K-PAC KP716 Hook Hoist Operation, Installation and Service Manual

9716--1

Operation,

Installation, and Service

Manual

KP716 HOOK HOIST

DEALER PREDELIVERY CHECK SHEET

TO BE CHECKED BY DEALER

DATE CUSTOMER

ADDRESS

DEALER

ADDRESS

COUNTY

MODEL

DEALER CHECK:

COUNTY

SERIAL NUMBER

6.

7.

4.

5.

1.

2.

3.

Check that all cylinders are full of hydraulic oil and free of air. Use Mobil DTE25 or equivalent.

Examine all hydraulic hoses to see that they are protected from damage.

Check that all decals are in place and legible.

Test the back--up and hoist--up alarms.

Check that all tail lights are functioning properly.

Engage the P.T.O. Check the dash light. Check for any unusual noises.

Check that the control handles correspond with directional decals.

8.

Make sure all lubrication points have been lubed.

DELIVERED BY:

DATE

3.

4.

1.

2.

CUSTOMER REVIEW SHEET

Owner’s manual provided.

Warranty card is filled out and mailed.

Review the safety warnings and cautions as listed in this manual.

Review the container loading, and unloading procedures.

5.

6.

Explain the importance of proper maintenance of the boom pivot, boom slide and hydraulic components.

Review all of the lubrication points.

DELIVERED BY:

DATE

1

Table of Contents

11/01

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 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

P17

P18

GRESEN VALVE ASSEMBLY P19

AIR CONTROLS (2 OR 3 SECTION SPOOLS) P21

REMOTE VALVE & CONTROLS P22

P11

P12

P13

P14

P15

P3

P5

P6

P7

P8

P9

P10

O4

O5

O6

O7

O7

O1

O1

O1

O1

O1

O9

2

3

4--5

1

1

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

P23

DIRECT MOUNT PUMP INSTALLATION A3

OIL TANK, VALVE AND HOSE INSTALLATION A4

HYDRAULIC TANK INSTALLATION

INSIDE CONTROL HANDLE INSTALLATION

VALVE CONTROL INSTALLATION

A5

A5

A5

Inside Control Handle Installation

Cable Connections

PNEUMATIC CONTROL INSTALLATION

Pneumatic Actuator Installation

Pneumatic Controller Installation (In Dash)

A6

A6

A6

A7

A7

Pneumatic Controller Installation (Tower)

Joystick Controller & 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

A10

A10

A10

A12

A7

A8

A8

A9

A10

A1

A2

A2

A2

A3

A1

A1

A1

P24

P25

P26

P27

P28

P29

2

KP716 SPECIFICATIONS

Rev.10/02

Chassis C.A.:

138”/156”(See pages A1, A2) L

Frame Width:

34”(Outside) + reinforcement thickness

G.V.W.:

33,000lbs. -- 52,000 lbs.

Frame Height:

41”top of chassis unladen

(varies with chassis)

Sub Frame:

Full length 5”x 3” tube

Load Rating:

32,000 lbs. with suitable G.V.W. including body weight

Dump Angle:

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 lbs.

Hydraulic Planetary:

4 ton or 6 ton 50’ of 7/16”cable w/hook, level wind feature

Cylinders:

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

Sliding “L” arm

K

2- full sub- frame locks

K

Cantilevered lock on hook

L

NOTE: DO NOT SPEC TRUCK BEFORE READING MOUNTING INSTRUCTIONS!

3

SAFETY DECALS

See Parts Listing page for part number and proper location.

4

SAFETY DECALS

See Parts Listing page for part number and proper location.

5

This page intentionally left blank.

6

P1

P2

MAIN FRAME ASSEMBLY

FOR MODELS --

138CA, 156CA

Item Part Number

1 62--351

Part Description

1/2NC x 4--1/2”GD5 Cap Screw

2 9615--00--13 Lift Cylinder Pin

3 63--108 1/2NC Nylon--Top Lock Nut

4 62--123 3/8NC x 3--1/2”GD5 Cap Screw

5

6

7

65--101

9274--415--3

63--134

1/8”STD. Zerk

Bolt Collar (Roller)

3/8NC Nylon--Top Lock Nut

8 64--154 Machine Bushing

9 9274--412--0 Outside Roller Assembly

10 9716--0--3

11 9716--0--14

Outer Boom Pivot Pin

Prop

12 62--547

13 62--300

1/2NC x 6--1/2”GD5 Cap Screw

1/2NC x 1”GD5 Cap Screw

14 9716--240--0 Hold Down Weldment, Right

15 9716--27--0

16 64--108

Main Pivot Shaft Weldment

1/2”STD. Flat Washer

17 9716--241--0 Hold Down Weldment, Left

18 62--462

19 63--107

20 99--197

1/2NC x 3--1/4”GD5 Cap Screw

1/2NC Lock Nut

Retainer Ring 1--1/4”

21 9716--00--12 Rod Pin, Extension Cylinder

22 60--724 1/8”DIA. x 1--1/4”Cotter Pin

23 9716--355--0 Hook Lock Weldment

24 64--146

25 60--272

26 23--707

5/8”SAE Flat Washer

5/8”DIA. x 3--1/2”Clevis Pin

Hydraulic Cylinder 6”x 56”

27 82--242

28 64--162

Shock Pad

1/2”SAE Flat Washer

29 9716--354--0 KP716 54”Inner Boom (138/156) 1

1

1

2

1

2

1

1

1

8

8

2

1

9

1

2

2

1

2

2

4

4

4

4

4

Qty.

7

4

8

4

30 9716--362--0 KP716 62”Inner Boom (138/156) 1

31 62--764 3/8NC x 3/4” Flat Head

Countersunk Allen Screw

4

32 9610--120--5A Inner Boom Pad (Large)

33 9610--00--10 Shim

2

2

34 9610--00--14 Shim 2

Item Part Number

35 65--113

36

38

9610--120--7

37 99--201

9606--108--8

Part Description

Zerk 1/4UNF

Cylinder Pin, Extension Cylinder

Retainer Ring 1”

Roller Shaft

10/02

Qty.

6

39 9606--105--0 Guide Roller Assembly

40 9606--108--10 Special Bolt

41 64--109 5/8”STD. Lock Washer

42 9606--108--9 Retainer Washer

43 64--199

44 62--803

45 64--103

3 x 2 x 10 Ga. Machine Bushing

3/8NC x 7/8”GD5 Cap Screw

3/8”STD. Lock Washer

46 64--165

47 9610--00--3

48 9610--00--4

49 9710--0--9

50 9610--120--2A Outer Boom Pad

51 60--109

3/8”SAE Flat Washer

Shim .06 (Pad Retainer)

Shim .12 (Pad Retainer)

Pad Retainer

P.T.O. Lock Pin

52 9716--438--0 Outer Boom Weldment

53 23--721 Hydraulic Cylinder, 3”x 35”

54 23--722 Hydraulic Cylinder, 3”x 48”

55

56

57

9716--238--0

9716--256--0

9615--303--0

Tilt Frame Weldment (138)

Tilt Frame Weldment (156)

Main Pin Weldment

58 9716--301--0 Lock Plate Weldment, Left

59 76--218 Spring, 1”OD x .125”W x 3.00”L

1

1

60 9615--00--6 Spring Retainer 1

1

1

1

1

1

1

2

2

2

8

2

2

8

8

2

6

2

2

2

1

2

1

61 63--167 5/16NC Nylon--Top Lock Nut

62 9716--302--0 Lock Plate Weldment, Right

63 9615--304--0 Lock Pin Weldment

64 62--432

65 76--180

5/16NC x 1”GD5 Cap Screw

Spring (painted)

66 9716--638--0 Main Frame Weldment

67 99--158 Locktite (250ml)

68 5210--563--3 Coupler 1

2

2

1

2

1

2

P3

This page intentionally left blank.

P4

LIGHTED BUMPER PARTS

FOR MODELS --

KP716

Item

1

Part Number

79--237

13

14

15

16

10

11

8

9

12

17

18

5

6

7

2

3

4

79--234

79--233

62--425

9274--0--461

79--236

79--235

79--253

79--293

79--509

79--294

79--296

9274--0--451

9274--546--0

79--254

62--362

63--139

79--250

4.25”Dia Rubber Grommet

Part Description

Lamp -- Stop/Tail/Turn

Lamp -- Back--up

3/8NC x 3/4”GD8 Hex Washer Thread Forming Screw

Bumper Cover

2”Dia. Rubber Grommet

Lamp -- 2”Dia. Clearance (Red)

Wiring Harness, Rear Bumper

Splice Connector 14 Ga to 18 Ga

Junction Box (Option)

Wiring Harness -- 30”

Beehive Light -- 2”Dia. Sealed

Cover Plate

Bumper Weldment

Lamp -- LPL Courtesy

5/16NC x 3/4”Cap Screw

5/16NC Lock Nut

Back--Up Alarm

1

2

1

1

2

1

1

2

1

4

2

1

7

2

8

5

11/01

Qty.

6

4

P5

STABILIZER

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 --

Item

7

8

5

6

9

1

2

K

3

4

K

Part Number

9716--850--0

64--119

21--1023

9716--855--0

9716--0--1

9274--26--0A

21--1022

Part Description

Stabilizer Main Weldment

3/16”DIA. x 1--3/4”Cotter Pin

1”STD. Flat Washer

Clevis Pin

3--3/4”x 10”Ret/Series Hydraulic Cylinder

Stabilizer Slide Weldment

Stabilizer Roller Shaft

Rear Roller Assembly

3--1/2”x 10”Ret/Series Hydraulic Cylinder

K

Included in cylinder assembly see pages P27 and P28

1

2

6

2

10/01

Qty.

1

2

1

1

P6

WINCH

9

10

11

12

13

14

7

8

5

6

FOR MODELS --

Item

3

4

1

2

Part Number

64--108

62--569

9716--860--2

82--295

62--805

9625--0--18

9716--860--1

62--815

64--107

63--106

9716--850--0

82--249

82--250

82--251

Part Description

1/2”STD. Flat Washer

1/2NC x 1--1/2”GD5 Cap Screw

Winch Cover Plate

Hd. Roller Fairlead for 10”Drum

M12 x 1.75 x 35 x 8.8 Cap Screw

Angle -- Winch Cover

Winch Mount / Cover

M12 x 1.75 x 25 x 8.8 Cap Screw

1/2”STD. Lock Washer

1/2NC Hex Nut

Stabilizer Main Weldment

9,000# Winch (30--282 Series)

12,000# Winch (30--286 Series)

Tensioner Wire Rope Kit 10”Drum

P7

1

1

1

1

4

4

1

8

4

1

1

1

3/03

Qty.

8

4

MISCELLANEOUS ELECTRICAL PARTS

FOR MODELS --

KP716

Item

1

Part Number

79--269

4

5

2

3

6

9716--0--30

79--248

62--422

63--141

79--496

7

8

9

79--563

79--564

79--565

Part Description

Hoist Up Light

Bracket -- Safety Switch

Remote Switch

1/4NC x 1--1/2”GD5 Cap Screw

1/4NC Hex Flange Serrated Nut

Din Plug

Solenoid Valve (40 GPM)

12V Relay 30 Amp

12V Relay Connector w/ Wire

1

1

1

10/02

Qty.

1

3

3

1

1

1

P8

ELECTRICAL SCHEMATIC

P9

SINGLE STEEL FENDERS

6

7

8

4

5

2

3

FOR MODELS --

ALL

Item

1

Part Number

9305--55--0A

9305--57--0A

9305--56--0

62--503

63--106

44--129

62--108

9274--0--1

63--134

Part Description

Standard Fender Weldment -- (Width = 25--1/2”)

Narrow Fender Weldment -- (Width = 22--1/4”)

Fender Support Weldment

1/2NC x 1--1/2”Set Screw

1/2NC Hex Nut

Mud Flap

3/8NC x 1”GD.5 Cap Screw

Mud Flap Backing Plate

3/8NC Self Locking Nut

M9706--22

11/00

1

4

2

2

Qty.

1

1

2

1

4

P10

SINGLE POLY FENDERS

DRILL HOLES FOR

CARRIAGE BOLTS.

FOR MODELS --

KP716

Item Part Number

1

2

3

K

4

K

5

K

6

K

44--190

82--255

Part Description

Poly Fender Kit Single Axle 26”

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

K

Items Included in Mounting Kit

P11

16

23

23

7

1/99

Qty.

1

1

TANDEM STEEL FENDERS

FOR MODELS -- KP716

Item

7

8

5

6

9

3

4

1

2

Part Number

9274--0--3501

9274--159--0

63--106

62--503

9274--148--0

9625--0--8

9274--162--1

9625--0--7

9274--50--6

Part Description

Gusset

Fender Weldment (102”Max)

1/2NC Hex Nut

1/2NC x 1--1/2”Square Head Cone Point Set Screw

Front Fender Tube Weldment

Front Fender Mounting Tube

End Cap w/ Hole

Rear Fender Mounting Tube

End Cap

2

2

2

2

2

4

4

2/02

Qty.

4

2

P12

TANDEM POLY FENDERS

FOR MODELS --

KP716

Item

1

2

3

4

5

Part Number

44--133 Dual Poly Fender

9274--115--1A Rear Fender Mount

9274--115--8 Center Fender Mount

9274--115--5

9274--115--6

Part Description

Front Fender Brace -- Left

Front Fender Brace -- Right

7/97

Qty.

4

2

2

1

1

P13

TOOL BOX

9

10

7

8

11

12

13

14

FOR MODELS -- ALL

Item Part Number

9274--110--0

1 9274--36--0

4

5

2

3

6

62--139

9274--35--1

53--126

64--108

63--107

75--109

62--598

64--110

9274--37--0

9274--48--0

62--401

9274--59--0A

9274--45--1

Part Description

Tool Box & Platform Assembly

Tool Box Weldment

1/2NC x 1--3/4”Carriage Bolt

Hinge Strap

Wear Sleeve

1/2”STD. Flat Washer

1/2NC Self Locking Nut

Plastic Plug

1/2NC x 1--1/2”GD5 Round Head Square Neck Bolt

5/8”STD. Flat Washer

Tool Box Lid Weldment

Tool Box Rack

1/2NC x 1”Cap Screw

Tank Mounting Weldment

Pipe

M9200--3

2

2

2

2

1

1

2

2

4

4

2

2

4

3/00

Qty.

1

1

P14

TOOL BOX

FOR MODELS --

KP716

Item

1

2

3

4

5

6

Part Number

9606--111--0

82--245

9606--112--0

62--708

63--110

64--110

Left Tank Strap Weldment

Part Description

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

6/97

Qty.

1

1

1

4

4

4

P15

P16

Item

5

6

7

3

4

1

2

36

37

38

39

32

33

34

35

28

29

30

31

24

25

26

27

20

21

22

23

16

17

18

19

12

13

14

15

10

11

8

9

48

49

50

51

52

53

44

45

46

47

40

41

42

43

Part Number

79--563

25--583

25--478

25--379

25--1175

25--448

25--2495

25--342

25--2502

25--449

24--1151

25--494

25--1182

24--1150

25--1180

25--493

24--363R

25--310

25--326

24--387R

25--363

23--707

23--722

23--721

24--375

25--300

25--301

25--304

21--1022

21--1023

25--2496

24--373R

25--2394

25--328

24--3042

25--485

SEE PG P7

25--2419

25--170

24--609

25--531

25--2402

25--235

9244--30--0A

25--2374

25--233

HYDRAULICS (KP716)

Part Description

1/2”x 284”(JIC) Black 2W Hose Assembly

3/4(M)JIC to 3/4(F)JIC Swivel Hydraulic Fitting

37 (M) Bulkhead Tee Hydraulic Fitting

1/2 x 56”(JIC) Black 2W Hose Assembly

1--1/16 O--Ring to 3/4JIC (M/M) Hydraulic Fitting

6”x 56--1/2”Hydraulic Cylinder

3”x 48”Hydraulic Cylinder

3”x 35”Hydraulic Cylinder

1/2”x 30”Parker 436 Hose Assembly

3/4(M) O--Ring to 3/4(M) JIC Adapter Hydraulic Fitting

O--Ring 37_ Flare 90_ Ell Hydraulic Fitting

37_ Flare Male coupler Hydraulic Fitting

3--1/2”x 10”Ret/Series Hydraulic Cylinder

3--3/4”x 10”Ret/Series Hydraulic Cylinder

Dual Counterbalance Valve

1/2”x 190”(JIC) Hydraulic Hose Assembly

Solenoid Valve -- N.C. (40 GPM)

1--1/16 O--Ring to 1--1/16JIC 90_ Hydraulic Fitting

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

2 Spool Control Valve (Reversed w/ Free Flow Spool)

1--1/16 O--Ring to 1--1/16 JIC Hydraulic Fitting

4--Way 3--Position (Rev V20) Valve Section

1--1/16(M) to 3/4NPT(F) 90 Hydraulic Fitting

3/4 x 20”Low Pressure Hose

Hose Clamp (1--3/16”to 1--3/8”)

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

3/4(M)O--Ring to 1/2NPT(F) 90_ Hydraulic Fitting

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

3/4(M) JIC to 7/8(M) O--Ring 90_ Hydraulic Fitting

Winch

Power Beyond Sleeve SAE #10 (V20 Valve)

1--1/4NPT to 1/1/4 Hose 90_ Hydraulic Fitting

3/4”x 96”(JIC) w/MTL Mega 3000 Hose Assembly

1--1/16(M) JIC to 1--1/4NPT (M) Hydraulic Fitting

31 GPM Pump (615)

Sight Gauge w/Temp 5”

Hydraulic Tank Weldment

3/4NPT Magnetic Plug

Oil Strainer -- 25 GPM

75--141

25--2387

25--487

24--1136

25--215

25--2247

25--2248

1--1/4NPT Close Nipple Hydraulic Fitting

1--1/4NPT(F) x 1--1/4NPT Ball Valve

(T--Bolt Type) Hose Clamp

1--1/4ID x 96”100R4 Hose Assembly

Filler Cap Assembly

In--Tank Filter

Filter Element

P17

1

1

2

1

1

1

1

10/02

Qty.

1

1

1

1

1

4

1

1

2

2

1

2

1

1

3

1

1

2

1

4/7

1

2

1

1

3

2

2

8

1

1

5

2

3

11

2

9

1

1

1

1

1

1

1

1

2

P18

GRESEN VALVE ASSEMBLY

9

10

7

8

5

6

3

4

1

2

FOR MODELS --

ALL

Item Part Number

25--2495

25--2409

25--2413

25--2508

25--2408

25--2502

25--2412

25--2411

Part Description

Gresen V20 2 Spool Valve Assembly (Reversed)

Main Relief Valve

Relief Valve Seal Kit (WH Std. Relief)

Valve Section -- 4 Way, 3 Position, Free Flow Spool (Reversed)

Valve Section Seal Kit

Valve Section -- 4 Way, 3 Position Spool (Reversed)

Outlet Cover

Hex Nut

Lock Washer

Studs

Inlet Cover

7/00

M9706--21

11/00

Qty.

1

1

1

1

1 / Section

1

1

3

1

6

6

P19

P20

M9716--12

KP716 AIR CONTROL 2 OR 3 SPOOL PARTS

FOR MODELS -- KP716

Item

1

2

3

Part Number

62--394

63--167

4 25--2495

5

K

25--2406

6

KD

82--124

7 9610--45--0

12

13

14

15

8

9

82--288

82--126

10

D

82--124

9274--196--0

11 9274--196--2

62--530

64--100

63--100

9274--196--3

30

31

32

33

34

26

27

28

29

20

21

22

23

16

17

18

19

9274--196--4

9274--196--1

62--342

62--115

64--104

64--103

63--102

82--157

24

K

82--199

25 62--485

64--158

64--170

63--151

82--166

82--163

82--168

82--167

Part Description

Hydraulic Tank -- 30 Gallon

5/16NC x 2--1/2”Cap Screw

5/16NC Nylon--Top Lock Nut

Control Valve 2 Spool (Rev. w/ Free Flow Spool) V20

Valve Section, 4--Way, 3--Position Spool

Air Line

Handle Kit, V--20 Valve

Air Activator Assembly

Compression Fitting 1/8NPT(M) -- 1/4”Tube 90_

Air Line

Air Control Tower Assembly

Tower

1/4NC x 1/2”Cap Screw

1/4”STD. Lock Washer

1/4NC Hex Nut

Cover

Cap (Used when not equipped with Item 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

Pneumatic Control Valve (1 valve)

#10NC x 1/2”Cross Recess Pan Head Machine Screw

P.T.O. Indicator Light

Air Valve

#10 Flat Washer

#10 External Tooth Lock Washer

#10 Hex Nut

1/4”Tube Union Tee Compression Fitting

3/8NPT Male 1/4”Tube Straight Compression Fitting

Pressure Protection Valve

1/4NPT Hex Nipple

10/01

4

1

4

4

1

1

1

4

1

1

1

4

1

4

4

4

4

1

1

14

14

14

1

2/3

5

80’

1

1

1

1

40’

2/3

Qty.

1

3

3

K

Used with 3--Spool Valve Assembly ONLY

D

This is a bulk quantity item. Specify the amount required when ordering.

P21

REMOTE VALVE & CONTROLS

FOR MODELS --

KP716

Item

1

2

3

4

5

6

10

K

11

12

13

14

15

16

17

7

K

8

K

9

K

Part Number

82--238

9274--0--1305

72--112

72--109

9610--0--17

9706--0--23

72--108

9610--108--1

25--2505

25--2199

25--2201

62--106

63--141

62--115

62--394

63--114

Part Description

Controller

Control Mount

Cable -- 84”Long

Cable -- 252”Long

Control Cable Bulkhead Plate

3 Cable Bracket

Clevis, 3/8”Hole

Valve Handle

V--20 Valve Linkage Kit

Link

Link Plate

Cotter Pin

Pin

Die Cast Bracket

Screw

1/4NC x 4”GD5 Cap Screw

1/4NC Hex Flange Serrated Nut

3/8NC x 1--1/2”Hex Washer Thread Cutting Screw

5/16NC x 2--1/2”GD5 Cap Screw

5/16NC Lock Nut

18

19

62--420

63--107

1/2NC x 1--1/4”GD5 Cap Screw

1/2NC Lock Nut

K

Items included in V20 Valve Linkage Kit

P22

10/01

2

2

1

1

Qty.

2

2

2

2

2

3

1

1

1

1

3

3

4

3

3

2

2

DIRECT MOUNT HYDRAULIC PUMP

FOR MODELS --

Item Part Number

25--2402

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

Part Description

Gear Pump

Snap Ring

Outboard Bearing

Seal

Shaft End Cover

Check Assemblies or Plug

Ring Seals

Roller Bearings

Pocket Seals

Thrust Plates

Integral Drive Shaft and Gear Set

Gasket Seals

Gear Housing

Port End Cover

Washer

Stud or Cap Screw

Nut

P23

M9610--7

Rev.2/99

2/01

Qty.

1

HYDRAULIC CYLINDER ASSEMBLY

23--707 6”x 55--1/2” Hydraulic Cylinder Assembly (LIFT)

Retracted -- 74--5/8” Extended -- 130--1/8” Stroke -- 55--1/2”

Item

1

2

3

K

4

K

5

6

K

7

8

9

10

K

11

12

K

13

K

14

15

16

K

17

K

18

19

20

21

22

Part Number

Manufacturer’s Label

Full Locknut

Wear Ring

Piston Seal

Piston

O--Ring

Stop Tube

Rod

Barrel Assembly

Wear Ring

Gland

O--Ring

Backup Washer

Set Screw

Cap

Rod Wiper

Rod Seal

3/8”Bolt

Nylon Lock Nut

Rod End Assembly

Part Description

25--2432 Counterbalance Valve

3/4”Port Plug

D

23--808 Seal Kit ( K Items Included in Kit)

D

Not Included in Cylinder Assembly

P24

Rod Dia. -- 2--3/4”

4/00

2

1

1

1

1

1

1

1

1

1

1

1

Qty.

1

1

2

1

2

3

1

1

1

1

GREEN HYDRAULIC CYLINDER ASSEMBLY

23--721 3”x 35” Green Hydraulic Cylinder Assembly (EXTEND)

Retracted -- 45” Extended -- 80” Stroke -- 35”

Item

1

2

3

4

5

K

6

K

7

Part Number

25--2433

8

9

10

K

11

K

12

K

13

14

K

15

K

16

D

23--803

Part Description

Manufacturer’s Label

Counterbalance Valve

Full Locknut

Piston

Piston Seal

O--Ring

Barrel Assembly

Rod Assembly

Head

Wear Ring

O--Ring

Back--up Washer

Lock Wire

Rod Seal

Rod Wiper

Steel Plug (not shown)

Seal Kit ( K Items Included in Kit)

D

Not Included in Cylinder Assembly

Rev.9/01

Rod Dia. -- 1--3/4”

9/01

1

1

1

1

1

1

1

1

1

1

1

1

1

Qty.

1

2

1

P25

HYDRAULIC CYLINDER ASSEMBLY (156 CA)

23--722 3”x 48” Hydraulic Cylinder Assembly (BOOM EXTEND)

Retracted -- 58” Extended -- 106” Stroke -- 48”

Item

1

2

3

4

5

K

6

K

7

Part Number

25--2433

8

9

10

K

11

K

12

K

13

K

14

K

15

D

23--803

Part Description

Manufacturer’s Label

Counterbalance Valve

Full Locknut

Piston

Piston Seal

O--Ring

Barrel Assembly

Rod Assembly

Head

Wear Ring

O--Ring

Back--up Washer

Rod Seal

Rod Wiper

Steel Plug (not shown)

Seal Kit ( K Items Included in Kit)

D

Not Included in Cylinder Assembly

Rev.9/01

Rod Dia. -- 1--3/4”

9/01

1

1

1

1

2

1

1

1

1

1

1

1

Qty.

1

2

1

P26

PRINCE HYDRAULIC CYLINDER

21--1022 3--1/2” X 10” PRINCE HYDRAULIC CYLINDER ASSEMBLY (Series)

Retracted -- 22--1/4” Extended -- 32--1/4” Stroke -- 10”

12/00

Rod Diameter -- 1--1/4”

Part Number Item

1

2

3

6

7

4

5

10

11

8

9

12

K

13

K

14

K

15

K

20

21

22

23

24

16

K

17

K

18

K

19

K

21--2131

21--376

21--2121

60--703

21--404

21--443

74--113

21--2088

Part Description

Piston Rod

Tube Assembly

Tie Rod Assembly

Butt

Gland Assembly

Piston

Clevis Assembly

Lock Nut

Clevis Pin

Seal Kit Decal

Port Plug

Bearing Ring

O--Ring

O--Ring

O--Ring

Back--Up Washer

Teflon Seal

U--Cup

Wiper

Bushing

3/16”DIA. x 1--3/4”Cotter Pin

Port Plug

Series Caution Decal

Cylinder WARNING Decal

Seal Kit ( K Items Included in Kit)

1

2

2

1

1

1

1

2

1

1

1

1

Qty.

1

1

4

3

1

1

4

1

1

1

2

1

P27

PRINCE HYDRAULIC CYLINDER

21--1023 3--3/4” X 10” PRINCE HYDRAULIC CYLINDER ASSEMBLY (Series)

Retracted -- 22--1/4” Extended -- 32--1/4” Stroke -- 10”

12/00

Rod Diameter -- 1--3/8”

Item

1

2

3

6

7

4

5

10

11

8

9

12

13

14

K

15

K

Part Number

21--2126

21--260

60--703

16

K

17

K

18

K

19

K

20

K

21

K

22

23

24

21--443

21--2117

74--113

D

21--808

Part Description

Piston Rod

Tube Assembly

Tie Rod Assembly

Butt

Gland

Piston

Clevis Assembly

Lock Nut

Port Plug

Port Plug

Bushing

Clevis Pin

3/16”DIA. x 1--3/4”Cotter Pin

Bearing Ring

O--Ring

O--Ring

O--Ring

Back--Up Washer

Teflon Seal

U--Cup

Wiper

Series Caution Decal

Seal Kit Decal

Cylinder Warning Decal

Seal Kit ( K Items Included in Kit)

2

1

2

4

3

1

1

1

1

1

1

1

Qty.

1

1

4

1

1

1

1

1

2

1

1

2

P28

DECALS

FOR MODEL -- KP716

12

13

14

15

10

11

8

9

Item

1

2

3

6

7

4

5

16

17

18

19

20

K

74--600

21

K

74--601

Part Number

74--598

74--596

74--593

74--579

74--276

74--481

74--476

74--286

74--485

74--490

74--475

74--288

74--302

74--387

74--484

74--477

74--297

74--478

74--486

K

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

Decal -- Caution Do Not Drive PTO

Decal -- Caution Set Brake

Decal -- Winch

Decal -- Danger Power Lines (Hooklift)

Decal -- Danger Hook Height Match

Decal -- American Hook Lift

Decal -- Warning Raised Hoist

Decal -- Danger Unit Operation

Decal -- Cylinder Lock

Decal -- American Hook Lift (6”x 9”)

Decal -- Caution Safety Instructions

Decal -- Warning Uneven Ground

Decal -- Important Operation Instruction

Decal -- Warning Align Container

Reflective Tape -- Red/White (NOT SHOWN)

Reflective Tape -- White (NOT SHOWN)

Specify exact quantity needed. See page A13 for suggested locations on truck frame

3/02

2

1

2

3

1

2

1

1

2

1

2

2

Qty.

2

1

3

1

1

1

1

20 Ft.

4

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 or any parts of the structure.

Before starting installation procedures, check the shipping list to ensure that all parts and accessories have been supplied.

Any missing items should be reported to K--PAC immediately.

MODEL

EQUIPMENT DIVISION OF

KRAUSE CORPORATION

HUTCHINSON, KANSAS

SERIAL

MODEL NUMBER

Know the model number of the KP716 being mounted.

MANUFACTURED IN COMPLIANCE WITH ANSI Z245

STANDARD IN EFFECT AT TIME OF MANUFACTURE.

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

M9716--28

KP716--138 183” 181.5” 161.50” 52.75”

KP716--156 201” 199.5” 179.50” 60.50”

E

SINGLE TANDEM

45”

28”

49”

49”

41”

41”

G

54”boom 62”boom

48”

48”

42”

42”

The KP716--138 / KP716--156 Hook Hoist is designed for a 30,000--46,000 lb. 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 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 KP716 Hook Hoist is designed to mount on a standard truck frame.

If there are unmovable obstructions on top of the truck frame, you must add spacers to raise the hoist frame to clear, or move the obstructions.

1. Compare the Truck Chassis with the

Hook Hoist ordered (138CA / 156CA

Hoist).

Compare the specification dimensions to determine how far forward on the chassis the Hoist can be mounted. It is best to mount as far forward as possible for optimum weight distribution. Suspension and fender to rear holdown are the main considerations.

See truck chassis

Cab--To--Axle or CA--to--Trunnion specifications formulas above.

2. If chassis is longer than the above

CA’s the chassis can be cut off 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.

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 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.

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. 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.

PUMP POSITION FOR:

M9610--19

Rev.4/00

4. Tighten all hardware.

M9305--46

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!

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.

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.

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. Re--install the tank and tighten the set screws into the drilled holes. Tighten the jam nuts.

Hydraulic hose routing

1. Weld a 3/8NC x 1” Bolt level with cylinder 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--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.

A5

M9716--39

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.

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 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

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, with no bends of less than 8” radius. The controls may be mounted flush in a 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_.

M9200--35

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 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.

5. Install the threaded portion of the cable assembly through the bulkhead weldment and replace the mounting nut.

6. Install the clevis provided to the cable end and the valve handle.

NOTE: The cable end should be parallel to the bulkhead weldment.

7. Tighten the cable mounting nut.

8. Screw the control head onto the cable.

M9200--36

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 dirt to attach the pneumatic actuators.

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 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 & 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

1. 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 location in the area between the mounting holes to run the air lines.

5. Drill a 2” to 3” DIA. hole through the floor of the truck. Remove all burrs and sharp edges.

Line the hole with a suitable grommet material.

6. Using the washers on the under side of the floor, attach the tower to the floor with 3/8” cap screws and lock nuts.

7. Mount the controller(s) to the tower top plate as shown.

After the controllers have been mounted, the plumbing of the air lines can be started.

1. Determine a suitable route for air lines.

2. Cut the necessary holes, remove all burrs, and add grommets to any sharp edges.

3. Determine the line length required, and cut two lines for each actuator.

4. Route the lines between the controllers and the actuators.

5. Bundle the lines together and secure them out of harm’s way.

Joystick Controller & Single Valve Controller

1. Simply square cut the end of the air line and connect each controller port to corresponding actuator port.

2. Attach the supply and exhaust lines as shown.

To remove an air line: Push the line in, hold the internal sleeve and pull the air line out of the fitting.

3. Attach the air lines to the valve actuators in the same manner.

Supply air line connection.

1. Run an air line between the supply port of the controllers and the outlet port of the P.T.O. air switch.

2. Route the exhaust port line out of the cab.

Start--up Procedure

1. Charge the air system of the truck and check all lines for leakage.

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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.

4. Wire remote switch to solenoid valve as shown, cap blue wire on relay harness (not used).

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BUMPER INSTALLATION

Lighted Bumper Installation -- Reference Parts pages P5, P8

1. Remove the cover plate over the right side access hole.

2. 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.

3. Install the wiring harness through the left side access hole.

4. Slip a grommet onto the harness leads and pull through the 5/8” DIA. hole.

5. Attach the ground wire to the bumper with a 3/8” self tapping screw.

6. Install the bumper lights as shown on parts page P5.

7. Connect the leads from the wiring harness to the truck wiring as shown on parts page P9.

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.

8. 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.

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. 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.

2. Weld solid all around, apron to stabilizer.

3. Brace lower part of stabilizer to truck frame with some type of angle brace, 1/2” x 2” Strap or stronger.

4. Install the wiring harness through the left side access hole.

5. Slip a grommet onto the harness leads and pull through the 5/8” DIA. hole.

6. Attach the ground wire to the bumper with a 3/8” self tapping screw.

7. Install the bumper lights as shown on parts page P5.

8. Connect the leads from the wiring harness to the truck wiring as shown on parts page P9.

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.

9. 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.

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10. 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 together or assembly will bind up and be damaged.

11. Loosen and remove nuts on studs at inlet plate. Add the stabilizer section 1 with o--rings 2 between inlet rd plate and 3 section as shown. Using the longer stud bolts 3 supplied,

L reassemble valve and torque nut to 15 Ft. Lbs.

12. Install (6) 3/4(M) O--Ring to 3/4(M) JIC Hydraulic fitting 8 into stabilizer cylinder and lock valve 7 as 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(M) JIC into 3rd section on control valve. Connect from control valve extend port to V2 port and retract port to V1 on lock valve 7 with hose 5. Connect from lock valve

7, port C2 to stabilizer cylinder base port on 21--1023 with hose

9. Connect cylinder rod end port to cylinder base port with hose 9.

Connect from cylinder 21--1022 rod port to C1 on lock valve 7.

Route hoses inside truck frame tied away from drive shaft, etc.

Make sure cylinders are in phase

IMPORTANT: DEPENDING ON THE POSITION OF MOUNTING

FEET AND PLATE USED, NEW HOLES MAY NEED TO BE DRILLED

FOR THE NEW STUD BOLTS WHEN THE STABILIZER VALVE

SECTION IS ADDED.

before connecting all hoses. If cylinders are out of phase when

L MAKE SURE ALL SURFACES AND SEALS ARE CLEAN

BEFORE REASSEMBLING THE VALVE.

first connecting hydraulics the stabilizer tubes and roller could be damaged. Hold valve open in retract direction to clear air and rephase cylinders.

NOTE: CYLINDER END PLATE AT ROD MUST BE ROTATED 90 TO LINE UP WITH

FITTING ON CYLINDER END PLATE IN LINE WITH PIN MOUNTING HOLE.

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HYDRAULIC SYSTEM START--UP PROCEDURE

Caution: Do not operate the pump until the system is filled with oil.

Damage to the pump bearing and shafts can occur.

1. 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. Check the hoist for loose parts, tools, clamps or chains.

3. Check the overhead area for obstructions.

4. Clear all equipment from under the rear of the hoist.

5. Slowly extend the cylinders. Check for binding, rubbing of hoses or metal--to--metal interference between hoist and truck parts.

6. Operate all hydraulic functions to the full capacity for approximately 5 minutes in order to bleed off any entrapped air from the hydraulic system.

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.

7. 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.

8. 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.

9. 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.

10. Operate the winch control and Free--Wheel Control to ensure that they are correctly adjusted and functioning properly.

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REFLECTIVE TAPE INSTALLATION

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