Operation, Installation, and Service Manual
Contents
1. 181 1 27 1386A1 4 3 x 48 156 CA 139 172 585640 Stabilizer Cylinder 1 3 1 2 x 10 Slave 182 senro WINCH 1 3 3 4 x 10 Slave 2264110 BUMPER 1 2 Low Pressure American S A E Hydraulic System 138 42 8 158CA Gear driven hydraulic pump 52 3 4 54 BOOM Braided and socked hose 50 1 2 62 BOOM Phenolic pads in boom Sliding L arm 2 fullsub framelocks N Z LL Cantilevered lock hook 3871557 985 28 NOTE DO SPEC TRUCK BEFORE READING MOUNTING INSTRUCTIONS 1001 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 an accident occurs see a doctor immediately Any fluid injected into2. 7 92741621 EndCapwHoe 2 8 9625 07 HearFenderMom ngTubo 2 9 92 4 50 0 EndCap 7 7 727 P12 TANDEM POLY FENDERS MS615 5 FOR MODELS KP716 7 97 Part Description Dual Poly Fender mame inn Rear Fender Mount Center Fender Mount P13 TOOL BOX FOR MODELS ALL 3 00 Part Description 9274 110 0 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 63 107 7 1 2NC Self Locking Nut 7 e 62598 NC x 1 1 22GD5 Round Head Square Neck Bok 2 9 64 110 SH STDFHaWaher 14 Sm4 45 1 Pipe P14 TOOL BOX STEEL TOOLBOX MOUNTS ARE WELDED TOOLBOX AND BOLTED TO FRAME MS606 4 3 37 FOR MODELS KP716 6 97 5 5 63 110 8NC Lock Nut 64 110 5 8 STD Flat Washer E E 4 4 4 6 p NE EM a S S pul pm 2 15 AL V Rev 6 02 M9718 3 HYDRAULICS KP716 10 02 Part Number Part Description Qty 1 24 363R 1 2 x284 JIC Black 2W Hose Assembly 3 4 M JIC to 3 4 F JIC Swivel Hydraulic Fitting 2 4 1 2 x 56 JIC Black 2W Hose Assembly 1 1 16 O Ring to 3 4JIC M M Hydraulic Fitting 5 6 x 56 1 2 Hydraulic Cylinder 7 3 x 48 Hydraulic Cylinder 23 721 3 x 35 H
3. American Hook Lift 6 x 9 10 01 M8718 11 3 02 3 S exact quantity needed See page AS for Suggested locations on truck frame P29 This page intentionally left blank P30 KP716 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 KP716 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 any parts of the structure 4 EGURPNENT DIVIBIGN g P P KRAUSE CORPORATION HUTCHINSON KANSAS Before starting installation procedures check the shipping list to ensure that all parts and accessories have been supplied Any missing items should be MODEL p 1
4. BANKED TOGETHER radius The controls may be mounted flush a control console side mounted or bank mounted together and through bolted shown above M92003 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 avoit 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 Install the control head end of the cable by first removing the cable retaining bolt 2 Slip the cable housing into the control head and replace the u retaining bolt 3 Check the control for free movement and correct valve control 4 To connect the cable to the valve handle start by removing the mounting nut from the cable assembly t We 5 Install the threaded portion of the cable assembly through the i bulkhead weldment and replace the mounting nut 6 Install the clevis provided to the cable end and the valve handle M9200 36 NOTE The cable
5. 92 6 plate and 3 section as shown Using the longer 2 stud bolts 3 supplied Xreassemble valve and torque nut to 15 Ft Lbs Install 6 3 4 M O Ring to 3 4 M JIC Hydraulic fitting 8 into stabilizer cylinder and lock valve Zas shown Install 4 3 4 F JIC to 3 4 M JIC 90 Fittings onto fitting 8 Install 2 3 4 M O Ring to 3 4 M JIC 90 fitting into valve 7 Install 2 7 8 M O Ring to 3 4 into 3rd section control valve Connect from control valve extend port to V2 port and retract to V1 on lock valve 7 with L hose 5 Connect from lock valve Z port C2 to stabilizer cylinder 5 base on 21 1023 with 9 Connect cylinder rod end port naa 1 8 SCALE to cylinder base port with hose 9 Connect from 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 frame 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 cylinders ee T 3 ER
6. 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 v EU EI of Truck Was k 0 to 14 9716 38 3 Weld a 3 8NC x 1 1 2 bolt in center of plate as shown Item 3 in photo to the right 4 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 Attach hoses using ONE hose clamp at locations 1 and 2 photo above TWO hose clamps at locations 3 and 4 photo at right Secure clamps with 3 8 lock nuts Adjust hoses to allow enough travel and return without getting caught in hoist Operate through full tilt and full separate boom travel M9716 39 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 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 IMPORTAN
7. the skin must be surgically removed within a few hours or gangrene may result 74 276 E DANGER TO DUMP LOAD INNER BOOM MUST FULLY EXTENDED AND SECURELY LATCHED TO TILT FRAME SLIDE LOCK SLIDE LOCK TILT FRAME TILT FRAME LOCK BARS DANGER HOOK AND BAIL HEIGHTS INNER BOOM INNER BOOM MUST MATCH NEVER ATTEMPT TO OVERRIDE INNER BOOM INTERLOCK SWITCH TILT FRAME OR LOAD WILL BE UNSTABLE AND NAY FALL CAUSING SERIOUS INJURY OR DEATH OPERATOR ANDIOR Failure to comply with warnings could allow inner boom and BYSTANDERS V tilt frame to separate resulting in serious injury or death 74 490 74 593 CAUTION DO NOT DRIVE WITH DANGER CAUTION STAND CLEAR P T O AER 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 CA U TI O N e VL 74 299 SET BRAKE BEFORE OPERATING WINCH 74 476 WARNING DO NOT ATTEMPT TO LOAD A CONTAINER UNLESS THE HOIST AND CONTAINER ARE CORRECTLY ALIGNED WARNING DO NOT LOAD UNLOAD OR T DUMP A CONTAINER ON KEEP THE CONTAINER RAILS SQUARELY UNEVEN GROUND ENGAGED WITH THE HOIST ROLLERS MORE FAILURE DO SO COULD CAUSE THE AND TURNING
8. 24 Air Control Mounting Plate 1 4NC x 3 4 Hex Washer Thread Cutting Screw 3 8NC x 1 1 2 Hex Washer Thread Cutting Screw 3 8 STD Flat Washer 3 8 STD Lock Washer 3 8NC Hex Nut Joystick Controller 82 199 Pneumatic Control Valve 1 valve 62 485 10NC x 1 2 Cross Recess Pan Head Machine Screw PTO Indicator Light 10 Flat Washer 10 External Tooth Lock Washer 10 Hex Nut ss 9 10 12 13 14 15 16 lt s L T8 19 20 22 23 24 25 26 27 28 29 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 3 1 2 Tube Union Tee Compression Fitting 3 8NPT Male 1 4 Tube Straight Compression Fitting Pressure Protection Valve 1 4NPT Hex Nipple 77 Used with 3 Spool Valve Assembly ONLY e This is a bulk quantity item Specify the amount required when ordering w w Gd CO O N P21 REMOTE VALVE amp CONTROLS CLEVIS PIN amp COTTER PIN INCLUDED WITH ITEM 5 CLEVIS M9706 23 Rev 10 00 FOR MODELS KP716 10 01 Part Number Part Description Qty 82 238 2 9274 0 1305 2 72 112 Cable 84 Long 72 109 Cable 252 Long 2 9610 0 17 9706 0 23 72 108 9610 108 1 25 2505 D 1 2 2 1 3 1 25 2199 25 2201 62 106 1 4NC x 4 GD5 Cap Screw 63 141 62 115 3 8NC x 1
9. 26 29 30 31 33 94 9 36 37 38 39 40 42 43 Es 1 1 1 1 1 6 9 33 34 35 36 37 38 39 40 41 42 43 44 45 47 48 50 51 52 53 17 HYDRAULIC SCHEMATIC STABIL CYLINDERS CONTROL VALVE SOLENOID r T Y TT 35 EXTENSION EXTENSION CYLINDER LIFT CYLINDER P18 WINCH VALVE LIFT 19 01 M9716 26 GRESEN VALVE ASSEMBLY Positioner End InletEnd O Y Outlet End View 7 00 M9706 21 FOR MODELS ALL 11 00 Part Desorption Relief Valve Seal Kit WH Std Relief HexNu C C j 25 2411 Inlet Cover P19 i SUPPLY NE SUPPLY 3 INSTALL VALVE WITH CONTROL HANDLES POINTING UP THROUGH SLOT IN TANK M9716 12 KP716 AIR CONTROL 2 OR 3 SPOOL PARTS FOR MODELS KP716 10 01 1 JJ HydraulicTank 30Galon Control Valve 2 Spool Rev w Free Flow Spool V20 1 Valve Section 4 Way 3 Position Spool Air Line 40 Handle V 20 Valve 2 Air Activator Assembly Compression Fitting 1 8NPT M 1 4 Tube 90 Air Line Air Control Tower Assembly Tower E 4 Pre 5 1 4NC x 1 2 Cap Screw 1 4 STD Lock Washer 1 4NC Hex Nut Cover Cap Used when not equipped with Item
10. 5210 5633 Cope This page intentionally left blank P4 LIGHTED BUMPER PARTS OPTIONAL 9716 32 FOR MODELS KP716 11 01 Part Description 6 79 286 Z Dia RubberGrommet Lamp 2 Dia Clearance Red 8 79 258 WiingHamess Rear Bumper 1 9 79 208 5 14 i8Ga 4 Beehive Light 2 Dia Sealed 5 16NC x 3 4 Cap Screw P5 STABILIZER CLEVIS PIN 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 9716 4 7 01 FOR MODELS 10 01 1 9716 850 0 Stabilizer Main Weldment 2 3 16 DIA 1 3 4 Cotter Pin C 64 119 1 SID Flat Washer 6 4 x Clevis Pin NOTE 21 1023 3 3 4 x 10 Ret Series Hydraulic Cylinder 6 9716 855 0 Stabilizer Side Weldment 8 9274 26 0A RearRollerAssembly SSCS 9 21 1022 3 1 2 x 10 Ret Series Hydraulic Cylinder P6 INSTALL BEFORE WINCH IN BUMPER USE 2 9606 51 1 TAB DO NOT USE PART SUPPLIED WITH WINCH INSTALLING FOR MODELS Hd Roller Fairlead for 10 Drum 9625 0 18 9716 860 1 9716 650 0 82 249 9 000 Winch 30 282 Series 82 250 12 000 Winch 30 286 Seri
11. 8 6 usao A4 HYDRAULIC TANK INSTALLATION REFER TO PARTS SECTION PAGE P17 1 Assemble valve hoses etc to tank before mounting tank Label hoses per illustration 2 Position and clamp the Tank Mounting Bracket behind the rear of the cab boundary per illustration NOTE It 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 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 apiece 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 afew hours or gangrene may result 3 Drill six 6 5 8 diameter holes as shown in illustration Use six 6 5 8NF x 2 1 2 GD5 Cap Screws 4 If remote pump is installed see Remote Mount Pump Installation pg A5 before proceeding 5 Install the Close Nipple Gate Valve and Hose Barb onto the Tank Assembly 6 Remove the Tank Assembly and drill 3 8 diameter holes on the marks 7 H Re install the tank and tighten the set screws into the drilled holes Tighten the jam nuts ydraulic hose routing 1 Weld a 3 8NC x 1 Bolt level with cylinder
12. CORNERS CONTAINER TO MISS THE HOIST ROLLERS SERIOUS PERSONAL INJURY AND CREATING AN UNSTABLE LOAD EQUIPMENT DAMAGE COULD RESULT S 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 TRAT BE AWARE OF POWERLINES AND OVERHEAD OBSTRUCTIONS CONTACT BY THE HOIST OR CONTAINER COULD CAUSE SERIOUS INJURY OR DEATH TO THE OPERATOR AND BYSTANDERS 74485 OPERATOR USING OUTSIDE CONTROLS STAND CLEAR OF CONTAINER WHEN LOADING AND UNLOADING CONTACT COULD CAUSE SERIOUS BODILY INJURY 74 596 2 WORKING AROUND RAISED HOIST THE HOIST MUST BE SUPPORTED BY THE HOIST PROP SEE HOIST P
13. GROUND TO FRAME REV 10 02 M9716 41 A9 BUMPER INSTALLATION Lighted Bumper Installation Reference Parts pages P5 P8 1 2 O Or E G Remove the cover plate over the right side access hole Align the lighted bumper with the holes in the apron Install 1 5 8NC 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 5 Connect the leads from the wiring harness to the truck wiring as shown on parts page 9 For 4 Wire systems If 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 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 term
14. M O 7 Z 59 21 SES o eri purs H IE 1 T l M N y o M ADDED SECTION INLET 5 8 4 f PORTS SHOWN FACING DOWN HYDRAULIC CYL NOTE CYLINDER END PLATE AT ROD MUST BE ROTATED 90 TO LINE UP WITH MS715 34 FITTING ON 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 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 bleed 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 fo
15. PotPug X Bushing a i 3 16 DIA x 1 3 2 Cotter Pin 21 443 P27 PRINCE HYDRAULIC CYLINDER 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 m Par Description EPIS F3 E 2 TubeAsemby E 3 TeRodAssemby 4 ec o 7 21 2126 OlvisAssemby ork Nie 9 PotPug 10 PotPug a Bushing Clevis Pin 3 16 DIA x 1 3 4 Cotter Pin 15 E i17 E O Hng 18 x Badk pWasher 2 19 x TetnSel E U Cp E o 25 UE 22 21 443 SeresCauionDeca e 21 8088 SealKt xlemsindudedinKi P28 INSIDE OF CAB CX NEXT TO CONTROLS FOR MODEL KP716 Decal Decal Decal Decal Decal 6 74 48 Decal Decal Decal EN 74 485 Decal 74 484 Decal x gt T mmm BACK OF CAB EYE LEVEL DECALS XH NOT IN 9716 50 0 ORDER SEPARATELY Part Description Important Valve Operation Danger Operating Outside Controls Danger Lock Must Be Engaged 32 000 Lbs Warning Hydraulic Safety Caution Do Not Drive PTO Caution Set Brake Winch Lines Hooklift
16. can be cut off Rev 2 02 shorter per difference Cut 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 A Caution Before cutting or drilling through the truck chassis be sure that all hoses wiring and lines are moved out of the path of the drill 3 Unpackage the KP716 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 bac
17. reported to K PAC immediately sn MODEL N U M B ER MANUFACTURED IN COMPLIANCE WITH ANSI Z245 STANDARD IN EFFECT AT TIME OF MANUFACTURE Know the model number of the KP716 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 B C D seb The KP716 138 KP716 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 information 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 or cab to trunnion Specification formula Determine shortest E dimension possible with desired suspension Also determine extra behind cab clearanc
18. the valve actuators in the T i same manner a id Supply air line connection 1 Run an air line between the supply port of the P T O controllers and the outlet port of the P T O air switch T 2 Route the exhaust port line out of the cab H a Start up Procedure 1 Charge the air system of the truck and check lines for leakage A8 SUPPLY 2 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 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 INNER BOOM HYDRAULIC INTERLOCK INSTALLATION 1 Position the switch mounting plate 9716 0 30 on main frame as shown 2 Weld switch mounting plate with 1 4 welds 3 Mount the remote switch 79 248 to mounting plate with 1 8NC x 1 1 4 Cap Screw and Hex Flange Lock Nuts Nuts 9716 0 30 BRACKET SAFETY SWITCH 79 248 REMOTE SWITCH MOUNT USING THREE 3 1 4NC X 1 1 4 SCREWS AND FLANGE NUTS 5 0 MIN FROM INSIDE EDGE OF MAIN FRAME TRUCK CAB 4 Wire remote switch to POWER solenoid valve as shown cap blue wire PTO LIGHT on relay harness not 5 used FUSE GROUND GROUND DIN CONNECTOR
19. 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 BACK UP LIGHTS ARE ON A10 10 11 12 Stabilizer Installation See parts illustration on P6 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 assembly will bind up and be damaged Loosen and remove nuts on studs at inlet plate Add the stabilizer section 1 with o rings 2 between inlet
20. 1 2 Hex Washer Thread Cutting Screw 62 394 5 16NC x 2 1 2 GD5 Cap Screw 63 114 5 16NC Lock Nut 62 420 1 2NC x 1 1 4 GD5 Cap Screw 63 107 1 2NC Lock Nut Items included in V20 Valve Linkage Kit P22 ltem a EA lt s 9 DIRECT MOUNT HYDRAULIC PUMP M9610 7 Rev 2 99 FOR MODELS 2 01 Part Description 25 2402 Gear Pump 1 Snap ing pari 2 f Outboard Bearing 3 Sea SsmfEndOwe CheckAssembliesorPlug HmgSels HolrBeaigs pri ESE pai Port End Cover Stud or Cap Screw Stud or Srem O OC o P23 HYDRAULIC CYLINDER ASSEMBLY A AN IN p 23 707 6 55 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 Number Part Description Qty Manufacturer s Label Full Locknut Wear Ring Piston Seal PROD 2 3 8 Bolt 25 2432 e 23 808 Seal Kit x Items Included in Kit e Not Included in Cylinder Assembly tem PatNumbr _ A REESE _ ____ ani eB C 4 Ee s Li 1 20 21 25232 2251 s _ 23 8 1 1 1 1 1 1 1 B
21. 9716 1 Operation Installation and Service Manual TRUCK MOUNTED HOOK HOISTS MODEL KP716 KP716 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 KP716 SPECIFICATIONS SAFETY DECALS OPERATING SECTION SAFETY FIRST OPERATING INSTRUCTIONS Hook Hoist Check List General Guidelines F
22. E OTHER SIDE TOOL BOX MAIN L gt P EAE 74 601 4 12 WHITE REFL INSTALL AS SHOWN EN U 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 A13 1 40 REV 2 28 02 This page intentionally left blank A14
23. K UP ALARM BACK UP LIGHTCWHITE AND GROUND RED STOP LIGHT AND GROUND LH TURN lt RED LIGHT AND GROUND RED CLEARANCE AND GROUND RELAY ROUNIBROUND TO FRAME FRAME Rev 10 02 M8718 37 SINGLE STEEL FENDERS Hook Hoist Frame FOR MODELS ALL 11 00 Pari Description 9305 55 0A Standard Fender Weldment Width 25 1 2 9305 57 0A Narrow Fender Weldment Width 22 1 4 Fender Support Weldment 1 2NC x 1 1 2 Set Screw T 2NC Hex Nut 6 8 P 7 8 63 134 3 8NC Self Locking Nut 4 f C P10 SINGLE POLY FENDERS DRILL HOLES FOR CARRIAGE BOLTS E M9615 6 1 93 a FOR MODELS KP716 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 3 NINI 6 pl FEET masa S pij S 50 Items Included in Mounting Kit P11 TANDEM STEEL FENDERS M9718 13 FOR MODELS KP716 2 02 Par Description 0 9274 0 3501 Gusset 4 9274 159 0 Fender Weldment 102 Max 2 T 2NC Hex Nut 62 503 7 1 2 1 1 2 Square Head Cone Point Set Screw 4 5 9274 148 0 FrontFenderTube Weldmont 6 9625 0 8 FrontFenderMowingTube 2
24. P24 GREEN HYDRAULIC CYLINDER ASSEMBLY Rev 9 01 23 721 3 35 Green Hydraulic Cylinder Assembly EXTEND 9 01 Retracted 45 Extended 80 Stroke 35 Rod Dia 1 3 4 1 Menaduerslabel 1 Fulton f cC O ti 6 I 7 Barrel Assembly Rod Assembly Head Wear Ring O Ring Back up Washer Lock Wire Hod Seal Rod Wiper Steel Plug not shown Seal Kit Items Included in Kit e 23 803 7 1 i l e 2 03 SENS si e Not Included in Cylinder Assembly P25 HYDRAULIC CYLINDER ASSEMBLY 156 CA Rev 9 01 23 722 3 x 48 Hydraulic Cylinder Assembly BOOM EXTEND 9 01 Retracted 58 Extended 106 Stroke 48 Rod Dia 1 3 4 Pari Description 1 Manufacturers Label 12 x X Bak upWase 4 RodS amp ed I Steel Plug not shown Seal Kit x Items Included in Kit e Not Included in Cylinder Assembly P26 PRINCE HYDRAULIC CYLINDER 347 j SAS 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 Par Description 1 2 TubeAsemby E 3 TeRodAssemby 4 S pedi 5 4GlandAssemby opazi e 9 24 86 j 2
25. ROP 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 PROPER PRECAUTIONS mej This page intentionally left blank Notes USE 67 LOCKTITE ON BOLTS MARKED WITH x P2 Rev 10 02 MS716 1 MAIN FRAME ASSEMBLY FOR MODELS 138CA 156CA 10 02 Zerk Em 9610 120 7 Cylinder Pin Extension Cylinder 62 351 1 2NC x 4 1 2 GD5 Cap Screw 9615 00 13 Lift Cylinder Pin 4 84 8 Ca 84 BNC 9 11 GDS Cap Saw 4 jem eso A 76 452 Bok Cotar Raley 44 06 0840 Cr e ssi 75 422 Ouse Roler 4 8 6540 3x2 10Ga Machine Busing 6 8 46 ONC 718 G5 Cap Sow npea Pe fe 28 61 165 SAE Fat Washer EJ 99 201 Retainer Ring 1 EX 3 TRNCx3 1H GDS Cap ole Pao Hydra 3735 Hydra Onda x T DIA 1 17 Coler Pin 5 8 DIA x 3 1 2 Clevis Pin Spring 1 OD x 125 W x 3 00 L Hydraulic Cynder 158 6 3859 5 Spem 1 82 40 54 ner Boom S858 G2 Inner Boom 98068 i 8 40 LUCI Countersunk Allen Screw 66 9716 638 0 MainFrameWeldmet 1
26. T 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 CONTROL CONSOLE SIDE MOUNTED OR BANK MOUNTED AND THROUGH BOLTED AS SHOWN IN ILLUSTRATION ON PAGE P22 2 Cut 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 P22 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 Refer to parts page P22 EEDSH Sine Choose a mounting location which is NTS MOUNTING 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 with no bends of less than 8
27. ation in the area between the mounting holes to run the air lines 5 Drilla 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 SINGLE UNIT CONTROL attach the tower to the floor with 3 8 cap screws and lock nuts 82 199 7 Mount the controller s to the tower top plate as shown EXHAUST After the controllers have been SUPPLY T mounted the plumbing of the air g 4200000 ENDVEW lines can be started HYDRAULIC 1 Determine a suitable route for 82 158 air lines i 2 Cut the necessary holes remove all burrs and add 7 Th grommets to any sharp edges 3 Determine the line length required and cut two lines for each actuator EPIS 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 mm in rare 1 Simply square cut the end of the air line and connect each controller port to M corresponding actuator Jovsnok Attach the supply and r exhaust lines HYDRAULIC VAVLE as shown To remove an air line Push the line in hold the internal sleeve and pull the air line out of the fitting i 3 Attach the air lines to
28. e for tarper toolbox or other accessories Then use the following formula to determine CA or CT to specify Single Axle CA E extra clearance Tandem Axle A E extra clearance The preceding illustrations provide dimensional guidelines for compatibility with containers 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 KP716 Hook Hoist is designed to mount on a standard truck frame If there are unmovable obstructions on top 22 3 4 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 specification dimensions to determine how far truce FRANE TO Horst MAIN FRAME 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 DETERMINED BY SUSPENSION TYPE AND TIRE SIZE fender to rear holdown are the main considerations See truck chassis an ch CHAMFER 2 Cab To Axle or CA to Trunnion 5 7 16 4 287 70 45 X specifications formulas above 2 If chassis is longer than the above 5 the chassis
29. end should be parallel to the bulkhead weldment 7 Tighten the cable mounting nut 8 Screw the control head onto the cable 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 Refer to parts section page P21 To install the pneumatic actuators to the hydraulic valve it is best to do so before assembling valve to hydraulic tank If this is not possible then remove the valve from the hydraulic tank M9716 29 Find a suitable area free of dust and _ MESE dirt to attach the pneumatic actuators 9 1 Set the hydraulic valve on the mounting base 2 Determine which spools are to be pneumatically controlled 3 Remove the positioner bonnet Item 2 above located on the back end of each spool opposite from the handle end 4 Using a 5 16 hex Allen wrench and a screw driver on the handle end of the spool remove the socket head cap screw Item 14 at right retaining the stop collar and spring NOTE It may be necessary to give the Allen wrench a sharp rap to break the socket head screw loose Discard the spring socket head screw and TWO spring collars Actuator Installation See parts page P21 The actuator is pre assembled and need not be disassembled For proper
30. es Tensioner Wire Rope Kit 10 Drum P7 MISCELLANEOUS ELECTRICAL PARTS TRUCK CAB HOIST UP LIGHT POWER 8 DIN CONNECTOR GROUND TO FRAME REV 10 02 Se 9716 41 FOR MODELS 716 10 02 Item Part Number Part Description 79 269 Hoist Up Light mi 9716 0 30 Bracket Safety Switch 79 248 Remote Switch 62 422 1 4NC x 1 1 2 GD5 Cap Screw 63 141 1 4NC Hex Flange Serrated Nut 6 79 446 DmnPlug Solenoid Valve 40 8 79 564 12VRelay30Amp peu i P8 1 MID BODY CLEARANCE 2 BEEHIVE LIGHT EXISTING TRUCK WIRING HARNESS LH TURN BRAKE LIGHT RH TURN BRAKE LIGHT TAIL CLEARANCE LIGHT BACK UP LIGHT GROUND WHITE WIRES BUMPER ELECTRICAL SCHEMATIC WIRING HARNESS SUPPLIED c 30 WIRING HARNESS JUNCTION BOX RED W BLACK STRIP OPTIONAL RED WITH YELLOW STRIP 3 YELLOW 30 WIRING HARNESS EE 2 BEEHIVE LIGHT MID BODY CLEARANCE POWER GROUND SOLENOID VALVE GROUND GROUND DIN CONNECTOR 79 FRAME SOLENOID VALVE 8 02 M8715 42 P9 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 BAC
31. inal 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 WIRING HARNESS INSTALLATION The KP716 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 o 9E NW Align the stabilizer with top hole in apron Install 1 5 8NC x 1 1 2 GD5 Cap 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 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
32. k 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 A warning Do not attempt 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 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 in
33. operation the following procedure must be adhered to 1 Remove bonnet from actuator assembly Item 2 Note Hold assembly bolt washer spring etc together 2 Install washer Item 3 onto bolt Item 1 and mount spacer Item 4 between actuator assembly and valve Screw bolt into valve spool and tighten 3 Install bolts and washer Item 5 amp 6 into valve to retain actuator and tighten 4 Install bonnet Item 2 and bolts Item 13 onto actuator and tighten 5 Check actuator by applying air pressure to each port and making sure valve spool shifts 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 A7 Pneumatic Controller Installation Tower See parts page P21 ik Determine a suitable location which is in a comfortable 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 4 343 DIA holes for the self tapping mounting bolts supplied with the tower 4 Determine a loc
34. or 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 REMOTE VALVE amp CONTROLS 01 01 01 01 04 05 O6 O7 O7 O9 P3 P5 P6 P7 P8 P9 P10 11 12 P13 P14 P15 P17 P18 P19 P21 P22 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 Installation Cable Connections PNEUMATIC CONTROL INSTALLATION Pneumatic Actuator Installation Pneuma
35. r 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 KP716 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 KP716 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 TAPE INSTALLATION REF ANSI STANDARD Z245 18983 2 2 16 VEHICLE CONSPICUITY 74 600 24 QUTSIDE EDGE OF BOTH FENDERS 74 600 48 BOTH SIDES ON HOIST MAINFRAME 74 600 247 ON HYDRAULIC TANK THIS SIDE OTHER SIDE TOOL BOX OR MAIN FRAME ALTERNATING COLOR OF RED WHITE EA COLOR 6 LENGTH CUT TO LENGTH AS SHOWN 74 600 807 OUTSIDE EDGE OF BOTH FENDERS ogra o nn DV Ar rr eee 49 ru gt HYDRAULIC THIS SID
36. stallation 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 install a direct mounted pump first of all determine the direction of rotation of the 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 iA Es MOUNT PUMP TO E PTO PER OWNER S PUMP POSITION FOR COUNTER CLOCKWISE CLOCKWISE ROTATION ROTATION macnumav Amrz ma cooma u 610 19 FRONT TVAE Rev 4 00 M9305 46 MOUNT PTO TO TRANSMISSION PER INSTRUCTIONS AND PTO 4 Tighten all hardware MANUFACTURER S INSTRUCTIONS A warning 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 m T I HYDRAULIC TANK TRUCK FRAME 5 8 18NF X 2 1 2 CAP SCREW 20 5 8 18NF HEX FLANGE LOCK NUT 20 9210 15 22 2 9244 59 0 DRILL PLATES amp TRUCK FRAME FOR 5 8 BOLT 9716 0
37. tic Controller Installation In Dash Pneumatic Controller Installation Tower Joystick Controller amp Single Valve Controller Start up Procedure INNER BOOM HYDRAULIC INTERLOCK BUMPER INSTALLATION Lighted Bumper Installation WIRING HARNESS INSTALLATION REAR STABILIZER INSTALLATION HYDRAULIC SYSTEM START UP 11 01 P23 P24 P25 P26 P27 P28 P29 Al Al A1 A1 A2 A2 A2 A3 A3 A4 5 5 5 A7 A7 A7 A8 A8 A9 A10 A10 A10 A10 A12 KP716 SPECIFICATIONS Rev 10 02 Chassis C A 138 156 See pages 1 A2 Frame Width 34 Outside reinforcement thickness 1 12 180 10 6138042 7 GVW 185 12804170 WINCH i 33 0005 52 000 Ibs Frame Height 41 top of chassis unladen varies with chassis 52 3 4 54 BOOM Sub Frame 50 1 2 62 BOOM Full length 5 x 3 tube Load Rating NI 4 2 32 000 Ibs with suitable G V W including B gel body 020 s rr poen Dump Angle 1847 TRACTED 47 with suitable body length Operating Pressure 3000 PSI Gear Pump 28 gpm 1500 rpm direct mount STD Operation In cab controls standard Hook Height 54 62 Weight 3 600 Ibs Hydraulic Planetary 4 ton or 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 35 138 547 BOOM 627 BOOM 121 2774
38. ydraulic Cylinder 24 375 1 2 x 30 Parker 436 Hose Assembly 25 300 3 4 M O Ring to 3 4 M JIC Adapter Hydraulic Fitting O Ring 37 Flare 90 Ell Hydraulic Fitting Ti 3 1 2 x 10 Ret Series Hydraulic Cylinder 3 3 4 x 10 Ret Series Hydraulic Cylinder 14 1 2 x 190 JIC Hydraulic Hose Assembly 7 8 M O Ring to 1 1 16 M Straight Hydraulic Fitting 7 8 M O Ring to 3 4 M JIC Adapter Hydraulic Fitting 3 4NPT M to 3 4 Hose Straight Hydraulic Fitting 1 1 16 M O Ring to 3 4NPT F Hydraulic Fitting 23 4 4 Way 3 Position Rev V20 Valve Section 25 1 1 16 M to 3 4NPT F 90 Hydraulic Fitting 26 24 1151 3 4 x 20 Low Pressure Hose 7 Hose Clamp 1 3 16 to 1 3 8 8 25 1182 1 1 2NPT M to 3 4NPT F Hex Reducer Fitting 3 4 x 276 Low Pressure Hose 1 2NPT M to 3 4 Hose End Hydraulic Fitting 1 3 4 M O Ring to 1 2NPT F 90 Hydraulic Fitting 1 2 Valve SD4 1 SV 2BLSD SAE 9 16 M O Ring to 3 4 M JIC Hydraulic Fitting 1 2 x 80 JIC 90 w Sleeve Mega 3000 Hose Assembly 2 3 4 M JIC to 7 8 M O Ring 90 Hydraulic Fitting 2 29 30 31 1 1 4NPT to 1 1 4 Hose 90 Hydraulic Fitting 2 3 4 x 96 w MTL Mega 3000 Hose Assembly 1 1 16 M JIC to 1 1 4NPT M Hydraulic Fitting 25 2374 3 4NPT Magnetic Plug 25 233 Oil Strainer 25 GPM 1 s ee 1 1 4NPT Close Nipple Hydraulic Fitting 1 25 2387 1 1 4NPT F x 1 1 4NPT Ball Valve 1 o sro a 2 1 1 4ID x 96 100R4 Hose Assembly 1 23 25
Download Pdf Manuals
Related Search