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.