swaploader SL-160 Parts And Operation Manual Download

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“Hooked on Quality”

P A R T S A N D O P E R A T I O N M A N U A L

HOIST SERIAL NUMBER

MODEL

SL-

160

Summary of Contents for SL-160

Page 1: ... Hooked on Quality PA R T S A N D O P E R AT I O N M A N U A L HOIST SERIAL NUMBER MODEL SL 160 ...

Page 2: ......

Page 3: ...r Assembly w Extension 2 19 Folding Bumper Assembly 2 21 Drop Down Bumper Assembly 2 23 Cab Guard Assembly 2 25 Fender Assembly Single Axle 2 27 Rear Light Bar Assembly 2 29 Roller Roller Mount 2 33 Toolbox Assembly 2 35 III OPERATION Loading a Container 3 1 Dumping a Container 3 2 Placing a Container on the Ground 3 3 Changing Hook Heights Adj Jib Option 3 4 Rear Roller Spacing Adjustment Instruc...

Page 4: ...5 6 Hoist Installation Kit 5 7 Base Cylinder Circuit 5 8 Tank Circuit 5 9 Pump Circuit 5 10 Manual Controls 2 Section 5 11 VI OPTIONS Adjustable Jib Sub Assembly 6 1 Cylinder Circuit BL 160 6 2 U Lock Assembly 6 3 Manual Controls 3 Section 6 4 Hoist Installation Kit EHV 6 5 Tank Circuit EHV 6 6 Tank Circuit 3 Section 6 7 Pump Circuit EHV 6 8 Hose Circuit EHV 6 9 Hose Circuit 3 Section EHV 6 10 ...

Page 5: ...ty 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 prompt efficient service when ordering 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 SwapLoade...

Page 6: ...ts 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 form Upon evaluation of the returne...

Page 7: ...ion 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 hold downs The container specifications must match the hoist specifications 6 Keep the containers and hoist in good working order DO NOT use if repairs are needed Perfo...

Page 8: ... 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 pr...

Page 9: ...YDRAULIC OIL SPECIFICATIONS 4 ONE 90P10 HYDRAULIC OIL FLAMMABLE 5 2 90P11 HOIST FALLING 6 ONE 90P12 LEVER CONTROL 7 ONE 90P13 SAFETY INSTRUCTIONS 8 2 90P14 SWAPLOADER JIB 9 ONE 90P18 RELIEF VALVE 10 ONE 90P78 HIGH PRESSURE FLUID 11 2 91P06 LUBRICATION POINTS 12 4 91P36 SL 160 13 2 90P91 ADJ JIB OPERATION Included with the Adjustable Jib option 1 5 ...

Page 10: ...ety Decals and their part numbers Please use when reordering replacement decals 90P07 OPERATIONS SERVICE MANUAL 90P08 HOIST BODY SPECIFICATIONS 90P09 HYDRAULIC OIL SPECIFICATIONS 90P10 HYDRAULIC OIL FLAMMABLE 90P11 HOIST FALLING 90P12 LEVER CONTROL 90P13 SWAPLOADER SAFETY INSTRUCTIONS 1 6 ...

Page 11: ...Section I Introduction 1 0 INT SL 160 90P14 SWAPLOADER JIB 90P18 RELIEF VALVE 90P78 HIGH PRESSURE FLUID 91P06 LUBRICATION POINTS 91P36 SL 160 90P91 ADJUSTABLE JIB OPERATION 1 7 ...

Page 12: ... is located at the front driver side of the hoist gray arrow on first picture The Serial Number is also stamped into the frame of the hoist on the top of the inner rail shown at the rear of the hoist red arrow on first picture An example of a 6 character serial number is shown in the second picture 1 8 ...

Page 13: ...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 or EHV system 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 to the hydraulic control value assembly 3 Instal...

Page 14: ...hat 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 NOTE THE ABOVE SPECIFICATIONS ARE A MINIMUM REQUIREMENT IT IS THE RESPONSIBILITY OF THE OWNER OPERATOR TO ENSURE THE COMPLETED CHASSIS MEETS OR EXCEEDS ALL F...

Page 15: ...llows for drilling into the truck chassis frame rails at 2 3 4 3 3 4 or 4 3 4 bolts are only required on two of the four lower mount bracket holes 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 17 32 diameter holes required and attach the brackets to the truck chassis with ...

Page 16: ...is fastened to the floor of the cab and the control cables are routed through additional holes drilled in the floor Your installation may require that additional brackets be fabricated or other modifications made 6 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 ...

Page 17: ...ded hub back over the cable 2 Turn 250 28 UNF jam nut onto cable threaded rod until it bottoms 3 Place clevis of threaded rod and bottom against jam nut Turn other 250 28 UNF jam nut onto threaded rod until it bottoms against clevis Align clevis so it will mate with spool terminal eye and secure jam nut against clevis 4 Slide the clevis onto terminal eye on spool and align the holes Insert clevis ...

Page 18: ...l notify the operator when the U Lock has been engaged or disengaged 1 Review all directions and diagrams provided before starting installation 2 Mount valve to the hoist s Main Frame and attach all hoses hose clamp assemblies and fittings as shown on Pg 6 10 3 Mount Indicator Light Box in the truck cab where it will be clearly visible to the operator 4 Route Indicator Light and Harness Pt No 40P6...

Page 19: ...ons Electric Over Hyd Valve SERVICE PARTS SL 160 ITEM PART QTY DESCRIPTION 1 12P53 1 Hose Assy 21 08 08FJ 08FJ90 2 12P59 1 Hose Assy 20 08 08FJ 08FJ45 3 13P25 1 Hose Assy 58 08 08FJ 08FJ45 4 13P32 1 Hose Assy 60 08 08FJ 08FJ45 5 22P82 1 Solenoid Operated Valve Coil 6 22P83 1 Solenoid Operated Valve Spool 7 22P84 1 Relief Valve Cartridge 3250 8 22P85 1 Dump Valve NOTE THE FIGURES BELOW DO NOT NECES...

Page 20: ...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 4 Hardwire or plug in provided 12V adapter for control box 2 8 ...

Page 21: ... SL 160 ITEM PART QTY DESCRIPTION 1 12P53 1 Hose Assy 21 08 08FJ 08FJ45 2 12P59 1 Hose Assy 20 08 08FJ 08FJ45 3 13P25 1 Hose Assy 58 08 08FJ 08FJ45 4 13P32 1 Hose Assy 60 08 08FJ 08FJ45 5 13P33 1 Hose Assy 63 5 08 08FJ 08FJ45 6 13P34 1 Hose Assy 66 08 08FJ 08FJ45 7 22P82 1 Solenoid Operated Valve Motor 8 22P83 2 Solenoid Operated Valve Cylinder 9 22P84 1 Relief Valve Cartridge 3250 10 22P85 1 Dump...

Page 22: ...in the cab for the control box location and install with mounting screws included The location should be such that the controls Pt No 22P95 can be easily reached while operating the truck 4 Route indicator light harness from control box to the U Lock Cylinder 5 Hardwire or plug in provided 12V adapter for control box 2 10 ...

Page 23: ...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 For most automatic transmission applications a CW right hand rotation pump is needed call SwapLoader for price and availability NOTE CONSULT THE PTO SUPPLIER WHENEVER UNCERTAI...

Page 24: ...he hydraulic pump as shown on Pg 5 10 3 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 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...

Page 25: ...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 2 Drill four 4 holes for 1 2 diameter bolts provided in the mount angle of ...

Page 26: ...corresponds to the movement of the cylinders per the figure below 6 Install all safety decals and product decals as shown on Pg 1 5 after final installation and painting have been completed 7 Fill out the Product Registration form online at https www swaploader com warranty registration NOTE FAILURE TO FILL OUT AND SUBMIT PRODUCT REGISTRATION WITHIN 15 DAYS OF INSTALLATION MAY POSSIBLY VOID THE WA...

Page 27: ...IS DRAWING PROVIDES THE CRITICAL SUB FRAME DIMENSIONS FOR COMPATABILITY WITH THE SWAPLOADER HOOK LIFT HOIST IT IS THE SUB FRAME SUPPLIER S RESPONSIBILITY TO PROVIDE A SUB FRAME OF SUFFICIENT CAPACITY WHICH PROPERLY SUPPORTS THE BODY CONTAINER WHEN USED WITH THE HOOK LIFT HOIST 4 SWAPLOADER MANUFACTURED 100 SERIES A FRAMES REQUIRE A 5 INCH LONGSILL HEIGHT 100 SERIES SUB FRAME DIMENSIONS HOIST COMPA...

Page 28: ...ATABILITY WITH THE SWAPLOADER HOOK LIFT HOIST IT IS THE SUB FRAME SUPPLIER S RESPONSIBILITY TO PROVIDE A SUB FRAME OF SUFFICIENT CAPACITY WHICH PROPERLY SUPPORTS THE BODY CONTAINER WHEN USED WITH THE HOOK LIFT HOIST 4 SWAPLOADER MANUFACTURED 200 SERIES A FRAMES REQUIRE A 6 INCH LONGSILL HEIGHT 200 SERIES SUB FRAME DIMENSIONS HOIST COMPATABILITY A B SL 2418HD 84 1 8 2137 mm 24 610 mm SL 225 110 3 4...

Page 29: ...ce 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 B Once the length has been determined for the vertical channels weld them to the bottom of the truck frame see additional ...

Page 30: ...SCONNECTED 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 2 ALL WELDS SHOULD BE DONE UTILIZING A LOW HYDROGEN WELDING PROCESS BUMPER LOCATION CHART DIM A DIMENSION B MAX SL 105 SL 145 SL 160 SL 212 SL 214 SL 220 SL 222 SL 240 SL 2418 SL 330 SL 400 SL 412 SL 406 SL 518 SL 520 SL 650 24 5 8 13 1 2 15 3 4 15...

Page 31: ... 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 B Once the length has been determined for the vertical channels weld them to the truck frame see additional notes on the next page 4 ...

Page 32: ...HE WELDER SHOULD BE AS CLOSE TO THE PART BEING WELDED TO AVOID THE POSSIBILITY OF ARCING ACROSS BEARINGS GEARS ETC 2 ALL WELDS SHOULD BE DONE UTILIZING A LOW HYDROGEN WELDING PROCESS BUMPER LOCATION CHART DIM A DIMENSION B MAX SL 105 SL 145 SL 160 SL 212 SL 214 SL 220 SL 222 SL 240 SL 2418 SL 330 SL 400 SL 412 SL 406 SL 518 SL 520 SL 650 24 5 8 1 3 4 22 1 2 21 3 4 25 1 4 21 3 4 21 1 2 21 1 4 24 1 ...

Page 33: ...onjunction with the Roller Assembly Pt No 10H90 and Roller Mount Brackets Assembly Pt No 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 C Fig C shows a width dimension of 56 1 2 This width can be adjusted if interfere...

Page 34: ... 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 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 TRUCK BODIES MATERIAL LIST FOR 51H44 ITEM PART QTY DESCRIPTION WT lb ea 1 51H45 2 Slip Bracket Wdmt 9 71 2 51H46 1 Bumper ...

Page 35: ...ty 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 A 2 Position drop down bumper on the longsills of the sub frame see Fig B C The mount brackets Pt No 51H17 need to be positioned correctly to allow for sufficient room for bumper cradles Pt No 51H19 see Fig B Weld mount brackets onto the longsills of the sub frame 3 P...

Page 36: ...lat Washer HT 10 12 00P98 6 Ø5 32 x 1 1 2 Cotter Pin 01 13 00P03 4 3 8 16 x 3 4 HHCS 11 14 00755 4 Ø3 8 Lock Washer 05 15 90P20 10 1 4 8 Grease Zerk 01 16 90P33 2 1 1 8 O D x 10 Spring 60 NOTE 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 ...

Page 37: ...should not be located within 2 3 8 of the truck frame edge see Fig A Drill Ø21 32 mount holes through cab guard channels 4 Mark mounting holes through the cab guard weldment onto truck frame Remove cab guard weldment and drill Ø2132 holes in truck frame 5 Attach cab guard weldment to truck frame using fasteners provided see Fig B MATERIAL LIST FOR 50H99 ITEM PART QTY DESCRIPTION WT lb ea 1 50H95 1...

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Page 39: ...r truck chassis 4 Mark mounting holes through the fender bracket weldment onto the fender Remove the bracket and drill Ø7 16 holes in fender see Fig C 5 Attach fender bracket weldments to ender using fasteners provided 6 Weld mounting plates Pt No 21H37 to fender tubes Pt No 21H61 7 Position fender tubes with mount plates on hoist main frame align with fender bracket weldments NOTE Fender tube len...

Page 40: ... 2 HHCS 0 07 9 01P21 16 3 8 16 UNC x 2 1 2 HHCS 0 09 10 90P24 2 Fender Aluminum 19 00 10 90P25 2 Fender Steel 35 00 Note Will include either 2 90P24 aluminum fender or 2 90P25 steel fender depending on order Installation is the same for both aluminum and steel fender NOTE 1 PRIOR TO ANY WELDING CONSULT THE TRUCK MANUFACTURE FOR ANY SPECIAL PRECAUTIONS THAT MAY NEED TO BE TAKEN TYPICALLY THE BATTER...

Page 41: ... interference Drill mounting holes as required and mount using fasteners provided See Fig C 5 Attach the taillight module to the stub light bar weldments with the fasteners provided see Fig C 6 Mount the identification light bar at top center of the center plate Pt No 63H08 using the fasteners provided see Fig C 7 Mount license lamp right of the license plate See Fig B using the fasteners provided...

Page 42: ...ate 27 33 3 00P44 6 3 8 16 x 1 1 2 HHCS 0 07 4 00P34 6 3 8 16 Locking Hex Nut 0 02 5 00771 6 Ø3 8 Flat Washer 0 01 6 01P18 4 5 8 11 x 3 HHCS 0 35 7 00P81 8 8 32 x 1 RHMS 8 00P82 8 8 32 Hex Nut 9 00P83 8 8 Lock Washer 10 40P32 1 Lic Light Assy w o Harness 11 40P34 REF License Lamp Harness 12 40P35 REF Id Light Bar Rail 13 40P37 REF Id Light Bar Harness 14 40P38 REF Junction Box Assembly 15 40P39 RE...

Page 43: ...Section II Installation Accessories 2 8 INS ACC LEDLB 2 31 ...

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Page 45: ...nd 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 A Also the roller axle center line should be approximately 1 11 16 below the bottom of the subframe longsill for roller clearance see Fig A 3 Some modification to the roller mount bracket may be required for the roller mount to fit properly If the ex...

Page 46: ...h the roller axle Pt No 10H31 and the fasteners provided see Fig C Grease the rollers before use 10H91 10H90 Figure B Figure C MATERIAL LIST FOR 10H90 AND 10H91 ITEM PART QTY DESCRIPTION WT lb ea 1 32H03 4 Roller Ear 11 95 2 10H12 2 Roller Wdmt 39 76 3 10H31 2 Roller Axle Wdmt 7 28 4 00P62 2 3 8 16 UNC x 1 Bolt 05 5 90P03 2 1 8 NPT Grease Zerk 01 6 00755 2 3 8 Dia Lock Washer 01 7 00P36 2 3 8 Dia ...

Page 47: ...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 A MATERIAL LIST FOR 10H92 OR 11H12 ITEM PART QTY DESCRIPTION WT lb ea 1 10H88 2 18 Toolbox Bracket 11 34 2 22H71 2 Toolbox Rubber Spacer 27 3 90P27 1 Aluminum Toolbox 50 00 3 90P37 1 Steel Toolbox 72 00 4 00784 8 1 ...

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Page 49: ...TROL LEVER BACKWARD THEN TILT THE ARM BACKWARD LEFT CONTROL LEVER BACKWARD STEP 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 WARNING MAKE SURE WORK AREA IS CLEAR OF PEOPLE AND OBSTACLES PRIOR TO ...

Page 50: ...RING LIFTING STEP 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 DISENGAGE THE P T O LOCK U LOCK IF INSTALLED ON HOIST DUMPING STEP 1 MOVE THE JIB FORWARD RIGHT CONTROL FORWARD TO ENSURE THAT THE CONTAINER IS LOCKED STEP 2 EXTEND THE MAIN LIFT CYLINDERS LEFT CONTROL BACKWARD CAUTION DO NOT ...

Page 51: ...NER TOUCHES THE GROUND RELEASE THE BRAKES TO FREE THE TRUCK FOR FORWARD MOVEMENT CAUSED BY THE CONTAINER STEP 3 ROTATE JIB ALL THE WAY BACK UNTIL 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 MOUNT OR DISMOUNT BODIES ON UNEVEN GROUND 3 DON T DRIVE WITH THE HOIST IN THE DUM...

Page 52: ...S PROCEDURE MAY RESULT IN POSSIBLE PROPERTY DAMAGE AND OR PERSONAL INJURY MAKE SURE WORK AREA IS CLEAR OF PEOPLE AND OBSTACLES PRIOR TO CHANGING THE HOOK HEIGHT ON THE ADJUSTABLE JIB STEP 1 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 STEP 2 RETRACT THE JIB RIGHT CONTROL LEVER BACKWARD STEP 3 TILT TH...

Page 53: ... TO TILT TELESCOPIC ARM REARWARD UNTIL THE DUMP CYLINDERS ARE FULLY EXTENDED REPLACE LOCK PIN AND SECURE WITH HITCH PIN 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 3 5 ...

Page 54: ... MAY RESULT IN POSSIBLE PROPERTY DAMAGE AND OR PERSONAL INJURY MAKE SURE WORK AREA IS CLEAR OF PEOPLE AND OBSTACLES PRIOR TO CHANGING THE HOOK HEIGHT ON THE ADJUSTABLE JIB STEP 1 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 STEP 2 TILT THE TELESCOPIC ARM TOWARD THE CAB LEFT CONTROL LEVER FORWARD S...

Page 55: ...HE TELESCOPIC JIB FULLY EXTENDED IN THE TRANSPORT POSITION AS SHOWN REPLACE THE LOCK PIN AND SECURE WITH HITCH PIN WARNING DO NOT REMOVE LOCK PIN ON THE ADJUSTABLE JIB WHILE JIB IS IN THE 54 HOOK POSITION AND THE TELESCOPIC ARM IN TRANSPORT POSITION AS SHOWN POSSIBLE PROPERTY DAMAGE AND OR PERSONAL INJURY MAY RESULT 3 7 ...

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Page 57: ...th as wide spacing HOIST STANDARD All SwapLoader hooklift hoists are made so that the rear rollers can be spaced at either the wide spacing or narrow spacing depending on the subframe design the only exception is the SL 105 which can only accommodate a wide spacing or 41 5 8 outside width Unless instructed otherwise SwapLoader will ship hoists with the rear rollers setup per the previously discuss...

Page 58: ...r spacer on first then place the rear roller back on the roller shaft 4 Replace and tighten the retaining bolts retaining washer and roller retainer WIDE TO NARROW ROLLER SPACING ADJUSTMENT To change a hoist from the wide roller spacing to a narrow roller spacing follow these instructions 1 Loosen and remove the retaining bolts washers and roller retainer 2 Remove the rear roller and roller spacer...

Page 59: ... 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 3 Check adjustments on mast lock safety latch mechanism Refer to the Mast Lock Inspection Instructions on Pg 4 4 of the Maintenance section 4 Check adjustments on the jib lockout valve R...

Page 60: ...Section IV Maintenance 4 0 MAI SL 160 LUBRICATION DIAGRAM LEGEND GW Grease Weekly GM Grease Monthly 4 2 ...

Page 61: ...on Nominal Flow Rating 25 GPM NOTE 1 ALWAYS CONSULT YOUR LOCAL HYDRAULIC OIL SUPPLIER FOR MORE INFORMATION 2 USE CAUTION WHEN OPERATING AT OR BEYOND THE RECOMMENDED TEMPERATURE EXTREMES 3 DO NOT OPERATE THE HOOKLIFT HOIST WHEN HYDRAULIC OIL TEMPERATURE ON TANK GAUGE EXCEEDS 160 F 71 C AS DAMAGE TO HYDRAULIC COMPONENTS CAN OCCUR ISO Grade 32 Company Name Brand Name Grade Castrol BP Paradene 32AW CI...

Page 62: ...nt 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 parts wear or become damaged and need replaced SwapLoader recommends that you regularly inspect all mast lock components for damage or wear see illustration below Inspect the safety latch see illustration below again make sure the latch bar is n...

Page 63: ...n the driver side of the hoist see Jib Lockout Valve Mount Detail on Pg 5 2 of the Parts Section 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 see 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 t...

Page 64: ... 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 SPECIFICATION SwapLoader Pt No Work Port Size Spool Type 21P28 3 4 16 ORB SAE 8 2 Way 2 Position N C Please contact your ...

Page 65: ...ameter 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 Should you not be able to source a hydraulic gauge locally SwapLoader can provide one at a reasonable cost Hyd Pressure Gauge Hose Assembly Pt No ...

Page 66: ...ter and attach the pressure gauge to the hydraulic control valve see illustration below 3 Start the truck and engage the P T O 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 5 Check the gauge for the maximum developed system pressure The SL 160 should have a reading of 3 250 ...

Page 67: ...the pressure gauge to the hydraulic control valve see illustration below 3 Start the truck 4 Push the lift dump circuit lever left until the lift dump cylinder bottoms out see illustration on the right Continue to push the lever forward until steps 5 6 are complete 5 Check the gauge for the maximum developed system pressure The SL 160 should have a reading of 3 250 PSI 6 With the pressure check co...

Page 68: ...t clamp assembly for the SwapLoader SL 160 hoist model For optimum performance out of your SwapLoader SL 160 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 since the clamp assembly has a fixed elevation inspect the clamp liner clamp plate and fa...

Page 69: ...atively the figure above is labeled showing which spool performs which function Press the button on the spool hold and then press the manual over ride button on the bottom of the valve shown in the figure to the right NOTE 2 A PHILLIPS SCREWDRIVER IS RECOMMENDED TO BE USED TO ASSIST IN PRESSING IN THE VALVE SPOOL BUTTON NOTE 3 PROPERLY WORKING PUMP PTO IS REQUIRED TO MOVE CYLINDERS NOTE 1 MAKE SUR...

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Page 71: ... 80 3 13H48 2 Tube Stop Sub Wdmt 50 5 Deg 3 02 6 04 4 13H65 1 Pivot Joint Sub Assembly 397 11 397 11 5 13H67 1 Main Frame Sub Assembly 948 23 948 23 6 13H74 1 Body Lock w Shelf Assembly 109 46 109 46 7 23H56 1 Lockout Valve Ramp 1 20 1 20 8 62H99 1 Logo Name Plate 0 29 0 29 9 90H89 1 Base Cylinder Circuit 21 44 21 44 10 00767 4 Washer Lock 5 8 Dia 0 01 0 04 11 00P24 4 Nut Hex 5 8 11 UNC Gr8 0 09 0...

Page 72: ...Gr8 0 02 0 48 8 00P31 2 HHCS 1 2 13 UNC x 1 1 4 0 14 0 28 9 00P68 24 FSCS 3 8 16 UNC X 1 1 4 SS 0 11 2 64 10 01P08 2 HHCS 5 16 18 UNC x 2 Gr8 0 12 0 24 11 01P20 1 SHCS 3 8 16 UNC x 1 3 4 Gr8 0 07 0 07 12 01P30 2 Washer Lock Disc 1 2 Pr 0 02 0 04 13 22P92 2 Hyd Cyl 5x2 25x43 219 90 439 80 14 90P71 6 Wear Pad 2 3 4x1 2x11 3 4 0 70 4 20 LIFT CYLINDER SERVICE PARTS 15 21P11 2 Counterbalance Valve Cart...

Page 73: ...2 HHCS 3 8 16 UNC x 1 Gr8 0 05 0 10 9 00P73 2 FHCS 1 2 13 UNC x 1 1 4 Gr8 0 11 0 22 10 00P86 2 Washer Lock Countersunk 1 2 0 06 0 12 11 01P25 6 SHCS 7 16 14 UNC x 1 1 2 Gr8 0 05 0 30 12 01P26 6 Washer Lock 7 16 0 01 0 06 13 01P28 2 Washer Lock Disc 3 8 Pr 0 01 0 02 14 01P30 2 Washer Lock Disc 1 2 Pr 0 02 0 04 15 80P09 2 Roller Assy 6 1 4 x2 1 4ID 37 03 74 06 16 90P03 6 Zerk Grease 1 8 NPT 0 01 0 0...

Page 74: ...4 3 54 10 00P05 1 Snap Ring Ext 1 Shaft 0 01 0 01 11 00P13 4 HHCS 3 8 16 UNC x 1 1 4 Gr8 0 10 0 40 12 00P55 1 Nut Lock 5 8 11 UNC Gr8 0 13 0 13 13 00P62 14 HHCS 3 8 16 UNC x 1 Gr8 0 05 0 70 14 01P16 12 FHCS 5 16 18 UNF x 1 1 4 Brass 0 03 0 36 15 01P28 18 Washer Lock Disc 3 8 Pr 0 01 0 18 16 01P43 1 HHCS 5 8 11 UNC x 7 1 2 Gr8 0 75 0 75 17 20P51 1 Hyd Cylinder 3 x 1 75 x 32 86 00 86 00 18 23001 12 ...

Page 75: ...75 6 27H06 1 Pivot Lock Bar 9 60 9 60 7 00P32 2 SHCS 3 8 16 UNC x 1 1 4 0 07 0 14 8 00P34 2 Nut Lock 3 8 16 0 02 0 04 9 01P28 3 Washer Lock Disc 3 8 Pr 0 01 0 03 10 01P30 2 Washer Lock Disc 1 2 Pr 0 02 0 04 11 01P48 2 HHCS 1 2 13 UNC x 3 Gr8 0 19 0 38 12 01P67 4 FHCS 1 4 20 UNC x 3 4 Brass 0 01 0 04 13 90P04 2 Spring Extension 7 8 OD x 6 Lg 0 40 0 80 14 91P21 2 Wear Pad 1 1 4 x 1 2 x 3 1 2 0 09 0 ...

Page 76: ...ad 2 3 4x1 2x3 1 4 0 19 0 19 3 24H67 1 Shim Jib 2 3 4 x 14GA x3 1 4 0 20 0 20 4 62H11 1 Cover Jib 5 1 4x11GAx5 1 4 0 90 0 90 5 00755 2 Washer Lock 3 8 Dia 0 03 0 06 6 00P03 2 HHCS 3 8 16 UNC x 3 4 0 04 0 08 7 01P50 4 FHCS 5 16 18 UNC x 3 4 0 02 0 08 DISC LOCK WASHER TORQUE SPECS BOLT SIZE SAE GR 8 ASS Y TORQUE FT LBS 3 8 50 7 16 80 1 2 120 5 8 230 3 4 380 7 8 400 1 400 5 6 ...

Page 77: ... 00P15 26 HHCS 1 2 13 UNC x 1 3 4 Gr8 0 20 5 20 10 00P19 3 HHCS 5 16 18 UNC x 2 3 4 0 02 0 06 11 00P20 3 Nut Hex 5 16 18 UNC 0 10 0 30 12 00P35 42 Nut Lock 1 2 13 UNC 0 05 2 10 13 00P56 4 HHCS 5 8 11 UNCS x 1 1 2 0 18 0 72 14 01P31 4 Washer Lock Disc 5 8 Pr 0 03 0 12 15 10P28 2 HHCS 5 16 x 1 1 4 0 03 0 06 16 10P29 2 Cover Plate Clamp 7 8 0 10 0 20 17 10P30 2 Clamp Assy Twin 1 2 0 04 0 08 18 00752 ...

Page 78: ... 42 08 08FJ 08FJ45 2 05 2 05 6 12P52 1 Hose Assy 38 08 08FJ 08FJ45 1 90 1 90 7 12P53 1 Hose Assy 21 08 08FJ 08FJ45 1 26 1 26 8 12P54 1 Hose Assy 17 08 08FJ 08FJ45 1 11 1 11 9 12P55 1 Hose Assy 31 06 08FJ 08FJ45 1 43 1 43 10 12P58 2 Adp Hyd 08MJ 08MJ 08MJ Tee 0 30 0 60 11 12P85 4 Adp Hyd 08FJ 08MJ 45 0 30 0 60 12 13P14 4 Adp Hyd 08FJ Cap 8 0 30 0 60 13 13P72 1 Hose Assy 78 08 08FJ 08FJ 4 68 4 68 14...

Page 79: ... 9 11P20 2 Worm Gear Clamp HSS16 0 10 0 20 10 12P16 2 Adp Hyd 08MJ 08MB 90 LL 0 30 0 60 11 12P17 2 Adp Hyd 10MB 08FB 0 30 0 60 12 12P21 1 Adp Hyd 16MP 12FP 0 20 0 20 13 12P22 1 Adp Hyd 12HB 12MP 0 30 0 30 14 12P23 1 Adp Hyd 12HB 12MB 90 0 60 0 60 15 12P29 1 Hose 3 4 X 24 LP 0 88 0 88 16 12P53 1 Hose Assy 21 08 08FJ 08FJ45 1 26 1 26 17 12P59 1 Hose Assy 20 08 08FJ 08FJ 1 22 1 22 18 20P05 1 Hyd Tank...

Page 80: ...T Bolt Clamp 1 1 2 Dia 0 10 0 20 2 10P32 1 Adp Hyd 10MJ 12MB 45 0 30 0 30 3 10P35 1 Adp Hyd 10MJ 12MB 0 30 0 30 4 10P61 1 Hose Assy 106 08 10FJ 10FJ90 3 80 3 80 5 12P18 1 Adp Hyd 16HB 16MB 0 40 0 40 6 12P19 1 Adp Hyd 10HB 10MP 0 3 0 30 7 12P20 1 Adp Hyd 20MP 16FP 0 30 0 30 8 12P28 1 Hose 1 X 120 LP 6 60 6 60 5 10 ...

Page 81: ...ESCRIPTION WT lb ea WT lb all 1 10H51 1 Valve Mount Bracket 8 20 8 20 2 20P08 2 Control Handle Cable 2 80 5 60 3 20P09 1 Control Console 2 Sect 4 10 4 10 4 20P10 2 Bonnet Kit V20 0 50 1 00 5 20P15 2 Control Cable Assy 84 Std 1 83 3 66 6 21P32 1 Hyd Valve V20 2 Sect 3250 27 00 27 00 5 11 ...

Page 82: ...This Page Intentionally Left Blank ...

Page 83: ... 1 Tube 2 1 2OD x 1 0 30 0 30 8 53586 1 Safety Snap Pin 3 8 Dia x 2 1 2 Lg 0 14 0 14 9 62H11 1 Cover Jib 5 1 4x11GAx5 1 4 0 90 0 90 10 00755 2 Washer Lock 3 8 Dia 0 03 0 06 11 00P03 2 HHCS 3 8 16 UNC x 3 4 0 04 0 08 12 00P34 1 Nut Lock 3 8 16 0 02 0 02 13 01P01 1 HHCS 3 8 16 UNC x 3 1 4 0 01 0 01 14 01P50 4 FHCS 5 16 18 UNC x 3 4 0 02 0 08 15 90P03 1 Zerk Grease 1 8 NPT 0 01 0 01 16 90P91 2 Decal ...

Page 84: ... 16 5 00P24 4 Nut Hex 5 8 11 UNC Gr8 0 09 0 36 6 01P40 4 HHCS 1 2 13 UNC x 2 1 2 Gr8 0 19 0 76 7 10P43 2 Adp Hyd 08MJ 08MJ BHD 0 30 0 60 8 13P14 2 Adp Hyd 08FJ Cap 0 03 0 06 9 13P50 2 Adp Hyd 06FJ 06MJ45 0 30 0 60 10 13P77 2 Adp Hyd 06MJ 06MP 062 Rstr 0 30 0 60 11 13P84 2 Hose Assy 62 06 06FJ 06FJ90 3 36 6 72 12 13P87 2 Adp Hyd 08FJ 06MJ 0 30 0 60 DISC LOCK WASHER TORQUE SPECS BOLT SIZE SAE GR 8 A...

Page 85: ...Dia x 2 0 02 0 04 5 00P55 2 Nut Lock 5 8 11 UNC Gr8 0 08 0 16 6 01P85 2 SS 5 8 11 UNC x 4 1 2 0 75 1 50 7 01P86 2 Washer ZP 5 8 Dia 0 04 0 08 8 01P87 4 Washer ZP 1 Dia 0 10 0 40 9 01P88 2 Pin Clevis 1 x 4 11 16 1 21 2 42 10 01P89 4 Washer Nylon 1 Dia 0 01 0 04 11 01P90 2 Pin Clevis 3 4 x 2 1 2 ZP 0 39 0 78 12 01P91 6 Washer SS 3 4 Dia 0 02 0 12 13 01P92 2 Pin Sltd Spring 5 32x1 1 2ZP 0 01 0 02 14 ...

Page 86: ...PTION WT lb ea WT lb all 1 13H76 1 Valve Mount Bkt 3 Sect 11 47 11 47 2 20P08 3 Control Handle Cable 2 80 8 40 3 20P10 3 Bonnet Kit V20 0 50 1 50 4 20P15 3 Control Cable Assy 84 STD 1 83 5 49 5 20P78 1 Control Console 3 Sect 0 60 0 60 6 22P94 1 Hyd Valve 3 Sect 3250 V20 45 00 45 00 6 4 ...

Page 87: ...x 8 3 4 4 41 8 82 5 25H91 2 Mount Bkt 8 1 4 x 11 3 68 7 36 6 00784 42 Washer Flat 1 2 Dia HT 0 01 0 42 7 00P01 16 HHCS 1 2 13 UNC x 1 1 2 Gr8 0 21 3 36 8 00P15 26 HHCS 1 2 13 UNC x 1 3 4 Gr8 0 20 5 20 9 00P35 42 Nut Lock 1 2 13 UNC 0 05 2 10 10 00P56 4 HHCS 5 8 11 UNCS x 1 1 2 0 18 0 72 11 01P31 4 Washer Lock Disc 5 8 Pr 0 03 0 12 DISC LOCK WASHER TORQUE SPECS BOLT SIZE SAE GR 8 ASS Y TORQUE FT LB...

Page 88: ...dp Hyd 20MP 16MP 0 70 0 70 2 11P20 2 Worm Gear Clamp HSS16 0 10 0 20 3 12P21 1 Adp Hyd 16MP 12FP 0 20 0 20 4 12P22 1 Adp Hyd 12HB 12MP 0 30 0 30 5 12P29 1 Hose 3 4 x 24 LP 0 88 0 88 6 20P05 1 Hyd Tank 15 Gallon 54 20 54 20 7 20P22 1 Hyd Filter Assembly 25 GPM 2 30 2 30 8 20P64 1 Hyd Filter Indicator 0 01 0 01 6 6 ...

Page 89: ...2 Worm Gear Clamp HSS16 0 10 0 20 12 12P16 3 Adp Hyd 08MJ 08MB 90 LL 0 30 0 90 13 12P17 3 Adp Hyd 10MB 08FB 0 30 0 90 14 12P21 1 Adp Hyd 16MP 12FP 0 20 0 20 15 12P22 1 Adp Hyd 12HB 12MP 0 30 0 30 16 12P23 1 Adp Hyd 12HB 12MB90 0 60 0 60 17 12P29 1 Hose 3 4 x 24 LP 0 88 0 88 18 12P53 1 Hose Assy 21 08 08FJ 08FJ45 1 26 1 26 19 12P59 1 Hose Assy 20 08 08FJ 08FJ45 1 22 1 22 20 13P80 2 Adp Hyd 08MJ 08F...

Page 90: ... lb all 1 10P21 2 T Bolt Clamp 1 1 2 Dia 0 10 0 20 2 10P32 1 Adp Hyd 10MJ 12MB 45 0 30 0 30 3 10P61 1 Hose Assy 106 08 10FJ 10FJ90 3 80 3 80 4 12P18 1 Adp Hyd 16HB 16MB 0 40 0 40 5 12P19 1 Adp Hyd 10HB 10MP 0 30 0 30 6 12P20 1 Adp Hyd 20MP 16FP 0 30 0 30 7 12P28 1 Hose 1 x 120 LP 6 60 6 60 6 8 ...

Page 91: ...J 08FJ 90 0 30 0 60 2 10P63 2 HHCS 5 16 x 1 3 4 0 03 0 06 3 10P64 2 Cover Plate Clamp 1 2 0 10 0 20 4 10P65 2 Clamp Assy Twin 7 8 0 04 0 08 5 12P53 1 Hose Assy 21 08 08FJ 08FJ45 1 26 1 26 6 12P59 1 Hose Assy 20 08 08FJ 08FJ 1 22 1 22 7 13P25 1 Hose Assy 58 08 08FJ 08FJ45 2 72 2 72 8 13P32 1 Hose Assy 60 08 08FJ 08FJ45 3 60 3 60 6 9 ...

Page 92: ...CS 5 16 x 1 3 4 0 03 0 06 5 10P64 2 Cover Plate Clamp 1 2 0 10 0 20 6 10P65 4 Clamp Assy Twin 7 8 0 04 0 16 7 12P53 1 Hose Assy 21 08 08FJ 08FJ45 1 26 1 26 8 12P59 1 Hose Assy 20 08 08FJ 08FJ45 1 22 1 22 9 13P25 1 Hose Assy 58 08 08FJ 08FJ45 2 72 2 72 10 13P32 1 Hose Assy 60 08 08FJ 08FJ45 3 60 3 60 11 13P33 1 Hose Assy 63 5 08 08FJ 08FJ45 3 81 3 81 11 13P34 1 Hose Assy 66 08 08FJ 08FJ45 3 96 3 96...

Page 93: ......

Page 94: ...1800 NE BROADWAY AVENUE DES MOINES IA 50313 TOLL FREE 888 767 8000 ...

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