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Model SL-240 Parts and Operations Manual

1. X NC 33L NOINN say tian 331 01 GAH day c NOINN 404 60 02 80 OSOL 2 8 SL 240 INS 09 2009 Attach the control cables to the control levers and route the cable through the holes in the cab Install the control levers in the console Levers should be installed such that when the levers are pushed forward the control cable is extended See Drawing No 90H64 Manual Control Assembly for control lever orientation Route the cables to the control valve location and attach them to the control valve with the bonnet connection kits provided Pt No 20P10 See the following instruction sheet for installation procedures The control cables supplied are 84 inches long Your particular mounting may require different length control cables which can be purchased locally or through Swaploader Take proper care when routing the control cables as a good cable path is essential for a proper operating system Keep bends in the cable path to a minimum and be as generous as possible Under no circumstances should any bend be tighter than an 8 radius Protect the cable from heat above 225 degrees F and avoid hot areas such as exhaust pipes etc Protect the cable from physical damages such as pinching or crush
2. 68 8018 5 gt 88402 GAH 7 20402 438 H3NIVH LS MNV L SATIVA GAH 5 dariddns GAH 18 2 SL 240 INS 09 2009 START UP PROCEDURE 1 Fill the hydraulic tank with hydraulic oil see oil specification in Maintenance Section 2 Prime the pump by loosening the clamp on the suction hose at the pump Pull the hose back off the fitting till the air 15 bled from the line Push the hose back on the fitting and retighten the clamp 3 Engage the and run the pump at idle 700 to 900 RPM Operate the cylinders at full stroke five to ten times to bleed the air from the lines and cylinders The cylinders were filled with oil during testing at the factory but some seepage may have occurred during shipping and installation Refill the hydraulic tank if needed during this sequence and do not let the pump run without oil 4 Check for leaks and tighten fittings as necessary 5 Verify the movement of the control levers corresponds to the movement of the cylinders per the figure below FRONT LOWER LOAD EXTEND LIFT JIB RAISE UNLOAD RETRACT 6 Install all safety decals and product decals per Drawing No 52H06 after final installation and painting have been completed The factory prior to shipment of a hoist will install some decals that have a premask layer The premask wil
3. INTRODUCTION 09 2009 90 08 HOIST BODY SPECIFICATIONS 90P09 HYDRAULIC OIL SPECIFICATIONS 90P10 HYDRAULIC OIL FLAMMABLE 90P11 HOIST FALLING 90P13 SWAPLOADER SAFETY INSTRUCTIONS 90P18 RELIEF VALVE INTRODUCTION 09 2009 1 6 90P52 PROP DECAL OPTIONAL 90P78 HIGH PRESSURE FLUID INTRODUCTION 09 2009 INSTALLATION INITIAL INSPECTION When the SwapLoader hoist is received from the factory you should inspect the hoist for damage which may have occurred in shipment If damage has occurred you should contact the shipper immediately Be sure to note any damage or missing items on bill of Lading You should then check the hoist to insure you have received all the parts as indicated by the Packing List and the Ship Loose Box List If you have any problems shortages or questions please contact SwapLoader U S A Ltd immediately GENERAL INSTALLATION PROCEDURE The installation of the SwapLoader on a truck chassis will generally follow these steps 1 Install hoist assembly onto truck chassis 2 Mount the hydraulic control valve to the hoist and install the hydraulic plumbing from the control valve to the hydraulic cylinders Then install the control levers in the cab and route the control cables or air lines if you have air shift controls to the hydraulic control value assembly 3 Install the hydraulic tank hydraulic filter an
4. e rm M e m e um x CD z 5 ad e z rm e 79 4 dTi 1 SWAPLORDER U S A LTD SWAPLOADER HOIST BASE ASS Y SL 240 52H05 REVB 08 04 09 14 42 PT 52H04 dwg PARTS LIST DESCRIPTION REMARKS 50H13 MAINFRAME PIN WELDMENT H84 MAINFRAME WELDMENT 42H11 JIB LOCKOUT VALVE MOUNT DISC LOCK WASHER TORQUE SPEC S SAE GR 8 ASS Y TORQUE FT LBS 21 6 AMIR SIZE e m 7 16 S wo S 3 5 1689 LOCK WASHER 3 86 LOCK WASHER 230 380 400 400 e ojo e else 79 N 3 3 gt gt 79 1 2 13 x 1 1 2 HHCS 3 8 16 x 1 1 4 HHCS 3 8 16 HEX NUT LUBRICATE BOLT THREADS BEFORE TORQUING THE ASSEMBLY OP68 3 8 16 x 1 1 4 FL HD SCR 0 5 16 18 x 2 HHCS 20 3 8 16 x 1 3 4 SOC HD SCR 3 1 29 DISC LOCK WASHER 21P63 HYDRAULIC CYLINDER 68 x 54 12 WEAR BLOCK c n a 79 N Li SwAPLOADER SWAPLOADER U S A LTD MAINFRAME SUB ASSEMBLY SL 240 52H04 REVA 08 05 09 15 12 PT 52H03 dwg PARTS LIST DESCRIPTION REMARKS ROLLER ASS Y PIVOT JOINT WELDMENT BODY LOCK WELDMENT PIVOT PIN WELDMENT MAIN PIVOT PIN WELDMENT PIVOT PIN CAP ROLLER SPACER 060 ROLLER RETAINER 5 86 LOCK WASHER 1 2 13 x 1 H
5. 1 2 HP x 21 0 RELIEF VALVE 1 B RPEC LDN FNJ SEE NOTE 3 7 2 90H79 5 MAINFRAME NS BLKHD FITTING REF JIC 10 FITTING ON THE UPPER BULKHEAD FITTING WITH 12P44 f HAS FIELD REPLACE 12 11898 12 DN OR REPAIR D IN WRITING Y QUAI WRITING BY 5 PANTIES THE PROPERTY ARE IN INCHES UNLI DETALED BY 06 25 04 DMK SWAPLOADER 06 29 04 DGS PRINT DISTRIBUTION TME HYD j IBLY JIT F CUSTOMER TRANG No 90H85 NOEL 28701 09 S878 dwq Page 6 of 7 SUBFRAME gt IN x 1 2 INA MIN SEE NOTE RECOMMENDATIONS F THE D SYSTEM RIFY THAT ATE REA RHANG AND LATCH PLATE EN y PLATE EN BODY LOCK NTO BODY LOCK EXISTS 1 ANY ALTER MUST BE AU THE PROPERTY OF RECIPIENT IN IN INCHES UNL SWAPLOADER IFICATIONS FOR ABILITY SYSTEM F
6. asl INSTALLATION INSTRUCTIONS continued 4 Mark mounting holes through the fender bracket weldment onto the fender Remove the bracket and drill 7 16 dia Holes in fender See FIG 3 5 Attach fender bracket weldments to fender using fasteners provided 6 Weld mounting plates Part No 21H37 to fender tubes Part No 21H61 7 Position fender tubes with mount plates on hoist mainframe align with fender bracket weldments NOTE Fender tube length may need to be modified to fit specific application MATERIAL LIST ITE WT Ib 8 Weld fender tubes to hoist mainframe If CEN SERERE PER EA attaching the fender tubes to the truck 5 198174 FENDER BRACKET WDMT 8 05 chassis an additional mount plate may 2 EEST i MOUNTING PLATE 109 need to be fabricated so the assembly can 214 RUBBER SPACER 5 be bolted to the truck chassis eee 5 48 00P34 3 8 16 UNC LOCKING NUT 02 9 Attach fender bracket weldment Part No T HET 23 10H74 to mounting plate Part No 21H37 x 8 24 00 44 3 8 16 UNC X 1 1 2 HHCS 07 using fasteners provided See FIG 3 9 16 01P21 3 8 16 UNC X 2 1 2 HHCS 09 10 8 00P99 3 8 16 UNC x 4 HHCS 11 90P36 FENDER STEEL TANDEM 77 00 TOTAL 228 86 HOIST MAINFRAME REF ADDITIONAL NOTE Prior to any weldin
7. DON T DRIVE WITH THE HOIST IN THE DUMP POSITION OR WITH THE HOOK TILTED BACK 3 4 MAINTENANCE MAINTENANCE INSTRUCTIONS WEEKLY SERVICE 50 OPERATIONS l Lubricate with grease Refer to Lubrication Diagram Lifting hook on jib Jib slide top bottom and side guides 2 Check hydraulic oil level With the hoist in the umm d transport position lift cylinders retracted and jib cylinder extended see diagram on front cover the oil level in the tank should read approximately one inch below the top of the glass sight on the temperature sight gauge see diagram gt 3 Check hydraulic hose and fittings for leaks Also check hydraulic hose for wear Repair and or retighten as necessary MONTHLY SERVICE 200 OPERATIONS 1 Lubricate with grease Refer to Lubrication Diagram Fittings on lift cylinders quantity 4 Front pins on rear pivot joint weldment quantity 2 Fittings on rear pivot pins and rollers quantity 4 2 Check all bolts and retighten as required 4 Check adjustments on mast lock safety latch mechanism Refer to the Mast Lock Inspection amp Adjustment Instructions on page 4 7 of the maintenance section 3 Check adjustments on jib lockout valve Refer to the Jib Lockout Valve Inspection amp Adjustment Instructions on page 4 9 of the maintenance section YEARLY SERVICE 1 Check for proper gapping on outer tube clamp assembly Refer to the Outer Tube Clamp Inspection amp
8. 11 and v 44 60 uutyz6 8 5 8 6 E 7 Z L ug x NIS NI X NI HVH uuie9e1 53 7 8 IN MIN 60 3 4 IN L 40 WOLLO 40 OL 891 8 59 NI v L 9 MO uie uuze QNI vE 1 e 1 0 Q NI v L WE UE 2 p dAL QVH NI c NI 2 21 SL 240 INS 09 2009 a EFCO Company 8 U S A LTD ox INSTALLATION INSTRUCTIONS Review all directions and diagrams provided before starting bumper installation 2 Trim truck frame to indicated dimensions See Fig 1 These dimensions will facilitate the mounting of the rear light assembly if it is also being mounted 3 Measure the distance from the bottom of the truck frame to the ground NOTE This should be performed on a level surface Based this measurement and the dimensions in Fig 1 the vertical channel P N 63H94 may need to be modified in length to meet the Office of Motor Carrier Safety OMCS regulations Regulation 393 86 requires that no bumper be located more than 30 off the ground when the truck is empty and the end of the bumper should not be located more than 24 from the extreme rear of the vehicle including truck bodies See Fig 2
9. CUSTOMER No TRANG No CMS 5 878 28701 09 Page 7 of 7 QTY LEVER ARM SLEEVE LONG SPRING SLEEVE SHORT SPRING SLEEVE 1 26 FLAT WASHER 2 B 1 2 13 HEX NUT SPRING D SECTION A A E F SERES 12401 28701 09 a EFCO Company 8 U S A LTD luminum 0H93 Steal GAH Diamond Plate Only INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting fender installation 2 Center fender above tire using block to maintain the proper height Fender should be approximately 5 above tire to allow for suspension movement See Fig 1 A maximum width of 48 from center of the truck to the outside edge of the fender should be maintained See Fig 2 3 Place fender bracket weldements Part No 10H74 on fender Position the brackets to avoid any mounting obstacles on hoist and or truck chassis Approximately 5 S N HOIST MAINFRAME REF TRUCK FRAME REF TIRE REF TRUCK All Figures are for Illustratio
10. An EFCO Company SWAPLOADER U S A LTD HOOK ON QUALITY Model SL 240 Parts and Operations Manual PN M 19 21454 Hoist Serial Number PREDELIVERY CHECK LIST SWAPLOADER MODEL SL 240 HOIST INSTALLATION Conducted by Date Dealer Customer I COMPONENT INFORMATION Hoist Serial No Truck Chassis Identification No GVW Distance from rear of cab to the Center Line of Rear Axle Tandem CA Distance From Center Line of Rear Axle Tandem to Rear of Hoist AF PTO Make Model Serial No of Engine RPM Hyd Pump Make Model Serial No II INSTALLATION TO CHASSIS Were there any problems installing the hoist to the truck chassis YES NO If yes please describe bolts checked for proper tightness Please include photos of the hoist installed on the truck chassis Be sure to include at least one photo from each side III CONTROLS Controls easy to reach from driver s seat Movement of controls correct per installation instructions SL 240 PRE PAGE 1 07 2009 PREDELIVERY CHECK LIST SWAPLOADER MODEL SL 240 HOIST INSTALLATION IV HYDRAULICS INSTALLATION Correct hydraulic oil level in reservoir Check for leaks Any abnormal noise during operation YES NO If yes explain WITH ENGINE OPERATING 1000 RPM RECORD THE FOLLOWING INFORMATION Cycle time for dump mode Up Sec Down Sec Cycle time for load unload mode Unload Sec Lo
11. NOTE toolbox hinge should be on the forward bottom edge 6 Mark position of mounting holes through brackets onto toolbox Remove toolbox and drill 9 16 dia holes 7 Mount toolbox to brackets using fasteners provided See Fig 1 TOOLBOX Aluminum 10H92 Steel 11H12 ame MATERIAL LIST DS 33 1 2 ALUMINUM TOOLBOX ONLY O ene sen sree roos a emm MEX HEAD BOLT mme METAL LOCKING NUT eB E SOCKET BUTTON HEAD BOLT 00P76 1 2 DIA NYLON FLAT WASHER eg RE TRUCK FRAME REF ALUMINUM TOOLBOX TOTAL 76 38 Tool Box Hinge 9 169 ets 1800 N E Broadway Avenue Box D Des Moines 5162065042 Telephone 515 266 3042 U S A LTD PREDELIVERY CHECK LIST SWAPLOADER MODEL SL 240 HOIST INSTALLATION Conducted by Date Dealer Customer I COMPONENT INFORMATION Hoist Serial No Truck Chassis Identification No GVW Distance from rear of cab to the Center Line of Rear Axle Tandem CA Distance From Center Line of Rear Axle Tandem to Rear of Hoist AF PTO Make Model Serial No of Engine RPM Hyd Pump Make Model Serial No II INSTALLATION TO CHASSIS Were there any problems installing the hoist to the truc
12. Adjustment Instructions on page 4 13 of the maintenance section 2 Change hydraulic oil replace hydraulic filter element and wash out suction strainer 3 Check main relief valve setting Refer to the Pressure Check Instructions on page 4 11 of the maintenance section Pressure should be 2 800 PSI minimum SL 240 MAI 4 1 07 2009 LUBRICATION DIAGRAM 46 J 3 led A o n G n LI E m Ed 02100 lt lt r a m Oo lt OJO 4 2 SL 240 MAI 07 2009 HYDRAULIC OIL SPECIFICATION amp INTERCHANGE CHART Select an ISO grade of Premium Anti Wear Hydraulic Oil that is optimum for your location HYDRAULIC OIL SELECTION CHART Ambient Temperature ISO Grade Range Viscosity SUS Q 100 F 32 10 to 85 46 10to 110 23 to 29 12 to 43 150 170 195 240 NOTE 1 Always consult your local hydraulic oil supplier for more information NOTE 2 Use caution when operating at or beyond the recommended temperature extremes NOTE 3 Do not operate the hooklift hoist when hydraulic oil temperature on tank gauge exceeds 160 F 71 C as damage to hydr
13. Use an appropriate welding process SL 240 INS 2 4 09 2009 14 ASSY NOLLVTIV ISNI LSIOH wvsn 5 gt IZ SATVA JOHINOO a 9i gt GAH 2 5 SL 240 INS 09 2009 CONTROLS INSTALLATION MANUAL 1 Attach the valve mount bracket Pt No 10H51 to the mainframe as indicated on Dwg No 90H64 with the fasteners provided 2 Mount the hydraulic control valve assembly Pt 20939 to the valve mount bracket as shown on Drawing No 90H64 with the fasteners provided 3 Install the hydraulic adapter
14. preferred Figure B Note The above specifications are a minimum requirement It is the responsibility SL 240 INS 2 2 09 2009 of the owner operator to ensure the completed chassis meets or exceeds all federal state and local regulations Also the hoist should not be used to lift and haul any load that exceeds the load rating of any of the individual components of the completed chassis tires axles suspension etc The clear frame dimension indicated in the picture above allows for the overall length of the hoist plus 5 inches for cab clearance and rear light bar mounting Extra frame length may be needed to allow for mounting additional accessories e g Cab Guard Tarper Light Kit etc For example when mounting a light kit on a truck with a long CA check that the hoist and the light kit are positioned far enough back to eliminate any interference between the fender and the light kit You should also consider the final weight distribution with regard to the bridge code when positioning the hoist 2 There are two types of mount brackets used on the Model SL 240 hoist as indicated in Figure C or Drawing No 52H34 They are the front mount brackets Pt No 60H60 and the rear mount brackets Pt No 60H61 Locate the mount brackets on the side of the hoist as indicated in Figure C These dimensions are flexible because of possible interference with chassis components Also a
15. right hand rotation pump is needed call SwapLoader for price and availability NOTE Consult the PTO supplier whenever uncertain about the correct pump rotation for a particular application The table below lists the SwapLoader part number for both left and right hand rotation pumps for the SL 240 hoist model L H Rotation R H Rotation MODEL Pump standard Pump special SL 240 20P24 20P43 HOW TO IDENTIFY PUMP ROTATION To better understand the effects of pump rotation we must consider the path that oil takes through the pump Oil enters the pump through the inlet suction port travels around the outside of the gears and is forced out through the outlet exhaust port Oil enters and exits the pump in the direction of its rotation LEFT HAND ROTATION we LEFT HAND ROTATION 0 A NND PUMP PUMP FLOW FLOW gt OO Mu OUT IN SUCTION o EXHAUST OPPOSITE ENGINE ROTATION PTO VIEW PUMP OPPOSITE ENGINE ROTATION PTO VIEW FROM VIEW FROM FRONT OF VEHICLE REAR OF VEHICLE 4 4 ENGINE ROTATION PTO ENGINE ROTATION PTO 2 BELLY DOWN gt PUMP FLOW or IN EXHAUST SUCTION RIGHT HAND ROTATION RIGHT HAND ROTATION pup Determine pump rotation by positioning the pump belly side down see illustration above Looking at the rear of the pump if the suction largest por
16. 16 x 1 1 2 FL HD SCR 0 04 BRASS 41801 3 86 050403 WASHER 00 E DETAIL C C SWAPLOADER U S A LTD TELESCOPIC JIB SUB ASSEMBLY 51H99 REVA 08 11 09 12 36 PT 52H01 dwg OUTER TUBE WDMT REF OUTER TUBE WDMT REF PIVOT JOINT WDMT REF 1 16 CLEARANCE REF DETAIL OUTER TUBE WDMT REF SEE DETAIL C C OPP HAND JIB WDMT REF JIB WDMT PARTS LIST DETAIL B B SEE DETAIL B B OPP HAND PIVOT JOINT WDMT REF SEE DETAIL OUTER TUBE WDMT REF e 79 N gt c 1 49 x 1 4 CLEWS 0 03 R 8 e ojlo e 79 gt 79 018 1 160 x 3 4 COTTER 0 01 1 89 x 1 COTTER PIN 0125 0 On ONNECTION BAR WELDMENT 17 60 SAFETY LATCH WELDMENT LATCH PIN WELDMENT x e DESCRIPTION WT Ib ea REMARKS 1 26 FLAT WASHER 007 3 8 16 HEX NUT 5 8 11 HEX NUT XT RETAINER RING FOR 3 46 5 16 18 x 1 2 HHCS 009 08 8 5 169 LOCK WASHER 7 86 x 6 SPRING TAKE UP WELDMENT 5 8 11 x 3 1 2 HHCS GR 8 LATCH STOP 010 12 30 RELEASE LEVER DETAIL C C SAFETY LATCH ASSEMBLY SL 240 52H01 REVA SWwAPLOADER SWAPLOADER U S A LTD 08 12 09 14 41 PT 52H34 dwg PARTS LIST DESCRIPTION REMARK 2H06 DECAL AS
17. REF 51H76 LEFT SIDE OUTER TUBE ASS Y REF 51H76 PARTS LIST DESCRIPTION 15 REMARKS OPR amp SERV MANUAL HOIST BODY SPEC HYD OIL SPEC HYD OIL FLAMMABLE HOIST FALLING LEVER CONTROL U SAFETY INSTRUCTIONS c 2 N 79 co cO cO 3 8 20170 GN e 70 SWAPLOADER JIB RELIEF VALVE SL 240 NE 90P78 HIGH PRESSURE FLUID 91 06 LUBRICATION POINTS e Z z z mlm mlm 20 518 70179 e B SWAPLOADER U S A LTD DECAL ASSEMBLY SL 240 52H06 REVB OPTIONS 08 26 09 15 08 PT 90H61 dwg HOIST CONTROL Li SEE NOTE 2 porc e ecc 1 4 18 NPTF AIR PORT SUPPLY PARTS LIST 20P72 CONTROL HANDLE ASSY 1 60 2294 20P95 ONE 20P74 AIR PRESSURE PROTECTION VALVE 2 rm B a rm z ziz f SECTION NOTE 1 20P95 AIR SHIFT KIT TO BE INSTALLED ON HYD CONTROL VALVE BY HOIST INSTALLER REFERENCE INSTALLATION INSTRUCTIONS INCLUDED WITH THE AIR SHIFT KIT 2 SEE DRAWING 90H60 FOR AIR SHIFT KIT PLUMBING DIAGRAM SWAPLOADER SWAPLOADER U S A LTD AIR CONTROL ASS Y 2 SECTION SL 220 222 240 2418 90H61 REVB 07 16 09 15 28 80 60 4 JIB CONT
18. cradles for squareness with respect to each other The bumper tube Part No 51H16 should come to rest within the bumper cradles when the container rests on the ground See Fig 2 amp 3 Weld bumper cra dles into place on longsills 3 17 32 1 Prior to any welding consult the truck manu facturer for any special precautions that may need to be taken Typically the batteries must be disconnected and the ground lead from the welder should be connected as close as possi ble to the part being welded to avoid the possi bility of arcing across bearings gears etc 2 During installation of the bumper check to make sure that the position of the bumper does not interfere with the loading and unloading of MATERIAL LIST PER EA 1 ohepvorARMRH 1608 un sse as Lr sene _ _5 0 ds en SUERO 2 OOP98 5 32 DIA X 1 1 2 COTTER PIN 00755 3 8 DIA LOCK WASHER 10 1 4 28 GREASE 1 1 8 OD X 10 SPRING SUB FRAME 8 1 o Note If width of the Longsills is under 41 5 8 add shims under the 51H17 brackets to get the dimension 1800 N E aranway Avenis Box D Des Moines Telephone 515 266 304 U S A LTD LTD U S A LOADER ES SWAP w a a 941144 FOL
19. obligations to incorporate such improvements in any unit which has been shipped or is in service It is recommended that users contact an authorized SwapLoader Distributor for the latest revisions INTRODUCTION 1 1 09 2009 SWAPLOADER U S A LTD 1800 N E BROADWAY DES MOINES IOWA 50313 LIMITED WARRANTY STATEMENT Effective September 1 2009 SwapLoader U S A Ltd SwapLoader warrants to the original purchaser of any new SwapLoader product sold by an authorized SwapLoader distributor or service center that such products are free of defects in material and workmanship All SwapLoader products with an original factory invoice date of September 1 2009 or later qualify for warranty as defined in this Limited Warranty Statement Repair or replacement of parts on SwapLoader products are covered under warranty for forty eight 48 months from date of Retail Sale by an authorized SwapLoader Distributor or service center subject to any applicable federal state or local taxes and not to extend beyond sixty 60 months from the original factory invoice date SwapLoader will at its discretion either repair the defective parts or replace them with equivalent parts subject to the conditions below e Labor charges authorized by the SwapLoader Warranty Department are covered under warranty for a period of twelve 12 months from the date of Retail Sale by an authorized SwapLoader Distributor or service center and not to extend beyond twenty f
20. of arcing across bearings gears etc 2 All welds should be done utilizing a low hydrogen welding process _ TRUCK FRAME REF 1800 NE Broadway Avenue Des Moines lowa U S A 50313 2644 Phone 515 266 3042 e Fax 515 313 4426 Toll Free 888 767 8000 E Mail sales swaploader net Web Site www swaploader com 05OCTO9 LOADER U S A LTD swap BUMPER ASSEMBLY DROP DOWN 54544 INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting bumper installation Typically a drop down bumper is needed when the rear of the container extends beyond the back of the truck such that the distance between the truck bumper and container rear exceeds 24 See Fig 1 Office of Motor Carrier Safety OMCS Regulation 393 86 requires that no bumper be located more than 30 off the ground when the truck is empty and the end of the bumper should not be located more than 24 from the extreme rear of the vehicle including truck bodies See Fig 1 DROP DOWN INSTALLATION INSTRUCTIONS continued 2 Position drop down bumper on the longsills of the sub frame See Fig 2 amp 3 The mount brackets Part No 51H17 need to be positioned correctly to allow for sufficient room for bumper cradles Part No 51H19 See Fig 2 Weld mount brackets onto the longsills of the sub frame 3 Position bumper cradles Part No 51H19 on the longsills of the sub frame Check bumper
21. outer tube look for any missing or bent components such as ears or pins Finally inspect the safety latch see illustration below again make sure there are no missing or bent components such as ears pins or latches Repair replace any missing or bent components prior to making any adjustment to the mast lock assembly refer to the mast lock safety latch assembly drawing for proper part numbers and identification of the components See Drawing No 52H01 in the Part List pages of the manual 100 amp 200 SERIES HOISTS Jib Weldment Adjustment Tube Jam Nut Spring Take U Adjustment Bolt p P Outer Tube Pivot Joint Weldment Weldment Release Lever Connection Bar Latch Bar Safety Latch 1 4 Clearance MAST LOCK LOCATION AND ADJUSTMENT ILLUSTRATION shown with the jib retracted SL 240 MAI 4 7 07 2009 ADJUSTMENT If after inspecting all mast lock components and making any necessary repairs the gap between the mast lock and latch bars on the pivot joint is still incorrect then an adjustment will need to be made Please complete the following steps 1 2 Retract the telescopic 16 until the cylinder completely bottoms out fully retracted Inspect the gap between the mast lock latch and the latch bar on the pivot joint Look for a clearance of approximately 1 4 1f not proceed to steps 3 5 Loosen the jam nut on the adjustment bolt Turn the adjustment bolt counter clockwise to increa
22. the main relief control valve has been broken SwapLoader will ship the replacement part by the most economical yet expedient means possible Expedited freight delivery will be at the expense of the owner e Warranty is expressly void if serial number plate or stamping is tampered with ITIS EXPRESSLY UNDERSTOOD AND AGREED THAT THERE ARE NO WARRANTIES MADE BY THE MANUFACTURER OR ITS AGENTS REPRESENTATIVES OR DISTRIBUTORS EITHER EXPRESSED IMPLIED OR IMPLIED BY LAW EXCEPT THOSE EXPRESSLY STATED ABOVE IN THIS STANDARD LIMITED WARRANTY AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP THE MANUFACTURER AND ITS AGENTS REPRESENTATIVES AND DISTRIBUTORS SPECIFICALLY DISCLAIM ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE SWL Warranty 083109 INTRODUCTION 1 2 09 2009 SAFETY SUGGESTIONS 1 Do not operate or service this equipment until you have been properly trained and instructed in its use and have read the operation and service manual 2 Do not operate this equipment on uneven ground 3 Do not drive with the hoist in the dump position or with the hook to the rear 4 Do not exceed 1 500 Engine RPM when operating the Power Take Off P T O Never leave the P T O in gear while transporting 5 The hoist must be used with containers that properly fit the hook and rear holddowns The container specifications must match the hoist specifications 6 Keep the containers and hoist in good
23. 21 Section View A A Position the C V S sub assembly with attached base plate bracket on side of the mainframe z channel See drawing 52H21 Drill the necessary 13 32 Dia holes into the z channel using the C V S sub assembly with attached base plate bracket as the pattern to aid in locating hole placement To allow for C V S sub assembly Part No 12H01 fastener clearance some notching of the z channel lip may be necessary Attach the C V S sub assembly and base plate bracket to the mainframe z channel with fasteners provided See drawing 52H21 Drain hydraulic oil level in the tank to just below the 1 1 4 NPT Port Remove the 90 degree hydraulic fitting Part No 11P07 that connects the upper hydraulic steel tubing to the top bulkhead fitting See drawing 90H97 Replace with a swivel tee hydraulic fitting Part No 12P44 and retighten the hydraulic fittings See drawing 90H85 Remove the 1 1 4 NPT plug from the hydraulic tank Install hydraulic fittings 12P20 amp 12P92 as shown and tighten See drawing 90H85 Install the two 90 degree hydraulic fitting Part No 12P69 into the hydraulic valve on the 12H01 C V S sub assembly and tighten See drawing 90H85 Attach the hydraulic hose Part No 13P02 between the C V S hydraulic valve and swivel tee hydraulic fitting Part No 12P44 and tighten See drawing 90H85 Determine the length of hose required to route the C V S hydraulic valve to the hydraulic tank the hydr
24. 3 PIVOT JOINT SUB ASSEMBLY BRONZE BEARING QTY 1 PER ROLLER Cock ck HYD CYLINDER x 54 FOR 52H04 MAINFRAME SUB ASSEMBLY CYLINDER BEARINGS CONTACT SWAPLOADER Cock ck 4 6 MAST LOCK INSPECTION amp ADJUSTMENT INSTRUCTIONS SwapLoader hook lift hoists come with a mast lock safety latch assembly that is located on the bottom side of the outer tube When the jib is extended the mast lock then engages the latch bars forks on the pivot joint making the jib outer tube and pivot joint into a continuous member for raising the container or body up into a dump mode With the jib fully retracted the mast lock then disengages the latch bars on the pivot joint allowing the hook lift to enter into the mount dismount cycle by pivoting around the front pins of the pivot joint A properly adjusted mast lock will function smoothly and clear the latch bars on the pivot joint approximately a 1 4 see illustrations below INSPECTION The mast lock assembly comes adjusted from the factory and should provide years of trouble free operation however there may come a time when an adjustment may be required Prior to making any adjustments SwapLoader recommends that you begin with inspecting all mast lock components for damage or wear see illustrations below First inspect the adjustment tube and bolt on the jib make sure nothing is missing or bent Next inspect the release lever and connection bar on the
25. ADP HYD BHD 2 11 23 ADP HYD ORB 90 2 11 27 ADP HYD BHD TEE ADP HYD SVL 45 HOSE ASS Y 1 2 HP x 31 1 2 12286 ASSY 1 2 HP x 20 HOSE ASS Y 1 2 HP x 21 12P88 HOSE ASS Y 1 2 HP x 47 HOSE ASS Y 1 2 HP x 102 4 3 HYD CYL 68 x 54 HYD CYL 49 x 34 REF 51 222 REF eio CYL 49 x 30 SL 240 REF BHD TEE UPPER ADP BHD TEE LOWER ADP HYD CYL 60 x 54 REF BHD UNION UPPER ADP LOWER ADP U S A LTD HYD SUB ASS Y BASE CYLINDER CIRCUIT SL 220 222 240 90H96 08 20 09 10 30 PT 90H97 dwg BHD UNION BHD TEE LOWER ADP UPPER ADP BHD UNION BHD TEE UPPER ADP LOWER ADP HYD CONTROL VALVE REF SEE NOTE 1 PARTS LIST DESCRIPTION 10P21 T BOLT CLAMP 1 1 29 BC 150 ADP HYD 0 70 5404 20 1 10P37 ADP HYD MP 90 0 30 2501 4 8 c e m e rm 0 0 73 HYD TUBING REAR TO VALVE 362 11 04 HYD ORB 90 05 ADP HYD ORB LL 90 ADP HYD ORB 1 H m zm e 0 P07 ADP HYD FMJIC SVL 90 6500 10 98 HOSE ASSY1 2HP x28 13 HOSE ASSY 1 2 HP x 33 152 ADP HYD HOSE INS MP 5110 Z Z rm 12P26
26. ADP HYD HOSE INS ORB 90 4601 16 12 0 60 3 HOSE 1 LP x 30 16 P6 ADP HYD JIC CAP 010 1304 0 4 ADP HYD MJIC ORB L HYDRAULIC FILTER 230 P25 HYDRAULIC TANK 25 GAL 0 64 INDICATOR GAUGE on 2 2 2 2 NIN 79 RO a e m N NOTE HYD TANK ASS Y CONSISTS OF TANK WELDMENT TANK MOUNTED STRAINER SIGHT GAUGE FILLER BREATHER CAP MAGNETIC DRAIN PLUG AND PORT PLUGS SWAPLORDER HYD SUB ASS Y CHASSIS TANK CIRCUIT SL 220 222 240 _________9 08 21 09 15 29 PT 90H98 dwg HYD PUMP REF SUPPLIED BY CUSTOMER HYD CONTROL VALVE REF TANK STRAINER REF 20P07 PARTS LIST DESCRIPTION REMARKS 10P78 1 3 40 T BOLT CLAMP TBC 175 ADP HYD ORB 6400 12 ADP HYD ORB 45 0 50 6802 12 16 24 ADP HYD HOSE INS ORB 0 60 4604 20 P25 ADP HYD HOSE INS 0 60 515 12P30 HOSE 1 1 4 LP x 148 974 21 6 ANIR 79 gt 79 ojo mlm PE e e rm e H rn HYD TANK REF 20P25 NOTE DRIVER SIDE INSTALLATION OF HYDRAULIC TANK SHOWN FOR SHORT WHEELBASE CHASSIS PLUMBING FOR HYDRAULIC TANK CAN BE ROUTED FOR PASSENGER SIDE INSTALLATION SwAPLOADER SWAPLOADER U S A LTD HYD SUB ASS Y PUMP CIRCUIT SL 220 222 240 2418 90H98 OUTER TUBE ASSY
27. DECALS safety decals and product decals installed per Drawing 52H06 ADDITIONAL COMMENTS SEND COMPLETED FORM TO SWAPLOADER U S A LTD 1800 N E BROADWAY AVENUE DES MOINES IOWA 50313 2644 RETAIN ONE COPY FOR YOUR FILE SL 240 PRE PAGE 2 07 2009 OPERATION OPERATING INSTRUCTIONS During all operations of the SwapLoader the speed of the engine should be maintained at 1 000 to 1 200 RPM assuming the ratio of the Power Take Off is about 100 LOADING A CONTAINER l Engage the P T O Refer to P T O manual for operation FRONT LOWER LOAD EXTEND LIFT JIB RAISE UNLOAD RETRACT 2 Retract the jib right control lever backward Then tilt the arm backward left control lever backward 3 Make sure the work area in front of the container is clear of people and obstacles Move the truck backwards until the hook engages the curved lifting bar of the container NEVER EXTEND THE JIB to reach the proper catching height rather tilt the arm SL 240 0PE 3 07 2009 WARNING Make sure work area is clear of people and obstacles prior to dumping or unloading containers SwapLoader strongly recommends that a back up alarm be installed on the truck chassis The operation of the hook hoist is that the truck is backed up to the body to pick it up and so there is a potential pinch point between the body and the hook 4 Cycle the arm forward left control lever forward making sure the cur
28. DING BUMPER 81H44 INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting bumper installation Typically a folding bumper is needed when the rear of the container extends beyond the back of the truck such that the distance between the truck bumper and container rear exceeds 24 See Fig 1 Office of Motor Carrier Safety OMCS Regulation 393 86 requires that no bumper be located more than 30 off the ground when the truck is empty and the end of the bumper should not be located more than 24 from the extreme rear of the vehicle including truck bodies See Fig 1 The folding bumper will need to be used in conjunction with the Roller Assembly 10H90 and Roller Mount Brackets Assembly 10H91 for the container to function properly 2 Locate the best position for the support bars between the cross members Fabricate four support bars out of 4 x 1 bar cut to the length needed to fit between the cross members See Fig 3 Figure 3 shows a width dimension of 56 1 2 This width can be adjusted if interference occurs with other items on the container but cannot exceed the width of the bumper tube Weld the four bars between the cross members 3 Weld the front 62H87 and rear 62H88 brackets to the support bars Be sure to maintain the dimensions as indicated so that the bumper folds properly See Fig 2 amp 3 4 Weld the Pivot arms 62H84 to the Bumper Tube Weldment 51H46 Be sure to maint
29. HCS 5 8 11 HEX NUT 5 8 11 x 1 3 4 HHCS 7 16 14 x 1 1 2 SOC HD SCR 0 7 8 9 x 1 3 4 HHCS 7 166 DISC LOCK WASHER 1 20 DISC LOCK WASHER 7 8 DISC LOCK WASHER 1 8 NPT ZERK STR DISC LOCK WASHER TORQUE SPEC S SAE GR 8 ASS Y TORQUE FT LBS Ne Ae x S IS 5 230 380 00 400 SIS LUBRICATE BOLT THREADS BEFORE TORQUING THE ASSEMBLY U S A LTD PIVOT JOINT SUB ASSEMBLY SL 240 52H03 REV 08 07 09 15 04 51 99 DISC LOCK WASHER TORQUE SPEC S SAE GR 8 ASS Y TORQUE FT LBS SIZE E 5 0 gt o I 0 SISIS gt S 400 400 I LUBRICATE BOLT THREADS BEFORE TORQUING THE ASSEMBLY PARTS LIST T 50802 CYLNDER PN 353 zoe sm7 567 51476 OUTER TUBE WIDMNT 495 65 4 52401 SAFETY LATOH ASSEMBLY 585 5 one eon WEAR Block e 2 CYLINDER RETANER 078 7 2 05 e 1630 o 03 _ one CORP 1 112 fems we 395 12 oNE 2P67 HYD CYUNDER 129 30 133001 135 2 0055 Lock washer WEAR BLOCK BEYOND SEE DETAIL C C oors 3 86 x 1 1 2 mos 096 668 17 0 00 46 RING FOR 1 1 49 19 4 00258 3 8
30. HOLE D PLACEMENT DRAW CONTAINER 06 25 04 CHECKED REVISION SHOWN CONTAINER VARIABILITY SYSTEM SEMBLY CUSTOMER TRAANG Ve 52121 28701 09 BHD UNION UPPER ADP Page 4 of 7 ATER REMARKS T BOLT CLAMP 24 T8C 150 P HYD MP 20 16 ADP HYD N ADP HYD HYD TUBING REAR TO VALVE B ADP HYD HOSE INS MP HYD HOSE INS ORB HOSE 1 LP X 30 ADP HYD MJIC ORB L HYD FILTER HYD TANK 0 INDICATOR GAUGE SEE NOTE 1 3 LDMENT TANK MOUNTED STRAINER IER CAP DRAIN PLUG AND PORT PLUGS REVISION G OTHER THAN AS FLOADER USA LTD ARE IN INCHES UNLESS OTHERWSE SHOWN SWAPLOADER 7 SUB ASSEMBLY TANK CIRCUIT TRANG 28701 09 Page 5 of 7 HYD 6801 10 8 HYD HOSE ASSY 1 2 HP x 48 2404 10 16
31. LOADER U S A LTD SWAP GUARD ASSEMBLY 50H99 INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting cab guard installation 2 Position cab guard weldment Part No 50H95 on frame with sufficient clearance between cab and cab guard See Fig 1 3 Determine location for mounting holes Mounting holes should not be located within 2 3 8 of the truck frame edge See Fig 1 Drill 21 32 dia mount holes through cab guard channels GUARD ASSEMBLY 80H99 INSTALLATION INSTRUCTIONS continued 4 Mark mounting holes through the cab guard weldment onto truck frame Remove cab guard weldment and drill 21 32 dia holes in truck frame 5 Attach cab guard weldment to truck frame using fasteners provided See Fig 2 MATERIAL LIST mem TUE PER EA gt owss Eme SWAPLOADER 1800 E Broadway Avenue Box D Des Moines 5 Telephone 515 266 3042 u S A LTD 10 CONTAINER VARIABILITY SYSTEM ASSEMBLY Hoist Models SL 220 SL 222 amp SL 240 INSTALLATION INSTRUCTIONS Review all directions and diagrams provided before starting the C V S installation Attach the base plate bracket Part No 23H76 to the C V S sub assembly Part No 12H01 with fasteners provided See drawing 52H
32. N 52H13 on the vertical channels P N 63H94 Position rear of bumper from rear of the hoist as indicated by the bumper location chart This is crucial in order to ensure that the container longsills do not contact the bumper during the dump cycle See Fig 1 amp 2 BUMPER LOCATION CHART DIM B Max PIMA 81145 51 180 pum SL 2418 5 A nid SL 650 245 8 193 4 221 2 2134 25 1 4 213 4 211 2 24 1 4 27 2258 18 1 2 21 20 1 2 23 3 4 20 1 2 20 223 4 2058 171 4 191 2 191 4 22 1 4 19 1 4 18 5 8 16 18 1 4 18 Dimensions assume 6 tall longsills For 8 tall longsills add 2 4 to the dimension shown All Figures are for Illustration Purposes Only 05 09 MATERIAL LIST m SRLS nn ni INSTALLATION INSTRUCTIONS continued 5 Weld the bumper weldment to the vertical channels See Fig 1 amp 3 WT Ib ITEM QTY P N DESCRIPTION PER EA 1 1 52H12 REAR BUMPER WDMT 95 66 2 2 63H94 VERTICAL CHANNEL 9 58 3 1 52H13 REAR BUMPER EXTENSIONS 58 42 TOTAL 173 24 ADDITIONAL NOTES 1 Prior to any welding consult the truck manufacture for any special precautions that may need to be taken Typically the batteries must be disconnected and the ground lead from the welder should be as close to the part being welded to avoid the possibility
33. NDER TOTAL See FIG 3 HOIST MAINFRAME REF ADDITIONAL NOTES Prior to any welding consult the truck manufacture for any special precautions that may need to be taken Typically the batteries must be disconnected and the ground lead from the welder should be as close to the part being welded to avoid the possibility of arcing across bearings gears etc 406 5 x 7 16 DIA HOLE 1800 NE Broadway Avenue Des Moines lowa U S A 50313 2644 Phone 515 266 3042 Fax 515 313 4426 Toll Free 888 767 8000 E Mail sales swaploader net Web Site www swaploader com 10 05 09 a EFCO Company U S A LTD INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting fender installation 2 Center fender above tire using block to maintain the proper height Fender should be approximately 6 above tire to allow for suspension movement See Fig 1 A maximum width of 48 from center of the truck to the outside edge of the fender should be maintained See Fig 2 3 Place fender bracket weldments Part No 10H74 on fender Position the brackets to avoid any mounting obstacles on hoist and or truck chassis Approximately 6 _ HOIST MAINFRAME REF TRUCK FRAME REF TIRE REF TRUCK All Figures are for Illustration Purposes Only 10 05 09
34. NLOAD RETRACT 5 Check the gauge for the maximum developed system pressure The SL 240 should have a reading of 2 800 PSI 6 With the pressure check complete release all functions and disengage the P T O Please contact your SwapLoader Distributor or SwapLoader USA should you have any questions regarding this procedure SL 240 MAI 4 12 07 2009 OUTER TUBE CLAMP INSPECTION amp ADJUSTMENT INSTRUCTIONS SwapLoader hooklift hoists come equipped with an outer tube clamp assembly located on the bottom of the outer tube at the opening where the jib telescopes in and out see illustration below On SwapLoader 100 amp 200 series hoist models the outer tube clamp assembly is adjustable in height INSPECTION The illustration below is a typical hoist clamp assembly for the 100 amp 200 series SwapLoader hoist models For optimum performance out of your SwapLoader SL 240 hooklift the gap between the top of the jib horizontal tube and the top inside surface of the outer tube should be kept between 1 16 to 1 8 see Section View A A below When a gap greater than 1 8 exists prior to making any adjustments inspect the clamp liner clamp bar and adjustment fasteners for excessive wear or damage see Section View A A below Replace any parts as needed see Drawing No 51899 in the Parts List pages of the manual If the clamp liner and other components are found to be or have been brought up to satisfactory condition but a gap greater th
35. OLES AND INSERT PIN EW NUT BACK FACE OF VALVE AAA II N TERMINAL ON ROD E FLUSH WIT FACE OF VALVE 3 screw NUT ON BOLT FLANGE 8 TO VALVE BODY SL 240 INS 2 10 09 2009 CONTROLS INSTALLATION AIR SHIFT OPTION 1 Attach valve mount bracket Pt 10H51 to the mainframe as indicated on Drawing No 90H61 with the fasteners provided 2 Mount the hydraulic control valve assembly Pt No 20P39 to the valve mount bracket as shown on Drawing No 90H61 with the fasteners provided Attach airshift kits Pt No 20P95 to the hydraulic control valve Reference installation instruction included with the airshift kits 3 Install the hydraulic adapters and connect the hydraulic hoses and tubing Pt Nos 10P73 11P98 and 11P99 to the control valve assembly as indicated on Drawing No 90H97 The tubing should be supported by the clamp assemblies that are provided in the Loose Parts Box See Drawing 52H34 4 Determine the best location in the cab for the control handle assembly Pt No 20P72 The location should be such that the controls can be easily reached while operating the truck A control handle console Pt No 51H27 is provided to facilitate the mounting of the control handles See diagram below 5 Install the air fittings an
36. Once the length has been determined for the vertical channels weld them to the truck frame See additional notes on next page Center the bumper weldment P N 52H12 on the vertical channels P N 63H94 Position rear of bumper from rear of the hoist as indicated by the bumper location chart This is crucial in order to ensure that the container longsills do not contact the bumper during the dump cycle See Fig 1 amp 2 gt BUMPER LOCATION CHART DIM B Max DIMA 80145 91220822 53808 814088 Sieso 245 8 1312 1534 1514 17 1414 14 161 2 18 22518 1214 1412 14 1534 13 12 34 15 2058 11 1414 1134 18 5 8 113 4 1112 All Figures are for Illustration Purposes Only 10 05 09 p Gorn 5 INSTALLATION INSTRUCTIONS continued 5 Weld the bumper weldment to the vertical channels See Fig 1 amp 3 MATERIAL LIST P N DESCRIPTION WT Ib 52H12 REAR BUMPER WDMT 63H94 VERTICAL CHANNEL TOTAL ADDITIONAL NOTES 1 Prior to any welding consult the truck manufacture for any special precautions that may need to be taken Typically the batteries must be disconnected and the ground lead from the welder should be as close to the part being welded to avoid the possibilit
37. P T O Selection Pump Installation Start Up Procedure VI 200 Series Subframe Dimensions 300 Series Subframe Dimensions Accessory Installation Bumper Assembly Bumper Assembly w Extension Bumper Assembly Folding Bumper Assembly Drop Down Cab Guard Assembly Container Variability System C V S Fender Assembly Single Axle Fender Assembly Tandem Axle Rear Light Bar Assembly Roller amp Roller Mount Toolbox Assembly OPERATION Loading a Container Dumping a Container Placing a Container on the Ground MAINTENANCE Weekly Service 50 Operations Monthly Service 200 Operations Yearly Service Lubrication Diagram Hydraulic Oil Specifications Hydraulic Filter Interchange General Maintenance Parts List Replacement Bearing List Mast Lock Safety Latch Inspection amp Adjustment Instructions Pressure Check Instructions PARTS LIST Base Assembly Mainframe Subassembly Rear Pivot Subassembly Telescopic Jib Subassembly Mast Lock Safety Latch Assembly Hoist Installation Kit Assembly Manual Control Assembly 2 Section Hyd Sub Ass y Base Cylinder Circuit Hyd Sub Ass y Chassis Tank Circuit Hydraulic Sub Assembly Pump Circuit Decal Assembly OPTIONS Air Shift Control Assembly 2 Section Air Circuit 2 Section SL 240 Rev 07 2009 INTRODUCTION SWAPLOADER U S A LTD TO THE CUSTOMER Your new SwapLoader Hoist was carefully designed and manufactured to give years of dependable se
38. ROL HOIST r CONTROL J r 1 4 O D NYLON TUBE BLACK AIR PRESS PROTECTION VALVE 20P74 REF HYD CONTROL VALVE ASS Y 20P88 REF W AIR SHIFT KITS 20P95 REF BRASS ADP PUSH ON TUBE CONTROL HANDLE ASS Y MP SVL 90 4 2 2 SECTION AIR d HYD ADP MP FMP 4 2 20P72 REF Q Oa 1 4 x HYD ADP MP FMP 4 2 BRASS ADP PUSH ON TUBE MP 4 2 O D NYLON TUBE BLACK pce ADP PUSH ON TUBE MP 4 4 1 4 18 NPTF PORT SUPPLY NOTE 1 FITTINGS AND TUBING SHOWN ARE PART OF THE 12P94 AIR LINE KIT 2 THE 12P94 AIR LINE KIT CONTAINS FITTINGS FOR MULTIPLE PLUMBING CONFIGURATIONS AND NOT ALL FITTINGS MAY BE UTILIZED SWAPLOADER SWAPLOADER U S A LTD AIR CIRCUIT CONTROL VALVE 2 SECTION SL 330 400 406 90H60 REVA U S A LTD a EFCO Company 1800 NE Broadway Avenue Des Moines lowa U S A 50313 2644 Phone 515 266 3042 Fax 515 313 4426 Toll Free 888 767 8000 E Mail sales swaploader net Web Site www swaploader com
39. SEMBLY NOT 5 0 e rm 0H60 FRONT BRACKET RSV REAR BRACKET 49 5 166 LOCK WASHER 00 de a F 436 0755 3 89 LOCK WASHER 2 67 PARTS 6 OPERATIONS MANUAL SHOWN 267 1 2 FLAT WASHER H T F 436 00785 5 80 FLAT WASHER 3 8 16 x 1 1 4 HHCS 0 06 GR 8 3 8 16 HEX NUT 1 2 13 x 1 3 4 HHCS 5 16 18 x 2 3 4 HHCS 0 06 GR 8 001 GR R R 8 8 8 8 5 16 18 HEX NUT 0 01 C C 8 oio e e 1 2 13 LOCKING HEX NUT 0 06 GR C 5 8 11 LOCKING HEX NUT 5 8 11 x 2 HHCS HEX BOLT 5 169 x 1 1 4 0P29 COVER PLATE 040 TCP T2 10 66 50 14 HYD CONTROL VALVE REF TTE LI E e ce SECTION B B SWAPLOADER SWAPLOADER U S A LTD HOIST INSTALLATION KIT ASS Y SL 240 52H34 PARTS LIST 1 ONE 10H51 VALVE MOUNT BRACKET WDMT 2 HYD VALVE ASSY 5 2 20 08 VALVE CONTROL HANDLE 4 ONE 20P09 CONTROL HANDLE MOUNT CONSOLE 4 05 5 2 20P10 BONNET CONNECTION KIT 6 2 20 15 CONTROL CABLE 84 LG HOIST CONTROL NOTE A 2 SECTION CONTROL VALVE ASS Y IS SHOWN A 3 SECTION CONTROL VALVE ASS Y IS REQUIRED WHEN A STABILIZER IS UTILIZED lt gt SWAPLOADER U S A LTD MANUAL CONTROL ASSY 2 SECTION SL 240 2418 90H64 REV A PARTS LIST DESCRIPTION 6 10239 HYD ORB 2 11P02
40. ULIC CYLINDER HYDRAULIC VALVE CARTRIDGE COUNTERBALANCE Cock ck HYDRAULIC PUMP GEAR 4 46 CID L H ROT Standard HYDRAULIC PUMP GEAR 4 46 CID R H ROT Optional SEAL KIT HYDRAULIC PUMP HYDRAULIC FILTER 15 GPM HYDRAULIC FILTER ELEMENT INDICATOR GAUGE FILTER owe aed HYDRAULIC TANK 25 GALLON STRAINER TANK MOUNTED 25 GPM SIGHT GAUGE HYDRAULIC TANK BREATHER CAP ASSEMBY HYDRAULIC TANK Cock ck 4 4 20P39 20P42 21P28 21P38 90P71 00755 OOP 14 00 68 60H31 00 58 60H11 00P79 SL 240 MAI 07 2009 HYDRAULIC CONTROL VALVE 2 SECT HYDRAULIC RELIEF VALVE CARTRIDGE 2800 PSI HYDRAULIC VALVE 2 WAY SEAL KIT FOR 21P28 WEAR PAD 12 Z CHANNEL 3 8 LOCK WASHER 3 8 16 HEX NUT 3 8 16 x 1 1 4 FL HD SCREW SST Cock ck CLAMP LINER OUTER TUBE 3 8 16 x 1 1 2 FL HD SCREW BRASS ck WEAR BLOCK 3 8 16 x 3 4 FL HD SCREW BRASS Cock ck 4 5 PT NO 51H88 50P26 51H89 50P26 80P09 23H07 21P63 SPL SL 240 MAI 07 2009 REPLACEMENT BEARING LIST DESCRIPTION PIVOT PIN FOR 52H03 PIVOT JOINT SUB ASSEMBLY BRONZE BEARING QTY 1 PER PIN Cock ck Gk MAIN PIVOT PIN FOR 52H03 PIVOT JOINT SUB ASSEMBLY BRONZE BEARING QTY 1 PER PIN ck ROLLER ASSEMBLY FOR 52H0
41. ad Sec Filter pressure PSI Main pressure controls in neutral PSI Main relief pressure when extending jib cylinder bottomed out PSI Main relief pressure when extending lift cylinders bottomed out PSI NOTE Connect pressure gauge to fitting provided on inlet section of Hyd Control Valve Ref Pt No 10P37 fitting on Chassis Tank Hyd Circuit Drawing No 90H97 V OPERATION Jib operates freely in both directions Jib cannot be extended or retracted when raised in dump position or when pivot joint is tilted in unload position Both safety hooks are fully engaged when jib is extended Parts and operators manual in cab Lubricate sliding jib and all grease zerks per installation instructions VI DECALS safety decals and product decals installed per Drawing 52H06 ADDITIONAL COMMENTS SEND COMPLETED FORM TO SWAPLOADER U S A LTD 1800 N E BROADWAY AVENUE DES MOINES IOWA 50313 2644 RETAIN ONE COPY FOR YOUR FILE SL 240 PRE PAGE 2 07 2009 SWAPLOADER U S A LTD 1800 N E BROADWAY AVENUE DES MOINES IA 50313 WARRANTY REGISTRATION CARD Model Serial No MOUNTED ON VEHICLE Manufacturer Model Year Wheel Base Chassis Serial PTO Type PTO Ratio DISTRIBUTOR Name print Address City State Zip The unit has been checked and serviced according to the Pre delivery inspection report The proper mechanical operation of the unit as described in the written operational instructions provided by Swa
42. ain the width dimension that was used to locate the support bars in Step 2 5 Assemble the Bumper Assembly to the Front and Rear Brackets See Fig 3 Refer to the Typical Bolted Connection See Fig 4 for all connections 6 Raise the bumper into the folded position several times to ensure the mecha nism works smoothly and freely MATERIAL LIST LENIN NN 3 a sup Brackerwowr anm 2 1 BUMPER TUBE 47 83 2 moram a suozarm S s em FRONT BRACKET FE se 8 3 4 DIA FLAT WASHER TOTAL 177 53 SUB FRAME REF ADDITIONAL NOTES 1 Prior to any welding consult the truck manufacturer for any special precautions that may need to be taken Typically the batteries must disconnected and the ground lead from the welder should be connected as close as possible to the part being welded to avoid the possibility of arcing across bearings gears etc 2 During installation of the bumper check to make sure that the position of the bumper does not interfere with the load ing and unloading of truck bodies BAR 4 X 1 X LENGTH SUPPLIED BY INSTALLER 1800 E Broadway Avenue Box D Des Moines Iowa U S A 50316 0386 U S A LTD Telephone 515 266 3042 Fax 515 266 3042
43. an 1 8 exists between the inner and outer tubes then proceed to the outer tube clamp adjustment steps below 1 16 TO 1 8 GAP OUTER TUBE ADJUSTMENT BOLT CLAMP BAR ADJUSTMENT NUT SEAR s OUTER TUBE H CLAMP LINER WEAR PAD SECTION VIEW A A JAM NUT OUTER TUBE CLAMP ASSEMBLY 100 amp 200 SERIES HOIST CLAMP ASSEMBLY ILLUSTRATION ADJUSTMENT Refer to the 100 amp 200 series Hoist Clamp Assembly Illustration above for the following adjustment steps 1 Loosen the jam nuts on the clamp bar adjustment bolt 2 Tighten the adjustment nuts equally so that the clamp bar is drawn up evenly Be sure to keep the jib horizontal tube level make sure the gap is even between the inner and outer tubes from left to right 3 Once the gap between the top of the jib horizontal tube and the top inside surface of the outer tube is between 1 16 to 1 8 the jam nuts can be tightened up SL 240 MAI 4 13 07 2009 PARTS LIST 08 04 09 08 54 PT 52H05 dwg PARTS LIST P N DESCRIPTION REMARK 51H99 TELESCOPIC JIB SUB ASS Y 2H0 PIVOT JOINT SUB ASS Y 2H04 MAINFRAME SUB ASS Y 0H96 HYDRAULIC ASSEMBLY 25 12 NOT SHO SERIAL TAG 2H34 HOIST INSTALLATION KIT OT SHO H9 CHASSIS TANK CIRCUIT OT SHO PUMP CIRCUIT OT SHO MANUAL CONTROL ASS Y SHO HYD PUMP GEAR SHO 3843 98 TOTAL 2 rm e m w e eie zz mm e 79 e
44. aulic components can occur Castrol BP ISO Grade 32 Company Name Brand Name amp Grade Paradene 32AW CITGO 32 Exxon Nuto H 32 Mobil DTE 24 DTE 13 Shell Tellus 32 SUNOCO Sun Vis 706 816 WR ISO Grade 46 Castrol BP Paradene 46AW CITGO A W 46 Exxon Nuto H 46 Mobil DTE 25 DTE 15 Shell Tellus 46 SUNOCO Sun Vis 747 821 WR HYDRAULIC FILTER ELEMENT SPECIFICATIONS amp INTERCHANGE CHART Company Name Filter Part Number Element Size Mounting Thread Filtration Rating Flow Rating Baldwin BT8443 Behringer BSO92E10N25 Donaldson P550255 Fleetguard HF6511 Flow Ezy FEE30 10L FPC FPE40 10N Brand of Element supplied from factory on hoist SL 240 MAI 07 2009 3 66 8 6 1 12 UNF 10 micron Nominal 25 GPM Company Name Filter Part Number Hydac 0085MA010P LHA SPE25 10 Norman 410 PTI F4E 040CCB Purolator 20201 Zinga AE 10L 4 3 PT NO 21P63 21P66 21P72 20P28 21P67 21P65 20P28 20P24 20P43 20P41 20P22 20P23 20P64 20P25 20P07 20P96 20P97 SL 240 MAI 07 2009 GENERAL MAINTENANCE PARTS LIST DESCRIPTION HYDRAULIC CYLINDER 69 X 54 Lift Dump SEAL KIT HYDRAULIC CYLINDER HYDRAULIC LINE ASS Y REPLACEMENT HYDRAULIC VALVE CARTRIDGE COUNTERBALANCE ck HYDRAULIC CYLINDER 3 1 2 X 30 Jib SEAL KIT HYDRA
45. aulic hose Part No 12P93 may need shortened s 22 prior to final installation See drawing 90H85 especially if Dep excess length exists The hydraulic hose Part No 12P93 22 comes with a reusable fitting that can be removed for purposes of shortening the hose Remove the reusable fitting and shorten hose assembly as required After hose has been a shortened lubricate the insert threads of the fitting and the 1 0 1 of the hose See Fig 1 Measure 1 3 16 inches from the end of the hose and mark the hose for the socket depth Screw the 18 87 hose into the socket left hand thread to the depth marked on 3 the hose Screw the insert into the socket until the insert touches the socket Clean the inside of the hose assembly by Figure 1 either clean compressed air through it or by flushing it 28JUL09 11 12 13 14 15 16 Page 2 of 7 Once the overall hose length is adjusted install between the C V S hydraulic valve and the hydraulic tank fittings See drawing 90H85 and tighten Remove both the hydraulic hose Part No 12P76 that connects from the upper bulkhead fitting inside the mainframe to the jib lockout valve Part No 21P28 and the 90 amp 45 degree hydraulic fittings Part No 11P23 amp 12P09 installed into the top side of the jib lockout valve See drawing 90H79 Replace with hydraulic fittings Part No 12P69 Qty 2 amp 13P04 hydraulic hose Part No 11P98 and relief valv
46. d hose as shown on Drawing No 90H60 Air Circuit Control Valve An air pressure protection valve Pt No 20P74 is provided so you can tap into the truck s air supply without jeopardizing the integrity of the air system The air hose is provided in a bulk length which you can cut to length as required for running the air lines Take care in routing the air lines and avoid hot areas such as exhaust pipes etc SL 240 INS 2 11 09 2009 Add 19H06 8170 0 0 0 15 19H06 1d 193 Z ASSV 1OH1NOO HIV B vsn 5 ONIBANA SION TIS 9NIMVSU 315 NI NOILYTIVISNI 12 443434 JA IVA 1041NOO 8 uiv 1404 NOLLOdS 445 9 Bro 150 2 12 SL 240 INS 09 2009 V 09H06 90v 00v 0 1S NOILOAS Z 3NTVA TOH LNOO usavoldums f 4 d zY GAH 2 06 IAS dN AGN L NO HSNd ddv 55 1HOd ALAN 8 dW 38n 1L NO HSNd dav 55 MOVIE 38nL NOTAN 0 dW 38n L NO HSNd dav s
47. d hydraulic plumbing between the hydraulic tank and the control valve assembly 4 Select and install the P T O on the truck transmission Note This can be done prior to hoist installation on the truck chassis 5 Install the hydraulic pump and the plumbing from the pump to the hydraulic tank and control valve assembly 6 Fill the hydraulic tank with oil bleed the air from the pump suction line and start up the unit Although SwapLoader attempts to include the mounts and attaching fasteners with each hoist unit your particular installation may require some additional mounts or modifications If you have problems with your installation please contact SwapLoader at 1 888 767 8000 as we may be aware of another customer who has installed a SwapLoader on a similar truck chassis SL 240 INS 2 1 09 2009 HOIST INSTALLATION TO TRUCK CHASSIS l Place the SL 240 hoist assembly on the truck chassis The truck chassis mounting surface should be flat without any steps or protrusions If necessary shim bars need to be added to ensure a flat surface on which to support hoist The truck chassis should meet the following minimum specifications See Figures A amp B RBM for each frame channel 900 000 in lb Total RBM 1 800 000 in lb Minimum clear frame rail for mounting 182 See Fig A amp B Front Axle Cap 12 000 Ib Min Total Rear Axle Capacity 20 000 Ib Min CA Dim 130 to 144 144 preferred CT Dim 120 to 132 132
48. d install a direct drive type P T O to the transmission Please contact your local truck equipment representative for the correct unit sized on the following criteria P T O Torque Rating Power at 1500 RPM Output Flange Hydraulic Pump Spined Shaft Specifications Hydraulic Pump Rotation Ratio of Pump RPM to Engine RPM 200 ft Ibs See Note 1 47 H P See Note 1 SAE B 4 Bolt 7 8 13T 16 32 D P L H As provided See Note 2 The hydraulic pump rotation can be reversed to R H by a qualified hydraulic technician or it can be sourced through Swaploader 8096 to 100 NOTE 1 P T O torque and power requirements are based on the unit operating at main relief pressure Normal operating pressure will be less NOTE 2 P T O output rotation will need to be R H clockwise as viewed looking at output flange of P T O for a L H Pump NOTE 3 Do not operate pump at speeds over 1500 R P M NOTE 4 Always disengage the P T O after each operating cycle SL 240 INS 09 2009 2 15 HOW TO IDENTIFY WHAT PUMP IS NEEDED The SwapLoader factory supplied pump is a bushing style gear pump because of the pressure requirements of the SwapLoader hooklift hoist By design the bushing style pumps are single rotation rotation specific SwapLoader hooklift hoists come standard with a CCW left hand rotation pump which will work for most manual transmission applications For most automatic transmission applications a CW
49. e assembly Part No 21P93 and tighten See drawing 90H85 Refill hydraulic tank to proper fluid level Verify that the C V S is operating properly Start the truck engage the P T O and then retract the jib cylinder full stroke Next while extending the jib cylinder back out have someone push or rotate the C V S lever arm forward toward the back of the truck cab The C V S is operating properly when the jib cylinder stops extending by rotating the C V S lever arm forward Containers to be used in conjunction with the C V S need modified by adding a stop tab to the side of the container longsill See drawing S 878 Dimensions given are a recommendation only When modifying containers for use with the C V S it is the primary responsibility of the installer to verify that adequate rear end overhang and full latch plate engagement into body locks exists for each container 28JULO9 Page 3 of 7 WT Ib REMARKS PER EAC EMARKS 11 23 16 HEX NUT B ES INTO THE 0 ON THE 121 AS INDICATED USE THE 12H01 amp 23H76 AS A PATTERN TO AID IN LOCATING
50. ee illustration on the next page this is most easily performed with the hoist back in a dismount mode If either part shows signs of wear or damage then replace or repair as needed With the jib lockout valve roller and valve ramp in good condition the next step is to check that the valve is positioned correctly with respect to the valve ramp While looking at the roller end of the jib lockout valve notice that the roller moves in and out of an end cap With the hoist pivot joint in the down position or horizontal to the hoist mainframe the valve ramp should be in contact with the jib lockout valve roller The roller should be depressed by the valve ramp so that 1 8 to 3 16 of the roller is exposed from the end cap see illustrations above and on next page SL 240 MAI 4 9 07 2009 Mainframe Ref Valve Mount Valve Ramp Base 1 8 to 3 16 of Mainframe Roller Exposed Adjustment Screw WA Valve Mount Ref Bracket Valve Ramp 1 Jib Lockout Sud Side Valve View View Mount Bracket Jib Lockout Screw 2 Typ Mount Bracket Valve Screw 2 Typ Pivot Joint Valve Mount Ref Bracket TOP VIEW SIDE VIEW JIB LOCKOUT VALVE ADJUSTMENT ILLUSTRATION ADJUSTMENT Should the jib lockout valve need adjustment the first step will be to loosen the mount bracket screws see illustration above Reposition the jib lockout valve with respect to the valve ramp by turning the adjustment screw on t
51. g consult the truck manufacturer for any special pre cautions that may need to be taken Typically the batteries must be dis connected and the ground lead from the welder should be as close to the Ca part being welded to avoid the 2X4 1 4 4 Q 6 possibility of arcing across bearings 9P CFR M js CENTERS gears etc J 7 16 DIA HOLE 1800 NE Broadway Avenue Des Moines lowa U S A 50313 2644 Phone 515 266 3042 Fax 515 313 4426 Toll Free 888 767 8000 E Mail sales swaploader net Web Site www swaploader com 11 02 99 a EFCO Company U S A LTD 10 05 09 LUG INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting rear light bar installation 2 Trim truck frame to indicated dimensions See Fig 1 This step may have already been preformed if a bumper was previously installed 3 Position center plate Part No 63H08 on the rear of the main frame Weld center plate to truck frame See Fig 2 amp Additional Notes 4 Position stub light bar weldment Part No 51H69 on truck frame Stub light bar weldment should be as high and as far back as possible on the truck frame to avoid interference with the bumper and fenders It may be necessary to modify the stub light bar weldment to avoid interference Drill mo
52. he valve mount bracket as follows Clockwise Adjustment Moves the jib lockout valve closer to the valve ramp Counter Clockwise Adjustment Moves the jib lockout valve away from the valve ramp Once the valve has been moved back into proper adjustment then tighten up the mount bracket Screws PART NUMBER amp SPECIFICATION sd e Pressure Flow Rate 21P28 3 4 16 ORB SAE 8 2 Way 2 Position N C 4 600 PSI Nominal 16 GPM Nominal Please contact your SwapLoader Distributor or SwapLoader USA should you have any questions regarding this procedure SL 240 MAI 4 10 07 2009 PRESSURE CHECK INSTRUCTIONS When performing a pressure check on a SwapLoader hook lift hoist we recommend that you use a calibrated pressure gauge that reads pressures up to 3 500 PSI a 0 to 5 000 PSI range gauge is recommended As a minimum the gauge should have 100 PSI graduation marks 50 PSI is preferred and a 3 inch diameter dial size 4 inch dial is preferred The pressure gauge should be outfitted with a female JIC 4 hydraulic adapter preferably located at the end of a 3 8 inch diameter high pressure hydraulic hose that is 2 to 3 foot in length see illustration below Hydraulic Adapter Swivel 4 Hydraulic Hose Assembly High Pressure 3 8 Dia x Pressure Gauge recommended r 0 to 5 000 PSI Range alee in length 4 Dia Dial Size 50 PSI Graduation Marks RECOMMENDED PRESSURE GAUGE ILLUSTRATION Sho
53. ing and do not use cable supports which may crush or deform the cable Allow room for flexing where the cable is attached to moving parts of the equipment so that the cable is neither kinked nor stretched SL 240 INS 2 9 09 2009 7 8 INSTALLATION PROCEDURE FOR A HYDRAULIC CONTROL CABLE TO HYDRAULIC VALVE WITH BONNET CONNECTION KIT Turn 750 16 UNF Jam Nut entire length of Threaded Hub back over the Cable Place Flange onto Sleeve Turn Flange Sleeve Assembly entire length of Threaded Hub back over the Cable Turn 250 28 UNF Jam Nut onto Threaded Rod until it bottoms Turn Terminal Eye onto Treaded Rod until it bottoms against Jam Nut Minor adjustments may be necessary to align Terminal Eye with spool yoke Slide the Terminal Eye into yoke on spool and align the holes Insert Clevis Pin through yoke and Terminal Eye holes Install Retaining Ring into groove between Terminal Eye and one side of the Yoke Now with the Cable attached to the valve and control head turn the Flange Sleeve Assemble back onto the Threaded Hub until it is flush with the valve face When turning on the Flange Sleeve Assembly make sure that the control head remains in neutral Thread the 750 16 UNF Jam Nut back over Threaded Hub and tighten against the Sleeve to lock in position Bring Flange into position on bolt assembly to valve housing NOTE FOR WORK SECTION NEXT TO INLET COVER USE SPACER KIT ETURN NUT 5 ALIGN H
54. k chassis YES NO If yes please describe bolts checked for proper tightness Please include photos of the hoist installed on the truck chassis Be sure to include at least one photo from each side III CONTROLS Controls easy to reach from driver s seat Movement of controls correct per installation instructions SL 240 PRE PAGE 1 07 2009 PREDELIVERY CHECK LIST SWAPLOADER MODEL SL 240 HOIST INSTALLATION IV HYDRAULICS INSTALLATION Correct hydraulic oil level in reservoir Check for leaks Any abnormal noise during operation YES NO If yes explain WITH ENGINE OPERATING 1000 RPM RECORD THE FOLLOWING INFORMATION Cycle time for dump mode Up Sec Down Sec Cycle time for load unload mode Unload Sec Load Sec Filter pressure PSI Main pressure controls in neutral PSI Main relief pressure when extending jib cylinder bottomed out PSI Main relief pressure when extending lift cylinders bottomed out PSI NOTE Connect pressure gauge to fitting provided on inlet section of Hyd Control Valve Ref Pt No 10P37 fitting on Chassis Tank Hyd Circuit Drawing No 90H97 V OPERATION Jib operates freely in both directions Jib cannot be extended or retracted when raised in dump position or when pivot joint is tilted in unload position Both safety hooks are fully engaged when jib is extended Parts and operators manual in cab Lubricate sliding jib and all grease zerks per installation instructions VI
55. l need to be removed after painting the hoist It is very important when removing the premask not to pull the premask out and away from the decal at a 90 angle but instead pull the premask straight down at a 180 angle to the decal surface Should problems occur with the premask pulling the decal loose wet the tack side of the premask with water via a spray bottle to weaken the adhesive bond while pulling straight down on the premask SL 240 INS 2 19 09 2009 7 Fill out pre delivery checklist and warranty card and mail to SwapLoader U S A Ltd NOTE CAUTION SL 240 INS 09 2009 Failure to fill out and return warranty card within 15 days of installation may possibly void the warranty The SwapLoader hoist must be used with bodies or containers that properly fit the front hook and the rear hold downs See figure S054 If possible pick up one of the containers that will actually be used with the SwapLoader hoist and verify the following Outside dimensions of the long sills match the guiding rollers on the hoist The front hook dimensions are correct for the hoist The rear hold downs of the container latch into the hold downs on the hoist Check for any interference between the container and any part of the hoist i e Hydraulic tank hydraulic tubing or hose hydraulic valve etc 2 20 790 LHOI3H MOOH 48 2 69 SNOISN3NIG 3l vddans 531935 002 uaavoldvMs gt 1 31ON 33S
56. llow for mounting the control valve assembly and the hydraulic tank You should consult the truck chassis supplier for any limitations regarding drilling mount holes in the truck chassis frame rails Typically the holes must be at least 2 34 from the top of the truck chassis rails Reference figure D amp E Once the locations of the mount brackets have been determined use the mount brackets as a template for marking the mounting holes in the truck chassis frame rails Drill the 21 32 diameter holes required and attach the brackets to the truck chassis with the 5 8 inch diameter bolts washers and locking hex nuts provided Torque to 220 ft lbs SL 240 INS 2 3 09 2009 3 Weld the mount brackets to the hoist mainframe as indicated on Figures D thru E You may need to modify the mount brackets or add shim plates to allow for variances in the width of the truck chassis as well as to allow for top rivets stepped channels etc gt 5 N _ tou 4 Figure D gt N N p FON i 4 Figure E Note Prior to any welding consult the truck manufacturer for any special precautions that may need to be taken Typically the batteries must be disconnected and the ground lead from the welder should be connected as close as possible to the part being welded to avoid the possibility of arching across bearings gears etc Note The hoist mainframe is made from high strength low alloy steel
57. m Upon evaluation of the returned parts once warranty is approved credit will be issued to the appropriate account for the approved warranty costs which may include parts labor and or freight e The warranty covers only defective material and workmanship It does not cover depreciation or damage caused by normal wear and tear accident mishap untrained operators or improper or unintended use The owner has the obligation of performing routine care and maintenance duties as stated in SwapLoader s written instructions recommendations and specifications Any damage resulting from owner operator failure to perform such duties shall void the coverage of this warranty The cost of labor and supplies associated with routine maintenance will be paid by the owner e event will SwapLoader the SwapLoader distributor or any company affiliated with SwapLoader be liable for business interruptions costs of delay or for any special indirect incidental or consequential costs or damages Such costs may include but are not limited to loss of time loss of revenue loss of use wages salaries commissions lodging meals towing hydraulic fluid travel mileage or any other incidental costs SwapLoader is not responsible for the removal or replacement of accessories fenders toolbox etc Warranty shall not apply if the equipment is operated at capacities in excess of factory recommendations Warranty is expressly void if the seal on
58. n Purposes Only 10 02 09 INSTALLATION INSTRUCTIONS continued 4 Mark mounting holes through the fender bracket weldment onto the fender Remove the bracket and drill 7 16 dia Holes in fender See FIG 3 5 Attach fender bracket weldments to fender using fasteners provided 6 Weld mounting plates Part No 21H37 to MATERIAL LIST fender tubes Part No 21H61 WE WE M QTY P N DESCRIPTION EA 7 Position fender tubes with mount plates on 1 4 10H74 FENDER BRACKET WDMT 8 05 hoist mainframe align with fender 2 4 21H37 MOUNTING PLATE 1 09 bracket weldments NOTE Fender tube 3 4 21H42 RUBBER SPACER 85 length may need to be modified to fit 4 4 21H61 FENDER TUBE 1 26 specific application 5 32 00P34 3 8 16 UNC LOCKING NUT 02 6 48 00771 3 8 DIA FLAT WASHER 05 8 Weld fender tube to hoist mainframe If 7 16 00P78 3 8 DIA NYLON WASHER attaching the fender tubes to the truck 8 16 00 44 3 8 16 UNC X 1 1 2 HHCS 07 chassis an additional mount plate may 9 16 01P21 3 8 16 UNC X 2 1 2 HHCS 09 need to be fabricated so the assembly 2 FENDER can be bolted to the to the truck chassis 90P24 FENDER ALUMINUM 19 00 90P25 FENDER STEEL 35 00 9 Attach fender bracket weldment Part No 10H74 to mounting plate Part No doa 21H37 using fasteners provided STEELFE
59. need to be added See Fig 2 4 Once the mount brackets are located on the container weld the roller mount brackets in place See Fig 1 5 Install the roller Part No 10H12 between the brackets with the roller axle Part No 10H31 and the fasteners provided See Fig 3 Grease the rollers before use MATERIAL LIST mpm meme CE 1 2 2 rome s 2 ROWER ALE wowr Ca os z wwe e sepa tockwasier 7 2 wena wasser EXISTING CROSS MEMBERS REF FABRICATED EXCEEDS 6 ROLLER MOUNT TO REF SWAPLOADER 1800 N E Broadway Avenue Box D Des Moines USA 0916 0500 9 e nes lowe U S A LTD SWAPLOADER U S A LTD TOOLBOX Aluminum 4009 Steel 14 12 INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting toolbox installation 2 Position toolbox brackets Part No 10H88 on truck chassis NOTE toolbox has an envelope of 18 x18 x36 See Fig 1 for hole dimensions 3 Mark position of mounting holes through brackets onto truck chassis Remove brackets and drill 9 16 dia holes 4 Mount toolbox brackets using fasteners provided See Fig 1 5 Position toolbox Part No 90P27 or 90P37 on brackets
60. our 24 months labor from the original factory invoice date e Warranty Registration Card must be returned within 15 days of Retail Sale of SwapLoader hoist to SwapLoader Des Moines Iowa If unit has not been registered then the warranty start date will revert to the original factory invoice date Warranty Registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the product registration form included in the SwapLoader hoist manual If the owner is not sure that product registration is completed then SwapLoader encourages them to contact us at 888 767 8000 to confirm e Defective parts must be reported to SwapLoader within 30 days of discovery on a SwapLoader warranty claim report form A Return Goods Authorization RGA number must be issued to the claiming party prior to the return of any defective part to be considered for warranty e Warranty service must be performed by a distributor or service center authorized by SwapLoader to sell and or service SwapLoader products which will use only new or remanufactured parts or components furnished by SwapLoader U S A Ltd SwapLoader will invoice the distributor or authorized service center for the replacement parts and freight Upon completion of the repair any defective parts to be returned for warranty consideration must be returned freight prepaid with a copy of the SwapLoader issued RGA form and a copy of the completed warranty claim report for
61. pLoader U S A Ltd has been discussed with the customer Date Installed Customer Name please print Date Inspected Address please print City State Zip please print Customer Phone Number required Customer Signature Distributor Signature Type of Application SwapLoader hoist will be used in O Waste Industry Landscaping Public Works Construction Tree Nursery General Construction O Recycling 1 Roofing Other 20070CT30 Aad 90HcS Ovc 1S AlaNassv WOAd 4115 4441 HOSIA NO 9 9 488 ASSY agni YILNO NO 51 04 1 90416 2 00143 4665344 84d06 3NO 02 5 01090 9190639 6 NO 8 830 014 5 2 8 SNOUORMISNI AL3VS 21806 9ZHLS ____ 21806 30 9 ASSY YILNO NmviisOH Z 6 3IgvAWV 4 10 01406 3NO O3S 10 6040630 1 2345 008 1510 80406 z TYnNYN A33S yd0 10806 e oi auo wau ism Slavd II III IV TABLE OF CONTENTS INTRODUCTION V Letter to Customer Warranty Statement Safety Suggestions INSTALLATION Initial Inspection Hoist Installation Controls Installation Hydraulic Tank Installation
62. rate the skin causing serious injury Avoid hazardous conditions by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard while protecting hands and body from the high pressure fluids 12 It is the responsibility of the owner to provide proper maintenance of the Safety Decals Regular inspection and replacing of Safety Decals that have any fading or damage which would impair their function should be done See the illustration on the following page for location of Safety Decals INTRODUCTION 1 4 09 2009 4 H a o VEL SS T 7 N 3 t TY ITEM QTY P N DESCRIPTION 1 2 90P07 OPERATION amp SERVICE MANUAL 2 2 90 08 HOIST BODY SPECIFICATIONS 3 ONE 90 09 HYDRAULIC OIL SPECIFICATIONS 4 ONE 90P10 HYDRAULIC OIL FLAMMABLE 5 2 90 11 HOIST FALLING 6 ONE 90P13 SAFETY INSTRUCTIONS 7 ONE 90 18 RELIEF VALVE 8 90 52 PROP DECAL 9 ONE 90P78 HIGH PRESSURE FLUID The following is a list of all the Swaploader Safety Decals and their part numbers Please use when reordering replacement decals T WARNING Do not operate or service this equipment until you have been properly trained and instructed in its use and have read the operation and service manual AW 90P07 OPERATIONS amp SERVICE MANUAL
63. rvice To keep it operating efficiently read the instructions in this manual thoroughly It contains detailed descriptions and instructions for the efficient operation and maintenance of your SwapLoader Each section is clearly identified so you can easily find the information that you need Read the Table of Contents to learn where each section is located instructions are recommended procedures only Throughout this manual you will come across Dangers Warnings or Cautions which will be carried out in bold type and preceded by the symbol as indicated to the left Be certain to carefully read the message that follows to avoid the possibility of personal injury or machine damage Record your SwapLoader Hoist serial number in the appropriate space provided on the title page Your SwapLoader dealer needs this information to give you prompt efficient service when you order parts It pays to rely on an authorized SwapLoader Distributor for your service needs For the location of the Distributor nearest you contact SwapLoader NOTE It is SwapLoader s policy to constantly strive to improve SwapLoader products The information specifications and illustrations in this publication are based on the information in effect at the time of approval for printing and publishing SwapLoader therefore reserves the right to make changes in design and improvements whenever it is believed the efficiency of the unit will be improved without incurring any
64. s and connect the hydraulic hoses and tubing Pt Nos 10P73 11P98 and 11P99 to the control valve assembly as indicated on Drawing No 90H97 The tubing should be supported by the clamp assemblies that are provided in the Loose Parts Box See Drawing 52H34 4 Determine the best location in the cab for the control levers Pt No 20 08 The location should be such that the controls can be easily reached while operating the truck A control lever console Pt No 20P09 is provided to facilitate the mounting of the control levers 5 Assemble and install the control lever console See diagram below Typically the console is fastened to the floor of the cab and the control cables are routed through additional holes drilled in the floor Your particular installation may require that additional brackets be fabricated or other modifications made SL 240 INS 2 6 09 2009 V Add v9H06 8Lvo O0vc 1S NOILOAS 2 ASSY TVnNVAN 5 gt air d 1 s 6 2 7 SL 240 INS 09 2009 0 2 220 029 15 JInoadlo SISSVHO 66 8018
65. se the gap or clockwise to decrease the gap Once the 1 4 clearance is achieved then tighten the jam nut Make sure to hold the adjustment bolt from turning when tightening the jam nut Please contact your SwapLoader Distributor or SwapLoader USA should you have any questions regarding this procedure SL 240 MAI 07 2009 JIB LOCKOUT VALVE INSPECTION amp ADJUSTMENT INSTRUCTIONS SwapLoader hook lift hoists have a jib lockout valve see illustration below to prevent accidental operation of the telescopic jib while the hoist is up in a dump mode Because the jib lockout valve can block the flow of hydraulic oil to the jib cylinder should the valve come out of adjustment the telescopic jib may experience a reduction in extension or retraction speed to the point of stalling out Roller Es Spring Cap JIB LOCKOUT VALVE ILLUSTRATION INSPECTION When a noticeable loss in extension or retraction speed of the telescopic jib is experienced the first step should be to inspect the jib lockout valve and valve mount ramp to ensure that they are adjusted properly and in good working order The jib lockout valve is located on the inside rail of the hoist mainframe approximately two thirds of the way back on the driver side of the hoist see Drawing No 52H04 in the Part List pages of the manual Visually inspect the jib lockout valve roller and the condition of the valve ramp on the hoist pivot joint without a container on the hoist s
66. se to the part being welded to avoid the possibility of arcing across bearings gears etc a EFCO Company 8 5 LTD 1800 Broadway Avenue Des Moines lowa U S A 50313 2644 Phone 515 266 3042 Fax 515 313 4426 Toll Free 888 767 8000 E Mail sales swaploader net Web Site www swaploader com 10 05 09 1 014 WNVSOVIG 10 05 09 LOADER U S A LTD SWAP ROLLER amp ROLLER MOUNT 40490 9 10H91 INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting the roller and roller mount installation 2 Locate position for roller mount brackets Part No 32H03 between cross sills of the container Rollers should be positioned as far back and as wide as possible for stability For hoist and folding bumper clearance do not place brackets any closer than 11 to the subframe longsill See Fig 1 Also the roller axle center line should be approximately 1 11 16 below the bottom of the subframe longsill for roller clearance See Fig 1 ROLLER MOUNT SUBFRAME LONGSILL CROSS MEMBER ROLLER amp ROLLER MOUNT 10H90 amp 10H91 INSTALLATION INSTRUCTIONS continued 3 Some modification to the roller mount bracket may be required for the roller mount to fit properly If the existing container cross members are wider than 6 a fabricated support member of 1 2 plate or thicker will
67. svug 2 7 dWa dW dav GAH 2 dW 38n L NO HSNd dav zLd0z HIV NOILO3S 2 ASSY TOHLNOO 488 96d0z SLIM 5 M 88402 ASSY JAYA 1OHLNOO GAH AlddflS uiv 499 72402 3ATVA NOILO3LOHd 55 AGNL 206 TAS AGN L dav ssvuag 15 3AV31 2 13 SL 240 INS 09 2009 SL 240 INS 09 2009 HYDRAULIC TANK INSTALLATION Select a location to mount the hydraulic tank Reference Figure F or Drawing No 90H64 for the suggested location of the hydraulic tank to the rear of the control valve assembly on the left hand side of the truck The hydraulic hoses have been sized for the tank to be mounted in this general area The tank can be located on the right hand side or behind the cab if necessary which means longer hoses may be required Drill four 4 holes for 5 8 inch diameter bolts provided in the mount angle of the hydraulic tank two per angle and the frame rails of the truck chassis Mount the hydraulic tank and install the hydraulic filter Install the hydraulic return hose and the hose barb fitting between the filter and the control valve assembly as shown on Drawing No 90H97 The hose length can be shortened if necessary Secure the hose to the barb fittings with the hose clamps provided Figure F 2 14 P T O SELECTION The next step is to select an
68. t is to the left side then the pump is a CCW or left hand rotation If the suction largest port is on the right side then the pump is CW or right hand rotation SL 240 INS 2 16 09 2009 SL 240 INS 09 2009 PUMP INSTALLATION Install the hydraulic pump to the P T O Bolts are not provided Install the hydraulic fittings into ports on the hydraulic pump as shown on Drawing No 90H98 Connect the suction hose assembly to the hydraulic tank 1 1 4 I D hose and route to the hydraulic pump in as short and straight line as possible Be sure to route the hose clear of exhaust components and of the drive shaft Extra hose is provided so the hose can be shortened to an appropriate length Install the hose on the hose barb fittings at the tank and at the pump and secure with the hose clamps provided NOTE Prior to startup this hose must be filled with oil The pressure hose from the hydraulic pump to the control valve assembly is not supplied with the hoist as it must be made to the proper length This hose must be purchased from a local hydraulic hose assembly supplier per the following specification Hose 3 4 inch Working Pressure 3000 PSI Hose Fitting Threads SAE 37 JIC 1 1 16 12 Install the pressure hose as indicated Tie up the pressure and suction hoses as necessary Again be sure the hoses are routed to avoid exhaust components and to stay clear of the drive shaft 2 17 0 2 222 022 15
69. uld you not be able to source a hydraulic gauge locally SwapLoader can provide one at a reasonable cost Hyd Pressure Gauge amp Hose Ass y Part No 22 10 PRESSURE CHECK STEPS 1 Locate the 90 male 4 hydraulic adapter SWL 10 37 found on the top of the hoist hydraulic control valve see illustration below SWL P N 10P37 SWL P N 10P38 Hydraulic Adapter 7 Hydraulic Adapter 90 4 4 cs Cap Hyd Tubing Ass y to rear of hoist Hyd Hose Ass y to front of hoist amp amp t Hyd Control Valve Ass y N PRESSURE CHECK HYDRAULIC ADAPTER LOCATION ILLUSTRATION This 90 male 4 hydraulic adapter is supplied by SwapLoader and should be installed in the hydraulic control valve at the time of the hoist installation see the hoist parts amp operations manual SL 240 MAI 4 11 07 2009 2 Remove the female 4 cap from the male 4 adapter and attach the pressure gauge to the hydraulic control valve see illustration below SWL P N 10P37 Hydraulic Adapter 90 4 4 Pressure Gauge Hyd Control Valve Ass y PRESSURE GAUGE TO HYDRAULIC ADAPTER ILLUSTRATION 3 Start the truck and engage the 4 Push the lift dump circuit lever forward until the lift dump cylinders bottom out see illustration below Continue to push the lever forward until steps 5 6 are complete FRONT LOWER LOAD EXTEND LIFT JIB Y Y RAISE U
70. unting holes as required and mount using fasteners provided See Fig 3 5 Attach the tail light module to the stub light bar weldments with the fasteners provided See Fig 3 6 Mount the identification light bar at top center of the center plate Part No 63H08 using the fasteners provided See Fig 3 7 Mount license lamp right of the license plate See Fig 2 using the fasteners provided See Fig 3 TRUCK FRAME CENTER R EF N PLATE CENTER INDENTIFICATION LIGHT RAIL LICENSE LAMP LICENSE PLATE REF JUNCTION BOX BEYOND TAIL LIGHT MODULE FIG 2 All Figures are for Illustration Purposes Only 10 05 09 Bae HES 8 Mount junction box on the back left side of center plate See Fig 2 using the fasteners provided See Fig 3 9 Route all wire harnesses into the junction box Wire harnesses must enter the junction box through a compression fitting Based on the size of the wire harness choose a compression fitting with an appropriately sized grommet Make wiring connections in junction box with wire harness from truck cab as indicated on wiring diagram See Fig 4 ADDITIONAL NOTES Prior to any welding consult the truck manufacture for any special precautions that may need to be taken Typically the batteries must be disconnected and the ground lead from the welder should be as clo
71. ved lifting bar is securely attached to the hook Release the brakes of the truck and steer to correctly align the truck with the container Watch the container rails to see that they come to rest centered on the rear rollers Do not extend the jib during lifting 5 When the container is resting on the frame move the jib forward all the way to ensure the container is held in the body locks right control lever forward DUMPING 1 Move the jib forward right control forward to ensure that the container is locked 2 Extend the main lift cylinders left control backward CAUTION DO NOT RETRACT THE JIB WHILE DUMPING Retracting the jib during dumping may unlock the mechanical jib latches which could allow the container to crash down onto the hoist and or abruptly unload SL 240 0PE 3 2 07 2009 PLACING A CONTAINER ON THE GROUND 1 Move the sliding jib all the way back right control backward until mechanical 16 latches unlock 2 Tilt the arm backwards left control backward When the container touches the ground release the brakes to free the truck for forward movement caused by the container 3 Rotate jib all the way till the container touches the ground Pull away from container and rotate jib back into the transport position WARNING 1 DON T OVER SPEED THE PUMP 1 500 RPM MAXIMUM 2 DON T DUMP ON UNEVEN GROUND SL 240 0PE 3 3 07 2009 WARNING CONTINUED SL 240 0PE 07 2009 3
72. working order DO NOT use if repairs are needed Perform periodic inspections and maintenance as required by the maintenance section of the operator s manual INTRODUCTION 1 3 09 2009 7 Make sure work area is clear of people and obstacles prior to dumping or unloading containers SwapLoader strongly recommendis that a back up alarm be installed on the truck chassis The operation of the hook hoist is that the truck 15 backed up to the body to pick it up and so there is a potential pinch point between the body and the hook 8 Any container which is on the hoist MUST be unloaded prior to performing any repairs or maintenance to the hoist Also DO NOT allow any person to work on or be under the hoist in a raised position without first installing adequate safety blocks to eliminate all possibility of the hoist accidentally lowering SwapLoader strongly recommends that if possible the container should be dismounted from the hoist prior to performing any maintenance to the hoist 9 It is the responsibility of the owner and or installer to insure that any additional safety devices required by state or local codes are installed on the SwapLoader Hoist and or Truck Chassis 10 Keep away from overhead power lines Serious injury or death can result from contact with electrical lines Use care when operating hoist near electrical lines to avoid contact 11 Avoid contact with high pressure fluids Escaping fluid under pressure can penet
73. y of arcing across bearings gears etc 2 All welds should be done utilizing a low hydrogen welding process TRUCK FRAME REF 1800 NE Broadway Avenue Des Moines lowa U S A 50313 2644 Phone 515 266 3042 e Fax 515 313 4426 Toll Free 888 767 8000 E Mail sales swaploader net Web Site www swaploader com 10 05 09 a EFCO Company U S A LTD LUI INSTALLATION INSTRUCTIONS 1 Review all directions and diagrams provided before starting bumper installation 2 Trim truck frame to indicated dimensions See Fig 1 These dimensions will facilitate the mounting of the rear light assembly if it is also being mounted 3 Measure the distance from the bottom of the truck frame to the ground NOTE This should be performed on a level surface Based this measurement and the dimensions in Fig 1 the vertical channel P N 63H94 may need to be modified in length to meet the Office of Motor Carrier Safety OMCS regulations Regulation 393 86 requires that no bumper be located more than 30 off the ground when the truck is empty and the end of the bumper should not be located more than 24 from the extreme rear of the vehicle including truck bodies See Fig 2 Once the length has been determined for the vertical channels weld them to the truck frame See additional notes on next page 4 Center the bumper weldment P N 52H12 with factory installed extensions P

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