Work Truck Hydraulic Outrigger System - Power
Contents
1. 4 POWEF PALCKEF 11 3010003373 Operators and bystanders must be clear of the stabilizing legs during operation Moving Stabilizers can cause serious personal injury Stabilizing legs must be on firm level ground that will not yield under load If the ground is soft or uneven use stabilizer pads to increase the bearing area Failure to do so may allow the vehicle to tip over which could result in death or serious personal injury During crane operation the tire on the opposite side of the lifting load should not leave the ground If this occurs the vehicle could tip over which could result in death or serious personal injury If the load is within the rating of the crane s load radius chart relocate the truck closer to the load POWEF PHPALCKEF Installation and Service Manual On Highway Stabilization System 10 0 Manual Out Hydraulic Down Operation Instructions 1 A A Locate the truck on level ground Set the truck parking brake and place if necessary place wheel chocks blocks under the front wheels before operating the stabilizers Disengage the indexing plunger Manually extend the passenger side stabilizer arm to full extension and secure using the indexing plunger To insure maximum vehicle stability be sure to fully extend the passenger side stabilizer arm before lowering the Stabilizing legs Hydraulically lower the stabilizing legs until they make solid contact with the ground Do2. 0 Manual Out Manual Down Parts List 88 86 RETRACTED 124 86 H EXTENDED 36 STROKE RY A RETRACTED 46 18 EXTENDED 20 STROKE PS SS gt SE ARs i les CB 2 meer Eug ll s 1070002604 extenD stas R AM i a 1070002634 Dt STABILIZER AM o dT ai Der BoT va x4aRabes e i s2 15 1130 SCREW v218xs SES 53 161030 1 2 HELICAL SPANG LOCK WASHER 7 1 84 Duer RI TT 85 s237 WEE ET 75 6 2070000507 INDEXING PLUNGER n 1 These items are contained in hardware kit 1010002738 2 These items are available individually POWEF PALCKEF 9 3010003373 Installation and Service Manual On Highway Stabilization System 9 0 Manual Out Hydraulic Down Installation Instructions AWARNING The stabilization system includes a center tube an extend stabilizer arm a fixed stabilizer arm two stabilizing legs and mounting Stabilizer components are hardware see assembly parts list heavy To avoid possible death or serious personal 1 Center Tube Installation Mount the center tube to the vehicle injury always follow safe so that it is supported at the truck frame Additional support at rigging and lifting practices both ends of the tube as shown in figure 3 is recommended if possible The tube can be welded or mechanically fastened to the supports Welding of the tube to the supports is to be done by a certified welder Proper mounting of the tube is the responsi
3. ALCKEF 5 3010003373 AWARNING Stabilizer components are heavy To avoid possible death or serious personal injury always follow safe rigging and lifting practices Figure 1 POWEF PALCKEF Installation and Service Manual On Highway Stabilization System 6 0 Hydraulic Out Aydraulic Down Installation Instruc tions The stabilization system includes a center tube an extend stabilizer arm with integral hydraulic extend cylinder a fixed stabilizer arm two stabilizing legs and mounting hardware see assembly parts list 1 Center Tube Installation Mount the center tube to the vehicle so that it is supported at the truck frame Additional support at both ends of the tube as shown in figure 1 is recommended if possible The tube can be welded or mechanically fastened to the supports Welding of the tube to the supports is to be done by a certified welder Proper mounting of the tube is the responsibility of the vehicle manufacturer Consult Power Packer for assistance Be sure to orient the center tube item 2 so the reinforcing weldments are up and the extend side is on the passenger side of the vehicle same side as the crane Also make sure there is access to the extend cylinder ports See figure 2 Install three wear pads item 5 5 in the extend side of the center tube as shown in figure 2 F 3010003373 Installation and Service Manual On Highway Stabilization System 2 Stabilizer Arm Installation The up a
4. PEOWER PACKER An Actuant Company Installation and Service Manual On Highway Stabilization System CONTENTS Part 3010003373 REV 0E Section Page 1 0 Receiving Instructions 2 2 0 Safety Issues 2 W ork Truck 3 0 Hydraulic Fluid S e Hydraulic Outrigger Systems 4 0 Operating Parameters 5 0 Hydraulic Out Down Parts 5 6 0 Hydraulic Out Down Installation 6 7 0 Hydraulic Out Down Operation 8 8 0 Manual Out Down Parts 9 9 0 Manual Out Hydraulic Down 10 Installation 10 0 Manual Out Hydraulic Down 12 Operation 11 0 Notes on Installation of Hydraulic 13 System 12 0 Warranty 14 800 745 4142 Fax 574 256 1248 info powerpackerus com www powerpackerus com Copyright 2014 Power Packer All rights reserved 3010003373 Installation and Service Manual On Highway Stabilization System 1 0 Important Receiving Instructions Visually inspect all components for shipping damage prior to installation Shipping damage is not covered by warranty If shipping damage is found notify carrier at once The carrier is responsible for all repair and replacement costs resulting in damage from shipment For most current manual see http www powerpackerus com Product descriptions and specifications are subject to change For specific versions related to your product contact us 2 0 Safety Issues Read all instructions warnings and cautions carefully Follow all safety precautions to avoid personal injury or property d
5. amage during system operation Power Packer cannot be responsible for damage or injury resulting from unsafe product use lack of maintenance or incorrect product and or system operation Do not remove warning labels tags or decals Contact Power Packer when in doubt as to the safety precautions and operations This manual follows a system of safety alert symbols signal words and safety messages to warn the user of specific hazards Failure to comply with these warnings could result in serious personal injury or death as well as damage to equipment or other property This is a Safety Alert Symbol that appears throughout this manual It is used to alert you to potential physical injury hazards Pay close attention to Safety Alert Symbols and obey all safety messages that follow this symbol to avoid possible serious personal injury or death Safety Alert Symbols are used in conjunction with certain Signal Words that call attention to safety messages or property damage messages and designate a degree or level of hazard seriousness The Signal Words used in this manual are WARNING CAUTION and NOTICE AWARNING WARNING indicates a hazardous situation that if not avoided could result in death or serious injury e CAUTION indicates a hazardous situation that if not avoided could A CAUTION result in minor or moderate injury NOTICE indicates information considered important but not hazard NOTICE related e g messages related to p
6. bility of the vehicle manufacturer Consult Power Packer for assistance Be sure to orient the center tube item 1 so the reinforcing weldments are up and the extend side is on the passenger side of the vehicle Same side as the crane Install three wear pads item 5 5 in the extend side of the center tube as shown in figure 4 Figure 3 10 3010003373 Installation and Service Manual On Highway Stabilization System 2 Stabilizer Arm Installation The up and down orientation of the bracket on the end of the stabilizer arms item 3 and 4 can be used to increase the range of mounting height for the stabilizer legs item 1 The stabilizer legs must be positioned to reach the ground before reaching their maximum stroke of 20 inches Once the extend stabilizer arm is oriented install three wear pads item 5 5 as shown in figure 4 Insert the extend stabilizer arm item 3 into the center tube Secure the extend stabilizer arm using the indexing plunger item 5 6 provided Insert the fixed stabilizer arm item 4 into the center tube Secure the fixed stabilizer arm using 5 long Le bolts item 5 2 lock washers Item 5 3 and nuts item 5 4 provided Torque nuts to 57 64 ft lbs 3 Stabilizing Leg Installation Mount the stabilizer legs item 1 to the mounting brackets using 4 long 12 inch class 5 bolts item 5 1 lock washers item 5 3 and nuts item 5 4 provided three per leg Torque nuts to 57 64 ft lbs Figure
7. e back pressure Sharp bends and kinks will internally damage the hose leading to premature hose failure e Do not drop heavy objects on hose A sharp impact may cause internal damage to hose wire strands Applying pressure to damaged hose may cause it to rupture e Keep hydraulic equipment away from flames and heat Excessive heat will soften packings and seals resulting in fluid leaks Heat also weakens hose materials and packings Protect hoses and hydraulic legs from weld spatter Hydraulic equipment must only be serviced by a qualified hydraulic technician Specific safety messages appear throughout this manual in the left hand column 3010003373 Mixtures of hydraulic fluid and fuel oil can cause seal damage resulting in subsequent sticking or sluggish action of the system and voids warranty Damaged seals must be replaced AWARNING Stabilization systems must be installed and operated within the design parameters of the crane and vehicle that they are intended to stabilize Failure to do so could result in death or serious personal injury as well as property damage POWEF PHPALCKEF Installation and Service Manual On Highway Stabilization System 3 0 Hydraulic Fluid Specifications RECOMMENDED HYDRAULIC FLUIDS FOR POWER PACKER Power Packer recommends using a quality ISO 32 Anti wear hydraulic fluid for most applications If operating in cold temperatures below freezing slow operation will occur I
8. eld WI 53964 800 745 4142 Fax 574 256 1248 info powerpackerus com www powerpackerus com POWEF PHPALCKEF 14
9. f slower operation in cold weather affects your operations we recommend using a fluid specially formulated for cold temperatures We have found that ISO 15 High Viscosity Index Anti wear hydraulic fluids work well with Power Packer systems to 20 F Some examples of these are Mobil DTE 10 Excel 15 Chevron Rando HDZ 15 Kendall Hyken Glacial Blu If consistently operating at temperatures below 20 F then we recommend hydraulic fluids conforming to MIL PRF 5606H or MIL H 5606A obsolete If you have any questions regarding fluid recommendations please call us 4 0 Stabilization System Operating Parameters Stabilization legs must be operated within design parameters Design parameters may vary from leg to leg and must be followed to ensure expected behavior and a safe operating environment Leg parameters are documented on each part number specific drawing 3010003373 Installation and Service Manual On Highway Stabilization System 5 0 Hydraulic Out Hydraulic Down Parts List EX TERED 46 STROKE HS Hp RETRACTED TALIE I a Ti G i 2 meer CENTERTUBE ll s IL 1070002896 EXTEND STABILERAPM a 1070002634 Dt STABILIZER ARMS St dT i Der Bom v23 xa Gabes e i 82 15 1130 Bunnen 53 161030 12 HELICAL SPRING LOCK WASHER 6 1 84 De Nor aex OOOO o o o e ss Sa Wann 6 1 These items are contained in hardware kit 1010002738 2 These items are available individually POWEF P
10. nd down orientation of the bracket on the end of the stabilizer arms item 3 and 4 can be used to increase the range of mounting height for the stabilizer legs item 1 The stabilizer legs must be positioned to reach the ground before reaching their maximum stroke of 20 inches Once the extend stabilizer arm is oriented install three wear pads item 5 5 as shown in figure 2 Insert the extend stabilizer arm item 3 into the center tube Insert the fixed stabilizer arm item 4 into the center tube Secure each stabilizer arm using 5 long Le bolts item 5 2 lock washers item 5 3 and nuts item 5 4 provided one per arm Torque nuts to 57 64 ft lbs 3 Stabilizing Leg Installation Mount the stabilizer legs item 1 to the mounting brackets using 4 long 12 inch class 5 bolts item 5 1 lock washers item 5 3 and nuts item 5 4 provided three per leg Torque nuts to 57 64 ft lbs Figure 2 Reinforcing Weldments Extend Cylinder Port Access POWEF PALCKEF 7 3010003373 Installation and Service Manual On Highway Stabilization System 7 0 Hydraulic Out Hydraulic Down Operation Instructions A WARNING Operators and bystanders must be clear of the stabilizing legs during operation Moving Stabilizers can cause serious personal injury A WARNING Stabilizing legs must be on firm level ground that will not yield under load If the ground is soft or uneven use stabilizer pads to increase the bearing a
11. not lift the truck Stabilizers increase vehicle stability only if the wheels remain firmly on the ground To store the legs hydraulically raise them until they are fully retracted Then manually retract the passenger side stabilizer arm and secure using the indexing plunger Do not move the passenger side stabilizer arm in or out with the legs extended Damage to the system may occur Do not move the truck with the stabilizer arm or the legs extended Property damage or personal injury may occur 12 3010003373 Installation and Service Manual On Highway Stabilization System 11 0 Notes on Installation of Hydraulic System See figure 5 for identification of pump manifold ports for hose routing CR Curb Rear hose to extend port of passenger side stabilization leg that extends out RR Road Rear hose to extend port of driver side stabilization leg that is fixed CF or RF hose to extend port of extend cylinder inside extend stabilizer arm use either port hydraulic out systems only Return hoses to any return port All are tied together Figure 5 ONNAM A bs a a h Return Ports POWEF PALCK EF 13 3010003373 Installation and Service Manual On Highway Stabilization System 12 0 Warranty For warranty information please contact the Power Packer Warranty Claims Department Warranty Claims Department 608 296 1107 Fax 608 296 1798 Power Packer 516 Hillcrest Drive Westfi
12. rea Failure to do so may allow the vehicle to tip over which could result in death or serious personal injury AWARNING During crane operation the tire on the opposite side of the lifting load should not leave the ground If this occurs the vehicle could tip over which could result in death or serious personal injury If the load is within the rating of the cranes load radius chart relocate the truck closer to the load POWEF PALCKEF As A Locate the truck on level ground Set the truck parking brake and if necessary place wheel chocks blocks under the front wheels before operating the stabilizers Hydraulically extend the passenger side stabilizer arm To insure maximum vehicle stability be sure to fully extend the passenger side stabilizer arm before lowering the stabilizing legs Hydraulically lower the stabilizing legs until they make solid contact with the ground Do not lift the truck Stabilizers increase vehicle stability only if the wheels remain firmly on the ground To store the legs hydraulically raise them until they are fully retracted Then hydraulically retract the passenger side stabilizer arm Do not move the passenger side stabilizer arm in or out with the legs extended Damage to the system may Do not move the truck with the stabilizer arm or the legs extended Property damage or personal injury may occur 3010003373 Installation and Service Manual On Highway Stabilization System 8
13. roperty damage POWER PACKER 2 3010003373 AWARNING A CAUTION POWEF PALCKEF Installation and Service Manual On Highway Stabilization System 2 1 Safety Precautions Failure to observe and comply with the following precautions could result in death or serious personal injury as well as property damage e Keep hands and feet away from hydraulic legs during operation e Do not handle pressurized hoses Escaping oil under pressure can penetrate the skin If oil is injected under the skin see a doctor immediately e Do not exceed equipment ratings Never attempt to lift a load weighing more than the capacity of the system Overloading can cause equipment failure e Never set relief valve to a higher pressure than specified Higher settings may result in equipment failure e Be sure setup is stable before lifting load Hydraulic legs should be placed on a flat surface that can support the load Do not bridge Where applicable use support pads for added Stability Do not weld or otherwise modify the hydraulic leg to attach a base or other support e Immediately replace worn and damaged parts To protect warranty use only Power Packer parts Failure to observe and comply with the following precautions could result in minor or moderate personal injury as well as property damage e Avoid damaging hydraulic hose Avoid sharp bends and kinks when routing hydraulic hoses Using a bent or kinked hose will cause sever
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