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Efco SWAPLOADER SL-145 Parts And Operation Manual

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Model SL-145
Parts and
Operations Manual
Hoist Serial Number: ____________________

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Summary of Contents for Efco SWAPLOADER SL-145

  • Page 1 Model SL-145 Parts and Operations Manual Hoist Serial Number: ____________________...
  • Page 2 WARRANTY REGISTRATION FORM HOIST INFORMATION MODEL: Signature: SERIAL NO.: Date Installed: Date Inspected: VEHICLE INFORMATION Manufacturer: Model: Year: Wheel Base: VIN: PTO Type: PTO Ratio: DISTRIBUTOR INFORMATION Company Name: Sales Person’s Name: Address: 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 &...
  • Page 3 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 4 III. CONTROLS Controls easy to operate from driver’s seat. Movement of controls correct, per installation instructions. IV. HYDRAULIC INSTALLATION Correct hydraulic oil level in reservoir, per installation instructions. Inspected for leaks. Any abnormal noise during hoist operation? If yes, please describe: With engine operating @ 1,000 RPM, record the following information: Cycle time for dump mode: Seconds Up...
  • Page 5 OUTER TUBE ASS'Y (REF) (11H73) (ON DASHBOARD) OUTER TUBE ASS'Y (REF) (11H73) (ON VISOR) DECAL ASSEMBLY SL-145 11H81 ~ REV A...

  • Page 6: 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 Mast Lock (Safety Latch) Assembly INSTALLATION Hoist Installation Kit Assembly Initial Inspection Manual Control Assembly, 2 Section Hoist Installation Hyd.
  • Page 7 INTRODUCTION...
  • Page 8 SWAPLOADER U.S.A., LTD. TO THE CUSTOMER Your new SwapLoader Hoist was carefully designed and manufactured to give years of dependable service. 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.
  • Page 9 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.

  • Page 10: 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 11 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.
  • Page 12 ITEM DESCRIPTION 90P07 OPERATION & SERVICE MANUAL 90P08 HOIST-BODY SPECIFICATIONS 90P09 HYDRAULIC OIL SPECIFICATIONS 90P10 HYDRAULIC OIL FLAMMABLE 90P11 HOIST FALLING 90P13 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.
  • Page 13 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 14 90P52 – PROP DECAL (OPTIONAL) 90P78 – HIGH-PRESSURE FLUID INTRODUCTION 09/2009...

  • Page 15: Installation

    INSTALLATION...

  • Page 16: 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. 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.

  • Page 17: Hoist Installation

    HOIST INSTALLATION TO TRUCK CHASSIS Place the SL-145 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 18 There are two types of mount brackets used on the Model SL-145 hoist as indicated in Figure B or Drawing No. 12H42. They are the front mount brackets (Pt. No. 22H38), and the rear mount brackets (Pt. No. 22H39). Figure B Locate the mount brackets on the side of the hoist as indicated in Figure C.
  • Page 19 Weld the mount brackets to the hoist mainframe as indicated on Figures C thru D. 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 Note: Prior to any welding, consult the truck manufacturer for any special...
  • Page 20 HYD CONTROL VALVE (REF) HYD TANK (REF) HOIST INSTALLATION KIT ASS'Y SL-145 12H42...

  • Page 21: Controls Installation

    CONTROLS INSTALLATION - MANUAL Attach the valve mount bracket (Pt. No. 10H51) to the mainframe as indicated on Dwg. No. 90H72 with the fasteners provided. Mount the hydraulic control valve assembly (Pt. No. 21P32) to the valve mount bracket as shown on Drawing No. 90H72 with the fasteners provided. Install the hydraulic adapters, connect the hydraulic tubing (Pt.
  • Page 22 HOIST CONTROL CONTROL (TYP) (TYP) (REF) HYD TANK (REF) MANUAL CONTROL ASS'Y - 2 SECTION SL-105/145/180 90H72 ~ REV A...
  • Page 23 BHD UNION LOWER ADP BHD UNION BHD TEE UPPER ADP UPPER ADP BHD TEE LOWER ADP HYD CONTROL VALVE (REF) (SEE NOTE 1) SL-145 90H90...
  • Page 24 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. 90H72 (Manual Control Assembly) for control lever orientation.
  • Page 25 INSTALLATION PROCEDURE FOR A HYDRAULIC CONTROL CABLE TO HYDRAULIC VALVE WITH BONNET CONNECTION KIT 1. Turn .750-16 UNF Jam Nut entire length of Threaded Hub back over the Cable. Place Flange onto Sleeve. 2. Turn Flange/Sleeve Assembly entire length of Threaded Hub back over the Cable. 3.

  • Page 26: Hydraulic Tank Installation

    HYDRAULIC TANK INSTALLATION Select a location to mount the hydraulic tank. Reference Figure E or Drawing No. 90H72 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.

  • Page 27: P.t.o. Selection

    P.T.O. SELECTION The next step is to select and 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: 125 ft.-lbs. (See Note 1) Power at 1500 RPM: 36 H.P.
  • Page 28 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). All SwapLoader hooklift hoists come standard with a CCW (left hand rotation pump), which will work for most manual transmission applications.

  • Page 29: Pump Installation

    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. 90H91. Connect the suction hose assembly to the hydraulic tank (1" I.D. hose) and route to the hydraulic pump in as short and straight line as possible.
  • Page 30 HYD PUMP (REF) TANK STRAINER (REF) (20P07) HYD TANK (REF) (20P05) HYD CONTROL VALVE (REF) SL-105/145/180 90H91...

  • Page 31: Start Up Procedure

    START UP PROCEDURE Fill the hydraulic tank with hydraulic oil (see oil specification in Maintenance Section.) Prime the pump by loosening the clamp on the suction hose at the pump. Pull the hose back off the fitting till the air is bled from the line. Push the hose back on the fitting and retighten the clamp.
  • Page 32 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 S025).
  • Page 33 100 SERIES SUB-FRAME CRITICAL DIMENSIONS 34 in. [864 mm] +3/8 5 3/8 in. BACK OF LIFT BAR [137 mm +10 - 0 ] BOTTOM OF LIFT BAR 1 1/4 in. Ø [32 mm] SEE NOTE 2 5 in. (MIN) TOP OF LATCH PLATE [127 mm] 3 in.
  • Page 34 REAR BUMPER ASSEMBLY (52H11) 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. Measure the distance from the bottom of the truck frame to the ground (NOTE: This should be performed on a level surface).
  • Page 35 REAR BUMPER ASSEMBLY (52H11) INSTALLATION INSTRUCTIONS (continued) Weld the bumper weldment to the vertical channels (See Fig. 1 & 3). ADDITIONAL NOTES: 1. Prior to any welding, consult the truck manufacture for any special precautions that may need to be taken.
  • Page 36 REAR BUMPER ASS’Y w/ EXTENSIONS (52H11 with 52H13 Extensions) 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. Measure the distance from the bottom of the truck frame to the ground (NOTE: This should be performed on a level surface).
  • Page 37 REAR BUMPER ASS’Y w/ EXTENSIONS (52H11 with 52H13 Extensions) INSTALLATION INSTRUCTIONS (continued) Weld the bumper weldment to the vertical channels (See Fig. 1 & 3). ADDITIONAL NOTES: 1. Prior to any welding, consult the truck manufacture for any special precautions that may need to be taken.

  • Page 40: Container Variability System - (C.v.s.)

    CONTAINER VARIABILITY SYSTEM ASSEMBLY (11H99) [Hoist Models: SL-145 & SL-180] 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 11H99 Section View A-A). Position the C.V.S.
  • Page 41 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 90H84), and tighten. Remove both the hydraulic hose [Part No. 12P55] that connects from the upper bulkhead fitting inside the mainframe to the jib lockout valve [Part No.
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  • Page 47: 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 48 FENDER ASSEMBLY, SINGLE AXLE Aluminum (10H93) / Steel (11H13) 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.

  • Page 51: Rear Light Bar Assembly

    REAR LIGHT BAR ASSEMBLY (51H68) 10/05/09...
  • Page 52 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 53 REAR LIGHT BAR ASSEMBLY (51H68) 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).
  • Page 59 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 60 III. CONTROLS Controls easy to operate from driver’s seat. Movement of controls correct, per installation instructions. IV. HYDRAULIC INSTALLATION Correct hydraulic oil level in reservoir, per installation instructions. Inspected for leaks. Any abnormal noise during hoist operation? If yes, please describe: With engine operating @ 1,000 RPM, record the following information: Cycle time for dump mode: Seconds Up...

  • Page 61: Operation

    OPERATION...

  • Page 62: 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). FRONT LOWER/LOAD EXTEND...
  • Page 63 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.

  • Page 64: Placing A Container On The Ground

    PLACING A CONTAINER ON THE GROUND Move the sliding jib all the way back (right control backward) until mechanical jib latches unlock. 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. Rotate jib all the way till the container touches the ground.
  • Page 65 WARNING: (CONTINUED) DON'T DRIVE WITH THE HOIST IN THE DUMP POSITION OR WITH THE HOOK TILTED BACK. SL-145.OPE 07/2009...

  • Page 66: Maintenance

    MAINTENANCE...

  • Page 67: Weekly Service (50 Operations)

    MAINTENANCE INSTRUCTIONS WEEKLY SERVICE - (50 OPERATIONS) Lubricate with grease (Refer to Lubrication Diagram) Lifting hook on jib Jib slide - top, bottom, and side guides Check hydraulic oil level. With the hoist in the transport position (lift cylinders retracted and jib cylinder extended –...
  • Page 68 SL-145.MAI 07/2009...
  • Page 69 HYDRAULIC OIL SPECIFICATION & INTERCHANGE CHART Select an ISO grade of Premium Anti-Wear Hydraulic Oil that is optimum for your location. HYDRAULIC OIL SELECTION CHART Ambient Temperature Range Viscosity ISO Grade °F °C SUS @ 100 °F -10 to 85 -23 to 29 150-170 10 to 110...
  • Page 70 GENERAL MAINTENANCE PARTS LIST PT. NO. DESCRIPTION 21P31 HYDRAULIC CYLINDER 5φ X 40 (Lift/Dump) 21P37 SEAL KIT, HYDRAULIC CYLINDER 21P69 HYDRAULIC LINE ASS’Y (REPLACEMENT) 20P28 HYDRAULIC VALVE CARTRIDGE, COUNTERBALANCE * * * * * * * * 20P51 HYDRAULIC CYLINDER 3φ X 32 (Jib) 20P89 SEAL KIT, HYDRAULIC CYLINDER 20P28...
  • Page 71 21P32 HYDRAULIC CONTROL VALVE, 2 SECT. 20P17 HYDRAULIC RELIEF VALVE CARTRIDGE (3250 PSI) * * * * * * * * 21P28 HYDRAULIC VALVE, 2-WAY 21P38 SEAL KIT FOR 21P28 * * * * * * * * 90P71 WEAR PAD, 12” – (Z-CHANNEL) 00755 3/8φ...
  • Page 72 REPLACEMENT BEARING LIST PT. NO. DESCRIPTION 11H42 PIVOT PIN (FOR 11H79 PIVOT JOINT SUB-ASSEMBLY) 23H08 BRONZE BEARING; QTY: 1 PER PIN * * * * * * * * 51H70 MAIN PIVOT PIN (FOR 11H79 PIVOT JOINT SUB-ASSEMBLY) 23H08 BRONZE BEARING; QTY: 1 PER PIN * * * * * * * * 80P09 ROLLER ASSEMBLY (FOR 11H79 PIVOT JOINT SUB-ASSEMBLY)
  • Page 73 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 74 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.
  • Page 75 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 76 Mainframe (Ref) Valve Mount Valve Ramp 1/8" to 3/16" of Base Mainframe Roller Exposed Adjustment Screw Valve Mount (Ref) Bracket Valve Ramp Jib Lockout Side Side Valve View View Mount Bracket Mount Bracket Screw (2-Typ) Valve Screw (2-Typ) Pivot Joint Valve Mount (Ref) Bracket...
  • Page 77 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).
  • Page 78 2. Remove the female JIC #4 cap from the male JIC #4 adapter and attach the pressure gauge to the hydraulic control valve (see illustration below). SWL P/N: 10P37 2500 2000 3000 1500 3500 Hydraulic Adapter 1000 4000 4500 MP/MJIC 90° (-4-4) 5000 Pressure Gauge Hyd Control Valve Ass'y...
  • Page 79 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-145 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 80 PARTS LIST...
  • Page 81 SWAPLOADER HOIST - BASE ASS'Y SL-145 11H80 ~ REV B...
  • Page 82 MAINFRAME SUB-ASSEMBLY SL-145 11H78 ~ REV E...
  • Page 85 OUTER TUBE WDMT (REF) JIB WDMT (REF) PIVOT JOINT WDMT (REF) JIB WDMT (REF) OUTER TUBE WDMT (REF) PIVOT JOINT WDMT (REF) 1/16 CLEARANCE SAFETY LATCH ASSEMBLY (REF) SL-145 10H40 ~ REV C...
  • Page 86 HYD CONTROL VALVE (REF) HYD TANK (REF) HOIST INSTALLATION KIT ASS'Y SL-145 12H42...
  • Page 87 HOIST CONTROL CONTROL (TYP) (TYP) (REF) HYD TANK (REF) MANUAL CONTROL ASS'Y - 2 SECTION SL-105/145/180 90H72 ~ REV A...
  • Page 88 HYD CYL 5Ø x 40 (REF) HYD CYL 3Ø x 32 (REF) BHD TEE LOWER ADP HYD CYL 5Ø x 40 (REF) BHD UNION UPPER ADP BHD TEE UPPER ADP BHD UNION LOWER ADP SL-145 90H89...
  • Page 89 BHD UNION LOWER ADP BHD UNION BHD TEE UPPER ADP UPPER ADP BHD TEE LOWER ADP HYD CONTROL VALVE (REF) (SEE NOTE 1) SL-145 90H90...
  • Page 90 HYD PUMP (REF) TANK STRAINER (REF) (20P07) HYD TANK (REF) (20P05) HYD CONTROL VALVE (REF) SL-105/145/180 90H91...
  • Page 91 OUTER TUBE ASS'Y (REF) (11H73) (ON DASHBOARD) OUTER TUBE ASS'Y (REF) (11H73) (ON VISOR) DECAL ASSEMBLY SL-145 11H81 ~ REV A...
  • Page 92 OPTIONS...
  • Page 93 INSTALLATION INSTRUCTIONS FOR SL-145 Review all directions and diagrams provided before starting the Electric over Hydraulic Valve Installation. Mount the 22P58 EHV to the hoist mainframe and attach all hoses, hose clamp assemblies and fittings as shown on drawing 91H22, 91H23 & 91H25 (also see Figures 1 &...
  • Page 94 Route control harness from valve into the truck cab. Determine the best location in the cab for the control box location and install with mounting screws (included). The location should be such that the controls can be easily reached while operating the truck. Figure 3 Insert power adapter into 12V outlet or hardwire to 12V battery.
  • Page 95 HOIST INSTALLATION KIT - EHV SL-145 12H80...
  • Page 96 EHV SUB-ASS'Y - PUMP CIRCUIT 100 SERIES 91H22...
  • Page 97 EHV SUB-ASS'Y - CHASSIS TANK CIRCUIT 100 SERIES 91H23...
  • Page 98 EHV SUB-ASS'Y - VALVE HOSE CIRCUIT SL-145 91H25 ~ REV. A...
  • Page 99 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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