Rev: A

Date: Aug 2009

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Model PCK-3530-SADP Direct Push Kit

Installation and Operation Manual

Use this manual ONLY if installing or operating a model PCK-3530-SADP kit on a trailer application. This manual should be kept inside the truck pulling the trailer or any waterproof compartment on trailer for reference when needed.

To Be Completed By Installer

Kit Serial Number:

Pump Installation and

Operation Manual #:

In Service Date:

Dealer:

Address:

City, State, Zip:

Dealer Phone Number:

Rev: A

Date: Aug 2009

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Your Kit Should Include the Following Components:

Item # Part # Part Description Qty

1 070005 POWER UNIT, SINGLE ACTING (DC4348) 1

2 020365 HINGE, DUMP BED 2

3 020367 SAFETY ARM, DUMP BODY 1

4 020366 CUP, DUMP SAFETY ARM 1

5 020986 FLAT, 1-1/2x10-1/2x3/16 1

6 A172002 HOSE ASSY, 110x3/8 HYD 4000 PSI 1

7 070021 HOSE FITTING, 6 F50X-S 3/8 O-RING 1

8 070023 HOSE FITTING, 6 C50X-S BP 3/8 O-RING 2

9 070033 LOAD CONTROL 1

10 090116 CABLE, 2 GA 16" BATTERY 2

11 100171 STRAP, 15" RUBBER 1

12 070004 3.5x30 CYLINDER, HYDRAULIC 1

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Date: Aug 2009

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PWR UNIT, Single ACTG

Item 1 Item 2

HINGE, DUMP BED

CUP, DUMP SAFETY ARM

Item 3 Item 4

SAFETY ARM, DUMP BODY

Item 5

FLAT, 1-1/2x10-1/2x3/16

HOSE ASSY, 110 X 3/8 HYD 4000 PSI

Item 6

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HOSE FITTING, 6 F50X-S 3/8 O-RING

Item 8

Item 10 Item 9

Item 12 Item 11

HOSE FITTING, 6 C50X-S BP 3/8 O-RING

LOAD CONTROL

CABLE, 2 GA 16" BATTERY

STRAP, 15" RUBBER

Item 7

3.5X30 HYDRAULIC CYLINDER

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Date: Aug 2009

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Message to the Trailer Manufacturer

This manual contains instructions on how to correctly install and operate the trailer hoist. These instructions are generalized, as each trailer is manufactured differently. This manual does not outline the operation of the hydraulic system, as there are many different types of hydraulic systems available and supplied by Premium Supply. It is important that the hydraulic system operation manual be supplied to the end user, along with this manual. Some trailer manufacturers will purchase and install a hydraulic system not supplied by Premium Supply. In this case, it is your responsibility to obtain the correct manual for the installation and operation of the hydraulic system. The hydraulic system manual should be supplied along with this manual and made available to the end user. The decals supplied with the PCK-3530-SADP kit are general in nature and are for the use of the kit. Because trailers vary between manufacturers, it is the responsibly of the manufacturer, not Premium Supply, to ensure that correct decals and warnings are obtained.

Important Weights For PCK-3530-SADP Kit Components

Kit (w/cylinder): 98lbs Hinges: 8lbs (ea) Body Prop: 14lbs

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Date: Aug 2009

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! Important Warnings !

! Installing or operating this kit without first understanding the proper installation and operation procedures can lead to serious injury or death. Always read and understand fully all installation and operation manuals before installing or operating this equipment. If you have any further questions, please contact Premium Supply.

! Connecting the cylinder to a hydraulic system with more pressure (PSI) or flow (GPM) than is recommended by Premium Supply can cause the cylinder to fail during operation. This could lead to damage, serious injury, or death. Be sure you have correct pressure and flow before operation. Consult Premium Supply if you are unsure about your hydraulic system.

! Adjusting the hydraulic pressure to more than the recommended setting may cause the cylinder to fail during operation. This could cause damage, serious injury, or death. NEVER adjust the pressure on your own. Consult the trailer manufacturer if the hydraulic pressure is in question. Only qualified personnel should adjust the hydraulic pressure. NEVER adjust the pressure to more than the recommended amount.

! Being under a raised body can result in serious injury or death should the body unexpectedly descend. Never position yourself or allow others to position themselves under a loaded body. Always prop an unloaded body with the supplied body prop. NEVER use the prop on a loaded body.

! Overloading a trailer can cause vehicle or trailer component damage resulting in injury or death. NEVER exceed the gross vehicle weight (GVW) or gross axle weight (GAW) rating of the trailer or your vehicle.

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! Damage to brake lines during the manufacturing and installation of the kit, as well as installing any hardware (bolts, nuts, brackets) in a way that they may rub and damage the brake system, can lead to brake failure. This can cause an accident that could cause injury or death. ALWAYS take adequate steps to prevent brake system damage during the installation of the kit, and take precaution to ensure that installed equipment does not interfere with brake system.

! Shorting of the electrical system can cause a fire or equipment damage that could lead to injury or death. ALWAYS disconnect the battery prior to installing, servicing, or repairing the power unit.

! Malfunctioning equipment can cause property damage, injury or death. ALWAYS have faulty equipment repaired before continuing use. Consult the trailer manufacturer if required.

! Welding, oxy-fuel cutting, or grinding can cause fuel to ignite. This can lead to injury or death. ALWAYS take adequate steps to avoid the ignition of fuel from fuel tanks when welding, oxy-fuel cutting, and/or grinding during installation.

! Heat from the vehicles exhaust system can cause hydraulic component failure. This could lead to a fire that can lead to injury or death. ALWAYS install equipment in locations where the exhaust system heat will not damage any components critical to operation.

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Date: Aug 2009

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Hydraulic System

The hydraulic system supplied with the PCK-3530-SADP trailer hoist manufactured by Premium Supply consists of components (pump, valves, reservoir, hoses, cylinder, etc) that are designed to be compatible with each other. All Premium Supply’s trailer kit liability and warranty will be voided if determined by Premium Supply that substituted hydraulic components were used that were incompatible with those supplied by Premium Supply. PCK-3530-SADP kit parameters are listed in the table below. These are listed as a general guide to ensure proper compatibility (when using other hydraulic components). If you have any questions, please contact Premium Supply.

Kit Model PCK-3530-SADP

Maximum Hydraulic Flow Rate 2 GPM

Maximum Pressure For “Raising”

Portion of Cycle

3200 PSI

Maximum Pressure For “Lowering”

portion of Cycle

N/A Single Acting Pump

Warning: If you substitute hydraulic components, it is your responsibility to verify that they are compatible with the other components supplied by Premium Supply. Incompatible components may cause failure of the cylinder that, in turn, could cause damage to the trailer, vehicle, other property, and cause human injury or death.

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Date: Aug 2009

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PCK-3530-SADP Trailer Application Data

Table 1

Trailer Length Overhang

Power Hoist Model PCK-3530-SADP (Capacity In Tons)

45 Deg Dump Angle

50 Deg Dump Angle

8’ 12” 8.5 8

9’ 12” 7.2 6.7

9’ 18” 8 7.5

10’ 12” 6.3 5.8

10’ 18” 6.9 6.4

10’ 24” 7.4 6.8

12’ 12” 5 4.5

12’ 18” 5.4 4.9

12’ 24” 6 5.6

Capacity Notes:

1) Capacities based on water level non diminishing loads 2) Hydraulic pressure relief set at 3200psi 3) Load is 8ft wide 4) Material density is no greater than 3500 lb/cubic yard 5) Cylinder is mounted per the mounting notes below

Table 2 Standard Mounting (Based on 12’ Trailer / 24” Overhang)

Dump Angle Dimension from Center of Cap End Pin to

Center of Rear Hinge (M)

45 Degrees 86”

50 Degrees 76”

Mounting Notes:

1) The above data is based on a 12’ trailer with 24” overhang, each length of trailer and overhang is different.

2) See “Installation Instructions” section for proper distance calculations for varying trailer lengths and overhangs.

PRECAUTION: Since applications vary, this data is provided as a general guide only

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Date: Aug 2009

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Installation Instructions

Installation Note: The following “installation instructions” are to be used as a guideline when installing the PCK-3530-SADP Kit. Since all trailers differ in their construction, it is not possible to be specific about every aspect of each installation.

1) Install Rear Hinge. To ensure proper operation, hinge assembly must be installed square with trailer frame. This hinge must be supported by the trailer frame with sufficient strength to support the operation of the trailer properly.

2) Install front cross-member to support the cap end of the cylinder. This cross-member should be mounted using the following equation: One Half Total Body Length – Overhang + 38” (Pin to Pin on Cylinder) = Final Mountng Dimension (Center of Rear Hinge to Front Cross-Member). Example: 12’ trailer with 24” overhang: 6’ (72”) – 2’ (24”) = 4’ (48”) + 38” = 86”. This final dimension (86”) is measured between the center of the rear hinge and the front cross-member.

3) The cylinder mounting height should be 10” from top of cross-member to center of mounting pin on cylinder.

4) Locate the cylinder on the trailer frame and ensure that cylinder mounting point is square and true and centered side to side within frame. Make sure to place cylinder within the distance dictated in Table 2 (Measurement M) and follow all mounting notes to ensure proper dumping angle.

5) Once cylinder is in final position, attach mounting bracket to cross-member.

6) Place dump body onto trailer frame and attach dump body frame members to rear hinges.

7) Attach cylinder to trailer body frame members. 8) Install the body prop. For more information regarding this

important step, please see “Body Prop” section of this manual.

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9) Install the hydraulic system. 10) Install the power unit/pump onto the trailer and attach securely. 11) Once power unit/pump is installed attach hydraulic hoses to power

unit/pump using the straight end of hose. 12) Route hydraulic hoses from power unit/pump to cylinder and attach

with provided fittings. 13) NOTE: The Load control fitting must be installed in the “cap” end

port of the cylinder (opposite of rod end port) using supplied fittings and adapters. Please refer to last page of this manual for further explanation.

14) Install and attach battery cables from power unit/pump to battery. 15) NOTE: For more information on the installation and startup of the

hydraulic pump/power unit please see manufacturer’s manual provided in the kit.

16) Install all decals onto trailer that are supplied with the PCK-3530-SADP kit. Refer to the “Decals” section of this manual for further explanation on placement of said decals.

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Date: Aug 2009

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! Important Installation Notes & Warnings !

Note: This manual MUST BE available to the end user of the trailer at time of purchase. It is suggested that this manual be placed inside the truck pulling the trailer, or any waterproof compartment on trailer for reference when needed. Note: The cross-members mentioned in the installation section are not supplied with the kit. These are to be supplied by the manufacturer of the trailer frame. Note: The horizontal distance between the cylinder cap pin and the rear hinge center as dictated by the “M” dimension on Table 2. In Table 1, the capacities for several applications and dump angles are tabulated for a variety of trailer combinations. Note: Placing the cylinder at a different measurement than what Table 2 dictates will affect the kit performance. Moving cylinder forward (longer dimension) will lessen the degree of dumping and increase capacity. Moving the cylinder towards the hinge-point (shorter dimension) will increase dump angle and lessen the capacity. Note: This manual does not outline the operation of the hydraulic system. This is done for the very reason that there are many different types of hydraulic systems available and supplied by Premium Supply. It is important that the hydraulic system operation manual be supplied along with this manual and made available to the end user.

Warning: Installation or operating this kit without first understanding the proper installation and operation procedures can lead to serious injury or death. Always read and understand fully all installation and operation manuals before installing or operating this equipment. If you have any further questions please contact Premium Supply. Warning: These aforementioned cross-members must be of sufficient strength to ensure safe and proper operation of cylinder during the dumping cycle.

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Warning: Do not install the PCK-3530-SADP kit to perform a dump angle of less then 45 degrees or more than 50 degrees. This can lead to an unsafe condition and cause cylinder failure that can cause serious injury or death. Warning: It is imperative that you, the installer, read and understand the hydraulic system manual that is being supplied by the manufacturer prior to initial operation. Warning: Installing or operating this kit without first reading and fully understanding the installation and operation instructions can lead to serious injury or death. Always read and fully understand all manuals prior to installing or operating this equipment.

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Date: Aug 2009

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Body Prop Installation

Installation Note: The following “installation instructions” are to be used as a guideline when installing the body prop supplied with the PCK-3530-SADP kit. Since all trailers differ in their construction, it is not possible to be specific about every aspect of each body prop installation.

1) Once you have completely installed the PCK-3530-SADP kit, raise the cylinder and block body in raised position.

2) Position the body prop base against the trailer frame and attach or fasten by welding.

3) Position the body prop hanger and fasten to trailer frame by welding. 4) Position body prop “cup” on trailer body and attach or fasten by

welding.

Finished Body Prop – Down Position

Finished Cup

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! Body Prop Installation Notes and Warnings !

Note: The body prop is designed to be used on an EMPTY body only. The purpose is to hold the empty body in the raised position when performing maintenance or inspection on the cylinder, trailer frame, or any component that requires work under an EMPTY body.

Note: The body prop hanger must be installed so that when the body is down and the prop is placed in the hanger, it is not allowed to bounce out of hanger.

Warning: Being under a raised body can result in serious injury or death should the body unexpectedly descend. Never position yourself or allow others to position themselves under a loaded body. Always prop an unloaded body with the supplied body prop. NEVER use the prop on a loaded body.

Warning: Do not perform any maintenance under a raised body without first blocking the body up with the body prop. Warning: Never use a body prop that is bent or damaged in any way. A damaged body prop will have reduced holding capacity and could result in serious injury or death.

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Safety Decals

Two “DANGER” decals, as shown below, are supplied with each Premium Supply Power Hoist. These decals should be positioned on each side of the trailer body in an easy to read location.

Note: The decals supplied with the PCK-3530-SADP kit are general in nature and are for the use of the kit. Because trailers vary between manufacturers, it is the responsibly of the manufacturer, not Premium Supply, to ensure that correct decals and warnings are obtained. Warning: Damaged or missing decals can cause improper operation and or use of the kit, which can lead to injury or death. If there are damaged or missing decals they should be replaced immediately.

For replacement decals contact Premium Supply:

Premium Supply 2038 West Interstate 30

Greenville, TX 75402

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Cylinder, Pump, and Body Prop Operation

Cylinder and Pump:

1) Read and understand all notes and warnings. If you do not fully understand any of these “cautionary” statements DO NOT OPERATE CYLINDER AND ASSOCIATED PARTS.

2) Inspect trailer, trailer dump body, cylinder and associated parts for any visual defects that may affect performance and/or operation. Make sure all joints are greased properly. All joints should be greased every 6 months.

3) Make sure trailer is located on a level surface, axles properly chocked, and load is distributed evenly.

4) Make sure there are no persons behind trailer or on either side within at least 50 feet.

5) Locate dump body controller. Once located, this is used to control the up and down function of the cylinder.

6) Use the “UP“ button to extend cylinder and dump load. 7) Once load has been dumped move trailer forward slightly. 8) Use the “DOWN” button at this point to retract cylinder into full down

position.

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Body Prop Operation

1) Raise trailer body to sufficient height and shut off hydraulic power to cylinder.

2) Grasp body prop rod and rotate into the up/vertical position. 3) Once vertical position is accomplished, push prop down into the

support bracket at base of prop. 4) SLOWLY lower the cylinder and body until the prop cup contacts the

vertical facing prop. 5) Reverse the above procedure to place prop back in its hanger for

transport (be sure to lower cylinder to full down position upon placing prop back in hanger).

Body Prop – In Operation

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! Cylinder, Pump, and Body Prop Notes and

Warnings !

Note: This manual does not outline the operation of the hydraulic system, as there are many different types of hydraulic systems available and supplied by Premium Supply. It is important that the hydraulic system operation manual be supplied to the end user, along with this manual.

Warning: It is imperative that you, the installer, read and understand the hydraulic system manual that is being supplied by the manufacturer prior to initial operation.

Warning: Installing or operating this hoist without first reading and fully understanding the installation and operation instructions can lead to serious injury or death. Always read and fully understand all manuals prior to installing or operating this equipment.

Warning: Stay out from under trailer body while cylinder is operating.

Warning: During the dumping operations no person should be allowed to stand in or move into the way of the cylinder operations or into an area where an upset load might fall.

Warning: NEVER leave trailer body raised or partly raised while trailer is unattended or while maintenance or service are being performed, unless body is properly braced up with body prop.

Warning: Never attempt to jerk or shock the trailer with the body raised to remove a stuck load. Jerking or shocking the trailer in this position can cause damage that can result in injury or even death. NEVER drive forward or rearward and stop quickly to “un-stick” the load. If load is stuck, lower trailer body and free the load.

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Warning: Attempting to dump a load on an un-level surface may cause the trailer to overturn. This can result in damage, serious injury, or death. ALWAYS raise body to dump load on a level surface both front to rear, and side to side. Warning: Being under a raised body can result in serious injury or death should the body unexpectedly descend. Never position yourself or allow others to position themselves under a loaded body. Always prop an unloaded body with the supplied body prop. NEVER use the prop on a loaded body.

_________________________________________

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Date: Aug 2009

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This kit is equipped with the Bridon Load Control valve. This unit is designed to control and meter flow of fluid from the cylinder in case of hose failure or leak. This valve should be installed / threaded into the cap end of the cylinder to meter the flow on the retract (or down) stroke. Please see drawing below for proper location of flow control valve.

For more information and to view a Bridon Load Control action video

please visit our website at:

www.premium-supply.com

http://www.premium-supply.com/