TBEI CRYSTEEL LB520, Manual

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1643725H (404416) 2020-09-28 4 1643725H (404416) 2020-09-28 5
TABLE OF CONTENTS
FOREWORD 2
SOME DO’S AND DON’TS FOR SAFE AND LONG SERVICE
3
OPERATION AND USE 3
INSTALLATION INSTRUCTIONS 6
LOCATE HOIST-SUBFRAME ASSEMBLY ON TRUCK 6
LOCATE BODY/HOIST ASSEMBLY ON TRUCK 7
LOCATE MOUNTING PLATES 7
DRILL TRUCK FRAME 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
INSTALL TIPPER BODY ON TRUCK 14
INSTALL OTHER BODY ON TRUCK 15
INSTALL BODY PROP BRACKET ON BODY LONGBEAM 16
INSTALL BODY GUIDES 16
INSTALL GREASE ZERKS AND LUBRICATE HOIST 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. 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 fittings.
ORBM O-Ring Boss - Male Thread
NPTM Pipe - Male Thread
NPTF Pipe - Female Thread
JICM JIC 37° - Male Thread
JICF JIC 37° - Female Thread