TBEI CRYSTEEL LB520 User manual

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LO-BOY
TRUCK HOIST
CRYSTEEL’S
LB520
Web Site E-Mail Phone (507) 726-2728
Website: www.TBEI.com
E-mail: [email protected]
THIS MANUAL MUST BE INCLUDED WITH THE VEHICLE
AFTER COMPLETING THE INSTALLATION.

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DATE PURCHASED __________________________________________________________________
HOIST SERIAL NUMBER ____________________________________________________________
CYLINDER SERIAL NUMBER ______________________________________________________
DEALER __________________________________________________________________
ADDRESS __________________________________________________________________
PHONE __________________________________________________________________
FOREWORD
Crysteel’s LB520 Hoist has been designed and intended for use on single-axle trucks with cab-to-axle
dimensions of 72 to 132 inches and body lengths of 9 to 16 feet.
This manual contains information necessary for the proper installation and operation of Crysteel’s Model
LB520 Hoist. Study it carefully before attempting to mount or use the hoist. With proper installation and
maintenance, the Crysteel Model LB520 Hoist 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. Usetheproperhydraulicuid.KEEPITCLEAN.Remembertochangeitregularly.
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. Whenthehoistcylinderreachestheendofthestroke,oilwillowthroughtheautomatic
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,becausethereservoirhassucientcapacitywhetherornotthehoistispowered
down.Youwillbenetfromtheadvantagesofthedoubleactinghoistonlyifyoupower
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.Thehydraulicsystemshouldbedrained,ushedandrelledwithproperhydraulicuid
atregularintervals.CAUTION:NEVERusehydraulicBRAKEFLUIDinthehydraulic
system.
11.Afteraddingorreplacingthehydraulicuid,cyclethehoistseveraltimestoremoveair
from the cylinders and hydraulic hoses.
2. Lubricateallgreasettingsevery100cyclesoreverytwomonths.Infrequentorinsu-
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. Checkallboltsandttingsregularly.Keepthemtight.Seetableonpage4fortorqueval-
ues.
9. Alwaysoperatehoistonarmandlevelsurface.
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
INSTALLATION INSTRUCTIONS 6
LOCATEHOIST-SUBFRAMEASSEMBLYONTRUCK 6
LOCATEBODY/HOISTASSEMBLYONTRUCK 7
LOCATE MOUNTING PLATES 7
DRILLTRUCKFRAME 7
WELD REAR HINGE AND SUBFRAME 8
SUPPORT FUEL FILL TUBE 8
HYDRAULIC PUMPS 8
MOUNT GEAR PUMP 8
MOUNT RESERVOIR/VALVE ASSEMBLY 9
INSTALL REMOTE VALVE CONTROL 9
INSTALL PUMP HOSES - 4 GPM 10
INSTALL PUMP HOSES - 6 GPM 10
INSTALL CYLINDER HOSES - GEAR PUMP SYSTEMS 11
ELECTRIC PUMP MOUNTING - GENERAL 12
ELECTRIC PUMP INSTALLATION - DOUBLE-ACTING 13
ADD HYDRAULIC OIL 13
POWER HOIST DOWN 14
INSTALLTIPPERBODYONTRUCK 14
INSTALLOTHERBODYONTRUCK 15
INSTALLBODYPROPBRACKETONBODYLONGBEAM 16
INSTALL BODY GUIDES 16
INSTALLGREASEZERKSANDLUBRICATEHOIST 17
INSTALL DECALS 17
LB520 CYLINDER PARTS 19
HYDRAULIC SYSTEM PARTS 20
FRAME & CYLINDER AND SUBFRAME PARTS 22
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.Tightenallnutsandboltstoaconsistentlevel.Usethefollowingtablefortorquevalues.
Size Grade2Torque Grade5Torque Grade8Torque
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
Thefollowingabbreviationsareusedindescribinghydraulicttings.
ORBM O-Ring Boss - Male Thread
NPTM Pipe - Male Thread
NPTF Pipe - Female Thread
JICM JIC 37° - Male Thread
JICF JIC 37° - Female Thread

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INSTALLATION INSTRUCTIONS
LOCATE HOIST-SUBFRAME ASSEMBLY ON TRUCK
The hoist-subframe assembly is normally mounted to the truck before attaching it to the body.
For Ford trucks, with a 40 gallon rear fuel tank, place the end of the subframe even with the end of the
truck frame, 47 1/2 inches behind the center of the rear axle.
For Ram trucks with a 52 gallon rear fuel tank, and GM trucks with a 40 gallon rear fuel tank, place the
end of the subframe 3 inches ahead of the end of the truck frame.
For trucks where the rear fuel tank does not extend behind the rear spring hanger, and for trucks with fuel
tanks mounted under the cab or outside the frame just behind the cab, mark the truck frame 36 inches be-
hind the center of the rear axle. This should be a minimum of 2 inches behind the rear spring hanger. The
truckframewillbecutoatthismark.
LOCATEBODY/HOISTASSEMBLYONTRUCK
Makesurethemarksforcuttingthetruckframeareaccurateandevenfromsidetoside.Cutothetruck
frame and grind the ends smooth. Place the subframe on the truck making sure it is even with the end of
thetruckframe,centeredsidetosideandsquarewiththetruckframe.Thereshouldbe3or31/2inches
clearance between the back of the cab and the front end of the subframe.
NOTE:Ifthetruckframehasrivetsinthetopange,addspacersbetweenthetruckframeandsubframe,
or counter sink the rivet heads into the subframe by drilling holes in the subframe. Do not remove the rivet
heads!
Fig. 1
MODEL LB520
Cab Clearance 3-5"
30"-36"
CAUTION: BE CAREFUL OF BRAKELINES, WIRING, ETC. INSIDE THE
TRUCK FRAME WHEN DRILLING THE TRUCK FRAME.
Use the following installation procedures when the body and hoist have been assembled at the factory.
Place the body and hoist assembly on the truck frame so there is 3 to 5 inches of cab clearance. Now,
check the location of the back end of the subframe. It should be a minimum of 2 inches behind the rear
springhanger.Thetruckframewillneedtobecutoevenwiththebackendofthesubframerails,as
shown in Fig. 3.
IfthetruckisaFordF450orF550,thebackedgeoftherearhingeshouldbeushwiththeendofthe
truck frame. If the truck is a Ram 4500 or 5500, then the end of the subframe should be 3 inches ahead of
the end of the truck frame.
Block up the back end of the body/hoist assembly and cut the truck frame as marked.
NOTE:Ifthetruckframehasrivetsinthetopange,addspacersbetweenthetruckframeandsubframe,
or counter sink the rivet heads into the subframe by drilling holes in the subframe. Do not remove the rivet
heads!
LOCATEMOUNTINGPLATES
There are six mounting plates, three for each side
- one at the front of the subframe, one at the hoist
mount and one between the hoist mount and the
rear hinge. Clamp the mounting plates to the truck
frame and to the subrame as shown in Figures 1
and 2. If desired, locate the plates to use existing
holes in the frame. Mark the mounting plates for
drilling. Repeat this for the other side.
For Dodge trucks, where the subframe is oset
foward from the end of the truck frame, be sure to
locate the rear mounting plate within 2 inches of
the rear hinge.
Drill 21/32” holes in the mounting plates and the truck frame. Bolt the mounting plates in place using 5/8
x 2 cap screws (grade 8) and hex lock nuts, tightening to 180-190 lb-ft.
DRILLTRUCKFRAME

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WELD REAR HINGE AND SUB-
FRAME
Make sure the body/hoist assembly or hoist/
subframe assembly is correctly located, cen-
teredonandsquarewiththetruckframe.Se-
curely weld the mounting plates to the sub-
frame. Add a plate (not supplied) to the end
of the truck frame rail. (See Fig. 3.) Securely
weld the plates to the end of the truck frame
rails and to the back end of the subframe. Do
this on both sides.
HYDRAULIC PUMPS
CrysteeloerstwodierenthydraulicsystemsforusewiththeModelLB520Hoist.Mountinginstruc-
tions can be found on the pages shown:
MOUNT GEAR PUMP
ThegearpumphasanSAE`A’mountingconguration,an11-toothsplinedshaftandatwo-boltmounting
ange,andisassembledforcounterclockwiserotation.Note:ThispumpwillmountdirectlytoChelsea’s
output type `AD’ or Muncie’s output type `T’. Crysteel Manufacturing recommends a PTO ratio of 100-
120%.Thisassuresaminimumpumpoperatingspeedof600RPM.CHECKTHEROTATIONOFTHE
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
gearpumptothePTOoutputangeusing3/8x1”capscrewsandlockwashers.
Theoptional6GPMgearpumphasanSAE`B’mountingconguration,a13toothsplinedshaftanda
four-boltmountingange,andisassembledforrotationineitherdirection.NOTE:Thispumpwillmount
directlytoChelsea’soutputtype`XK’orMuncie’soutputtype`D’.CrysteelManufacturingrecommends
a PTO ratio of 100-120%. This assures a minimum pump operating speed of 600 RPM. Bolt the gear pump
tothePTOoutputangeusing1/2x11/4capscrewsandlockwashers.
PTO driven Gear Pump with Remote Reservoir/Valve Page 8
Electric Pumps - General Page 12
Electric Pumps - Double-Acting Page 13
SUPPORTFUELFILLTUBE
Ifnecessary,constructsupportsforthefueltanklltubes.Constructthesupportsothatitdoesnotinter-
fere with any portion of the body or hoist operation.
MOUNT RESERVOIR/VALVE ASSEMBLY
The reservoir/valve assembly should be mounted on the same side of the truck as the pump and as high as
possible for reliable pump performance. The slotted end of the valve spool should be towards the front of
the truck so the valve control cable can be easily connected. The mounting brackets for the reservoir/valve
assembly can be used to mount the reservoir/valve assembly outside the truck frame or inside between
the truck frame rail and the driveshaft. Determine where to mount the reservoir/valve assembly and bolt
themountingbracketstothereservoir/valveassemblyusing3/8x1capscrews,atwashersandhexlock
nuts. Locate the reservoir/valve assembly and clamp the mounting brackets to the truck frame. See Fig.
4. If inside the truck frame, make sure there is enough clearance for the drive line and hot exhaust pipes.
THE ENGINE EXHAUST MUST NEVER BLOW DIRECTLY ONTO THE RESERVOIR/VALVE AS-
SEMBLY. Insert the spacers in the mounting brackets and mark the truck frame for drilling using the pump
mounting brackets as guides
CAUTION: BE CAREFUL OF BRAKELINES, WIRING, ETC. INSIDE THE
TRUCK FRAME WHEN DRILLING THE TRUCK FRAME.
INSTALL REMOTE VALVE CONTROL
Temporarily assemble the valve control head to the pedestal using 5/16 x 2 1/4” machine screws and hex
nuts.Placethisassemblyontheoorofthecab.Makesurethereisenoughroomtooperatethevalvecon-
trolandthegearshiftleverandtoadjusttheseat.Checkbelowtheoorforobstructionsandcablerouting.
Relocatethevalvecontrolifnecessary.Marktheoorusingthepedestalasatemplateanddrill1/4”holes
for the mounting screws and a 3/4” hole for the control cable. Assemble the control cable to the valve
control head and assemble the valve control head and cover to the pedestal using 5/16 x 2 1/4” cap screws
andhexlocknuts.Insertthecontrolcablethroughtheholeintheoorandmountthepedestaltotheoor
using 5/16 x 1/2 machine screws and hex lock nuts. Make sure the valve control lever is in its center detent
position.Keepthecontrolcableawayfromhotexhaustpipesandrotatingdriveshafts.Thecontrolcable
should not have any sharp bends or kinks in it (these will make the control harder to operate).
Install the 3/4” hex jam nut onto the valve end of the control cable and turn it past the threads. Insert the

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Fig. 5
INSTALL PUMP HOSES - 4 GPM
Study Fig. 6 very carefully before connecting the hoses. Install a 3/4” 90° street elbow and a 3/4” hose
barb in the suction port on the bottom of the reservoir. Install a 1 1/16 ORB x 3/4” hose barb in the suction
port of the pump and install a 3/4” ID suction hose. Secure the suction hose in place using hose clamps.
Install a 1 1/16 ORB x 1/2 NPT 90° swivel adapter in the `IN’ port of the control valve and a 7/8 ORB x
1/2 NPT adapter in the pressure port of the pump. Connect a 72” long 1/2” ID hose between the pump and
the valve.
end of the cable through the bonnet clamp. Install the bonnet onto the control cable and turn it past the
threads also. Install the 1/4” hex jam nut and terminal eye on the core rod of the cable. Lock the terminal
eye to the core rod of the cable using the hex jam nut. Place the terminal eye in the slot of the valve spool;
insert the short pin through the valve spool and terminal eye and secure it in place with the `E’ ring.
Threadthebonnetontotheendofthecablesoitrmlytouchestheendofthevalve.(Donotover-or
under -tighten the bonnet as either would move the valve spool out of its neutral position.) Remove two
cap screws from opposite corners of the seal retainer plate. Slide the bonnet clamp onto the bonnet and
secureittothevalveusingthe1/4x11/4”capscrews,lockwashersandatwashers.Lockthebonnetto
the cable using the 3/4” hex jam nut. See Fig. 5.
INSTALLPUMPHOSES-6 GPM
Study Fig. 6 very carefully before connecting the hoses. Install a 3/4” 90° street elbow and a 3/4” hose
barb in the suction port on the bottom of the reservoir. Install a 1 1/16 ORBM x 3/4’’ hose barb in the
suction port of the pump and install the suction hose. Secure the suction hose in place using hose clamps.
Install a 1 1/16 ORB x 1/2 NPT 90° swivel adapter in the `IN’ port of the control valve and install a 1 1/16
ORBM x 1/2 adapter in the pressure port of the pump. Install a 72” long 1/2” ID hose from the pump to
the valve.
INSTALLCYLINDERHOSES-GEARPUMPSYSTEMS
Install 90° swivel adapters in the work ports of the control valve and in the ports on the cylinder. Connect
the36”long1/2”IDhosewith7/8JICttings,fromthe`B’portonthecontrolvalvetothebaseendport
onthecylinder.Connectthe60”long1/2”IDhosewith7/8JICttings,fromthe`A’portonthecontrol
valve to the rod end port on the cylinder. This will raise the hoist when the control lever is pulled back and
lower it when pushed forward.
NOTE: The `A’ port is the `power-down’ port and has a pressure of only 500-1000 PSI at engine idle; the
`B’ port has full system pressure.
Fig. 6

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CAUTION: BE CAREFUL OF BRAKELINES, WIRING, ETC. INSIDE THE
TRUCK FRAME WHEN DRILLING THE TRUCK FRAME.
Drill 17/32” holes in the truck frame and bolt the reservoir/valve assembly in place using 1/2 x 2 3/4 cap
screws and hex lock nuts, tightening to 90 to 100 lb-ft.
For rated performance, the voltage at the power unit must be a minimum of 12VDC. This should be
measured between the large terminal of the start solenoid (where the battery cable is connected) and the
power unit base, where it is bolted to the mounting bracket. NOTE: Grounding of the power unit is just
as important as the installation of the positive battery cable. It is easier to get a good ground by using a
second battery cable.
Connect the large terminal on the motor start solenoid to the positive terminal on the battery with a #0
gauge battery cable. Connect the negative terminal on the battery to the grounding hole on the power unit
with a #0 gauge battery cable. See Figure 8. Check the voltage between the large terminal on the start
solenoid and the power unit base.
ELECTRICPUMPINSTALLATION-DOUBLE-ACTING
Install 9/16 ORB x 3/4 JIC 90° swivel adapters in both work ports on the electric pump. If needed, for
good hose routing, install 3/4 JIC x 3/4 JIC 90° swivel adapters to both of these adapters. Connect the
shorter3/8IDhosewith3/4JICttingsfromthe‘C1’portonthepumptothebaseendportonthecylin-
der.Connectthelonger3/8”IDhosewith3/4JICttingsfromthe‘C2’porttotherodendport.
NOTE: The ‘C2’ port is the power down port and has only 500 PSI maximum pressure.
ADDHYDRAULICOIL
Useaqualityhydraulicuidof150SSU@100°Fwhichcontainscorrosionandoxidationinhibitors
andafoamdepressant.ThisisapproximatelytheequivalentofSAE10Worlighterweightoil.Dexron
automatictransmissionuidshouldbeusedintheelectricpumps.Fillthehydraulicreservoirusingthe
following table.
KEEP THE OIL CLEAN. USE CLEAN CONTAINERS, FUNNELS AND
OTHER EQUIPMENT!
ELECTRICPUMPMOUNTING-GENERAL
The electric power unit should be mounted behind the cab, either to a mounting bracket in the subframe
or to mounting brackets bolted to the truck frame as shown in Fig. 7. If using the bracket in the subframe,
bolt the double-acting power unit with the motor towards the passenger’s side to the bracket provided
using3/8x1capscrewsandatwashers,tighteningto24to26lb-ft.Boltthesingle-actingpowerunit
withthemotortowardsthedriver’ssidetothebracketprovidedusing3/8x1capscrewsandatwashers.
, tightening to 24 to 26 lb-ft Insert the 3 x 5 rubber pad under the end of the tank and clamp the tank to the
mounting bracket with the 33” long cable tie.
If separate mounting brackets are used, chose the location for mounting the power unit, bolt one mount-
ing angle to the power unit using the 3/8 x 1 hex head cap screws, tightening to 24 to 26 lb-ft. Clamp the
mounting bracket to the truck frame. Clamp the second mounting angle to the truck frame so it supports
the far end of the reservoir. Insert a rubber pad between the mounting angle and the reservoir; and secure
it in place with a tie strap. Mark the truck frame for drilling using the pump mounting angles as guides.
Fig. 7
ELECTRIC POWER UNIT
MOUNTING
ANGLE
RUBBER PAD
TIE STRAP
Fig. 8
Locate the control in the cab and route the cable out of the cab through a hole in the back of the cab. Con-
nect the control to the electric power unit using the 4-pin connector set.
After completing the wiring, install the motor start switch cover over the start switch and secure with a
tie strap.
Start Switch
Cover
Fig. 9
Connect Ground Cable
Double-Acting
Power Unit
Connect Power Cable
Hyd System Reservoir Size FluidRequired Initial Fill
Gear Pump w/ Valve/Tank 6 Gal 5.5 Gallons 4 Gallons
Electric Double-Acting 7.5 Quarts 13.5 Quarts 7.5 Quarts

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POWER HOIST DOWN
Before mounting the body, the hoist must be completely closed to make certain that the hoist gives full lift
height and performance. Make sure the lift angles are straight up and down.
For hydraulic systems with the direct mount gear pump, start the truck engine, engage the PTO and power
down the hoist to “bottom-out” the hydraulic cylinder and the hoist frame. Place the hoist valve control in
the “hold” position. Both the hoist frame and the hydraulic cylinder are now completely closed.
For hydraulic systems with the double-acting electric pump, press and hold the `DOWN’ push-button on
the control to “bottom-out” the hydraulic cylinder and the hoist frame. Release the `DOWN’ push-button.
Both the hoist frame and the hydraulic cylinder are now completely closed.
INSTALL OTHER BODY ON TRUCK
Study the diagram in Fig. 10 before installing the body. Make sure there is enough clearance under the
bodyforthehoisttot.Theinsideofthelongbeamsshouldbeboxedintoprovideaatsurfaceforweld-
ing the body and hoist together. Carefully measure the location of the hoist lift plate and mark this location
on the inside of the longbeams and box in the inside of the longbeams. Place the body on the truck with
3to5inchesofclearancebehindthecab.Makesurethereissucientclearancebetweenthebodyand
the reservoir/valve assembly. Relocate the reservoir/valve assembly if necessary. Carefully align the body
longbeams to the subframe rails. Securely weld the rear hinge bracket to the longbeams. Securely weld the
hoist lift plates to the boxed-in sections of the longbeams.
DO NOT WORK UNDER A RAISED BODY UNLESS THE BODY IS
SECURELY BLOCKED OR PROPPED IN THE RAISED POSITION.
Ifthebodyandsubframehavebeenassembledatthefactory,nishweldingthehoistliftbracketstothe
llplatesontheinsideofthelongbeams.
93.00 FOR 45INSTALLATIONS
84.00 FOR 50INSTALLATIONS
Fig. 10
INSTALL TIPPER BODY ON TRUCK
Place the Tipper body on the subframe so the front of the body and the front end of the subframe are even.
Makesurethereissucientclearancebetweenthebodyandthereservoir/valveassembly.Relocatethe
reservoir/valve assembly if necessary. Carefully align the body longbeams to the subframe rails. Securely
weld the rear hinge bracket to the longbeams. Securely weld the hoist lift plates to the boxed-in sections
of the longbeams.
DO NOT WORK UNDER A RAISED BODY UNLESS THE BODY IS
SECURELY BLOCKED OR PROPPED IN THE RAISED POSITION.

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INSTALL BODY GUIDES
Two body guides have been included and should be mounted near the front of the subframe. Clamp the
body guides to the outside of the subframe as shown in Fig. 12. The body guide should be tight against the
outside of the longbeams of the body. Securely weld the body guides to the subframe.
2. Raise the prop arm to a free standing position by allowing the prop arm to rest against the
rearangeoftheproppivot.Thetopoftheproparmwillswinginunderthelongbeam.
4. Tooperatethebodyprop,raisethebodytothedesiredheight,shutoallpower,raisethe
prop arm to a free standing position. Lower the body slowly until the longbeam bracket
contacts the prop arm saddle. DO NOT POWER HOIST DOWN!
5. To place the body prop in the storage position, raise the body to clear the body prop sad-
dle, lower the body prop to the storage position and lower the body.
3. Slowly lower the body until the bottom of the longbeam rests on the body prop saddle.
Place the longbeam bracket against the outside of the longbeam so the legs straddle the
prop arm saddle. Securely weld this bracket to the body. (See Fig. 11.)
INSTALL BODY PROP BRACKET ON BODY LONGBEAM
The body prop is designed and intended to support an EMPTY truck body in the raised position. Using the
body prop permits service work to be performed safely beneath a raised body. It is mounted on the outside
of the subframe on the driver’s side.
BODY PROP
SUBFRAME
Fig. 12
LONGBEAM BRACKET
PROP
PIVOT
Fig. 13
TRUCK FRAME
SUBFRAME
LONGBEAM
BODY
GUIDE
BODY
LONGBEAM
LONGBEAM BRACKET
Fig. 11 Fig. 12
1. Raise the body more than half way up.
INSTALLGREASEZERKSANDLUBRICATEHOIST
Install grease zerks on the hoist and lubricate the hoist in the following locations:
Upper Crosstube.............................................................2 Fittings
Lower Crosstube ............................................................2 Fittings
Cylinder Base Pivot .......................................................1 Fitting
Rear Hinge ......................................(already installed) 2 Fittings
Body Prop ........................................(already installed) 1 Fitting
Lubricateallttingsatregularintervals,atleasteachtimethetruckchassisislubricated.Thereareex-
tremely high forces on the bearings surfaces within the hoist frame. It pays to be generous in lubricating
the hoist to insure proper operation and long life.
Thecenterhingeandthecylindercrossheaddonotneedtobegreased.Thesepivotpointsareequipped
with self lubricating composite bearings that do not need lubrication.
ONE OF THE MOST COMMON REASONS FOR HOIST PROBLEMS IS FAILURE BY THE OPERA-
TOR TO LUBRICATE THE HOIST.
INSTALLDECALS
After the body and hoist have been installed and painted, install the decals in the following locations:
1. Decal 1642842 Mount in the cab above the valve control.
(400640)
2. Decal 1642848 Mount on the body longbeam near the body prop. (one on each side)
(400719)
3. Decal 1642846 Mount on the body prop arm.
(400661)
4. Decal 1643067 Mount on the outside of the body longbeams near the front of the body.
(401576) (one on each side).
5. Decal 1642844 Mount on the body longbeam on the drivers side.
(400643)
6. Decal 1643068 Mount in the cab in a prominent location.
(401577)
7. Decal 1642843 Mount in the cab in a prominent location.
(400642)
Seetheillustrationsonthefollowingpagefordecalidentication.(SeeFig.11.)

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Fig. 13
1642848 (400719)
1643067 (401576) 1642844 (400643)
1643068 (401577) 1642843 (400642)
1642842 (400640) 1642846 (400661)
2
13
18 17 16 15
14
12
11
10
9
8
6
5
4
3
1
7
19
LB520 CYLINDER PARTS
20
ITEM DESCRIPTION LB520 QTY
1. Cylinder Shaft Assy 1621556 1
2. Cap Ring 1635171 1
3. Set Screw 1/4 x 3/16 1642724 1
4. Wiper 1642878 1
5. Cylinder Head 1637938 1
6. Shaft Seal 1642765 1
7. O-Ring 1642766 2
8. O-Ring 1642767 1
9. Cylinder Piston 1629601 1
10. Piston Seal 1642764 1
11. Hex Jam Nut 1642995 1
12. Cylinder Tube Assy 1621554 1
13. Plug 7/8-14 ORB 1642807 1
14. Plug 3/4-16 ORB 1642805 1
15. Ball 3/8 1642679 1
16. Bypass Valve Pin 1642894 1
17. O-Ring 1642907 1
18. Bypass Valve Body 1642893 1
19. BypassValveKit 1621569 1
20. CylinderSealKit 1621640 1
21. Cylinder Assy 1621532

1643725H (404416) 2020-09-2820 1643725H (404416) 2020-09-2821
ITEM DESCRIPTION PART NO. QTY.
1. Reservoir/Valve Carton 6 Ga 3250 PSI (includes items 2 through 10) 1621943 1
2. Reservoir Weldment 6 Ga 1621925 1
3. Hex Jam Nut 7/8-14 1643196 1
4. Cone Washer 7/8 1643197 1
5. O-Ring .755 ID x .097 CS 1643198 1
6. Cap Screw, Soc Hd 5/16-18 x 2 1643205 1
7. Lock Washer 5/16 1642733 1
8. Control Valve 30 GPM 3250 PSI -10 Port 1643185 1
9. Breather Cap 1644723 1
10. Pipe Plug 3/4 Magnetic 1642794 1
11. Adapter 7/8 ORBM x 7/8 JICF 90° 1643724 2
12. Adapter 7/8 ORBM x 1/2 NPTF 90° 1642969 1
13. Hose 1/2 NPT x 72” RM/RM 3500 PSI 1643015 1
14. Pipe Elbow 3/4 Street 1643226 1
15. Hose Barb 3/4 NPTM x 3/4 1643017 1
16. Hose Clamp #24 1643011 2
17. Suction Hose 3/4 ID x 72” 1643805 1
18. Hose Barb 1 1/16 ORBM x 3/4 1643228 1
19. Adapter 1 1/16 ORBM x 1/2 NPTF 1283139 1
19A. Adapter 7/8 ORM x 3/8 NPTF 1642813 1
20. Cap Screw 1/2-13 x 1 1/4 Gr 8 1642726 4
20A. Cap Screw 3/8-16 x 1 Gr 5 1642714 2
21. Gear Pump 6 GPM B 4-Bolt 1644773 1
21A. Gear Pump 4 GPM A 2-Bolt 11 Tooth 1645052 1
22. Cable, Valve Control - 96” 1643210 1
Cable, Valve Control - 72” 1643209 1
Cable, Valve Control - 84” 1643332 1
Cable, Valve Control - 120” 1643211 1
Cable, Valve Control - 144” 1643212 1
Cable, Valve Control - 180” 1643213 1
23. Hex Lock Nut 5/16-18 1642962 5
24. Clamp Plate, Pedestal 1631026 1
25. Machine Screw 5/16-18 x 1/2 1643329 2
26. Pedestal Channel, Short - RVC 1630851 1
27. Machine Screw 5/16-18 x 2 1/2 1643233 3
28. Remove Valve Control w/ Center Detent (RVC) 1643208 1
29. Pedestal Bracket, Short - RVC 1630850 1
30. ValveConnectionKit-Prince5100 1643215 1
31. Hex Lock Nut 3/8-16 1643177 4
32. Flat Washer 3/8 1642732 4
33. Cap Screw, Hex Hd 3/8-16 x 1 Gr 5 1642714 4
34. Cap Screw 1/2-13 x 2 3/4 Gr 8 1643730 4
35. Flat Washer 1/2 1642739 8
36. Spacer VT Mounting 1632739 4
37. Assy VT Mounting 1622700 2
38. Hex Lock Nut 1/2-13 1642984 4
HYDRAULIC SYSTEM PARTS
46
45
44
41
39
42
40
43
34
36
35
37
38
47
48
49
51
21A
20A
19A

1643725H (404416) 2020-09-2822 1643725H (404416) 2020-09-2823
ITEM DESCRIPTION PART NO. QTY.
39. Cable Tie - 33” 1643817 1
40. Rubber Pad 1/4 x 3 x 5 1643881 1
41. Breather Cap, Splash Resistant 1644498 1
42. Electric Power Unit - DA 2219241 1
43. Cover Solenoid Service 1644330 1
44. Adapter 9/16 ORBM x 3/4 JICM 1643375 2
45. Control Station W/Cord, 4 Wire DA Pistol 2296414 1
46. Keeper,PistolGrip 2296415 1
47. Hose 7/8 JIC x 48” SF/SF 4000 PSI 1643360 1
Hose 7/8 JIC x 84” SF/SF 4000 PSI 1644009 1
48. Hose 7/8 JIC x 72” SF/SF 4000 PSI 1643804 1
Hose 7/8 JIC x 108” SF/SF 4000 PSI 1644010 1
49. Adapter 7/8 ORBM x 7/8 JICM 90° 1643724 1
50. Decal - Hoist Control 1643216 1
51. Adapter 3/4 ORBM x 7/8 JICM 90° 1643723 1
ITEM DESCRIPTION LB520 QTY
1. Hoist Frame Assy 1622670 1
2. Cylinder Assy 1621532 1
3. Cap Screw 1/2-13 x 3 3/4 Gr 8 1642721 2
4. Hex Lock Nut 1/2-13 1642984 14
5. Cap Screw 3/4-10 x 4 1/2 Gr 8 1642956 1
6. Hex Lock Nut 3/4-10 1642957 1
7. Cap Screw 1/2-13 x 1 1/4 Gr 8 1642726 8
8. Grease Zerk 1/8 NPT 1642699 7
9. Frame & Cylinder Assy 1622669 1
ITEM DESCRIPTION LB520 QTY
1. Subframe Assy - 9’ 50° 1289363 1
Subframe Assy - 10’ 50° 1289636 1
Subframe Assy - 11’ 50° 1289616 1
Subframe Assy - 12’ 50° 1289624 1
Subframe Assy - 14’ 50° 1289620 1
Subframe Assy - 10’ 45° 1289640 1
Subframe Assy - 14’ 45° 1289628 1
2. Body Guide 1630827 2
3. Mounting Plate 1631206 2
4. Cap Screw 5/8-11 x 2 Gr 8 1643313 12
5. Hex Lock Nut 5/8-11 1643070 12
6. Body Prop Longbeam Bracket 1634760 1
7. Body Prop Arm Assy - Left 1623886 1
8. Spring Pin 1/4 x 3 1642757 1
9. Grease Zerk 1/8 NPT 1642699 2
10. Grease Zerk 1/8 NPT 90° 1642713 1
FRAME&CYLINDERANDSUBFRAMEPARTS

1643725H (404416) 2020-09-2824
CRYSTEEL MANUFACTURING, INC.
CRYSTEEL MANUFACTURING’S
5YEARCUSTOMERSATISFACTIONPLEDGE
& WARRANTY
Crysteel oers the most comprehensive warranty in the truck equip-
ment industry. Crysteel warrants each product against defects in mate-
rial and workmanship for 60 months from the in-service date.
For the full Customer Satisfaction Pledge and Warranty information,
please visit our website.
http://www.crysteel.com
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