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HR-520 HOIST
Installation & Operation Manual
To Be Filled In By Installer
Hoist Serial #:______________________________________
Pump Installation
And Operation Manual#:______________________________
In Service Date:_____________________________________
Dealer:____________________________________________
Address:___________________________________________
City, State, ZIP:_____________________________________
Dealer Phone Number:_______________________________
Use this manual only if installing or operating a model HR-520 hoist. This manual should be kept in truck
glove compartment for reference when needed.
Original Revision: May 1, 1997
Current Revision: (H) February 26, 2014
Stock#: 1656321 (035775)
Website: www.TBEI.com
E-mail: sales@TBEI.com
Phone: 1-800-869-9162 Rugby
1-800-255-4345 DuraClass
1-800-533-0494 Crysteel
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Related Manuals for TBEI Rugby HR-520
Summary of Contents for TBEI Rugby HR-520
- Page 1 Website: www.TBEI.com E-mail: sales@TBEI.com Phone: 1-800-869-9162 Rugby 1-800-255-4345 DuraClass 1-800-533-0494 Crysteel HR-520 HOIST Installation & Operation Manual To Be Filled In By Installer Hoist Serial #:______________________________________ Pump Installation And Operation Manual#:______________________________ In Service Date:_____________________________________ Dealer:____________________________________________ Address:___________________________________________ City, State, ZIP:_____________________________________ Dealer Phone Number:_______________________________ Use this manual only if installing or operating a model HR-520 hoist.
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Page 2: Table Of Contents
Contents Warnings ………………………………………………………………………….3-4 Caution .........................5 Assembly ......................6-13 Decal Location ....................13-14 Operation .........................15 Parts List ......................16-17 Stock No. 1656321 (03 5775) -
Page 3: Warnings
Warnings WARNING: Installing or operating this hoist 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. WARNING: Welding, oxy-fuel cutting, or grinding sparks can cause fuel to ignite which in turn can lead to injury or death. - Page 4 serious injury, or death. Never adjust the pressure on your own. Consult the manufacturer if the hydraulic pressure is in question. Have only a qualified person set the hydraulic pressure. Never adjust the pressure to more than the recommended amount. WARNING: Fluid under pressure can pierce the skin and enter bloodstream, causing serious injury or death.
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Page 5: Caution
Caution The hydraulic system supplied with a given hoist manufactured by Rugby Manufacturing Co. is made up of components (pump, valves, reservoir, hoses, cylinder, etc.) that are designated to be compatible with each other. If you substitute hydraulic components, it is your responsibility to BE SURE they are compatible with the other components supplied by Rugby Manufacturing Co. -
Page 6: Assembly
Assembly Instructions: Body Prop Installation: A body prop is supplied with every HR-520 hoist package kit. Insert the body prop into the body prop bracket, making sure that the handle hook is pointing towards the hoist. (Figure 1) Fasten the body prop to the body prop bracket with the supplied 1/2” x 3” hex screw &... - Page 7 Hoist/Sub-frame Assembly: Position the hoist into the sub-frame and secure with four 1/2” x 1 1/2” flange bolts and nuts. To keep the hoist straight, align the saddle brackets of the hoist with the corresponding brackets in the sub-frame. (Figure 2) NOTE: Torque all 1/2”...
- Page 8 Fasten the very rear end of the sub-frame to the truck by welding the rear hinge angle to the chassis frame as shown in Figure 4. Position a mounting angle under each saddle flat located on each side of the sub-frame.
- Page 9 NOTE: Torque all 1/2” fasteners to 90 ft. lb. Finally, weld each mounting angle to its respective saddle flat. (Figure 6) NOTE: DO NOT weld mounting angles or saddle flats to the truck frame. Stock No. 1656321 (03 5775)
- Page 10 Cut excess frame off behind the sub-frame rear hinge. IMPORTANT: If the truck has fuel tanks located between the chassis frame rails, run the fillwell spout between the chassis frame rails through one of the sub-frame side channel knockouts and outside the chassis frame rails for access to refueling the truck. If an alternate location is needed for the fillwell spout, other than the knockout locations provided, cut a hole in the sub-frame side rail at the preferred location.
- Page 11 Slide each of the lifting shafts against the inside of the long beam channel. Weld the lifting shaft to secure the shaft to the long beam as shown in Figure 8. With the shaft secured, slide the lock collars against the hoist lifting tube and lock them there by tightening the 3/8 set screw.
- Page 12 Install all grease fittings. For grease fitting locations, refer to Figure 7. Torque each grease fitting to 70 in. lb. Grease all grease fittings upon installation. Stock No. 1656321 (03 5775)
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Page 13: Decal Location
IMPORTANT: All hoist and sub-frame grease fittings should be greased at least every time the truck itself is greased. With the hoist and body completely installed, cycle the hoist several times to rid the hydraulic circuit of air. IMPORTANT: Several different types of pump and hydraulic components are available to power the HR-520. - Page 14 WARNING: Missing or damaged decals can lead to accidents which may cause serious injury or death. If any decals are missing or damaged, they must be replaced. To obtain replacement decals, contact your “Rugby” dealer or contact: Rugby Manufacturing Co. Industrial Park 515 1st Street NE Rugby, ND 58368...
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Page 15: Operation
Operation of Body Prop WARNING: Being under a raised body can result in serious injury or death should the body inadvertently descend. Never position yourself or allow others to position themselves under a loaded body. Always prop the unloaded body up using the body prop or props supplied. -
Page 16: Parts List
HR-520 Hoist w/ 60” CA Sub-Frame Stock No. 1656321 (03 5775) - Page 17 HR-520 Hoist w/ 84” CA Sub-Frame Stock No. 1656321 (03 5775)