swaploader SL-220 Parts And Operation Manual
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swaploader SL-220 Parts And Operation Manual

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Model SL-220
Parts and
Operations Manual
Hoist Serial Number: ____________________

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Summary of Contents for swaploader SL-220

  • Page 1 Model SL-220 Parts and Operations Manual Hoist Serial Number: ____________________...
  • Page 3 City, State & Zip: Phone: The unit has been checked and serviced according to SwapLoader’s Pre-delivery Check List. The proper mechanical operation of the unit as described in the written Parts & Operations Manual, provided by SwapLoader USA, Ltd., has been discussed with the customer.
  • Page 5 PRE-DELIVERY CHECK LIST INSPECTOR’S INFORMATION Inspected By: Signature: Distributor: Date Installed: Customer: Date Inspected: I. COMPONENT INFORMATION Hoist Model: Hoist Serial No.: Chassis VIN: Chassis Make & Model: Chassis GVWR: Distance from rear of cab to the centerline Chassis CA / CT: of rear axle/tandem.
  • Page 6 Parts & Operations Manual cover or at the back of the Parts List section in the Manual). Additional Comments: COMPLETE & SAVE TO YOUR COMPUTER. RETAIN A COPY FOR YOUR FILES. ONCE COMPLETE, FAX (515-313-4426) OR EMAIL (sales@swaploader.net) A COPY BACK TO SWAPLOADER! 1800 NE Broadway Ave., Des Moines, IA 50313 • www.swaploader.com •...

  • Page 9: Table Of Contents

    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 & Adjustment Instructions Pressure Check Instructions SL-220/222 Rev. 07/2009...
  • Page 11 INTRODUCTION...
  • Page 13 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.
  • Page 14 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.

  • Page 15: Safety Suggestions

    SAFETY SUGGESTIONS 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. Do not operate this equipment on uneven ground. Do not drive with the hoist in the dump position or with the hook to the rear.
  • Page 16 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.
  • Page 17 SAFETY INSTRUCTIONS 90P18 RELIEF VALVE 90P52 PROP DECAL 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. WARNING 90P07 – OPERATIONS & SERVICE MANUAL INTRODUCTION 09/2009...
  • Page 18 90P08 – HOIST-BODY SPECIFICATIONS 90P09 – HYDRAULIC OIL SPECIFICATIONS 90P10 – HYDRAULIC OIL FLAMMABLE 90P11 – HOIST FALLING 90P13 – SWAPLOADER SAFETY INSTRUCTIONS 90P18 – RELIEF VALVE INTRODUCTION 09/2009...
  • Page 19 90P52 – PROP DECAL (OPTIONAL) 90P78 – HIGH-PRESSURE FLUID INTRODUCTION 09/2009...

  • Page 21: Installation

    INSTALLATION...

  • Page 23: Initial Inspection

    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.

  • Page 24: Hoist Installation

    HOIST INSTALLATION TO TRUCK CHASSIS Place the SL-220 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 &...
  • Page 25 There are two types of mount brackets used on the Model SL-220 hoist as indicated in Figure C or Drawing No. 52H32. They are the front mount brackets (Pt. No. 60H60), and the rear mount brackets (Pt.
  • Page 26 Note: The hoist mainframe is made from high strength low alloy steel. Use an appropriate welding process. SL-220.INS 09/2009...
  • Page 27 SL-220.INS 09/2009...

  • Page 28: Controls Installation

    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-220.INS 09/2009...
  • Page 29 SL-220.INS 09/2009...
  • Page 30 SL-220.INS 09/2009...
  • Page 31 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.
  • Page 32 HOLES AND INSERT PIN SCREW NUT BACK FACE OF VALVE VALVE BODY SCREW SCREW FLANGE SLEEVE BACK TERMINAL EYE ON ROD SCREW FLANGE SLEEVE FLUSH WITH BOLT FLANGE FACE OF VALVE TO VALVE BODY SCREW NUT ON 2-10 SL-220.INS 09/2009...
  • Page 33 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. 2-11 SL-220.INS 09/2009...
  • Page 34 2-12 SL-220.INS 09/2009...
  • Page 35 2-13 SL-220.INS 09/2009...

  • Page 36: Hydraulic Tank Installation

    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 SL-220.INS 09/2009...

  • Page 37: P.t.o. Selection

    Hydraulic Pump Rotation: 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. Ratio of Pump RPM to Engine RPM: 80% to 100% NOTE 1: P.T.O.
  • Page 38 CW (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-220 hoist model: L.H. Rotation R.H.

  • Page 39: Pump Installation

    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 SL-220.INS 09/2009...
  • Page 40 2-18 SL-220.INS 09/2009...

  • Page 41: Start Up Procedure

    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. 2-19 SL-220.INS 09/2009...
  • Page 42 (i.e.: Hydraulic tank, hydraulic tubing or hose, hydraulic valve, etc.) When the SL-220 hoist is equipped with a standard 53-7/8” fixed jib see subframe Drawing No. S054, otherwise when equipped with the optional 53-7/8” to 61-3/4” adjustable dual height jib see subframe Drawing No.’s S054, S288 or S905.
  • Page 47 This is crucial in order to ensure that the container longsills do not contact the bumper during the dump cycle (See Fig. 1 & 2). BUMPER LOCATION CHART DIM B. (Max) DIM. A SL-220/222 SL-330 & SL-406 & SL-105 SL-145 SL-180...
  • Page 48 REAR BUMPER WDMT 95.66 (REF) 63H94 VERTICAL CHANNEL 9.58 TOTAL 114.82 FIG. 3 1800 NE Broadway Avenue, Des Moines, Iowa, 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...
  • Page 49 This is crucial in order to ensure that the container longsills do not contact the bumper during the dump cycle (See Fig. 1 & 2). BUMPER LOCATION CHART DIM B. (Max) DIM. A SL-220/222 SL-330 & SL-406 & SL-105 SL-145...
  • Page 50 VERTICAL CHANNEL 9.58 52H13 REAR BUMPER EXTENSIONS 58.42 TOTAL 173.24 FIG. 3 1800 NE Broadway Avenue, Des Moines, Iowa, 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 05OCT09...

  • Page 59: Container Variability System - (C.v.s.)

    CONTAINER VARIABILITY SYSTEM ASSEMBLY (52H21) [Hoist Models: SL-220, SL-222 & 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 52H21 Section View A-A).
  • Page 60 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.
  • Page 61 Page 3 of 7 28JUL09...
  • Page 62 Page 4 of 7 28JUL09...
  • Page 63 Page 5 of 7 28JUL09...
  • Page 64 Page 6 of 7 28JUL09...
  • Page 65 Page 7 of 7 28JUL09...

  • Page 67: Fender Assembly, Single Axle

    FENDER ASSEMBLY, SINGLE AXLE Aluminum (10H93) / Steel (11H13) (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.
  • Page 68 TRUCK bearings, gears, etc. (REF) 4 @ 6” CENTERS 7/16 DIA. HOLE 1800 NE Broadway Avenue, Des Moines, Iowa, 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...

  • Page 69: Fender Assembly, Tandem Axle

    FENDER ASSEMBLY, TANDEM AXLE Steel (11H14) 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”...
  • Page 70 SPACER CENTERS possibility of arcing across bearings, gears, etc 7/16 DIA. HOLE 1800 NE Broadway Avenue, Des Moines, Iowa, 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...

  • Page 71: Rear Light Bar Assembly

    REAR LIGHT BAR ASSEMBLY (51H68) 10/05/09...
  • Page 72 REAR LIGHT BAR ASSEMBLY (51H68) INSTALLATION INSTRUCTIONS 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.
  • Page 73 FIG. 3 1800 NE Broadway Avenue, Des Moines, Iowa, 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...
  • Page 74 10/05/09...
  • Page 79 PRE-DELIVERY CHECK LIST INSPECTOR’S INFORMATION Inspected By: Signature: Distributor: Date Installed: Customer: Date Inspected: I. COMPONENT INFORMATION Hoist Model: Hoist Serial No.: Chassis VIN: Chassis Make & Model: Chassis GVWR: Distance from rear of cab to the centerline Chassis CA / CT: of rear axle/tandem.
  • Page 80 Parts & Operations Manual cover or at the back of the Parts List section in the Manual). Additional Comments: COMPLETE & SAVE TO YOUR COMPUTER. RETAIN A COPY FOR YOUR FILES. ONCE COMPLETE, FAX (515-313-4426) OR EMAIL (sales@swaploader.net) A COPY BACK TO SWAPLOADER! 1800 NE Broadway Ave., Des Moines, IA 50313 • www.swaploader.com •...

  • Page 81: Operation

    OPERATION...

  • Page 83: Loading A Container

    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 Engage the P.T.O. (Refer to P.T.O. manual for operation).
  • Page 84 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...

  • Page 85: Placing A Container On The Ground

    Rotate jib all the way till the container touches the ground. Pull away from container and rotate jib back into the transport position. WARNING: DON'T OVER SPEED THE PUMP 1,500 RPM MAXIMUM. DON'T DUMP ON UNEVEN GROUND. SL-220.OPE 07/2009...
  • Page 86 WARNING: (CONTINUED) DON'T DRIVE WITH THE HOIST IN THE DUMP POSITION OR WITH THE HOOK TILTED BACK. SL-220.OPE 07/2009...

  • Page 87: Changing Hook Heights

    With the telescopic arm in the transport position (as shown); remove the hitch pin from the lock pin. Then pull the lock pin loose from the jib arm. Lock pin secured with hitch pin Retract the jib (right control lever backward). See Fig. A (Pg. 3-1). SL-220.OPE 07/2009...
  • Page 88 WARNING: Do not remove lock pin on the adjustable jib while jib is in the 36” hook position and the telescopic arm is tilted rearward (as shown). Possible property damage and/or personal injury may result. SL-220.OPE 07/2009...
  • Page 89 With the telescopic arm in full load/unload position (as shown); remove the hitch pin from the lock pin. Then pull the lock pin loose from the jib arm. Lock pin secured with hitch pin Tilt the telescopic arm toward the cab (left control lever forward). See Fig. A (Pg. 3- SL-220.OPE 07/2009...
  • Page 90 WARNING: Do not remove lock pin on the adjustable jib while jib is up in the 54” hook position and telescopic arm in transport position (as shown). Possible property damage and/or personal injury may result. SL-220.OPE 07/2009...

  • Page 91: Maintenance

    MAINTENANCE...

  • Page 93: Weekly Service (50 Operations)

    Inspection & Adjustment Instructions on page 4-13 of the maintenance section. Change hydraulic oil, replace hydraulic filter element, and wash out suction strainer. 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-220.MAI 07/2009...
  • Page 94 SL-220.MAI 07/2009...
  • Page 95 Filter Part Number Company Name Filter Part Number Baldwin BT8443 Hydac 0085MA010P Behringer BSO92E10N25 SPE25-10 Donaldson P550255 Norman Fleetguard HF6511 F4E-040CCB Flow Ezy FEE30-10L Purolator 20201 FPE40-10N Zinga * AE-10L * Brand of Element supplied from factory on hoist. SL-220.MAI 07/2009...

  • Page 96: General Maintenance Parts List

    * * * * * * * * 20P25 HYDRAULIC TANK, 25 GALLON 20P07 STRAINER, TANK MOUNTED - 25 GPM 20P96 SIGHT GAUGE, HYDRAULIC TANK 20P97 BREATHER CAP ASSEMBY, HYDRAULIC TANK * * * * * * * * SL-220.MAI 07/2009...
  • Page 97 CLAMP LINER – (OUTER TUBE) 00P58 3/8-16 x 1-1/2 FL HD SCREW (BRASS) * * * * * * * * 60H11 WEAR BLOCK – (JIB) 00P79 3/8-16 x 3/4 FL HD SCREW (BRASS) * * * * * * * * SL-220.MAI 07/2009...

  • Page 98: Replacement Bearing List

    ROLLER ASSEMBLY (FOR 51H93 PIVOT JOINT SUB-ASSEMBLY) 23H07 BRONZE BEARING; QTY: 1 PER ROLLER * * * * * * * * 21P63 HYD CYLINDER 6φ x 54 (FOR 51H94 MAINFRAME SUB-ASSEMBLY) CYLINDER BEARINGS; CONTACT SWAPLOADER * * * * * * * * SL-220.MAI 07/2009...
  • Page 99 MAST LOCK INSPECTION & ADJUSTMENT INSTRUCTIONS All 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.
  • Page 100 5. 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.
  • Page 101 JIB LOCKOUT VALVE INSPECTION & ADJUSTMENT INSTRUCTIONS All 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.
  • Page 102 Work Port Size Spool Type Pt. No. (Maximum) (Maximum) 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. 4-10 SL-220.MAI 07/2009...

  • Page 103: Pressure Check Instructions

    50 PSI Graduation Marks RECOMMENDED PRESSURE GAUGE ILLUSTRATION Should you not be able to source a hydraulic gauge locally, SwapLoader can provide one at a reasonable cost (Hyd. Pressure Gauge & Hose Ass’y – Part No. 22P10). PRESSURE CHECK STEPS 1.
  • Page 104 LIFT RAISE/UNLOAD RETRACT 5. Check the gauge for the maximum developed system pressure. The SL-220 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.
  • Page 105 INSPECTION The illustration below is a typical hoist clamp assembly for the 100 & 200 series SwapLoader hoist models. For optimum performance out of your SwapLoader SL-220 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”...
  • Page 107 PARTS LIST...
  • Page 109 SWAPLOADER HOIST - BASE ASS'Y SL-220 51H95 ~ REV A...
  • Page 110 MAINFRAME SUB-ASSEMBLY SL-220/222 51H94 ~ REV A...
  • Page 111 PIVOT JOINT SUB-ASSEMBLY SL-220/222 51H93 ~ REV B...
  • Page 112 WEAR BLOCK BEYOND SEE DETAIL C-C TELESCOPIC JIB SUB-ASSEMBLY SL-220 51H91...
  • Page 113 SEE DETAIL C-C (OPP. HAND) OUTER TUBE WDMT (REF) SEE DETAIL B-B JIB WDMT (REF) SEE DETAIL C-C PIVOT JOINT JIB WDMT WDMT (REF) (REF) OUTER TUBE SEE DETAIL A-A WDMT (REF) SAFETY LATCH ASSEMBLY SL-220/222 51H92 ~ REV A...
  • Page 114 HYD TANK HYD CONTROL (REF) VALVE (REF) (REF) HOIST INSTALLATION KIT ASS'Y SL-220 52H32...
  • Page 115 HOIST CONTROL CONTROL (TYP) (TYP) (REF) HYD TANK (REF) MANUAL CONTROL ASS'Y - 2 SECTION SL-220/222 90H30 ~ REV C...
  • Page 117 BHD UNION LOWER ADP BHD TEE UPPER ADP BHD UNION UPPER ADP BHD TEE LOWER ADP HYD CONTROL VALVE (REF) (SEE NOTE 1) SL-220/222/240 90H97...
  • Page 118 HYD PUMP (REF) TANK STRAINER HYD TANK (REF) (20P07) (REF) (20P25) SUPPLIED BY CUSTOMER HYD CONTROL VALVE (REF) HYD. SUB-ASS'Y - PUMP CIRCUIT SL-220/222/240/2418 90H98...
  • Page 119 OUTER TUBE ASS'Y (REF) (51H75) (ON DASHBOARD) OUTER TUBE ASS'Y (REF) (51H75) (ON VISOR) DECAL ASSEMBLY SL-220 51H96 ~ REV B...
  • Page 121 OPTIONS...
  • Page 123 HOIST CONTROL CONTROL (TYP) 1/4-18 NPTF PORT SUPPLY AIR CONTROL ASS'Y - 2 SECTION SL-220/222/240/2418 90H61 ~ REV B...
  • Page 124 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 HYD ADP, MP/FMP (-4-2) LEAVE EXHAUST PORT OPEN (20P72) (REF) BRASS ADP, PUSH-ON TUBE/ MP SVL 90°...
  • Page 125 SEE DWG IN PARTS LIST NOTE: 1. FOR ADJUSTABLE JIB FIELD SUBSTITUTION ADD: ONE 52H36 JIB - ADJUSTABLE ASS'Y DEDUCT: ONE 51H73 JIB WDMT - 53-7/8" TELESCOPIC JIB SUB-ASSEMBLY SL-220 51H91 w/ ADJUSTABLE JIB OPTION...
  • Page 128 1800 NE Broadway Avenue, Des Moines, Iowa, 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...

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