Rugby SR-Series User manual

Read this manual thoroughly prior to installation and operation. This manual out-
lines the installation and operation of an SR Series Hoist & Sub-frame manufac-
tured by Rugby Manufacturing Co. This manual should be kept readily accessible
for any potential operator at all times. Contact your dealer or a Rugby Manufactur-
ing customer service representative at 800-869-9162 or www.rugbymfg.com
with any questions or concerns.
INSTALLATION AND OPERATION MANUAL
SR-SERIES HOIST
1841488
Serial Number: __________________________________________
In-Service Date: _________________________________________

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Table of Contents
Section 1: Safety ...........................................................................3
Section 2: Introduction...................................................................6
Serial Number ........................................................................6
Specifications.........................................................................6
Capacity Charts......................................................................7
Torque Chart ..........................................................................9
Section 3: Installation ..................................................................10
Body Prop Installation...........................................................10
Hoist and Sub-frame Assembly.............................................11
Hoist and Sub-frame Installation ..........................................13
Section 4: Decal Locations ..........................................................20
Section 5: Operation ....................................................................21
Raising the Prop Body ..........................................................21
Lowering the Prop Body .......................................................21
Section 6: Maintenance ...............................................................21
Section 7: Exploded Views ...........................................................22
4016B Model .......................................................................22
4020 Model..........................................................................24
5020 Model..........................................................................26

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Section 1: Safety
This manual provides guidelines and instructions for correctly operat-
ing and maintaining your Rugby Manufacturing Co. product. Any and all
people that own and operate a Rugby Manufacturing dump trailer are
recommended to read and fully understand each section in this manual.
Throughout this manual, the three following types of labels will be used:
Danger, Warning, and Caution. For the safety of the operator, it is impera-
tive that all labels are obeyed.
DANGER
Indicates imminent danger. Failure to follow this instruc-
tion will result in death or serious injury.
WARNING
Indicates a possibly impending danger. Failure to follow
this instruction can result in death or serious injury.
CAUTION
Indicates a hazardous situation or unsafe practice which,
if not avoided, could result in injury or component
damage.
In all cases, Rugby products are sold with the understanding that the pur-
chaser agrees to thoroughly train all operating and maintenance person-
nel in the correct and safe installation and operation of hoist equipment
and to provide adequate supervision of personnel at all times.
Read the following in its entirety before connecting, operating or repair-
ing equipment. Purchasers and operators also should be familiar with
the current version of any applicable OSHA regulations, standards and
guidelines.
Should any questions arise concerning safe and proper procedures,
contact Rugby Manufacturing Co. to the installation or use at
[phone] or [phone].

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The hydraulic system supplied with an SR-Series hoist manufactured by
Rugby Manufacturing Co. is made up of components (pump, valves, res-
ervoir, hoses, cylinder, etc.) designed to be compatible with each other.
Several different types of pump and hydraulic components are available
to power the SR-Series hoists. Refer to the pump and hydraulic compo-
nent Installation and Operation Manual for more information.
DANGER
It is the installer’s responsibility to ensure any substitut-
ed components are compatible with Rugby Manufactur-
ing Co. components. Incompatible hydraulic components
may cause failure of the hoist, which in turn, could
damage the vehicle, damage other property, and cause
death or injury.
If hydraulic components are substituted, it is the installer’s responsibility
to be sure they are compatible with the components supplied by Rugby
Manufacturing Co. Incompatible hydraulic components may cause failure
of the hoist which in turn could damage the truck, damage other prop-
erty, and cause human injury or death. 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.

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DANGER
Avoid bouncing or jerking of the hoist. This may result in
component failure, injury or death.
DANGER
Never raise or drive a raised body against another object.
This may result in property damage, injury or death.
DANGER
Never connect the hoist to a hydraulic system with more
pressure (psi) or flow (gpm) than is recommended. This
may result in component failure, injury or death.
DANGER
Never operate the hoist until bystanders are free & clear
of the hoist and body. This may result in injury or death.
DANGER
Never exceed the gross vehicle weight (GVW) or gross
axle weight (GAW) rating of your vehicle. This may result
in component damage, injury or death.
CAUTION
Unlatch tailgate prior to elevating a loaded dump body as
excessive forces on the rear of the dump body may result
in component failure.

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Section 2: Introduction
Serial Number
This information is required for any warranty or service inquiries, and
should be recorded on the front cover of this manual for easy reference.
The serial number is located on the hoist serial number plate. Figure 1.
Serial Number
Plate
Figure 1: Serial Number Location (SR-5020 Model Shown)
Specifications
Model
Maximum
Hydraulic Flow
Rate
(gpm)
Pressure
(PSI)
Down Pressure
(PSI)
4016B / 4020 4-6 3200 1000
5020 6-9

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Capacity Charts
The following charts are to be used as a reference when determining
capacity based on overhang.
SR-4016B
Body Length
(feet)
CA
(inches)
Rear Overhang
(inches)
Capacity 50ӿDump
(tons)
8 60 6 12.1
9 60 6 10.6
9 60 18 14.1
10 84 6 9.4
11 84 6 8.5
11 84 18 10.5
12 84 18 9.4
12 84 30 12.1
12 108 6 7.7
14 108 18 7.7
Mounting Height 9.75”
Minimum Longsill Height 5”
Mounting Distance 71.5”

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SR-4020
Body Length
(feet)
CA
(inches)
Rear Overhang
(inches)
Capacity 50ӿDump
(tons)
9 60 6 12.8
10 84 6 11.5
11 84 6 10.3
11 84 18 12.8
12 84 18 11.5
12 108 6 9.4
14 108 18 9.4
Mounting Height 10.5”
Minimum Longsill Height 6”
Mounting Distance 84.6”
SR-5020
Body Length
(feet)
CA
(inches)
Rear Overhang
(inches)
Capacity 50ӿDump
(tons)
10 84 6 12.9
11 84 18 13.2
11 84 6 10.8
12 84 30 17.0
12 84 18 13.2
12 108 6 10.8
14 108 30 13.2
14 108 18 10.8
14 120 18 10.8
14 120 6 9.1
16 120 42 13.2
16 120 30 10.8
Mounting Height 11.3”
Minimum Longsill Height 7”
Mounting Distance 90.25”

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Torque Chart
The following chart is to be used as a guide during installation.
Size
Grade 2
(lb-ft)
Grade 5
(lb-ft)
Grade 8
(lb-ft)
1/4-20 3-4 6-7 10-11
1/4-28 4-5 8-9 11-12
5/16-18 8-9 14-15 21-22
5/16-24 9-10 15-16 21-22
3/8-16 17-18 24-26 37-40
3/8-24 19-20 28-30 40-43
1/2-13 38-42 60-65 90-100
1/2-20 43-47 70-75 95-105
5/8-11 75-80 122-130 180-190
5/8-18 85-90 145-150 200-210
3/4-10 132-140 220-230 315-330
3/4-16 152-160 250-260 355-370

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Section 3: Installation
Body Prop Installation
DANGER
The body prop is only to be used to prop an unloaded
body. Serious injury or death can occur if the body prop
is misused.
A body prop and the required hardware is supplied with every SR-series
hoist package. For instructions on how to raise and lower the body prop,
refer to the Operation section of this manual on page 21.
Bracket
Holder
Figure 2: Body Prop Installation Location
1. Insert the body prop into the body prop bracket (Figure 2).
2. Fasten the body prop to the body prop bracket using the supplied
hardware.
3. Lower the body prop to the down position and align with slot until the
body prop rests against the top of the holder.

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Hoist and Sub-frame Assembly
A full breakdown of the hoist and sub-frame components can be found
in the Exploded Views section of this manual page 22.
Figure 3: Saddle Tube Location
1. Slide the saddle shaft into the lower tube of the hoist so that approxi-
mately 4 inches extend past the tube on each side. (Figure 3)
Figure 4: Sub-frame Positioning
2. Position the hoist into the sub-frame by aligning each end of the sad-
dle shaft into the sub-frame brackets. Then secure the saddle shaft
to the sub-frame with the provided hardware as shown in Figure 4.
Refer to page 9 for torque guidelines.

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Optional Sub-Frame Extension
3/8" Extension Hardware
Sub-frame Rail
Figure 5: Sub-frame Extension Kit
3. Position the provided 3/8” spacers under each sub-frame rail as far
forward as possible. Secure to rail by welding as shown in Figure 5.
NOTE: Optional 12” or 24” bolt-on sub-frame extensions can be
installed to convert the 9’ sub-frame to a 10’ or 11’ as required.

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Hoist and Sub-frame Installation
AH
Rear Axle
Rear Hinge
Axle to Rear Hinge
(AH)* Application
34” Standard
46” Ford (with rear fuel tank)
49” Chevrolet and Dodge (with rear fuel tank)
* Approximate dimensions
Figure 6: Hoist Position
1. Position the assembled hoist and sub-frame onto the truck frame us-
ing the application chart shown in Figure 6.

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------------------------------- OR ---------------------------------
2.00
CRITICAL
WELD AREA
2.00
MIN
2.00
MIN
8.25
MAX
2.00
CRITICAL
WELD AREA 8.25
MAX
8.25
MAX
8.25
MAX
2.00
CRITICAL
WELD AREA
2.00
CRITICAL
WELD AREA
2.00
MIN
2.00
MIN
Figure 7: Mounting Angle Location
2. Locate the ideal mounting angle location along the chassis frame
while keeping within the guidelines shown in Figure 7. Ensure the
weld from the sub-frame to the mounting angle will be positioned
directly below the saddle tube.
NOTE: Optional 10 gauge rivet spacers may be positioned under the
mounting angle and the rear hinge angle to clear rivets on the truck
frame.
DANGER
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
tanks during equipment installation.

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DANGER
Heat from the vehicle 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 components.
Sub-Frame
Chassis Frame
3/8" Spacer
Mounting
Angle
Mounting Angle
Chassis Frame
Sub-Frame
2.0
Both
Sides
Figure 8: Sub-frame Mounting
3. Secure each mounting angle to the truck frame by drilling two 17/32”
diameter holes and bolting the mounting angles to the truck frame
using two 1/2” GR5 bolts and nuts (Figure 8).
4. Weld each mounting angle to the sub-frame rail, keeping within the
guidelines shown in Figure 8. Do not weld the mounting angles to the
chassis frame.

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Chassis Frame
Chassis Frame
Both
Sides
Both
Sides
Rear Hinge Bracket
.18
Rear Hinge Angle
Rear Hinge Bracket
.18
Figure 9: Rear Hinge Installation Location
5. Weld the rear hinge angle to the chassis frame as shown in Figure 9.
6. Cut any excess frame off behind the sub-frame rear hinge.

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Guide Plate
Lift Bracket
Lock Collar
Set Screw
Upper Hoist Tube
Body Guide Plate Locations
Figure 10: Lift Shaft Installation
7. Slide a lock collar onto each lifting shaft, and then slide the shafts
into each end of the upper hoist tube (Figure 10).
8. Install a body guide plate onto each sub-frame rail using a set of
bolt holes provided. Fasten guides using the supplied hardware
(Figure 10).

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Long
Beam
Chassis Frame
Rear Hinge
Bracket
Chassis
Frame
Both
Sides
Both
Sides
Lift Bracket
.18
.18 .18
Long Beam
Rear Hinge Bracket
Both
Sides
.18
Chassis
Frame
Long
Beam
Figure 11: Body to Sub-frame Installation
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 11.
10. Slide each lift bracket against the inside of the long beam channel.
Then weld the lift bracket to the outside of the long beam (Figure 11).
11. With the lift bracket secured, slide the lock collars against the hoist
lifting tube and lock them in place by tightening the 3/8” set screw.

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Grease
Locations
Grease
Locations
Figure 12: Grease Fitting Locations
12. Install and grease the fittings as shown in Figure 12.

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Section 4: Decal Locations
DANGER
Missing or damaged decals can lead to accidents which
may cause serious injury or death. Replace any missing
or damaged decals immediately by contacting a Rugby
dealer or Rugby Manufacturing Co..
Two Body Prop Operation decals are supplied with each SR-series hoist.
These decals must be positioned as shown in Figure 13 on both the left-
and right-hand sides of the truck. The chosen decal location should be
free of any viewing obstructions.
Body Prop Decal
Location Area
Figure 13: Body Prop Decal Location
Two Danger decals are supplied with each SR-series hoist. These decals
must be positioned as shown in Figure 14 on both the left- and right-hand
sides of the truck. The chosen decal locations should be free of any view-
ing obstructions.
Danger Decal
Location Area
Figure 14: Danger Decal Location