LOAD KING 80-160 Operator's Manual

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OPERATORS MANUAL

LOAD KING

80-160

REV B

DECEMBER, 2020

Table of Contents

Summary of Contents for LOAD KING 80-160

Page 1 OPERATORS MANUAL LOAD KING 80-160 REV B DECEMBER, 2020...
Page 2 Page Intentionally Blank...
Page 3 WARNING Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. These chemicals can be emitted from or contained in other various parts and systems, fluids and some component wear by-products.
Page 4 Load King has been producing first-class heavy equipment since 1956. Cutting-edge innovation and engineering excellence make us the market leader. Load King is a key part of the Custom Truck One Source family of brands, offering standard and custom trailers, vocational equipment, and a full line of Boom Trucks and truck cranes.
Page 5: Table Of Contents
2. Safety Safety Introduction....................1 Product Safety Decals....................2 Safety Definitions Used in this Manual..............2 General Safety......................7 Safety Sign Maintenance..................7 80-160 Safety Sign Locations................8 Safety Guidelines....................26 Personal Protection Equipment................27 Workplace Safety....................28 Effects of Wind Conditions ..................37 Lightning Storm....................39 Temporary Interruption of Crane Operations............40 Resuming Crane Operations................43...
Page 6 80-160 Contents Extending and Retracting the Jib Pull-out Section..........17 Counterweight Installation ..................19 4. Description Of Machine and Controls Controls in the Cab....................1 Upper Controls and Instruments.................16 Universal Symbol Identification................19 Power Take-Off....................23 Carrier Controls and Instruments ................25 Side-Stow Jib......................26 Rated Capacity Indicator and ATB...............28 Rated Capacity Indicator System..............28...
Page 7 Operator Aids ......................10 Load Handling Operations ..................11 Max. Load and Boom Angle Charts..............12 Using the Maximum Load Chart..............12 Load Rating Chart Interpretation..............14 Operating Radius...................20 Boom Angle Placards..................21 Operating the Unit....................22 Operator Shutoff Devices................22 Operating the Unit..................25 Jump Starting an Engine- Booster Cable Instructions........26 Unusual Operating Conditions...............27 Initiating Operation..................31 Arm and Hand Signals..................32...
Page 8 80-160 Contents 9. Maintenance Maintenance Introduction..................1 Cold Weather Package Specification..............2 Cold Weather Package Recommendations............3 Safety Practices.....................7 General Work Practices..................9 Storing Components....................10 Cleanliness......................11 Operator Observation..................12 Maintenance Checks and Lubrication..............13 90-Day Maintenance Items...................15 Semi-Annual Maintenance Items ................16 Machine Maintenance Checklist................17 Hydraulic Hoses....................20 Filters and Maintenance..................22...
Page 9 Drive Shaft Maintenance..................67 Brake System Maintenance.................70 Air System Maintenance..................71 Hydraulic System Maintenance................72 ATB System......................76 Storage.........................78 Machine Storage....................79 Chrome Cylinder Rod Storage................80 Restoration to Service..................81 10. Specifications Wire Rope Specifications..................1 Vehicle Dimensions....................2 Pumps and Function Speeds.................5 11. Troubleshooting Introduction......................1 General Procedure....................3 Hydraulics - General....................4 Operator Controls....................5 Siwng Circuit......................6...
Page 10 80-160 Contents Repairs-Adjustments-Remarks Log...............5 Torque Wrench Extensions..................6 Welding Instructions....................8 Hydraulic System....................10 Pressure Settings-Pumps & Valves..............10 Pumps......................17 Rotary Manifold....................18 Rotation System....................20 Inspection of Rotation Bearing Clearance............20 Swing Reducer....................22 Electrical System....................23 Fuse Block-Operator’s Cab................23 Relay & Fuse Block-Chassis................25 Electrical System Collector Ring..............26 Maintenance -Free Battery Testing..............28...
Page 11: Introduction
Load King manuals in the shipment of each product. It is company policy to provide this information for the owner or user of the equipment. It is expected that the owner or user will utilize these manuals and standards to provide the appropriate information and training to those people who are to operate, maintain and supervise the use of equipment.
Page 12: Nomenclature
80-160 Introduction Nomenclature This manual contains instructions and information on the operation, maintenance, lubrication and adjustments of the Boom Truck. The operator should not attempt to operate the machine before he has gained a thorough understanding of the material presented in the following pages. To aid in understanding the contents of this manual, the following terms will always have the meanings given whenever they are used.
Page 13: Intended Use
The crane is designed exclusively for assembly type, non-duty cycle operations. Use of this product in any other way is prohibited and contrary to its intended use. Other crane applications outside of the intended use statement above must be approved in writing by Load King.
Page 14: Bulletin Distribution And Compliance
Introduction Bulletin Distribution and Compliance Safety of product users is of paramount importance to Load King. Various bulletins are used by Load King to communicate important safety and product information to dealers and machine owners. The information contained in bulletins is tied to specific machines using the machine model number and PIN/serial number.
Page 15: Contacting Manufacturer
Contacting Manufacturer At times it may be necessary to contact the manufacturer of this machine. When you do, be ready to supply the model and PIN/serial number of your machine, along with your name and contact information. At minimum, the manufacturer should be contacted for: •...
Page 16: Transfer Of Machine Ownership
80-160 Introduction Transfer of Machine Ownership Complete the New Owner Registration Form on the following page. The Model Name, Product Identification Number (PIN), and serial number is located on a plate inside the operator’s cab. The six- digit serial number is shown on a plate on the outside of the operator’s cab.
Page 17 LOAD KING WARRANTY DATA RECORD Warranty Form Submission Date Date of Delivery Model Number Dealer Address Customer Address Record this information at the time that warranty registration form is completed and returned to Load King.
Page 18 Page Intentionally Blank...
Page 19: Safety
Owners, Users, and Operators: Load King appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: Comply with OSHA, Federal, State, and Local Regulations.
Page 20: Product Safety Decals
80-160 Safety Product Safety Decals Safety Definitions Used in this Manual The following table describes text and symbols used to highlight important information. Signal Word Symbol Explanation Danger is used to alert readers about an immediate and serious hazard that will DANGER likely be fatal.
Page 21 SYMBOLS AND PICTORIALS Hazard Avoidance CRUSH HAZARD Stay Clear of Moving Turret and Crushing of fingers Boom. or hand - force applied two directions (pinched). CRUSH HAZARD Keep clear of moving machine. Death or Serious Injury can result from contact with moving machine.
Page 22 80-160 Safety Hazard Avoidance Hand Entanglement Keep Hands Clear in Pulley / Winch. of Winch and Load Line. Entanglement in Stay Clear of Drive Shaft. Rotating Shafts. ENTANGLEMENT Keep away from fan HAZARD and belt when engines running. Rotating parts can...
Page 23 Hazard Avoidance BURN HAZARD No smoking. No flame. Fuel and fumes can Stop engine. explode and burn. BURN HAZARD Allow surfaces to cool before Contact with hot servicing. surfaces can cause burns. Falling from height. Use personnel lift or appropriate ladder to reach high places.
Page 24 80-160 Safety Hazard Avoidance CRUSH HAZARD Stay Clear of Outriggers. Contact with moving outriggers can result in death or serious injury. Electrical Shock / Stay Sufficient Electrocution from Distance From Crane to Power Line Electrical Power Contact. Lines. These are general safety rules, that must be followed. You are also required to read and understand the Operators Manual as there are instructions that are more detailed, specific to this machine.
Page 25: General Safety
General Safety Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they will damage the safety sign material.
Page 26: 80-160 Safety Sign Locations
80-160 Safety 80-160 Safety Sign Locations Right Hand Side View Left Hand Side View...
Page 27 Rear View Front View...
Page 28 80-160 Safety Upper Cab...
Page 29 Crush Hazard Stay clear of moving boom or turrent. Contact with moving boom or turrent can result in death or serious injury. Injection Hazard Fluid escaping under pressure can penetrate skin and result in serious injury. Crush Hazard Stay clear of moving Relieve pressure before disconnecting machine.
Page 30 80-160 Safety Fall Hazard Stay off crane boom/ jib, load line, and Falling can result in hook. death or serious injury.
Page 31 HAND SIGNALS STOP EMERGENCY STOP Do not deface or remove this label from the machine. Order replacement labels from your Load King dealer. Arm extended, palm down, move Both arms extended, palms down, move arms arm back and forth horizontally.
Page 32 80-160 Safety DESCRIPTION OF MOVEMENT HOIST. Forearm vertical, forefinger pointed up, move hand in small horizontal circles. LOWER. Arm extended down, forefinger pointed down, move hand in small horizontal circles. USE MAIN HOIST. Tap fist on head; then use standard signals.
Page 33 Crush Hazard Crush Hazard Stay clear of Verify lock pin is fully outrigger path and engaged in jib.Read Contact with moving Contact with falling contact point. and understand outriggers can result lattice jib can result operator’s manual in death or serious in death or serious before using or injury.
Page 34 80-160 Safety Electrocution Hazard Stay clear of machine Contact with electric power lines will result in death or serious injury. Entaglement Hazard Keep hands clear of moving winch/ Contact with moving load line. load line can result in death or serious...
Page 35 Electrocution Hazard Contact with electric power lines will result in death or serious injury. Before operating the machine, contact the electric power line owner to disconnect, move or insulate power lines. Improper lifting of personnel can result in death or serious injury Use of this machine to hoist, lower, swing or otherwise handle personnel must only be done in compliance with OSHA 1926.1431 and ANSI B30.23.
Page 36 80-160 Safety Fall/Crush Hazard Two blocking the crane can result in death or serious injury. Do not allow hook block to contact the boom tip. Check ATB system after installation of each line and at start of every work shift. Read and understand operator’s manual.
Page 37 Fall Hazard Use the provided access system. Falling can result in death or serious injury. Crush Hazard Contact with moving outriggers can result in death or serious injury. Stay clear of outrigger path during operation. Turn machine off and remove key before servicing.
Page 38 80-160 Safety Explosion / Burn Hazard Battery explosion and/or contact with corrosive acid will result in death or serious injury. Keep all open flames and sparks away. Wear appropriate personal protective equipment, including gloves, face shield and long sleeve shirt. Read manuals. If you...
Page 39 Crush Hazard Stay clear of suspended loads. Contact with falling Never go below a load can result in suspended load. death or serious. injury Unexpected machine response from improper operation of free swing or free float boom functions can result in death or serious injury.
Page 40 80-160 Safety Explosion/Burn No Smoking Hazard Keep all open Fuel and fumes can flames and sparks explode and burn, away. resulting in death or serious injury. Stop engine before adding fuel. Crush Hazard Contact with falling load can result in death or serious injury.
Page 41 Close and latch securely before driving this crane Electrocution Hazard Before operating the machine, Contact with electric contact the power lines will result electrical power in death or serious line owner to injury. disconnect, move or insulate power lines.
Page 42 80-160 Safety Riding Hazard Sudden or unwanted machine movement can result in death or serious injury. Riding on this machine can result in death or serious injury. Lift arm before entering or exiting cab. No riders. Stay out of upper structure cab during...
Page 43 Fall Hazard Falling can result in death or serious injury. Use the provided access system.
Page 44: Safety Guidelines
80-160 Safety Safety Guidelines These are general safety rules, that must be followed. You are also required to read and understand the Operators Manual as there are instructions, which are more detailed specific to this machine.
Page 45: Personal Protection Equipment
Personal Protection Equipment Before beginning operation, service or maintenance conduct a hazard assessment to determine appropriate personal protective equipment for the working conditions and the operating environment. For more information refer to the applicable OSHA 1910.132 Standards, ANSI Standards, Federal, State, Local and Jobsite Regulations.
Page 46: Workplace Safety
80-160 Safety Workplace Safety HANDLING PERSONNEL Cranes can only be used to lift people when it is the least hazardous way to do the job. (See OSHA 1926.1431, 1926.550g, and ASME / ANSI B30.23.) TRAINING AND KNOWLEDGE Safe operation must always be the operator’s most important concern.
Page 47 OPERATOR’S RESPONSIBILITIES Keep people, equipment and material outside of the work area. 10. Signal person(s) must be used when the operator’s vision is blocked or when working in hazardous areas such as near power lines or people. 11. Keep a fully charged fire extinguisher and first aid kit in the operator’s cab at all times and be familiar with the use of these items.
Page 48 80-160 Safety RESPONSIBILITIES OF ALL CREW MEMBERS Unsafe conditions and/or practices must be corrected. Obey all warning signs. Watch out for your safety and the safety of others. Know and understand proper machine erection and rigging procedures. Alert operator and signal person of hazards, such as power lines, unstable ground, etc.
Page 49 PLANNING THE JOB 10. Determine how the load will be rigged. 11. Determine the lift radius, boom angle and the rated lifting capacity of the crane. 12. Always pre-plan the course of each lift to determine the best route to reach the load’s target destination.
Page 50 80-160 Safety OPERATOR AIDS CHECK Ensure that the listed items are in place and operational. Boom angle indicator. Backup Alarms. ATB devices. Overload Protection, Load Indicators, Rated Capacity Indicator. OPERATION OVERLOAD PROTECTION Know the weight and characteristics of all loads to be lifted.
Page 51 OPERATION SETUP Be sure the load bearing surface is strong enough to support the machine with lifted load. Be sure the crane is level. Check frequently and re-level when necessary. Stay away from rotating cranes. Erect barricades to keep people away. Make sure these areas are clear before swinging.
Page 52 80-160 Safety POWER LINE SAFETY Electrocution Hazard Contact with electric power lines will result in death or serious injury. Maintain Required Clearance LINE VOLTAGE REQUIRED CLEARANCE 0 TO 50 kV 10 FT ( 3.0 M) 500 TO 200 kV 15 FT (4.6 m) 2000 TO 350 kV 20FT (6.1 m)
Page 53 POWER LINE SAFETY If contact occurs, stay on crane until the boom is cleared or until the electrical current is turned off. If contact occurs, keep all personnel away from the crane. If you must leave the crane, JUMP WITH BOTH FEET TOGETHER COMPLETELY CLEARING THE MACHINE. Continue jumping with both feet together to leave the area.
Page 54 80-160 Safety OPERATIONAL AIDS - EMERGENCY PROCEDURES When operational aids are inoperative or malfunctioning, the following requirements shall apply for continued use or shutdown of the crane. Steps shall be taken to schedule repairs immediately. The operational aids shall be put back into service as soon as replacement parts, if required, are available and the repairs and calibration can be carried out.
Page 55: Effects Of Wind Conditions
Effects of Wind Conditions Lifting Constraints The crane can be used safely by following the values given in the load capacity tables up to a wind speed of 20 mph (32 km/h) on a load surface of 11.7 ft^2/ton (1.1 m²/tonne). Check the forecast and monitor wind speed conditions near the job site.
Page 56 80-160 Safety Pay attention to the wind speed values in table below in relation to the information in the WARNING section of the LOAD CHART. Any governmental regulations applicable to the job site must also be observed. Wind Force Wind Speed...
Page 57: Lightning Storm
Lightning Storm When lightning is striking in the vicinity of the crane, the operator should never attempt the following procedures: • Getting into the operator’s cab or attempting to get onto the carrier, superstructure or boom assembly. • If on the machine, do not try to get off the machine. If you are in the operator’s cab during an electrical storm, stay in the cab.
Page 58: Temporary Interruption Of Crane Operations
80-160 Safety Temporary Interruption of Crane Operations As a general rule, if it is not possible to maintain sufficient control over a rigged crane, the boom and the equipment shall be taken down if the crane’s operations are interrupted and may be left unsupervised.
Page 59 • Check for leakage and unintended (slow) movement on all load bearing hydraulic cylinders and winches: Outrigger vertical cylinders Boom lifting cylinder(s) Hoist winch Boom extension cylinder(s) NOTE: Slight movement can also be due to changing oil temperature (e.g. slight cylinder movement due to sun warming or hydraulic oil cooling).
Page 60 80-160 Safety Slow retraction of outrigger support cylinders, lift cylinders and/or telescoping cylinders on unpinned telescoping systems (e.g. due to changes in ambient and oil temperature, leakage). • Vandalism. Any or a combination of the above may result in the following events: •...
Page 61: Resuming Crane Operations
Resuming Crane Operations Before crane operation is resumed after a period of inactivity/crane being unattended, the operator is required to check the condition of the crane and its location. Whenever the operator has left the cab, the Rated Capacity Limiter (RCL) settings must be verified and reset.
Page 62: Ending Crane Operations
80-160 Safety Ending Crane Operations Prior to leaving the crane, the operator must be certain the crane is in a condition acceptable to be left unattended. End of Operations checklist 1. _________ Is the load fully on the ground and unhooked from the crane? 2.
Page 63: Turning/Driving In Reverse
Turning/Driving in Reverse While operating a mobile crane in reverse, the risk of accident or injury is greater and extra caution must be exercised. Risk of accidents and personnel injury or death is increased when operating in reverse. The following cautions must be observed at all times: •...
Page 64: Parking The Vehicle
80-160 Safety Parking the Vehicle NOTE: Parking Instructions only apply to mobile cranes. Failure to adequately a secure parked vehicle may result in vehicle roll-off and injury or death to personnel and/or damage to property. Risk of Death The following conditions must be strictly adhered to by the crane operator: •...
Page 65: Lock Out & Tag Out
Lock Out & Tag Out Occupational Health & Safety Code of Federal Regulations number 1910.147 requires that employers establish and follow a Lock Out & Tag Out procedure and train their employees in that procedure before any employee can operate, service or maintain any piece of power equipment. Employers are required to make periodic inspections to see that their Lock Out &...
Page 66 80-160 Safety Who must apply a lock & tag • Any person working on the equipment. • Foreman or other person responsible for the work being done. • If several people are working on a machine at the same time, each person must apply his or her own lock and tag.
Page 67: Access/Egress
To provide safe access and egress to/from the crane, Load King provides a number of steps, ladders and handrails allowing three-point access to all areas of the crane where it is necessary for the operator to be when moving from the ground to the operator’s cab or from the operator’s cab to the ground.
Page 68 80-160 Safety Operator’s cab steps and grab handles with lower steps deployed NOTE: Use 3 pts of contact when entering both cabs.
Page 69 NOTE: Do not use item 4 Console Arm lift handle as a grab handle for entering or exiting the operator’s cab.
Page 70 80-160 Safety Access / Egress-Rear...
Page 71: Personal Safety
Personal Safety SLIP AND FALL PREVENTION Always wait until machine has stopped before getting on and off the equipment. Do not use controls or steering wheel as hand holds. Keep the machine clean and dry. Remove all oil, grease, mud, ice and snow from walking surfaces. Store all tools, rigging and other items in the tool box.
Page 72: Seat Belts
80-160 Safety Seat Belts SOME SUGGESTED USAGE AND MAINTENANCE INSTRUCTIONS FOR SEAT BELTS: Wear your lap belt low and snug. Lift joystick arms on both LH & RH side to easily access the seat belt while seated. Pull out auto-retracting seat belt male end on LH side and attach to fixed buckle receptacle on RH side with a noticable click.
Page 73: Assembly
Assembly Erecting the Jib Do not lower the boom to an angle below 1°. This action could cause the jib to disengage and drop off. Make sure that nobody enters the area over which the jib will swing. Retract the boom fully before mount the jib. The jib cannot be mounted/stowed if the boom is extended even slightly.
Page 74 80-160 Assembly Install the pin (1) after the middle folding section align with the fixed ramp. Remove the pin (2) and swing out the folding section of tri-fold ramp. Install the pin (2) after the folding section align with the middle folding section.
Page 75 Install the pins (5) on both upper and lower mounting holes of the Jib. Pull the lever (6) to disengage the secondary pivot pin. 10. Use jib deployment cylinder (4) to push jib off the ramp. Disengage the jib deployment cylinder hook by lifting the cylinder up and rotating out of the latch.
Page 76 80-160 Assembly 11. Swing jib with guide rope until the left side mounting holes of jib line up with the boom mounting holes. Install lower left-hand pin (6). 12. Remove pin (7) from guide sheave kickstand. 13. Flip up guide sheave (8) and reinstall pin (7) in upper hole.
Page 77 14. Reeve cable through guide sheave (8) and sheave (9) at end of jib base section. 15. Install winch line and socket to jib base dead-end (10).
Page 78 80-160 Assembly 16. Winch up using jib remote control until 4th pin comes into alignment and install 4th pin (11). 17. Remove the guide rope.
Page 79: Changing The Offset Of The Jib
Changing the Offset of the Jib 0º Offset Hole 20º Offset Hole 40º Offset Hole Jib Offset Angle: “Jib offset angle” refers to the angle formed by the centreline of the jib and the centreline of the boom. The jib is mounted on the boom head and is used for lifting a relatively light load to a higher location.
Page 80 80-160 Assembly Remove the jib offset pin (4) from the 0° offset hole (1). Install the offset pin (4) at the 20° offset hole (2). Refer to the Fig. which shows that the jib is at 20° offset angle position.
Page 81 Remove the jib offset pins (4) from the 20° offset hole (2) and keep the pin (4) in the toolbox. Refer to the Fig. which shows that the jib is at 40° offset angle position. 10. Reverse the above procedure to return the jib to 0° offset position.
Page 82 80-160 Assembly Mounting the folding Jib Section Lattice Section Tubular Section Before mounting the folding Jib assembly, wind speed indicator and / or hazard light (optional) including bracket must be completely removed from the jib head. At a later point, when the folding Jib is fitted, the hazard light and the rotor of the wind speed indicator must be fitted on to the head of the folding Jib.
Page 83 Remove the mounting pins (2) from lattice sections of the jib. Swing the tubular section of jib with guide rope until the left side mounting holes line up with the left side mounting holes of lattice sections of the jib. Install the upper and lower mounting pins (2).
Page 84 80-160 Assembly Remove the guide rope. Reeve the hoist line over the tubular jib sheave (3).
Page 85: Spooling Wire Rope On Drums
Spooling Wire Rope on Drums Care must be exercised when installing wire rope on the winch drum. Improper spooling can. result in rope damage through crushing, kinking, dog- legs, abrasion and cutting. Poorly installed wire rope will also adversely affect the operating characteristics of the machine by causing uneven application of force and motion.
Page 86 80-160 Assembly Apply braking force to the reel flange in order to prevent overrun as the rope is being drawn off. Loops formed by overrun can cause kinks and doglegs in the rope, resulting in damage and premature rope failure. A timber or block forced against the shipping reel flange can be used to provide the required braking force.
Page 87 Never use a steel hammer or pry bar to move the rope over on the drum. These tools can easily damage the rope. After the rope is wound onto the winch drum, reeve the cable as desired. Use only factory supplied sockets, wedges and pins of the proper size; make no substitutions.
Page 88 80-160 Assembly Final seating of the wedge is accomplished by making lifts of gradually increasing loads. avoid imposing shock loads on the rope until the wedge is firmly in place. After the wedge has been firmly seated, a short length (6 inches) of the cable should be secured to the free end of the wire rope to act as a stop as shown.
Page 89: Cable Sockets
Cable Sockets ROPE SIZE PART NUMBER DESCRIPTION WHERE USED 3/4" 218534 WEDGE FREE END OF ROPE 3/4" 1234-44 SOCKET FREE END OF ROPE 3/4" 216529 WEDGE MAIN & AUX. DRUM WEDGE POCKET The wrong cable wedge could permit the wire rope to work loose and detach itself from the drum;...
Page 90 80-160 Assembly Use only factory supplied sockets, wedges and pins of the proper size; make no substitutions. Follow the procedure below when installing wedge type sockets on wire rope. Be certain the correct socket and wedge are used. Lead the rope through the socket, form a large loop and draw the rope end back through the socket.
Page 91: Hoist-Line Reeving
Hoist-Line Reeving Auxiliary Winch Winch Dead End Main Winch Idler Sheave 5 Sheave Load Sheave 4 Sheave Block Sheave Dead End for Even Parts of Line Dead End for Odd Parts of Line...
Page 92 80-160 Assembly NOTE: Sheaves in Boom Head and Hook Block are Numbered from Left to Right as viewed from the Operator’s Station. “D” indicates Pinned End of Rope. BOOM HEAD HOOK BLOCK PARTS OF LINE (LOAD SHEAVE) (BLOCK SHEAVE) 1 4 D...
Page 93 Attach the ATB weight to the ATB switch and to the first part of line as shown on the previous page. The ATB chain should be 48 inches long. Verify that the chain is not twisted or knotted after installation. Test the ATB system by lifting the ATB weight.
Page 94: Cable Reeving
80-160 Assembly Cable Reeving CABLE REEVING When reeving the machine for any job, remember that hoisting and lowering speeds decrease as the number of parts of line increases. For the most efficient use of the machine, it is desirable to use the minimum number of required parts for lifting the anticipated loads.
Page 95: Dead Ending Wire Rope In Socket
Dead Ending Wire Rope in Socket Below are shown the three different ways to dead end wire rope: Loop Back Method Special Clip Method Extra Piece Same Size Rope Clipped to Main Rope Method...
Page 96: Counterweight Installation
80-160 Assembly Counterweight Installation INSTALLATION FROM FRAME DECKING TO MAIN COUNTERWEIGHT NOTE: The counterweight slabs are an integral part of this crane. When the crane is to be traveled at highway speeds, a portion of these slabs are intended to be moved to and carried on the counterweight supports on the deck of the crane in order to equalize the axle loading.
Page 97 With engine idling slowly, press rocker switch to the “UP” position to raise the counterweight slabs tightly against the shell of the counterweight. Install horizontal pins item #2 and locking pins item #3 on each side to attach the stack to the counterweight.
Page 98 80-160 Assembly...
Page 99: Description Of Machine And Controls
Description Of Machine and Controls Controls in the Cab Upper Control Switch Panel Rear Wall Upper Operator’s Cab Top Working Light - press top part of switch to activate roof work lights. Front Working Light - press top part of switch to activate the front working light.
Page 100 80-160 Description Of Machine and Controls Windscreen Wiper Sliding Door Sliding Door (Inside Controls) Door Release Knob - to unlock door from the closed position for exiting cab or to move the door to the open position. B - Door Open Release Knob - to unlock the door from the full open position, so door can be closed.
Page 101 Button No. Function KW - push button #1 turns ON and OFF the AC and heater system. HEAT - selecting button #2 turns ON Heat Mode. In Heat mode, the highest temperature setting is Hard Heat and the temperature in the cab can rise to 120°...
Page 102 80-160 Description Of Machine and Controls Cab Interior Controls Upper Switch Panel Upper Switch Panel A - Cab Work Light B - Roof Wiper C - Roof Washer D - Windscreen Wiper E - Windscreen Washer...
Page 103 HVAC VENT - Air vents not only control direction, but also flow. They can be closed to direct air where needed most. Stereo Radio and CD Player (Option) Dome Light 10. Storage Compartment 11. Beacon / Rotary Light (option) Beacon / Rotary Light (option)
Page 104 80-160 Description Of Machine and Controls 12. Cab Tilt Switch - hold down upper part of switch and cab will tilt from 0° - 20°. Hold down lower part of switch to return tilt angle of cab to 0°. Do not activate Cab Tilt Switch while swinging the upper structure. Due to hydraulic...
Page 105 KEEP CLEAR OF THIS AREA DURING CAB TILTING Keep hands and feet clear of exterior operator’s cab area during tilting. Sound horn before tilting cab to make personnel aware of cab movement. Outrigger Extend / Retract switch Outrigger Extend / Retract switch...
Page 106 80-160 Description Of Machine and Controls 14. LH Control Lever Operator’s Seat Controls...
Page 107 LH Control Lever Accomodates the controls for turret slewing, release of the superstructure rotation brake, telescopic boom extension / retraction, auxilary winch and two speed winch. Safety switch device is in the L. H. armrest. Lowering the armrest will activate both joystick controls. Exiting and egress of cab the Left Hand armrest must be in the UP position to prevent accidental manuevers.
Page 108 80-160 Description Of Machine and Controls Boom Telescope Switch - Pushing upward and forward on the rocker switch will extend the boom sections. Pulling downward on the switch will retract the boom sections. OPERATION WITH ONLY ONE WINCH Push forward on center rocker switch to extend the boom sections. The speed of the boom extend is proportional to the throttle setting and movement of the switch.
Page 109 15. RH Control Lever THROTTLE LOCK MAIN WINCH HS MAIN WINCH ON/OFF SWING PARK BRAKE RH Control Lever The RH joystick commands load lifting and lower with the main winch, raising and lowering the telescopic boom, two speed winch control, winch disable and horn. Push WINCH DISABLE switch to “DISABLE”...
Page 110 80-160 Description Of Machine and Controls Internal to the joystick handle is a thumper indicator that is felt by the operators hand to assist in the speed the winch drum is traveling when the MAIN WINCH joystick is moved forward or backward.
Page 111 17. Roof Hatch Lock Handle retain control of both raise / lower handles when unlatching (19) until hatch is fully open. Pull down on both handles when closing hatch and rotating (19) lock handles. Keep head clear when pulling hatch down.
Page 112 80-160 Description Of Machine and Controls Windscreen Lock & HVAC Vent 18. Windscreen Lock 19. Emergency Stop Button - Push to stop Engine operation. Push in on red button and rotate clockwise to reset button prior to restarting engine.
Page 113 20. Fire Extinguisher - The fire extinguisher is mounted inside the operator’s cab next to the seat base accessable from the outside of the cab with the door in the open position or from the seated position inside the cab. A - Gauge - check daily to verify the charge level needle is in the “Green”...
Page 114: Upper Controls And Instruments
80-160 Description Of Machine and Controls Upper Controls and Instruments Operator’s Seat Controls Seat Control Arm (Down Position) - When arm is in “DOWN” or horizontal position, engine running, the joystick control is “live”. Use lift handle on arm to rotate arm to “UP” position when entering or exiting the cab.
Page 115 Armrest Adjustment Knob - Loosen knob and position armrest can be adjusted up / down to operator’s preference. Retighten knob to lock in position setting. Arm-Fore / Aft Adjustment Knob - Loosen knob and arm will slide forward or rearward so joystick can be comfortably positioned to operator’s preference.
Page 116 80-160 Description Of Machine and Controls Retractable Seat Belt - Before operating crane, attach seat belt. Lift RH arm to up position will allow easier access for latching or unlatching seat belt. Press red button on seat belt to unlatch and exit seat and cab.
Page 117 Control Sreens This section is intended to familiarize the operator with the control screens provided for the operation of this machine. Home page screen Outrigger controls screen...
Page 118 80-160 Description Of Machine and Controls Cab controls screen Lifting controls screen...
Page 119: Universal Symbol Identification
Universal Symbol Identification This section is intended to familiarize the operator with the controls and instruments provided for the operation of this machine. It should be emphasized, however, that merely knowing the controls is inadequate preparation for operating hydraulic cranes. Do not attempt to operate the machine until the other sections of this manual have been covered.
Page 120 80-160 Description Of Machine and Controls ELECTRICAL SYSTEM ON HEADLIGHTS WASHER IGNITION ON FAST ENGINE DIAGNOSTIC IGNITION SLOW INCR / IDLE ADJ INCREASE AXLE DISENGAGE / RANGE INCR / IDLE ADJ DECREASE KEY - ACC SHIFT...
Page 121 ENGINE STOP KEY - OFF DIFF LOCK OFF HIGH SPEED REAR AXLE KEY - ON KEY SWITCH LOW SPEED REAR AXLE KEY - START PTO OUT DIFF LOCK ON PTO IN ENGINE WARN...
Page 122 80-160 Description Of Machine and Controls MIRROR HEAT SUSPENSION RAISE / LOWER TAG AXLE LIFT ABS-DIAGNOSTIC...
Page 123: Power Take-Off
Power Take-Off Disengage PTO before driving truck. Failure to do so will cause damage to the transmission and hydraulic pump. Transmission Mounted, Electric Clutch Shift PTO’s Allison Transmission Eaton Fuller Manual Transmission To Engage PTO Set parking brake. Shift transmission to neutral Engage PTO with rocker switch on dash (item 1 as shown below).
Page 124 80-160 Description Of Machine and Controls PTO Engage Switch...
Page 125: Carrier Controls And Instruments
Carrier Controls and Instruments OUTRIGGER CONTROL BOX-Carrier Frame Notice: When deploying outriggers, raise evenly on all jacks. Do not extend rear jacks alone without extending front jacks or damage can result to the cranes frame structure. EXTEND SWITCH: This switch is used to FRONT LEFT JACK SWITCH: This switch is extend the outrigger.
Page 126 80-160 Description Of Machine and Controls OUTRIGGER CONTROLS SCREEN Outrigger controls screen...
Page 127: Side-Stow Jib
Side-Stow Jib DESCRIPTION A optional jib extensions is available to provide additional boom reach. The jib is a 30-58 ft. (9.1m - 17.67m) side stow swing-on. It is a bi-fold with a lattice section and a tubular section. Total Weight: 2,400 lbs. (1089 kg) The optional jib extension is pinned directly to the ends of the sheave pins.
Page 128 80-160 Description Of Machine and Controls Before stowing the jib, ensure that no personnel or obstacles are in the swing path of the jib.
Page 129: Rated Capacity Indicator System
Rated Capacity Indicator and Anti-Two Block Rated Capacity Indicator System The Load King Boom Truck is equipped with the Greer Insight Rated Capacity Indicator System. The operator is provided with a continuous readout of rated capacity, approach to overload, and two-block condition.
Page 130: Atb Components
80-160 Description Of Machine and Controls Anti-Two-Block Components CABLE REEL The ATB cable is wound onto a spring loaded cable reel which is bolted to the left side of the boom base. The reel allows the cable to pay-out and pay-in as the length of the boom is changed. The cable reel has slip rings which allow electric current to flow even while the reel is turning.
Page 131: Inspection
Inspection Pre-Start Inspection The following items should be checked each day before start-up and the start of operations. Also see “Daily Check.” on page 138. ENGINE OIL The level should be at the full mark. COOLANT The level should be near the bottom of fill neck in coolant tank when cold. DIESEL EXHAUST FLUID Check diesel exhaust fluid (DEF) or Urea tank level is full.
Page 132 80-160 Inspection GENERAL CONDITION Inspect the machine in general for wear, leakage, and damage. AIR TANKS Open the air tank drain cocks to blow out moisture and sediment. FUEL FILTER See carrier chassis supplier recommendations for service. See also, “Daily Check.” on page 138.
Page 133: Suggested Hydraulic Crane Inspection Checklist
Suggested Hydraulic Crane Inspection Checklist This check list is to be used in addition to the information provided in this manual to properly operate and maintain the machine. ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED * VISUAL INSPECTION (Complete Machine)
Page 134 80-160 Inspection ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED MACHINE LUBRICATION ATTACHMENT PIN BOLTS MUFFLER / EXHAUST SYSTEM ALL CONTROL MECHANISMS INSTRUMENT GAUGES CLUTCHES & BRAKES WIRE ROPE, SHEAVES & GUARDS TWO BLOCK DAMAGE PREVENTION SYSTEM...
Page 135 ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED HORN PROPER CABLE SPOOLING WEDGE SOCKETS AXLE FLUID LEVEL SWING REDUCER FLUID LEVEL DRIVE SHAFTS & U JOINTS TIRE & WHEEL CONDITION & INFLATION PRESSURE REGULATORS AIR CLEANER ELEMENT CLUTCH &...
Page 136 80-160 Inspection ITEMS TO BE INSPECTION SATISFACTORY ADJUST REPAIR INSPECTED & CODE CHECKED FAN BELT TENSION STRUCTURAL MEMBERS & WELDS BOOM INSPECTION BATTERIES & STARTING SYSTEM TRANSMISSION FILTER ENGINE OIL FILTER ENGINE FUEL FILTER SWING BEARING BOLT TORQUE MACHINERY GUARDS LOAD CHART &...
Page 137 REPAIRS - ADJUSTMENTS - REMARKS ITEM REQUIREMENT DATE...
Page 138: Daily Check (8 Hours)
80-160 Inspection Daily Check (8 Hours) __ Perform Daily Lubrication __ Check Hydraulic Reservoir Fluid Level __ Fill Fuel Tank __ Check Engine Oil Level __ Check Coolant Level __DEF Aftertreatment Fluid (Urea) Tank Level (Tier 4 engines only) __ Check Hydraulic Cylinder Mounting Bushings and Pins __ Check Hydraulic Components including hoses.
Page 139: Weekly Check (40 Hours)
Weekly Check (40 Hours) __ Perform The Daily Check __ Perform Weekly Lubrication __ Check Swing Reducer Oil Level __ Check Axle Oil Level (after initial change) __ Check Battery Condition __ Check Tire Pressure And Condition __ Check Air System Safety Valve __ Check Torque on Wheel Lug Nuts __ Check Hydraulic Cylinders and Rods __ Make Thorough Inspection of Wire Rope...
Page 140: Monthly Check (80 Hours)
80-160 Inspection Monthly Check (80 hours) __ Perform Daily and Weekly Checks __ Perform Monthly Lubrication __ Check Engine Belts __ Check Hydraulic Reservoir for Moisture __ Check all Slider Pads __ Have Hydraulic Oil sample Analyzed __ Clean Radiator & Oil Cooler Exterior...
Page 141: Quarterly Checks (250 Hours)
Quarterly Checks (250 Hours) __ Perform Daily, Weekly and Monthly Checks __ Perform Quarterly Lubrication __ Drain Fuel Tank of Water and Sediment if necessary __ Check Brake Shoes for Wear Condition __ Change Transmission Oil and Shift Air Filter __ Change Hydraulic Return Line Filters __ Replenish Cooling System Corrosion Inhibitor (refer to engine manufactures manual) __ Check Engine Manufacturer’s Manual for additional Maintenance Requirements...
Page 142: Semiannual Checks (1000 Hours)
80-160 Inspection Semiannual Checks (1000 Hours) __ Perform Daily, Weekly, Monthly and Quarterly Checks __ Perform Semiannual Lubrication __ Clean Crankcase Breather __ Check Hydraulic Reservoir Relief Valve __ Clean Hydraulic Reservoir Intake Suction Filter __ Check Air Dryer Desiccant for Signs of Oil Accumulation...
Page 143: Annual Check (1500 - 2000 Hours)
Annual Check (1500 - 2000 Hours) __ Perform Daily,Weekly, Monthly, Quartly and Semiannual Checks __ Perform Annual Lubrication __ Disassemble Winch and Inspect __ Drain And Clean Hydraulic Reservoir __ Change Hydraulic Fluid (unless checked by oil analysis). __ Drain and Refill the Winch Lubricant __ Change Axle Oil __ Check the hose lines (see Hydraulic Hose topic in the Maintenance section of this manual).
Page 144: Crane Boom
80-160 Inspection Crane Boom MAIN BOOM INSPECTION & MAINTENANCE PROCEDURE Task Action • Broken wire rope or cut strands. Replace • Corrosion of wire rope. Replace • Wire rope kinking, crushing, un-stranding, bird caging, main strand Replace displacement or core protrusion.
Page 145 NOTES: The disassembly of boom is a recommendation for proper inspection related to wear, corrosion, cracks or breakage of components. If crane is used in a highly corrosive environment due to salts or chemicals, then inspection and maintenance intervals should be more frequent than shown above.
Page 146 80-160 Inspection If any indicator decals are missing or illegible (either triangle markers or boom length numbers), order the applicable items through your distributor.
Page 147: Wire Rope Inspection
Wire Rope Inspection Safe operation of your Load King Boom Truck is dependent on the proper use of wire rope in all operations. The ideal situation is to remove a wire rope from service after receiving maximum service life, but without sacrificing safety. The end point of useful service life is determined by regular inspections of the wire rope by competent personnel.
Page 148 80-160 Inspection 1/32” For rope diameters 3/8” through 1/2” 3/64” For rope diameters 9/16” through 3/4” 1/16” For rope diameters 7/8” through 1 1/8” REDUCTION OF WIRE ROPE DIAMETER...
Page 149: Wire Rope Inspection Record
Wire Rope Inspection Record WIRE ROPE INSPECTION RECORD (Refer to Wire Rope User’s Manual for Criteria) PLACE OF INSPECTION DATE DESCRIPTION OF CRANE Make Model Serial No. Type and arrangement of attachments Date of Last Rope Inspection Hours and Time of Service Since Last Inspection Results of Inspection Rope Type and Size...
Page 150: Mobile Crane Load Test Inspection
80 to 100 wind turbines at one location within a few weeks). Load King strictly prohibits operators to overload any crane. Safety equipment such as load limit devices prevent overloads being raised; the corresponding bridging / override switch is only provided for emergency situations or when the load limiter fails (as determined in the operating instructions).
Page 151 If load tests are required by laws mandating checking the assembly of the crane, 100% of the permitted load of the crane in the given configuration must not be exceeded. This applies to all Load King mobile cranes for the static and dynamic load tests. A period of 5 minutes is sufficient for static tests.
Page 152 If a load test is required (by law), the test conditions must correspond with the conditions during the scheduled lift. It is acceptable to Load King to carry out a load test for a given crane configuration with reduced loads (below the max. capacity), but at a greater radius, up to the maximum radius (max. load...
Page 153: Operating Instructions
Operating Instructions Job-Site Job Site Setup Procedure Position vehicle on solid level ground, fully set parking brake, and place transmission in neutral. Refer to Power Take-Off section of Operator’s manual for PTO engagement due to the differences in activation, transmission types and PTO locations. When the pump PTO is engaged, allow hydraulic oil to warm up by circulating to prevent pump damage.
Page 154: Outrigger Positioning
80-160 Operating Instructions Outrigger Positioning Before conducting any boom operation you must extend all outriggers to a firm and level surface. In the event that other conditions exist such as: loose or sandy soil, crusty or frosty surface with soft soil underneath, icy or slick pavement, sloping surfaces, etc., you will be required to restrict your operations.
Page 155 OBSERVE CAUTION NOTES ON OUTRIGGER MOVEMENT WHENEVER SETTING UP OR STOWING OUTRIGGERS.
Page 156: Work Site Position
80-160 Operating Instructions Work Site Position The best possible work site should always be sought when you are positioning the crane. An ideal location is where the ground is firm, level and dry. The crane should be situated in close proximity to the work area.
Page 157: Cold Weather Operation
Cold Weather Operation The best possible work site should always be sought when you are positioning the crane. An ideal location is where the ground is firm, level and dry. The crane should be situated in close proximity to the work area.
Page 158: General Operational Issues
80-160 Operating Instructions General Operational Issues Ignition Switch-Carrier Cab & Upper Operator’s Cab When moving from the carrier cab to the upper cab: NOTE: The carrier cab ignition switch must be in the “OFF” position for the upper craning cab...
Page 159: General Rules
WHEN USING A MULTIPART LOAD LINE, BOOM EXTENSION MUST BE LIMITED TO MAINTAIN (3) FULL WRAPS ON WINCH DRUM. The proper maintenance and care of the wire rope load line on your Load King Boom Truck is most important. Refer to standard ANSI/ ASME B30.5 for wire rope inspection and maintenance procedures as well as special provisions for handling maximum rated loads with rotation resistant ropes.
Page 160: Safety Devices
Operating Instructions Safety Devices The safety devices on your Load King Boom Truck are described below. These devices will help you maintain control of a load should power or hydraulic line failure occur. You must understand the function and operation of these devices so that a continual check on their performance can be made.
Page 161: Training And Operator Qualifications
Training and Operator Qualifications It is extremely important that you have a thorough knowledge of all the operating characteristics of your crane. This crane will not be safe if improperly used! Crane operation shall be limited to personnel with the following minimum qualifications: Designated, competent and experienced persons.
Page 162: Operator Aids
80-160 Operating Instructions Operator Aids Anti-Two-Block The ATB system will sense the presence of the load block in close proximity to the boom tip and will automatically interrupt the operation of those boom functions which could bring the load block in contact with the boom tip.
Page 163: Load Handling Operations
Load Handling Operations Before moving a load, you must study the capacity placards carefully and adhere the load capacities and radii of operation given. During operations when lifting, swinging, or extending the load, the controls should always be metered when beginning or terminating movement to prevent sudden starting or stopping which imposes undue shock loads on the equipment.
Page 164: Max. Load And Boom Angle Charts
80-160 Operating Instructions Max. Load and Boom Angle Charts Using the Load Chart The crane load charts list rated load for various boom lengths and load radii. There are many different load charts depending on the various crane boom modes, counterweight options, outrigger positions, etc.
Page 165 Example: Hook block 750 lbs Slings 215 lbs Object being lifted 19,000 lbs Total lifted load 19,965 lbs It is important that you know the weight of any material that you attempt to handle. This can be determined by use of a dynamometer or scales. Swinging of a suspended load can cause the load to drift away from the crane.
Page 166: Operating Radius
80-160 Operating Instructions Operating Radius Center Line of Bearing Load Radius Center Line of Load...
Page 167: Boom Angle Placards
Boom Angle Placards 1006843 CAUTION CAUTION - Do not extend jib into this area unless boom is fully retracted.
Page 168: Operating The Unit
80-160 Operating Instructions Operating the Unit Operator Shutoff Devices Anti-Two-Block SYSTEM Inspect all ATB switches found on the boom, jib and auxiliary sheave heads for damage. Check the freedom of the counterweight attached to these switches; and also, that the counterweight is attached around correct line of hoisting cable in the proper manner.
Page 169 LEGEND Signals for drivers of the crane in the crane cab Signals for people in the crane's danger zone Execution speed of the crane movements...
Page 170 80-160 Operating Instructions EMERGENCY STOP The (RED) emergency stop button (1) is located on the lower part of the dash to the left of the steering wheel column in the operator’s cab. In an emergency, this button can be pushed in to stop all crane functions including engine operation.
Page 171: Operating The Unit
Operating the Unit Now that you are familiar with the controls and function of the Load King Boom Truck, practice making some typical job applications. As with any piece of equipment, practice is required to develop the coordination and knowledge necessary for smooth and efficient operation.
Page 172: Jump Starting An Engine- Booster Cable Instructions
80-160 Operating Instructions Jump Starting an Engine- Booster Cable Instructions Position the vehicle with the booster battery adjacent to the vehicle with the discharged battery so that booster cables can be connected easily to the batteries in both vehicles. Make certain vehicles do not touch each other.
Page 173: Unusual Operating Conditions
Unusual Operating Conditions Special problems in maintenance and operation are caused by unusual conditions such as extremes in heat, cold and humidity, high altitude, salt water, and dusty or sandy work sites. When operating under such conditions, special precautions must be taken to prevent damage, minimize wear, and avoid component deterioration.
Page 174 80-160 Operating Instructions During extremely cold weather, it is advisable to remove and store the battery in a heated area when the crane is to remain idle for any extended period. Water added to the battery can freeze before it mixes with the electrolyte. During very cold weather, add water to the battery just prior to, or during operation of the crane.
Page 175 Air circulation around the engine and battery must not be restricted. Keep air intake and exhaust openings clear of leaves, paper or other foreign matter which may restrict air flow. Keep the engine clean of dirt, grease and other substances which inhibit heat dissipation. Use sound judgment in operating the engine.
Page 176 80-160 Operating Instructions HIGH ALTITUDES Variations in altitude alter the fuel/air mixture burned in the engine and affect the engine’s performance. At high altitudes, atmospheric pressures are lower and less oxygen is available for combustion of the fuel. Above 10,000’ the engine fuel injectors may have to be changed to ensure proper performance.
Page 177: Initiating Operation
Initiating Operation If possible, position the unit at the job site in such a manner as to assure all work operations can be performed without repositioning the truck (see Work Site Position on page 156). However, strict observance of load weight, radius and maximum load rating must always be complied with. Set parking brake securely.
Page 178: Arm And Hand Signals
HAND SIGNALS STOP EMERGENCY STOP Do not deface or remove this label from the machine. Order replacement labels from your Load King dealer. Arm extended, palm down, move Both arms extended, palms down, move arms arm back and forth horizontally.
Page 179: Lifting The Load
Lifting the Load Follow recommended procedures for work site position, outrigger positioning, and control metering. Always inspect downhaul weight, load line, hook and/ or any load handling equipment for damage or excessive wear before use. The following general instructions should be adhered to each time a lifting operation is performed. IT IS IMPORTANT THAT YOU KNOW THE WEIGHT OF ANY MATERIAL THAT YOU ATTEMPT TO HANDLE.
Page 180: Making A Typical Lift
80-160 Operating Instructions Making a Typical Lift LIFT PROCEDURE In making lifts, the operator must successfully coordinate several crane functions. These include the boom raise/lower, boom extend/retract, load hoist/lower and swing functions. Although experienced operators tend to operate two or more of these functions simultaneously, the lift procedure can be broken down into the following sequence of operations.
Page 181 Use the load rating chart attached to the crane to interpret the conditions and limitations that exist when making a lift with the crane. The determining factors are lifted load, radius, boom angle, working position, hoist line reeving, tire pressure, travel data, and use of a jib. The examples given in this section are given for your interpretation of the terminology used on the chart -(see Load Rating Chart Interpretation topic).
Page 182 80-160 Operating Instructions Swing the boom over the load. Upper structure swing is controlled by the swing joystick. To swing the upper structure to the RIGHT (CW), move the LH joystick to the direction of required swing which requires moving the joystick to the RIGHT.
Page 183 Lower the hook block to the load and fasten the hook. Before making any crane lift, make sure the hook is properly engaged with the slings, or lifting device employed to make the lift. Be certain the hook latch is not supporting any of the load. Hook latch is intended to retain loose slings or devices under slack conditions.
Page 184 80-160 Operating Instructions Swing and spot the load over the location where it is to be deposited. 10. Lower the load and unfasten the hook. When spotting the load it may be necessary to alter the boom length or boom angle.
Page 185: Moving The Unit
Moving the Unit Removable Counterweight INSTALLATION TO FRAME DECKING NOTE: The counterweight slabs are an integral part of this crane. When the crane is driven, the counterweights slabs may need to be moved from the upper to the deck or removed from the crane to meet local weight restrictions and axle weight limits.
Page 186 80-160 Operating Instructions With the crane still running, move to a position on the decking facing the counterweight RAISE / LOWER switch item #1. Remove the long horizontal pins item #2, and the locking pins item #3 that secure them, from the...
Page 187 NOTE: If one or both pins will not release, it may be necessary to slightly lower one side of the slabs and raise the other to get the first pin removed, then slightly lower the side still pinned and pull the other side up tightly to remove the second pin.
Page 188: Vehicular Operation
80-160 Operating Instructions Vehicular Operation This Hydraulic Crane is capable of both on-road and limited off-road travel. The kind of travel undertaken determines how the carrier is operated. Before moving the crane, either around the work site or between sites, carefully consider the terrain type, road conditions, and any hazards likely to be encountered en route.
Page 189 Release the Parking Brake. 10. Push in the clutch (if equipped with a manual transmission). 11. Select the desired transmission range. OFF-THE-ROAD OPERATION Good judgement in the selection of gear range and route of travel is essential when operating off the road.
Page 190: Traveling Around The Jobsite
80-160 Operating Instructions Traveling around the Jobsite When traveling around a job site, it is very important that the crane operator is very aware of what is happening with the crane as well as with other vehicles and personnel on the job site. The crane operator should observe the following rules as well as good common sense while moving a crane around a job site.
Page 191 Outrigger Beam Lock Pin - shown in (locked) position, lift bolt, rotate pin clockwise until bolt drops into slot lowest position which will prevent beam from extending. Never drive crane without locking all (4) four pins. Outrigger Pad Storage - Insert lockpin as shown above (1) one place on each pad and repeat this procedure on (4) four outrigger pads.
Page 192 80-160 Operating Instructions Travel Setup- Jib Extended w / hook ball rigged (Figure 1) Travel Setup- Jib Extended w / hook ball & hook block rigged (Figure 2) SETUP CWT “OFF BOOM SWING TRAVELING SPEED / “ON” LOCATION LOCATION LOCK-...
Page 193: Roading The Unit
UNATTENDED. Fully retract all outriggers. Disengage Power Take Off (PTO). THE LOAD KING BOOM TRUCK IS NOT A PICK AND CARRY CRANE. NEVER DRIVE TRUCK WITH BOOM EXTENDED OR ELEVATED, OR WITH A LOAD SUSPENDED FROM LOAD LINE HOOK. NEVER LEAVE THE WORK SITE OR REPOSITION THE TRUCK CRANE WITHOUT FIRST SECURING THE BOOM IN ROAD TRAVEL POSITION AND FULLY RETRACTING ALL OUTRIGGERS.
Page 194: Towing Or Pushing Vehicle
80-160 Operating Instructions Towing or Pushing Vehicle The engine cannot be started by pushing or towing.
Page 195: Dolly
Dolly Increased risk to accidents due to fitting dolly! Drive with special care when a dolly is attached. Particular care is required in curves (swerving outwards, drifting sideways, shifting center of gravity). Note the boom hoist cylinder must be completely retracted, otherwise there is a risk of the dolly failing to maintain sufficient contact with the ground.
Page 196 80-160 Operating Instructions Electric connection for dolly lighting equipment - rear. Compressed air connection (yellow) for braking. Compressed air connection (red) for supply output. ABS socket 7-pole. Dolly coupling (If a dolly coupling is part of our scope of delivery).
Page 197 Carrier engine running and PTO engaged. Place main boom (lengthways) on the dolly, fasten and secure. Work Boom Hoist lever to reduce pressure in the boom cylinder. If pressure can not be relieved in the boom cylinder do not proceed with further steps. Falling boom - never attempt to connect bypass hoses unless boom is fully supported on the boom rack or boom dolly.
Page 198 80-160 Operating Instructions 12. Open the superstucture locking device by pressing buttons - Swing Brake Switch (friction) to open (unlocked) position and Swing Lock Switch (gear) to open (unlocked) position in the cranes operator’s cab. 13. Install Swing Lock Pin Block (item 1) as indicated in graphic below.
Page 199 15. Remove superstructure side access cover by lifting on the (2) rubber “T” handles at the top of cover to access the Swing circuit hydraulic valve handle and air valve knob. 16. Pull the knob (1) to unlock the handle (2). Then rotate handle (2) clockwise to float for boom dolly transport.
Page 200 “free float” swing circuit. Immediately pull vehicle over to side of road to troubleshoot the problem. Contact your local Load King service representative if indicator light can not be reset to “GREEN” and light RED light remains “ON”.
Page 201 Open Swing gear brake Risk of tilting due to swinging (slewing) the superstructure! When the swing gear brake is open, the superstructure can rotate involuntarily (influenced by wind / tilting position of the crane vehicle). The crane vehicle can overturn when this happens. For this reason only open / lock open the Swing Brake (friction) and Swing Lock (gear) when the boom is fastened to the dolly.
Page 202: Emergency Procedures
80-160 Operating Instructions Emergency Procedures Emergency Procedures When operational aids are inoperative or malfunctioning, the following requirements shall apply for limited (temporary) use or shutdown of the crane. Steps shall be taken to schedule repairs and recalibration immediately. The operational aids shall be put back into service as soon as replacement parts, if required, are available and the repairs and recalibration can be carried out.
Page 203: Emergency Boom Retraction
Emergency Boom Retraction The LOAD KING Boom Truck is equipped with a pilot operated holding cartridge in the base of the extension cylinder. This cartridge provides a means of supporting loads in a static condition to prevent any inward creep. It also provides support in the event of a ruptured line, or hydraulic failure.
Page 204: Emergency Lowering Of Boom
Operating Instructions Emergency Lowering of Boom The LOAD KING Boom Truck is equipped with a proportional solenoid holding cartridge in the base of the lift cylinder. This cartridge provides a means of supporting loads in a static condition to prevent any downward creep.
Page 205: Emergency Rotation
Emergency Rotation The 80-160 is equipped with a spring applied, hydraulic released brake. If hydraulic pressure is not available from the machine, a hand pump or other means of supplying 400 psi must be provided to swing the crane in emergency situations.
Page 206 Page Intentionally Blank...
Page 207: Disassembly
Disassembly Side Stow Jib Stowage Before stowing the jib, ensure that no personnel or obstacles are in the swing path of the jib. Retract the boom fully before stowage the jib. The jib cannot be mounted/stowed if the boom is extended even slightly.
Page 208 80-160 Disassembly Remove the cable from the guide sheave (3) and sheave (4) at end of jib base section. Remove the pin (5) from the upper hole and flip down the guide sheave (6).
Page 209 Install the pin (5) in the guide sheave kickstand. Remove the lower left-hand pin (7).
Page 210 80-160 Disassembly 10. Swing the jib with guide rope until the jib come and rest on the tri-fold ramp. 11. Engage the jib deployment cylinder with the jib deployment cylinder hook. Use jib deployment cylinder (8) to pull the jib inwards of the ramp.
Page 211 13. Remove the pins (10) from the both upper and lower mounting holes. 14. Retract the jib deployment cylinder (8) fully using the jib remote control. Make sure that the jib should lock on the storage bracket (11) properly. 15. Remove the pin (12) from the tri-fold ramp and fold the 1 folding section to counterclockwise.
Page 212 80-160 Disassembly 16. Install the pin (12) on the locking hole to lock the 1st folding section with middle folding section of the ramp. Remove pin (13) and fold the middle folding section of the ramp to clockwise. 17. Install pin (13) on the locking hole to lock the middle folding section of the ramp.
Page 213: Transportation
Transportation Transporting the Crane The boom must be stowed in the boom rack before transporting the crane. Restrain the boom extend sections by snugging the hook block against the boom head, or secure the boom head back to the base section of the boom with chains or cable when transporting the crane on a semitrailer.
Page 214: Instructions For Loading And Unloading
80-160 Transportation Instructions for Loading and Unloading LOADING EQUIPMENT Prior to operation, read and understand the manuals provided with this equipment. Also read and follow all general safety rules. PREPARE TRAILER Assure that any ramps are in position or trailer is otherwise prepared for loading and path of travel is clear for loading.
Page 215: Maintenance
Maintenance Maintenance Introduction A regular program of periodic preventive maintenance is essential to prolong crane operating life, maximize efficient service and minimize downtime. This section details a series of checks and procedures which are to be performed at daily, weekly, monthly and semiannual intervals. These intervals are stated both in terms of calendar periods and hours of operation.
Page 216: Cold Weather Package Specification
Maintenance Cold Weather Package Specification The standard Load King Stinger series of cranes can operate in temperatures down to -25C (-12F). For operating below this temperature a Cold Weather Package option would be required. With this package the crane can operate to -40C (-40F). To operate in these extreme weather conditions, proper start up and recommended operating procedures must be followed.
Page 217: Cold Weather Package Recommendations
Use of the fluids recommended and installation of the specific heaters can be ordered from your Load King Parts Department. Install the correct lubricant in each area of the crane, engine, hydraulic tank, fuel, axles, bearings, bushings, winches, swing drives and steering fluid.
Page 218 80-160 Maintenance Starting Recommendations Check the air cleaner daily before starting the machine. If you operate the machine in heavy snow, attach a burlap sack loosely to the pre-cleaner. Keep the burlap sack away from heated parts. In order to assist in warm-up, block the radiator. Blocking the radiator will restrict air from the fan.
Page 219 18°C to 21° C (64°F to 70°F) shop area will have a lower tire pressure in freezing conditions. Load King recommends the use of dry nitrogen gas to inflate the tires for cold conditions. When nitrogen gas (N2) is used, there will not be a build up of ice crystals around valve stem which could hold the valve open.
Page 220 Difference Between Shop and Outside Temperature (°F) Inflation Pressure (psi) Additional Cold Weather Operation Issues Contact your Load King Service Representative or Cummins Engine Service Representative if you have any questions regarding extreme environment operation or service of your crane.
Page 221: Safety Practices
Safety Practices Ensure parking brake is applied prior to performing any repairs. Lower all loads to the ground so load line is slack. Move all controls to neutral position. Disengage the PTO and turn off ENGINE Attach a caution sign to the start controls warning personnel that the unit is being serviced. DO NOT stick hands or tools into any hole in boom sections while power is on or boom sections are moving.
Page 222 80-160 Maintenance DO NOT SPILL OR DUMP OIL Keep open flame away. Injury could result if not cleaned up. Oil is a regulated/hazardous waste. Capture oil when repairing or draining systems. Disposal must conform to state/federal regulations. Do not overfill containers or reservoirs.
Page 223: General Work Practices
General Work Practices The following points are effective work practices that make the job go smoother and provide for the best quality in the repair of the crane. Before disconnecting wires, hoses or tubes, tag them for proper identification at reassembly. Before removing a component (pump, motor, valve, etc.), match mark its mounting position in relation to the adjacent component Before disassembling any multiple section component (pump, motor, valve, etc.), mark the position...
Page 224: Storing Components
80-160 Maintenance Storing Components Store new components (valves, pumps, motors, cylinders, hoses, tubes, fittings) in a clean, dry indoor location. DO NOT unpack components or remove port plugs until the components are needed. Once unpacked, carefully inspect each component for damage that may have occurred during shipping.
Page 225: Cleanliness
Cleanliness When removing a component from the crane, thoroughly clean the area around it to prevent dirt from entering the mating component or the hydraulic system. Cover all openings with plastic to prevent dirt and water from entering. Carefully clean the area around fittings before disconnecting hoses and tubes and the mating ports of all components to prevent dirt and water from entering.
Page 226: Operator Observation
80-160 Maintenance Operator Observation As the operator, it is your responsibility to observe and report any unusual sounds, odors, or other signs of abnormal performance that could indicate trouble ahead. On a routine basis the following items should be checked before starting or while operating the crane.
Page 227: Maintenance Checks And Lubrication
Maintenance Checks and Lubrication The following are the recommended maintenance instructions for the Load King Boom Truck. The outrigger hinge points do not require lubrication either. The MASTER LUBE CHART above shows the proper lubricants to use and the frequency of lubrication.
Page 228 80-160 Maintenance WEEKLY CHECKS The following weekly checks should be performed in addition to the daily checks: Check mechanical linkages for signs of wear or binding. Lubricate as necessary with 10 weight motor oil. With all boom sections retracted, move boom side to side and check for missing wear pads between boom sections and excess clearance or looseness in rotation gearbox (more than 2”-4”...
Page 229: 90-Day Maintenance Items
90-Day Maintenance Items The following maintenance procedures should be done every 90 days in addition to the daily, weekly, and monthly checks: Check and reset the rotation gear backlash. Torque rotation gear mounting bolts. (See Torque Specs - SAE & Metric on page 361).
Page 230: Semi-Annual Maintenance Items
80-160 Maintenance Semi-Annual Maintenance Items The following checks should be done semi-annually in addition to the daily, weekly, and monthly checks: Torque the mainframe mounting bolts. (See Torque Specs - SAE & Metric on page 361). Check Hydraulic system pressures and adjust as necessary.
Page 231: Machine Maintenance Checklist
Machine Maintenance Checklist DAILY CHECK (8 HOURS) ___ Perform Daily Lubrication ___ Check Boom Front Slider Pads ___ Check Hydraulic Reservoir Fluid Level ___ Drain Air Tanks ___ Fill Fuel Tank ___ Check Wire Rope and Related Components ___ Check Engine Oil Level ___ Check Air Cleaner ___ Check Coolant Level ___ Check Controls...
Page 232 80-160 Maintenance MONTHLY CHECK (100 - 200 HOURS) ___ Perform Daily and Weekly Checks ___ Check all Slider Pads ___ Perform Monthly Lubrication ___ Have Hydraulic Oil Sample Analyzed ___ Check Engine Belts ___ Clean Radiator & Oil Cooler Exterior ___ Check Engine Manufacturer’s Manual for...
Page 233 ANNUAL CHECK (1500 - 2000 HOURS) ___ Perform ___ Change Hydraulic Fluid (unless checked by Daily,Weekly,Monthly,Quartly and oil analysis). Semiannual Checks ___ Perform Annual Lubrication ___ Drain and Refill the Winch Lubricant ___ Disassemble Winch and Inspect ___ Change Axle Oil ___ Drain and Clean Hydraulic Reservoir ___See Transmission Maintenence Section ___Hydraulic Hoses (See Hydraulic Hose topic in...
Page 234: Hydraulic Hoses
/ or leakages in the hydraulic system that should be taken care of immediately. In addition to these daily checks, Load King recommends annual inspections of all hose assemblies as a part of the maintenance of the crane. Older cranes may require more frequent inspections.
Page 235 Recommended Hydraulic Hose Maintenance & Replacement Schedule: Task Minimum Maintenance Checking the hose lines Annually Recommended replacement of hose lines Every 6 years Recommendations for the replacement of hydraulic hose assemblies: If replacement of hydraulic hose assemblies is required, it is recommended to use original spare parts from the OEM or hose assemblies according to the OEM specification which includes the fittings, bulk hose material and manufacturing process.
Page 236: Filters And Maintenance
The most economical operation of the hydraulic system results from the use of a premium quality oil and conscientious preventative maintenance in accordance with this manual. Load King recommends the following oil, because of its quality and availability.
Page 237 Your Load King Crane will have been filled with Shell Tellus S2 V 46 hydraulic oil unless otherwise specified. Different manufacturer’s use chemical formulations which may not be compatible. Therefore, at a minimum, you must verify that any makeup oil added is compatible with the oil already in the system.
Page 238: Diesel Exhaust Fluid Specification
80-160 Maintenance Diesel Exhaust Fluid Specification For engines using Selective Catalytic Reduction (SCR) operating in the United States and Canada, it is also strongly recommended that the Diesel Exhaust Fluid (DEF) used be certified by the American Petroleum Institute (API). This would be indicated by a symbol on the container/dispensing system showing adherence to the API Diesel Exhaust Fluid Certification Program.
Page 239 Under Left Side of Vehicle Diesel Exhaust Fluid (DEF) Fill Location Battery Box Storage NOTE: The following information is for reference and is to be used as a guideline only. There are many factors that determine Diesel Exhaust Fluid (DEF) shelf life , with temperature and duration being two of the major determining contributors.
Page 240 80-160 Maintenance NOTE: To assist in preventing Diesel Exhaust Fluid from deteriorating when stored in the vehicle’s DEF tank. locate and plug the tank’s venting to seal the tank exposure to the atmosphere. Handling Diesel Exhaust Fluid is not harmful to handle, but can be corrosive to certain materials, over time. Metals that may be affected include carbon steels, iron, zinc, nickel, copper, aluminum and magnesium.
Page 241 If only water has been added to the Diesel Exhaust Fluid (DEF) tank, drain the Diesel Exhaust Fluid (DEF) tank, flush with distilled water and refill with new and/or known good Diesel Exhaust Fluid (DEF) . Check the Diesel Exhaust Fluid {DEF) concentration after completing the refill. Freezing Do NOT add any chemicals/additives to the Diesel Exhaust Fluid in an effort to prevent freezing.
Page 242: Tires
80-160 Maintenance TIRES MAINTENANCE CHECK As a part of the WEEKLY MAINTENANCE CHECK inspect the tires and rims for damage. Cuts, bruises, snags, punctures, and abrasions should be repaired before they can cause tire failure. Bent, cracked, or loose rims should be repaired or replaced.
Page 243 TIRE MATCHING Unmatched tires on tandem drive units will cause tire wear and scuffing and possible damage to the drive units. Consequently, we recommend the tires be matched to within 1/8” of the same rolling radius; 3/4” of the same rolling circumference. Tandem units-IMPORTANT: The four largest tires should never be installed on one driving axle or the four smallest tires on the other driving axle.
Page 244: Tire Maintenance
80-160 Maintenance Tire Maintenance MAINTENANCE CHECK As a part of the WEEKLY MAINTENANCE, inspect the tires and rims for damage. Cuts and bruises, snags, punctures, and abrasions should be repaired before they can cause tire failure. Bent, cracked or loose rims should be repaired or replaced.
Page 245 SAFETY PRECAUTIONS FOR MOUNTING OR DEMOUNTING RIMS AND WHEELS DO’S AND DON’TS DON'T Deflate tires completely prior to Do not use loads or inflation pressures demounting by removing the valve core. exceeding the manufacturer’s recommendations. Replace bent, cracked,worn, corroded, Don’t re-inflate a tire that has been run flat or damaged parts.
Page 246 80-160 Maintenance Re-inflation of any type of tire and rim assembly that has been operated in a run flat or under inflated condition (80% or less of recommended operating pressure) can result in serious injury or death. The tire may be damaged on the inside and can explode while you are adding air.
Page 247: Aluminum Decking & Fender Maintenance Procedure
Aluminum Decking & Fender Maintenance Procedure Salt spray, road salts, lime dust, battery acid, or mildly corrosive liquid can cause a condition called oxidation or even etching of the aluminum, which discolors the surface. A number of methods are used to stop the corroding affects of the surface.
Page 248: Swing Lock Maintenance
80-160 Maintenance Swing Lock Maintenance Daily check operation of Swing Lock air cylinder (1) and pin engagement. If cylinder stroke is not fully extending or retracting, check air pressure to cylinder extend and retract port and electrical connector cylinder. See switch no. (46) in the upper RH controls of the operator’s cab for locking and unlocking actuation of the air cylinder.
Page 249: Hvac
HVAC MONTHLY SIGHT CHECK - OPERATOR’S The following checks must be carried out monthly by the operator. State of heating hoses and refrigerant hoses - Check of the connections, leak checks and routing of the hoses and fittings. The hose clamping are to be tightened if necessary. Electric - Check electric connections are mated and retained.
Page 250 80-160 Maintenance Fresh Air Intake Filter - Check fresh air intake paper filter at rear of unit and clean if necessary. Do not use high pressure air on filter or allow water to contact filter. Condensation Drain Tube - Check to make sure tube is not clogged located at bottom of unit.
Page 251 Fault Cause Remedy No or insufficient heating power Oil supply temperature to low Wait until the engine is warm Heat exchanger fins Check heat exchanger and contaminated clean it if necessary Filter contaminated Clean or change filter Heat exchanger does not have oil flowing through it.
Page 252 80-160 Maintenance Fault Cause Remedy Cooling performance air flow to low because filter is Clean or change filter pay insufficient contaminated attention to the air flow direction Blower flow impeded Check air ducts and outputs for blockages, eliminate fault External air / recirculation air...
Page 253: Wire Rope And Reeving
Wire rope and reeving MAINTENANCE All wire ropes in active service should be inspected DAILY along with spooling, sheaves, wedge sockets, and any other wire rope fittings for damage. Once WEEKLY a through wire rope inspection should be made by a competent inspector. A record should be kept of the inspections using the form WIRE ROPE INSPECTION RECORD on page 149.
Page 254 The wrong rope will not function properly and may even be dangerous. Load King permits the use of rotation resistant wire rope. Other types are not approved. When rotation resistant rope is used, the working load shall not exceed 1/5 (20%) of the rated breaking strength.
Page 255: Lubrication
Lubrication Lubrication Introduction A regular program of periodic preventive maintenance is essential to prolong crane operating life, maximize efficient service and minimize downtime. This section details a series of checks and procedures which are to be performed at daily, weekly, monthly and semiannual intervals. These intervals are stated both in terms of calendar periods and hours of operation.
Page 256 80-160 Maintenance Check battery box - For battery condition Crane boom - Check for: * Hook block for wear or damage * Two block system for proper function * Cable and cable spooling on winch * Cylinder pin connections for wear Check tires, axles, and drive lines, for wear or damage.
Page 257: Master Lubrication Chart
Master Lubrication Chart TOP VIEW BOOM BLOCK...
Page 258 80-160 Maintenance TABLE 1 LEGEND: CHK..CHECK LUB..LUBRICATE ..CHANGE FILTER ..DRAIN & REFILL *REFER TO OPERATORS MANUAL DESCRIPTION LUBRICANT QUANTITY OUTRIGGER LEG PIVOT ARMS AS REQ’D HO - SEE TABLE 2 - KEEP OIL LEVEL BETWEEN INITIAL INITIAL HYDRAULIC RESERVOIR...
Page 259: Hydraulic Oil Requirements
Hydraulic Oil Requirements The hydraulic system is filled with a Shell Tellus S2 V 46 premium hydraulic oil. This hydraulic oil is recommended for a broad range of operating” temperatures but the end user is ultimately responsible for determining if the oil is” appropriate for their specific operating conditions or if another hydraulic oil is required.
Page 260 80-160 Maintenance Oil Viscosity Selection Chart Oil Viscosity Selection Chart Color Legend GREEN Recommended - Component Manufacturer's Optimal Range YELLOW Continuous - Component Manufacturer's Limits for Continunous Operation Intermittent - Limited Operation Range The factory-filled hydraulic oil is recommended for most operating conditions and for a wide range of oil operating temperatures as measured in the reservoir.
Page 261 Check that the oil viscosity matches that recommended for the operating temperature. Check pressure settings – Is a pump failing or a relief set to low? Reduce the duty cycle of the machine. Consult an Authorized Load King Dealer. The following hydraulic oils are not recommended: ●...
Page 262 80-160 Maintenance OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME Nuto-H 32 Rando Oil HD A2 (5w-20) Nuto-H 46 Rando Oil HD 32 Mobil Oil Corp. Texaco Inc. (USA) Nuto-H 68 Rando Oil HD 46 Rando Oil HD 68...
Page 263: Turntable And Swing Pinion
Turntable and Swing Pinion Swing Bearing Grease Port Swing Gear Grease Port Lubricate every 100 operating hours as follows: Inject grease as recommended below through both grease zerks item (1) and (2) located in the operator’s cab on the right console forward of the cup holder. Machine is to be slowly rotated at least two complete revolutions while injecting grease.
Page 264 80-160 Maintenance Some lubricants recommended by the manufacturer are: MOBIL TEXACO SUNOCO AMOCO EXON RACE Mobilux EP1 Mutifak EP1 Prestige 742EP Amolith EP1 Beacon EP1 GEAR Mobilux EP1 Mutifak EP1 Prestige 742EP Amolith EP1 Beacon EP1 NOTE: Other manufacturers’ lubricants of the same quality are suitable.
Page 265: Cable Lubrication Methods
Cable Lubrication Methods GENERAL We are covering the more commonly used methods of lubricating cable (wire rope). For special cable lubrication problems consult the cable manufacturer. HOT APPLICATION A heated bath is placed in the path of the wire rope, and the rope is passed through the hot lubrication over sheaves and a center guide wheel.
Page 266 80-160 Maintenance DRIPPING A container can be placed above the sheave, so that the rope can be lubricated by opening a spigot. Sheaves are the best location for lubricating operating wire ropes, because the wires and strands open somewhat as they bend along the groove.
Page 267 SWABBING AND PAINTING Lubricant can be swabbed on with rags, or painted on with a brush. Both are quick methods which can be made part of the operating routine. SPRAYING A light lubricant containing solvents can be applied to a wire rope by a properly directed spray nozzle. AEROSOL SPRAYING Installations requiring only small amounts of lubricants, or only occasional applications, may find the new aerosol cans of lubricant useful.
Page 268: Boom Lubrication
80-160 Maintenance Boom Lubrication 6 SECTION BOOM Fully extend the front & rear outriggers, and level the retracted boom over the front of the machine. This procedure will require (2) people; one to operate the boom to position the grease zerks in the access holes and the other person to grease the boom and signal the operator when the zerks are aligned with the holes.
Page 269 Extend the second section to line up the 1 zerk hole in second section of boom with zerk in 3 section. Grease the zerk on each side of the 2 section (10) shots as shown. Repeat previous step for each access hole going forward in the second section as the 3 section is extended.
Page 270 80-160 Maintenance Fully extend the boom, one cylinder extends section 2 and the other cylinder extends section 3, 4, 5 and 6. 10. Grease the bottom and both sides of boom sections 3, 4, 5 & 6 on surfaces (similar to step 9) where wear pad contact can be seen.
Page 271 12. Using a roller that is 3”-3 1/2” wide, roll grease on top and bottom of each section where you see, thru each port hole, that the wear pads have made contact with the metal surfaces, as shown. 13. No greasing of the 6 (tip section) is required.
Page 272 80-160 Maintenance 14. To lubricate the Base Boom Pins, locate the (2) zerks - items 3 & 4 on each Base Boom Pin as shown in photo below. Lubricate until grease starts extruding from the end of tube. Repeat on other side of boom.
Page 273: Boom Lubrication And Wear Pads Inspection Record
BOOM LUBRICATION & WEAR PADS INSPECTION RECORD PLACE OF INSPECTION DATE DESCRIPTION OF CRANE Serial # Make Model Boom Length & Jib Length DATE OF LAST BOOM LUBRICATION INSPECTION HOURS AND TIME OF SERVICE SINCE LAST INSPECTION RESULTS OF INSPECTION Wear Pads Location of Pads Conditions Noted...
Page 274: Swing Reducers
Keep case breather item (2) clear of dirt and debris. All swing drive gearboxes from Load King are shipped with an additive to the gear oil of 5 oz (148 ml) of ethylene glycol for cold weather protection. If gear oil in the unit is changed, Load King recommends the same amount of ethylene glycol is added to prevent freeze up of unit due to internal condensation.
Page 275: Slider Pads
Slider Pads The front bottom slider pad should be checked daily for wear. The remainder of the slider pads should be checked monthly for wear. All the slider pads contain a chamfer (1) on the wearing surface. When this chamfer (1) is worn off, the slider pad must be replaced.
Page 276: Swing System Maintenance
80-160 Maintenance Swing System Maintenance Swing Bearing Bolting Procedure MAINTENANCE CHECK It is very important to perform periodic swing bearing bolt checks. The bolts MUST BE KEPT TORQUE TIGHTENED to a rating as indicated in chart below. After the first day, and again after the initial 40 hours of machine operation, check and tighten the bolts.
Page 277 SWING BEARING TORQUE PROCEDURE A number of causes can reduce tension in the bolts when torquing and after use. These include rust on the threads, damaged or rough threads on bolts or nuts, shanks of bolts which hang up on holes, etc. All of these causes have a tendency to absorb the torque when bolts are being tightened.
Page 278: Winch Lubrication
80-160 Maintenance Winch Lubrication RECOMMENDED PLANETARY GEAR OIL Field experience, supported by engineering endurance tests, indicates the use of the proper gear oil and a program of regular preventative maintenance will help provide extended gear train life and reliable hoist brake performance.
Page 279: Wire Rope Lubrication
Wire Rope Lubrication New wire rope is lubricated during manufacturing, but this lubrication is only adequate for initial storage and the early stage of operation. To prevent the damaging effects of corrosion and to reduce wear, the wire rope must be lubricated at regular intervals. The lubrication interval and the type of lubricant to be used depend on the type of wire rope, the severity of duty, and the type of corrosive elements the wire rope is subjected to.
Page 280: Drive Shaft Maintenance
80-160 Maintenance Drive Shaft Maintenance Rotating shafts can be dangerous. You can snag clothes, skin, hair, hands, etc. This can cause serious injury or death. Do not work on a shaft (with or without a guard) when the engine is running.
Page 281 SLIDING SPLINE SECTIONS Steel drive shaft splines should be lubricated with good extreme pressure (EP) grease as recommended by lubricant manufacturers. Extreme pressure grease satisfying NLFI Grade 1 has been adapted by the factory. Relube spline at the intervals prescribed below. Apply grease gun pressure to lubrication zerk (2) until lubricant appears at pressure relief hole (1) in welch plug at the sleeve yoke end of spline.
Page 282 80-160 Maintenance LUBRICANTS A high quality extreme pressure (EP) grease recommended by lubrication manufacturers for universal joints should be used. Lithium soap base greases meeting National Lubricating Grease Institute (NLGI) Grade 1 and Grade 2 specifications are preferred. The use of greases which tend to separate and cake should be avoided.
Page 283: Brake System Maintenance
Brake System Maintenance REAR BRAKES Using a pressure gun, lubricate the brackets and slack adjusters. An application of lubricant should be applied to the grease fittings each time (weekly) a general lubrication of chassis components is required. Grease should be supplied to the bracket until it begins to squirt out around the camshaft adjacent to the slack adjuster.
Page 284: Air System Maintenance
80-160 Maintenance Air System Maintenance Inadequate delivery pressure or defective component operations can generally be traced to leakage, blocked lines, or the build up of moisture and sediment in the system. A regular program of periodic maintenance is an essential part of air system operation. The materials presented here are listed in accordance with the MAINTENANCE CHECK LIST in Section 4.
Page 285: Hydraulic System Maintenance
Hydraulic Oil Fluid Level Gauge - on right side of tank MODEL HYDRAULIC TANK CAPACITY 80-160 165 GAL. (625 Liters) Retract all cylinders to return the maximum amount of oil to the reservoir and note the oil level in the indicator tube.
Page 286 80-160 Maintenance HYDRAULIC CYLINDERS Check the cylinder mounting brackets, bushings, and pins for wear, alignment, tightness, and damage. If misalignment or excessive play or wear are detected, replace the defective pin or bushing. Check the rod eye welds for cracks and breaks and have damaged welds repaired.
Page 287 Fill Cap Return Filter (inside the cover) Before discarding the old filter element, examine the type of material trapped in it. This may indicate which, if any, hydraulic system components are deteriorating. 1000 HOURS: HYDRAULIC RESERVOIR Drain and clean the hydraulic reservoir. Change the hydraulic oil.
Page 288 80-160 Maintenance A change interval cannot be established which would apply to all oils and all operating conditions of temperature and cleanliness. However, a reputable brand of turbine grade oil can be expected to deliver 1000 hours of service under average operating conditions. Although conditions may necessitate shorter change intervals, do not use hydraulic oil for more than 1000 hours, unless oil analysis is used.
Page 289 Anti-Two-Block System MAINTENANCE This crane is equipped with an ATB system for both main boom head and jib which sounds a horn (when in the “on” position) and lights a light when a two-blocking condition is imminent. The system will also electrically disconnect the circuit for winching up or extending the boom in the event of an imminent 2-block condition.
Page 290 80-160 Maintenance THROTTLE CONTROL The throttle control consists of cables and clevis ends. Adjustment is dependent on cable travel and the adjusted length of the clevis rods. Adjustment is not required as long as the full range of engine rpm is available in response to control input.
Page 291: Storage
Storage Storage Machines being placed in storage must be adequately protected from deterioration during the period of idleness. This will ensure that they can be restored to active service with a minimum effort. Before removing this hydraulic crane from service for extended periods, it should be prepared for storage as prescribed in the following paragraphs.
Page 292: Machine Storage
80-160 Maintenance Machine Storage Machines being placed in storage must be adequately protected from deterioration during the period of idleness. This will ensure that they can be restored to active service with a minimum effort. Before removing this hydraulic crane from service for extended periods, it should be prepared for storage as prescribed in the following paragraphs.
Page 293: Chrome Cylinder Rod Storage
Chrome Cylinder Rod Storage Hard chrome plating is primarily applied to steel cylinder rods for its wear resistant properties, although it does provide considerable corrosion resistance as well. Once the chrome-plated rod is assembled into a cylinder and put into service, the hydraulic fluid on the surface of the rod provides all the corrosion resistance required for the rod during its life cycle.
Page 294: Restoration To Service
80-160 Maintenance Restoration to Service Remove the MACHINE from storage via the following procedure: Remove preservative lubricants from all surfaces. Check all fluid levels, adding or draining as required. Lubricate the machine according to Group 4, making certain that all points with grease fittings are lubricated.
Page 295: Specifications
WEIGHT 1.24 LBS/FT MINIMUM BREAKING STRENGTH - 36.0 TONS Load King permits the use of rotation resistant wire rope. Other types are not approved. When rotation resistant rope is used, the working load shall not exceed 1/5th (20%) of the rated breaking strength. The retirement criteria shall be as follows:...
Page 296: Vehicle Dimensions
80-160 Specifications Vehicle Dimensions 80-160 DIM. (in.) FREIGHTLINER KENWORTH WESTERN STAR 336.0 336.0 336.0 55.0 55.0 55.0 55.0 55.0 55.0 474.9 474.9 474.9 68.0 68.0 68.0 42.0 42.0 42.0 77.0 77.0 77.0 237.3 (Front) 237.3 (Front) 237.3 (Front) 229.6 (Rear) 229.6 (Rear)
Page 297 DIM. (in.) FREIGHTLINER KENWORTH WESTERN STAR 35.94 161.0 14.5 18.6 12.9 27.87 27.87 27.87...
Page 298 80-160 Specifications 156.0 312.0 199.93 310.82 580.7 NOTE: For dimensions not listed, contact Load King Engineering Department- Boom Truck group.
Page 299: Pumps And Function Speeds
FUNCTION SPEEDS The following chart is a list of the speeds you can expect from the Load King Stinger Boom Truck which are an approximate value. All speeds are one complete cycle. For instance, the swing time is for one complete 360°...
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Page 301: Troubleshooting
Troubleshooting Introduction A regular program of periodic preventive maintenance is essential to prolong crane operating life, maximize efficient service and minimize downtime. This section details a series of checks and procedures which are to be performed at daily, weekly, monthly and semi annual intervals. These intervals are stated both in terms of calendar periods and hours of operation.
Page 302 80-160 Troubleshooting Check battery box - For battery condition Crane boom - Check for: ● Hook block for wear or damage ● Two block system for proper function ● Cable and cable spooling on winch ● Cylinder pin connections for wear Check tires, axles, and drive lines, for wear or damage.
Page 303: General Procedure
General Procedure KNOW THE SYSTEM Study this manual and learn what makes the machine “tick”, how it should behave, sound and smell. OPERATE THE MACHINE Test operate all machine functions. Note all abnormal sounds, odors and movements. Always proceed in the most logical order to determine the cause. INSPECT THE MACHINE Look for leaks, listen for the source of abnormal sounds, detect the origin of unusual odors.
Page 304: Hydraulics - General
80-160 Troubleshooting Hydraulics - General Before any troubleshooting is attempted, become fully acquainted with the following two (2) basic fundamental facts of a hydraulic system: SPEED The speed of a hydraulic function is directly related to the system flow. A reduction in speed of a cylinder or motor is caused by an insufficient quantity of oil being delivered to the component.
Page 305: Operator Controls
Operator Controls WITH THE ELECTRICALLY CONTROLLED VALVES on the outriggers, two (2) spools must be checked. The extend and retract valves are in the diverter valve. The function valves are in 2 sectional valves - one for the front outriggers and one for the rear outriggers. To operate an outrigger cylinder, the extend valve or the retract valve plus a function valve must shifted by the solenoids.
Page 306: Siwng Circuit
80-160 Troubleshooting Siwng Circuit SWING COMPLETELY INOPERATIVE CAUSE REMEDY Mechanical swing lock applied, if equipped Disengage the swing lock Swing brake applied Disengage the swing brake Spring brake stuck in applied position Disassemble swing brake and free-up unit Swing valve main relief valve stuck in open See section on “Relief Valves”...
Page 307: Boom Hoist Circuit
Boom Hoist Circuit BOOM DRIFTS DOWN CAUSE REMEDY Hold valve not seating properly Replace hold valve Hoist cylinder by-passing See section on “Cylinder Leakage” BOOM HOIST ONLY - INOPERATIVE OR ERRATIC CAUSE REMEDY Boom will drift down Repair or replace hold valve Boom won’t lower Repair, replace, or backflush hold valve Boom hoist cylinder binding...
Page 308: Telescope Circuit
80-160 Troubleshooting Telescope Circuit TELESCOPE FUNCTION ONLY - WILL NOT OPERATE CAUSE REMEDY Load too great Move lever to first position, not “high speed”. Reduce load or set boom length before lifting load Both port relief valves sticking See section on “Relief Valves”...
Page 309: Winch Circuit
Winch Circuit WINCH WILL NOT DEVELOP MAXIMUM LINE PULL CAUSE REMEDY Main relief valve is set too low Readjust the main relief Main relief valve is sticking See section on “Relief Valves” Winch motor worn excessively or damaged See section on “Fluid Motor” Piston pump worn excessively or damaged See section on “Pumps”...
Page 310 80-160 Troubleshooting WINCH CHATTERS WHEN LOWERING CAUSE REMEDY The winch hold valve is set wrong or is Check the hold valve setting. If the winch malfunctioning continues to chatter, the holding valve is sticking. Inspect it for worn or damaged seals or...
Page 311: Outrigger Circuit
Outrigger Circuit ALL OUTRIGGERS INOPERATIVE CAUSE REMEDY Electrical malfunction See section on “Electrical Controls” Outrigger relief valve malfunctioning See section on “Relief Valves” Outrigger diverter valve malfunctioning Repair or replace Line to or from pump plugged or liner collapsed Clear blockage or replace hose Low oil level Add oil as required Gear pump worn or damaged...
Page 312: Swing Pumps Circuit
80-160 Troubleshooting Swing Pumps Circuit FAILURE OF PUMP TO DELIVER FLUID CAUSE REMEDY Pumps not engaged Engage pumps Low fluid level in reservoir Add recommended oil and check level Oil intake suction filter plugged Clean filter Air leak in suction line, preventing priming or...
Page 313 PUMP MAKING NOISE CAUSE REMEDY Pump disconnect not engaged Shut engine off and engage pump disconnect Partially clogged intake line, intake filter or Clean out intake filter screen or eliminate restricted intake pipe restriction. Be sure suction line is completely open Air leaks: At pump intake pipe joints...
Page 314 80-160 Troubleshooting BREAKAGE OF PARTS INSIDE PUMP HOUSING CAUSE REMEDY Excessive pressure above maximum pump rating Check relief valve setting Seizure due to lack of oil Check reservoir level, oil filter and possibility of restriction in suction line more often...
Page 315: Swing Circuit Control Valves
Swing Circuit Control Valves STICKING PLUNGERS CAUSE REMEDY Excessively high oil temperature See section on “Excessive Heating of Oil in System” Dirt in oil Change oil. Clean system. Fittings too tight Check torque Valve warped from mounting Loosen valve mounting bolts and check Excessively high flow in valve Check to see if hoses from pump are not crossed or reversed...
Page 316 80-160 Troubleshooting POOR HYDRAULIC SYSTEM PERFORMANCE OR FAILURE CAUSE REMEDY Dirt in relief valve Disassemble and clean Relief valve defective See section on “Relief Valves” Load too heavy Check line pressure Internal valve crack Replace valve Plunger not at full stroke...
Page 317 Swing Circuit Control Valves CAN’T GET PRESSURE CAUSE REMEDY Poppet stuck open or dirt under seal Check for foreign matter between poppets and their mating members. Members must slide freely ERRATIC PRESSURE CAUSE REMEDY Poppet seal damaged Replace damaged parts. Clean dirt and remove surface marks for free movement PRESSURE SETTING NOT CORRECT CAUSE...
Page 318: Fluid Motor
80-160 Troubleshooting Fluid Motor MOTOR WILL NOT TURN CAUSE REMEDY Pumps not engaged Engage pumps No oil Fill reservoir to proper oil level Pump broken Replace pump Relief valve stuck open or set too low Clean and free relief valve spool and adjust to...
Page 319 LEAK BETWEEN HOUSING AND WEAR PLATE OR BETWEEN WEAR PLATE AND GEROLER ASSEMBLY CAUSE REMEDY Motor housing bolts loose Clean mating surfaces and tighten nuts to appropriate value Pinched “O” ring seal Replace LEAK AT OIL PORTS CAUSE REMEDY Damaged seal or “O” ring Replace “O”...
Page 320: Cylinders
80-160 Troubleshooting Cylinders CYLINDER STICKING OR BINDING CAUSE REMEDY Damaged parts Repair or replace Dirt or contamination Check oil condition. Check filters. Clean or replace filter elements. Change oil if condition requires it Loose parts Tighten cylinder rod eyes, if loose. Check cylinder heads and tighten, if loose.
Page 321: Cylinder Leakage
Cylinder Leakage Hydraulic cylinders may retract due to the cooling of the oil in cylinder. Oil shrinks approximately 1% per 25°F of cooling, or as an example, if a cylinder is extended 100" and cools 100°F, it will shrink 4". TELESCOPE CYLINDER If excessive leak-down is encountered, check items in the following sequence: With boom offside and horizontal, extend the boom approximately 6 ft.
Page 322 80-160 Troubleshooting BOOM LIFT CYLINDER The suggested procedure for identifying the specific cause of leak-down should be performed in the following sequence: ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE, not completely extended, with a boom length sufficient to winch up a convenient payload approximately one (1) foot from ground level. Shut off engine.
Page 323: Excessive Heating Of Oil In System
Excessive Heating of Oil In System HEATING CAUSED BY POWER UNIT (RESERVOIR, PUMP, RELIEF VALVE, AND COOLERS) CAUSE REMEDY Relief valve set at a higher or lower pressure than Reset relief valve to recommended pressure specified. Excess oil dissipated through increased slippage in various parts, or through relief valve Internal oil leakage due to wear...
Page 324: Electrical Controls
80-160 Troubleshooting Electrical Controls ELECTRICAL FAILURE CAUSE REMEDY Rocker switch sticking Remove switch, check if hole is too tight. Cut out decal or file hole larger Tripped circuit breakers Reset breaker Disconnected or broken wires Replace or repair Open circuit Check with test light.
Page 325: Two-Block System
Two-Block System PANEL LIGHT & HORN WILL NOT COME ON WITH BOOM SWITCH WEIGHT LIFTED (IF EQUIPPED WITH DISCONNECTS, CONTROLS WILL NOT ENGAGE) CAUSE REMEDY Burned out fuse Check and replace fuse (8 amp only). Broken wire Check voltage in control panel between terminals #0 and #37.
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Page 327: Service / Parts
Service / Parts General Service Information Machine productivity, longevity and low cost performance depend on periodic maintenance, troubleshooting and proper service and adjustment procedures. As the operator, it is your responsibility to detect any unusual sounds, odors or other signs of abnormal performance that could indicate trouble ahead.
Page 328: Outrigger Position Sensors
80-160 Service / Parts Outrigger Position Sensors If your crane is equipped with Outrigger Position Sensors-each outrigger beam will contain (2) two proximity sensors for determining the location of outrigger beams at retracted position and full extension. Also, there will be a (1) one proximity sensor located at the pivot pin area of each beam swing cylinder.
Page 329 Proximity Sensor - Outrigger Swing & Outrigger Beam (Retracted) Proximity Sensor - Outrigger Beam (Extend)
Page 330: General Work Practices
80-160 Service / Parts General Work Practices The following points are effective work practices that make the job go smoother and provide for the best quality in the repair of the crane. Before disconnecting wires, hoses or tubes, tag them for proper identification at reassembly.
Page 331: Repairs-Adjustments-Remarks Log
Repairs-Adjustments-Remarks Log ITEM REQUIREMENT DATE...
Page 332: Torque Wrench Extensions
80-160 Service / Parts Torque Wrench Extensions In some applications, a standard torque wrench and socket cannot be fitted to the bolt(s) to be tightened because of restricted access. In other instances, the torque value specified cannot be obtained because sufficient force cannot be applied to the standard length wrench.
Page 334: Welding Instructions
80-160 Service / Parts Welding Instructions When doing repair welding on your unit take precaution attaching your ground to the component being repaired. This will reduce the chance of arcing through a bearing, cylinder, etc., damaging the component. Paint should be removed from the surface to be used as the “ground”...
Page 335 All welding procedures and welding operator qualifications shall be in accordance with ISO5817-C when welding on load sustaining members. Refer to ISO2553 for interpretation of welded joints symbols on drawings. Special Considerations for Welding Painted Surfaces When welding or cutting steel coated with a certain paint systems, the worker is exposed to decomposition products (metal fumes, gases or vapors, particulate) which vary depending on the type of process being used to weld or cut, the nature of the base metal, and the type of coating system.
Page 336: Hydraulic System
80-160 Service / Parts Hydraulic System Pressure Settings-Pumps & Valves Setting hydraulic pressure is a complex operation and should be performed only after satisfying the following conditions. Warm the hydraulic oil to greater than 80° F. Always check pressure settings at maximum engine speed in PTO mode.
Page 337 Retract the boom completely and continue to retract over relief with the engine running at full governed rpm. Initially, set the retract port relief valve item (1) to obtain a reading of 3500 psi. 80-160 Pressure Settings Piston Pumps & Boom Valve...
Page 338 80-160 Service / Parts Description Type Comments Notes Boom Valve Main Relief 324 4700 Clipper Relief Must increase the PC setting on the pump and the LS pressure to set check) the main relief setting. The main relief setting is located on the inlet section of the boom valve.
Page 339 Gauge port to measure pump pressure Pilot Pressure Set to 435 psi (30 bar) (requires installation of a pressure tap, and only adjusted or checked by Load King Authorized Service) Main Relief See Main Relief setting of Boom Valve Pressure Settings chart...
Page 340 80-160 Service / Parts SWING RELIEF Check the swing relief using the following procedure: NOTE: Prior to checking the swing relief valve pressure setting the main Diverter Valve relief must be set to the proper pressure of 3500 psi. Operate the machine to warm the oil if necessary.
Page 341 FUNCTION PRESSURE SETTING (PSI) Cab Tilt Up Cab Tilt Counter Balance 1000 psi (70 bar) Counterweight Counter Balance 2900 psi (200 bar) Counterweight Lift Counterweight Lower Jib B Swing Brake B Swing B Park Brake Load Sense Relief Valve 2900 psi (200 bar) Swing A Swing Brake A Jib A...
Page 342 80-160 Service / Parts MAIN RELIEF IN DIVERTER VALVE ADJUSTMENT Use the 5000 psi test gauge and check as follows: If main relief in diverter valve needs to be adjusted, proceed as follows: Attach the gauge at the quick disconnect in the diverter valve at G port (3), located on the L.H. side of the front outrigger box.
Page 343: Pumps
Pumps GENERAL INSTRUCTIONS This machine is equipped with a tandem pump to which is “piggybacked” on a single pump. Allison Transmission Eaton Transmission PISTON PUMP - HYDRAULICS (BOOM FUNCTIONS) GEAR PUMP - OUTRIGGERS & SWING GEAR PUMP - HVAC In the event of pump failure, we strongly recommend that you contact your local distributor. However, should you decide to facilitate the repair of these units - CONSULT THE MANUFACTURER’S REPAIR MANUAL - read all of the steps used in disassembly and all of the steps used in building up the unit.
Page 344: Rotation System
80-160 Service / Parts Rotation System Inspection of Rotation Bearing Clearance It is not feasible to make an analysis of the condition of the rotation gear while it is on the unit. There are too many variables involved for this to be accurate.
Page 345 Dial Indicator Clamp Position #1 Any new bearing being installed on a Load King Boom Truck should not have more than. 004 - .007 radial clearance. Any bearing taken off a unit which has .030 - .050 radial clearance should be screened carefully for roughness while rotating.
Page 346: Swing Reducer
LUBRICATION All swing drive gearboxes from Load King are shipped with an additive to the gear oil of 5 oz (148 ml) of ethylene glycol for cold weather protection. If the gear oil in the unit is changed, Load King recommends...
Page 347: Electrical System
Electrical System Fuse Block-Operator’s Cab Located above the RH console is the cab fuse block which requires periodic checking for fuse replacement if issue is detected in one of the circuits listed below in chart description.
Page 348 80-160 Service / Parts Fuse No. Rating in Amps Function 20 A SPOTLIGHT ACC POWER TO LOWER IGNITION TO LOWER ROOF WASH PUMP 7.5 A SEAT HEATER 15 A ROOF WIPER FRONT WASH PUMP 20 A FRONT CAB WORK LIGHTS...
Page 349: Relay & Fuse Block-Chassis
Relay & Fuse Block-Chassis Located near boom rack under decking access lid is a relay / fuse block which requires periodic checking for relay or fuse replacement if issue is detected in one of the circuits listed below in chart description. AMP RATING (Fuse) DESCRIPTION RELAY - 12 VDC...
Page 350: Electrical System Collector Ring
80-160 Service / Parts Electrical System Collector Ring ELECTRICAL COLLECTOR RING When troubleshooting the electrical system, always check the collector ring first to see that spring loaded brushes are centered in the bands. Keep free of any foreign material. Keep the setscrews on the collector ring frame tight. Otherwise, the wire harness may wrap up as the machine is swung.
Page 351 SHIELD POTENTIOMETER SHIELD NOTE: The above circuit chart applies to Load King Stinger 80-160 series cranes. The collector ring circuits are self-cleaning and if crane has been out of service for an long time period, by rotating the upper structure 360 degrees 10-20 times should clean off the copper brush circuits.
Page 352: Maintenance -Free Battery Testing
80-160 Service / Parts Maintenance -Free Battery Testing VISUAL INSPECTION CAUSE REMEDY Visible damage, terminal leakage, etc Cannot be used. Replace ELECTROLYTE LEVELS & STATE OF CHARGE NOTE: PROCEED DIRECTLY TO CAUSE THAT APPLIES CAUSE REMEDY Level at top of plates. Water cannot be added...
Page 353 VOLTAGE CHART Minimum Required Voltage Estimated Electrolyte Temperature Under 15 Second Load 70°F 21°C & above 60°F 16°C 50°F 10°C 40°F 4°C 30°F -1°C 20°F -7°C 10°F -12°C 0°F -18°C If water can be added to a battery, a hydrometer reading of 1.225 @ 80°F (27°C) can be used instead of the 12.4 Voltage reading.
Page 354 Page Intentionally Blank...
Page 355: Appendix
Appendix Conversion Tables DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH Fractions of an Inch Decimals of an inch Millimeters 1/64 0.0156 0.397 1/32 0.0313 0.794 3/64 0.0469 1.191 1/16 0.0625 1.588 5/64 0.0781 1.985 3/32 0.0938 2.381 7/64 0.1094 2.778 0.1250...
Page 356 80-160 Appendix Fractions of an Inch Decimals of an inch Millimeters 0.5000 12.700 33/64 0.5156 13.097 17/32 0.5313 13.494 35/64 0.5469 13.891 9/16 0.5625 14.287 37/64 0.5781 14.684 19/32 0.5938 15.081 39/64 0.6094 15.478 0.6250 15.875 41/64 0.6406 16.272 21/32 0.6563...
Page 357 WEIGHTS AND MEASURES LIQUID MEASURE (U.S.) 4 gills 1 pint 2 pints 1 quart 4 quarts 1 gallon 7.48 gallons 1 cu. ft. 240 gallons of water 1 Ton 340 gallons of gasoline 1 Ton LIQUID MEASURE (METRIC) 1 litre 0.0353 cu.
Page 358 80-160 Appendix CIRCULAR MEASURE 60 seconds 1 minute 60 minutes 1 degree 90 degrees 1 quadrant 360 degrees 1 circumference ELECTRICAL UNITS 1 kilowatt 1.34 H.P. 1 horsepower 746 watts SURVEYOR’S MEASURE 7.92 inches 1 link 100 links 66 feet...
Page 359: Average Weight Of Materials
Average Weight of Materials MATERIAL KG/CU. METER KG/CU. FOOT 1 CU. YARD Ashes - Piled Dry 560.70 Brick Bats 881.10 1485 Cement - Portland 1505.88 2538 Charcoal 400.50 Cinders 881.10 1485 Clinker - Portland Cement 1361.70 2295 Clay - Dry, in Lumps 1009.26 1701 Clay - Compact, Natural Bed...
Page 360 80-160 Appendix MATERIAL KG/CU. METER KG/CU. FOOT 1 CU. YARD Limestone - 1 1/2 or 2 Graded 1361.70 2295 Limestone - Above 2 Graded 1281.60 2160 Phosphate, Acid (Fertilizer) 1361.70 2295 Phosphate, Rock 1281.60 2160 Pyrites 2167.70 3645 Salt 929.16...
Page 361: Torque Specs -Sae & Metric
Torque Specs -SAE & Metric NOTE: Refer to specific instructions for individual components super-cede these values.
Page 362 80-160 Appendix...
Page 363: California Proposition 65 Warning
California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
Page 364: Lead Warning - State Of California
80-160 Appendix Lead Warning - State of California Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals, and related accesories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
Page 365: Greer Element Vga Operator's Manual
Greer Element VGA Operator’s Manual Your crane is set up with a Rated Capacity Limter (RCL) Element VGA system. Completely read the attached manual in the Appendix section before attempting to operate the crane. For Troubleshooting the system refer to your SHOP MANUAL-CD where you will find an ELEMENT VGA Troubleshooting manual.
Page 366 80-160 Notes...
Page 367 Crane Limited Product Warranty Load King LLC (“Load King”) warrants to the original Buyer its new Products will be free, under normal use and service, of any defects in material or workmanship for a period of (i) three years (36 months), or (ii) 3,000 hours of operation, whichever event shall occur first.; provided, however, labor and travel are not covered by this warranty after the earlier of (i) 24 months or (iii) 2,000 hours of operation. In addition, the warranty period is five years (60 months) for structural crane weldments (boom section, jib, outrigger beam, subbase, frame, mounting anchors, mast, turntable). Each of those aforementioned periods shall commence at the date of initial installation or commission; provided, however, those periods, in the case of a distributor of Load King, shall commence no later than six (6) months after the date of shipment by Load King. Parts fitted during a warranty repair will take on the remaining warranty time period only. The foregoing warranties shall be honored provided that Load King receives written notice of the defect within thirty (30) days of its discovery, but in no event later than fifteen (15) days after the expiration of the applicable warranty period, and it has been established that (i) the Product has been maintained and operated within the limits of rated and normal usage and in strict compliance with Load King’s operating and maintenance manuals, (ii) the defect did not result in any manner from the intentional or negligent action, inaction or abuse by Buyer or any third party, and (iii) in the case of structural warranty, all annual inspections have been completed by an authorized Load King service center. If it cannot be established that conditions (i), (ii) and (iii) above have been met, then this Warranty shall not cover the alleged defect. If requested by Load King, the defective Product must be returned to Load King, or other location designated by Load King, for inspection. Load King reserves the right to review the Product’s maintenance procedures to determine if any alleged defect is covered under this Warranty. Delivery inspection forms are required for warranty validation and processing. Load King’s obligation and liability under this Warranty is expressly limited to, at Load King’s sole option, repairing or replacing, with new or remanufactured parts or components, any part, which appears to Load King upon inspection to have been defective in material or workmanship. Replacement parts will be provided to Buyer subject to Load King’s current warranty claim handling processes. All Products replaced under this Warranty become the property of Load King. Accessories, assemblies and components included in the Product, which are not manufactured by Load King, are subject to the warranty of their respective manufacturers. Load King does not provide any warranty and Load King specifically disclaims any liability relating to the boom‐truck carriers; however, Purchaser may be entitled to the respective boom‐truck carrier OEM’s pass‐through warranty (subject to any registration requirements). This Warranty shall be null and void if parts (including wear parts) other than genuine Load King Parts are used in or attached to the Product or if serial numbers have been altered, defaced, or removed with respect to Load King’s Products or if the Product has been altered without Load King’s written agreement. LOAD KING MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, AND MAKES NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. No employee or representative is authorized to modify this Warranty unless such modification is made in writing and signed by an authorized officer of Load King. This warranty is continuous for the above stated periods, and “stopping and restarting” such periods (“stop and go”) is not accepted by Load King. Load King’s obligation under this Warranty shall not include the items listed below as “Items not covered by this Warranty.” NO TRANSFERABILITY OF THIS WARRANTY: This Warranty is limited to Buyer or, if sold through a distributor of Load King, to the first End User of the Product, and ...
Page 368 Load King 7701 Independence Ave, Kansas City, MO 64125 Parts: (816) 241- 8387 Service: (833) 281-7911 Email: info@loadkingmfg.com...

LOAD KING 80-160 Operator's Manual

1 Introduction

2 Safety

3 Assembly

4 Description of Machine and Controls

5 Inspection

6 Operating Instructions

7 Disassembly

8 Transportation

9 Maintenance

10 Specifications

11 Troubleshooting

12 Service / Parts

13 Appendix

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