Rugby LR-416 User manual

RUGBY MANUFACTURING CO.
INDUSTRIAL PARK
515 1st St. NE.
RUGBY, NORTH DAKOTA 58368
1656299
LR-416, LR-165, LR-25
INSTALLATION AND
OPERATION MANUAL
Use this manual ONLY if installing or operating an LR-416, LR-165, or LR-25 hoist. This manual
should be kept in truck glove compartment for reference when needed.
Features LR-416 P/N 03 3021, LR-165 P/N 03 3018, LR-25 P/N 03 3019
FIRST EDITION: July 1, 1997
LATEST EDITION: N (July 28, 2020)
To Be Filled In By Installer
Hoist Installed: _____________________________
Hoist Serial #: ______________________________
Pump Installation and Operation Manual #: ______________
In Service Date: _____________________________
Dealer: ____________________________________
Address: ___________________________________
Dealer Phone Number: _______________________

The following step-by-step instructions are to be followed as a general guideline when installing the
LR-416, LR-165, or LR-25 hoist assembly.
IMPORTANT FACTS ABOUT THIS MANUAL
This manual does not cover the installation and operation of the body prop or body props. The installation
and operation of the body prop is covered in manual No. 1656575. Every LR-416, LR-165, and LR-25
application sold by Rugby Manufacturing Co. includes manual No. 1656575 Body Prop Manual.
Also, this manual does not cover the installation and operation of the hydraulic system. There are four
different hydraulic systems available for some or all of the hoist models (LR-416, LR-165, or LR-25).
The four types of hydraulic systems and their respective installation and operation manuals are listed below:
Installation & Operation
Manual Part Number Type of Hydraulic System
1656296 Drive Shaft Driven Pump w/ Mid-Latch Control Cable
1656569 Split "M" (Direct Mount Pump w/ Remote 9 Quart Reservoir) &
Tower Control
1656317 Electric Single Acting Pump w/ Push Button Control
1656318 Electric Double Acting Pump w/ Push Button Control
Depending on the type of hydraulic system purchased, one of the above manuals will be included in every
LR-416, LR-165,or LR-25 sold by Rugby Manufacturing Co. Before installing the hoist, be sure you have
the proper manuals to do the job. If you do not have the correct manuals, contact Rugby Manufacturing Co.
1

2
"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 designed 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. Incompatible hydraulic components may cause
failure of the hoist which in turn could damage the truck, damage other property, and cause human injury or
death.
All Rugby Manufacturing Company's liability and warranty for a given hoist will be voided if it is
determined by Rugby Manufacturing Co. that substituted hydraulic components were used that were
incompatible with those supplied by Rugby Manufacturing Co.
Several hoist hydraulic parameters are given in the following table, these parameters are given as a general
guide. To ensure component compatibility, consult Rugby Manufacturing Co.

WARNINGS:
Warning: Not installing or operating equipment correctly can cause component damage or an
accident which may cause injury or death. "Always" install and operate equipment in
accordance with manufacturer's instructions. Read and understand this manual fully
before proceeding.
Warning: Welding, oxy-fuel cutting, or grinding sparks can cause fuel to ignite which in turn can
lead to injury or death. "Always" take adequate steps to avoid ignition of fuel from fuel
tanks when welding, grinding, or oxy-fuel cutting during equipment installation.
Warning: Heat from the truck's exhaust system can cause hydraulic component failure and may lead
to a fire which could cause injury or death. "Always" install equipment in locations where
heat from the exhaust system will not damage any hydraulic component.
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
body props supplied. "Remember" body props are to be used only on an "unloaded"
body.
Warning: Malfunctioning equipment can cause property damage, injury or death. "Always" have
faulty equipment repaired before continuing its use. If required, consult the manufacturer.
Warning: Overloading of a truck can cause truck component damage or an accident which may
cause injury or death. "Never" exceed the gross vehicle weight (GVW) or the gross axle
weight (GAW) rating of your vehicle.
Warning: The inadvertent shorting of the truck's electrical supply can cause a fire or equipment
damage that could lead to injury or death. "Always" disconnect the vehicle battery prior
to installing, servicing or repairing the pump.
Warning: Never install a cable on a truck while the body is raised without first blocking, bracing, or
propping the body up to prevent the body from inadvertently falling when the control
valve lever is moved. A falling body will result in serious injury or death if the control
valve lever is moved while someone is under the non-supported body.
Warning: Damage to brake lines during equipment installation, or installing bolts or equipment in
such a way that the line will rub and become damaged can lead to brake failure which can
cause an accident and can lead to severe injury or death. "Always" take adequate
steps to prevent brake line damage during installation and isolate brake lines from
installed equipment.
3

4
Capacities are based on water level, non-diminishing loads. Because of variations in truck equipment and
cab axles (CA), the data contained in this sheet is provided only as a general guide.

5
Capacities are based on water level, non-diminishing loads. Because of variations in truck equipment and
cab axles (CA), the data contained in this sheet is provided only as a general guide.

6
Capacities are based on water level, non-diminishing loads. Because of variations in truck equipment and
cab axles (CA), the data contained in this sheet is provided only as a general guide.

7
ASSEMBLY INSTRUCTIONS:
1. Mark the location for the rear hinge. This location should be immediately behind a truck cross
member, approximately 32" behind the center of the rear axle on single axle trucks. Refer to Figure 1
for the specific hoist model you are installing.
2. Cut a notch in each truck chassis frame rail as illustrated in Figure 2.
3. Position the rear hinge angle in the notch cut in Step 2. The rear hinge angle is 37 3/16" wide and
should be centered side to side in the notch as illustrated in Figure 3. Weld the rear hinge angle to
each of the truck chassis frame rails.
NOTE: This hinge assembly is designed for a truck longsill spacing of 34" and is not recommended
for any other width.
4. Locate the hoist on the truck frame making sure to center the hoist right and left and to square
the hoist with the truck frame. The LR-416, LR-165, and LR-25 are designed to rest on the
truck frame as shown in their respective Figure 1. A portion of the hoist extends below the
truck frame level; therefore, the hoist may be moved slightly forward to avoid truck cross
members. The distance between the rear hinge center and saddle center (Figure 1) is referred
to as the "M" dimension. In Table A, the "M" dump angles are tabulated.
NOTE: Moving the hoist along the truck frame will affect the hoist's performance. A forward
movement will reduce the dump angle and increase capacity, while a rearward movement will
increase dump angle and decrease capacity.

8
5. Slide a lock collar onto each lifting shaft. Slide a lifting shaft with collar into each end of the
hoist lifting tube (Figure 4).
6. Position a mounting angle under each hoist saddle. Secure each mounting angle to the truck frame
by drilling two 17/32" dia. holes and bolting the large mounting angle to the truck frame. Finally,
weld each mounting angle to its respective hoist saddle. See Figure 5.
NOTE: DO NOT weld mounting angles or saddle flats to the truck frame.
NOTE: All fasteners used in the above steps are 1/2" x 1 1/2" hex cap screws, lock washers, and
nuts. Torque all 1/2" fasteners to 90 ft. lb.
NOTE: The hoist saddle must set directly on the truck frame. If rivet interference is encountered,
countersink the rivet heads into the hoist saddle.
7. Install the hydraulic system using the Pump Installation & Operation Manual for the type of
pump being installed.
NOTE: A listing of the Pump Installation & Operation Manuals is given on page #1 of this
manual.
8. Position and secure the liner (sleeper) to the truck frame. The LR-416 or LR-165 hoist requires at
least 5 3/4" of clearance above the truck frame. As an example, if 4" long beams are on the truck
body, a liner of at least 1 3/4" will be required to gain enough room, 5 3/4", for mounting the LR-
416 or LR-165. Similarly, an LR-25 requires 7 1/2" of clearance.
9. Position the body with the long beams (just long beams if they are separate from body) onto the
truck frame.
NOTE: A clearance of at least 2" is required between the truck cab and the closest point on the
truck body.

9
10. Position the rear hinge brackets against the long beams. Once in position, weld the rear hinge
brackets to the body long beams as shown in Figure 6.
11. Slide each of the lifting shafts against the inside of the channel long beam. Weld the lifting shaft
to secure the shaft to the long beam as shown in Figure 7. With the shaft secured, slide the lock
collars against the hoist lifting tube and lock them by tightening the 3/8" set screw (refer to
Figures 4 and 7). Torque each set screw to 24 ft./lb.
12. Install all grease fittings. For grease fitting locations, refer to Figures 8, 9 or 10 on page 10.
Torque each grease fitting to 70 in./lb. Lubricate all grease fittings upon installation.
IMPORTANT: Hoist should be greased periodically or every time truck is greased.
13. With the hoist and body completely installed, cycle the hoist several times to rid the hydraulic
circuit of air.
14. Referring to Body Prop Manual #03 6034, install body prop.
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.

10

11
DECAL LOCATION:
Two 03 6039 "Danger" decals, as shown on this page, are supplied with each LR-416, LR-165, and LR-25.
These decals must be positioned as shown in Figure 11.
LOCATE 1 CAUTION DECAL (1656318) ON THE TRUCKS
LEFT FRAME RAIL, AND LOCATE 1 CAUTION DECAL
(1656318) ON THE TRUCKS RIGHT FRAME RAIL. LOCATE
THE CAUTION DECAL IN THE AREA OF THE FRAME RAIL
SHOWN BELOW. THE CHOSEN DECAL LOCATION
SHOULD BE FREE OF ANY VIEWING OBSTRUCTIONS.
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
1656850

12
ITEM
PART #
DESCRIPTION
QTY
1
1653827
SCREW, ½-13 X 1-1/2 HHC GR5 PLT
4
2
1620051
SCREW, ½-13 X 2-1/2 HHC GR8 PLT
2
3
1653838
SCREW, 5/8-11 X 4 HHC GR8 PLT
1
4
1653845
SET SCREW, 3/8-16 X 5/8 SQR HD BLK
2
5
1653860
NUT, ½-13 HEX GR5 STL PLT
4
6
1642984
NUT, ½-13 NYLOCK –NE GR8 STL
2
7
1643070
NUT, 5/8-11 NYLOCK –NE GR5 STL
1
8
1537022
WASHER, SAE ½ FLAT, PLATED
8
9
1653880
WASHER, ½ LOCK PLATED
4
10
1520370
FITTING, ¼-28” THREAD FORMING GREASE
7
11
1654905
COLLAR, 2.00 LOCK
2
12
1655676
SADDLE BRKT ASSY, SET, 416/165/25
2
13
1655695
BRACKET, LR-416/165/25 LIFT
2
14
1655917
BRACKET, MOUNTING ANGLE
2
15
1656861
FRAME, LR-416 WELDMENT
1
16
1315035
CYLINDER ASSY, LR-416
1
LR-416 PARTS LIST

13
ITEM
PART #
DESCRIPTION
QTY
ITEM
PART #
DESCRIPTION
QTY
1
1653827
SCREW, ½-13 X 1-1/2 HHC GRK PLT
1
9
1653921
PIN, 5/16” X 3-1/2” ZP COTTER
2
2
1537022
WASHER, SAE ½ FLAT, PLATED
10
10
1656145
CYLINDER, 5” X 16”
1
3
1653880
WASHER, ½ LOCK PLATED
1
11
1653838
SCREW, 5/8-11 X 4 HHC GR8 PLT
1
4
1653860
NUT, ½-13 HEX GR5 STL PLT
2
12
1643070
NUT, 5/8-11 NYLOCK-NE GR5 STL
1
5
1655917
BRACKET, MOUNTING ANGLE
4
13
1653845
SET SCREW, 3/8-16 X 5/8 SQR HD BLK
2
6
1655676
SADDLE BRKT ASSY, SET, 416/165/25
4
14
1654905
COLLAR, 2.00 LOCK
2
7
1520370
FITTING, ¼-28” THREAD FORMING GREASE
8
15
1655695
BRACKET, LR-416/165/25 LIFT
2
8
1655044
CYLINDER PIN SHAFT, LR-165/25
4
16
1654927
HOIST FRAME, LR-165
1

14
ITEM
PART #
DESCRIPTION
QTY
ITEM
PART #
DESCRIPTION
QTY
1
1653827
SCREW, ½-13 X 1-1/2 HHC GR5 PLT
4
9
1653921
PIN, 5/16”X 3-1/2”ZP COTTER
2
2
1537022
WASHER, SAE ½ FLAT, PLATED
8
10
1656145
CYLINDER, 5”X 16”
1
3
1653880
WASHER, ½ LOCK PLATED
4
11
1653838
SCREW, 5/8-11 X 4 HHC GR8 PLT
1
4
1653860
NUT, ½-13 HEX GR5 STL PLT
4
12
1643070
NUT, 5/8-11 NYLOCK-NE GR5 STL
1
5
1655917
BRACKET, MOUNTING ANGLE
2
13
1653845
SET SCREW, 3/8-16 X 5/8 SQR HD BLK
2
6
1655676
SADDLE BRKT ASSY, SET, 416/165/25
1
14
1654905
COLLAR, 2.00 LOCK
2
7
1520370
FITTING, ¼-28”THREAD FORMING GREASE
10
15
1655695
BRACKET, LR-416/165/25 LIFT
2
8
1655044
CYLINDER PIN SHAFT, LR-165/25
1
16
1655034
HOIST FRAME, LR-25
1
© 1997,1998, 2000, 2001, 2002, 2003, 2005, 2020 Rugby Manufacturing Co.
s:\acaddwg\manuals\035753-M.p65
LR-25 HOIST FRAME