Rugby SR-Series User manual

Rugby Manufacturing SR-Series Hoist Manual
1841488E Rugby Manufacturing 24-APR-21
INSTALLATION AND OPERATOR’S
MANUAL
IMPORTANT!!
Read this manual thoroughly prior to installation and operation. This manual outlines the
installation and operation of an SR-series hoist & sub-frame manufactured by Rugby
Manufacturing Co. This manual should be kept readily accessible for any potential operator at
all times. Should you have any questions or concerns, please contact your dealer or a Rugby
Manufacturing customer service representative before use.
Toll Free: 1-800-869-9162 • Office: 1-701-776-5722 • Fax: [phone]
Visit www.rugbymfg.com for further information.
Serial Number:
In Service Date:

Rugby Manufacturing SR-Series Hoist Manual
1841488E Rugby Manufacturing ToC
Table of Contents
How to Use This Manual .......................................................................... 1
Labels ..........................................................................................................................1
Reference Information .......................................................................... 2-4
Serial Number..............................................................................................................2
Capacity Chart.............................................................................................................3
Torque Values Chart....................................................................................................4
General Safety ...................................................................................... 4-5
Hydraulic System......................................................................................................4-5
Installation .......................................................................................... 6-15
Body Prop Installation..................................................................................................6
Hoist & Sub-frame Assembly....................................................................................7-8
Hoist & Subframe Installation..................................................................................8-13
45° Application Sub-frame Modification ....................................................................14
Decal Locations ......................................................................................................... 15
Operation................................................................................................16
Body Prop Operation.................................................................................................. 16
Maintenance...................................................................................... 16-17
Diagrams...............................................................................................................16-17

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How to Use This Manual
This manual provides guidelines and instructions for correctly operating and
maintaining your Rugby Manufacturing 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.
Labels
Throughout this manual, the three following types of labels will be used: Danger,
Warning, and Caution. For the safety of the operator, it is imperative that all labels are
obeyed.
Danger: Indicate[s] a hazardous
situation which, if not avoided, will
result in death or serious injury.
Warning: Indicate[s] a hazardous
situation which, if not avoided,
could result in death or serious
injury.
Caution: Indicate[s] a hazardous
situation which, if not avoided, could
result in minor or moderate injury.

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Reference Information
Serial Number
This information is required for any warranty or service inquiries, and should be
recorded on the front page of this manual for easy reference.
The serial number is a decal located on the spacer plate of the hoist. (Figure 1).
Figure 1: Serial Number Locations
SR-4016
SR-4016B
SR-4020
SR-5020

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Capacity Charts
The Capacity Charts (Figure 2, 3, 4, 5) are to be used as a reference when determining
capacity based on overhang.
NOTE: Approximately 10% additional capacity can be attained on an SR-4016 or SR-
4016B application if sub-frame and hoist are installed at 45°. A sub-frame modification
kit can be ordered from Rugby Mfg. if this installation is desired. Refer to the 45°
Application Sub-frame Modification section of this manual for additional information
and instructions.
Figure 2: SR-4016 Capacity Chart
Figure 3: SR-4016B Capacity Chart
Figure 5: SR-5020 Capacity Chart
Figure 4: SR-4020 Capacity Chart

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Torque Value Chart
The Torque Values Chart (Figure 6) is to be used as a guide during installation.
General Safety
Hydraulic System
The hydraulic system supplied with an SR-series hoist manufactured
by Rugby Manufacturing Co. is made up of components (pump, valves,
reservoir, hoses, cylinder, etc.) that are 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
component Installation and Operation Manual for more information.
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 property, 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.
Figure 6: Torque Values

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Bouncing or jerking of the hoist is to be avoided as it may
result in component failure, injury or death.
Unlatch tailgate prior to elevating a loaded dump body as
excessive forces on the rear of the dump body may result in
component failure.
Overloading of a truck can cause truck component damage,
injury or death. Never exceed the gross vehicle weight
(GVW) or gross axle weight (GAW) rating of your vehicle.
Do not operate the hoist until bystanders are free & clear of
the hoist and body.
Connecting the hoist to a hydraulic system with more
pressure (psi) or flow (gpm) than is recommended can lead
to damage, serious injury, or death.
Do not raise or drive a raised body against another object.
Doing so could result in equipment or property damage,
injury or death.
SR-SERIES HOISTS
4016/4016B/4020
5020
MAXIMUM HYDRAULIC FLOW
RATE (GPM)
4-6
6-9
MAXIMUM UP PRESSURE
(PSI)
3200
3200
MAXIMUM DOWN PRESSURE
(PSI)
1000
1000
Figure 7: Hydraulic Information Chart

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Installation
Body Prop Installation
A body prop & 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.
1. Insert the body prop into the body prop bracket (Figure 8).
2. Fasten the body prop to the body prop bracket using the supplied hardware.
3. Lower the body prop to the down position & align with slot until the body prop
rests against the top of the holder.
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.
Figure 8: Body Prop Location

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Hoist & Sub-frame Assembly
A full breakdown of the hoist & sub-frame components can be found in the Diagrams
section of this manual.
4. Slide the saddle shaft into the lower tube of the hoist so that approximately 4
inches extend past the tube on each side. (Figure 9.)
2. Position the hoist into the subframe by aligning each end of the saddle shaft into
the subframe brackets.
3. Secure the saddle shaft to the sub-frame with the provided hardware as shown in
Figure 10. Refer to Figure 6 for torque guidelines.
Figure 9: Saddle Tube Location
Figure 10: Sub-frame Positioning

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Hoist & Sub-frame Assembly cont.
4. Position the provided 3/8” spacers under each sub-frame rail as far forward as
possible. Secure to rail by welding as shown. (Figure 11)
NOTE: Optional 12” or 24” bolt-on sub-frame extensions can be installed to convert the
9’ subframe to a 10’ or 11’ as required. For optional 45° dump angle applications, refer
to the 45° Application Sub-frame Modification section.
Hoist & Sub-frame Installation
Figure 11: Sub-frame Extension Kit
Figure 12: Hoist Position

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Hoist & Sub-frame Installation
1. Position the assembled hoist & sub-frame onto the truck frame using the
application chart shown in Figure 12.
2. Locate the ideal mounting angle location along the chassis frame while keeping
within the guidelines shown in (Figure 13). Ensure that the weld from the
subframe to the mounting angle will be positioned directly below the saddle tube.
NOTE: Optional 10ga rivet spacers may be positioned under the mounting angle and
the rear hinge angle to clear rivets on the truck frame.
Figure 13: Mounting Angle Location
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.
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 components.

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1841488E Rugby Manufacturing Page 10
Hoist & Sub-frame Installation
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” GR8
bolts and nuts (Figure 13).
4. Weld each mounting angle to the sub-frame rail, keeping within the guidelines
shown in (Figure 13). Do not weld the mounting angles to the chassis frame.
5. Next, weld the rear hinge angle to the chassis frame as shown in Figure 14.
6. Cut any excess frame off behind the sub-frame rear hinge.
Figure 13: Sub-frame Mounting
Figure 14: Rear Hinge Installation Location

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Hoist & Sub-frame Installation
7. Slide a lock collar onto each lifting shaft, and then slide the shafts into each end
of the upper hoist tube (Figure 15).
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 15: Lift Shaft Installation

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Hoist & 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 16.
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 16).
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.
Figure 16: Body to Sub-frame Installation

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Hoist & Sub-frame Installation cont.
12.Install and grease the fittings as shown in Figure 17.
Figure 17: Grease Fitting Locations

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45° Application Sub-frame Modification
This section outlines the steps required to convert the standard SR-4016 50° application
sub-frame into a 45° application sub-frame. Additional modifications to cross-members
or other platform/dump body components may be required.
1. Contact Rugby MFG to order the required kit for this modification: 1867517 -
EXTENSION, 45 DEGREE SF MOD PCBLK.
2. Locate the Ø 1/8” x 1-1/2” slot found on the left and right sub-frame channels.
3. Cut through the left and right sub-frame channels at the cut centerline as shown
in Figure 18.
4. Insert an extension between the front and rear portion of the sub-frame rails and
install the 1/2” hardware.
5. Cut off the excess from the front of the sub-frame channels as applicable to
return the sub-frame channel to the original 102” overall dimension.
6. The sub-frame is now set up for a 45° dump angle. Continue installing the hoist
and sub-frame per the Hoist & Sub-frame Installation section of this manual.
Figure 18: 45° Sub-frame Modification

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Decal Locations
Two Body Prop Operation decals are supplied with each SR-series hoist. These decals
must be positioned as shown in (Figure 19). The chosen decal location should be free
of any viewing obstructions.
Two Danger decals are supplied with each SR-series hoist. These decals must be
positioned as shown in (Figure 20) on both the left and right hand sides of the truck.
The chosen decal locations should be free of any viewing obstructions.
NOTE: To obtain replacement decals, contact your Rugby dealer or Rugby
Manufacturing Co.
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 immediately.
Figure 19: Body Prop Decal Location
Figure 20: Danger Decal Location

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Operation
Body Prop Operation
1. Raise unloaded body to sufficient height and shut off all power.
2. While positioning yourself as far as possible from underneath the truck, grasp
prop from latched position.
3. Rotate prop upwards to vertical position.
4. Push down until the prop locks in vertical position.
5. To lower the body prop for operation of truck, “reverse” the above procedure.
Maintenance
Grease all hoist and rear hinge grease fittings every 100 cycles or every two months.
Some grease fittings are in hard to find locations - Refer to Figure 15 for all grease
fitting locations. Check hardware regularly and retighten as needed. Refer to Figure 3
for torque guidelines. Check hydraulic components regularly for any leaks or signs of
wear. Replace damaged or leaking components as needed. Refer to the pump or
hydraulic components installation and operation manual for more service information.
Diagrams
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.
ITEM
PART #
DESCRIPTION
QTY
1
1822323
FRAME, SR-4016 PCBLK HOIST
1
2
1831466
CYLINDER, 5.50 X 16
1
3
1822321
SUBRRAME, 09’ SR-4016 PCBLK
1
4
1839407
PROP, BODY PCBLK
1
5
1653917
PIN, 1/8” X 1” PLATED COTTER
1
6
1857937
PIN, ½” X 2.75” ZP CLEVIS
1
7
1822289
BRACKET, SR LIFT
2
8
1653845
SET SCREW, 3/8-16 X 5/8 SQR HD, BLK
2
9
1656191
LOCK COLLAR, 2.25
2
10
1620051
HHC SCREW, ½-13 X 2.5, GR. 8, PLT
2
11
1642984
NUT, 1/2-13 NYLOCK - NE, GR8 STL
4
12
1653838
HHC SCREW, 5/8-11 X 4 , GR8, PLT
1
13
1643070
NUT, 5/8-11 NYLOCK - NE, GR. 5 STL
1
14
1520370
FITTING, 1/4-28 THREAD FORMING GREASE
7
15
1581116
SERIAL NO. PLATE, POLY W/MASK
1
16
1822332
SHAFT, SADDLE PIVOT
1
17
1653835
HHC SCREW, 1/2-13 X 4 GR5 PLT
2
18
1822291
PLATE, SUBFRAME BODY GUIDE
2
19
1577459
BOLT, 1/2-13 X 1-1/2 FLG GR5
4
20
1576016
NUT, 1/2-13 FLANGE, GR5 STL, PLT
4
21
1535863/
1851733
KIT, SUB-FRAME EXTENSION (OPTIONAL)
1
Figure 21: SR-4016/4016B Sub-frame and Hoist

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ITEM
PART #
DESCRIPTION
QTY
1
2117068
FRAME, SR-4020 PCBLK HOIST
1
2
1315043
CYLINDER, 5.5 X 20 HR-550
1
3
2193587
SUBFRAME, 09" SR-4020
1
4
1839407
PROP, BODY PCBLK
1
5
1653917
PIN, 1/8" X 1" COTTER
1
6
1857937
PIN, 1/2" X 2.75" ZP CLEVIS
1
7
1822289
BRACKET, SR LIFT
2
8
1653845
SET SCREW, 3/8-16 X 5/8 SQR HD BLK
2
9
1656191
COLLAR, 2.25 LOCK
2
10
1653835
SCREW, 1/2-13 X 4 HHC GR5 PLT
2
11
1642984
NUT, 1/2-13 NYLOCK - NE GR8 STL
4
12
1653838
SCREW, 5/8-11 X 4 HHC GR8 PLT
1
13
1643070
NUT, 5/8-11 NYLOCK - NE, GR. 5 STL
1
14
1520370
FITTING, 1/4-28 THREAD FORMING GREASE
7
15
1581116
SERIAL NO. PLATE, POLY W/MASK
1
16
1898583
SHAFT, SADDLE PIVOT
1
17
1653835
SCREW, 1/2-13 X 4 HHC GR5 PLT
2
18
1831125
PLATE, BOLT-ON PCBLK BODY GUIDE
2
19
1577459
BOLT, 1/2-13 X 1-1/2 FLG GR5
4
20
1576016
NUT, 1/2-13 FLANGE GR5 STL PLT
4
21
1535863/
1851733
KIT, SUB-FRAME EXTENSION (OPTIONAL)
1
ITEM
PART #
DESCRIPTION
QTY
1
1844062
FRAME, SR-5020 PCBLK HOIST
1
2
1621268
CYLINDER, 6 X 20, 2.5 ROD, 2.0 NECK
1
3
1653838
HHC SCREW, 5/8-11 X 4, GR8, PLT
1
4
1643070
NUT, 5/8-11 NYLOCK - NE, GR. 5 STL
1
5
1520370
FITTING, 1/4-28 THREAD FORMING GREASE
7
6
1581116
SERIAL NO. PLATE, POLY W/MASK
1
7
1844096
SHAFT, 5020 CYL PINNING
1
8
1653921
COTTER PIN, 5/16" X 3-1/2" PLATED
2
9
1844097
SUBFRAME, 09' SR-5020 PCBLK
1
10
1822332
SHAFT, SADDLE PIVOT
1
11
1653835
HHC SCREW, 1/2-13 X 4 GR5 PLT
2
12
1642984
NUT, 1/2-13 NYLOCK - NE, GR8 STL
2
13
1839407
PROP, BODY PCBLK
1
14
1857937
PIN, 1/2" X 2.75" ZP CLEVIS
1
15
1653917
PIN, 1/8" X 1" PLATED COTTER
1
16
1822289
BRACKET, SR LIFT
2
17
1656191
LOCK COLLAR, 2.25
2
18
1653845
SET SCREW, 3/8-16 X 5/8 SQR HD, BLK
2
19
1831125
PLATE, BOLT-ON PCBLK BODY GUIDE
2
20
1577459
BOLT, 1/2-13 X 1-1/2 FLG GR5
4
21
1576016
NUT, 1/2-13 FLANGE, GR5 STL, PLT
4
22
1535863/
1851733
KIT, SUB-FRAME EXTENSION (OPTIONAL)
1
Figure 23: SR-5020 Sub-frame and Hoist
Figure 22: SR-4020 Sub-frame and Hoist