Operation, Installation, & Service Manual
Contents
1. Jio STAND CLEAR EN WHEN THIS UNIT IS IN OPERATION FAILURE TO DO 80 COULD RESULT IN SERIOUS PERSONAL INJURY hu HOOK AND BAIL HEIGHTS MUST MATCH ACAUTION AWARE OF POWERLINES AND OR LOAD WILL BE UNSTABLE OVERHEAD OBSTRUCTIONS AND MAY FALL CAUSING CONTACT BY THE HOIST OR CONTAINER NS d SERIOUS INJURY OR DEATH COULD CAUSE SERIOUS INJURY OR DEATH TO THE OPERATOR AND DO NOT LIFT WITH INNER BOOM TOOPERATORANDOR BYSTANDERS EMEN Mp n BYSTANDERS Be pee 74 490 IMPORTANT ACAUTION RETRACT BOOM BEFORE UNLOADING 22 07 1 OBSERVE AND PRACTICE ALL SAFETY AND w EN OPERATING RULES AS ESTABLISHED BY YOUR LOAD EXTEND COMPANY AND THOSE INCLUDED IN MANUAL LOAD 4 4 ESSERE 2 KEEP CLEAR OF HOIST FRAME WHEN RAISING OR LOWERING 3 DO NOT WORK ON OR UNDER THE HOIST as UNLESS PROPERLY BLOCKED AND SECURED 4 DO NOT EXCEED THE MAXIMUM RATING FOR HOOK ARM EXTENSION BOOM HOOK OPERATING LIMITS STATED BY THE MANUFACTURER 5 OPERATE ON LEVEL GROUND UNLOAD RETRACT 6 DISTRIBUTE LOAD EVENLY UNLOAD HOOK EXTENSION 7 DO NOT DRIVE TRUCK WITH P T O ENGAGED t BOOM j 8 BE SURE TRUCK IS CLEAR OF ANY OVERHEAD ELECTRICAL WIRES OR OBSTRUCTIONS BEFORE X are RAISING HOIST2. Rev 7 04 9525 54 MAIN ASSEMBLY FOR MODELS 3 05 Left Saddle Weldment Right Saddle Weldment Cylinder See HYDRAULICS See INNER OUTER BOOM ASSEMBLY Rear Pivot Weldment 63 164 1 4 Nylon Top Lock Nut 64 101 1 4 STD Flat Washer 62 393 5 8NC x 6 Cap Screw 62 770 1 ANC x 1 1 2 Flat Countersunk Head Cap Screw Nylatron Pad Latch Weldment 5 8NC x 10 Cap Screw Locking Shaft 76 220 Spring 9625 00 9 Spring Retainer 63 152 5 8NC Nylon Top Lock Nut 9625 14 0 Boom Pivot Pin Parts for Single Roller Shown on both sides of hoist 1 2NC x 1 1 2 Cap Screw Pivot Pin 1 2NC x 5 Hex Flange Cap Screw 1 2NC Hex Flange Serrated Nut Machine Bushing Guide Roller Assembly Includes Item 24 N Or OF 4 Bushing Rear Roller Shaft Spacer Guide Roller Retainer 1 STD Lock Washer Zerk Special Bolt Retaining Ring Parts for Double Roller Shown on left side only e 9625 0 13 Rear Pivot Shaft 65 113 Zerk 9625 00 13 Special Bolt 64 118 1 STD Lock Washer 9625 00 12 Guide Roller Retainer 9625 0 15 Spacer 64 208 Machine Bushing 9625 10 0 Guide Roller Assembly Includes Item 40 53 159 Bushing 9625 25 0 Double Roller Arm Weldment Includes Item 42 53 159 Bushing 9625 0 14 Guide Roller Retainer 62 236 1NC x 2 1 2 Cap Screw 9625 274 0 Main Frame Weldment 5 5 5 E
3. ADJUST IF NEEDED 5 1 2 ADJUST IF NEEDED 1 4 WELD ALL AROUND 1 IMPORTANT Before cutting off support weldment be sure to establish that there is clearance for top of filter and for cab or fuel tank 2 Out off support weldment and weld to bottom of saddles before mounting to truck frame 3 See page A7 for saddle installation instructions 4 After mounting saddles to truck install pipes 9274 45 1 Some adjustment on support weldment may be required to get pipes to slide through both weldments 5 Locate hydraulic tank assembly per dimension shown in illustration above Secure hydraulic tank and tool box if ordered to pipe with 1 2NC x 1 Socket Head Cap Screw in bushing if not mounting tool box cut off pipe as required 6 Weld pipes into place with 1 4 welds 7 Do Not Use horizontal mounting tube 9625 00 25 and vertical mounting tube 9625 00 22 on this type of installation 8 Weld bulkhead plate 9625 00 26 onto pipe as close to center of the pipe as possible 9 Install fittings and hoses See Hydraulic Schematic on page P4 Route hoses to clear sharp obstructions and to protect hoses from wear 10 Be sure to install hoses on the proper valve bank Each valve section performs a specific operation The routing of the hoses from the Lift Cylinder to the bulkhead tees must be done carefully Make sure hoses are not twisted and have adequate flexibility during oper
4. WINCH VALVE MOUNT INSTRUCTIONS WELD PLATE AS NEEDED HUTCHINSON KANSAS Determine how valve handle is to operate horizontal or vertically install valve mounting plate as preferred Valve can also be mounted on fender plate Install hydraulic fittings on valve before mounting to plate Valve handles are not to extend past plane of fender Inlet and outlet could change as to the mounting of the valve See page P25 A21 Rev 7 04 71 PNEUMATIC CONTROL INSTALLATION INSTRUCTIONS The pneumatic controller provided with the K PAC Hook Hoist are dual three way regulating valves Output of the controllers is proportional to the control lever position and is balanced against the force of an internal spring Pneumatic Actuator Installation Model VA20 Low Bo To install the pneumatic actuators to the hydraulic valve it may be necessary to remove the Find a suitable area free of dust and dirt to attach the pneumatic actuators 1 2 3 First loosen the hose clamp and disconnect the hose between the valve and the oil filter Next remove the 90 hose fittings and the valve mounting bolts DISCARD THESE PARTS Set the hydraulic valve on the mounting base Determine which spools are to be pneumatically controlled Remove the positioner bonnet located on the back end of each spool opposite from the handle end Using
5. sure there is ample hose to rotate outer boom completely Attach hoses to frame ad H as shown with 4 hose ER clamps 25 1151 4 Bolts 462 718 amp 4 Nuts 463 177 Weld bolts 62 718 to frame making sure hoses do not sag into sub frame Cut off plate if installed WIRING HARNESS INSTALLATION The KP625 630 should be wired in the manner recommended by the truck manufacturer and should adhere to the laws governing vehicles of the same classification Install the side marker light assembly and connect the electrical wiring harness for the brake lights rear marker lights and reverse lights HYDRAULIC SYSTEM START UP PROCEDURE 1 Caution Do not operate the pump until the system is filled with oil Damage to the pump bearing and shafts can occur Fill the reservoir up to 2 from the top of the tank with a high quality of SAE 10 hydraulic oil i e Shell Tellus 22 Texaco Rando 22 or Mobile DTE 25 IMPORTANT NEVER USE A FOAMING DETERGENT TYPE OIL 2 3 4 5 10 Check the hoist for loose parts tools clamps or chains Check the overhead area for obstructions Clear all equipment from under the rear of the hoist Slowly extend the cylinders Check for binding rubbing of hoses or metal to metal interference between hoist and truck parts Operate all hydraulic functions to the full capacity for approximately 5 minutes in order to blee
6. i EQUIPMENT DIVISION OF KRAUSE CORPORATION MODEL NUMBER kansas Know the model number of unit being mounted Use this MODEL model number whenever referring to assembly parts listing pages The number is stamped on a Name Plate SX 2 which is located on the frame member MANUFACTURED IN COMPLIANCE WITH ANSI Z245 STANDARD IN EFFECT AT TIME OF MANUFACTURE TANDEM AXLE TRUCK CHASSIS Eb REV 11 02 25 14 The KP625 630 Hook Hoist is designed for a 52 000 Ib G V W R chassis with 174 unobstructed behind cab to axle chassis clearance Some truck suspensions will allow less frame cut off than others It is desirable to have the axle back as far as possible so a longer cab to axle chassis can be used Note This information is supplied for guidelines only and does not assure the installer of other mounting considerations 227 is the minimum cab to frame cut off dimension and should be increased if a tarper or toolbox etc is to be added Also be aware of exhausts etc behind the cab A2 POWER TAKE OFF INSTALLATION A Caution The power take off selection should be done with care For diesel engines the P T O should be 85 to 100 of engine R P M For gas engines the P T O should be 65 to 80 of engine R P M The direct mounted pump requires a SAE mounting flange and must accept a 7 8 13 tooth splined shaft A waring Do not att
7. x Items Included Kit Green Hydraulics 23 901 Items Included Kit Texas Hydraulics P18 KP630 LIFT CYLINDER ASSEMBLY 23 711 7 x87 Hydraulic Cylinder Assembly 2 03 Retracted 106 Extended 193 Stroke 87 Rod Dia 3 3 4 Part Number ay 1 3 2 2 25 2432 2 2 21 40 169 22 99 220 Retaining Ring 23 812 Seal Kit x Items Included in Kit Green Hydraulics 23 902 Seal Kit Items Included in Kit Texas Hydraulics 1 17 18 9 A 5 o l OF gt 3 19 STABILIZER CYLINDER ASSEMBLY 23 718 4 x12 1 2 Hydraulic Cylinder Assembly 2 01 Retracted 22 3 4 Extended 35 1 4 Stroke 12 1 2 Rod Dia 2 1 2 1 E 5 6 A 2 2 Spherical Bushing o CD D 25 2433 2 Tube Assembly 23 813 Seal Kit Items Included in Kit Green Hydraulics 23 902 Seal Kit x Items Included in Kit Texas Hydraulics 1 1 1 1 1 A C3 12 13 ELM 15 B P20 DIRECT MOUNT HYDRAULIC PUMP M9625 13 FOR MODELS 6 97 Number 25 24 SmpRng 2 f OubordBeang Se
8. BOOM te CYLINDER STABILIZER CYLINDER REV 4 9 99 HYDRAULICS FOR MODELS KP625 KP630 SERIAL 1001 1015 7 99 5 1 1 16 to 1 1 16 F 7 1 2 x 24 JIC 90 Black 2W 292948 Swivel 45 Hydraulic Fitting 33 283002 Assembly z 1 1 16 O Ring to 1 1 16 M 3 4 M JIC to 7 8 M O Ring 90 29 342 JIC Hydraulic Fitting Hydraulic Fitting 3 25 710 6 1 2 x 87 D A Hydraulic Lift 82 250 12 0004 Winch 30 286 Series Cylinder Model KP625 36 75 161 1 1 4NPT Square Head Black 7 x 87 D A Hydraulic Lift Pipe Plug 23 711 2 Cylinder Model KP630 37 75 160 2NPT Square Head Black Pipe 1 E 25 561 7 8 O Ring to 1 1 16 M 90 Plug Hydraulic Fitting 25 2374 3 4 Magnetic Plug 23 712 4 x 62 Hydraulic Boom Cylinder 25 2423 50 Gal Hydraulic Tank Weldment 6 24 6459 8 4 x336 IIC Black 2W Hose 25 2424 77 Gal Hydraulic Tank Weldment 25 300 E to 3 4 M JIC 40 25 233 25 GPM Oil Strainer aa a 2558 VAIN NPTt01 174 F NPT 4 Xx 12 1 2 D A Hydraulic m 90 Hydraulic Fittin Stabilizer Cylinder y 9 75 141 1 1 Close Nipple EJ 25 1180 Hydraulic Fitting asair o a O ETETE NE 10 25 494 Hose Clamp 1 3 16 1 3 8 2 1 14 M NPT to 1 1 4 Hose 24 1114 3 4 Low Pressure Bulk 100R4 n 25 1178 Hydraulic Fitting Hydraulic H
9. HUTCHINSON KANSAS HUTCHINSON KANSAS EXTENSION PLATE 3 4NF x 2 1 2 SCREW THIS INSTALLATION IS TYPICAL BOTH SIDES CAN BE INSTALLED DIFFE TLY 3 4NF HEX FLANGE LOCK NUT REQD AND I RENTL ACCORDING TO DIFFERENT TRUCK MODELS GUSSET PLATE WELD 1 Locate proper height for PINTLE HOOK cut a 7 3 4 hole through REAR PIVOT WELDMENT plate centered between side channels Align the HITCH MOUNTING WELDMENT with the 7 3 4 DIA hole in the rear pivot weldment plate Weld the hitch mounting weldment in place using 3 8 WELD ALL SIDES 2 Weld the D RINGS onto hitch mounting plate per customer specifications using 3 8 WELD 3 Weld EXTENSION PLATES to ends of CROSS SUPPORT TUBE using 3 8 Weld Lift CROSS SUPPORT TUBE weldment into position under truck frame and tack weld into place Weld EXTENSION PLATES CROSS SUPPORT TUBE to truck frame using 3 8 WELD 4 Weld GUSSET PLATE to CROSS SUPPORT TUBE and REAR PIVOT WELDMENT 5 Bolt on PINTLE HOOK to HITCH MOUNTING WELDMENT with 6 3 4NF x 2 1 2 Cap Screws and 3 4NF Hex Flange Lock Nuts Torque bolts REV 7 04 M9625 26 A18 FOLDING ICC BUMPER INSTALLATION m CONNECTION WELDMENT m ICC LIGHTED BUMPER WELDMENT LEVEL BUMPER RED LIGHT W GROMMET amp PLUG Lento SS gt gt HUTCHINSON KANSAS M9625 27 REV 7 04 1 Assemble ICC Lighted Bumper Weldment Connection Weldment Mounting Lug
10. 4 5 6 7 8 o f Pocket Seals 79 21 COMMERCIAL INTERTECH VALVE SECTION 25 9625 12 YY imi Rev 10 98 FOR MODELS Commercial Intertech Valve Work Sections 10 98 Part Description Handle Service Kit Includes Pins amp Bushings O Ring O Ring Teflon Back Up Ring 5 O Ring Kit Section 1 Per Section MERE HE NEZ i CEN P22 COMMERCIAL INTERTECH VALVE Stabilizer 9 M9625 11 Rev 6 99 FOR MODELS ALL 4 98 Part Description Hydraulic Valve Assembly 2 Spool Inlet Section AA880 4 Way Section Free Flow MA7 4 Way Section Cylinder Outlet Section CY80080 ou 21 Inlet Section AA880 4 Way Section Free Flow 4 Way Section Cylinder Outlet Section CY80080 eu pu 23 GRESEN VALVE PARTS Die Ba LH Th al Ne S 9625 54 FOR MODELS V42 VALVE w o LOCKOUT Item Part Description 2 Spool Direct Control Valve
11. Hose Assembly 60 24 3988 1 2 x 277 Hose Assembly Check pump ports before ordering P9 HYDRAULIC WINCH WITH STABILIZER LIFT CYLINDERS IE 288 C CE GD T 88 SEE 5996 6 6999 233 9 P10 5 a 3 77377 7 2 RR a BOOM CYLINDER 01000 PPPA M9625 63 REV WINCH HYDRAULICS FOR MODELS KP625 KP630 SERIAL 1015 amp HIGHER 2 03 82 299 Tube Hose Clamp E XN 62 118 3 8NC x 2 1 2 GD5 Cap Screw 63 134 3 8NC Nylon Top Lock Nut 3 8 STD Flat Washer e Hydraulic Tube Assembly 187 Long 6 25 300 3 4 M O Ring to 3 4 M JIC Hydraulic Fitting 7 25 301 3 4 to 3 4 O 902 Hydraulic Fitting 7 8 25 2394 Minch Control 25 604 1 1 4 M JIC to 3 4 M Hydraulic Fitting 24 388H 1 2 x 51 3 4 Black 2W Hose Assembly Hd Roller Fairhead for 10 Drum Tensioner Wire Rope Kit 10 Drum Cable w Hook M12 x 1 3 4 x 45mm x 8 7 8 Cap Screw 1 5 8 M O Ring to 1 1 4 F NPT x 90 Hydraulic Fitting Nipple 1 1 4 x 6 Galvanized Pipe Assembly 1 1 4 F NPT to 1 1 4 Hose End x 90 Hydraulic Fitting 1 5 16 x 2 1 4 Hose Clamp Low Pressure Hose 1 1 4 Cut to Fit 12 000 Ib Winch 1 5 16 M O Rng to 1 5 16
12. back up the truck until the hook jaw engages the A Frame bar Stop the vehicle set the brake and engage the P T O If truck is equipped with stabilizer option activate stabilizer extending roller to ground stabilizing back end of truck M9625 29 O3 E Push the rotation control forward to move the Rotation Boom forward until the bottom of the rack or container is approximately 10 inches above the guide rollers at the back of the truck The operator may be required to release the brake so that the truck can be steered until the guide rollers align with the sills of the rack or container Operator be aware when using stabilizer It may be better to drag a container on some terrain If the sills on the bottom of the rack or container are not in line with the guide rollers and the truck the operator must reposition 72 xd 4 G When the sills and rollers line up continue to activate the control to move the rack or container onto the hoist sub frame By releasing the brake and allowing the truck to roll back under the load dragging the rear end of the rack or container along the ground can be minimized H Continue the loading procedure until the rack or container is off the 10 ground and re apply the CM brake to eliminate further movement of the a i CN truck m aes 3 M9625 30 The Rotation Control should be activated until the boom 15 com
13. 3 Pin Retaining Ring 2 6 79 492 ____ RedLightw GrommetandPlug 2 2 Sealed Light Red 5 __ 27 LIGHTED REAR BUMPER HUTCHINSON KANSAS HUTCHINSON KANSAS 2 47 Part Description Mud Flap 3 8NC x 1 GD5 Cap Screw 3 8NC Nylon Top Lock Nut proe UU P28 PINTLE HITCH Em i A HUTCHINSON KANSAS HUTCHINSON KANSAS Torque to 250 Ft Lbs Rev 7 04 42 FOR MODELS KP625 KP630 10 98 Hitch Mounting Weldment 5 63 289 S ANF HexFlangeLockNut 6 62 757 3 4 x2 1 2 CapScrew 6 P29 MISCELLANEOUS ELECTRICAL PARTS TRUCK CAB HOIST UP LIGHT POWER PTO LIGHT 992926 PTO GROUND SOLENOID VALVE PUR DIN CONNECTOR gt e GROUND 6 TO FRAME REV 10 02 SSS 9716 41 FOR MODELS KP625 KP630 2 03 Part Number Part Description 79 269 Hoist Up Light 9716 0 30 Bracket Safety Switch 79 248 Remote Switch 62 422 1 4 x 1 1 2 GD5 Cap Scre 63 141 1 4NC Hex Flange Serrated Nut Din Plug 79 563 Solenoid Valve 40 GPM 1 2V Relay 30 Amp 79 565 12V Relay Connector w Wire _______ CO P30 GROUND WHITE WIRES TO BUMPER MID BODY CLEARANCE 2 BEEHIVE LIGHT WIRING HARNESS SUPPLIED EXISTING TRUCK WIRING
14. 74 600 607 74 800 607 QUTSIDE EDGE OF HYD CYL LEFT SIDE OUTSIDE EDGE 84 ON RIGHT SIDE CYL a BOTH 74 601 4 12 WHITE REFL INSTALL AS SHOWN REFLECTIVE TAPE LOCATIONS AND LENGTHS ARE FOR REFERENCE YOUR REFLECTIVE TAPE LOCATION MAY DIFFER DUE TO EQUIPMENT OPTIONS REFLECTIVE TAPE TO COVER TRUCK CHASSIS OR HOIST FRAME PER ANSI STANDARD 2245 1 1999 REV 7 04 MS625 65 A29 This page intentionally left blank A30
15. SS ES SADDLE WELDMENT VERTICAL MOUNTING TUBE 1 4 WELDS 1 4 WELD BOTH SIDES BOTH ENDS BOTH ENDS SADDLE MOUNTING PLATE BULKHEAD PLATE CAN BE MOUNTED HORIZONTAL OR VERTICAL ET SADDLE RT SADDLE WELDMENT WELDMENT 1 4 WELD 1 4 WELD BOTHSIDES VERTICAL ALL AROUND MOUNTING TUBE 1 4 WELD ALL AROUND HORIZONTAL VIEW MOUNTING TUBE Rev 11 02 9625 23 A8 SAFETY LATCH INSTALLATION 3 8 WELD BOTH SIDES DO NOT WELD FRAME FLANGE LATCH PLATE 9525 0 24 PIVOT SPACER PLATE TRUCK FRAME SEE PAGE A6 50 00 REF NOTE WHEN PIVOT IS IN UNLOCKED POSITION IT MUST CLEAR LATCH BAR REF AS SHOWN WHEN HOIST 18 IN ATTACH LATCH PLATE TO PIVOT SPACER PLATE MOUNT MUST WITHSTAND DOWN POSITION PIVOT SHOULD MOVE FREELY LOAD OF 1500 LBS IN ALL DIRECTIONS ARQUND LATCH BAR IT SHOULD NOT TOUCH IMPORTANT Safety Latch Plate must be installed correctly per the following instructions 1 Retract inner boom completely to position latch in load unload mode to determine latch clearance with any nearby cross members Extend inner boom to position latch in unlatched mode for forward clearance 2 f mounting spacer plate is located under pivot of outer boom adjust latch plate to dimension before welding to pivot spacer plate DO NOT WELD TO TRUCK FRAME FLANGE 3 The latch plate must be welded secure enough to withstand at least
16. mo aw e 2 e 32 9625 0 13 P15 STABILIZER ASSEMBLY FOR MODELS 1 2NC 1 805 Cap Screw 2 64 107 1 2 STD Lock Washer 3 9625 820 0 Stabilizer Shaft Weldment aa Hydraulic Cylinder See HYDRAULICS s ems zerk 6 9625 815 0 Stabilizer Roller Weldment Rod End Pin 8 9625 850 0A Stabilizer Weldment 9 9625 08 1 Head End Pin 99 188 2 Retaining Pin E P16 MS625 3 Rev 7 98 KP625 LIFT CYLINDER ASSEMBLY 23 710 6 1 2 x 87 Hydraulic Cylinder Assembly LIFT 2 03 Retracted 106 Extended 193 Stroke 87 Rod Dia 3 1 2 Part Number ay 1 1 3 2 2 25 2432 2 2 21 40 169 22 99 220 Retaining Ring 23 811 Seal Kit x Items Included in Kit Green Hydraulics 23 900 Seal Kit Items Included in Kit Texas Hydraulics 1 17 18 9 A 5 o l 0 OF gt 3 17 BOOM CYLINDER ASSEMBLY 23 712 4 x62 Hydraulic Cylinder Assembly EXTEND 2 01 Retracted 78 Extended 140 Stroke Rod Dia 2 1 2 Da ae o O Ring Back Up Washer Retaining Ring 7 Bleeder Plug 38 Spacer 23 814
17. 3 Spool Direct Control Valve Inlet Cover Relief Valve Reset to 2800 PSI Motor Section Cylinder Section Standard Outlet Gresen Outlet Power beyond O Ring Large O Ring Small 3 8NC x 5 1 2 GD5 Cap Screw for 2 Spool Valve 3 8 STD Lock Washer 3 8NC x 8 Stud Bolt for 3 Spool Valve 3 8NC Hex Nut Relief Valve Seal Kit Mem 4 122621 9 anl Po P24 WINCH VALVE PARTS 6 99 Oy M9625 55 Part Description Relief Valve Assembly 82 296 Standard Lever 82 297 Standard Safety Lever Part Number 2481 25 gt lt o o e 1 LO FOR MODELS P25 12 0002 WINCH 9 4 USE BOLTS AND WASHERS SUPPLIES WITH WINCH 4 EA 12 1 75 45 8 cual SS HUTCHINSON KANSAS 579 HUTCHINSON KANSAS Rev 7 04 M9625 69 FOR MODELS KP625 KP630 2 03 Part Description Qty Winch Plate Bolt On 12 0004 Winch 30 286 Series 82 252 64 108 Ooo EE Oy 8 NE Due to the winch close proximity to Back Plate Tensioner may have to be installed in different location P26 FOLDING BUMPER HUTCHINSON KANSAS Rev 7 04 25 41 FOR MODELS KP625 KP630 2 99 Part Description 9625 21 0 Connection Weldment 9625 20 0 Lighted Bumper Weldment 3 9625 19
18. 64 170 10 External Tooth Lock Washer 4 EI Compression Fitting 63 151 10 Hex Nut 4 5 Pressure Protection Valve 82 125 Compresion Fitting 1 8NPT M 82 167 T ANPT Hex Nipple 1 4 Straight Tube 27 2 Spool Valve Assembly 82 166 1 4 Tube Union Tee Compression 3 Spod Valve Assembly Fitting 82 316 Pneumatic Actuator Assembly 14 9274 196 2 ion Fitti 14 80 195 Compression Fitting 1 8NPT M ES Cap Used when not equipped to 1 4 Tube Straight 15 9274 196 4 1 18 9274 196 4 with 3 Section x For 3rd Section Only P37 VIEW THROUGH REAR WINDOW OF CAB INSIDE OF CAB NEXT TO CONTROLS FOR MODELS KP625 KP630 74 482 2 74 485 Decal Decal Decal Decal Decal Decal Decal 8 74 606 6 74 276 EA 74 495 9 74 300 pp prp APPLY AT EYE LEVEL ON CAB 6 ON TOP OF TANK Ae oem EN Loe ee MO Gu Decal Decal Decal Decal Decal Decal Reflective Tape Red White Reflective Tape White Decal DECALS 8 2 140 PESE ma Rev 7 04 9625 9 7 04 Part Description CAUTION Inner Boom DANGER Powerlines Trademark DANGER Hook Height Must Match CAUTION Proper Training WARNING High Pressure K PAC 50 000 Lbs 60 000 Lbs Stand Clear IMPORTANT Operation Instructions WARNI
19. Large Steel Tool Box Right Tank Strap Weldment 5 8NC x 2 1 2 GD 8 Cap Screw 5 8NC Lock Nut 6 64 10 15 8 STD Flat Washer ALUMINUM TOOL BOX FOR MODELS KP625 KP630 Part Description 82 248 Left and Right Hand Mounting Brackets 82 276 Large Aluminum Tool Box 62 708 5 8NC x 2 1 2 GD8 Cap Screw 63 110 5 8NC Lock Nut 64 110 5 8 STD Flat Washer P2 TOOL BOX ASSEMBLY FOR MODELS ALL 6 94 _ Part Description Tool Box amp Platform Assembly Tool Box Weldment 1 2NC x 1 3 4 Carriage Bolt Hinge Strap Wear Sleeve 1 2 STD Flat Washer 6 63 17 7 1 2 Self Locking Nut 7 75405 PesicPhg 5 442 1 17 Round Head Square Neck Bot 9 8857 Fiat Washer P3 HYDRAULICS 60 GALLON TANK FOR MODELS KP625 KP630 SERIAL 1049 amp HIGHER 2 01 1 1 16 M JIC to 1 1 16 F Swivel 45 Hydraulic Fitting 1 1 16 M O Ring to 1 1 16 M JIC Hyaraulic Fitting 4 x 62 D A Hydraulic Cylinder 4 23 710 6 1 2 x87 D A Hydraulic Cylinder Model 25 2 28 711 7 x87 D A Hydraulic Cylinder Model KP630 2 7 8 M O Ring to 1 1 16 M JIC 90 Hydraulic Fitting 2 6 82 308 3 4 x 62 1 1 16JIC x 90 Hose Ass
20. bottom of tank assembly and the ground 1 Locate SUPPORT WELDMENT 9274 59 0A next to saddle weldment as close as possible with top of support weldment flush with top of frame Drill 6 holes for 5 x 2 1 2 Cap Screws and Lock Nuts Locate SUPPORT WELDMENT on opposite side so that bushings line up Install pipes 9274 45 1 Locate hydraulic tank assembly per dimension shown Secure hydraulic tank and tool box if ordered to pipes with 1 2NC x 1 Socket Head Cap Screws in bushings Install fittings and hoses see page P4 HYDRAULICS for schematic of parts Route hoses to clear sharp obstructions and to protect from wear Be sure to install hoses on the proper valve bank Because each valve section performs a specific operation the routing of the hose from the lift cylinders to the bulkhead tees must be done carefully Make sure that hoses are not twisted and have adequate flexibility during operation A11 OPTIONAL HYDRAULIC TANK MOUNTING INSTRUCTIONS REF CUT OFF SUPPORT WELDMENT a HEAD PLATE 1 4 WELD 1 4 WELD ALL AROUND ALLOW ADEQUATE CLEARANCE FOR CAB OR FUEL TANK BEFORE WELDING ON CUT OFF SUPPORTS WELDMENTS CLEAN ALL HYDRAULIC COMPONENTS AND KEEP ALL HOSES TUBES VALVES AND FITTINGS CAPPED UNITILL THEY ARE TO BE INSTALLED
21. 1500 Ibs of force in any direction Material and parts supplied may require modification for proper fit up on various truck chassis REV 1 03 MS625 44 A9 RAMP MOUNTING INSTRUCTIONS WELD TUBES TO SADDLE TOP PLATE WELD END PLATE TO TUBES WELD RAMP TO CROSS REIN PLATE WELD RAMP AND SPACER TO TUBES Cn om gt 7 CROSS TUBE MS625 57 A10 60 GAL HYDRAULIC TANK INSTALLATION Rev 2 03 M9625 24A Clean all hydraulic components and keep all hoses tubes valves and fittings capped until they are to be installed BE SURE TO READ THE SAFETY INFORMATION THAT FOLLOWS Warning Escaping fluid under pressure can penetrate the skin causing serious injury 4 Avoid the hazard by relieving pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result IMPORTANT When mounting hydraulic tank watch clearance on top of filter If more room is desired lower the tank accordingly Check for adequate clearance between
22. 9274 115 9 to guide plate Adjust center fender bracket 8274 115 10 before welding to tube 5 Match drill fenders and attach to brackets with bolts Locknuts flatwashers and M9625 76 A14 REAR STABILIZER INSTALLATION RETAINING RING REAR TAIL WELOMENT HEAD END 1 2NC x 1 GDS CAP SCREW PIN 1 2 STD LOCK WASHER NOTE GREASE 4 x 12 1 2 HYD CYLINDER STABILIZER WELDMENT meee END PIN STABILIZER SHAFT WELDMENT STABILIZER ROLLER WELDMENT 1 Slide STABILIZER WELDMENT into REAR PIVOT WELDMENT Install STABILIZER CYLINDER using HEAD END PIN and ROD END PIN with 2 RETAINER RING to hold pins in place 2 Install STABILIZER ROLLER WELDMENT using STABILIZER SHAFT WELDMENT and 1 2NC x 1 Cap Screw Lock Washers 3 Install hydraulic components using parts shown on pages 4 5 4 Install all hoses along inside of truck frame Secure hoses on inside of truck frame IMPORTANT INSTALL STABILIZER INTO REAR TAIL WELDMENT BEFORE MOUNTING ONTO TRUCK Rev 6 02 MS625 40 A15 Attach clamp to hose and bolt to welded base Weld Clamp Mounting Base here approx location A WARNING Before working on around a raised hoist the hoist must be supported by a hoist prop or a rigid structure strong enough to prevent hoist from falling Failure to use proper support could result in serious injury or death y Loop hoses as shown
23. CA This page intentionally left blank or SAFETY FIRST Read and understand this operator s manual before operating the hoist Be sure safety decals are clean and in place Never position yourself or any other person under any raised portion of the hoist unless the hoist is firmly resting on blocks Never operate this unit unless the hydraulic system including the cylinders and lines are full of oil and free of air Warning Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Check the area for power lines and overhead obstructions Be sure the area and container are clear of personnel Do not load dump or unload a container on uneven ground Do not move the truck while the hoist and container are raised A raised load creates a top heavy unstable load Do not use any method to hold a valve open which will not let the valve automatically close when released Check the pivot bushing and slide pads for excessive wear Check all snap rings and shaft securing
24. End Hydraulic Fitting 1 1 1 4 x 94 10084 Hose Ld 16 25 487 1 516 2 1 4 Hose 4 25 343 1 5 8 M O Ring to 1 1 4 Hose End x 90 Hydraulic Fitting 1 1 A a 25 170 1 1 4 to 1 1 4 Hose 90 Fitting 4 75 161 1 1 4NPT Square Head Black Pipe Plug 23 713 4 x 12 1 2 D A Cylinder ax 12 12 DA Cylinder T 1 4 M NPT to 1 1 4 F NPT x 90 Hydraulic Fitting 21 25 233 25 2430 SewceElemnt 1 25 235 ight Gauge w Temperature 5 24 198 1 1 4 x 30 100R4 Hose 1 1 5 8 O Ring to 1 1 4 F NPT x 90 Hydraulic Fitting 1 1 4 F NPT to 1 1 4 Hose End x 90 Hydraulic Fitting 1 5 8 M O Ring to 1 5 16 M JIC 90 Hydraulic Fitting 25 602 7 1 1 4 M to 1 5 16 M 90 Hydraulic Fitting 1 5 16 M O Ring to 1 5 16 M JIC Hydraulic Fitting 1 5 16 M O Ring to 1 1 16 M JIC Hydraulic Fitting 1 1 16 O Ring to 1 1 16 F JIC Swivel 90 Hydraulic Fitting 3 4 x 62 1 1 16 M F Black 3000 PSI Hose Assembly 37 1 1 1 16 M O Ring to 1 1 16 M JIC Hyaraulic Fitting 1 3 4 x 60 1 1 16 JIC Black 3000 PSI Hose Assembly Hydraulic Tube Assembly 187 Long 2104 3 4 37 1 1 16 Black Hose Assembly 25 2462 Hydraulic Valve Assembly 3 Spoo Nipple 1 1 4 x 6 Galvanized Pipe Assembly x 2 1 2 GD5 Cap Screw eck pump ports before ordering P7
25. HARNESS LH TURN BRAKE LIGHT RH TURN BRAKE LIGHT TAIL CLEARANCE LIGHT BACK UP LIGHT SD IHNEN 30 WIRING HARNESS JUNCTION BOX OPTIONAL LON 30 WIRING HARNESS 2 BEEHIVE LIGHT MID BODY CLEARANCE PTO GROUND L SOLENOID VALVE GROUND GROUND DIN CONNECTOR 19 FRAME SOLENOID VALVE 715 42 8 12 2002 POWER RED W BLACK STRIP RED WITH YELLOW STRIP YELLOW P31 RED CLEARANCE AND GROUND RH LIGHT AND GROUND RED STOP LIGHT AND GROUND BACK UP LIGHT WHITE AND GROUND WHITE TAG LIGHT AND GROUND RED CLEARANCE AND GROUND RED CLEARANCE AND GROUND RED CLEARANCE AND GROUND BACK UP ALARM BACK UP LIGHTCWHITE AND GROUND RED STOP LIGHT AND GROUND LH LIGHT AND GROUND RED CLEARANCE AND GROUND RELAY ROUNDBROUND TO FRAME FRAME Rev 10 02 715 37 TANDEM STEEL FENDERS 15 10 FOR MODELS 25 KP630 REPAIRS 7 97 Part Description Mounting Kit Includes x Items 4 0 5 16 x 3 Carriage Bolt x Left Angle Bracket x 1 2 5 fRihntBract 24 6 7 16 7 2 2 16 P32 TANDEM STEEL HEAVY DUTY K PAC FENDERS MS625 53 FOR MODELS KP625 KP6
26. HITCH INSTALLATION FOLDING BUMPER INSTALLATION INSIDE CONTROL HANDLE INSTALLATION PNEUMATIC CONTROL INSTALLATION SOLENOID VALVE CONNECTION SINGLE ROLLER ASSEMBLY DOUBLE ROLLER WELD INSTRUCTIONS DOUBLE ROLLER ASSEMBLY REFLECTIVE TAPE INSTALLATION Rev 6 02 P25 P26 P27 P28 P29 P30 P31 P32 P33 P34 P35 P36 A1 A2 A2 A2 A3 A5 A6 7 A9 A10 A11 A12 A13 A14 A15 A16 A17 A17 A18 A21 A22 A23 A24 A25 SAFE Y DECALS See parts listing page for part number and proper location A WARNING CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving The Jaskot o the hase appears abnormal DO NOT EXCEED 1600 ENGINE There is any Mud RPM WHEN OPERATING pressure before disconnecting hydraulic lines Tighten alt connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor The couplings are damaged The hose is damaged or kinked immediately Any fluid injected into The reiaforcement is visible through the jacket POWER TAKE OFF the skin must be surgically removed within a few hours or gangrene may result 74 276 i DANGER DANGER DANGER 74 299
27. Hydraulic Fitting 1 5 8 M O Ring to 1 5 16 M Hydraulic Fitting 1 x 37 1 5 16JIC 3000 PSI Black Hose Assembly 25 419 1 5 16 M F JIC Swivel Tee Hydraulic Fitting 1 1 16 M JIC to 1 5 16 F JIC Swivel 90 Hydraulic Fitting 3 4 x 37 1 1 16 Black Hose Assembly 1 1 16 M O Ring to 1 1 16 M JIC x 90 Hydraulic Fitting 28 Priority Flow Divider Cartridge 1 5 16 M O Ring to 1 5 16 M JIC Hyaraulic Fitting Priority Flow Divider Body 1 5 16 M O Ring to RID JIC 90 Hydraulic Fitting 1 32 25 2463 Power Beyond Outlet Cover Grese 1 55 725 2800 Inlet Cover Gresen 1 8 6 Ss Cm for power 3 4 M to 7 8 M O Ring x 90 Hydraulic Fitting JAM JIC to Swivel x 90 Hydraulic Fitting 1 2 x 68 90 Black Hose Assembly 3 4 x 70 1 1 16 M F Black Hose Assembly P11 INNER OUTER BOOM ASSEMBLY FOR MODELS 4 00 8 99 204 2 internal Retaining 2 4 9625 00 14 Extension OylinderRod 5 sft 62768 iENCxS HexFengeCapSuew z o 63 146 1 2NC Hex Flange Serrated Nt 2 7 63 64 Nylon Top LockNut O Je 1 4NC x 1 1 2 Flat Countersunk Head Cap Screw 22 62769 SNCxT HexFlngeSenstedBot e 1 2 STD Flat Washer 2 s3esars mem Sw P13 1 7
28. a 5 16 hex allen wrench and a screw driver on the handle end of the spool remove the socket head cap screw retaining the stop collar and spring NOTE may be necessary to give the allen wrench a sharp to break the socket head screw loose Discard the spring socket head screw and TWO spring collars 5 POSITIONER CAP BONNET SCREW Installing the Airshift Operator 1 2 gt e9 Install the original O Ring Item C the back up ring Item D and the new retaining plate Item 1 on the cap end of the spool Slide of the spring guides Item 3 VA35 of Item 20 the stop tube Item 4 spring Item 2 and the other spring guide Item 3 5 or 3B VA20 Note that has holes on the stripper bolt Apply 2 or 3 drops of Loctite RC680 about halfway down the threaded hole in the spool Screw the stripper bolt Item 5 into the spool and torque to 180 in Ibs Carefully slide the spool back into the housing from the cap end Lubricate all seals with Parker Super O Ring Lube or equivalent Place the spacer tube Item 6 into the recess in the retainer plate Item 1 Be sure the drain hole is down Pull on the piston rod Item 19 until you feel it bottom out on the flange Item 14 Slide the spacer tube Item 7 on the end of the piston rod Insert the end of the piston rod into the slot in the stripper bolt Install the retainer plate Item 8 over the seal retainer Item 15 Apply 2 or 3 drops
29. between the PTO housing and the lock tabs M9305 42 Tighten the top and bottom nuts to 30 30 Lbs Ft of torque Check the backlash on the input gear gear the meshes with transmission gear by feeling through the inspection hole previously uncovered in step 7 above The amount of rotational movement of the PTO gear should be only 006 to 012 reference a thin gasket in your installation kit is 010 thick The thin gasket 010 thick will change the backlash approximately 006 The amount of movement of the input gear would be only about the same distance as this gasket thickness At least one gasket must be used On Allison transmissions only the single 035 gasket will be required 006 012 BACKLASH NOTICE For some Warner W80 applications a maximum of one thin gasket 010 is required If backlash is too excessive remove the gasket and use loctite gasket eliminator sealant 13M51717 20 ounce tube has been provided with the PTO for these applications Do NOT stack more than 4 gaskets together Finish the mounting by installing all the cap screws or stud nuts provided in the mounting kit Torque all mounting bolts to the required torque as specified in step 6 above Replace shifter cover or inspection cover plate on the PTO Run the truck engine with transmission and PTO in neutral for a few seconds and listen for unnatural noises A whine noise indicates the PTO is mounted too tig
30. bolts to be sure they are tight OPERATING INSTRUCTIONS K PAC WARRANTY INFORMATION Congratulations on the purchase of the KP625 630 Hook Hoist Krause Corporation takes pride in engineering and manufacturing products which are of the finest quality and highest standard As a result we stand behind any K PAC Equipment product or component claimed to be defective during the warranty period To avoid delays with the service process please read the warranty instructions in the first section of this manual at the time of the vehicle purchase and complete and return the supplied warranty card HOOK HOIST CHECK LIST A B C D E Check hydraulic oil level with all cylinders retracted Grease all lubrication points ____ Rollers are free to rotate Tires are properly inflated The container hook lock is free to move and works properly O1 K PAC Equipment Division of GENERAL GUIDELINES FOR OPERATION OF HOIST LOADING A CONTAINER OR FLAT RACK Caution which the hoist is to be operated is level clear of personnel as well as obstacles overhead and the ground Operating on a unlevel surface could cause damage to the load or hoist equipment Note Before loading the flat rack or container onto the hoist inspect the load to ensure that the materials to be transported are securely fastened to the tie downs and that all fasteners are in good condition Inspect the flat rack o
31. of Loctite 262 inside the tapped holes in the housing Put the washers Item 9 on the 1 1 4 cap screws Item 10 Push the cap screws through the retaining plate and screw them into the valve housing Be sure all parts are properly aligned and seated Torque the cap screws to 25 30 in Ibs This completes the conversion A22 SPECIFICATIONS Pilot Pressure 100 psi minimum 150 psi maximum 30 psi nominal shift pressure required to start spool movement 1 8 NPT Pilot Ports Spool D eii NEC 1 LS o Uu Eure Assembly Notes amp 20 0 0 LESSE ss Zo Em octite LZ a b RUM en Loctite 262 SS WS i eure Cr aA V i Al SS SS orque to 25 30 in Ibs AN 2 Nome 75in Ibs Torque to 180 in Ibs 2 Back up Ring GB N G9 WV W lt Drain Hole 9 6 1 SpacorTw 8 1 Retainer Plate 9 2 Pneumatic Controller Installation In Dash If the controllers are to be mounted in the cab dash an area 3 25 high and 1 38 wide for the single unit must be clear of any obstruction to a depth of 3 50 behind the panel The joystick requires an area 3 38 high 3 38 wide and 3 5 deep Pneumatic Controller Installation Tower 1 Determine a suitable location which is in a comfortabl
32. of the air line and connect each controller port to corresponding actuator port 2 Attach the supply and exhaust lines as shown 82 316 To remove an air line Push the line in hold the internal sleeve and pull the air line out of the fitting ze JOYSTICK 3 Attach the airlines to SN 99 the valve actuators in the same manner P T O SWITCH p Supply air line connection B 1 Run air line between the supply port of the T controllers and the outlet port of the P T O air 82 125 1 Switch F 2 Route the exhaust port line out of the cab Start up Procedure P T O E 1 Charge the air system of the truck and check all En lines for leakage T 2 Operate the controllers and check for correct hydraulic valve movement 7 NOTE The controllers pressurize the port toward which the handle is moved If the function is to be AIR SUPPLY reversed exchange the air lines at the controller or actuator 3 After the correct connections have been made and the hoist has been completely installed engage the P T O to check out the operation of the hoist A24 INNER BOOM HYDRAULIC INTERLOCK INSTALLATION 1 5 0 MIN Position the switch mounting plate 9716 0 30 on main frame as shown IMPORTANT The switch MUST BE positioned UNDER the tilt frame If the switch is positioned under the boom the boom will not retr
33. 1 1 2 Cap Screws and Lock Washers Center hoist on truck frame with REAR PIVOT WELDMENT set against REAR MOUNTING PLATES Weld REAR PIVOT WELDMENT to REAR MOUNTING PLATES using 3 8 weld continuous To locate SADDLE WELDMENTS use lift cylinders Install lift cylinder to outer boom and to saddles using SPECIAL BOLT RETAINER and Lock Washers see page P14 P15 IMPORTANT CYLINDER MUST BE FULLY RETRACTED BEFORE DRILLING HOLES Clamp saddle weldments to outside and top of truck frame Match drill holes for 5 8NC x 2 Cap Screws and 5 8NC Hex Flange Lock Nuts Locating of VERTICAL MOUNTING TUBES and HORIZONTAL MOUNTING TUBE weld vertical mounting tube approximately centered on bottom plates of saddles Before welding make sure there are no obstructions between the LEFT and RIGHT SADDLES see page A8 Install HORIZONTAL MOUNTING TUBE between VERTICAL MOUNTING TUBES ALL WELDS TO BE 1 4 Install SADDLE MOUNTING PLATE on top of SADDLE WELDMENTS and weld with 1 4 welds Locate BULKHEAD PLATE on HORIZONTAL MOUNTING TUBE as close to center of the tube as possible See illustration on page A8 A7 LEFT SADDLE WELDMENT RIGHT SADDLE WELDMENT BULKHEAD PLATE HORIZONTAL VERTICAL 9625 00 26 MOUNTING TUBE MOUNTING TUBE 4 9525 00 23 9625 00 22 DRILL FOR 5 8 DIA BOLTS BOTHSIDES SADDLE MOUNTING PLATE 9625 00 16 eui 5 CYLINDER A
34. 30 4 02 Part Description Fender Weldment 2 1 2NC x 1 1 2 Square Head Cone Point Set Screw 2 Front Fender Tube Weldment 2 Front Fender Mounting Tube 2 5 _ 9274 50 5 EndCapFrnt _ 2 9625 0 7 RearFenderMouning Tibe 2 EE E 7 9274 50 66 EndCapRer 2 9274 0 3501 Gusset 2 P33 PLASTIC TANDEM FENDERS MS625 77 FOR MODELS KP625 KP630 2 03 Part Description 9274 0 3501 Gusset 2 9625 0 26 Front Tube Support 24 3 8NC x 1 1 2 GD5 Cap Screw 24 24 3 8 STD Flat Washer 24 11 5 7 0 2 9274 115 9 Center Tube Fender Support 3 9274 115 10 Center Fender Support pe SOS 2 2 2 2 2 2 2 24 24 2 2 E 2 9274 115 b FendeBrace RH 2 2 2 3235 P34 COMMERCIAL INTERTECH REMOTE VALVE amp CONTROLS FOR MODELS 2 SPOOL VALVE REPAIRS Part Description Controller Tower Cable 72 82 282 Remote Valve Control Connection Kit 3 ANC Hex Nut 1 4NC Hex Nut Cotter Pin 1 8NF x 1 Socket Head Cap Screw Collar Tube x Items included in Remote Valve Control Connection Kit P35 MS606 6 3 97 7 98 1 1 1 25 2405 Commercial Intertech VA20 2 Spool Valve 1 1 8 STD Flat Washer 2 1 8 STD Lock Washer 2 Connec
35. BE CAREFUL BE ALERT USE GOOD JUDGEMENT A DANGER LOCK BAR MUST FULLY ENGAGED TO DUMP CONTAINER WARNING 00 NOT LOAD UNLOAD OR DUMP A CONTAINER ON UNEVEN GROUND A LOADED CONTAINER CREATES A TOP HEAVY LOAD USE CAUTION WHEN DRIVING ON UNEVEN GROUND AND TURNING CORNERS SERIOUS PERSONAL INJURY AND EQUIPMENT DAMAGE COULD RESULT 74 510 74 297 ENGAGED OR PARTIALLY ENGAGED SPECIFICATIONS REV 11 02 ume D SEND RET AD CT NR 25 14 Chassis 176 See page A1 A2 Weight 6 000 Ibs Frame Width 34 Outside reinforcement thickness Hydraulic Planetary 6 ton 75 of 7 16 cable w hook level Min G V W R 52 0005 wind feature Sta Frame Height To 42 top of chassis unladen 6 5 x 87 KP625 Sub Frame Full length 5 x 7 tube 74 x 87 KP630 Load Rating With suitable G V W R including body Boom Cylinder 4 x 62 Stabilizer weight Oylinder 4 x 12 5 50 000 Ibs KP625 60 000 Ibs KP630 Dump Angle 50 with suitable body length Operating Pressure 2 800 PSI Gear Pump 40 gpm 1600 1800 rpm direct mount STD Cylinders Twin double acting cylinder Low Pressure S A E Hydraulic System Gear driven hydraulic pump Nylatron pads in boom Sliding L arm 2 full sub frame locks Operation In cab controls standard Hook Height 62 176
36. IGHT W GROMMET amp PLUG PIN RETAINING RING 1 4 ALL AROUND LUGS HUTCHINSON KANSAS 2 SEALED LIGHT RED 2 FLUSH MOUNTING GROMMET amp PLUG M9606 26 BANK MOUNTED AND THROUGH BOLTED AS SHOWN IN ILLUSTRATION ON PAGE P35 2 Out out a hole for the control cables and drill four 4 7 16 DIA mounting holes 3 Mount the control handle and brackets as shown in parts drawing on page P35 Be sure that control handle movement corresponds with the direction decal as shown on page O2 A19 WINCH MOUNTING PLATE INSTRUCTIONS TUBE HOSE ROUTING ANGLE WINCH COVER WINCH MOUNTING PLATE 9625 0 1 0 0 ca ANGLE WINCH COVER WINCH MOUNTING PLATE 1 4 WELD WELD ALL AROUND 1 If hoist has a light bar across rear tail unit move light bar down to allow winch mounting plate to be installed 2 Install winch mounting plate and angle winch cover as indicated relocate light bar move wire connector if needed 3 Locate where winch would sit on mounting plate establish approximately where hydraulic lines will need to pass through rear tail plate 4 Cut out a rectangular hole in rear tail plate to allow a 3 x 1 1 2 tube to be welded in place Bevel both sides of tubing to protect hoses from damage 5 Hoses and hydraulic fittings to be installed on winch before mounting winch to plate See pages P10 amp P11 MS625 70 A20
37. NG Uneven Ground DANGER Engage Lock Bar NOT SHOWN NOT SHOWN Hook Patent gt a 2 2 cg mimi oi mi 2o o mi2 x Specify exact quantity needed See page A for suggested locations on truck frame P38 HYDRAULIC SCHEMATIC WINCH VALVE L STABILIZER CYLINDER CONTROL VALVE SOLENOID E UO IE AME 2 LI EXTENSION EXTENSION CYLINDER This page intentionally left blank 40 KP625 KP630 HOIST MOUNTING INSTRUCTIONS Study the names and locations of the parts and familiarize yourself with the hook hoist before starting the installation Reading the step by step instructions that follow will be helpful SAFETY Read all of the Safety Notations in the following instructions for your own protection Accidents can be prevented by recognizing the cause of an accident before it can happen ASSEMBLY Select an area for installation that will be large enough to accommodate the completed unit The surface of the work area should be as level as possible Use the proper hand tools to insure proper bolt tightness Refer to the chart below for the recommended torque values for different sizes of bolts Proper Bolt Use DO not use these values if a different torque value or tightening procedure is given for a specific application Torque values listed are for general use only Check tightness of fasteners periodical
38. NSTALLATION PENDEN BARRE PLATE GUSSET neds he 9274 0 3501 3 X 3 X 20 U Ecce CENTER FENDER MOUNTING TUBE FENTER SPENDER SUPRORT 9274 115 8 FRONT TUBE SUPPORT 2 X 2 X 28 88 9825 0 26 3 8 X 3 8 X 30 plc B FENDER BRACE LEFT amp RIGHT 8274 1554 amp 5 FENDER BRACE CUTOFF 27 25 CLEARANCE FOR GUSSET HOLES TO OUTSIDE FENDER BRACE CUT OFF TO 28 5 HOLES TO OUTSIDE WELD ALL AROUND GUSSET AND FRONT TUBE SUPPORT TO GUIDE PLATE AND EXTENSION PLATE WELD ALL AROUND CENTER TUBE SUPPORT TO SPACER PLATE WELD ALL AROUND TUBE TO SIDE PLATE WELD FENDER BRACE TQ MOUNTING TUBE 4 LOC WELD EXTENSION PLATE 2525 0 27 TO GUIDE PLATE WELD END 9274 162 1 TO MOUNTING TUBE 2 1 Set FENDER above tire with top of fender Level with top of tilt frame tubes center fenders front and back over tires Locate and weld fender mounting tube 9625 0 8 to side plate of stabilizer Locate and weld front tube support 9625 0 26 to guide plate Locate SPACER PLATE 9625 0 6 and weld to bumper and mounting tube on fenders 2 Locate and weld END CAP 9274 50 65 on 3 sq tubes Locate and weld END CAP with hole 9274 162 1 on front tube support Weld fenders braces on mounting tubes four Locations 4 Locate and weld center tube fender MERE
39. ONS K PAC Warranty Information Hook Hoist Check List General Guidelines for Operation Loading A Container or Flat Rack Dumping A Container Unloading Flat Racks Bins or Container PARTS SECTION 30 TOOL BOX 48 TOOL BOX ALUMINUM TOOL BOX TOOL BOX ASSEMBLY HYDRAULICS 60 Gallon 5 1049 amp Higher HYDRAULICS 50 Gallon Ser1015 1048 HYDRAULICS Ser 1001 1015 WINCH HYDRAULICS Ser 1015 amp Higher INNER OUTER BOOM ASSEMBLY MAIN ASSEMBLY STABILIZER ASSEMBLY KP625 LIFT CYLINDER BOOM CYLNDER ASSEMBLY KP630 LIFT CYLINDER ASSEMBLY STABILIZER CYLINDER ASSEMBLY DIRECT MOUNT HYDRAULIC PUMP COMMERCIAL INT VALVE SECTION COMMERCIAL INTERTECH VALVE GRESEN VALVE PARTS a won O1 O1 O1 O1 02 02 05 05 P1 P2 P2 P3 P4 5 P6 7 P8 9 P10 11 P12 13 P14 15 P16 P17 P18 P19 P20 P21 P22 P23 P24 WINCH VALVE PARTS FOLDING BUMPER LIGHTED REAR BUMPER PINTLE HITCH TANDEM STEEL FENDERS HEAVY DUTY STEEL TANDEM FENDERS TANDEM POLY FENDERS REMOTE VALVE amp CONTROLS REMOTE CONTROLS AIR CONTROLLER DECALS HYDRAULIC SCHEMATIC INSTALLATION SECTION SAFETY INSTALLATION MODEL NUMBER TANDEM AXLE TRUCK CHASSIS POWER TAKE OFF INSTALLATION DIRECT MOUNTED PUMP INSTALLATION HOOK HOIST MOUNTING SAFETY LATCH BAR INSTALLATION RAMP MOUNTING INSTRUCTIONS 60 GAL HYDRAULIC TANK INSTALLATION STEEL FENDER INSTALLATION REAR STABILIZER INSTALLATION WIRING HARNESS INSTALLATION HYDRAULIC SYSTEM START UP PINTLE
40. Operation Installation amp Service Manual TRUCK MOUNTED HOOK HOISTS MODELS KP625 KP630 Congratulations You have just purchased a quality designed and manufactured K PAC Product Advanced features have been designed into all K PAC equipment for modern waste disposal operations As with any investment a return is expected and the return received from this investment will be in the form of maximum performance during many years of dependable service In order to maintain quality performance of the new K PAC investment it is important that all of the information in the manual be reviewed and studied carefully before operation The contents provide operating instructions installation instructions maintenance instructions parts information and information on how to make adjustments Itis suggested that owner operators read American National Standard Safety Requirements for refuse handling and hauling of collection and compaction equipment Copies may be purchased from the AMERICAN NATIONAL STANDARDS INSTITUTE 1430 BROADWAY NEW YORK NEW YORK 10018 Elimination of the hazards listed in this manual should not be construed as providing guarantees that the equipment will meet or exceed all standards or regulations or will be completely safe to all personnel The operator should inspect and review the equipment after it is in his possession for adequacy in safety for the function for which it will be used READ ALL THE SAFE
41. Rotation control to pivot the Rotation Boom away from the back of the truck until the load touches the ground Note If the rack or container does not have rollers the truck brake should be carefully released and the truck be allowed to roll forward use the foot brake to gain control of the forward movement leaving the rear end of the rack or container to pivot until it is in full contact with the ground RETRACTED HOOK ARM M9625 33 lt lt G Continue to pivot the rotation arm until the hook arm jaws can be disconnected from the A Frame connection bar t When the Hook Arm Jaws are clear of the Frame Connection Bar disen gethe P T O and after ensuring that the path is clear move the truck forward about three feet Re engage the P T O and parking brake and activate the control to pivot the Rotation Boom fully forward until it reaches its resting position J Activate the Hook Arm Control and extend the Hook Arm towards the truck cab O6 30 TOOL BOX STEEL TOOLBOX MOUNTS ARE WELDED TOOLBOX AND BOLTED TO FRAME 4 3 97 FOR MODELS KP625 KP630 4 98 4 __62 708 S 8NC x 2 1 2 GDBCapSeew 14 EL P1 48 TOOL BOX STEEL TOOLBOX MOUNTS ARE WELDED TOOLBOX AND BOLTED TO FRAME 3 98 FOR MODELS KP625 KP630 Part Description Left Tank Strap Weldment 2 82 277
42. S 9 25 22 HOOK HOIST MOUNTING INSTRUCTIONS NOTE RIGHT and LEFT sides can be established by standing behind the truck frame and looking towards the front or the direction of travel The KP625 KP630 Hook Hoist is designed to be mounted on a standard truck frame If there are unmovable obstructions on top of the truck frame you must add spacers to raise the hoist frame to clear or move the obstructions NOTE Check Safety Latch Bar installation pg 9 to determine if Safety Latch interferes with frame cross member See illustration for height clearance from hoist frame to bottom of Safety Latch Minor front to rear positioning may make Latch installation easier 1 10 11 12 13 Compare the Truck Chassis with the Hook Hoist ordered Compare the specification dimensions to determine how far forward on the chassis the Hoist can be mounted It is best to mount as far forward as possible for optimum weight distribution Suspension and fender to rear holdown are the main considerations If chassis is longer than recommended the chassis can be cut off shorter per difference The minimum would be determined by suspension components air pods etc NOTE If bolts pipe pipe fittings hydraulic fittings hoses etc are substituted for the hardware supplied with the hoist the installer must use parts of equal quality and service strength NOTE It may be necessary to relocate air tanks fuel tank battery cases
43. TY DECALS ON THE EQUIPMENT WATCH FOR THE SAFETY SYMBOL AND READ THE INFORMATION THIS IS FOR YOUR OWN PROTECTION Member of WASTEC KP625 KP630 HOOK HOIST DEALER PREDELIVERY CHECK SHEET TO BE CHECKED BY DEALER CUSTOMER DATE ADDRESS COUNTY DEALER ADDRESS COUNTY MODEL SERIAL NUMBER DEALER CHECK 1 Check that all cylinders are full of hydraulic oil and free of air Use Mobil DTE25 or equivalent 2 Examine all hydraulic hoses to see that they are protected from damage 3 Check that all decals are in place and legible 4 Test the back up alarm 5 Check that all tail lights are functioning properly 6 Engage the P T O Check the dash light Check for any unusual noises 7 Check that the control handles correspond with directional decals 8 Make sure all lubrication points have been lubed DELIVERED BY DATE CUSTOMER REVIEW SHEET 1 Owner s manual provided 2 Warranty card is filled out and mailed 3 Review the safety warnings and cautions as listed in this manual 4 X Review the container loading and unloading procedures 5 X Explain the importance of proper maintenance of the boom pivot boom slide and hydraulic components 6 Review all of the lubrication points DELIVERED BY DATE Table of Contents WARRANTY DEALER PREDELIVERY CHECK SHEET CUSTOMER REVIEW SHEET TABLE OF CONTENTS SAFETY DECALS HOOK HOIST SPECIFICATIONS OPERATING SECTION SAFETY FIRST OPERATING INSTRUCTI
44. WELD 4 50 3 8 WELD TYP 3 8 WELD CENTER GUSSET ON PLATE 2 5 7 27 DOUBLE KOLLER ASSEMBLY INSTRUCT TONS 35 75 917 98 AFTER MODIFYING MAINFRAME PER DOUBLE ROLLER WELDING INSTRUCTIONS INSTALL REAR TAIL WELDMENT TO MAIN FRAME WELDMENT WITH ONE EACH REAR PIVOT SHAFT ADD ONE EACH MACHINE BUSHING 5 TO EACH SIDE INSTALL ONE EACH DOUBLE ROLLER ARM WELDMENT 10 ON EACH SIDE RETAIN EACH SIDE WITH ONE EACH MACHINE BUSHING 5 ONE EACH SPACER 4 ONE EACH SPECIAL BOLT ITH ONE EACH LOCK WASHER 1 ASSEMBLE DOUBLE ROLLER ARM WELDMENT INSTALL ON EACH PIN ONE EACH SPACER 4 ONE EACH MACHINE BUSHING 5 ONE EACH GUIDE ROLLER ASSEMBLY 9 ONE EACH MACHINE BUSHING 5 ONE EACH GUIDE ROLLER RETAINER 6 AND LOCITITE ONE EACH HEX HD CAP SCREW 7 5 58 REV 2BAUGSS A28 REFLECTIVE TAPE INSTALLATION REF ANSI STANDARD 1245 ode 2 2 16 VEHICLE CONSPICUITY 74 600 247 OUTSIDE EDGE OF BOTH TARPER ARMS 74 600 24 OUTSIDE EDGE OF BOTH TARPER ARMS NN 74 500 247 QUTSIDE EDGE OF HYD TANK He TANK SIDE ONLY 74 600 607 OUTSIDE EDGE OF BOTH FENDERS ALTERNATING Eu RED WHITE H EA COLOR LENG CUT TO LENGTH AS SHOWN 74 600 247 QUTSIDE EDGE OF HYD TANK TANK SIDE ONLY
45. act when hooking to a container or load Weld switch mounting plate with 1 4 welds Mount the remote switch 79 248 to mounting plate with 1 8NC x 1 1 4 Cap Screws and Hex Flange Lock Nuts 9716 0 30 BRACKET SAFETY SWITCH 79 248 REMOTE SWITCH MOUNT USING THREE 3 1 4NC X 1 1 4 CAP SCREWS AND FLANGE NUTS FROM INSIDE EDGE OF MAIN FRAME TRUCK CAB Wire remote switch to solenoid valve as shown cap blue wire POWER on relay harness not used FUSE LIGHT GROUND GROUND DIN CONNECTOR je PE TOS 10 02 9716 41 25 SINGLE ROLLER ASSEMBEY INSTRUC TIONG ay 2 2 9 INSTALL REAR ROLLER SHAFT 5 CENTER SHAFT ON MAIN FRAME WELDMENT ET 35 75 MAIN FRA 4 TWO EACH ON BOTH SIDES INSTALL MACHI 2 AND INSTALL GUIDE ROLLER ASSEMBLY 3 SIDE RETAIN GUIDE ROLLER ASSEMBLIES WITH O E WELDMENT INSTALL SPACER E BUSHING ON EACH EACH MACHINE BUSHING 2 ONE EACH GUIDE ROLLER RETAINER 6 ONE EACH LOCK WASHER 7 AND ONE EACH GREASE ZERK ON EACH SIDE A26 DOUBLE WULEERN WELDING CUT BUSHING OFF FLUSH REWELD GRIND FLAT CIF FRAME NOT SUPPLIED WITH BUSHING CUT OFF IMPORTANT STOPS MUST BE INSTALLED OR UNIT WILL NOT SAFELY FUNCTION 3 8 WELD 31 0 REF M 15 5 REF 77 3 8
46. ation Rev M9625 68 A12 STEEL KRAUSE FENDER INSTALLATION REAR MOUNTING TUBE FRONT FENDER MOUNTING TUBE TENDER PLATE 9625 0 7 9625 0 8 25 X 25 X 2925 3 x 3 29 EL vw 0 GUSSET FRONT FENDER TUBE WELDMENT END CAP WITH HOLE 9274 0 3501 8214 148 0 9214 182 1 U 3 5 X 3 5 X 25 88 FRONT FENDER MQUNTING TUBE FENDER WELDMENT SPACER PLATE WELD ALL AROUND GUSSET AND FRONT MOUNTING TUBE WELD TO GUIDE PLATE WELD SPACER PLATE TO BUMPER AND FENDER WELD ALL AROUND REAR MOUNTING TUBE TO MOUNTING PLATE WELD FRONT TUBE WELDMENT TO FENDER WELDMENT WELD END CAP WITH HOLE TO TUBE WELDMENT Set FENDER above tire with top of fender Level with top of tilt frame tubes center fenders front and back over tires Locate and weld rear mounting tube 9625 0 7 to rear mounting plate Locate and weld front mounting tube 9625 0 8 to guide plate Locate and weld TUBE WELDMENT 9274 148 0 to rear of Fender weldment Locate fender weldment 9274 159 0 on mounting tubes Locate SPACER PLATE 9625 0 6 and weld to bumper and mounting tube on fender Locate and weld END CAP 9274 50 5 on 2 5 sq tube Locate and weld END CAP with hole 9274 162 1 to front tube weldment Secure fenders on mounting tubes with FOUR 4 62 503 1 2NC x 1 1 2 Square Head Cone Point Set Screw Rev 6 02 MS825 81 A13 PLASTIC KRAUSE FENDER FENDER MOUNTING TUBE I
47. d off any entrapped air from the hydraulic system A warning Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Perform a loading procedure with a flat rack or dump bin to put the hydraulic system under load and check all connections and components for leaks If no leaks are visible remove and replace the rack or bin on the KP625 630 4 to 5 times to ensure that all moving parts are functioning freely and properly Load the flat rack or bin with a load comparable to the full capacity of the KP625 630 and perform the loading and unloading procedure to ensure that all hydraulic lines and moving parts are functioning properly under load Operate the winch control and Free Wheel Control to ensure that they are correctly adjusted and functioning properly A17 PINTLE HITCH INSTALLATION HITCH MOUNTING REAR PIVOT WELDMENT WELDMENT 9625 500 0 CUT 7 3 4 DIA HOLE 9625 23 IN REAR TAIL WELDMENT PLATE FOR PINTLE HITCH dei AIR POD AT HEIGHT SPECIFIED BY CUSTOMER 2 5 16 CROSS TUBE SUPPORT D RING WELD ALL AROUND PINTLE HOOK
48. e location for the driver and not in the way of the transmission lever 2 Position the lower bolt holes so that the bolts will miss any cable wires or structural members in or under the cab floor 3 Mark and drill the four 4 44 DIA holes for the mounting bolts Determine a location in the area between the mounting holes to run the air lines 5 Drill a 2 to 3 DIA hole through the floor of the truck Remove all burrs and sharp edges Line the hole with a suitable grommet material 6 Using the washers on the under side of the floor attach the tower to the floor with 3 8 cap screws and lock nuts p A23 7 Mount the controller s to the tower top plate as shown After the controllers have been mounted the SINGLE UNIT CONTROL plumbing of the air lines can be started It may be necessary for the installer to provide some 75 168 additional hardware and pneumatic ERO fittings to complete the installation 1 Determine a suitable route for air E lines An 2 Cut the necessary holes E Me remove all burrs and 82 126 82 12 82 316 grommets to any sharp edges May be included 3 Determine the line length nea required and cut two lines for each actuator 4 Route the lines between the controllers and the actuators 5 Bundle the lines together and secure them out of harm s way Joystick Controller amp Single Valve Controller 1 Simply square cut the end
49. embly 8 24 640 3 4 x62 1 1 16 M F Black 3000 PSI Hose Assembly 2 9 25 604 1 1 16 M JIC to 3 4 M JIC Hydraulic Fitting 3 4 M O Ring to 3 4 M JIC Hydraulic Fitting 1 2 x 36 3 4JIC Black 3000 PSI Hose Assembly 1 1 4NPT Close Nipple 1 1 4 F NPT to 1 1 4 F NPT Ball Valve 14 25 1178 1 1 4 NPT to 1 1 4 Hose End Hydraulic T 1 5 16 x 2 1 4 Hose Clamp 1 1 4 x 94 100R4 Hose 1 1 4 M to 1 1 4 F x 90 Hydraulic Fitting 1 20 25 2471 21 25 2247 OlFiterAssemby o 22 75 160 j2NPTSquaeHeadPipePlug 1 1 1 4 x 19 100R4 Suction Hose ight Gauge w Temperature 5 Hydraulic Tank Weldment 1 1 4 NPT to 1 1 2 NPT Pipe Bushing 1 1 4 to 1 1 4 Hose Hyaraulic Fitting 1 5 16 x 2 1 4 Hose Clamp I Bolt Style 29 1 5 8 M O Ring to 1 1 4 F x 90 Hydraulic Fitting 1 1 1 4 M NPT to 1 1 4 Hose x 90 Hydraulic Fitting 1 31 25 2487 HydrauicValve Assembly Q Spoo 25 2488 Hydraulic Valve Assembly 3 Spool 1 5 16 M O Ring to 1 1 16 M JIC Hyaraulic Fitting 4 1 5 16 M O Ring to 1 5 16 M JIC Hydraulic Fitting 1 x 96 1 5 16JIC 90 Black Hose Assembly 1 5 8 M O Ring to 1 5 16 M JIC 90 Hydraulic Fitting 1 1 4 M NPT to 1 5 16 M 90 Hydraulic Fitting 36 5161 11 1 4 Square Head Black Pipe Plug 2 1 5 8 O Ring to 1 1 4 Hose End x 90 Hydraulic Fittin
50. empt to install or service any power take off with your truck engine running Put the ignition keys in your pocket before getting under the truck Do not allow truck engine to be started while workmen are under the truck Block truck wheels with suitable chocks before working under the truck A warning sure to block any raised body or mechanism before working on or under For P T O installation follow the P T O manufacturer s installation instructions When installation is completed refill the transmission with fluid and run engine for 5 to 10 minutes to check for leaks y v 1 the equipment Installed power take offs must never be shifted in or out of gear by any means except by the controls in the cab of the truck Stay clear of spinning driveshafts to avoid becoming entangled and injured Run transmission in neutral Determine sound of transmission before PTO is installed A noise in the transmission gear may be more noticeable after is installed 2 For manual shift transmissions drain transmission fluid For automatic transmissions do not drain the transmission fluid Remove cover plate Place a shop towel in the opening to prevent dirt from getting into the transmission M9305 40 Clean mounting pad Check transmission for proper PTO driver gear and location Start engine and depress clutch pedal fully while a helper observes the PTO driver gear to see if it stops rotating I
51. f the gear does not come to a complete stop within a few seconds the clutch linkage on the truck must be adjusted before installing the PTO Check PTO driver gear for condition A nick or blemish may cause excessive noise when PTO is mounted Rock transmission gears by hand to get the feel for gear backlash manufactured into transmission gear set Open the PTO carton and find the mounting kit studs and cap screws enclosed with your PTO Visual inspection of the PTO will indicate which mounting holes in the PTO will NOT accept cap screws Torque the studs to 30 35 Lbs Ft 6 bolt pad or 45 50 Lbs Ft 8 bolt A3 7 10 11 12 13 Remove the shifter cover or the inspection cover plate from the PTO by removing the hex head cap screws on the cover plate With PTO s which do NOT have an inspection cover plate hold the out put shaft and rock input gear to get the feel of backlash built into the PTO This feel will be helpful when fitting PTO to transmission See step 10 Place mounting gasket from your kit over the studs already installed on the transmission thin coating of grease is recommended on gaskets to help seal and to hold them in place during installation Do not use a permanent sealant on gaskets because you may need to change them later Use Grease ONLY 9 Mount the PTO to the studs with the copper washers lock tabs and nuts provided NOTE The copper washers must be installed
52. forward until the hoist is lowered to the full down which raises thetruck s center of gravity Use caution when dumping a sticky or frozen load to prevent the truck from rolling over Activate the dumping controls raising hoist to maximum dumping angle The truck can be moved forward from the dumping site by disengaing the P T O and brake When area is clear move the truck forward several feet only Re engage the P T O and brake Active the control to lower the tilt frame back into the down position on the truck chassis Secure the door s on container Disengage P T O and drive safely M9625 32 position UNLOADING FLAT RACKS BINS OR OTHER CONTAINERS FROM THE HOIST SYSTEM A Position the rear of the truck approximately 10 feet in front of the desired resting place for the rack or container This will allow for the distance the rack or container will travel during the unloading procedure Put the truck transmission in neutral and engage the parking brake Inspect the desired area for obstruction both around and overhead and instruct all persons to stand clear of the equipment Inspect the load on the truck to ensure that it will remain stable during the unloading procedure Engage the truck s P T O and activate the Hook Arm Control to retract the Hook Arm completely This procedure will push the rack or container away from the back of the truck cab and disengage the locking mechanism O5 F Activate the
53. g 4 Tighten all hardware A waning Direct mounted hydraulic pumps weighing more than 50 Lbs should be supported at the rear by a strap attached to the transmission MOUNT PUMP TO PTO PER OWNER S L MANUAL MOUNT PTO TO TRANSMISSION PER INSTRUCTIONS AND PTO MANUFACTURER S INSTRUCTIONS M9305 46 A5 d Ul HOOK HOIST INSTALLATION MOUNTING SPACER REAR MOUNTING PLATE CONNECTION PLATE GUIDE PLATE 8 00 25 0 92625 00 7 9525 00 65 9625 00 5 CONNECTION PLATE REAR CONNECTING SPACER REAR PIVOT WELDMENT REAR PIVOT SHAFT WELDMENT I REAR SPACER PLATE LATCH PLATE ex 3635 1821 8625 0 24 227 MIN LONGER IF TARPER IS ADDED 118 8 _ LOCATE CLOSE USE CONNECTION SPACER MOUNT ING PLATE BETWEEN FRAME SPACER Nes WEL A GUIDE PLATE 5 8 DIA REAR BOLT CONNECTING PLATE 15 TO SPACER PLATES DRILL FOR 5 8 DIA BOLT d REAR MOUNTING PLATE 174 CT DRILL 750 DIA WELD CONNECTOR PLATE TO 12 HOLES PER PLATE GUIDE PLATE AND SPACER PLATE LATCH PLATE PAGE AS MOUNTING SPACER REAR PIVOT SHAFT WELDMENT SHIM IF NEEDED WELD SPACER PLATE TO GUIDE PLATE BOTH SIDES SUPPORT SPACER 3 4X3x8 L SHIM IF NEEDED 5 1 2 REF REAR PIVOT WITHOUT TARPER WELD REAR PIVOT WELDMENT WELDMENT TO REAR MOUNTING PLATE Rev 3 05 BOTH SIDE
54. g 3 4 x 62 1 1 16 M F Black 3000 PSI Hose Assembly 1 1 1 16 M O Ring to 1 1 16 M JIC Hydraulic Fitting 42 24 66 3 4 60 1 1 16 JIC Black 3000 PSI Hose Assembly 2 Hydraulic Tube Assembly 187 Long 3 4 x 37 1 1 16 Black Hose Assembly Bulkhead Tee 1 1 16 JIC Hydraulic Fitting 46 82 299 Tube Hose Clamp 7 1 1 1 4 8 S BNC x 2 1 2 GD5 Cap Screw eck pump ports before ordering BA 5 a 4 AAAS P5 fs MS625 60 REV 1640699 P6 HYDRAULICS 50 GALLON TANK FOR MODELS KP625 KP630 SERIAL 1015 1048 8 00 1 1 16 M JIC to 1 1 16 F Swivel 45 Hydraulic Fitting 1 1 16 M O Ring to 1 1 16 M JIC Hyaraulic Fitting 4 x 62 D A Hydraulic Cylinder 4 23 710 6 1 2 x87 Hydraulic Cylinder Model P625 2 28 7131 7 7 Hydraulic Cylinder Model KP630 2 7 8 M O Ring to 1 1 16 M JIC 90 Hydraulic Fitting 2 6 82 308 3 4 x 62 1 1 16JIC x 90 Hose Assembly 8 24 640 3 4 x62 1 1 16 M F Black 3000 PSI Hose Assembly 2 9 25 604 1 1 16 M JIC to 3 4 M JIC Hydraulic Fitting 3 4 M O Ring to 3 4 M JIC Hydraulic Fitting 1 2 x 36 3 4JIC Black 3000 PSI Hose Assembly 1 1 4NPT Close Nipple 1 1 4 F NPT to 1 1 4 F NPT Ball Valve 14 25 1178 1 1 4 NPT to 1 1 4 Hose
55. ht Add gasket s A clatter noise indicates a loose mount Remove gasket s A tight mounted PTO will cause undercutting of gears and result in premature gear failure If okay repeat test with PTO engaged Accaution Keep Transmission running time as short as possible until transmission is refilled with lube 4 14 Refill transmission with fluid and run engine for 5 to 10 minutes to check for leaks 15 Install the appropriate shifter kit components On air system only you will not receive any air through the pressure protection valve to the PTO system until your main valve tank pressure exceeds 65 PSI 16 If your system contains a driveline between the PTO and another product and if you have noise in your system that was not there before the angularity of your driveline may be the cause Check driveline angularity and reduce the total angularity to less than 15 and be sure that the shafts are parallel within 37 Awarnina Direct mounted hydraulic pumps weighing more than 50 Lbs should be supported at the rear by a strap attached to the transmission DIRECT MOUNTED PUMP INSTALLATION 1 To install a direct mounted pump first of all determine the direction of rotation of the PTO from the illustration below 2 Align the splined shaft on the pump with the splines in the PTO 3 Install the four 1 2NC x 2 GD 5 Cap Screws and Lock Washers Be sure the pump flange is fully seated onto the PTO housin
56. ly Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical grade Fasteners should be replaced with the same or higher grade higher grade fasteners are used these should only be tightened to the strength of the original Tighten plastic insert or crimped steel type lock nuts to approximately 110 percent of the dry torque values shown in the chart below applied to the nut not to the bolt head Tighten toothed or serrated type lock nuts to the full torque value NOTE Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings Dry means plain or zinc plated without any lubrication Tighten lubricated bolts to approximately 8096 of dry bolts DRY BLACK OR PLATED BOLTS BOLT SIZE WRENCH SIZE GRADE 2 GRADE 5 GRADE 8 We is 8 199 7 89 175 45 STRETCHED AREA 7N N SAE SAE SAE OVER TORQUED BOLT GRADE 2 GRADE 5 GRADE 8 2 A1 INSTALLATION If a forklift is to be used to lift the unit from the transport vehicle to the installation area care should be taken not to engage chains or hooks to areas of the Hook Hoist which may cause damage to hydraulic hoses or any parts of the structure Before starting installation procedures check the shipping list to ensure that all parts and accessories have been supplied Any missing items should be reported to K PAC equipment immediately
57. or any other accessories mounted in this area Caution Before drilling through the truck chassis be sure that all hoses wiring and lines are moved out of the path of the drill Set REAR MOUNTING PLATES 3 4 above frame using spacer provided and level across to each other Use rear mounting plates as a pattern for cutting of frame at proper distance indicated or needed Match drill 3 4 DIA 12 holes per plate attach with 3 ANF x 2 Hex Flange Bolts and 3 ANF Hex Flange Lock Nuts Attach rear cross plate Locate and install GUIDE PLATES on each side of truck frame NOTE Guide plates can be moved to avoid obstructions See installation on following page attach guide plate to frame drill for 5 x 2 Cap Screws 5 8NC Hex Flange Lock Nuts Guide plate can be located before or after hoist is set on truck frame Install spacer next to guide plate both sides before installing connection plate After guide plates have been located and installed weld CONNECTION PLATE to each guide plate with 1 4 weld Locate and install MOUNTING SPACER on each side of truck frame as close to rear boom pivot as possible Drill for 5 BGNC x 2 GD8 Cap Screw and 5 8NC Hex Flange Lock Nut MOUNTING SPACER can be located before or after hoist is set on truck frame Unpackage KP625 630 Hook Hoist and prepare to lift onto truck frame Set hoist on truck frame Assemble REAR PIVOT WELDMENT onto hoist frame with REAR PIVOT SHAFT WELDMENT and 1 2NC x
58. ose 16 Ft 1 1 2NPT to 3 4NPT Hex 9587 clamp TSBOE Type n 25 1182 Reducer STD Unit x 25 344 ane ae 25 1187 1 1 4 M NPT to 1 5 16 M JIC Hydraulic Fitti 14 25 184 MNPTto3 ANPTHexReduer 1 E Ely Bx 79 508 40 GPM Solenoid Valve 1 24 648R UA 2W Hose Assembly 1 7 10 12 14 15 16 25 583 1 1 16 M O Ring to 1 1 16 F EN me 39 GPM Pump Commercial Intertech 17 8 19 20 2 1 1 1 JIC Swivel 909 Hydraulic Fitting 1 5 16 M JIC to 3 4 M NPT Ka Ri AP 25 588 1 1 5 8 O Ring to 1 1 4 Hose ELM 90 Hydraulic Fitting 25 343 90 Hydraulic Fitting 1 25 1186 TEEM ICT TM NPT Tee app 1 1 4NPT to 1 1 4 Hose 90 inch Unit Hydraulc Fitting 19 24 1136 1 1 4 1 0 x 96 100R4 Hose 20 75 210 3NPT to 2NPT Reducer Bushing 25 235 Sight Gauge w Temp 5 24 450 1 x 7 1 2 Hydraulic Tube 25 506 1 Flareless Tube Ferrule 25 554 1 Flareless Tube Nut 25 2247 In Tank Filter 25 2480 25 215 Filler Cap Assembly 1 5 16 M JIC to 1 5 16 F 29 418 90 Hydraulic Fitting 25 493 3 4 M O Ring to 1 2 F NPT 1 EIN E 90 Hydraulic Fitting CREE CNN a 45 47 50 5 52 53 54 55 56 57 1 5 16 F JIC to 1NPT 90 EJ AN Hydraulic Fitting 3 4 x 336 1 1 16JIC 90 2490 Black 2W Hose Assembly 1 1 16 M Bulkhead 2 08 Hydraulic Fitting 3 3 4 x 37 1 1 16JIC Black
59. pletely lowered l Activate the Hook Arm Control to extend the Hook Arm which will pull the rack or container toward the truck cab to engage the rack or container lock with the two safety locks on the hoist sub frame J IMPORTANT Retract stabilizer gt after loading is completed Disengage the P T O Observe road and weather conditions and drive with the caution required for a vehicle under load M9625 31 04 DUMPING A CONTAINER A caution Be sure that the truck is on firm level ground before dumping A B 9 If one side of the load breaks loose in this high center of gravity position a truck on unstable footing may roll over on its side When the path is clear back the K PAC Hoist to the dumping site Put the transmission in the neutral position and engage the P T O or switch the hydraulic pump on and engage the truck brake Be sure dumping path is clear including overhead obstructions and that the truck is on firm level ground Release door s on container and fasten open with safety chain onto container Inner boom should be fully extended when preparing to dump NEVER retract inner boom past locking mechanism on hoist Note A hydraulic safety interlock prevent the operator from retracting the inner boom as boom is lifted off truck frame Check that this safety feature is operating correctly Caution This hoist dumps the load from a container at a very steep angle Caution Do not drive
60. r container to ensure that it is clear of all obstructions and persons and that it is not fastened or stuck to the ground Caution Do not attempt to load a container with faulty equipment Check the condition of the hook safety latch boom pivot and the inner boom slide pads Be sure that the height of the hoist hook is compatible with the container Do not lift a container heavier than the rated capacity of the hoist IMPORTANT READ OWNER S MANUAL RAISE 22 STABILIZER EXTEND UNLOAD 02 Inspect the condition of the A Frame and be sure that the combined weight of the pay load and the flat rack or container does not exceed the 50 0007 equipment Before activating either control ensure that the area around the hook hoist is clear of persons high voltage overhead wires and other obstructions A Line up the hoist truck boom with the rack or container hook If this is not possible the rack or container can be picked and loaded from within a 30 arc either side of center B Engage the parking brake depress the clutch and engage the P T O Activate the In Cab Control to slide the Hook Arm back to the fully retracted position this is very important This also disengages the locking for dumping C Activate the In Cab Control to pivot the Rotation Boom from the back of the cab to the container A Frame positioned behind the truck D Disengage the P T O and brake
61. s and hardware 2 Install 4 LUGS per dimension shown 12 7 8 before attaching top lugs Make sure that the bumper weldment is level 3 Tack weld the mounting lugs to the rear of the stabilizer apron 4 Tack weld the Mounting Lugs for the Connection Weldment link to the tilt frame in the center as shown 5 Operate the hoist into the dumping mode to check the ICC Bumper folding operation Weld the Mounting Lugs around as shown 7 nstall and wire lights etc routing wires carefully to prevent damage during hoist operation INSIDE CONTROL HANDLE INSTALLATION Locate controls to right of floor gear shift Route the control cables under the seat and through the back of the truck cab Seal the cable holes with grommets The right lever cable should be connected to the right side control valve and the left lever cable to the left control valve 1 Choose a mounting location which is convenient and comfortable for the operator and provides adequate clearance for control lever movement NOTE Check the underside of the cab for reinforcement members air lines wiring harnesses and linkages before cutting into the floor GOOD CABLE PATH IS ESSENTIAL FOR PROPERLY OPERATING SYSTEM BE SURE THAT THE LOCATION CHOSEN ALLOWS THE CABLE TO BE LED EASILY AWAY FROM THE CONTROL WITH NO BENDS OF LESS THAN 8 RADIUS THE CONTROLS MAY BE MOUNTED FLUSH IN A CONTROL CONSOLE SIDE MOUNTED OR CLEAR L
62. tor GRESEN REMOTE CONTROLS MATCH DRILL OR WELD DRILL 376 DIA HOLE THROUGH VALVE HANDLE 9625 52 Rev 8 00 FOR MODELS 6 99 Part Description Valve Control Tower 2 Tower 3 E E Cable Assembly 84 Long _____ __4 Cable Assembly 252 Long qm 4 Control Cable Bulkhead Plate Clevis Assembly Pin Included 6 x 25 2129 Vertcal Handle Pin MESE 8 x 60 727 Cotter Pin 9 x 25 2128 SidePlate S x 60 248 GlvsPin 11 60 727 CoterPin 12 x 25 2127 HandleBracket 18 x 62 541 1 4 x 3 4 Slotted Fillister Head Machine Screw Le pU 52 E es Included 25 250 Hydraulic Handle Kit P36 AIR CONTROLLER M9625 43 FOR MODELS 3 05 Pari Desorption 62 530 x 172 Cap Screw 178 1747 Tube 90 82 157 Joystick Controller 16 Compression Fitting 3 5 82 199 Joystick Controller 9274 196 3 EN TANC x 3 4 Hex Washer Thread 18 63 102 Cutting Screw i9 38 STD Lock Washer 4 S SH each saon Heac Machine Screw 21 12 6 9274 196 T ArContolMoun ngPlate T 8 66 _ 9 Thread Cutting Screw 64 158 10 Flat Washer 4 24 82 163 3 8NPT M 1 4 Tube Straight
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