearing flange facing away from crank handle. 2. Insert tarp roller shaft end through the passenger side hole in the cab guard. 3. Slide crank through hole in cab guard on driver’s side and into the tarp roller. 4. Slide 2nd bearing on to protruding shaft end with flange against cab guard. 6. Attach the bearings using the 1/4-20 x .50” Long button head screws and nuts provided. 7. Drive roll pin through hole in crank shaft to
secure shaft to cab guard.
Page 13
Crank handle shown with bearing mounted.
Drive Roll Pin through this hole on driver’s side of cab guard.
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy S. "WHERE WORKMANSHIP IS EVERYTHING" Chambersburg PA 17202 Tel. 800 - 755 - 3867 Fax. 717 –375-2975 WWW.TruckCraft.COM
8. Unfold tarp and stretch
narrow width across crank shaft, lining up grommets along shaft.
9. Use radiator clamps, opening them up and wrap-
ping them around crank shaft, and threading them through the tarp, one per grommet, to at-tach the tarp to the shaft. Keep tarp taught from side to side.
10 Slide batten board through looped
end of tarp until board is centered in tarp. In center of the board, in the narrow side, (at the very end of tarp), drill a 3/16" hole into the edge of the board about 3/8" deep. Using the supplied eye screw, start it in the drilled hole and turn until tight.
11. Attach supplied rope to eye bolt and wind tarp onto
crank shaft.
Page 14
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy. S. "WHERE WORKMANSHIP IS EVERYTHING" Chambersburg, Pa. 17202 Tel. 800 / 755 - 3867 Fax. 717 / 375 – 2975 WWW.TruckCraft.COM
B2-00636 TC-101 Magnum/TC121 Ultra
Tarp Kit (Option)
Parts List (1) Tarp - B4-00576 (1) Roller - B3-00288 (1) Crank - B3-00286 (1) Crank Grip - A4-00358 (1) Batten Board - A4-00417 (2) Flange Bearings - A4-00408 (4) Clamps, Worm Gear - A4-00407 (1) Roll Pin - P4-00410 (1) Screw Eye - P4-00411 (1) Rope - R5-00412 (4) 1/4" x 1/2" Screws - P4-00574
(4) 1/4” - 20 NC Nuts - P4-00566
Page 15
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy. S. "WHERE WORKMANSHIP IS EVERYTHING" Chambersburg, Pa. 17202 Tel. 800 - 755 - 3867 Fax. 717 - 375 – 2975 WWW.TruckCraft.COM
C2-00599 TC-121 ULTRA
Side Board Installation Kit (OPTION)
INSTALLATION INSTRUCTIONS
1. Bolt the side board mounting brackets to the bent tubes forming a right hand and left hand assembly. Use the 5/16" stainless steel bolts and locking nuts for this pur-pose. The nuts go on the rear side of the assembly.
2. Insert the tube assemblies into the holes in the box rail of the dumper. 3. Align the brackets so that they are parallel with the sides of the box rails and mark
the center of each hole (in the bottom of the brackets) onto the top of the box rail. 4. Remove the assemblies and drill a 7/16" hole down through the top and bottom of
the box rail. Caution: Be sure that your drill is perpendicular to the top of each box rail.
5. Loosen the fasteners on the tube coupling and slide it over one of the free ends of
either the left or right hand assembly. 6. Assemble the left and right hand assemblies onto the dumper. Insert the 3/8"
stainless steel bolts through the brackets and the box rail and tighten. 7. Slide the tube coupling over the ends of both tubes and tighten.
Page 16
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy. S. "WHERE WORKMANSHIP IS EVERYTHING" Chambersburg, Pa. 17202 Tel. 800 / 755 - 3867 Fax. 717 / 375 – 2975 WWW.TruckCraft.COM
Page 17
TRUCKCRAFT CORPORATION 5751 Molly Pitcher Hwy. S. "WHERE WORKMANSHIP IS EVERYTHING" Chambersburg, Pa. 17202 Tel. 800 / 755 - 3867 Fax. 717 / 375 – 2975 WWW.TruckCraft.COM
Page 18
Page 19
See above Installation Manual for complete installation instructions on the TC-131 D-ICER.
Page 20
1720
2
101
121