Rugby MONARCH User manual

Original Revision: June 9, 2006
Current Revision: (J) May 5, 2014
Stock#: 1657447 (036226)
ELECTRIC MONARCH
PUMP
Installation & Operation Manual
To Be Filled In By Installer
Pump Model #:______________________________________
Pump Serial #:______________________________________
Hoist Model #:______________________________________
In Service Date:_____________________________________
Dealer:____________________________________________
Address:___________________________________________
City, State, ZIP:_____________________________________
Dealer Phone Number:_______________________________
Use this manual only if installing or operating a Monarch electric pump on a TBEI or Rugby hoist. This
manual should be kept in the glove compartment of the truck, or if installed on trailer, the glove
compartment of the truck pulling the trailer or any weatherproof compartment on the trailer for reference
when needed.
Website: www.TBEI.com
E-mail: [email protected]
Phone: [phone] Rugby
1-800-255-4345 DuraClass
1-800-533-0494 Crysteel

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Contents
Warnings
…………………………………………………………………….….3-4
Descriptions
…………………………….………………………………….….5-7
Installation
.........................................................................................................8-18
Operation
..........................................................................................................19-21

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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. 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 or trailer.
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: Connecting the hoist to a hydraulic system with more pressure (psi) or flow
(gpm) than is recommended by the hoist manufacturer can cause the hoist to fail during
the dumping of a load. This could lead to damage, serious injury, or death. Be sure you
have the correct pressure and flow. Consult the manufacturer if you do not know the
recommended pressure and flow.
WARNING: Adjusting the hydraulic pressure to more than the recommended setting
may cause the hoist to fail during the dumping of a load. This could cause damage,

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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. Always wear eye protection and protective clothing when
working around hydraulic systems.
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.
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: Do not raise or drive a raised body against a power line. Bring body in
contact with a power line or power source will result in serious injury or death by
electrocution.
WARNING: Do not raise or drive a raised body against another object. Doing so could
result in equipment damage or property damage, bodily injury or death.
WARNING: Do not dump while on uneven ground or if vehicle is in an uneven position
from side to side. Dumping unevenly can cause vehicle to overturn and cause equipment
or property damage, personal injury, or death.
WARNING: Stay clear of dump body when dumping. Moving vehicle parts or the
moving load could cause injury or death.
WARNING: Check load making sure that rocks or any other object will not spill out of
vehicle while transporting load. Falling objects can cause equipment damage or property
damage, bodily injury or death.
WARNING: Make sure all doors are closed and latched before moving vehicle.
Swinging doors or falling objects can cause equipment or property damage, bodily injury
or death.

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Descriptions
NOTE: This manual contains descriptions of hydraulic fittings. In describing these
fittings, special designations are used. These designations and their meanings are as
follows:
SPECIAL DESIGNATION
MEANING
MB MALE O-RING BOSS
FB FEMALE O-RING BOSS
MJ MALE JIC
FJ FEMALE JIC
FJX FEMALE JIC SWIVEL
FJX90 FEMALE JIC SWIVEL ELBOW
MP MALE PIPE THREAD (NPT)
FITTING DESIGNATION
THREAD SIZE
4MB 4FB 4MJ 4FJ 7/16”-20
6MB 6FB 6MJ 6FJ 9/16”-18
8MB 8FB 8MJ 8FJ 3/4”-16
4MP 1/4” NPT
12MP 3/4” NPT

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The type of fittings that are included will vary, depending on the model of the hoist being
installed. Refer to Figure 1a thru 1f, depending on the type of hoist and pump model that
is being installed.
For all of the units, a restricted fitting is supplied. This fitting reduces the speed at which
the hoist closes, to prevent damage to the truck or trailer frame. This fitting must be
installed in the base end of the hoist cylinder.
NOTE: All connections rely on O-ring or flare/face sealing methods. Therefore, no
thread sealant or tape of any kind is required to seal the joints.
The following charts are included to aid in the identification of hoses. Please note that
several different lengths of hoses are available for each type.
HOSE “A”
1/4” 6FJX-4FJX90
PART NUMBER LENGTH
STANDARD
SUPPLY
(Base end of cylinder)
1654546 (008238) 5’ LR-3510
1654547 (008239) 6’
1654548 (008240) 8’
1654576 (008332) 9’

Stock#: 1657447 (036226) 7
HOSE “B”
1/4” 6FJX-6FJX
PART
NUMBER LENGTH STANDARD SUPPLY (Base end of cylinder)
STANDARD
RETURN
(Rod end of
cylinder)
1654514 (008172) 4’ HR-520
1654515 (008173) 5’ LR-416/165/25, HR-540/550 LR-3510, HR-520
1654516 (008174) 6’ LR-416/165/25
1654518 (008176) 8’ HR-540/550
1654564 (008320) 9’
1654575 (008331) 10’
HOSE “C”
3/8” 6FJX-6FJX
PART
NUMBER LENGTH STANDARD SUPPLY (Base end of cylinder)
STANDARD
RETURN
(Rod end of
cylinder)
1654520 (008178) 4’
1654521 (008179) 5’ LR-26/623/28
1654522 (008180) 6’
1654523 (008181) 7’ LR-26/623/28
1654524 (008182) 8’
1654569 (008325) 9’
1654574 (008330) 10’
This manual contains information necessary for the proper installation and operation of
an electric power unit. This manual applies only to a Monarch unit supplied from TBEI
or Rugby. If you have a different power unit, refer to that manufacturer’s directions. With
proper installation, use, and regular maintenance, this power unit will give many years of
trouble free service.

Stock#: 1657447 (036226) 8
Installation
POWER UNIT ATTACHMENT:
The power unit should be mounted in a protected area near the hoist. For longevity of the
unit and related components, do not mount near exhaust system components or in the
path of road splash from the vehicle’s tires.
NOTE: Mount the unit horizontally so that the reservoir is level for full use of the
reservoir capacity.
WARNING: Check for potential clearance issues with vehicle brake lines, air lines, wire
harnesses, etc. before determining the power units location. Avoid damage to lines or
installing components that could rub against lines and cause system failures. Such
failures could lead to property damage, serious injury or death.
Securely attach the pump to the frame using two 3/8”-16 x 1” flange bolts in the front,
and one 3/8”-16 x 1” flange bolt at the back of the tank. Tighten to 33 ft/lbs torque.
HOSE CONNECTIONS:
Install all fittings and hoses. Tighten all of the connections, except the connection
between the base end port and the hose. Leave the connection between the base end port
and the hose loose at this time.

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Stock#: 1657447 (036226) 15
ELECTRICAL:
1. Route a copper American Wire Gage (AWG) #0 cable from the battery to the power
unit. Connect one end to the negative battery terminal. Connect the other end to the
power unit’s aluminum valve block with a 5/16”-18 x 3/4” hex cap screw as shown
in Figure 3.
CAUTION: The high current demands of the power unit require a direct connection
between the negative post of the battery and the power unit. Never rely on the
vehicle’s ground circuit, which could lead to property damage or reduced hoist
lifting capacity during peak loads.
NOTE: Avoid routing locations where power cables may rub against any sharp edges of
the vehicle, get pinched or be exposed to excessive heat. Install approved sheathing
over each cable in critical areas.
2. Route a copper AWG #0 cable from the battery to the power unit - do not connect
the cable to the positive battery terminal until Step 2 of the Fill and Prime section.
Install the provided 250 amp inline fuse no further than 12 inches from the battery.
At the power unit, insert the supplied rubber terminal boot over the end of the cable
and the black wire as shown in Figure 2. Fasten the cable end and black wire to
“Point A” on the solenoid start switch. Tighten to 35 in/lbs torque. Snap rubber
terminal boot over stud to complete connection. Make sure all connections on
solenoid start switch are secure.
WARNING: Never tighten battery cable stud, marked “Point A”, to more than 35 in/lbs
torque and never tighten control stud, marked “Point B”, to more than 15 in/lbs
torque. Exceeding the torque rating for either stud can cause unit to malfunction,
which could lead to property damage, serious injury or death.
3. (Double-Acting or Single-Acting if equipped) Place the solenoid cover over the
solenoid and secure in place with the tie strap provided.
4. The hoist should only be used with the operator in a safe location. Locate the hoist
control station in a safe location.

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FIGURES 2a & 3a
SINGLE-ACTING SCHEMATICS
*If 2 wire coil – ground wire.

Stock#: 1657447 (036226) 17
FIGURE 2b & 3b
DOUBLE-ACTING SCHEMATICS
*If 2 wire coil – ground wire.

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FILL & PRIME:
1. Fill the reservoir with automatic transmission fluid (ATF), such as Dexron
®
II
Type A.
2. Secure the unit’s power cable to the positive battery terminal to complete the
electrical installation and allow operation of the unit.
3. Place a drip pan or other suitable container below loose hose fitting at base
end of cylinder.
4. Press “UP” pushbutton on control station to begin priming the unit. Once oil
begins flowing steadily from loose fitting, release pushbutton and tighten
fitting.
5. Operate unit several times starting with short cylinder strokes and increasing
length with each successive stroke.
6. Recheck oil level often and add as necessary to keep pump from picking up
air.
7. After hoist has been fully raised and lowered repeatedly to purge air from
cylinder, lower hoist and check oil level in reservoir. With the hoist down, the
reservoir should be full within 1.5” of the top. DO NOT OVERFILL!
8. Install filler/breather cap in reservoir fill hole.

Stock#: 1657447 (036226) 19
Operation Instructions
WARNING: Being under or near a raised body can result in injury or death should the
body unexpectedly descend or tip. Hoist must be activated with operator in control at a
safe location. No one must be allowed to enter the area under a raised body while the
hoist is in operation.
WARNING: Being under a raised body can result in serious injury or death should the
body unexpectedly descend. Never position yourself or allow other 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. When two props are provided, both props must be used.
DANGER:
1. Stay out from under body when hoist is operating.
2. During dumping operations, no one must be allowed to stand in or move
through the area where the body and hoist operate or into an area where an
upset load might fall.
3. Controls must be in a safe location and operator must remain at controls
during dumping operation. Controls must be located in a location where it
is not possible to be under body during dumping operation.
4. Never leave body raised or partly raised while the truck or trailer is
unattended or while performing maintenance or service under body, unless
body is braced to prevent accidental lowering.
5. Do not attempt to raise a loaded body when the truck or trailer is on un-
level ground.
6. Never jerk or shock a raised body to loosen a stuck load.
WARNING: Freeing a stuck load during dumping, with the body raised, by jerking or
shocking the trailer, may cause damage to the truck or trailer, serious injury or death.
Never drive forward or rearward and stop quickly with the load up or otherwise shock
the load. If a load is stuck in the body, lower the body, then free the load.
WARNING: Attempting to dump a load on un-level ground may cause the truck or
trailer to over turn, and can result in damage, serious injury or death. Always dump the
load on ground that is level front to rear as well as level side to side.
WARNING: Overloading a hoist can cause component damage or an accident which
may cause injury or death. Never exceed the hoist’s rated lift capacity.
WARNING: Damaged or malfunctioning equipment may cause injury or death. Repair
or replace any damaged or malfunctioning equipment before continuing its use.

Stock#: 1657447 (036226) 20
NOTE: Always use clean automatic transmission fluid (ATF) in the power unit. Do not
mix types. Check oil level monthly and add as needed (see Fill & Prime instructions) to
prevent unit from pumping air. Change fluid annually to remove condensation and
entrapped debris.
Check the following monthly to ensure proper operation:
1. Wiring, electrical connectors, power cables (positive and ground), valves, and
coils for any corrosion, rust or loose bolts. Electrical components must be kept
free of corrosion and rust in order to function properly.
2. Hoses/fittings for any cracks, leaks or any other exterior damage. Tighten all
fittings as needed.
3. Plastic reservoir for leaks or other damage.
4. Vent cap for any dirt or debris.
SINGLE ACTING:
Raise the hoist by pressing and holding the “UP” pushbutton on the control station. This
activates the power unit and directs oil to the base end of the hoist cylinder. Releasing the
pushbutton will stop raising the hoist and will hold its position.
NOTE: The power unit is equipped with a factory-set hydraulic relief valve that will
bypass at 3200 PSI when the hoist reaches a fully raised position or whenever the load
being lifted exceeds the hoist capacity. Care should be taken not to let the pump bypass
for long periods of time, as this will put stress on the whole hydraulic and electrical
system. To stop the pump from bypassing, release the “UP” button on the control station.
Lower the hoist by pressing and holding the “DOWN” pushbutton on the control station.
This activates the solenoid valve and directs oil from the cylinder back to the power
unit’s reservoir. Releasing the pushbutton will stop lowering the hoist and it will hold its
position.
DOUBLE ACTING:
Raise the hoist by pressing and holding the “UP” pushbutton on the control station. This
activates the power unit and directs oil to the base end of the hoist cylinder. Releasing the
pushbutton will stop raising the hoist and it will hold its position.
NOTE: The power unit is equipped with a factory-set hydraulic relief valve that will
bypass at 3200 PSI when the hoist reaches a fully raised position or whenever the load
being lifted exceeds the hoist capacity. Care should be taken not to let the pump bypass
for long periods of time, as this will put stress on the whole hydraulic and electrical
system. To stop the pump from bypassing, release the “UP” button on the control station.