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Operation, Installation, and Service Manual

1. Rev 8 02 M9710 2 HYDRAULICS MODEL KP710 FOR MODEL KP710 2 07 1 2 x 65 JIC 3000 PSI Hose Assembly 1 2 x 82 Hydraulic Tube Assembly 3 4 M JIC to 3 A4 F JIC 90 Swivel Hydraulic Fitting 5 7477277137 M Bukhead Tee 2 6 474884 1 2 x 30 3000 PSI Hose Assembly 6 8 4630 X 5x49 3 4 600 3244 Hydraulic Cylinder Assembly 2 8 4514 S x3sHydauicCyinderAssemby Ti 3 x 48 Hydraulic Cylinder Assembly 3 4 M O Ring to 3 4 M Adapter Hydraulic Fitting 3 410 x 155 Suction Hose 4 717 WeNPTM toSMHoseEndHydauicFiing 3 4 M O Ring to 1 2NPT F 900 Hydraulic Fitting aen Valve 504 1 6 28510 5 9 16 M O Ring to 3 4 M Hydraulic Fitting 2 1 2 x 162 JIC Black 2W Hose Assembly 1 1 2 x 24 90_ Black 2W Hose Assembly 3 4 M JIC to 7 8 M O Ring 90 Hydraulic Fitting 24 49531 9 000 F Winch 80 282 Sere 7 47883 80 286 Series 25 47786 ax 18 Low Pressure Hose o 1 7 8 M O Ring to 3 4 M JIC Adapter Hydraulic Fitting 30 1 1 16 M to 3 ANPT 90 Hydraulic Fitting 3 4 x 60 JIC 3000 PSI Hose Assembly 1 1 16 M JIC to M Hydraulic Fitting 5 6 45 In Tank Filter 45734 Filter Element Long
2. M9710 21 A10 Assemble Winch to Deluxe Bumper using supplied hardware Mount hydraulic control to Deluxe Bumper using supplied hardware Route hydraulic lines from hydraulic control to winch See P2 P3 Assemble control linkage Test fit and adjust linkage prior to mounting Remove linkage after test fitting see A13 A14 Install Deluxe Bumper w Winch as explained in DELUXE BUMPER INSTALLATION below Mark and cut hole in truck frame for winch control rods as required Make sure rods DO NOT DRAG or HIT truck frame or bumper 8 Install control rods Check adjustment from test fit adjust if needed and secure in place with lock nuts on rods Route hoses along truck frame to hydraulic tank from winch control Connect to hydraulic system using fittings supplied 9 Assemble cable guide rollers to bumper 10 Operate winch after completing hydraulic system connections Check for leaks and proper operation Adjust controls if required DELUXE BUMPER INSTALLATION Using a floor jack or suitable lifting device assemble Deluxe Bumper to the rear of the truck chassis the top flange of the Deluxe Bumper should fit between the truck chassis and the KP710 frame 2 After aligning assembly drill 21 32 diameter holes through top flange of the truck chassis using the hole of the hoist frame as a guide Install bolts in holes bu
3. 24 15 167 49 7 87 35 3 8 367BOOM 53 54 BOOM 145 3 47 120CA 133 3 4 108 138 1 27 120CA 126 1 27 108CA 1587 120CA 146 108CA T r __ U 20 120CA 108 108CA 317 337 BO0M 28 367800 10 54 BOOM 1947 155CA 24 15 167 49 7 8 1827 15 164 138CA 1767 138CA 4 3 3 4 537 54 BOOMD 60 1 27 627800 174 13 167 156CA 156 13 16 138CA 217 547800 1387 138CA 14 627800 1567 156 8 02 M9710 16 SPECIFICATIONS AND FEATURES INCLUDE Rev 7 21 00 Chassis C A Frame Width G V W Frame Height Frame Load Rating Dump Angle Operating Pressure Gear Pump Operation Hook Height 108 120 138 156 34 Outside reinforcement thickness 33 000lbs Min To 40 top of chassis Lo Pro recommended 108 120 CA Full length 3 w x 6 h square tube 20 000 Ibs with suitable G V W including body weight 5
4. XNOTEX STEEL TOOLBOX MOUNTS ARE WELDED TO TOOLBOX AND BOLTED TO FRAME FOR MODELS KP710 Part Number 9606 111 0 82 245 9606 112 0 62 708 5 Part Description Left Tank Strap Weldment Steel Tool Box Right Tank Strap Weldment 5 8NC x 2 1 2 GD 8 Cap Screw 5 8NC Lock Nut 5 8 STD Flat Washer 63 110 64 110 P1 Lm R 2 LIFT CYL 4 PORTS FACING DOW PP 2 Tu R d EXT CYL fe 1 fr 7 5 LIFT CYL i PORTS FACING DOWN PORTS SHOWN FACING DOWN 6 de 8 3r 3 2909 to lel NS MANUAL VALVE VIEW LOOKING AT TOP OF TANK
5. P24 ELECTRICAL SCHEMATIC FOR DELUXE BUMPER OPTION LED LAMPS ARE POLARITY SENSITIVE IF A LAMP DOES NOT FUNCTION SWITCH BULLET TERMINAL CONNECTIONS GROUND 1 AUXILIARY 42 LEFT TURN STOP 5 Wire eM RIGHT TURN 8 TAIL HARNESS 7 5 GnEEN RIG 3 YELLOW LEFT DUMMY 4 RE PED PS DO NOT REMOVE DUMMY PLUGS IF TERMINAL IS NOT UTILIZED DETAIL B Left amp Right Sides B BLACK BLUE BROWN GREEN HARNE YELLOW GROUND BLACK AUXILIARY Da YELLOW LEFTTURN 3 RED STOP 5 Wire 2 WHITE GREEN RIGHTTURN 5 BACK UP reo TAIL ge 1 WHTE BACK UP DETAIL A REMOVE DUMMY PLUGS FROM FEMALE BULLET TERMINALS 5 AS NECESSARY DO NOT REMOVE DUMMY PLUGS IF TERMINAL IS NOT UTILIZED AUXILIARY FUNCTION CAN BE UTILIZED TO ADD WORK LIGHTS IF DESIRED OR IN WHITE 1 CONNECTING HOIST UP BACK UP ALARM BLACK 2 SEE DETAL A E l BLUE Z 3X IDENTIFICATION HN T LAMPS ROWN B LACK B REEN S YELLOW 3 WHITE BACK UP WHITE BLACK LOO YELLOW LOO WHI 5 5 SEE BACK UP HOIST LP ALAR o 5 NOTE WHEN
6. A B i LIFT LIFT CYLINDER LIFT CYLINDER E __ 1 LL an 4 B A REV 10 07 M9710 1 P21 HOIST UP LIGHT RUCK CAB HOIST UP LIGHT WHITE REMOTE SWITCH Im 3 COLORED PREVIOUS STYLE POWER PTO LIGHT GROUND TO FRAME PTO GROUND USE WITH 79 250 BACK UP ALARM SINGLE FUNCTION Rev 2 08 M9S710 23 FOR MODELS KP710 2 07 Part Description Qty Hoist Up Light Requires 3 4 DIA Hole 79 269 Hoist Up Light Requires 7 8 DIA Hole Pigtail 16 Bracket Safety Switch Remote Switch 1 4NC x 1 1 4 GD5 Cap Screw 1 4NC Hex Flange Serrated Nut Current P22 HOIST UP LIGHT amp BACK UP ALARM w HOIST UP ALARM HOIST UP LIGHT AND BACK UP ALARM WITH HOIST UP ALARM NEG BATTERY FOS NEG Q WBL L PLUGS INTO GROUND CIRCUIT HOISTUP LIGHT Teen id I
7. 605 8 3 8 STD Lock Washer 8 27 1 8 Shim Pad Retainer 97009 fe o T 30 2024 OuterBoom Pad _____ 2 38699 Sm I 8 5 FLAT RACK M9210 33 56 99 FOR MODELS KP710 4 02 9606 45 88 B 58252 gt Flanged Wear Bushing 3 4 O D x 5 8 I D 2 966 455 RolePn 74 Retainer Ring 5 ___9602 8 0 ___ Slider Tube Weme 3 6 ___9602 2 04 lOCBumperWedment f3 60 217 374 DIA x 5 Clevis Pin 3 4 DIA ClevisPin 9 8 64 113 3 4 STD Flat Washer 9 60 724 1 8 DIA x 1 1 4 Cotter Pin P6 HYDRAULIC TANK ASSEMBLY km Fi M9706 20 7 00 FOR MODELS KP710 id PartNumber Part Description _ PatNumer 2 L1 9610 85 U HysauTakWedmen TA 2 25 285 Sight Gauge w Temp 9 64 18 SH6 STD LockWasher 62 763 5 16N x T ocket Head Cap Screw 2 25 2375 In Tank Filter TIFO8 025 G MM 25 184 TNPTioS ANPTReducerHydraulcFi ng ________ _ 1 8 25 1190 3 4 M NPT to 3 4 F
8. N N NI P19 DELUXE BUMPER AND OPTIONAL WINCH Rev 2 08 M9606 34 FOR MODELS KP710 2 08 Qty Item Part Description 1 3 8NC Nylon Top Lock Nut Tensioner Wire Rope Kit 10 Drum Cover Plate Left 3 0008 Winch 4 SA Washer Thread 2 0002 Winch emote Clutch Assembly see pages A11 A14 Ex 82 252 FTI Supplied with Clutch Control Kit 6 SeepageP3 Winch Control Valve 8 99 200 Retainer Ring 5 8 9 64 200 ___ 700 5 810 x 1 16 Bushing 10 9606 45 4A Roller amp 53 152 Flanged Bushing 3 4 OD x 5 8 ID 9606 45 5 Roller Pin 82 298 Yoke Kit 5 16UNF Threads 62 118 3 8NC x 2 1 2 GD5 Cap Screw 1 P20 KP710 HYDRAULIC SCHEMATIC MANUAL CONTROL VALVE a N 4 D WINCH VALVE 122 WINCH CONTROL VALVE T B A EXTENSION 4 B i CYLINDER x EXTENSION
9. 1 gt FTT I XX 000 688 NI k n gt TE KP706 HOLD DOWN LOCATION 108 CA REF 120 CA REF 138 CA REF 1 ALIGN TANK MOUNTING BRACKETS WITH TOP AND ENDS OF TANK TACK WELD IN PLACE 2 PICK LOCATION FOR TANK ON TRUCK FRAME FREE OF INTERFERENCE 3 AFTER VERIFYING A CLEAR LOCATION ON TRUCK FRAME WELD BRACKETS SOLID TO TANK 4 POSITION TANK w BRACKETS IN DESIRED LOCATION ON TRUCK FRAME AND USING TRUCK FRAME DRILL DRILL TWO 11 167DIA HOLES THRU EACH BRACKET AND TRUCK FRAME 5 BOLT TANK TO TRUCK FRAME USING FOUR 5 8NC X 2 1 276D5 BOLTS amp LOCK NUTS 15 ALIGN REAR HOIST ANGLE AND BACK OF TRUCK bie jen FRAME FOR PROPER HOOK HOIS KP710 HOLD DOW A e D E 156 CA REF NOTE FRAME CUT OFF MAY VARY BAS BE SURE HOIST WILL FIT BEFORE CUTTING TRUCK FRAME ED ON C A OF TRUCK AND OR SPRING SHACKLE CLEARANCE Rev 11 00 M9710 19 A5 VALVE CONTROL INSTALLATION The optional cable controls supplied with K PAC equipment 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
10. d Allow room for flexing where the cable is attached to moving parts of the equipment so that the cable is neither kinked nor stretched 5 Choose a mounting location which is convenient and comfortable for the operator and provides adequate clearance for the control lever movement Check the underside of the cab for reinforcement members air lines wiring harnesses and linkages before cutting into the floor Be sure the location chosen allows the cable to be led easily away from the control Reversing control direction usually is not necessary In most cases the direction of the lever movement for a given valve function can be changed by switching the hydraulic lines at the valve If this is not an option control operation can be changed simply by turning the cable controller 180 Cut a hole for the control cables to pass through If using the control mount provided mark and drill 4 343 diameter holes for the 3 8 self tapping screws provided A6 Cable Connections 1 Remove the screw from the cable controller where the cable end will install Do NOT remove the other screws passing through the cable control housing 2 Screw the hex threaded cable CABLE CONTROLLER end into the cable controller end Moving the cable controller handle will allow easier access to start the thread If the hex threaded cable end is not visible make certain the cable is free to slide back and forth and shake the cable end with the
11. 1 5 16NC x 1 Hex Head Cap Screw 5 16 STD Flat Washer 5 16NC Nylon Top Lock Nut 23 5 16NC x 1 1 4 Carrier Bolt 17 44 220 Ironman Mud Flap 24 x 24 9724 0 1 62 367 S 6NC x 3 4 Hex Flange Serrated Bok 8 63 140 3 8NC Hex Flange Serrated Nut 8 DN END P15 INSTALL VALVE WITH CONTROL HANDLES POINTING UP THROUGH SLOT IN TANK Rev 10 04 M9200 86 AIR CONTROLS FOR MODEL KP710 2 07 1 j HydauicTank 20Galon Cd 1 5 16NC x 2 1 2 805 Screw 2 2 eee ERI UD ES 1 1 10 14 11 14 12 14 13 1 1 1 4 3 8NC x 1 1 2 Hex Washer Thread Cutting Screw 4 10NC x 1 2 Cross Recess Pan Head Machine Screw 23 Indicator Ligh t 24 0 0 0 1 4 4 1 1 4 Tube Quick Lock Tee 1 3 8NPT Male 1 4 Tube Straight Compression Fitting PI Pressure Protection Valve customer supplied 82 167 1 4 Hex Nipple 74 478 Decal Important Operation Instructions 28 29 30 1 32 1 33 1 P17 AIR CONTROLLER ASSEMBLY 55774 62 344 KIT INCLUDES CONTROLLER WITH STRAIGHT HANDLE CLEAR CAP 2 SWIVEL CONNECTORS 2 O RINGS AND LONGER SCREWS TO RETAIN SECTIONS 62 345 KIT INCLUDES ELECTRIC PTO SWITCH AND WIRING FOR MODELS ALL 2 07 Tower Cover
12. 74 596 Decal Warning Stand Clear 74 491 Decal 20 000 Lbs 74 600 Reflective Tape Red White NOT SHOWN 74 601 Heflective Tape White NOT SHOWN pecify exact quantity needed See page A16 for suggested locations on truck frame 5 On 2 no 03 ys 2 P26 INSTALLATION SECTION PROPER BOLT USE DO NOT use these values if a different torque value or tightening procedure is given for a specific application Torque values listed are for general use only Check tightness of fasteners periodically Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical grade Fasteners should be replaced with the same or higher grade If higher grade fasteners are used these should only be tightened to the strength of the original Tighten plastic insert or crimped steel type lock nuts to approximately 110 percent of the dry torque shown in chart applied to the nut notto the bolt head Tighten toothed or serrated type lock nuts to the full torque value NOTE Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings Dry means plain or zinc plated without any lubrication Tighten lubricated bolts to approximately 8096 of dry bolts OVER TORQUED BOLT BLACK OR PLATED BOLTS BOLT SIZE WRENCH SIZE GRADE 2 GRADE 5 GRADE 8
13. I 12 RC RENE e Included in Cylinder Assembly P9 HYDRAULIC CYLINDER ASSEMBLY 156 CA gt 222 Rev 9 01 23 722 48 Hydraulic Cylinder Assembly BOOM EXTEND 9 01 Retracted 58 Extended 106 Stroke 48 Rod Dia 1 3 4 Fari Description 1 ManufacturersLabel 78 o Et 4 Pson 7 E 8 RodAssembly 1 9 Head 10 x WeaHng O Hng 1 12 x Bac upWasher pis X E 22 Steel Plug not shown Seal Kit x Items Included in Kit aaa e Not Included in Cylinder Assembly P10 MUNCIE PUMP amp CLUTCH ASSEMBLIES M9305 23 Pari Description e c 25 2139 H Series Pump 1 f Shaft Seal Front Cover Bushings Balance Seal 5 WearPlate 6 Gase 7 BodySel 8 9 PumpHosng WoodufKey Pulley Clutch 1 2NF Hex Locking Jam Nut 1 P11 DIRECT MOUNT HYDRAULIC PUMP M9610 7 Rev 1 99 6 97 Part EE 25 2391 Gear Pump nap Hing Outboard Bearing haft End Cover Check Assemblies or Plug EE ingSels PoWetSeds
14. Inner Boom Weldment 3 39 9274 412 0 Outside Roller 12 40 _ 9610 520 0 Main Frame Weldment 9 62 718 3 8NC x 1 Flat Head Allen Bolt 6 10 9610 120 5A Boom Pad Large 1 por Large ES 9610 27 0 Main Pivot Shaft Weldment 42 64 199 3 x 2 x 10 Ga Machine Bushing 9610 00 10 Shim 06 Thick a 0610 00 14 Shim 12 Thick 9610 00 12 Rod Pin Extend Cylinder 64 109 5 8 STD Lock Washer 4 9606 108 10 Special Bolt 3506 106 9 99 197 1 1 4 DIA Retaining Ring 46 9606 105 0 Guide Roller Assembly 23 721 3 x 35 Hydraulic Cylinder a 23 722 3 x 48 Hydraulic Cylinder 9606 108 8 Roller Shaft 48 63 108 1 2NC Nylon Top Lock Nut 9610 120 7 Pin Extend Cylinder 62 351 1 2NC x 4 1 2 GD5 Cap 1 Screw 99 201 1 DIA Retaining Ring 9606 208 15A Lock Plate KP706 9610 620 0 Outer Boom Weldment 120 PE 9610 638 0 Outer Boom Weldment 9606 208 22 Hold Down Spacer KP706 62 395 1 2NC x 6 GD5 Cap Screw 19 9610 26 0 End Pin Weldment Lift 2 NEN 2 1 2 STD Flat Washer 64 108 1 2 STD Flat Washer 64 107 1 2 STD Lock Washer 5 2 62 420 55 9610 80 0 Rt Hold Down Weldment 1 KP710 56 9610 81 0 Lt Hold Down Weldment 1 KP710 2 1 2NC x 1 1 4 GD5 5 Screw 23 703 5 x 49 3 4 Hydraulic Cylinder 62 351 1 2NC x 4 1 2 GD5 Cap Screw 9710 0 15 Rest 3 8 SAE Flat Washer 8 15 24 eram
15. JNLVIOT 503 95040 HL NJI S3NIV LNOO VO X04 VI 404 VI 404 VO 80 X04 Q3LON SV l1d3OX3 X 9 wh E 0317104 iva 15 0 NO NMOQ G IOH la 4 ae H VAXEXY m NMOQ 010H 38NnL 55042 9 19 B MV8 40 OvG HOH 1368 JO Move 14 FEM 1452 aang 40 146 0 ies DOE ETD yanng JO MOVE 14 105 40 Liz Neel 2 nica 1366 JO MOVS 14 6 OO9 1364 3dAng8 JO MOVE 132 2 ava i M3dADH 40 2 8 137 NESL ETA H3JAngS 40 MOVE Liz OlBoM OLZ d GZ A21 This page intentionally le
16. PTO Exhaust Auxiliary In Auxiliary Out After the control tower has been mounted the air lines can be routed The air line tubing is color coded as shown in table at right To remove an air line from a fitting push the line in hold the internal sleeve of the fitting then pull the air line out 1 4 6 Pass the air lines through the hole lined with grommet material in the floor Route the exhaust air line outside of the truck cab Determine a suitable route for the air lines to the control valve Avoid sharp bends sharp edges and heat sources Install supplied elbow fittings into pneumatic actuators Connect the air lines to the elbow fittings in the pneumatic actuators Bundle the air lines together and secure out of harm s way A decal with an assortment of 94 diameter labels are provided with the owner s manual These decal labels can be applied to the under side of the clear plastic caps to identify the function of each pneumatic control handle After the decals have been applied snap the clear covers into the handles Start up Procedure 1 2 Charge the air system of the truck and check all lines for leakage Operate the controllers and check for correct hydraulic valve movement NOTE The controllers pressurize the port toward which the handle is moved the function is to be reversed exchange the air lines at the controller or actuator After the correct connections have been made and
17. Rotation Boom from the back of the cab to the container A Frame height position behind the truck D Disengage the P T O and brake and back up 2 the truck until the NL M9710 6 hook jaw engages the A Frame bar Stop the vehicle set the brake and engage the P T O E Push the rotation control forward 2 to move the Rotation Boom forward until the bottom of the rack or container is approximately 10 inches above the guide rollers at the back of the truck The operator may be required to release the brake so that the truck can be steered until the guide rollers align with the sills of the rack or container F If the sills on the bottom of the rack or container are not in line with the guide rollers and the truck the operator must reposition G When the sills and rollers line up continue to activate the control to move the rack or container onto the hoist frame By releasing the brake and allowing the truck to roll back under the load dragging the rear end of the rack or container along the ground can be minimized H Continue the loading procedure until the rack or container is off the ground and re apply the brake to eliminate further movement of the truck The Rotation Control should be activated until the sills of the rack or container are in full contact with the hoist frame M9710 7 l Activate the Hook Arm Control to extend the Hook Arm which will pull the rack or container towards t
18. be disconnected from the A Frame connection bar H When the Hook Arm Jaws are clear of the A Frame Connection Bar disengage the P T O and after ensuring that the path is clear move the truck forward about three feet Re engage the P T O and parking brake and activate the control to pivot the Rotation Boom fully forward until it reaches its resting position J Activate the Hook Arm Control and extend the Hook Arm towards the truck cab O5 Winch Operation Optional Equipment A caution Set brake before operating winch The winch controls are located at the rear of the truck on the driver side TOP LEVER CONTROLS WINCH UNDER POWER SECOND NOTCH ONLOWER Fl LEVER LOCKS WINCH CONTROL 5 39 IN FREE WHEEL POSITION EORI TIT M9710 10 gt a M9710 11 There are two levers the top lever operates the winch under power and the bottom lever operates the free wheel control on the winch To operate the winch in the free wheel mode raise the lever and position it into the second notch To lock the free wheel lever in the free wheel position lower the lever until the second notch rests in the bottom of the key hole The winch cable can then be pulled out to the desired length without restraint Note The cable should never be pulled out beyond a single wrap of cable on the drum The winch can be returned to the power position by lifting the free wheel lever and pulling it out so that the first notch locks int
19. chassis the remote cable controls may be installed Cable Control Mounting 1 IMPORTANT On the hydraulic control valve remove the screws holding the spool cover plate Position the handle assembly on the valve face and install the screws provided with the handle kit Install the clevis pin and cotter pin Mount the valve to the underside of the mounting plate located on top of the hydraulic tank assembly with the handles sticking up through the rectangular cutout Position the control cable bulkhead plate on the top of the hydraulic tank assembly Install the control cable bulkhead plate with 1 2 cap screws and nuts or weld If necessary temporarily assemble the threaded cable end to the bulkhead plate for proper positioning with the valve handles Mount the cable controllers to the control mount supplied Other mounting options are shown in the following illustration parts not supplied FLUSH SIDE BANKED MOUNTING MOUNTING TOGETHER OS a Agood 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 M9200 35 should any bend be tighter than an 8 radius b Protect the cable from heat above 225 F and avoid hot areas such as the exhaust system etc C Protect the cable from physical damage such as pinching or crushing and do not use cable supports which may crush or deform the cable 2790 ac
20. damage 3 Check that all decals are in place and legible 4 Test the back up and alarms if equipped 5 Check that all tail lights are functioning properly 6 J 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 HOOK HOIST SPECIFICATIONS SAFETY DECALS OPERATING SECTION SAFETY FIRST OPERATING INSTRUCTIONS Hook Hoist Check List General Guidelines for Operation Loading A Container or Flat Rack Dumping A Container Unloading Flat Rack or Container Winch Operation Option Flat Rack Operation Option Flat Rack Specifications Loading a Vehicle onto a Flat Rack K PAC Warranty Information PARTS SECTION TOOL BOX HYDRAULICS MAIN FRAME FLAT RACK HYDRAULIC TANK GREEN CYLINDER 5 x 49 3 4 GREEN CYLINDER 3 x 35 GREEN CYLINDER 3 x 48 MUNCIE PUMP amp CLUTCH ASS
21. inner boom to a rearward position 2 Position the mounting plate 9716 0 30 on hoist frame as shown 3 Weld the switch mounting plate to hoist frame with 19 groove welds 4 Mount the remote switch 79 248 to the mounting plate with 1 4NC x 1 1 4 Cap Screws 8 Hex Flange Nuts 5 Pick a suitable location on the truck dash which is plainly visible to the operator for the Hoist Up warning light 6 Drill a 3 4 Dia hole for the light The Hoist UP decal is to be located under or near the warning light DO NOT install light at this time 7 Pigtails with bullet terminals are provided The 9710 25 female bullet terminals will be used at the hoist up 5 02 light The male bullet terminals on the pigtail may be cut off if not used A15 SWITCH IN CENTER 2 9 10 NX BRACKET FLUSH WITH TOP EDGE OF FRAME 11 Ne 12 Connect the wires per the wiring in Hoist Up Light and Back Up Alarm with Hoist Up Alarm in the Parts Section in this manual NOTE The optional Air Control Tower also has a hoist up light Power wires from both lights can be T connected and ground wires can be T connected Do not wire in series as if one light should fail neither light would function CAUTION The LED warning light is polarity sensitive Connect the bullet terminals from the white ground wire of the light to the pigtail wire running to groun
22. of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Check the area for power lines and overhead obstructions Be sure the area and container are clear of personnel Do not load dump or unload a container on uneven ground Do not move the truck while the hoist and container are raised A raised load creates a top heavy unstable load Do not use any method to hold a valve open which will not let the valve automatically close when released Check the pivot bushing and slide pads for excessive wear Check all snap rings and shaft securing bolts to be sure they are tight OPERATING INSTRUCTIONS HOOK HOIST CHECK LIST A Check hydraulic oil level with all cylinders retracted E F G H c Grease all lubrication points B C Rollers are free to rotate D Tires are properly inflated E The container hook lock is free to move and works properly GENERAL GUIDELINES FOR OPERATION OF HOIST LOADING A CONTAINER OR FLAT RACK A Caution Besurethe area in which the hoistis to be operated is level clear of personnel as well as obstacles overhead and on the ground Operating on a unlevel surface could cause damage to the load or hoist equipment O1 Loading a Container or Flat Rack onto the KP710 Hook Hoist Note Before loading the flat rack or con
23. position desired mark and match drill 11 16 Dia holes into frame Attach Tank with 5 8 x 2 1 2 Bolts and lock nuts provided Install valve fittings and hoses as shown on Parts Section pages P2 P3 HYDRAULICS for routing proper valve bank and function to cylinder etc Install sleeve over bundle of hoses for protection Route hoses to clear sharp obstructions to protect from wear Be sure to install hoses on proper valve bank because the valve sections are different The routing of the hoses from the Lift Cylinders to bulkhead tees must be done carefully MAKE SURE that hoses are not twisted and will have adequate flexibility during operation 4 IMPORTANT POSITION MOUNTING PLAT E AS FAR KP710 O ALIGN BRACKET WITH TOP EDGE ALIGN BRACKETS WITH TANK ENDS TANK MOUNT ING BRACKET HOL 4 REQ D 11 167D1A ES FORWARD AS POSSIBLE BOTH SIDES HOLD DOWN t ES 863 000 XX d D
24. started while workmen are under the truck Block truck wheels with suitable chocks before working under the truck 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 A2 DIRECT MOUNTED PUMP INSTALLATION COUNTER CLOCKWISE CLOCKWISE 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 Install the four 2 1 2NC x 2 GD 5 Cap Screws and Lock Washers Be sure the pump flange is fully seated onto the PTO housing MOUNT PUMP TO PTO PER OWNER S PUMP POSITION FOR ER MANUAL ROTATION ROTATION Jjmrz mmrz MICHOMDU FRONT M9305 46 MOUNT PTO TO TRANSMISSION PER M9610 19 INSTRUCTIONS AND PTO Rev 7 99 MANUFACTURER S INSTRUCTIONS 4 Tighten all hardware A warning Direct mounted hydraulic pumps weighing more than 50 Lbs should be supported at the rear by a strap attached to the transmission FUE
25. 0 with suitable body length 3000 PSI 23 gpm 1500 rpm direct mount STD In cab controls standard 54 62 138 156 CA Weight Hydraulic Planetary Cylinders 33 36 54 108 120 CA 2 650 Ibs 4 ton or 6 ton 50 of 7 16 cable w hook level wind feature Twin double acting 5 x 50 Cylinder 3 x 35 Boom Oylinder 108 120 138 CA 3 x 48 Boom Cylinder 156 CA Low Pressure American S A E Hydraulic System Gear driven hydraulic pump Braided and socked hose Phenolic pads in boom Sliding L arm 2 Container Locks Gravity lock on hook SAFETY DECALS See Parts Listing page for part number and proper location AWARNING 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 You have reason to believe it may he abnormal There is any fluid leakage Search for leaks with a piece of B C D The couplings are damaged E F cardboard Protect hands and body from high pressure fluids The hose is damaged or kinked The reinforcement is visible ihrough the jacket If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result 74 2
26. 3 8 9 16 20 33 45 7 16 5 8 32 52 70 1 2 3 4 50 80 105 5 8 15 16 100 150 210 3 4 1 1 8 160 260 375 7 8 1 5 16 175 415 600 1 1 1 2 250 625 880 1 1 8 1 11 16 375 850 1400 1 1 4 1 7 8 530 1100 1765 1 1 2 2 1 4 930 1400 2540 STRETCHED AREA 73 7 GRADE 2 GRADE 5 GRADE 8 KP710 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 KP710 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 mi
27. 400 kg models there is a ring Carefully pull the gear housing away from the drum support Remove the old gasket from the drum support gear between the gear housing and the drum support This should be taken off with the gear FELT MARK housing and should not be separated if possible See Figure 2 2 e cooker HEAD BOLTS Remove the detent assembly or the clutch shaft retainer from the DETENT gear housing depending on which winch model ASSEMBLY you have NOTE Models with a detent assembly be sure that the steel ball is taken out so it will not fall into the gear train See Figure 3 Pull the clutch shaft out of the gear housing This shaft will not be needed for the remote clutch assembly See Figure 3 Place the O Ring from the kit onto the remote clutch shaft and apply a small amount of all purpose grease to the O Ring Slide the clutch shaft into the gear housing The shaft must be installed with the stop pins oriented toward the detent as shown in Figure 4 Install the detent assembly provided with the kit back into the gear housing in the order shown The large detent spacer is used for 9 000 FIGURE 3 M9606 39 CLUTCH Ib 4 100 kg winch models and the small detent SHAFT spacer for the 12 000 Ib 5 400 kg models STOP PINS NOTE To make sure that the steel ball is O RING in the groove of the clutch shaft tilt the gear housing back a little while instal
28. 76 2 rwy ACAUTION DO NOT ATTEMPT TO OPERATE EQUIPMENT WITHOUT PROPER TRAINING STAND CLEAR 1 OBSERVE AND PRACTICE ALL SAFETY AND OPERATING RULES AS ESTABLISHED BY YOUR COMPANY AND THOSE INCLUDED IN MANUAL WHEN THIS UNIT I IN OPERATION 2 KEEP CLEAR OF HOIST FRAME WHEN RAISING OR LOWERING FAILURE TO DO SO COULD RESULT IN SERIOUS PERSONAL INJURY 8 DO NOT WORK ON OR UNDER THE HOIST mi UNLESS PROPERLY BLOCKED AND SECURED Ms 7 HOOK AND BAIL HEIGHTS 4 DO NOT EXCEED THE MAXIMUM RATING FOR HOOK OPERATING LIMITS STATED BY THE MUST MATCH MANUFACTURER 5 OPERATE ON LEVEL GROUND OR LOAD WILL BE UNSTABLE e DISTRIBUTE LOAD EVENLY CAU TI AND MAY FALL CAUSING 7 DO NOT DRIVE TRUCK WITH P T O ENGAGED nr OR DEATH DO NOT EXCEED 1600 ENGINE TO OPERATOR ANDOR RAISING HOIST RPM WHEN OPERATING BYSTANDERS BE CAREFUL BE ALERT M 7 USE GOOD JUDGEMENT POWER TAKE OFF VL 74208 CAUTION A WARNING 2 DO NOT LOAD UNLOAD OR 4 ud DUMP A CONTAINER ON L UNEVEN GROUND A LOADED CONTAINER CREATES A D TOP HEAVY LOAD USE CAUTION 1 WHEN DRIVING ON UNEVEN GROUND DO NOT LIFT WITH INNER BOOM AND TURNING CORNERS INNER BOOM MUST BE RETRACTED SERIOUS PERSONAL INJURY AND EXTENDED BEFORE LIFTING EQUIPMENT DAMAGE COULD RESULT 74 482 74 297 IMPORTANT RETRACT BOOM BEFORE UNLOA
29. CONNECTING HARNESSES PIGTAILS AND LAMPS CONNECT PER LIKE NUMBERS SHOWN Rev 2 08 ABOVE AS WRE COLORS MAY DIFFER BLACK MRE MAY CONNECT TO BROWN WIRE ETC 9710 28 25 DECALS L L li ses a 3 2 F n L dur 4 _ _ o VIEW Du VIEW THROUGH CAB WINDOW BOTH SIDES OF OUTER BOOM 11 ON CAB AT EYE LEVEL INSIDE OF CAB NEXT TO CONTROLS Rev 7 07 M9710 20 FOR MODELS KP710 10 07 Part Description diy 9710 50 0 Decal Kit Includes e Items Below 74 485 Decal DANGER Powerlines Hookli 74 482 Decal CAUTION Inner Boom 74 478 Decal IMPORTANT Operation Instructions 74 486 Decal WARNING Align Container 74 297 Decal WAHNING Uneven Ground 74 276 Decal WARNING Hydraulic Safety 74 627 Decal Iron Man 8 74 648 Decal Krause Trademark 9 74 490 Decal DANGER Hook Height Must Matc ii je 74 477 Decal 171 i2 je 74 300 Decal DANGER Stand Cear 3 Decal CAUTION Set Brake
30. DING A WARNING ARM LEVER LEVER 74 478 DO NOT ATTEMPT TO LOAD A CONTAINER UNLESS THE HOIST AND CONTAINER ARE EXTEND CORRECTLY ALIGNED KEEP THE CONTAINER RAILS SQUARELY HOOK ARM u EXTENSION BOOM ENGAGED WITH THE HOIST ROLLERS FAILURE TO DO SO COULD CAUSE THE UNLOAD EXTENSION RETRACT CONTAINER TO MISS THE HOIST ROLLERS CREATING AN UNSTABLE LOAD 74 486 OPERATING SECTION SAFETY ALERT SYMBOL BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY THIS SYMBOL IDENTIFIES IMPORTANT SAFETY MESSAGES CAREFULLY READ THE MESSAGE THAT FOLLOWS TEN MOST COMMON HAND SIGNALS USED IN THE FIELD SLOW IT DOWN 4 RAISE LOWER STOP THE THE THE EQUIPMENT EQUIPMENT ENGINE THIS FAR TO GO SAFETY FIRST A Read and understand this operator s manual before operating the hoist B Be sure safety decals are clean and in place C Never position yourself or any other person under any raised portion of the hoist unless the hoist is firmly resting on blocks D Never operate this unit unless the hydraulic system including the cylinders and lines are full of oil and free of air A warning Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Search for leaks with a piece
31. E 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 A waring Escaping fluid under pressure can penetrate the skin causing serious injury a 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 NOTE Use pipe sealant on pipe thread joints ONLY Refer to parts drawing on page P2 for steps listed below 1 2 Attach the Hydraulic Tank mounting brackets to the side of the tank as shown in the following illustration Align mounting brackets with top edge and ends of tank Tack weld Mount Tank Assembly onto truck as shown Watch clearance on top of hoist If more clearance is desired then lower tank accordingly Check for adequate clearance between bottom of tank assembly and the ground Clamp Tank Assembly to truck frame in desired position Check mounting bracket location on frame leaving adequate room for installation of cables and plumbing If present location does not work move to suitable location and weld mounting brackets to tank as shown above With Tank Assembly in
32. EMBLIES DIRECT MOUNT HYDRAULIC PUMP GRESEN VALVE ASSEMBLY FENDERS SUPPORT TUBES MUD FLAPS PLASTIC FENDERS AIR CONTROLS AIR CONTROL TOWER ASSEMBLY REMOTE VALVE amp CONTROLS N O1 O1 O1 O1 O1 04 04 06 06 06 07 O8 P1 P3 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P17 P18 P19 DELUXE BUMPER w OPTIONAL WINCH HYDRAULIC SCHEMATIC HOIST UP LIGHT HOIST UP LIGHT amp BACK UP ALARM ELECTRICAL PARTS ELECTRICAL SCHEMATIC DECALS INSTALLATION SECTION SAFETY INSTALLATION MODEL NUMBER TRUCK CHASSIS SPECIFICATIONS CLUTCH PUMP INSTALLATION Fanbelt Clutch Pump Installation Mounting Bracket For Clutch Pump POWER TAKE OFF INSTALLATION DIRECT MOUNTED PUMP INSTALLATION FUEL TANK ADJUSTMENT HOOK HOIST MOUNTING OIL TANK VALVE AND HOSE INSTALL CABLE CONTROL INSTALLATION HYDRAULIC PRESSURE GAUGE PNEUMATIC CONTROL INSTALLATION TAILBOARD INSTALLATION DELUXE BUMPER w OPTIONAL WINCH DELUXE BUMPER INSTALLATION INSTALLATION INSTRUCTIONS FOR REMOTE CLUTCH KIT WIRING HARNESS INSTALLATION HOIST UP LIGHT INSTALLATION HYDRAULIC SYSTEM START UP REFLECTIVE TAPE INSTALLATION SHEET KP710 PAD amp SHIM REPLACEMENT KP710 BOOM CYLINDER REPLACEMENT 36 TO 33 BOOM INSTRUCTION SHEET 9710 SUB ILLUSTRATION Rev 2 08 P20 P21 P22 P23 P24 P25 P26 A1 A1 A1 A1 A2 A2 A2 A2 A3 4 A6 A8 A10 A10 A11 A11 A15 A15 A16 A17 A18 A18 A19 A21 SPECIFICATIONS
33. Hose Clamp 1270 5 16NC x 3 GD5 Cap Screw 3 M to 1 C5511 1 1 4NPT F x 1 1 4 Ball Valve M to 1 3 3 37 38 9 0 4 43 44 WE x 36 MELA EA zs 440 1 ITEM 58 IS INSTALLED AFTER HOIST IS INSTALLED ON TRUCK 1 EXTEND BOOM NOTE BENT EDGE CONTACTS BOTTOM BOOM PLACE ITEM 58 9710 0 15 SO THAT 3 WELD IN PLACE WITH 4 1 WELDS 2 RAISE BOOM 1 4 AT POINT Rev 1 04 17 M9710 AS SHOWN ABOVE SEE PHOTO ON PAGE A4 P4 MAIN FRAME FOR MODELS ALL 2 07 9610 120 3A Inner Boom Pad Small 60 701 5 32 DIA x 1 1 4 Cotter Pin 64 146 5 8 SAE Flat Washer 9610 538 0 Frame Extension Weldment 9610 355 0 Plate Weldment 54 62 138 9606 15 0 Hook Lock Weldment 367 i 9610 556 0 ipid Extension Weldment 60 270 5 8 DIA x 3 Clevis Pin 1 ES 33 9610 28 0A End Pin Weldment Lift 2 82 242 Shock Pad Cylinder A Flg Washer 63 134 Nylon Top Lock Nut 62 300 1 2NC x 1 GD5 Cap Screw 65 101 1 8 STD Zerk 8 9610 136 0 36 Inner Boom Weldment 9274 415 3 Bolt Collar Roller 9610 54 0 54 Inner Boom Weldment 37 62 123 3846 x 3 1 2 605 Cap 2 al e 9610 62 0A 62 Inner Boom Weldment Screw 9610 354 0A 54 Inner Boom Weldment 64 154 3 1 8 x 2 1 8 x 10 Ga 10 362 0 62
34. IegralD iveShafrandGearSet ae P12 GRESEN VALVE ASSEMBLY Positioner End Inlet End Outlet End View 7 00 9706 21 FOR MODELS ALL 11 00 Part Description Relief Valve Seal Kit WH Std Relief LokWaser 25 2411 P138 FENDERS SUPPORT TUBES amp MUD FLAPS Hook Hoist Frame Match Drill 4 Holes 562 DIA M9706 22 Rev 3 01 FOR MODELS ALL PatNumber Part Description OO I 22 87 720864 9305 55 0A Standard Fender Weldment Width 25 1 2 9305 57 0A Narrow Fender Weldment Width 22 1 4 E d 9305 56 0 Fender Support Weldment i 62 503 1 2NC x 1 1 2 Set Screw 44 129 62 108 3 8NCx 1 GD 5 Cap Screw 9274 0 1 Mud Flap Backing Plate 1 8 63 134 3 8NC Self Locking Nut Lx 9 9610 0 13 Fender Mounting Bracket Optional 14 PLASTIC FENDERS 5 DRILL HOLES FOR CARRIAGE BOLTS IRON MAN Rev 2 07 M9706 29 FOR MODELS KP710 2 07 L9 6 8 NEC PI Part Number Part Description 44 190 Set of Plastic Fenders 52 44 188 Set of Plastic Fenders 44 82 255 Mounting Kit for 44 190
35. L TANK SAFETY If needed remove the fuel straps holding fuel tank and lower the fuel tank to a safe shielded position during hoist installation 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 KP710 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 108CA 120CA 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 Recommended frame cutoff would be 38 from axle Center Line to rear of frame If chassis is longer than the above CA s the chassis can be cut off shorter per difference 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 drilling through the truck chassis be sure thatall hoses wiring and lines are move
36. N AIR CONTROL TOWER COLORED CLIP BULLET CONNECTORS FROM PIGTAIL AS NECESSARY MX 9 WHITE ENGAGED lt HOIST UP LIGHTS IN ARE H POLARITY SENSITIVE PTO OFF TRUCK CAB BLACK REV 2 08 M9710 29 FOR MODELS KP710 2 07 Part Description Hoist Up Light for 3 4 DIA hole 6 79 248 Remote Switch o Jm 79 610 Back Up Alarm Dual Function 8 79 606 Pigtail 21 P23 ELECTRICAL PARTS RED CLEARANCE LAMPS MOUNT ET WIDEST PONT OF VEHCLE FACING FL re 0 00 5 H O N DASH HOIST UP LIGHT Pari Description Main Wiring Harness Rear Sill Wiring Harness Rear 1 0 Harness 2 Conductor Harness LED Lamp Red 6 79 589 Grommet For 2 Round Lamp Led Lamp 2 Round Red 8 79 590 Grommet For Oval Lamp 9 79 613 LED Lamp Oval S T T Back Up Lamp Oval 79 491 License Plate Bracket amp Lamp 12 79 606 Pogan r 13 79 58 Piga Tig 14 79 610 Alarm Dual Funcion o 15 9716 0 80 SwihMouningPlaie 3 1 1 Hemote Switch cor 1 4 x 1 1 4 GD5 Cap Screw 3 63 141 1 4NC Hex Flange Serrated Nut Items not included with tailboard no bumper
37. NPT Service Tee Hydraulic Fitting BENE 26 rag M 10 25 285 Oi Strainer 25 GPM 1 75 161 1 l ANPTSquareHeadBlackPipsPug O 1 P7 HYDRAULIC CYLINDER ASSEMBLY B B 3 4 5 6 0 8 9 o 0277 4 9 a 2 xl 2 2221 M Ta H b BUSS AN M M A 23 703 5 x 49 3 4 Hydraulic Cylinder Assembly LIFT 4 00 Retracted 60 Extended 109 3 4 Stroke 49 3 4 Rod Dia 2 1 2 Part Description 1 Manufacturers Label 25 2433 Counterbalance Valve 3 J O Back up Washer Lock Wire Lock Washer teel O Ring Plug 4 _ 0 2 23 804 Seal Kit x Items Included in Kit e Included in Cylinder Assembly P8 GREEN HYDRAULIC CYLINDER ASSEMBLY Rev 9 01 23 721 3 x35 Green Hydraulic Cylinder Assembly EXTEND 9 01 Retracted 45 Extended 80 Stroke 35 Rod Dia 1 3 4 1 ManWaduerslabl ees 6 7 Barrel Assembly Hod Assembly Head Wear Hing f OJ 2 5 Back up Washer Lock Wire Rod Seal Hod Wiper Steel Plug not shown e 23 803 eal Kit Items Included in Kit __8 2 EQUI CV l L 9 29 809
38. Operation Installation and Service Manual TRUCK MOUNTED HOOK HOISTS MODEL KP710 A note to our customers parts managers and dealers This manual has been prepared to assist you in the proper use daily care and operation of your new K PAC equipment It contains specific information on the many built in features of your equipment the accessories and options that are available general specifications and instructions for making minor adjustments Read this manual carefully before operating your K PAC equipment and keep it in a convenient location for later reference In order to ensure that you have the most current owner s manual available for your equipment we have added a revision code to each manual Please note the information listed below and specify when placing service calls or ordering parts Manual for Model KP710 This manual covers models beginning with Serial f 2000 Manual 9710 1 Rev ISSUED TO ISSUED BY Owner s Name Krause Dealer Mailing Address City City State State Date of Purchase Warranty K PAC EQUIPMENT DIVISION OF KRAUSE CORPORATION P O BOX 2707 Hutchinson Kansas 67504 2707 The Krause Corporation herein referred to as Krause Hutchinson Kansas expressly warrants each new product manufactured by it to be free from defects in materials and workmanship under normal use for a period of 365 days from date of shipment from Krause to the original retail purchaser Kra
39. Stainless Steel Air Line 1 4od SAE J844 Type A 6 82 346 Connector Swivel SSCS CT 82 333 Pneumatic Controler Section 8 74 636 Decals Controls O 9 82348 274x Doubled Quantities Reflect 2 Sections 3 Sectionsx P18 CABLE CONTROLS Rev 4 07 M9706 23 FOR MODELS KP710 10 07 en 1 82 238 ontroller 2 ontrol Mount 2 2 3 able 108 Long Eee able 156 Long ESRA L 7210 Cable 252 Long 8 4 98610 0 17 Control Cable Bulkhead Plate 9610 0 23 Control Cable Bulhead Plate 0 1 72 108 Clevis Kit Includes ONE each of fem 2 3 8 X Geisw3BHod X LEG Pn ee nn a 810450 Handle Kit Incudesxtiems 2 3 8 9610 10 T M T TA 25 255 20 Valve Linkage Kit Includes Elgar o eer ink Plate Ss ss TR i8 25 2310 i14 x 25 220 15 62 106 3 9 ess i4NCx amp GDsCapSrew 0 8 18 624207 iPNCxi i4 GDsCapScew 12727 63 107 1 2NC Lock Nut
40. TALLATION INSTRUCTIONS Danger This clutch pump is for a 12 Volt D C circuit Immediately upon unpacking the clutch pump check for shipping damage by spinning the clutch by hand If any metallic rubbing is heard do not attempt to repair the clutch Return the clutch to Muncie for replacement This package should contain the following Clutch Pump Sta Kon Terminals 12 Foot Length of Wire Butt Splice Rocker Switch amp Light Switch Mounting Bracket a Ring Terminals Screws Lockwashers amp Nuts 2 Star Washers PO N amp O In Line Fuse Fanbelt Clutch Pump Installation Mounting Bracket For Clutch Pum K PAC has clutch pump engine mounting kits for selected engines Contact K PAC for further information For complete pump installation follow pump manufacturer s instructions POWER TAKE OFF INSTALLATION A caution A Warning A Warning The power take off selection should be done with care For diesel engines the P T O should be 85 to 100 of engine R P M For gas engines the P T O should be 65 to 80 of engine R P M The direct mounted pump requires a SAE B 2 bolt mounting flange and must accept a 7 8 13 tooth splined shaft Do not attempt to install or service any power 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
41. ack from the hoist according to the normal unloading procedures and leave the hook engaged to the A Frame Connecting Bar This will ensure that the flat rack does not move while the vehicle is being loaded onto the rack Place the truck s transmission in the neutral position set the parking brake and engage the P T O Place the winch into the free wheel position Pull the winch hook and cable through the guide slot located at the front of the rack and out until the hook reaches the vehicle Connect the hook to a bridle or V Strap so that the vehicle can be loaded in the manner recommended by the vehicle manufacturer Return to the winch control disengage the free wheel and activate the winch cable control to put minor tension on the cable If the vehicle to be loaded is disabled straighten the wheels to ensure proper loading place the d transmission in neutral and release the parking brake Return to the winch and operate the control to load the vehicle onto the flat rack Connect two safety chains to the front of the loaded vehicle and secure them to the front of the rack making sure to remove as much slack from the chains as possible M9710 13 Disconnect the winch cable and hook from the vehicle and retract the cable completely Attach two more chains to the rear of the loaded vehicle and connect the opposite end of the chains to the chain slots on the rear of the flat rack deck Attach chain bi
42. al damage to the unit p Test the operation of the assembly The control should move freely through the correct travel arc there should not be interference between the lock nuts on the clutch shaft and clutch rod The decal can be applied to the mounting surface as shown Figure 10 only if the clutch is Engaged with the control pushed in See Figure 7 DO NOT USE THE DECAL IF THE CLUTCH IS ENGAGED WHEN THE CONTROL IS PULLED OUT ROD END CLUTCH ROD HEX Figure 10 M9606 46 A14 WIRING HARNESS INSTALLATION A license lamp and bracket are provided with the hoist Mount the bracket in a location at the rear of the truck that will not be obstructed A three lamp bar is provided with the tailboard to mount at the horizontal center of the tailboard This meets the Federal Lighting Guide for Identification Lamps on the rear S T T lamps side marker lamps rear clearance lamps and back up lamps are also required but are not provided with the tailboard Wiring harnesses and a complete set of lights is provided with the Deluxe Bumper option The KP710 should be wired in the manner recommended by the truck manufacturer and should adhere to the laws governing vehicles of the same classification Refer to Parts section pages P20 for bumper parts identification P24 for electrical parts identification and location and page P25 for electrical schematic 1 Connect the 79 591 Main Wiring Harness to the truck s wiring re
43. d Connect the bullet terminals from the colored wire of the light to the pigtail wire running to the power source Verify the light works before proceeding Slide the rubber grommet off of the light base then push and seat the grommet into the drilled hole The outside edge of the grommet should be flush with the mounting surface Insert the light into the grommet by gently pressing in the light Check that the Hoist Up warning light is ON Rotate inner boom back to normal position Light should go OFF BACK UP ALARM and HOIST UP ALARM With hoists so equipped the dual function Back Up Alarm also functions as a Hoist Up Alarm 1 Locate and mount the back up alarm at the rear of the truck 2 Wire the back up alarm per page P29 in this manual Test back up alarm and hoist up alarm IMPORTANT Back up alarm should sound only when the back up lights are on The Hoist Up alarm should be a warble sound and start functioning when the hoist is slightly raised 4 Install Alarm Must Sound decal inside the cab in full view of the operator HYDRAULIC SYSTEM START UP PROCEDURE 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 an If an accident occurs see a doctor im
44. d out of the path of the drill 4 Unpackage the KP710 Hook Hoist Main Frame and prepare to lift it onto the truck chassis 5 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 frame over the truck chassis 10 11 12 Lower the frame onto the chassis so that the back angle on the frame aligns with the end of the truck frame See illustration Attach the 9610 00 2 Mounting Brackets as shown in illustration M9710 19 on opposite page Reposition Brackets as necessary to not interfere with existing truck brackets Install Front Roller Frame extension as shown and weld With frame square on truck chassis weld TEN 9610 00 2 Mounting Brackets in place on frame Using a 17 32 drill bit drill holes into the chassis rails matching the Mounting Brackets on the frame Insert the 1 2 bolts with flat washers through the brackets and truck frame install lock washers and nuts Tighten all nuts and bolts per bolt torque chart at beginning of this section matching the bolt grade Hold down installation KP706 Hold downs KP710 Hold downs or both can be installed on this unit Install per illustration on page A5 Also see parts pages for hardware callouts if needed Install Boom Rest 9710 0 15 as shown in photo at right weld instructions shown on page P4 OIL TANK VALV
45. e winch control and Free Wheel Control to ensure that they are correctly adjusted and functioning properly REFLECTIVE TAPE INSTALLATION REF ANSI STANDARD Z245 1 1999 Z 2 16 VEHICLE CONSPICUITY 74 600 24 ALTERNATING COLOR OF RED WHITE EA COLOR 6 LENGTH CUT TO LENGTH AS SHOWN 74 600 247 OUTSIDE EDGE OF FENDERS C o f FETA 1 127 ON FRAME EXTENDER 74 600 12 12 UON FARNE MIS ON TANK THIS SIDE OUTSIDE OF BOTH ON FRAME OPPOSITE SIDE CONTAINER GUIDES n 74 500 127 X 74 601 4 12 WHITE REFL INSTALL AS SHOWN 74 600 12 BACK END OF BOTH FENDERS REV 2 04 M9705 32 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 Z245 1 1999 A17 KP710 PAD AND SHIM REPLACEMENT Refer to pages P4 and P5 in this manual 1 2 3 9 Extend boom From the outer boom remove the screws item 25 that retain the
46. emoved in step 5 Insert inner boom into outer boom Replace the pad retainers using shims as necessary between the outer boom and the pad retainers to minimize clearances between the outer boom and the inner boom Apply Loctite to screw threads Align cylinder with pin hole and install rod pin and retaining ring A18 MODIFICATION 36 BOOM INTO 33 BOOM ALIGN LINES WITH CUT QUT ON ORIGINAL 367 HOOK AREA CUTOUT ON SID UNIT AREA TOJCUT DUT MARK PATTERN ON HOOK CUT HOOK MATCHING PATTERN LINES FOR 33 HOOK SHOWN BEFORE CUT OUT WITH TEMPLATE AFTER CUT OUT CUT OUT TEMPLATE This page intentionally left blank A20 E des 9 20 6 2 V 95 VO LMVd Ad 3lva 517 Vo eel VO 80l 1 IVS ava INOILVHOHHOI ASNVY M NOISIAIG Ovd M M 4 818 J ims x l l IC gt D 503 0241 VI 503 HLONJI OL 119 aam M a NIS en HAL V S38ni NO TIIM OL 5 Ozz ener s NONY OL TIS 9 01 NN M3OMO 18 SSHOWLLV 31 i La Nen 31VJ01
47. end in the downward position M9200 36 CONTROL HEAD END OF CABLE 3 Install the control head end of the cable CONTROL CABLE into the cable controller Reinstall the BULKHEAD PLATE cable controller screw passing through DRILL 375 DIA the groove in the end of the cable HOLE THRU i HANDLE IF housing 4 Check the control for free movement correct valve control 5 To connect the cable to the valve handle start by removing the mounting nut from the cable assembly Large nut in the photo above 6 Install the threaded portion of the cable assembly through the bulkhead weldment and replace the mounting nut 7 Install the clevis provided to the cable end The cable end should be parallel to the bulkhead weldment 8 Locate the clevis on the control valve handle If a hole is not provided in the control valve handle for the clevis drill a 375 diameter hole through the valve handle as illustrated Install pin and keeper included with clevis 9 Do a final check of the controls for free movement and correct valve control HYDRAULIC PRESSURE GAUGE 1 Locate and remove plug from port used for pressure gauge 2 Install Pressure Gauge with fittings or adapters as needed 3 Remove Acorn Nut from adjusting screw 4 Loosen Jam Nut 5 Using allen wrench adjust to proper pressure 6 Tighten Jam Nut holding adjustment screw in position 7 Re install Acorn Nut 8 Test unit for prope
48. ferring to the electrical schematic 2 Connect the other wiring harnesses to the 79 591 Main Wiring Harness No splicing is required nor is it recommended 3 Attach the white ground wires with ring terminals on the left and right sides to the bumper with 1 4 screws 4 Install lamp grommets into bumper Connect the wiring harnesses to the lights using information provided on page P25 Connect white wires of lamps to ground as LED lights may be polarity sensitive 5 Clearance lamps must be installed near the widest point of truck to indicate truck width and be visible from the back of the truck 79 580 lamps are provided These can be mounted into a 75 DIA hole placed in the fenders fender bracket or other fabricated bracket To install connect the lamp to the 2 conductor harness by connecting the bullet terminals Slide the rubber grommet off of the lamp base then push and seat the grommet into the 75 DIA hole Insert the lamp base into the grommet and gently push in The 2 conductor harness male bullet terminals can be plugged into connectors provided in the main wiring harnesses 6 Test lights for proper working order If marker lamps or identification lamps do not illuminate switch wire leads to check if polarity is correct If S T T or Back Up lamps do not work check to be sure connections are secure and that wiring harness connected to truck wiring system is wired correctly HOIST UP LIGHT INSTALLATION 1 Retract and rotate
49. ft blank A22
50. ge the container with the safety locks Disengage the P T O and drive safely A caution Caution Do notpull forward until the hoistis lowered to the full down position Unloading Flat Racks Bins or Other Containers from the Hoist System A Position the rear of the truck approximately 10 feet in front of the desired resting place for the rack or container This will allow for the distance the rack or container will travel during the unloading procedure Put the truck transmission in neutral and engage the parking brake Inspect the desired area for obstruction both around and overhead and instruct all persons to stand clear of the equipment Inspect the load on the truck to ensure that it will remain stable during the unloading procedure Engage the trucks P T O and activate the Hook Arm Control to retract the Hook Arm completely This procedure will push the rack or container away from the back of the truck cab M9710 8 O4 F Activate the Rotation control to pivot the Rotation Boom toward the back of the truck until the load touches the ground Note f the rack or container does not have rollers the truck brake should be carefully released and the truck be allowed to roll forward use the foot brake to gain control of the forward movement leaving the rear end of the rack of container to pivot until it is in full contact with the ground G Continue to pivot the rotation arm until the hook arm jaws can
51. h a 135 arc from Engaged to Free SOCKET n iet CLUTCH HEAD BOLT Spool positions as shown The lever must also LEVER BOTH SIDES travel symmetrically about the centerline as shown in Figure 7 CLUTCH SHAFT ENGAGED POSITION CONTROL FREE Figure 6 SPOOL lt lt v POSITION k Attach the ball joint rod end onto the clutch lever using the three 3 8 flat washers 3 8NC Hex head nut and bolt as shown in Figure 8 Figure 7 135 M9606 43 A138 Bolt the lock plate to an appropriate mounting surface NOTE Bolts for mounting the lock plate are not provided See Figure 9 m Screw the plastic knob onto the lock rod using the lock washer provided See Figure 9 BALL JOINT HOD END CLUTCH LEVER LOCK WASHER PLASTIC KNOB BOLT 19606 M9606 45 Fi Figure 8 Figure 9 n The lock rod and the clutch lever should both be in the same position either Engaged or Free Spool Make allowance for the length of thread needed in the lock rod and rod end Thread size of the clutch rod is determined by the remote clutch kit part number o Thread the clutch rod into the ball joint rod end and tighten with the appropriate hex nut Attach the lock rod to the clutch rod and lock with the hex nut See Figure 10 Adjust the length of the clutch rod so the clutch lever travels through the correct arc See Figure 7 The clutch lever must not be forced past the travel stop since this will result in intern
52. he back of the truck cab to engage the rack or container sills with the four safety locks on the hoist frame J Disengage the P T O Observe road and weather conditions and drive with the caution required for a vehicle under load O3 DUMPING A CONTAINER A caution Be sure that the truck is on firm level ground before D 9 J K dumping If one side of the load breaks loose in this high center of gravity position a truck on unstable footing may roll over on its side When the path is clear back the K PAC Hoist to the dumping site Put the transmission in the neutral position and engage the P T O or switch the hydraulic pump on and engage the truck brake Be sure that the path is clear including overhead and retract the hook arm to move the container back from the cab and free of the safety locks on the frame IMPORTANT INNER BOOM MUST BE COMPLETELY RETRACTED BEFORE RAISING THE HOIST Activate the rotation control until the container begins to touch the ground When the material has been dumped activate the Rotation Boom to lift the bin off the ground Disengage the P T O and drive the hoist forward about three feet Re engage the P T O and brake Active the control to rotate the arm forward to raise the container from the ground Hook arm should still be completely retracted Continue to pivot the rotation arm towards the cab until the container rests against the frame Extend the hook forward to enga
53. ighten the assembly using a flat screwdriver through the rear fitting port into the end of the piston item 12 DO NOT USE AN AIR GUN Secure the actuator assembly to the valve body using the four 4 socket head cap screws and lock washers items 4 amp 7 Test for proper alignment by turning the valve spool The spool should rotate freely Mount the valve and install fittings SLOT PLATE RETAINER IPARKER GRESEN V 20 SPOOL PARKER GRESEN V 20 THE ASSEMBLY BY HAND USING A SCREWDRIVER M9806 7 A8 APPLY REMOVABLE M9806 8 Pre Assembled Pneumatic Control Tower Installation See Parts Section page P18 1 2 3 Determine a suitable location which is in a comfortable location for the driver and not in the way of the transmission lever Position the lower bolt holes so that the bolts will miss any cable wires or structural members in or under the cab floor Mark and drill the four 4 343 diameter holes for the 3 8 self tapping screws supplied for the tower Determine a location in the area between the mounting holes to run the air lines Drill a 2 to 3 diameter hole through the floor of the truck Remove all burrs and sharp edges Line the hole with the grommet material supplied Using the washers on the underside of the floor attach the tower to the floor with the 3 8 screws and lock nuts Supply Winch Cable In Winch Cable Out Hoist Raise On Hoist Raise Off
54. ility Neither does this warranty apply to normal maintenance service and parts or to normal deterioration due to wear and exposure Any service part sold by Krause shall be warranted for thirty 30 days from date of shipment from our factory No credit for labor will be allowed under this warranty if the part upon our inspection proves to be non defective To the extent allowed by applicable law this warranty is expressly in lieu of other warranties expressed or implied in fact or by law including any implied warranty of merchantability of fitness for a particular purpose The remedies of repair or replacement as set forth are the only remedies under this warranty Krause disclaims any obligations or liability for loss of time inconvenience commercial loss or direct consequential special or incidental damages This warranty is in lieu of any other obligation or liability of Krause of any nature whatsoever by reason of the manufacture sale lease or use of such products and Krause neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with such products KP710 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
55. ling This will help the steel ball into place See Figure 4 DETENT h Install a new gasket onto the ASSEMBLY drum support being sure to line up the holes of the gasket with the holes in the drum support It may be easier to hold the gasket in place if you apply a slight coat of grease to the gasket face M9606 40 A12 NOTE If the ring gear was separated from the gear housing 12 000 Ib models only a new gasket should be installed there also See Figure 5 i While keeping the felt marks lined up bolt the gear housing back onto the drum support Torque the socket head bolts to 100 120 Lb in DRUM SUPPORT M9606 41 NOTE HEAD BOLTS The gear housing may need to be lined up before bolting down For housing to line up properly it may be necessary to slightly rotate the ring gear inside the gear housing Also the detent assembly can be temporarily removed but must be installed before bolting down the gear housing See Figure 5 j Bolt the clutch lever onto the clutch shaft using a 3 8 flat washer and 3 8NC hex nut See Figure 6 The position of the clutch lever on the clutch shaft may be adjusted for different control locations but the WARN supplied decal can only be used if the clutch is in the Engaged position with the control pushed Figure 5 Figure 7 shows a typical installation where the S FLAT WASHER decal can be used The clutch lever should always travel throug
56. mediately Any fluid injected into may result the skin must be surgically removed within a few hours or gangrene 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 Ur ode O 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 A16 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 7 Perform a loading procedure with a flat rack or dump bin to put the hydraulic system under load and check all connections and components for leaks 8 If no leaks are visible remove and replace the rack or bin on the KP710 4 to 5 times to ensure that all moving parts are functioning freely and properly 9 Load the flat rack or bin with a load comparable to the full capacity of the KP710 and perform the loading and unloading procedure to ensure that all hydraulic lines and moving parts are functioning properly under load 10 Operate th
57. nders to remove the slack from the chains and check to ensure that the loaded vehicle is properly secured O7 M Continue to load the flat rack onto the K PAC hoist in the normal manner M9710 14 N Put the transmission of the vehicle to be transported in park if automatic or in gear if manual and set its brake O Re examine the safety chains and reconnect the magnetic tail lights NOTE Amber beacon lights may be necessary in some states when transporting vehicles M9710 15 K PAC Warranty Information Congratulations on the purchase of the KP710 Hook Hoist K PAC Equipment Division of Krause Corporation takes pride in engineering and manufacturing products which are of the finest quality and highest standard As a result we stand behind any K PAC Equipment product or component claimed to be defective during the warranty period To avoid delays with the service process please read the warranty instructions in the first section of this manual at the time of the vehicle purchase and complete and return the supplied warranty card O8 PARTS SECTION THE FOLLOWING ILLUSTRATED PARTS SECTION HAS BEEN COMPILED TO REFLECT PART NUMBERS REQUIRED TO ORDER PARTS AND TO SUPPORT THE INSTALLATION SECTION FOR DIMENSIONS AND DESCRIPTIONS OF ALL PARTS BOLTS PINS ETC THE OPERATOR CAN ALSO IDENTIFY PART NAMES TO CLARIFY PROPER OPERATIONAL STEPS TOOL BOX
58. o the key hole To power the winch cable in or out be sure that the free wheel lever is locked in the first notch before activating the winch power control lever To retract the cable hydraulically pull the power control lever towards the front of the truck To extend the cable hydraulically push the power control lever towards the rear of the truck The cable will stop when the control is in the neutral position Read the winch manufacturer s instructions for more information on the winch operation Note Never jam any of the Hoist Hydraulic Controls into the operating position Flat Rack Operation Optional Equipment The optional K PAC flat rack can be used to transport a variety of materials and equipment including automobiles It can be equipped with stake pockets and head board Flat Rack Specifications 17 1 2 feet 92 inches 2 080 Ibs 7 000 Ibs O6 Note Do not concentrate loads on small areas of the K PAC flat rack Concentrated loads should be distributed by placing planks of hardwood on the deck of the rack before placing the load Magnetic tail lights may need to be installed on the rear end of the flat rack when being transported on the hoist in order to comply with vehicle lighting regulations Loading a Vehicle onto the Flat Rack A M9710 12 Back the hoist approximately 20 feet in front of the vehicle to be transported Disconnect and remove the magnetic tail lights Unload the flat r
59. r operation re adjust to correct pressure if needed 9 Remove test Pressure Gauge and re install plug Re test unit checking for leaks and proper operation AT PNEUMATIC CONTROL INSTALLATION INSTRUCTIONS The optional pneumatic controller provided with K PAC equipment are dual three way regulating valves Output of the controllers is proportional to the control lever position and is balanced against the force of an internal spring Pneumatic Actuator Installation The pneumatic actuator has been partially assembled and pre lubricated for ease of installation The actuator does not have to be disassembled for installation Remove the valve if previously installed Find a suitable area free of dust and dirt to attach the pneumatic actuators Set the hydraulic valve on its mounting base Determine which spools are to be pneumatically controlled From the valve assembly 1 Qro b d Remove and discard the original retainer screws and valve spring cover Retain the handle end of the spool Remove and discard the 5 16 shoulder bolt from the end of the valve spool exposed by the removal of the valve spring cover Remove and discard the original centering spring and two original centering cups Insure the original seal retainer on the valve spool is properly seated Apply a small bead of removable thread lock to the threads of the spool adapter item 1 Holding the spool on the opposing end hand t
60. shims and pad retainer items 27 and 28 Remove retaining ring item 13 and rod pin item 12 connecting the boom cylinder item 14 to the inner boom item 8 Carefully slide the inner boom out of the outer boom item 17 to access the wear pads On the inner boom remove screws item 9 that retain the shims and pads items 10 11 30 and 31 Replace the pads using shims as necessary between the inner boom and the pads to minimize clearances when assembled with the outer boom Apply Loctite to screw threads Insert inner boom into outer boom Add or remove shims if necessary Replace the pad retainers using shims as necessary between the outer boom and the pad retainers to minimize clearances between the outer boom and the inner boom Apply Loctite to screw threads Align cylinder with pin hole and install rod pin and retaining ring KP710 BOOM CYLINDER REPLACEMENT Refer to pages P4 and P5 in this manual 1 2 3 From the outer boom remove the screws item 25 that retain the shims and pad retainer items 27 and 28 Remove retaining ring item 13 and rod pin item 12 connecting the boom cylinder item 14 to the inner boom item 8 Carefully slide the inner boom out of the outer boom item 17 Remove retaining ring item 16 and rod pin item 15 connecting the stationary end of the boom cylinder item 14 Remove replace the boom cylinder and install rod pin and retaining ring r
61. ssing items should be reported to K PAC equipment immediately MODEL NUMBER Know the model number of the KP710 being mounted Use this model number whenever referring to the assembly or parts listing pages The number is Mii aue stamped on the Name Plate which is located on the n EQUIPMENT DIVISION OF KRAUSE CORPORATION b HUTCHINSON KANSAS M MADE IN USA NUFACTURED OMPLIANC front frame member STANDARD IN EFFECT AT TIME OF MANUFACTURE TRUCK CHASSIS D FTI T G 5 E 18 xDimension goes from rearmost point of cab exhaust to axle Rev 5 06 d 17 i 2 i9 NA 35 5 NA 40 1779 15687 t NA NA 59 605 W 19975 i NA 2 NA 59 605 The KP710 120 Hook Hoist is designed for a minimum of 33 000 Ibs G V W R chassis with a minimum of 108 to 156 unobstructed behind cab to axle chassis clearance ww O 3 40 i59 13667 i 28 159 NA 355 59 NA PIS a 1 The preceding illustration provides dimensional guidelines for compatibility with containers etc If the chassis is higher or lower than the 40 dimension shown then the lowest hook pickup dimension will change accordingly CLUTCH PUMP INS
62. t DO NOT TIGHTEN yet Adjust bumper so it is square with truck frame and clamp in position Match drill SIX 21 32 holes in side plates through truck frame Make sure area behind holes is clear of objects Install bolts in holes just drilled adjust bumper to proper position tighten bolts the proper specs check bumper for correct alignment INSTALLATION INSTRUCTIONS FOR THE REMOTE CLUTCH KIT Fits all WARN INDUSTRIAL 9 000 and 12 000 Ib winches Items Included in this Kit Gr BON NO 1 Remote Clutch Assembly 2 Instructions 3 Replacement parts list NOTE It is easier to install the kit with the winch removed from the vehicle These illustrations show the assembly of the remote clutch to a SERIES 9 and 12 winch only therefore you should carefully read these instructions before you start a If the winch is equipped with a safety latch remove the socket head bolts SOCKET HEAD holding the latch onto the gear housing BOLTS NOTE Although the GEAR safety latch will not be HOUSING used with this kit you must reinstall the two bolts to fill the FIGURE 1 tapped holes in the gear housing See Figure 1 to the right b With the winch lying horizontal remove gear housing to the drum support NOTE M9606 37 Before removing the gear housing mark the placement of the housing on the drum support with a felt This will make installation easier See Figure 2 A11 C NOTE On 12 000 Ib 5
63. tainer onto the hoist inspect the load to ensure that the materials to be transported are securely fastened to the tie downs and that all fasteners are in good condition Inspect the flat rack or container to ensure that it is clear of all obstructions and persons and that it is not fastened or stuck to the ground Caution Do not attempt to load container with faulty equipment Check the condition of the hook safety latch boom pivot and the inner boom slide pads Be sure that the height of the hoist hook is compatible with the container Do not lift a container heavier than the rated capacity of the hoist HOOK ARM EXTENSION BOOM UNLOAD HOOK EXTENSION ARM BOOM LEVER LEVER Inspect the condition of the A Frame and be sure that the combined weight of the pay load and the flat rack or container does not exceed the 20 0007 equipment Before activating either control ensure that the area around the hook hoist is clear of persons high voltage overhead wires and other obstructions A Line up the hoist truck boom with the rack or container hook If this is not possible the rack or container can be picked and loaded from within a 30 arc either side of center 02 B Engage the parking brake depress the clutch and engage the P T O Activate the In Cab Control to slide the Hook Arm back to the fully retracted position this is very important fis C Activate the In Cab Control to pivot the
64. the hoist has been completely installed engage the P T O to check out the operation of the hoist A9 TAILBOARD INSTALLATION Using a suitable device assemble tailboard unit to the rear of the chassis The top flange of tailboard assembly should fit between the truck chassis and the KP710 frame After aligning the assembly drill 21 32 diameter holes through the top flange of the chassis using the holes in frame as templates and bolt in position OPTIONAL WINCH INSTALLATION includes Deluxe Bumper WINCH INSTALLATION 1 Assemble winch for Remote Clutch Kit hydraulic fitting on winch leave loose for adjustment springs See illustration below Supplied with Clutch Control Kit Spring on Cable Tensioner Kit Ear to be mounted on winch frame DO NOT Get Spring Too Tight Supplied with Winch See pages A11 A14 for instructions Install Install cable guide on winch with MATCH DRILL HOLES E MOUNT TO TRUCK FRAME SECURE WITH 5 8NC x 221787 SCREW 5 8NC LOCK NUT 6 REQD N kd Nu y e m bU C INSTALL BEFORE INSTALLING WINCH IN BUMPER USE 2 9606 51 1 TAB DO NOT USE PART SUPPLIED WITH WINCH
65. use s obligation under this warranty is limited to repairing and or replacing at its option any part or parts within the applicable warranty period as set out above which shall be returned by the owner or any Krause authorized dealer to the factory and which shall disclose to Krause s satisfaction to be defective Krause may at its option elect to grant adjustments in the field through an authorized representative and may thereby elect to waive the requirement that parts be returned to Krause s factory All claims shall be processed through your Krause authorized dealer A new warranty period is not established for replacements Replacements are warranted for the remaining portion of the original warranty period The repair or replacement of defective parts under this warranty will be made without charge to the owner except for transportation Krause does not warranty electric motors hydraulic pumps and cylinders accessories and other parts not manufactured by Krause but supplied with or as a part of Krause products Krause will however obtain and pass on any adjustments provided by the manufacturers of such parts under these manufacturer s warranties The provisions of this warranty do not apply to any product or parts which have been subject to misuse negligence or accident or which have been repaired or altered outside of Krause s factory in any way so as in the judgement of Krause to affect adversely its performance or reliab

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