CRYSTEEL LO-BOY User manual

1644526G (406807) 2020-SEP-211
LO-BOY
TRUCK HOIST
CRYSTEEL’S
Web Site E-Mail Phone [phone]
www.crysteel.com [email protected] Toll Free [phone]
Website: www.TBEI.com
E-mail: [email protected]
THIS MANUAL MUST BE INCLUDED WITH THE VEHICLE
AFTER COMPLETING THE INSTALLATION.

1644526G (406807) 2020-SEP-2121644526G (406807) 2020-SEP-213
DATE PURCHASED __________________________________________________________________
HOIST SERIAL NUMBER ____________________________________________________________
CYLINDER SERIAL NUMBER ______________________________________________________
DEALER __________________________________________________________________
ADDRESS __________________________________________________________________
PHONE __________________________________________________________________
FOREWORD
Crysteel’s LoBoy hoists have been designed for use on single-axle trucks with cab-to-axle dimensions of
60 to 150 inches for use with bodies of 8 through 18 feet in length and on tandem axle trucks with cab-to-
tandem center dimensions of 102 to 126 inches for use with bodies from 14 to 18 feet in length. Bodies
normally used with these hoists are grain bodies and platforms. This manual contains the information
needed for the proper installation and operation of these hoists.
These instructions are for installing and maintaining all models of LoBoy hoists. With proper installation,
use, and regular maintenance, Crysteel’s LoBoy truck hoists will give many years of trouble free service.
When ordering parts, be sure to give serial number of hoist and cylinder. The serial number of the hoist
is stamped into the hoist frame near the base end of the cylinder. The serial number of the cylinder is
stamped on the barrel of the cylinder near the base. For future reference, copy these numbers NOW in the
space provided above. Order parts by number and description as given in the parts listing in this manual.
1. Engage PTO from cab and adjust engine speed to fast idle.
OPERATIONANDUSE
SOMEDO’SANDDON’TSFORSAFEANDLONGSERVICE
1. Usetheproperhydraulicuid.KEEPITCLEAN.Remembertochangeitregularly.
2. ALWAYS operate the hoist from inside the cab of the truck.
3. If the hydraulic hose connections are correct, the hoist should raise when the hoist control
lever is pulled back, hold when the lever is in the center detent, and lower when the lever
is pushed forward.
4. To raise the hoist, pull the control lever back. To hold the body in a raised position, place
the control lever in its center detent position. To lower the hoist, push the control lever
forward.
5. ALWAYS return the hoist control lever to its center detent position after each use.
6. Whenthehoistcylinderreachestheendofthestroke,oilwillowthroughtheautomatic
bypass valve built into the piston inside the cylinder and return to the reservoir.
7. It is advisable to run the PTO to “power down” or lower the hoist because this will act as
an hydraulic lock to hold the hoist in the lowered position. It is not necessary to do this,
however,becausethereservoirhassucientcapacitywhetherornotthehoistispowered
down.Youwillbenetfromtheadvantagesofthedoubleactinghoistonlyifyoupower
down.
8. To make use of the hydraulic lock feature, place the hoist control lever in the center hold
position after the hoist is powered down. This places the pressure on the valve, where it
belongs, not on the pump.
9. DO NOT LEAVE THE PTO IN GEAR WHILE TRANSPORTING. THIS CAN CAUSE
SEVERE DAMAGE TO THE PTO OR HYDRAULIC PUMP.
10.Thehydraulicsystemshouldbedrained,ushedandrelledwithproperhydraulicuid
atregularintervals.CAUTION:NEVERusehydraulicBRAKEFLUIDinthehydraulic
system.
11.Afteraddingorreplacingthehydraulicuid,cyclethehoistseveraltimestoremoveair
from the cylinders and hydraulic hoses.
2. Lubricateallgreasettingsevery100cyclesoreverytwomonths.Infrequentorinsu-
cient lubrication will cause hoist failure and possibly injury or death.
3. ALWAYS carefully block up the body, using the body prop, before working under it.
4. Do not “race” the engine when unloading.
5. Do not load the hoist beyond its capacity.
6. DO NOT tamper with the hydraulic relief valve. This will void the warranty. It can cause
severe damage to the hoist and cylinder.
7. Never leave the PTO in gear while transporting. It could ruin the hydraulic pump, the PTO
or the transmission.
8. Checkallboltsandttingsregularly.Keepthemtight.Seetableonpage4fortorqueval-
ues.
9. Alwaysoperatehoistonarmandlevelsurface.
10. Always make sure area around truck is clear and safe for hoist operation and dumping.

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TABLE OF CONTENTS
FOREWORD 2
SOME DO’S AND DON’TS FOR SAFE AND LONG SERVICE 3
OPERATION AND USE 3
LOCATE AND INSTALL REAR HINGE 6
LOCATE HOIST 7
MOUNT HOIST FRAME 8
HYDRAULIC SYSTEMS 8
INSTALL GEAR PUMP - BERT, CHARLIE & DANIEL 8
INSTALL GEAR PUMP - DAVID, ERNIE & FLOYD 9
MOUNT RESERVOIR/VALVE ASSEMBLY - BERT, CHARLIE & DANIEL 9
MOUNT RESERVOIR/VALVE ASSEMBLY - DAVID, ERNIE & FLOYD 10
INSTALL HOIST CONTROL 11
INSTALL HOSES - BERT, CHARLIE & DANIEL 12
INSTALL HOSES - DAVID, ERNIE & FLOYD 13
ADD HYDRAULIC FLUID 14
ELECTRIC POWER UNIT MOUNTING - GENERAL 15
INSTALL HOSES - SINGLE-ACTING 16
INSTALL HOSES - DOUBLE-ACTING 17
ELECTRIC DOUBLE-ACTING 17
ADD HYDRAULIC FLUID 18
MOUNT BODY 19
INSTALL BODY GUIDE PLATES 19
INSTALL BODY PROP 20
INSTALLGREASEZERKSANDLUBRICATE 21
MOUNT DECALS 22
HOIST PARTS - BERT, CHARLIE, DANIEL, DAVID, ERNIE & FLOYD 23
CYLINDER PARTS 25
HYDRAULIC SYSTEM PARTS - BERT, CHARLIE, DANIEL 26
HYDRAULIC SYSTEM PARTS - DAVID, ERNIE, FLOYD 29
CAPACITY FORMULA 32
SPECIFICATIONS 32
INSTALLATION INSTRUCTIONS
GENERAL INFORMATION
It is a good idea to look through these installation instructions before beginning to mount the hoist and
hydraulic system.
When welding, protect the truck’s electrical, air and brake systems by disconnecting, removing or cover-
ing.Tightenallnutsandboltstoaconsistentlevel.Usethefollowingtablefortorquevalues.
Size Grade2Torque Grade5Torque Grade8Torque
1/4-20 3-4 lb-ft 6-7 lb-ft 10-11 lb-ft
1/4-28 4-5 lb-ft 8-9 lb-ft 11-12 lb-ft
5/16-18 8-9 lb-ft 14-15 lb-ft 21-22 lb-ft
5/16-24 9-10 lb-ft 15-16 lb-ft 21-22 lb-ft
3/8-16 17-18 lb-ft 24-26 lb-ft 37-40 lb-ft
3/8-24 19-20 lb-ft 28-30 lb-ft 40-43 lb-ft
1/2-13 38-42 lb-ft 60-65 lb-ft 90-100 lb-ft
1/2-20 43-47 lb-ft 70-75 lb-ft 95-105 lb-ft
5/8-11 75-80 lb-ft 122-130 lb-ft 180-190 lb-ft
5/8-18 85-90 lb-ft 145-150 lb-ft 200-210 lb-ft
3/4-10 132-140 lb-ft 220-230 lb-ft 315-330 lb-ft
3/4-16 152-160 lb-ft 250-260 lb-ft 355-370 lb-ft
Thefollowingabbreviationsareusedindescribinghydraulicttings.
ORBM O-Ring Boss - Male Thread
NPTM Pipe - Male Thread
NPTF Pipe - Female Thread
JICM JIC 37° - Male Thread
JICF JIC 37° - Female Thread

1644526G (406807) 2020-SEP-2161644526G (406807) 2020-SEP-217
LOCATE AND INSTALL REAR HINGE
On single-axle trucks, the rear hinge must be located as close as possible behind the rear spring hanger.
This will be 32 to 36 inches behind the center of the rear axle. On tandem axle trucks the center of the rear
hinge should be located 42 to 50 inches behind the center of the rear tandems. Mark the rear of the truck
frame for notching as shown in Figure 1. Notch the truck frame as marked. Make sure the rear hinge is
squarewiththetruckframeandatthecorrectheight.Thetopsurfaceoftherearhingebracketshouldbe
ushwiththetopoftheanglemountingbracketsofthehoistframeasshowninFigure1.Securelyweld
the rear hinge to the truck frame. Cap the ends of the truck frame under the rear hinge. Weld the capping
plates to the ends of the truck frame and to the bottom side of the rear hinge angle.
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  
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
On tandem-axle trucks, place the gussets in the corners formed by the truck frame rail and the rear hinge
frameangle.Raisethefrontendofthegussetsoittouchesthetopangeofthetruckframerail.Besure
that the gusset does not interfere with the rear hinge operation. Securely weld the gussets to the rear hinge,
thetruckframerailandthetopangeofthetruckframerail.
LOCATEHOIST
Determine where to mount the hoist on the truck. Please refer to the chart in Fig. 4 for the relationship
between dump angle and “D” dimension. Measure forward from the center of the rear hinge pin and mark,
on the truck frame, the location of the front crosstube of the hoist frame. Place the hoist on the truck frame
and clamp the hoist pivot pads to the truck frame. The back end of the hoist must be supported by a cross-
member in the truck frame. The top of this crossmember may be up to 1” below the top of the truck frame.
The “CM” dimension shows the location for this crossmember. Make sure the hoist frame is centered on
andsquarewiththetruckframe.
Ifdesired,thehoistcanbeturnedendforendfora‘Reverse’mount.Thisdoesnotaecttheliftingcapac-
ity.
WARNING! LOCATING THE REAR HINGE FARTHER BACK THAN
RECOMMENDED MAY CAUSE UNDUE STRESS IN THE TRUCK FRAME,
AND MAY CAUSE INSTABILITY DURING THE LIFTING CYCLE!
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    
 
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
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      
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96”

1644526G (406807) 2020-SEP-2181644526G (406807) 2020-SEP-219
MOUNT HOIST FRAME
Thehoistpivotpadsmustrestatonthetruckframe.Ifthehoistpivotpadssitonrivetheadsinthetruck
frame, either move the hoist or drill holes in the pivot pads to clear the rivets. On the driver’s side, clamp
the hoist mount/prop pivot the lower hoist pivot pad and to the outside of the truck frame. On the passen-
ger side, clamp a hoist mounting angle to the lower hoist pivot pad and to the outside of the truck frame.
Mark the truck frame for drilling. See Figure 5.
CAUTION: BE CAREFUL OF BRAKELINES, WIRING, ETC. INSIDE THE
TRUCK FRAME WHEN DRILLING THE TRUCK FRAME.
Drill 21/32 diameter holes in the truck frame using the hoist mounting angles as guides. Bolt the prop
pivot and mounting angle to the truck frame using 5/8 x 2 hex bolts and hex lock nuts, tightening to 180 to
190 lb-ft. Securely weld the lower hoist pivot pads to the mounting angles. DO NOT WELD THE HOIST
PIVOTPADSTOTHETRUCKFRAME!Removetheclamps.
HYDRAULIC SYSTEMS
CrysteeloersPTOdriven,gearpumphydraulicsystemsforusewithallmodelsofLoBoyhoists.Crys-
teelalsooerselectricpowerunits,bothsingle-anddouble-acting,forallmodelsexceptH-25(Henry).
Mounting instructions can be found on the pages shown:
MOUNT RESERVOIR/VALVEASSEMBLY- B-5 (BERT), C-8 (CHARLIE)& D-9
(DANIEL)
Determine which side of the truck to mount the reservoir/valve assembly. The same side as the PTO open-
ingonthetransmissionwouldbeideal.Using3/8x1”capscrews,atwashersandhexlocknuts,boltthe
reservoir mounting angles to the reservoir/valve assembly so the exposed end of the valve spool is toward
the cab (See Fig. 7). This makes it much easier to connect the valve control cable to the valve. Place this
assembly against the outside of the truck frame on the same side as the pump. Mark the truck frame for
drilling using the mounting angles as guides. Make sure there is enough clearance for hot exhaust pipes.
THE ENGINE EXHAUST MUST NEVER BLOW DIRECTLY ONTO THE RESERVOIR/VALVE AS-
SEMBLY.
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





PTO driven Gear Pump with Remote Reservoir/Valve Page 8
Electric Pumps - General Page 15
Electric Pumps - Single-Acting Page 16
Electric Pumps - Double-Acting Page 17
INSTALLGEAR PUMP- B-5(BERT),C-8(CHARLIE)& D-9(DANIEL)
ThegearpumphasanSAE`A’mountingconguration,an11-toothsplinedshaftandatwo-boltmounting
ange,andisassembledforcounterclockwiserotation.Note:ThispumpwillmountdirectlytoChelsea’s
output type `AD’ or Muncie’s output type `T’. Crysteel Manufacturing recommends a PTO ratio of 100-
120%.Thisassuresaminimumpumpoperatingspeedof600RPM.CHECKTHEROTATIONOFTHE
PTO!Ifitisoppositeoftheengine,thenthepumpcanbeusedasitis.IfthePTOrotationisthesameas
the engine, then the pump will need to be reversed. (See instructions included with the pump.) Bolt the
gearpumptothePTOoutputangeusing3/8x1”capscrewsandlockwashers.
INSTALLGEAR PUMP- D-10 (DAVID), E-15 (ERNIE)& F-18 (FLOYD)
The gear pump for the D-10 (David), E-15 (Ernie) and F-18 (Floyd) hoists has an SAE `B’ mounting
conguration,a13toothsplinedshaftandafour-boltmountingange,andisassembledforrotationin
eitherdirection.NOTE:ThispumpwillmountdirectlytoChelsea’soutputtype`XK’orMuncie’soutput
type `D’. Crysteel Manufacturing recommends a PTO ratio of 100-120%. This assures a minimum pump
operatingspeedof600RPM.BoltthegearpumptothePTOoutputangeusing1/2x11/4capscrews
and lock washers.
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





CAUTION: BE CAREFUL OF BRAKELINES, WIRING, ETC. INSIDE THE
TRUCK FRAME WHEN DRILLING THE TRUCK FRAME.