switch-n-go™ installation manual · go model number you have purchased to fit your truck’s ca.,...

Switch-N-Go™ Installation Manual



1) Safety Precautions Statement

2) Descriptive Terms Used in this Manual

3) Frame Preparation

4) Set-up of Hoist (alignment to truck frame)

5) Fastening Hoist to Truck Frame

6) Grounding of Switch-N-Go™

7) Wiring the Pendant

8) Proper Hydraulic Pressure Setting

9) Wire Rope Installation

10) Fluid Fill, Lubricate & Test Unit

11) Bumper Installation

12) Lighting Harness

13) Plastic Fender Installation

14) Stainless Fender Installation

15) Trouble Shooting

Appendices

A) Center of Gravity for Various Models

B) Prop Rod Safety Warnings

C) Part Reorder Listing and Diagram

D) Pre-Delivery Checklist and Customer Unit Demonstration


1. SAFETY PRECAUTION

NOTICE!

ONLY AUTHORIZED PERSONNEL TRAINED AS INSTALLERS OF TRUCK BODIES, WHO ARE AWARE OF

FEDERAL AND STATE D.O.T. REGULATIONS, LOCAL REGULATIONS, AND HAVE AN “UPFITTERS

LICENSE” SHOULD INSTALL THIS SYSTEM. THIS MANUAL IS WRITTEN ONLY FOR THOSE ALREADY

TRAINED WITH KNOWLEDGE OF NEUTRALIZING FUEL TANKS, KNOWLEDGE OF DRILLING AND

WELDING RESTRICTIONS ON TRUCK FRAMES, ETC.

Read the installation instructions before beginning. This will save lost time and unneeded steps.

As trained installers, please use your safety training to disarm mechanical energy, hydraulic energy,

explosive energy and electrical energy.

Finally, the job is not complete until you have verified the safety decals, tested the unit, and completed the

Pre-Delivery Checklist, which includes on-job-training to the new owner.

Thank you for your professionalism.

The Switch-N-Go™ Team


Frame Preparation

A. Clear the top of the truck frame of all obstructions that would not permit the Switch-N-Go™

Hoist Frame Assembly subframe to sit directly on the truck frame.

B. Depending on the make, year, and model of the truck, the frame may have a hump over the

rear axle of the truck. This is most common on the 4-wheel drive Mitsubishi. If it does, it will

be necessary to shim up the subframe accordingly. This will create a flat plane for the

subframe to rest upon.

C. Depending on whether the truck is new or used (a truck body of some sort

previously

installed), it may be necessary to add or subtract to the rear of the truck frame.

D. To determine what length your frame should be, depends on what Switch-N-

Go Model number you have purchased to fit your truck’s CA., and fuel tank layout.

E. If you have Switch-N-Go™ Loader:

9S-516-XX*, truck frame length from back of cab to end of frame is 9 foot (108”).

9-516-XX*, truck frame length from back of cab to end of frame is 9 foot (108”).









4. Set-Up of Hoist

A. Once you have created a flat, obstruction-free area on top of the truck frame, you are ready

to position the Switch-N-Go™ “Hoist Frame Assembly.”

B. Position the “Hoist Frame Assembly” down onto the prepared truck frame. It is important to

position the front of the hoist rails a minimum of 2” from the back of the cab. (See figure 1).

[NTEA recommendation to prevent cab slap].

C. Align the side of the “Sub-Frame” with the frame of the truck.

Note: Make sure that the Hoist Frame Assembly subframe is not resting on anything but the

truck frame rails, or shims. If it is resting on something else (like a fuel tank fill hose, wires,

etc.), alteration will have to be made in order to continue installation.

D. For specific information on proper hydraulic pressure settings, refer to the Warn Industrial

Winch Manual.


5. Fastening “Hoist Frame Assembly” to Truck Frame

A. Once you have positioned the Switch-N-Go™ “Hoist Frame Assembly”, it may be

necessary to add or subtract to the end of the truck frame. The truck frame must be even

with the rear pivot point of the “Hoist Frame Assembly”. Failure to install as prescribed

may cause a malfunction of the Switch-N-Go™ truck system, which may cause serious

injury or death (see figure 2).

B. Fasten the rear half of the sub-frame to the truck by welding the two frame tie-down

brackets onto the sub-frame. Drill corresponding holes through the truck frame, and

attach in place using two (2) ½” x 1 ½” hex cap screws, lock washers and nuts, and flat

washers (both sides). The tie-down brackets should be located as close as possible to

the rear pivot point to insure stability. Shown also in (figure 2).

C. Place the mounting angles under the lower pivot angles and against the truck frame.

Clamp them securely into place. Drill through the frame and install the mounting angle

with two (2) grade 8 ½” x 1 ½” hex cap screws, lock washers, hex nuts, and flat washers

(both sides). (See figure 3.)

Note: Do not weld the mounting angles to the truck frame. This may void the truck warranty.

D. Weld each end of the lower pivot angle to its mounting angle as shown in drawing (figure

3). Note the welding symbols. Do not weld to the truck frame.

E. Place a third set of tie down brackets (no closer than 12”, to the back of the cab of the

truck).

Note: On the 12-620-15/13-620-15 and the 14-620-15, it will be necessary to add an additional set

of tie down bracket


6. GROUNDING OF SWITCH-N-GO™

Run a (supplied) 48” #2 ground cable from the negative (-) terminal of the battery to the front

of the truck chassis frame (this is in addition to what the truck has).

7. Wiring the Pendant Each hoist has two Pollack Socket connectors for the control pendant. The pendant is

intended to be disconnected between uses for safety reasons so the unit is not accidentally

activated while driving.

7A.1 Install the Pollack socket in the cab. Cab installations are usually on the cab floor or

dash within easy reach of the driver. If a floor application, choose the mounting spot:

drill 1” through the floor. Fasten the Pollack Socket to the floor with two self-tapping

screws. (See Figure 10A for Electric Installation, See Figure 10B for Hydraulic Installation) Wire up per 7.A.2 & 7.A.3 below.

NOTE: Both Pollack Sockets will be wired at the “Pendant” wire location in Figure 10. 7.A.2 Proceed to strip all the control wires to allow for an insulated connector crimp, to be

placed on each wire. Place the supplied crimp on each end previously stripped.

7.A.3 Place the colors of wires, onto the studs marked for the corresponding color as shown

in (Figure 10A or 10B). Do not connect the white wires (ground) wire for the cab

pendant port when completing a HD installation. The stud marked yellow represents

orange in the junction box.

7.A.4 Run a (supplied) 1/0 battery cable from the connector block attached to the subframe

front cross member to the positive (+) side of the battery. Be sure to securely fasten

all cables to the truck chassis or the subframe. (Figure 9)


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8. Proper Pressure Setting


Setting the Pressure Reducing Valve to the winch if it needs to be

different than the 2000 setting

(This will be the middle solenoid valve on the manifold and the Reducing Valve is a PBDB-LAN)

Remove ¼” NPT Plug from EBP Block and install 3000 PSI Gauge Lower Hoist the whole way and look at Pressure Gauge. It should read

approximately 2000 PSI The setting can be increased or decreased as required on the winch circuit. To

do this, loosen the jam nut on the PBDB-LAN and then turn the threaded stem with a 5/32” hex wrench.

Clockwise will increase the setting & counter-clockwise will reduce the setting. One turn will adjust the valve by approximately 600 PSI


9.Wire Rope Installation

A. Install the wire rope by pushing the end of the wire rope into the anchor hole in the drum

tube. NOTE: A small piece of tape around the end of the wire rope will make installation much easier. The wire rope must extend to the other end of the hole.

B. Torque the set screw to 12 – 15 lb.ft.

C. Do not over tighten, as this may cause the set screw threads to be damaged.

D. 9,000/12,000 and 15,000 lb. Warn Winches

The wire rope on the Warn E & H Series winches is wrapped the same. The cable feeds out from topside. See figure below.

Recessed Winch 10. Fluid Fill, Lubricate & Test Unit

A. Fill the Hydraulic Power Pack with proper oil. Shown below.

SWITCH-N-GO™ MODEL NO.

RESERVOIR CAPACITY

TOTAL FLUID REQ’D.

9-516-XX & 10-516-XX 4 Quarts 7.5 Quarts 11-520-XX 4 Quarts 9.0 Quarts

12-620- thru 14-620-XX 4 Quarts 12 Quarts

WARNING: WHEN PERFORMING MAINTENANCE ON A RAISED HOIST ALWAYS HAVE PROP

ROD IN PLACE.


PROCEDURE:

STEP 1 Do these steps with no truck body on the Hoist Frame Assembly.

STEP 2 Remove the reservoir breather. With the hoist in the down position, fill the reservoir

with ATF-Dextron II (Mobile DTE 13 or grade 32 hydraulic oil) – 3.5 quarts for 516,

520 and 620.

STEP 3 Raise the hoist halfway (22-25 dump angle, approx. 8” of cylinder stroke). Set prop

rod for safety. (Note: this will not work on the 620 hoist.)

STEP 4 Fill the reservoir with an additional 2 qts. for 516 and 3 qts. for 520.

STEP 5 Raise the hoist completely.

STEP 6 Refill the reservoir with the remaining fluid required.

A. Lubricate at all grease fitting locations shown in (Figure 12).

B. Lubricate Winch drum assembly and wire rope with a wire rope compound such as

Century WRC 21 or equivalent to.

C. Test Unit after all fluids have been checked and filled, and all lubrication points have been

properly greased. Test to see that all functions of the Pendant Controller work in

accordance with the decal located under the toggle switches, such as the Hoist UP toggle

should raise the hoist rails, etc.

D. Check all hydraulic fittings for leaks. Search for leaks with a piece of paper,

protect hands and body from high-pressure fluid leaks. Wear protective eyewear and

gloves for this procedure.

E. Check all nuts and bolts for tightness.

F. Check to make sure that the prop rod is in proper working condition.

Check to make sure that all wire connections are tightly fastened and secure and free of any

pinch point or sharp edge that may cause premature damage to the electrical system.


(Figure 12)

Grease Fitting Diagram


11. Installing the Bumper (See Figure 10)

1. Make sure the rear of the truck is clear of obstructions (lights, brackets, etc.),

and that the ends of the truck frame are square and even with the hoist

subframe.

2. Line the top plate of the bumper up evenly with the bottom edge of the angle

iron on the subframe. Make sure the bumper is tight against truck frame.

3. Weld the top edge of plate on the bumper to the edge of the angle iron on the

hoist subfame and also weld the plate to the truck frame side. (Do not weld on

the flanges of the frame). Visually inspect all welds for defects. High-Quality

welds must be maintained, as they are critical for joint integrity.

4. Smooth up the welds and touch-up paint with matching color.

5. On the backside of the bumper, in the center of the 3”x 6” tube, drill a 13/16 hole

for the wiring harness of the light kit to go through. De burr the hole.

6. Install the “weather tight” fitting in the hole, along with the wiring harness and

lights.

7. Mount the gusset plates properly to insure strength on the joint.


12. Lighting Harness: WIRING DIAGRAM FROM TRUCK-LITE


22.5” PLASTIC FENDERS


19.5” PLASTIC FENDERS


STAINLESS STEEL FENDERS


TROUBLESHOOTING PROBLEM Hoist will not raise

Hoist will not lower

Pump spews oil out of tank Winch will not move in either direction

REASON

•Bad wire in pendant •12 V battery supply disconnected •Lack of oil in reservoir •Bad ‘G’ coil •Bad ‘R’ coil •Prop rod is engaged or out •Too much rear overhang weight

•12 VDC supply disconnected •Lack of oil in reservoir •Foreign obstruction between hoist rails and sub frame •Broken or cut hydraulic line to C2 port •Clogged breather cap •Valve stuck part way in -Load raises hoist cylinder faster than pump can receive oil to tank •12VDC power disconnected •Winch motor burned up

SOLUTION

•Fix broken wire in pendant by tracing up the wire from the “up” button •Reconnect the 12VDC supply, or, if applicable, replace or reset fuse. •Fill oil reservoir and check for leaks or clogged breathers. •Replace ‘G’ coil •Replace ‘R’ coil •Return prop rod into the “transport” or “up” position •Move load forward before lowering •Reconnect the 12 VDC supply, or, if applicable, replace or reset fuse. •Fill oil reservoir and check for leaks or clogged breathers. •Remove any foreign object •Fix or repair hydraulic line leaks or breaks •Clean breather cap •If hoist valve does not resume normal function; take a look at the ‘R’ and ‘G’ coils. •Take valve out and look for foreign objects. • Load too heavy Reconnect the 12 VCS supply Replace winch motor


PROBLEM

Winch moving out when “in” button is pushed Winch moving in when “out” button is pushed Winch does not pull load on Winch will not unload

the load

REASON

•Wires to “in” and “out” buttons are reversed •Winch was respooled in the wrong direction •Wire wedged between bottom layers of wire rope •Wires to “in” and “out” buttons are reversed •Winch was respooled in the wrong direction •Wire wedged between bottom layers of wire rope •Too much pay load for winch

•12VDC power disconnected •Too much ground resistance •Broken or disconnected band wire in pendant •Too many layers of wire rope on winch •Box may be frozen down. •Winch motor burned up -Shock loading gear damage •12VDC power disconnected

•Wire to push button in pendant is broken or disconnected

SOLUTION

•Reverse wires to buttons in pendant •Run wire rope all the way out, and respool in the correct direction according to the winch direction decal •Dislodge cable then check for damage. •Reverse wires to buttons in pendant •Run wire rope all the way out, and respool in the correct direction according to the winch direction decal •Dislodge cable then check for damage. •Remove pay load off the apparatus to be loaded •Reconnect 12VDC supply, or if applicable, replace or reset fuse. •Get into the cab, and roll the truck underneath the load. •Fix or replace pendant cable or wire •Reduce the number of layers by shortening the cable to 25’ in length. •During cold weather, put boards on the ground and set the container on them. •Replace motor in winch. -Replace gears in winch •Reconnect 12VDC supply, or, if applicable, replace or reset fuse. •Replace or fix wire or pendant cable


PROBLEM

Winch cable pulls out of the winch Winch motor and cable getting too hot during operation All other winch problems

Winch nor hoist will respond

REASON

•Body lock did not disengage •Not enough wire rope wraps around the drum of the cable winch •Too much shock load created by excessive slack in cable •Set screw in drum was not torqued to proper specification •Too long of a cycle time for heavy loads •Bad motor brushes are getting worn out •Internal grounding of DC motor •Insufficient DC power source •Winching loads above rated capacity of winch •Bad, broken, or frayed connection -Two different winch systems are employed on different capacity systems -Pendant disconnected -12VDC power disconnected

SOLUTION

•Pull load ahead by depressing the winch “in” button to allow

the body lock to drop out. •Must maintain five wraps of wire rope at all times. •Always keep slack down to a minimum. •Be sure that set screw on drum is torqued to proper settings.

•Reduce cycle time down to fifty seconds on, five minutes off.

•Replace brushes and/or motor •Replace motor •Check alternator, battery, and wires for damage and corrosion. •Keep all loads less than the rated load of the truck. •Check all connections

-See specific winch manual attached for particular troubleshooting table and fixes -Reconnect -Test battery


Pat. Pending

9,000, 12,000, or 15,000 Pound Lifting Capacity

Detachable Truck Body System

The Switch-N-Go™ body changing system allows you to interchange truck bodies simply and easily in a matter of minutes. Set a loaded body on the ground or pick up a loaded body. You can even dump like a dump truck. All of this is in one system. Switch-N-Go™ is lighter weight and half the cost of similar systems available in the market. It adds only 500 pounds more to the chassis weight than an ordinary dumping system. Switch-N-Go™ is designed to run with electrically powered hydraulics. This saves you the expense of adding a power take-off and pump to your automatic transmission. The standard winch is rated at a 9,000-pound capacity. The scissor hoist will achieve a 50-degree dump angle, perfect for dumping mulch, asphalt, compacted soil, and so much more. We strive to supply you with high quality products with moderate pricing. Because of this, the frame of the hoist is powder coated to ensure long life and all of the moving parts have grease fittings. We have kept everything easy-to-operate and maintain, giving you quality and simplicity while keeping the cost down.

With all this in mind . . . who wouldn’t buy a Switch-N-Go™!


APPENDIX B

Body Prop Use and Warnings

Body prop(s): Federal Regulation 1926.01, Paragraph 10, requires the use of a body prop.

Accordingly, all Rugby Hoist Units will have included as a standard item a body prop (safety strut).

See Paragraphs D.1 and D.2 below.

WARNING

Do not place arms, hands, or any part of the body between the truck longitudinals (long beams) or

moving parts to push the body prop release/locking pin.

Do not use the body prop(s) to support a loaded truck body.

Read operation of safety strut and caution labels before operating the hoist.

1. The body prop is designed for use only when the truck body is empty. The purpose of the

body prop is to provide a safety strut for use when maintenance or repairs are performed

on an unloaded truck body in the raised position.

2. One (1) body prop shall be furnished for truck bodies up to and including 16 feet.

3. Raise body to sufficient height and shut off all power.

4. Grasp prop from latched position by turning prop handle clockwise while pushing handle

in.

5. Grasp prop handle at arm’s length and rotate prop upwards to vertical position

6. Push down until prop locks in vertical position.

7. Using inside-the-cab controls, lower body slowly until prop contacts hoist.

CAUTION: Do not power hoist down while on prop.

8. To lower prop for operation of truck, "reverse" the procedure of the above five steps

WARNING

Use extreme care when reseating the body prop(s) in the locked position.


Owner: _______________________________ Address: _______________________________ Phone: _______________________________ Email: _______________________________

Switch-N-Go™ Hoist Frame Warranty Highlights Statement Deist Industries, Inc. warrants each new Switch-N-Go™ hoist frame to be free from defects in material and workmanship under normal use and service. Deist Industries, Inc. obligation under this warranty extends for a period of one (1) year after initial installation and is limited to “approved” labor for the replacement of any defective part or material, as well as the replacement of any defective part. This warranty excludes any other obligation by Deist Industries, Inc. for the cost of labor, transportation or any other cost arising out of such replacement. This warranty shall not apply to any unit, which has been subject to misuse, misapplication, abuse, negligence, alteration or accident. This warranty excludes any obligation by Deist Industries, Inc. for loss of product, downtime, or any other incidental or consequential damage incurred anytime. In no event shall Deist Industries, Inc. liability under this warranty exceed original purchase price of the product. It should additionally be noted that Deist Industries extends all supplier warranties.

Deist Industries, Inc. does not assume nor authorizes anyone to assume for it any other obligation or liability in connection with its products.

It is the installer’s responsibility to insure that the installation is completed according to Deist Industries, Inc. recommendation and the prevailing federal, state and local statutes. It is the Distributors’ responsibility to complete this predelivery checklist and to insure that the ultimate user understands how to operate in a safe manner and the need for regular service and maintenance by a Deist Industries, Inc. Distributor.

THIS STATEMENT OF WARRANTY HIGHLIGHTS IS FURTHER AND FULLY STATED IN YOUR OPERATION MANUAL. THAT WARRANTY IS THE ONLY WARRANTY APPLICABLE TO SWITCH-N-GO™ HOIST FRAME UNITS MANUFACTURED BY DEIST INDUSTRIES, INC. AND IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Installer/Distributor Pre-Delivery Check List: Note: The Deist Industries, Inc. installer/distributor must test each of the items indicated below and check them off as inspected in the column provided. The installer/distributor must sign in the space provided below that the tests have been completed. Failure of Deist Industries, Inc. installer/distributor to be present at the time of equipment start-up shall void any labor obligation under this warranty. PLACE A CHECK MARK IN THE APPROPRIATE BOX:

□ 1. Check hydraulic oil tank for proper oil level.

□ 2. Check that the high-pressure side of the pump is connected to the cap end of the cylinder and that there are no leaks.

□ 3. Demonstrate attaching the pendant. Assure that the buttons are moving as labeled for both winch and hoist operations.

□ 4. Discuss shock loading of the winch and how to prevent it.

□ 5. Check to see that all grease points are properly lubricated and in working condition.

□ 6. Check to make sure that all electrical connections and wire are tight and free from all areas of pinching, or cutting hazards.

□ 7. With hoist frame installed, mechanically test it to its extreme of operation, such as hoist fully raised and lowered, winch fully extended and retracted of cable. Also, if a body is included, demonstrate loading and unloading the body.

□ 8. The product has been demonstrated to the customer, and customer fully understands the operation of the Switch-N-Go™ unit, including all of the safety decals, which are applied to the unit as indicated in the operation manual.

□ 9. The operation manual and winch manual has been issued to the end user.

□ 10. Show the customer where the Gross Vehicle (GVW) rating is located by the driver’s door jam; if possible, get total unloaded vehicle weight, subtract the two numbers to get maximum net legal payload. Write on cover of operator’s manual.

The pre-delivery inspections above have been completed and I was present at the time of equipment start-up.

______________________________________________ __________________________________________________ Installer Company Name Signature

I have accepted delivery of the equipment listed above and it is operating properly. Authorized operators have been or will be instructed in and understand the proper methods and use of the system.

_______________________________________________ ___________________________________________________ Owner’s Signature Inspection Date

_______________________________________________ ____________________________________________________ Model# Serial Number Installer/Distributor: Keep a copy on file to validate warranty and give end user customer a copy, send or fax a copy to:

Deist Industries, Inc., 3550 Perry Highway Hadley, PA 16130 Fax 724-253-4955 2013 Deist Industries, Inc. Form # PSW-101

switch-n-go™ installation manual · go model number you have purchased to fit your truck’s ca.,...

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