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Rugby SR Series Installation And Operation Manual

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INSTALLATION AND OPERATION MANUAL
SR-SERIES HOIST
1841488
Serial Number: __________________________________________
In-Service Date: _________________________________________
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.

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  • Page 1 In-Service Date: _________________________________________ 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.

  • Page 2: Table Of Contents

    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...

  • Page 3: Section 1: Safety

    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.
  • Page 4 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.
  • Page 5 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.

  • Page 6: Section 2: Introduction

    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)

  • Page 7: Capacity Charts

    Capacity Charts The following charts are to be used as a reference when determining capacity based on overhang. SR-4016B Body Length Rear Overhang Capacity 50 Dump (feet) (inches) (inches) (tons) 12.1 10.6 14.1 10.5 12.1 Mounting Height 9.75” Minimum Longsill Height 5”...
  • Page 8 SR-4020 Body Length Rear Overhang Capacity 50 Dump (feet) (inches) (inches) (tons) 12.8 11.5 10.3 12.8 11.5 Mounting Height 10.5” Minimum Longsill Height 6” Mounting Distance 84.6” SR-5020 Body Length Rear Overhang Capacity 50 Dump (feet) (inches) (inches) (tons) 12.9 13.2 10.8 17.0...

  • Page 9: Torque Chart

    Torque Chart The following chart is to be used as a guide during installation. Grade 2 Grade 5 Grade 8 (lb-ft) (lb-ft) (lb-ft) Size 1/4-20 10-11 1/4-28 11-12 5/16-18 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...

  • Page 10: Section 3: Installation

    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.

  • Page 11: Hoist And Sub-Frame Assembly

    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.
  • Page 12 3/8" Extension Hardware Sub-frame Rail Optional Sub-Frame Extension 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’...

  • Page 13: Hoist And Sub-Frame Installation

    Hoist and Sub-frame Installation Rear Axle Rear Hinge Axle to Rear Hinge Application (AH)* 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.
  • Page 14 2.00 2.00 CRITICAL CRITICAL 2.00 8.25 WELD AREA WELD AREA 2.00 8.25 ------------------------------- OR --------------------------------- 2.00 2.00 CRITICAL CRITICAL 2.00 8.25 WELD AREA WELD AREA 2.00 8.25 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.
  • Page 15 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. Mounting Angle Sub-Frame...
  • Page 16 Rear Hinge Bracket Both Sides Chassis Frame Rear Hinge Bracket Rear Hinge Angle Both Sides Chassis Frame 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. 1841488G April 2022...
  • Page 17 Upper Hoist Tube Set Screw Lock Collar Lift Bracket Guide Plate 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.
  • Page 18 Long Beam Both Sides Rear Hinge Bracket Chassis Frame Long Long Lift Bracket Beam Beam Both Both Sides Sides Rear Hinge Bracket Chassis Chassis Frame Frame Figure 11: Body to Sub-frame Installation 9. Position the rear hinge brackets against the bottom side of the long beams.
  • Page 19 Grease Locations Grease Locations Figure 12: Grease Fitting Locations 12. Install and grease the fittings as shown in Figure 12. April 2022 1841488G...

  • Page 20: Section 4: Decal Locations

    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.

  • Page 21: Section 5: Operation

    Section 5: Operation 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. Raising the Prop Body 1. Raise the unloaded body to the sufficient height and shut off all power.

  • Page 22: Section 7: Exploded Views

    Section 7: Exploded Views 4016B Model 1841488G April 2022...
  • Page 23 1643070 Nut, 5/8-11 Nylock - NE, GR. 5 STL 1520370 Fitting, 1/4-28 Thread Forming Grease 1581116 Serial No. Plate, Poly w/Mask 1313141 Decal, Rugby Logo Medium 1313146 Decal, Made In USA 1841516 Decal, SR-4016 Model 1839407 Prop, Body PCBLK 1898583...

  • Page 24: 4020 Model

    SR4020 Model 1841488G April 2022...
  • Page 25 SR4020 Parts List Item Part # Description 2117068 Frame, SR-4020 PCBLK Hoist 1315043 Cylinder, 5.5 X 20 HR-550 2193587 Sub-frame, 09’ SR-4020 1839407 Prop Body PCBLK 1653917 Pin, 1/8” x 1” Cotter 1822289 Bracket, SR Lift 1653845 Set Screw, 3/8-16 X 5/8 SQR HD, BLK 1656191 Collar, 2.25 Lock 1653838...

  • Page 26: 5020 Model

    SR5020 Model 1841488G April 2022...
  • Page 27 SR5020 Parts List Item Part # Description 1844062 Frame, SR-5020 PCBLK Hoist 1621268 Cylinder, 6 X 20, 2.5 Rod, 2.0 Neck 1653838 Screw, 5/8-11 X 4 HHC GR8 PLT 1643070 Nut, 5/8-11 Nylock - NE, GR5 STL 1581116 Serial No Plate, Poly w/ Mask 1844096 Shaft, 5020 Cylinder Pinning 1653921...
  • Page 28 Capacity ratings, features, and specifications vary depending upon the model and type of service. Application approvals must be obtained from Rugby Mfg Co; contact your representative for application approval. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice.

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1841488

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