Operation, Installation, and Service Manual
Contents
1. 2 M9716 3 P16 HYDRAULICS 816 1 07 1 2 x 284 Black 2W Hose Assembly 3 4 to 3 4 F JIC Swivel Hydraulic Fitting 3 25 8326 37 M BukheadTeeHydrauicFi ing 2 4 24 887H 1 2 56 JIC Black 2W Hose Assembly 03 5 6 __23 707 _____ 6 55 172 Hydraulic Cyinder 7 8 24 3036 1 2 x 30 JIC w SL Hose Assembly 9 25 80 3 4 M O Ring to 3 4 M JIC Adapter Hydraulic Fitting 3 1 2 x 10 Ret Series Hydraulic Cylinder 3 3 4 x 10 Ret Series Hydraulic Cylinder 14 Dual Counterbalance Valve 1 2 x 190 JIC Hydraulic Hose Assembly olenoid Valve N C 40 GPM 25 583 1 1 16 O Ring to 1 1 16 90 Hydraulic Fitting 18 25 478 7 8 M O Ring to 1 1 16 M Straight Hydraulic Fitting 19 25 3 9 7 8 M O Ring to 3 4 Adapter Hydraulic Fitting e 25 448 1 1 16 M O Ring to 3 ANP T F Hydraulic Fitting 1 25 2495 1 25 342 1 25 2502 1 25 449 1 1 16 M to 3 ANPT F 90 Hydraulic Fitting 1 24 1151 3 4 x 20 Low Pressure Hose 25 494 2 2 1 1 2NPT M to 3 4NPT F Hex Reducer Fitting 1 1 3 4 M O Ring to 1 2NPT F 90 Hydraulic Fitting Valve SD4 1 SV 2BLSD SAE 9 16 M2. M3716 S 7 01 FOR MODELS 1 07 Par Number 1 2 STD Flat Washer 8 RN 1 2NC x 1 1 2 GD5 Cap Screw Winch Cover Pae C T T Hd Roller Fairlead for 10 Drum 1 MI2xT175x835x88 CapScew 4 9625 0 18 Ange WinchCovr T 9716 860 1 Winch Mount Cover Mi2x175x25x88CapScew 8 BCS 1 2 STD Lock Washer 4 1 2NC Hex Nut 4 tabilizer Main Weldment 1 12 000 Winch 30 286 Series La Tensioner Wire Rope Kit 10 Drum P7 MISCELLANEOUS ELECTRICAL PARTS TRUCK CAB a 2 HOST UP LIGHT COLORED A TS RELAY a i bi WHITE DE EVIDUS STYLE GROUND GREEN TO FRAME LICHT WHITE L 30 BLUE ER lee Wee La DN ROUND ER E FOR MODELS KP816 2 07 ____ Part Description ten 73 79 580 Hoist Up Light LED requires 3 4 DIA hole 79 269 Hoist Up Light requires 7 8 DIA hole 2 79 581 Pigtail 16 Ft 9716 0 30 Bracket Safety Switch ES 1 4NC x 1 1 2 GD5 Screw 63 141 1 4 Hex Flange Serrated Nut 7 79
3. LIFT CYLINDER 10 01 M9716 26 P18 GRESEN VALVE ASSEMBLY Positioner End Inlet End Outlet End View 7 00 9706 21 FOR MODELS ALL 11 00 Part Description Relief Valve Seal Kit WH Std Relief LokWaser 13 d 25 2411 P19 INSTALL VALVE WITH CONTROL HANDLES POINTING UP THROUGH SLOT IN TANK M9716 12 KP816 AIR CONTROL 2 3 SPOOL PARTS FOR MODELS KP816 10 01 1 jHydauicTank 30Galon Control Valve 2 Spool Rev w Free Flow Spool V20 1 Air Activator Assembly 2 Compression Fitting 1 8NPT M 1 4 Tube 90 5 1 40 2 3 3 9274 196 0 Air Control Tower Assembly 9274 196 2 196 1 196 1 14 1 4 STD Lock Washer 14 1 1 1 1 4 x 3 4 Hex Washer Thread Cutting Screw 4 3 8NC x 1 1 2 Hex Washer Thread Cutting Screw 4 4 3 8 STD Lock Washer 4 10NC x 1 2 Cross Recess Pan Head Machine Screw PTO Indicator Light 2 Valve 7 3 8NPT Male 1 4 Tube Straight Compression Fitting KE EE Used with 3 Spool Valve Assembly ONLY e This is a bulk quantity item Specify the amount required when ordering 4 1 1 4 1 1 4 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 3 w w o 21 AIR CONTROLLER ASSEMBLY
4. 55774 62 344 KIT INCLUDES CONTROLLER WITH STRAIGHT HANDLE CLEAR CAP 2 SWIVEL CONNECTORS 2 O RINGS AND LONGER SCREWS TO RETAIN SECTIONS 62 345 KIT INCLUDES ELECTRIC PTO SWITCH AND WIRING FOR MODELS ALL 1 07 Tower Cover Stainless Steel Air Line 1 4od SAE J844 6 82 36 Connector Swivel 82 333 Pneumatic Controler 5 L 8 74 636 Decals Como O oo 9 82348 ____ 28k 274x Doubled Quantities Reflect 2 Sections 3 Sectionsx 22 VALVE amp CONTROLS H V CLEVIS PIN amp COTTER PIN INCLUDED WITH ITEM 5 CLEVIS 18 4 6 19 5 d 71849 n i VALVE 1M 1019 Rev 10 00 FOR MODELS 816 1 07 Tem ay 2 2 Cable 108 Long Cable 156 Long 4 i 5 Clevis 3 8 Hole 2 7 i 3 i n 1 4NC x 4 GD5 Cap Screw 3 8NC x 1 1 2 Hex Washer Thread Cutting Screw 5 16NC x 2 1 2 GD5 Cap Screw 1 2NC x 1 1 4 GD5 Cap Screw P23 2 3 4 sch sch sch sk N O O1 A W N DIRECT MOUNT HYDRAULIC PUMP M9610 7 Rev 2 99 2 01 eem EE 25 2402 Gear Pump nap Hing Outboard Bearing haft End Co
5. Note f 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 of container to pivot until it is in full contact with the ground O5 G Continue to pivot the hook arm until the hook be disconnected from the Frame connection bar Rev 7 04 M9716 19 H When the Hook Arm hook is clear of the A Frame Connection Bar disengage the 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 Hook Arm fully forward until it reaches its resting position J Activate the Hook Arm Control and extend the Hook Arm towards the truck cab WINCH OPERATION OPTIONAL EQUIPMENT A Caution Set brake before operating winch The winch controls are located at the rear of the truck on the driver side There are two levers the outside lever operates the winch under power and the inside lever operates the free wheel control on the winch 9716 20 Rev 7 04 9716 21 To operate the winch turn the lever back per illustration on winch To lock the free wheel lever in the free wheel position turn lever forward per illustration on winch O6 The winch cable can then be pulled out to the desired length without restraint Note The cable s
6. o Po 8 Items Included in Mounting Kit P11 TANDEM STEEL FENDERS po S 2 MEC e M9716 13 FOR MODELS KP816 2 02 Part Description 9274 0 3501 usset TNC Hex Nut E MC 2 EE 1 2NC x 1 1 2 Square Head Cone Point Set Screw 4 9274 148 0 Front Fender Tube Weldment 9625 6 86 FronFenderMoutingTube 9274 162 1 EndCapw Hoe O 2 39625 0 7 Rear Fender Mounting Tube 2 74 50 6 4 O 9274 159 0 Fender Weldment 102 Max P12 TANDEM POLY FENDERS 00 M9615 5 FOR MODELS KP816 7 97 Part Description 44 133 Dual Poly Fender 2 2 1 1 Rear Fender Mount Center Fender Mount bes 7 1 TOOL BOX FOR MODELS ALL 1 07 Part Description _ 9274 110 0 _ Tool Box amp Platform Assembly Tool Box Weldment 1 2NC x 1 3 4 Carriage Bolt Hinge Strap 4 Wear Sleeve 5 1 2 STD Flat Washer 1 2NC Self Locking Nut 7 Plastic Plug 10 11 12 13 ul Sue 14 TOOL BOX
7. 74 297 SAFETY DECALS See Parts Listing page for part number and proper location ACAUTION DO NOT ATTEMPT TO OPERATE EQUIPMENT WITHOUT PROPER TRAINING 1 OBSERVE AND PRACTICE ALL SAFETY AND OPERATING RULES AS ESTABLISHED BY YOUR COMPANY AND THOSE INCLUDED IN MANUAL 2 KEEP CLEAR OF HOIST FRAME WHEN RAISING OR LOWERING 3 DO NOT WORK ON OR UNDER THE HOIST UNLESS PROPERLY BLOCKED AND SECURED 4 DO NOT EXCEED THE MAXIMUM RATING FOR HOOK OPERATING LIMITS STATED BY THE MANUFACTURER OPERATE ON LEVEL GROUND DISTRIBUTE LOAD EVENLY DO NOT DRIVE TRUCK WITH P T O ENGAGED BE SURE TRUCK IS CLEAR OF ANY OVERHEAD ELECTRICAL WIRES OR OBSTRUCTIONS BEFORE RAISING HOIST BE CAREFUL BE ALERT USE GOOD JUDGEMENT BE AWARE OF POWERLINES AND OVERHEAD OBSTRUCTIONS CONTACT BY THE HOIST OR CONTAINER COULD CAUSE SERIOUS INJURY OR DEATH TO THE OPERATOR AND BYSTANDERS m 74 485 OPERATOR USING OUTSIDE CONTROLS STAND CLEAR OF CONTAINER WHEN LOADING AND UNLOADING CONTACT COULD CAUSE SERIOUS BODILY INJURY 74 596 BEFORE WORKING AROUND RAISED HOIST THE HOIST MUST BE SUPPORTED BY THE HOIST PROP SEE HOIST PROP OPERATING INSTRUCTIONS FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH IF THE HOIST PROPS CANNOT BE USED CONSULT THE MAINTENANCE SECTION OF THE OPERATORS MANUAL FOR THE PROPE
8. 1 LC I 2 2 TY P28 PRINCE HYDRAULIC CYLINDER x 1 1 WN WS 21 1023 3 3 4 X10 PRINCE HYDRAULIC CYLINDER ASSEMBLY Series 12 00 Retracted 22 1 4 Extended 32 1 4 Stroke 10 Rod Diameter 1 Pari Description EE EPIS 2 TubeAssemby E 3 TeHodAssemby 4 4 EES E 5 Gand E RE EE 8 7 21 8126 OlevsAssemby LI 8 lokNu 9 PotPug 10 PotPug a Bushing 12 21 20 3 16 DIA x 1 3 4 Cotter Pin EE M x Bearing Rng 15 x O Hng E 18 x Badk pWasher 2 19 Lo Seal 320 E IER E LL Wer 22 2 45 Series Caution Decal 21 2117 SealKtDeca 4 113 oylinder Warning Desa E pe Seat it hers Included P29 DECALS QO cijooob Kaka v X
9. IMPORTANT A GOOD CABLE PATH IS ESSENTIAL FOR A 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 BANK MOUNTED AND THROUGH BOLTED AS SHOWN IN ILLUSTRATION ON PAGE P23 2 Cut out a hole for the control cables and drill four 4 7 16 DIA mounting holes Mount the control handle and brackets as shown in parts drawing on page P23 Be sure that control handle movement corresponds with the direction decal as shown on page O2 VALVE CONTROL INSTALLATION 1 Control Handles remove the bolts holding the spool cover plate position the handle assembly on the valve face and install the longer bolts Install the clevis pin and cotter pin The cable controls supplied with the K PAC Hoists are a high quality assembly which seal out moisture are corrosion protected and engineered to minimize backlash lost motion After the hoist and hydraulic tank are mounted to the truck chassis the remote cable controls may be installed Inside Control Handle Installation FLUSH SIDE BANKED Refer to parts page P23 MOUNTING MOUNTING TOGETHER Choose a mounting location which is convenient and comfortable for the operator and provides adequate clearance for control lever movement Be sure the location chosen allows the cable to be led easily away from the control
10. hoist frame O3 l Activate the Hook Arm Control to gt Rev 7 04 extend the Hook Arm which will pull M9716 17 the rack or container toward the truck cab to engage the rack or container sills with the two safety locks on the hoist frame J Raise stabilizer after loading is completed K Disengage the P T O Observe road and weather conditions and drive with the caution required for a vehicle under load DUMPING A CONTAINER A caution Be sure that the truck is on firm level ground before dumping 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 A When the path is clear back the K PAC Hoist to the dumping site Put the transmission in the neutral position and engage the or switch the hydraulic pump on and engage the truck brake C Be sure dumping path is clear including overhead obstructions and that the truck is on firm level ground D Release door s on container E Inner boom should be fully extended when preparing to dump NEVER retract Hook Arm past being fully engaged in locking mechanism on hoist Caution This hoist dumps the load from a container at very steep angle which raises the truck s center of gravity Use caution when dumping a sticky or frozen load to prevent the truck from rolling over F Activate the hoist controls raising hoist to maximum dumping angle G The truck can be moved f
11. with no bends of less than 8 radius 9200 3 The controls may be mounted flush in control console side mounted or bank mounted together and through bolted as shown above Control operation can be changed simply by turning the control valve through 180 IMPORTANT A good cable path is essential for a properly operating system Keep bends in the cable path to a minimum and as generous as possible Under no circumstances should any bend be tighten than an 8 radius Protect the cable from heat above 225 Fahrenheit and avoid hot areas such as exhaust pipes etc Protect the cable from physical damage such as pinching or crushing and do not use cable supports which may crush or deform the cable Allow room for flexing where cable is attached to moving parts of the equipment so that the cable is neither kinked or stretched A6 Cable Connections 1 7 8 Install the control head end of the cable by first removing the cable retaining bolt Slip the cable housing into the control head and replace the retaining bolt Check the control for free movement and correct valve control To connect the cable to the valve handle start by removing the mounting nut from the cable assembly Install the threaded portion of the cable assembly through the bulkhead weldment and replace the mounting nut p Install the clevis provided to the cable end and the valve handle ul NOTE The cable end should be p
12. Installation Cable Connections PNEUMATIC CONTROL INSTALLATION Pneumatic Actuator Installation Pre Assembled Pnematic Control Tower Start up Procedure INNER BOOM HYDRAULIC INTERLOCK BUMPER INSTALLATION Lighted Bumper Installation WIRING HARNESS INSTALLATION REAR STABILIZER INSTALLATION HYDRAULIC SYSTEM START UP REFLECTIVE TAPE INSTALLATION 2 07 P22 P23 P24 P25 P26 P27 P28 P29 P30 Al Al Al Al A2 A2 A2 4 5 A6 A6 A8 A9 A9 A10 A10 A10 A10 A12 A13 KP816 SPECIFICATIONS Chassis C A 138 156 See pages 1 A2 Frame Width 34 Outside reinforcement thickness G V W 33 000 52 000 Ibs Frame Height 41 top of chassis unladen varies with chassis Sub Frame Full length 5 x 3 tube Load Rating 32 000 Ibs with suitable G V W including body weight Dump Angle 47 with suitable body length Operating Pressure 3000 PSI Gear Pump 28 1500 rpm direct mount STD Operation In cab controls standard Hook Height 54 62 Weight 3 600 Ibs Hydraulic Planetary 4 ton 6 ton 50 of 7 16 cable w hook level wind feature Twin double acting 6 x 55 1 2 Cylinder Boom Cylinder 3 x 35 138CA 3 x 48 156 CA Stabilizer Cylinder 1 3 1 2 x 10 Slave 1 3 3 4 x 10 Slave Low Pressure American S A E Hydraulic System Gear driven hydraulic pump Braided and socked hose Phenolic pads in boom Sli
13. O Ring to 3 4 M JIC Hydraulic Fitting 1 2 x 80 JIC 90 3000 PSI Hose Assembly 2 3 4 M JIC to 7 8 M O Ring 90 Hydraulic Fitting Power Beyond Sleeve SAE 10 V20 Valve 1 1 4NPT to 1 1 4 Hose 90 Hydraulic Fitting 374 x 96 JIC w MTL Mega 3000 Hose Assembly 40 1 1 16 V to 1 1 4NPT M Hydraulic Fitting 22 Oil Strainer 25 GPM EM Man e T T 4NPT Close Nipple Hydraulic Fitting EE EES T Bolt Type Hose Clamp RE 17 HYDRAULIC SCHEMATIC a WINCH VALVE POWER BEYOND PLUG L WINCH B A t STABILIZER CYLINDERS M mn p A BE CONTROL VALVE SOLENOID gt SAFETY VALVE X A enn EXTENSION 4 e EXTENSION CLE EE d p e LIFT LIFT CYLINDER 4 1 9 9 S 1 a LK ER 5 a Se H IL d i 7
14. USE 67 C LOCKTITE ON BOLTS MARKED WITH Rev 10 02 M9715 1 P2 MAIN FRAME ASSEMBLY FOR MODELS 138 156 1 2NC x 4 1 2 605 Cap Screw lee Tewes a DE e wee 1 8 STD Zerk co 0 Few m Te 5 8 DIA x 3 1 2 Clevis Pin 1 Hydraulic Cylinder 6 x 55 1 2 2 62 764 3 8NC x 3 4 Flat Head 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 Countersunk Allen Screw 9610 120 5A Inner Boom Pad Large 1 07 elen zur ______ 64 109 5 8 STD Lock Washer 2 3 8NC x 7 8 GD5 Cap Screw 3 8 SAE Flat Washer 2 2 2 2 2 23 722 Hydraulic Cylinder 3 x 48 9716 238 0 Tilt Frame Weldment 138 1 9716 256 0 Tilt Frame Weldment 156 1 9716 301 0 Lock Plate Weldment Left 1 sl messa Item included in 9716 84 0 Pad amp Shim Kit 2 76 218 Spring 1 OD x 125 W x 3 007L 1 Di DI Hydraulic Cylinder 3 x 35 E D 68 9615 303 0 Pin Weldment 1 P3 This page intentionally left blank P4 LIGHTED BUMPER PARTS OPTIONAL 10 ol 9 06 NIO7Z16 352 FOR MODELS KP816 Part Description 4 25 Dia Rubber Grommet Lamp Stop Tail Turn 62 425 9274 0 461 e 79 295 Dia Rubb
15. s transmission in the neutral position set the parking brake and engage the P T O Place the winch into the free wheel position D Pull the winch hook and cable through the guide slot located at the front of the rack and out until the hook reaches the vehicle E Connect the hook so that the vehicle can be loaded in the manner recommended by the vehicle manufacturer Rev 7 04 M9716 22 O7 Return to the winch control disengage the free wheel and activate the winch cable control to put minor tension on the cable Rev 7 04 7 9716 23 If the vehicle to be loaded is disabled straighten the wheels to ensure proper loading place the transmission in neutral and release the parking brake Return to the winch and operate the control to load the vehicle onto the flat rack Connect tie down straps or chains to the front of the loaded vehicle and secure them to the front of the rack making sure to remove as much slack from the tie downs as possible Disconnect the winch cable and hook from the vehicle and retract the cable completely Attach a strap or chains to the rear of the loaded vehicle and connect the opposite end of the strap to the slots on the rear of the flat rack deck Check to ensure that the loaded vehicle is properly and tightly secured Put the transmission of the vehicle to be transported in park if automatic or in gear if manual and set its brake Continue to load the flat rack
16. sure they are tight OPERATING INSTRUCTIONS HOOK HOIST CHECK LIST A Check hydraulic oil level with all cylinders retracted E F G H Grease all lubrication points C Rollers are free to rotate D Tires are properly inflated E The container hook lock is free to move and works properly HOIST PROPS A warning Before working around a raised hoist the hoist must be supported by the hoist props Failure to do so could result in serious injury or death TO ENGAGE Remove klick pin keeper and remove lock from the tab allowing the prop to swing down RAISE HOIST until gravity positions the props above the angle stops on the subframe Slowly power the hoist down until each prop is in the bottom of the slot Do not power down past end of slot in the props or damage to props or shearing of the pivot bolts will occur TO DISENGAGE RAISE HOIST and swing props up to metal tab and install klick pin Periodically inspect the props and pivot bolts for damage Replace and or repair as needed 9810 O1 GENERAL GUIDELINES FOR OPERATION HOIST LOADING A CONTAINER OR FLAT RACK A Caution Besurethe area in which the hoistis to be operated is level clear of personnel as well as obstacles overhead and on the ground Operating on an 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 materia
17. the path of the drill WELD 100 3 8 WELD BOTH SIDES OF TRUCK FRAME TO HOIST MAIN FRAME DETERMINED BY SUSPENSION TYPE AND TIRE SIZE 3 Unpackage the KP816 Hook Hoist Main Frame and prepare to lift it onto the truck chassis 4 With the Truck Chassis prepared as previously illustrated safely attach chains and lift the hoist with a heavy duty fork lift or some other suitable lifting device Move and position the sub frame over the truck chassis A2 5 Lower the sub frame onto the chassis so that the back plate on the sub frame aligns with the end of the truck frame See illustration 6 Attach 2 9210 15 22 Front and 6 9716 0 8 Rear Mounting Brackets as shown in illustration on page A4 7 Using a 5 8 drill bit drill holes into the chassis rails matching the Mounting Brackets on the sub frame 8 Insert the 5 8 bolts through the brackets and truck frame install nuts Tighten all nuts and bolts per bolt torque chart at beginning of this section matching the bolt grade POWER TAKE OFF INSTALLATION 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 B 2 bolt mounting flange and must accept a 7 8 13 tooth splined shaft Do not attempt to install or service any power t
18. ur XNOTEx STEEL TOOLBOX MOUNTS ARE WELDED TO TOOLBOX AND BOLTED TO FRAME FOR MODELS KP816 Part Number 9606 111 0 82 245 9606 112 0 62 708 5 Part Description Left Tank Strap Weldment Steel Tool Box Right Tank Strap Weldment 5 8NC x 2 1 2 GD 8 Cap Screw 5 8NC Lock Nut 5 8 STD Flat Washer 63 110 64 110 15 2 4 Le EXT CYL x 2 PORTS FACING DOW N y SS E NC PORTS IN END OF CYL BLOCKE A N CY CAN 2 2 A PORTS FACING DOWN 2 21 1022
19. 496 Din Plus 8 79 563 Solenoid Valve 40 GPM 9 79 564 12V Relay 30 Amp 1 79 565 12V Relay Connector w Wire P8 ELECTRICAL SCHEMATIC 1 GROUND WHITE WIRES TO BUMPER WIRING HARNESS SUPPLIED WE BROWN RED CLEARANCE AND GROUND q 30 WRNG HARNESS GREEN RHTURN RED LIGHT AND GROUND JUNCTION BOX DEE RED STOP LIGHT GROUND OPTIONAL BLUE EXISTING TRUCK BACK UP LIGHT WHITE AND GROUND WIRING HARNESS WHITE TAG LIGHT AND GROUND LA bel LH TURN BRAKE LIGHT 12 q Rog J Be RH TURN BRAKE LIGHT Sen 1 TAIL CLEARANCE LIGHT e RED CLEARANCE AND GROUND BACK UP LIGHT d e e RED CLEARANCE AND GROUND M RED CLEARANCE AND GROUND BLUE BACK UP ALARM BLUE BACK UP LIGHT WHTE AND GROUND RED WITH YELLOW STRP Ny RED STOP LIGHT AND GROUND YELLOW c 30 WIRING HARNESS 4 LHTURN RED LIGHT AND GROUND 2 BEEHVE LIGHT M EROM e RED CLEARANCE AND GROUND MD BODY CLEARANCE T
20. 6 22 55 TO DUMP LOAD INNER BOOM MUST BE FULLY EXTENDED AND SECURELY LATCHED TO TILT FRAME SLIDE LOCK SLIDE LOCK TILT FRAME T TILT FRAME 1 LOCK BARS HOOK AND BAIL HEIGHTS be INNER BOOM X INNER Boom MUST MATCH NEVER ATTEMPT TO OVERRIDE N INNER BOOM INTERLOCK SWITCH TILT FRAME gt OR LOAD WILL UNSTABLE AND MAY FALL CAUSING SERIOUS INJURY OR DEATH TO OPERATOR AND OR Failure to comply with warnings could allow inner boom and BYSTANDERS tilt frame to separate resulting serious injury death 74 593 CAUTION DANGER CAUTION DO DRIVE WITH STAND CL P T O ENGAGED STAND CLEAR DO NOT EXCEED 1600 ENGINE WHEN THIS UNIT IS IN OPERATION RPM WHEN OPERATING FAILURE TO DO SO COULD RESULT IN POWER TAKE OFF SERIOUS PERSONAL INJURY A CAU Tl D Xd 74 299 SET BRAKE BEFORE OPERATING WINCH Ti AWARNING SC WARNING DO NOT ATTEMPT TO LOAD A CONTAINER UNLESS THE HOIST AND CONTAINER ARE CORRECTLY ALIGNED DO NOT LOAD UNLOAD OR T DUMP A CONTAINER ON KEEP THE CONTAINER RAILS SQUARELY UNEVEN GROUND ENGAGED WITH THE HOIST ROLLERS LEE E FAILURE TO DO SO COULD CAUSE THE AND TURNING CORNERS CONTAINER TO MISS THE HOIST ROLLERS SERIOUS PERSONAL INJURY AND CREATING AN UNSTABLE LOAD EQUIPMENT DAMAGE COULD RESULT
21. 9 1 2 9 UT qs o Remove the cover plate over the right side access hole Align the lighted bumper with the holes in the apron Install 1 5 8 x 1 1 2 GD 5 Cap Screws Lock Washers and Hex Nuts Torque to specifications Weld solid to Sub Frame top and bottom Add bracing angled up to truck frame Do not weld brace to truck frame add bolt plate or weld to hoist frame Install the wiring harness through the left side access hole Slip a grommet onto the harness leads and pull through the 5 8 DIA hole Attach the ground wire to the bumper with a 3 8 self tapping screw Install the bumper lights as shown on parts page P5 Connect the leads from the wiring harness to the truck wiring as shown on parts page P9 For 4 Wire systems f truck has 5 Wire system do not tie the Stop Light and Turn Light together Instead tie both the Left Hand and Right Hand Stop Light wires together Back Up Alarm 1 To install the back up alarm run the white and blue leads with bullet sockets through the left side cover plate Install the cover plate with four 4 3 8 self tapping screws See drawing on parts section page P5 A Attach the back up alarm to the cover plate with two 2 3 8 self tapping screws B Connect the white wire to the terminal on the alarm and the blue wire to the terminal C Install the Alarm Must Sound decal in the cab in FULL VIEW of the operator IMPORTANT THE BACK UP ALARM SHOULD SOUND WHEN THE BAC
22. K C J a d 5 19 BACK OF EYE LEVE OGE INSIDE OF CAB um NEXT TO CONTROLS XNOT IN 9716 50 0 ORDER SEPARATELY DEE FOR MODEL KP816 7 04 Part Description Decal Important Valve Operation Decal Danger Operating Outside Controls Decal Danger Lock Must Be Engaged Decal 32 000 Lbs Decal Warning Hydraulic Safety 6 74 481 J BDecal Caution Do Not Drive PTO Decal Caution Set Brake Decal Winch 9 74 48 Decal Danger Power Lines Hooklift 3 15 17 4 0 DCH KP816 HOIST MOUNTING INSTRUCTIONS STUDY 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 INSTALLATION 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 bolt chart on the previous page for the recommended torque values for different sizes of bolts If a forklift is to be used to lift the KP816 from the transport vehicle to the installation area care should be taken not to engage chains or hooks to areas of the Hook Hoist whic
23. K UP LIGHTS ARE ON WIRING HARNESS INSTALLATION The KP816 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 Install the bumper plate cover on both sides Install rear identification light assembly REAR STABILIZER INSTALLATION 1 2 D Joo P Align the stabilizer with top hole in apron Install 1 5 8 x 1 1 2 GD5 Screw Lock Washer and Hex Nut Level stabilizer and torque to specifications Weld solid all around apron to stabilizer Brace lower part of stabilizer to truck frame with some type of angle brace 1 2 x 2 Strap or stronger Install the wiring harness through the left side access hole Slip a grommet onto the harness leads and pull through the 5 8 DIA hole Attach the ground wire to the bumper with a 3 8 self tapping screw Install the bumper lights as shown on parts page P5 Connect the leads from the wiring harness to the truck wiring as shown on parts page P9 For 4 Wire systems f truck has 5 Wire system do not tie the Stop Light and Turn Light together Instead tie both the Left Hand and Right Hand Stop Light wires together Back Up Alarm 1 To install the back up alarm run the white and blue leads with bullet sockets through the left side cover
24. N THE EQUIPMENT WATCH FOR THE SAFETY SYMBOL AND READ THE INFORMATION THIS IS FOR YOUR OWN PROTECTION Member of d WASTEC KP816 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 and hoist up alarms 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 Review the container loading and unloading procedures 5 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 KP816 SPECIFICATIONS SAFETY DECALS OPERATING SECTION SAFETY FIRST OPERATING INSTRUCTIO
25. NS Hook Hoist Check List Hoist Props General Guidelines For Operating Hoist Loading a container or flat rack Dumping a container Unloading flat racks or containers Winch Operation Optional Equipment Flat Rack Operation Loading a vehicle onto a flat rack K PAC WARRANTY INFORMATION PARTS SECTION MAIN FRAME ASSEMBLY LIGHT BUMPER PARTS STABILIZER WINCH MISCELLANEOUS ELECTRICAL PARTS ELECTRICAL SCHEMATIC SINGLE STEEL FENDERS SINGLE POLY FENDERS TANDEM STEEL FENDERS TANDEM POLY FENDERS TOOL BOX TOOL BOX HYDRAULICS HYDRAULIC SCHEMATIC GRESEN VALVE ASSEMBLY AIR CONTROLS 2 OR 3 SECTION SPOOLS aon O1 O1 O1 O1 02 02 04 05 06 07 07 09 5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P17 P18 P19 P21 AIR CONTROLLER ASSEMBLY REMOTE VALVE amp CONTROLS DIRECT MOUNT HYDRAULIC PUMP HYDRAULIC CYLINDER ASSEMBLIES 6 x 55 1 2 Lift Cylinder 3 x 35 Extend Cylinder 3 x 48 Boom Extend Cylinder 3 1 2 x 10 Stabilizer Cylinder 3 3 4 x 10 Stabilizer Cylinder DECALS INSTALLATION SECTION SAFETY INSTALLATION INFORMATION MODEL NUMBER CHASSIS SPECIFICIATIONS Truck Chassis Cab to Axle Formula Truck Chassis Cab to Trunnion Formula HOIST MOUNTING INSTRUCTIONS POWER TAKE OFF INSTALLATION DIRECT MOUNT PUMP INSTALLATION OIL TANK VALVE AND HOSE INSTALLATION HYDRAULIC TANK INSTALLATION INSIDE CONTROL HANDLE INSTALLATION VALVE CONTROL INSTALLATION Inside Control Handle
26. Operation Installation and Service Manual TRUCK MOUNTED HOOK HOISTS MODEL KP816 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 SAFETY DECALS O
27. R PRECAUTIONS 74288 This page intentionally left blank SAFETY FIRST A Read and understand this operator s manual before operating the hoist B Be sure safety decals are clean and in place C Never position yourself or any other person under any raised portion of the hoist unless the hoist is firmly resting on blocks D 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 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 K Check all snap rings and shaft securing bolts to be
28. RLL PLATES amp TRUCK FRAME FOR BOLT 8 4 06 MS716 27 HYDRAULIC TANK INSTALLATION REFER TO ILLUSTRATION PAGE 4 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 Assemble valve hoses etc to tank before mounting tank Label hoses per illustration Install the Close Nipple Gate Valve and Hose Barb onto the Tank Assembly Position and clamp the Tank Mounting Brackets behind the rear of the cab boundary per NOTE may be necessary to relocate air tanks fuel tanks battery cases or any other accessories mounted in this area Check bolt sides for clearance on hydraulic tank and toolbox mounting Drill six 6 1 2 diameter holes in each bracket as shown in illustration Install 1 2NF x 2 1 2 GD5 Cap Screws and 1 2NF GDB Lock Nuts Center in tank mounting brackets then install 1 2 13NC Screws Remove the Tank Assembly and drill 3 8 diameter holes on the marks 2 3 illustration 4 5 6 T Re install the Tank and tighten the 1 2 13NC x 1 Cap Screws into the drilled holes Hyd Attach hoses usi
29. RUCK CAB HOIST UP LIGHT COLORED RELAY m e WHITE g PREVIOUS STYLE POWER LSE GROUND GREEN TO FRAME 2187 PTO LIGHT WHITE a 50 BLACK BLUE B RED SOLENOID VALVE RELAY CONNECTOR M h PTO E REMOTE SWITCH NC n HOST PTO POWER E 87 LS s 930 GROUND SES DIN CONNECTOR PTO a 7 SOLENOD GROUND VALVE GROUND cm 19 07 TO FRAME REMOTE PTO R1 86 85 s s Rev 1 18 07 2 MS716 37 P9 SINGLE STEEL FENDERS Hook Hoist Frame FOR MODELS ALL md 1 9305 55 0A Standard Fender Weldment Width 25 1 2 zz 9305 57 0A Narrow Fender Weldment Width 22 1 4 9305 57 04 9305 56 00 Fender Support Weldment 62 503 1 2NC x 1 1 2 Set Screw 2 63 106 1 2NC Hex Nut IE uM o O 4 44 220 Mud Flap 62 108 3 8NC x 1 GD 5 Cap Screw Lr enor Wd Flap Baking Pats 9274 0 1 Mud Flap Backing Plate 8 63 134 3 8NC Self Locking Nut 10 SINGLE POLY FENDERS 5 DRILL HOLES FOR e CARRIAGE BOLTS M9615 6 Rev 1 99 FOR MODELS KP816 1 99 Part Number Part Description Qty 44 190 Poly Fender Kit Single Axle 26 82 255 Mounting Kit for 44 190 5 16NC x 1 Hex Head Cap Screw 5 16 STD Flat Washer 5 16NC Nylon Top Lock Nut 5 16NC x 1 1 4 Carriage Bolt Ej
30. ULIC TANK 74 600 127 THIS SIDE OTHER SIDE BOTH SIDES ON TOOL BOX OR MAIN FRAME HOIST MAINFRAME ALTERNATING COLOR OF RED WHITE EA COLOR 6 LENGTH CUT TO LENGTH AS SHOWN 74 600 12 AOL eT MATNFRAME 74 600 247 OUTSIDE Gei OF o BOTH SIDES ON BOTH FENDERS HOIST MAINFRAME N 177 74 600 247 ON HYDRAULIC TANK THIS SIDE OTHER SIDE TOOL BOX OR MAIN FRAME 74 601 4 127 WHITE REFL INSTALL AS SHOWN REFLECTIVE TAPE LOCATIONS AND LENGTHS ARE FOR REFERENCE YOUR REFLECTIVE TAPE LOCATION MAY DIFFER DUE TO EQUIPMENT OPTIONS REFLECTIVE TAP E TO COVER TRUCK CHASSIS OR HOIST FRAME PER ANSI STANDARD Z245 1 1999 Rev 1 07 9716 40 1 This page intentionally left blank A14
31. ake off with your truck engine running 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 Be sure to block any raised body or mechanism before working on or under 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 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 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 2 1 2NC x 2 GD 5 Cap Screws and Lock Washers Be sure the pump flange is fully seated onto the PTO housing man MOUNT PUMP TO 72 8 PUMP POSITION FOR b MANUAL COUNTER CLOCKWISE CLOCKWISE ROTATION ROTATION amr JAmrz macwuomayv 10 19 FRONT M9305 46 MOUNT PTO TO TRANSMISSION PER Rev 4 00 INSTRUCTIONS AND PTO 4 Tighten all hardware MANUFACTURER S INSTRUCTIONS A warni
32. arallel to the bulkhead weldment Tighten the cable mounting nut M9200 36 Screw the control head onto the cable lt bai PNEUMATIC CONTROL INSTALLATION INSTRUCTIONS The optional pneumatic controller provided with K PAC equipment 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 The pneumatic actuator has been partially assembled and pre lubricated for ease of installation The actuator does not have to be disassembled for installation 1 DF onm Remove the valve if previously installed Find a suitable area free of dust and dirt to attach the pneumatic actuators Set the hydraulic valve on its mounting base Determine which spools are to be pneumatically controlled From the valve assembly a Remove and discard the original retainer screws and valve spring cover b Retain the handle end of the spool Remove and discard the 5 16 shoulder bolt from the end of the valve spool exposed by the removal of the valve spring cover c Remove and discard the original centering spring and two original centering cups d Insure the original seal retainer on the valve spool is properly seated Apply a small bead of removable thread lock to the threads of the spool adapter item 1 Holding the spool on the opposing end hand tighten the assembly using a flat screwdriver throug
33. caping 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 container 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 container on the KP816 4 to 5 times to ensure that all moving parts are functioning freely and properly Load the flat rack or container with a load comparable to the full capacity of the KP816 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 12 REFLECTIVE INSTALLATION REF ANSI STANDARD Z245 T9889 Z 2 16 VEHICLE CONSPICUITY BE or 4 600 127 74 600 48 o BOTH SIDES ON BOTH FENDERS HOIST MAINFRAME ASIST MATNFRAME H mw 2 74 600 247 2 ON HYDRA
34. ding L arm 2 full sub frame locks Cantilevered lock on hook NOTE DO NOT SPEC TRUCK BEFORE READING MOUNTING INSTRUCTIONS 24 3 4 49 1 2 r3 1 FRAME HEIGHT 7 547 BOOM 62 BOOM k 18 18 85 C 138CA rz WTNFH 1 156 910 WINCH 27 Eed 1387 155 138CA 9716 6 10 01 SAFETY DECALS See Parts Listing page for part number and proper location 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 INSPECT the hose assembly before each use REPLACE the hose assembly immediately if A The jacket of the hose appears abnormal B You have reason to believe it may be abnormal C There is any fluid leakage D The couplings are damaged E The hose is damaged or kinked F The reinforcement is visible through the jacket 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 74 27
35. e valve D s and torque nut to 15 Ft Lbs ea A Install 6 3 4 M O Ring to 3 4 M JIC Hydraulic fitting 8 into stabilizer cylinder and lock valve Z KE shown Install 4 3 4 F JIC to 3 4 JIC 90 is Fittings onto fitting 8 Install 2 3 4 O Ring to 3 4 M JIC 90 fitting into valve 7 Install 2 7 8 M O Ring to 3 3 4 M into 3rd section on control OL valve Connect from control valve HO SAN extend port to V2 port and retract y 4 port to V1 on lock valve 7 with DJ 4 L H hose 5 Connect from lock valve 7 port C2 to stabilizer cylinder x Z OC a base port on 21 1023 with hose e 9 Connect cylinder rod end port 1 8 SCALE to cylinder base port with hose 9 NE Connect from cylinder 21 1022 IMPORTANT DEPENDING ON THE POSITION OF MOUNTING rod port to C1 on lock valve 7 FEETANDPLATE USED NEW HOLES MAY NEED TO BE DRILLED Route hoses inside truck tang FOR THE NEW STUD BOLTS WHEN THE STABILIZER VALVE tied away from drive shaft etc SECTION IS ADDED Make sure cylinders are in phase MAKE SURE ALL SURFACES AND SEALS ARE CLEAN before connecting all hoses If BEFORE REASSEMBLING THE VALVE cylinders are out of phase when first connecting hydraulics the stabilizer tubes and roller could be damaged Hold valve open in retract direction to clear air and rephase cylinde
36. een mounted the air lines can be routed The air line tubing is color coded as shown in table at right To remove an air line from a fitting push the line in hold the internal sleeve of the fitting then pull the air line out Pass the air lines through the hole lined with grommet material in the floor Route the exhaust air line outside of the truck cab Determine a suitable route for the air lines to the control valve Avoid sharp bends sharp edges and heat sources Install supplied elbow fittings into pneumatic actuators Connect the air lines to the elbow fittings in the pneumatic actuators Bundle the air lines together and secure out of harm s way A decal with an assortment of 94 diameter labels are provided with the owner s manual These decal labels can be applied to the under side of the clear plastic caps to identify the function of each pneumatic control handle After the decals have been applied snap the clear covers into the handles Start up Procedure 1 2 Charge the air system of the truck and check all lines for leakage Operate the controllers and check for correct hydraulic valve movement NOTE The controllers pressurize the port toward which the handle is moved If the function is to be reversed exchange the air lines at the controller or actuator After the correct connections have been made and the hoist has been completely installed engage the P T O to check out the operatio
37. er Grommet 79 235 Lamp 2 Dia Clearance Red a 79 288 Wiring Hames Rear Bumper L9 79 293 11 79 284 79 296 Beehive Light 2 Dia Sealed 5 16NC x 3 4 Cap Screw 19 20 19 82 340 Grommet Nut 1 4 20 62 701 1 4NC x 1 Hex Washer Thread Forming Screw P5 1 4 1 STABILIZER 4 3 CLEVIS amp COTTER PIN INCLUDED WITH CYL REF VIEW ONLY IMPORTANT STABILIZER CYLINDER MUST BE RUN AND CYCLED SEVERAL TIMES TO GET THEM IN PHASE BEFORE HOOKING TO ROLLER SHAFT DAMAGE CAN OCCUR TO SHAFT IF THIS IS NOT DONE FOR MODELS 1 07 Part Description Stabilizer Main Weldment 2 8 16 DIA x 1 3 4 Cotter Pin 3 64 119 1 STD Flat Washer 4 80 271 ____ Pin 3 3 4 x 10 Ret Series Hydraulic Cylinder 6 H 9716 0 1 tabilizer Roller Sha 9716 855 0 Stabilizer Slide Weldment 8 9274 26 0A Rear Roller Assembly 21 1022 3 1 2 x 10 Ret Series Hydraulic Cylinder Included in cylinder assembly see pages P28 and P29 P6 ES joo INSTALL BEFORE INSTALLING WINCH BUMPER USE 2 9606 51 1 TAB DO NOT USE PART SUPPLIED WITH WINCH
38. ges the locking for dumping C Activate the In Cab Control to pivot the Hook Arm from the back of the cab to the container A Frame behind the truck Extend Unload Direction D Disengage the and brake and back up the truck until the hook jaw engages the A Frame bar Stop the vehicle and engage the Rev 7 04 M9716 15 If truck is equipped with stabilizer option and you are loading a heavy load lower stabilizer to the ground stabilizing back end of truck E Push the rotation control to move the Hook Arm forward Retract Load until the bottom of the rack or container is approximately 10 inches above the guide rollers at the back of the truck The operator must steer while loading until the guide rollers align with the sills of the rack or container F sills on the bottom of the rack or container are not in line with the guide rollers and the truck the operator must reposition G When the sills and rollers line up continue to activate the control to move the rack or container onto the hoist By 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 ground and apply the brake to eliminate further movement of the truck The Rotation Control should be activated until the sills of the rack or container are in full contact with the
39. h may cause damage to hydraulic hoses or any parts of the structure EQUIPMENT DIVISION 09 Before starting installation procedures check the PAC KRAUSE CORPORATION shipping list to ensure that all parts and accessories L HUTCHINSON KANSAS have been supplied Any missing items should be won reported to K PAC immediately SERIAL _____ L N U M BER MANUFACTURED IN COMPLIANCE WITH ANSI Z245 STANDARD IN EFFECT AT TIME OF MANUFACTURE 9 Know the model number of the KP816 being mounted Use this model number whenever referring to assembly or parts listing pages The number is stamped on a Name Plate which is located on the frame member CHASSIS SPECIFICATIONS SINGLE AXLE TRUCK TANDEM AXLE TRUCK 527 8 9716 28 Pre VETE RED 5 t mE SINGLE TANDEM KPB16 138 1815 16150 8 0 199 5 The KP816 138 KP816 156 Hook Hoist is designed for a 30 000 46 000 Ib G V W R chassis with 138 156 unobstructed behind cab to axle or trunnion chassis clearance Some truck suspensions will allow frame cut off less than 38 It is desirable to have the axle back as far as possible so a longer cab to axle chassis can be used If the suspension allows shorter than 21 then check fender clearance This is based on a K PAC single axle fender Note This informa
40. h the rear fitting port into the end of the piston item 12 DO NOT USE AN AIR GUN Secure the actuator assembly to the valve body using the four 4 socket head cap screws and lock washers items 4 amp 7 Test for proper alignment by turning the valve spool The spool should rotate freely Mount the valve and install fittings M9806 7 7 PLATE RETAINER IPARKER GRESEN V 20 PRTJ APPLY REMOVABLE SPOOL PARKER GRESEN V 20 THE ASSEMBLY BY HAND USING A SCREWDRIVER Pre Assembled Pneumatic Control Tower Installation See Parts Section page P22 1 2 3 Determine a suitable location which is in a comfortable location for the driver and not in the way of the transmission lever Position the lower bolt holes so that the bolts will miss any cable wires or structural members in or under the cab floor Mark and drill the four 4 343 diameter holes for the 3 8 self tapping screws supplied for the tower Determine a location in the area between the mounting holes to run the air lines Drill a 2 to 3 diameter hole through the floor of the truck Remove all burrs and sharp edges Line the hole with the grommet material supplied Using the washers on the underside of the floor attach the tower to the floor with the 3 8 screws and lock nuts Winch Cable In Winch Cable Out Hoist Raise On Hoist Raise Off PTO Supply Exhaust Auxiliary After the control tower has b
41. hould never be pulled out beyond a single wrap of cable on the drum The winch can be returned to the power position by rotating lever to back per winch illustration To power the winch cable in or out be sure that the free wheel lever is locked in the power position To retract the cable hydraulically pull the power control lever To extend the cable hydraulically push the power control lever The cable will stop when the control is in the neutral position Read the winch manufacturer s instructions for more information on the winch operation Note Never jam any of the Hoist Hydraulic Controls into the operating position FLAT RACK OPERATION Note Do not concentrate loads on small areas of the flat rack Concentrated loads should be distributed by placing planks of hardwood on the deck of the rack before placing the load Magnetic tail lights may need to be installed on the rear end of the flat rack when being transported on the hoist in order to comply with vehicle lighting regulations Loading a Vehicle onto the Flat Rack A Back the hoist approximately 20 feet in front of the vehicle to be transported Disconnect and remove the magnetic tail lights if used B Unload the flat rack from the hoist according to the normal unloading procedures and leave the hook engaged to the A Frame Connecting Bar or disconnect if necessary Note f the truck or flat rack slides E u when loading reconnect hook C Place the truck
42. ls to be transported are securely fastened to the tie downs and that all fasteners are in good condition Inspect the flat rack or 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 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 4 e EXTEND RAISE BOOM STABILIZER 3 RETRACT LOWER B 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 32 000 equipment Before activating either control ensure that the area around the hook hoist is clear of persons high r ac voltage overhead wires and other obstructions e e Rev 7 04 7 9716 14 A Line up the hoist truck boom with the rack or container hook If this is not possible the rack or container be picked and loaded from within 30 arc either side of center 02 B Engage the parking brake depress the clutch and engage the Activate the In Cab Control to slide the Hook Arm back to the fully retracted position this is very important This also disenga
43. n of the hoist A8 INNER HYDRAULIC INTERLOCK INSTALLATION 1 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 retract when hooking to a container or load 2 Weld switch mounting plate with 1 4 welds 3 Mount the remote switch 79 248 to mounting plate with 1 4NC x 1 1 4 Cap Screw Hex Flange Lock Nuts Nuts M9716 9 5 9716 0 30 10 01 BRACKET SAFETY SWITCH 79 248 REMOTE SWITCH MOUNT USING THREEC3 1 4NC X 1 1 47 5 0 4 SCREWS AND FLANGE NUTS MIN FROM INSIDE EDGE OF MAIN FRAME 4 Wire remote switch to TRUCK CAB solenoid valve as 7 OLORED shown ie _____ RELAY WHTE PREVIOUS STYLE POWER GROUND GREEN FUSE TO FRAME LIGHT WHITE Le bs BLACK BLUE PN RED SOLENOD VA EE ma SS POWER GROUND CONNECTOR GROUND m REV 1 19 07 GROUND M9716 4 TO FRAME BUMPER INSTALLATION Lighted Bumper Installation Reference Parts pages P5 P
44. ncluded in Kit __ ht E 4 e 23 808 memi s e Not Included in Cylinder Assembly P26 HYDRAULIC CYLINDER ASSEMBLY 156 n Rev 9 01 23 722 x 48 Hydraulic Cylinder Assembly BOOM EXTEND 9 01 Retracted 58 Extended 106 Stroke 48 Rod Dia 1 3 4 Part Desorption 1 __ Manufacturer s Label BEER E _ DS 7 _ 8 RodAssembly 1 9 Head 10 x WeaHng O o O Hng 1 1 x Bac upWashe ij X E Steel Plug not shown Seal Kit x Items Included in Kit e Not Included in Cylinder Assembly 27 PRINCE HYDRAULIC CYLINDER i H aoe 21 1022 3 1 2 X10 PRINCE HYDRAULIC CYLINDER ASSEMBLY Series 12 00 Retracted 22 1 4 Extended 32 1 4 Stroke 10 Rod Diameter 1 1 4 Parr Description 1 Piston Rod 2 TbeAsemy E 3 TeRodAssemby 4 Xr 5 GlndAssemby _ 9 21 876 i1 PotPug i4 x O Hng i Bushing ee 3 16 DIA x 1 3 4 Cotter Pin 21 404 21 443 21 2088 SealKit Items Included in Kit 138 14 5 23
45. ng Direct mounted hydraulic pumps weighing more than 50 Lbs should be supported at the rear by a strap attached to the transmission A3 OIL TANK VALVE AND HOSE INSTALLATION 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 1 R EE E eS lt INSTALL 1 2 13NC SCREW 2 DRILLE HOI IN 9274 45 1 9210 15 22 9244 59 0 TANK MOUNTING BRACKETS SE TUS 3 TOOLBOX m g 9274 45 11 PPE 2 THS END OF PIPES CAN BE CUI OFF WITHOUT TOOLBOX OPTION INSTALL 1 2 13NC SCREW 4 o 1 2 20NF X 2 1 2 SCREW 12 1 2 20NF HEX LOCK NUT 12 5 8 18NF X 2 1 2 CAP SCREW 20 5 8 18NF HEX FLANGE LOCK NUT 20 WELD 2 W 7 9716 0 8 6 KEEN 4 ELD D
46. ng ONE hose clamp at locations 1 and locations 3 and 4 photo at right Secure clamps with Adjust hoses to allow enough travel and return without getting caught in hoist Operate through full tilt and full separate boom travel raulic hose routin n 1 Weld a 3 8NC x 1 Bolt level with cylinder DES Re mounting plate on both sides as shown Item 1 in photo to the left 2 Weld a 3 8NC x 1 Bolt approximately 5 to 6 in front of angled plate on the inside just above bottom of side plate both sides Item 2 as shown in photo to the left M9716 39 Rear of Truck M9716 38 Weld a 3 8NC x 1 1 2 bolt in center of plate as shown Item 3 in photo to the right Weld a 3 8NC x 1 1 2 bolt to bottom inside of rear apron on main frame approximately 8 in from frame edge as shown Item 4 in photo at right 2 photo above TWO hose clamps at 3 8 lock nuts A5 INSIDE CONTROL HANDLE INSTALLATION 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 convenient mounting location which is 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
47. on 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 See truck chassis 3 8 X 45 CHAMFER Cab To Axle or specifications formulas above 2 PLACES 2 f chassis is longer than the above E the chassis be cut off S Rev 2 02 shorter per difference end of frame per illustration shown at right Measure and mark truck frame per axle location and type i e single tandem Measure assembled hoist to be sure adequate room is available behind truck cab between bumper and tires and between fender and tires After double checking your measurements step cut the frame to dimension Grind the top of each cut to a 3 8 x 45 chamfer to clear radius on top of hoist main frame rear apron Install hoist mainframe and weld to truck frame as shown The minimum would be 1 behind the rear spring shackle 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 or any other accessories mounted in this area Caution Before cutting or drilling through the truck chassis be sure that all hoses wiring and lines are moved out of
48. onto the K PAC hoist in the normal manner as described previously in this manual Rev 7 04 M9716 24 O8 Re examine the downs reconnect the magnetic tail lights if needed Note Amber beacon lights may be necessary in some states when transporting vehicles gt Rev 7 04 M9716 25 K PAC Warranty Information Congratulations on the purchase of the KP816 Hook Hoist K PAC Equipment Division of 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 O9 This page intentionally left blank O10 Notes BOTTOM PAD INSTALLAT I ON SIMULAR
49. orward from the dumping site by disengaging the P T O and brake When area is clear move the truck forward several feet H Re engage the and brake Active the control to lower the tilt frame back into the down position on the truck chassis l Disengage the P T O J Secure the door s on container K Drive safely 4 m gt nw p EIL aen Rev 7 04 M9716 18 caution Do not pull forward until the hoist is lowered to the full down position 04 UNLOADING FLAT RACKS 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 Rev 7 04 M9716 17 B Put the truck transmission in neutral and engage the parking brake C Inspect the desired area for obstruction both around and overhead and instruct all persons to stand clear of the equipment D Inspect the load on the truck to ensure that it will remain stable during the unloading procedure E Engage the trucks 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 F Activate the Rotation control Extend to pivot the Hook Arm away from the back of the truck until the load touches the ground
50. plate Install the cover plate with four 4 3 8 self tapping screws See drawing on parts section page P5 A Attach the back up alarm to the cover plate with two 2 3 8 self tapping screws B Connect the white wire to the terminal on the alarm and the blue wire to the terminal C Install the Alarm Must Sound decal in the cab in FULL VIEW of the operator IMPORTANT THE BACK UP ALARM SHOULD SOUND WHEN THE BACK UP LIGHTS ARE ON A10 10 11 12 Stabilizer Installation See parts illustration on Install stabilizer cylinders from bottom of stabilizer bumper into each outside pocket as shown Make sure rod end cylinder head has been rotated to align ports with pins Ports must face to front of truck and align through holes in front side of bumper Install pins washers and cotter pins as shown Install stabilizer slide weldment into bumper blocking up so they stay in place Next assemble shaft and roller and pin cylinder to shaft to retain assembly together Be sure both cylinders are completely retracted before completing the hydraulic installation NOTE Hydraulic cylinders are rephasing slave cylinders and must start out together or assembly will bind up and be damaged o Loosen and remove nuts on studs at inlet plate Add ELLE the stabilizer section 1 with o rings 2 between inlet EN plate and 374 section as shown Using the longer WY stud bolts 3 supplied reassembl
51. rs PAR ADDED S K ES LU mE e 21 1022 e 4 c5 21 1023 mm V2 i PORTS SHOWN lt FACING DONN HYDRAULIC CYL NOTE CYLINDER END PLATE AT ROD MUST BE ROTATED 90 TO LINE UP WITH EE FITTING CYLINDER END PLATE IN LINE WITH PIN MOUNTING HOLE A11 HYDRAULIC SYSTEM START UP PROCEDURE 1 A 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 Mobil DTE 25 IMPORTANT NEVER USE A FOAMING DETERGENT TYPE OIL Qr m 309 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 bleed off any entrapped air from the hydraulic system A warning Es
52. tion is supplied for guidelines only and does not assure the installer of other mounting considerations Dimension A 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 measuring from the rearmost obstruction A1 Truck Chassis cab to axle cab to trunnion Specification formula Determine shortest E dimension possible with desired suspension Also determine extra behind cab clearance for tarper toolbox or other accessories Then use the following formula to determine CA or CT to specify Single Axle CA A E extra clearance Tandem Axle CT A E extra clearance The preceding illustrations provide dimensional guidelines for compatibility with containers etc If the chassis is higher or lower than the 41 dimension shown then the lowest hook pickup dimension will change accordingly 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 KP816 Hook Hoist is designed to mount on a standard truck frame there are unmovable obstructions on top ki 2234 a of the truck frame you must add spacers to raise the hoist frame to clear or move the obstructions 1 Compare the Truck Chassis with the Hook Hoist ordered 138CA 156CA Hoist Compare the specificati
53. ver Check Assemblies or Plug ingSels i RolerBeaings O PoWetSeds IegralD iveShafrandGearSet I I T PotEndCoer HE 24 HYDRAULIC CYLINDER ASSEMBLY SEN AA 2 Sr I 23 707 6 x55 1 2 Hydraulic Cylinder Assembly LIFT 4 00 Retracted 74 5 8 Extended 130 1 8 Stroke 55 1 2 Rod Dia 2 3 4 Item Part Description Qty Manufacturer s Label Full Locknut Wear Ring Piston Seal X Rod Barrel Assembly ________ 2 pA Pp LINZ _ LI pS ________ EN 25 2492 2 1 1 1 1 1 1 Backup Washer 2 3 8 Bolt 25 2432 2 1 Pog 2 23 808 eal Kit Items Included in Kit e Not Included in Cylinder Assembly 5 7 10 i 12 13 14 15 6 ES 25 GREEN HYDRAULIC CYLINDER ASSEMBLY Rev 9 01 23 721 3 x35 Green Hydraulic Cylinder Assembly EXTEND 9 01 Retracted 45 Extended 80 Stroke 35 Rod Dia 1 3 4 1 MenWaduerslabel G G a 71800 SCHERER I 7 Barrel Assembly Rod Assembly Head Wear Hing gt Z 5 Back up Washer Lock Wire Rod Seal Hod Wiper Steel Plug not shown e 23 803 eal Kit Items I
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