TBEI Rugby HR-520 User manual

Original Revision: May 1, 1997
Current Revision: (H) February 26, 2014
Stock#: 1656321 (035775)
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.
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
Caution
.........................................................................................................................5
Assembly
..............................................................................................................6-13
Decal Location
..............................................................................................13-14
Operation
.................................................................................................................15
Parts List
.............................................................................................................16-17

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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,

Stock No. 1656321 (03 5775) 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. 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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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.
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 parameters are given in the following table. These parameters are given as a
general guide. To ensure component compatibility, consult Rugby Manufacturing Co.

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Assembly Instructions:
Body Prop Installation:
A body prop is supplied with every HR-520 hoist package kit.
1. Insert the body prop into the body prop bracket, making sure that the handle
hook is pointing towards the hoist. (Figure 1)
2. Fasten the body prop to the body prop bracket with the supplied 1/2” x 3” hex
screw & locknut. Tighten locknut until body prop binds when moved, and
then back off locknut just until body prop slides freely.
3. While pushing the handle in, lower the body prop to the down position. (The
handle should be resting against the bottom of the Y groove).
4. With the handle still pushed in, rotate the handle until the handle hook locks
against the bottom of the Y-groove bracket.
NOTE: To raise and lower body prop, see the “OPERATION” section of this manual.

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Hoist/Sub-frame Assembly:
1. 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” fasteners to 90 ft. lb.
NOTE: Ensure that both saddle brackets are firmly seated against the bottom of the sub-
frame after the hardware is tightened. It may be necessary to clamp the saddle bracket
and sub-frame together to prevent a gap from existing between the two surfaces.
2. Position the hoist with sub-frame on the truck frame as shown in Figure 3.

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3. 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.
4. Position a mounting angle under each saddle flat located on each side of the
sub-frame. Secure each mounting angle to the truck frame by drilling two
17/32” Dia. holes and bolting the mounting angles to the truck frame using
two 1/2” x 2” GR 8 bolts, four flat washers, two lock washers and two nuts.
(Figure 5).

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NOTE: Torque all 1/2” fasteners to 90 ft. lb.
5. 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.

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6. 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. Hole must not
exceed 3” in diameter; or disturb the top or bottom flanges of the side rail and must be
completely contained in the web portion of the side rail.
7. Slide a lock collar onto each lifting shaft. Slide a lifting shaft with collar into
each end of the hoist lifting tube (Figure 7).
8. Position the body with the long beams (just long beams if they are separate
from body) onto the sub-frame.
NOTE: A clearance of at least 2” is required between the truck cab and the closest point
on the truck body.
9. Position the rear hinge brackets against the bottom side of the long beams.
Once in position, weld the rear hinge brackets to the body long beams as
shown in Figure 8.

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10. 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. Torque each set screw to
24 ft. lb.

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11. 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.

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IMPORTANT:
All hoist and sub-frame grease fittings should be greased at least
every time the truck itself is greased.
12. 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. For installation information and operation, refer to the Installation
and Operation Manual for your particular pump and hydraulic components.
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.
Decal Locations:
Two 1654044 (03 6039) “Danger” decals are supplied with each HR-520. These
decals must be positioned as shown in Figure 9.

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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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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. Remember body props are to be used only on an unloaded
body.
1. Raise body to sufficient height and shut off all power.
2. Grasp prop from latched position by turning prop handle clockwise while pushing
handle in.
3. Grasp prop handle at arms length and rotate prop upwards to vertical position.
4. Push down until prop locks in vertical position.
5. Using inside-the-cab controls, lower body slowly until prop contacts hoist.
CAUTION:
Do not power hoist down while on prop.
6. To lower prop for operation of truck, “reverse” the procedure of the above five
steps.

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HR-520 Hoist w/ 60” CA Sub-Frame

Stock No. 1656321 (03 5775) 17
HR-520 Hoist w/ 84” CA Sub-Frame