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swaploader SL-650 Parts And Operation Manual

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Model SL-650
Parts and
Operations Manual
Hoist Serial Number: ____________________

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Summary of Contents for swaploader SL-650

  • Page 1 Model SL-650 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

    TABLE OF CONTENTS INTRODUCTION PARTS LIST Letter to Customer Base Assembly Warranty Statement Mainframe Subassembly Safety Suggestions Rear Pivot Subassembly Telescopic Jib Subassembly INSTALLATION Mast Lock (Safety Latch) Assembly Hoist Installation Kit Assembly Initial Inspection Manual Control Assembly, 2 Section Hoist Installation Hyd.
  • 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-650 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): RBM for each frame channel: 2,750,000 in.-lb.
  • Page 25 There are three types of mount brackets used on the Model SL-650 hoist as indicated in Figure B or Drawing No. 43H03. They are the spring mount brackets (40H31), and the front mount brackets (Pt. No. 81H23), and the rear mount brackets (Pt. No. 81H24).
  • Page 26 Weld the mount brackets to the hoist mainframe as indicated on Figures C 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. Figure C Figure D SL-650.INS 09/2009...
  • Page 27 Note: The hoist mainframe is made from high strength low alloy steel. Use an appropriate welding process. SL-650.INS 09/2009...
  • Page 28 SL-650.INS 09/2009...

  • Page 29: 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-650.INS 09/2009...
  • Page 30 SL-650.INS 09/2009...
  • Page 31 SL-650.INS 09/2009...
  • Page 32 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 33 Flange Adapter / Flange / Sleeve Assembly, make sure that the control head remains in the neutral position. 6. Tighten the .750-16 UNF Jam Nut against the Sleeve and lock in position. 7. Bring Flange into position on bolt assembly to valve housing. 2-11 SL-650.INS 09/2009...
  • Page 34 The air hose is provided in 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. 2-12 SL-650.INS 09/2009...
  • Page 35 2-13 SL-650.INS 09/2009...
  • Page 36 2-14 SL-650.INS 09/2009...

  • Page 37: Hydraulic Tank Installation

    Drawing No. 91H11. The hose length can be shortened if necessary. Secure the hose to the barb fittings with the hose clamps provided. Figure F 2-15 SL-650.INS 09/2009...

  • Page 38: 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 39 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-650 hoist model: L.H. Rotation R.H.

  • Page 40: Pump Installation

    SAE 37° (JIC) 1 5/16-12 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. 2-18 SL-650.INS 09/2009...
  • Page 41 2-19 SL-650.INS 09/2009...

  • Page 42: 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. 2-20 SL-650.INS 09/2009...
  • Page 43 Fill out pre-delivery checklist and warranty card and mail to SwapLoader U.S.A., Ltd. NOTE: Failure to fill out and return warranty card within 15 days of installation may possibly void the warranty. CAUTION: The SwapLoader hoist must be used with bodies or containers that properly fit the front hook and the rear hold-downs (See figure S288).

  • Page 45: Stabilizer Installation (Optional)

    The following diagram gives the approximate position of the stabilizer roller from the top of the truck chassis frame rail with the mounts as provided by SwapLoader. When extended down, the roller should touch the ground only when the vehicle is loading a heavy container.
  • Page 46 FRONT LOWER LOWER/LOAD EXTEND LIFT RAISE RAISE/UNLOAD RETRACT Operate the stabilizer through 5 to 8 cycles to remove the air from the hydraulic cylinders and lines. 2-24 SL-650.INS 09/2009...
  • Page 47 (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 SL-2418 SL-650 & SL-240 SL-400 SL-505/545 24 5/8” 13 1/2 15 3/4 15 1/4 14 1/4 16 1/2 22 5/8”...
  • 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 (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 SL-2418 SL-650 & SL-240 SL-400 SL-505/545 24 5/8” 19 3/4 22 1/2 21 3/4 25 1/4 21 3/4 21 1/2 * 24 1/4 * 22 5/8”...
  • 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: 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 60 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 61: Rear Light Bar Assembly

    REAR LIGHT BAR ASSEMBLY (51H68) 10/05/09...
  • Page 62 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 63 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 64 10/05/09...
  • Page 69 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 70 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 71 OPERATION...

  • Page 73: 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 74 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 75: 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-650.OPE 07/2009...

  • Page 76: Operating The Stabilizer

    When finished with loading or unloading the container the stabilizer roller should be raised prior to disengaging the P.T.O. To raise the stabilizer, push backward on the left control lever until the roller is all the way up. SL-650.OPE 07/2009...

  • Page 77: Maintenance

    MAINTENANCE...

  • Page 79: 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 3,500 PSI minimum). SL-650.MAI 07/2009...
  • Page 80 SL-650.MAI 07/2009...
  • Page 81 Filter Part Number Company Name Filter Part Number Baldwin BT-388-10 Hydac 0180MA010P Can Flo RSE60-10N SPE60-10 Case D-130046 Norman Donaldson HSM6047 Parker 927736 Fleetguard R750-H-0825A 51860 HF6711 Zinga * LE-10 * Brand of Element supplied from factory on hoist. SL-650.MAI 07/2009...

  • Page 82: General Maintenance Parts List

    * * * * * * * * 20P86 HYDRAULIC TANK, 30 GALLON LS 21P16 STRAINER, TANK MOUNTED - 50 GPM 20P96 SIGHT GAUGE, HYDRAULIC TANK 20P97 BREATHER CAP ASSEMBY, HYDRAULIC TANK * * * * * * * * SL-650.MAI 07/2009...
  • Page 83 00P68 3/8-16 x 1 1/4 FL HD SCREW (BRASS) * * * * * * * * 60H11 WEAR BLOCK – (JIB) 00P79 3/8-16 x 3/4 FL HD SCREW (BRASS) * * * * * * * * SL-650.MAI 07/2009...

  • Page 84: Replacement Bearing List

    ROLLER ASSEMBLY (FOR 42H45 PIVOT JOINT SUB-ASSEMBLY) 23H07 BRONZE BEARING; QTY: 1 PER ROLLER * * * * * * * * 21P75 HYD CYLINDER 7-1/2φ X 82 (FOR 42H43 MAINFRAME SUB-ASS’Y) CYLINDER BEARINGS; CONTACT SWAPLOADER * * * * * * * * SL-650.MAI 07/2009...
  • Page 85 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 86 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 87 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 88 Work Port Size Spool Type Pt. No. (Maximum) (Maximum) 21P29 7/8-14 ORB (SAE 10) 2-Way, 2-Position N.C. 4,600 PSI (Nominal) 24 GPM (Nominal) Please contact your SwapLoader Distributor or SwapLoader USA should you have any questions regarding this procedure. 4-10 SL-650.MAI 07/2009...

  • Page 89: 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 90 LIFT RAISE/UNLOAD RETRACT 5. Check the gauge for the maximum developed system pressure. The SL-650 should have a reading of 3,500 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 91 OUTER TUBE CLAMP ASSEMBLY INSPECTION INSTRUCTIONS All 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 400 series hoist models the outer clamp assembly is fixed in height.
  • Page 93 PARTS LIST...
  • Page 96 MAINFRAME SUB-ASSEMBLY SL-650 42H43 ~ REV A...
  • Page 97 (BEYOND) (BEYOND) (BEYOND) PIVOT JOINT SUB-ASSEMBLY SL-650 42H45 ~ REV D...
  • Page 98 WEAR BLOCK BEYOND SEE (LOCTITE DETAIL C-C CONNECTION) (LOCTITE CONNECTION) TELESCOPIC JIB SUB-ASSEMBLY SL-650 42H44...
  • Page 99 PIVOT JOINT OUTER TUBE WDMT (REF) WDMT (REF) JIB WDMT (REF) 1/16" CLEARANCE (REF) SAFETY LATCH ASSEMBLY SL-650 42H46 ~ REV C...
  • Page 103 HOIST CONTROL CONTROL (TYP) (TYP) (REF) HYD TANK (REF) MANUAL CONTROL ASS'Y - 2 SECTION SL-505/545/650 90H49 ~ REV A...
  • Page 104 HYD CYL 7 1/2Ø x 82 (REF) HYD CYL 4 1/2Ø x 52 (REF) BHD TEE UPPER ADP HYD CYL 7 1/2Ø x 82 (REF) BHD TEE LOWER ADP BHD UNION UPPER ADP BHD UNION LOWER ADP SL-650 91H10...
  • Page 105 BHD UNION LOWER ADP BHD TEE UPPER ADP BHD UNION BHD TEE UPPER ADP LOWER ADP HYD CONTROL VALVE (REF) (SEE NOTE 1) SL-650 91H11...
  • Page 106 HYD PUMP (REF) TANK STRAINER HYD TANK (REF) (21P16) (REF) (20P86) SUPPLIED BY CUSTOMER HYD CONTROL VALVE (REF) HYD SUB-ASS'Y - PUMP CIRCUIT SL-505/545/650 91H09...
  • Page 107 OUTER TUBE ASS'Y (ON DASHBOARD) (REF) OUTER TUBE ASS'Y (REF) (ON VISOR) DECAL ASSEMBLY SL-650 42H47 ~ REV A...
  • Page 109 OPTIONS...
  • Page 111 HOIST CONTROL CONTROL (TYP) 1/4-18 NPTF PORT SUPPLY AIR CONTROL ASS'Y - 2 SECTION SL-505/545/650 90H47 ~ REV C...
  • Page 112 HYD CONTROL VALVE ASS'Y (20P59) (REF) W/ AIR SHIFT KITS (20P71) (REF) CONTROL HANDLE ASS'Y BRASS ADP, PUSH-ON TUBE/ MP SVL 90° (-4-2) 2 SECTION AIR LEAVE EXHAUST PORT OPEN (20P72) (REF) BRASS ADP, PUSH-ON TUBE/ MP SVL 90° (-4-2) BRASS ADP, PUSH-ON TUBE/MP (-4-2) BRASS ADP, PUSH-ON TUBE/MP (-4-2) 1/4 O.D.
  • Page 113 HOIST CONTROL CONTROL STABILIZER CONTROL (TYP) (TYP) MANUAL CONTROL ASS'Y - 3 SECTION SL-505/545/650 90H50 ~ REV B...
  • Page 114 AIR CONTROL ASS'Y - 3 SECTION SL-505/545/650 90H48 ~ REV C...
  • Page 115 BRASS ADP, PUSH-ON TUBE/ MP SVL 90° (-4-2) BRASS ADP, PUSH-ON TUBE/MP (-4-2) 1/4 O.D. NYLON TUBE, BLACK 1/4 O.D. NYLON TUBE, BLACK BRASS ADP, PUSH-ON TUBE/MP (-4-4) AIR PRESS PROTECTION VALVE (20P74) (REF) 1/4-18 NPTF PORT SUPPLY SL-650 90H45 ~ REV B...
  • Page 116 TRUCK FRAME (REF) TRUCK FRAME (REF) 2" - 3" GROUND CLEARANCE LOCTITE 00P03 INTO 42H64 22 11/16 62 1/4 STABILIZER FINAL ASSEMBLY 42H62...
  • Page 117 CONTROL VALVE ASS'Y (REF) HYD CYL 3Ø x 6 (REF) (21P84) HYDRAULIC SUB-ASSEMBLY STABILIZER CIRCUIT 90H83...
  • Page 120 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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