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The Rugby Manufacturing SR-Series Hoist is a robust and versatile hydraulic system designed for dump body applications, facilitating the lifting and lowering of truck bodies for material discharge. This manual provides comprehensive guidelines for its installation, operation, and maintenance, ensuring safe and efficient use. The hoist system is engineered to integrate seamlessly with various truck chassis, offering adaptability for different body lengths and configurations.
The primary function of the SR-Series Hoist is to provide the mechanical force necessary to elevate a dump body, allowing for the controlled discharge of materials. This is achieved through a hydraulic cylinder that extends and retracts, driving a scissor mechanism to raise and lower the body. The hoist system is designed to handle significant loads, with different models (SR-4016, SR-4020, SR-5020) offering varying capacities and suitable for different body lengths and rear overhangs. The system includes a sub-frame that provides structural support and integrates the hoist with the truck chassis. An essential safety feature is the body prop, which is designed to securely hold an unloaded body in a raised position during maintenance or inspection, preventing accidental lowering. The hydraulic system, comprising components such as a pump, valves, reservoir, hoses, and cylinder, works in concert to generate and control the hydraulic pressure required for operation. The design emphasizes compatibility of these components to ensure optimal performance and safety.
The SR-Series Hoist is designed for straightforward operation, with clear instructions provided for both installation and daily use. During installation, the manual guides users through the assembly of the hoist and sub-frame, including the proper positioning of the saddle shaft and securing it with specified hardware. Critical steps involve aligning the hoist and sub-frame onto the truck frame, considering factors like axle-to-rear hinge distance, and ensuring correct mounting angles. Welding is a key part of the installation process, with specific instructions on critical weld areas and precautions to avoid fuel ignition. Optional sub-frame extensions are available to adapt the hoist to different body lengths, and a 45° application sub-frame modification kit allows for specialized dump angles.
For daily operation, the hoist is controlled via its hydraulic system. Users are cautioned to read the pump and hydraulic component installation and operation manual for detailed instructions on controlling the system. A crucial aspect of usage is the body prop operation. To raise the body prop, the unloaded body is first lifted to a sufficient height, and all power is shut off. The prop is then grasped from its latched position, rotated upwards to a vertical position, and pushed down until it locks. To lower the body prop, the procedure is reversed. The manual explicitly states that the body prop is only to be used with an unloaded body, highlighting the severe risks of misuse.
Safety is paramount in the operation of the SR-Series Hoist. The manual includes multiple "DANGER" and "CAUTION" labels to emphasize critical safety protocols. Operators are warned against bouncing or jerking the hoist, raising or driving a raised body against objects, and connecting the hoist to a hydraulic system with excessive pressure or flow. Overloading the truck beyond its gross vehicle weight (GVW) or gross axle weight (GAW) rating is strictly prohibited. Additionally, the tailgate must be unlatched before elevating a loaded dump body to prevent component failure. Bystanders must be clear of the hoist and body during operation. Decals indicating body prop operation and general danger are supplied and must be positioned in visible locations on both sides of the truck. These decals serve as constant reminders of safety procedures and warnings.
Regular maintenance is essential to ensure the longevity and safe operation of the SR-Series Hoist. The manual outlines key maintenance tasks, including lubrication and hardware inspection. Grease fittings on the hoist and rear hinge require lubrication every 100 cycles or every two months. The manual provides a diagram illustrating the locations of these grease fittings, some of which may be difficult to find.
Hardware, such as bolts and nuts, must be checked regularly and retightened as needed. The manual includes a comprehensive torque values chart, specifying the correct torque for various bolt sizes and grades (Grade 2, Grade 5, Grade 8). Adhering to these torque guidelines is crucial for maintaining the structural integrity of the hoist system.
The hydraulic components, including the pump, valves, reservoir, hoses, and cylinder, also require regular inspection. Operators should look for any leaks or signs of wear. Damaged or leaking hydraulic components must be replaced promptly to prevent system failure, injury, or death. Further service information for hydraulic components can be found in their respective installation and operation manuals. The manual also warns against installing equipment in locations where heat from the truck's exhaust system could damage hydraulic components, emphasizing the importance of proper heat management.
The serial number plate, located on the rear spacer plate of the hoist, is vital for warranty and service inquiries and should be recorded on the front page of the manual for easy reference. In case of missing or damaged safety decals, replacements must be obtained immediately from a Rugby dealer or Rugby Manufacturing Co., as these decals are critical for operator safety. By following these maintenance guidelines, users can ensure the continued safe and efficient performance of their SR-Series Hoist.
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