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CUSTOM TRUCK LOAD KING 10-47 Operator's Manual

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OPERATORS MANUAL
LOAD KING
10-47
REV A
SEPTEMBER 06, 2019

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Summary of Contents for CUSTOM TRUCK LOAD KING 10-47

  • Page 1 OPERATORS MANUAL LOAD KING 10-47 REV A SEPTEMBER 06, 2019...
  • Page 2 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 3 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 4 Page Intentionally Blank...

  • Page 5: Table Of Contents

    Table of Contents Introduction ......................9 Construction and Industrial Equipment Product Safety ........ 9 Nomenclature..................... 10 Standards....................11 Intended Use....................12 Bulletin Distribution and Compliance............13 Contacting Manufacturer ................14 Transfer of Machine Ownership ..............15 Safety ....................... 17 Safety Introduction..................17 Product Safety Decals ................
  • Page 6 10-47 Contents Rated Capacity Indicator System ............ 75 ATB Components................76 Inspection....................... 79 Pre-Start Inspection ................79 Suggested Hydraulic Crane Inspection Checklist ........81 Daily Check (8 Hours)................86 Weekly Check (40 Hours)................ 87 Monthly Check (80 hours) ............... 88 Quarterly Checks (250 Hours) ..............89 Semiannual Checks (1000 Hours) ............
  • Page 7 Emergency Boom Retraction............123 Emergency Lowering of Boom ............. 124 Emergency Rotation ..............125 Emergency Retraction of Outriggers ..........126 Roading the Unit ................... 127 Maintenance....................129 Safety Practices ..................129 General Work Practices ................ 131 Cold Weather Package Specification ........... 132 Storing Components ................
  • Page 8 10-47 Contents Service / Parts ....................185 Hydraulic System Description............... 185 Control Valves and Pressures ............... 187 Pumps and Flow Speeds ..............192 Outrigger and Cylinder Maintenance and Troubleshooting ....193 Topping Cylinder................193 Outrigger Cylinder................196 Extension Cylinder ................. 201 Boom Maintenance, Adjustment and Repair ........

  • Page 9: Introduction

    Introduction Construction and Industrial Equipment Product Safety It is the responsibility of the owner of the equipment to be knowledgeable about federal, state and local regulations that effect the total usage of the equipment, and responsibility to working personnel and the public. Since regulations are subject to change, and also differ from one locality to another, this manual makes no attempt to provide such information.

  • Page 10: Nomenclature

    10-47 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.

  • Page 11: Standards

    Standards Many aspects of crane operation and testing are discussed in standards published by the American National Standards Institute. These Standards are updated on an annual basis with addendum, which are sent by American Society for Mechanical Engineers (ASME) to the original purchasers of the standard.

  • Page 12: Intended Use

    10-47 Introduction Intended Use This mobile crane is designed to lift, lower, move, and position freely suspended loads within its rated capacity while on firm, level ground. 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.

  • Page 13: Bulletin Distribution And Compliance

    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 14: Contacting Manufacturer

    10-47 Introduction 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 15: Transfer Of Machine Ownership

    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 16 10-47 Introduction 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 17: Safety

    Safety Safety Introduction Owners, Users, and Operators: Load King Cranes 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 18 10-47 Safety 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. Warning is used to alert readers about the potential for serious injury or death WARNING or serious damage to equipment.

  • Page 19: Product Safety Decals

    SYMBOLS AND PICTORIALS Hazard Avoidance CRUSH HAZARD Stay Clear Moving Turret Crushing and Boom. fingers or hand - force applied directions (pinched). CRUSH HAZARD Keep clear of moving machine. Death or Serious Injury can result from contact with moving machine. Safety Alert personnel Symbol...
  • Page 20 10-47 Safety Hazard Avoidance Entanglement in Stay Clear of Drive Shaft. Rotating Shafts. ENTANGLEMEN Keep away from T HAZARD fan and belt Rotating parts when engine s can cause running. Stop personal injury. engine before servicing. Explosion / Burn Keep all open Hazard flames and Will cause death,...
  • Page 21 Hazard Avoidance BURN HAZARD Allow surfaces to Contact with hot cool before surfaces can servicing. cause burns. Falling from height. Use personnel lift or appropriate ladder to reach high places. Maintain 3-Point Contact when using access system. Check ATB Two blocking the crane can cause System.
  • Page 22 10-47 Safety Hazard Avoidance Electrical Stay Sufficient Shock Distance From Electrocution Electrical Power from Crane Lines. Power Line Contact. 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 23: Safety Sign Maintenance

    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 24: Personal Protection Equipment

    10-47 Safety 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. Common Types of PPE Safety Glasses –...

  • Page 25: Workplace 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. Do not operate this crane until you have been trained in its operation.
  • Page 26 10-47 Safety 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 27 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. MANAGEMENT RESPONSIBILITIES Operators must be competent, physically fit and, if required, licensed.
  • Page 28 10-47 Safety PLANNING THE JOB 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. 13. Identify the location of gas lines, power lines, or other structures and determine if the crane or structures need to be moved.
  • Page 29 OPERATOR AIDS CHECK ATB devices. Overload Protection, Load Indicators, Rated Capacity Indicator. OPERATION OVERLOAD PROTECTION Know the weight and characteristics of all loads to be lifted. Place the boom lifting point directly above the load when lifting. The load radius will increase when the load is lifted due to boom deflection.To compensate for the boom deflection, maintain the radius by raising the boom.
  • Page 30 10-47 Safety POWER LINE SAFETY Determine whether there are power lines in the area before starting any job. Only operate around power lines in accordance with Federal, State and Local Regulations as well as ASME B30.5 (latest edition). Never remove materials from under powerlines with a crane if the boom or machine is capable of contacting them.
  • Page 31 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 50kV 10 FT ( 3.0M) 500 TO 200kV 15 FT (4.6m) 2000 TO 350kV 20FT (6.1m) 350 TO 500kV 25FT (7.6m)
  • Page 32 10-47 Safety 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.
  • Page 33 OPERATIONAL AIDS - EMERGENCY PROCEDURES When a load indicator, rated capacity indicator, or rated capacity limiter is inoperative or malfunctioning, the designated person responsible for supervising the lifting operations shall establish procedures for determining load weights. Loads with unknown weights shall not be lifted without a properly functioning load indicating device.

  • Page 34: Effects Of Wind Conditions

    10-47 Safety 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 kph - force 5) on a load surface of 11.7 ft^2/ton. Check the forecast and monitor wind speed conditions near the job site.
  • Page 35 Gentle Breeze 8 - 12 12 - 19 Leaves and small branches move, banners lift Mild Breeze 12 - 18 20 - 28 The wind raises dust and leaves. Branches move Fair Breeze 18 - 24 29 - 38 Small bushes sway.

  • Page 36: Lightning Storm

    10-47 Safety 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.

  • Page 37: Temporary Interruption Of Crane Operations

    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. The following instructions are valid for every mobile crane, regardless of the type, the configuration, the rigging mode and the environment: •...
  • Page 38 10-47 Safety • The crane location and configuration does not create hazards to the road traffic, e.g. risk of collision with surrounding obstacles; this may require a specific risk assessment prior to leaving the crane unattended. • Check for leakage and unintended (slow) movement on all load bearing hydraulic cylinders and winches: Outrigger vertical cylinders Boom lifting cylinder(s)
  • Page 39 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 40: Resuming Crane Operations

    10-47 Safety 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 41: Ending Crane Operations

    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 42: Turning/Driving In Reverse

    10-47 Safety 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 43: Parking The Vehicle

    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 44: Lock Out & Tag Out

    10-47 Safety 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.
  • Page 45 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 46: Access/Egress

    10-47 Safety Access/Egress Access/Egress Safety Access and egress from the crane operator's cab must always be accomplished using a three- point system. Either two-feet and a hand or two hands and a foot should be in contact with the crane while moving from the ground into the operator's cab or moving from the operator's cab to the ground.

  • Page 47: 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.

  • Page 48: Seat Belts

    10-47 Safety Seat Belts SOME SUGGESTED USAGE AND MAINTENANCE INSTRUCTIONS FOR SEAT BELTS Wear your lap belt low and snug. Manually adjustable lap belts and shoulder harnesses are adjusted by pulling the loose end of the webbing through the buckle or adjuster. Seat belts using automatic-locking or emergency-locking retractors are self-adjusting.

  • Page 49: Assembly

    Assembly Wire Rope Reeving Reeving diagram for the main hoist line are shown. The number of parts of line used will depend on the load to be lifted. Refer to the maximum load chart located on riding seat for the required reeving. Hoisting and lowering speeds will be reduced as the number of parts of line increase.
  • Page 50 10-47 Assembly MULTIPLE PARTS OF LINE EXAMPLES 2 Parts of Line Boom Point Sheave 3 Parts of Line Dead End 4 Parts of Line Load Block Sheave Guide Sheave...

  • Page 51: 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 52: Jib Mounting

    10-47 Assembly Jib Mounting Some models are equipped with an optional side stow jib. Instructions for installing the jib follow. DO NOT RIDE OR CLIMB ON BOOM OR JIB. SERIOUS INJURY OR DEATH COULD OCCUR. USE A LADDER OR SUITABLE PLATFORM TO REACH ELEVATED PIN LOCATIONS.
  • Page 53 Arrow indicates PIN to be removed. Arrow indicates PIN to be removed. Reinstall top and bottom guide pins and retainers in the sheave head. Arrow indicates PIN to be installed. Remove load line from boom head sheave and allow it to hang off the side of the boom.
  • Page 54 10-47 Assembly Remove two pins and retainers from outer pin stow bracket. If holes in the jib do not line up with the holes in the boom head, readjust the boom head by slightly extending, then fully retracting the boom. Install two pins and retainers from pin stow bracket, to fasten jib in place on the right side of the boom.
  • Page 55 NOTE: If any force is required to install any of the four jib pins, it should not be more than a few hits from a machine hammer. Raise boom to horizontal position. JIB WILL SWING UNCONTROLLED IF BOOM IS NOT HORIZONTAL. THERE IS A DANGER OF BODILY HARM IF THE JIB IS NOT PROPERLY CONTROLLED.
  • Page 56 10-47 Assembly Arrow shows location of jib pin in stow bracket. Confirm jib is pinned to boom head and then remove pin from jib pin stow bracket on boom. Do not remove pins until Step 7 has been completed. 11. Extend the boom approximately 15 inches so the jib stow bar is clear of the front jib stow bracket at the boom head.
  • Page 57 13. Swing jib into extended position. If it is difficult to bring the jib around you may slightly lower the boom angle and re-attempt. CONTROL MOVEMENT OF THE JIB 14. Due to the weight of the jib, most times it is difficult to get the top pin of the jib to the boom head installed.
  • Page 58 10-47 Assembly 15. Downward pressure can then be applied to the jib sheave head to facilitate top curb side pin alignment and installation by the boom down function. NOTE: If any force is required to install any of the four jib pins, it should not be more than a few hits from a machine hammer.
  • Page 59 EXTENDING SECOND JIB STAGE Unstow ATB cable from jib base section. Remove ATB switch, retaining pin, and plug from the boom head. Reinstall on jib head. PLUG SWITCH RETAINING PIN...
  • Page 60 10-47 Assembly Remove ATB plug from base of jib and install in open receptacle on boom head. JIB BASE RECEPTACLE PLUG Raise boom to angle high enough to allow the jib to be extended without contacting the ground. Fasten a tag line to the anchor point on the jib head.
  • Page 61 Remove lock pin and retainer from rear of jib. Pull second stage jib out until it contacts jib stop pin. Insert jib lock pin into extend position and secure with retaining pin. Push back on second stage to ensure lock pin is securing second stage.
  • Page 62 10-47 Assembly Remove ball or block from wire rope. 10. Winch out enough cable to reach over the sheave of the jib. 11. Place wire rope over boom head sheave. If machine is equipped with a sheave retaining bracket, make sure the bracket slot is aligned with guide pin so it is held upright.
  • Page 63 12. Route cable through jib cable retainer and over jib sheave. Install sheave pin and retainer. CABLE RETAINER 13. Attach ball or block to wire rope with pin and retainer.
  • Page 64 Page Intentionally Blank...

  • Page 65: Description Of Machine And Controls

    Description Of Machine and Controls Power Take-Off Disengage PTO before driving truck. Failure to do so will cause damage to the transmission and hydraulic pump. There are several styles of PTOs used on various equipment. Refer to the following pages" for operation of the PTO.
  • Page 66 10-47 Description Of Machine and Controls Release parking brake (if necessary).

  • Page 67: Controls

    Controls With the dual operator control stations the Load King Stinger Cranes can be operated from either side of the unit. The controls on the console are: Boom Swing, Telescope,Hoist and Boom Raise. Engine Start/Stop, Outrigger System and Signal Device. All controls and direction of actuation for desired movement are identified by the information placards mounted on top of the control console or control knobs.

  • Page 68: Outrigger Stow Pins

    10-47 Description Of Machine and Controls Outrigger Stow Pins THE CRANE’S OUT & DOWN OUTRIGGER HORIZONTAL BEAMS ARE EQUIPPED WITH A MANUAL STOW LATCH PIN. Engage pin at end of each beam before roading unit to prevent inadvertent horizontal movement. ENGAGED Disengage pin at end of each beam before extending.
  • Page 69 DISENGAGED...

  • Page 70: Outrigger Controls

    10-47 Description Of Machine and Controls Outrigger Controls ALL THE OUTRIGGERS ON THIS UNIT CAN BE OPERATED FROM EITHER SET OF DUAL CONTROLS. DO NOT OPERATE OUTRIGGERS WITHOUT DETERMINING CLEARANCE FROM OBSTRUCTIONS OR PERSONNEL. SIGNAL DEVICE - Push button to sound truck horn as an audible signal to warn other personnel in the area.
  • Page 71 REAR CURB SIDE REAR STREET SIDE NOTE: Always extend outrigger completely before lowering. THE CRANE’S OUT & DOWN OUTRIGGER HORIZONTAL BEAMS ARE EQUIPPED WITH A MANUAL STOW LATCH PIN.

  • Page 72: Boom And Winch Controls

    10-47 Description Of Machine and Controls Boom and Winch Controls SWING - Push lever to rotate boom counterclockwise, pull lever to rotate boom clockwise. BOOM TELESCOPE - Push lever to extend boom, pull to retract boom. WINCH (COMBINED FLOW 2-SPEED) - Push lever to lower loadline, pull lever to raise loadline.
  • Page 73 EMERGENCY STOP - Push to stop engine in case of emergency. Rotate clockwise to release button to allow machine to be started again.

  • Page 74: Front Stabilizer

    10-47 Description Of Machine and Controls Front Stabilizer Front outrigger must be used when working off the front of the truck crane. This outrigger is only used with the continuous rotation option.

  • Page 75: Rated Capacity Indicator And Atb

    Rated Capacity Indicator and ATB Rated Capacity Indicator System Load King Boom Truck equipped with Greer MicroGuard Rated Capacity Indicator System. The operator is provided with a continuous readout of rated capacity, approach to overload, and two-block condition. Refer to the Greer Operation and setup manual, located in back of this manual, for proper maintenance and setup of unit.

  • Page 76: Atb Components

    10-47 Description Of Machine and Controls ATB 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.
  • Page 77 UNLOADER PARTS GROUP The unloader valve solenoid manifold is located on top of the console assembly, under the swing drive cover. The valve contains two electrically operated solenoids which operate to either contain or unload a pilot signal. (Note: One solenoid is exclusively for the 2-speed winch.) When the solenoid is energized, it is closed and no oil is permitted to pass through the valve.
  • Page 78 10-47 Description Of Machine and Controls Boom Control Valve Orifice Topping Pilot Line Piston Winch Pilot Line Typical Anti-Void Winch Valve Body One-Way Check Winch Unloader Valve Return Manifold Unloader Tank Line Boom Control Valve 2-Speed Winch Regenerative Line Boom Inlet ATB Unloader Valve Winch Inlet Extension Pilot Line...

  • Page 79: Inspection

    Inspection Pre-Start Inspection The following items should be checked each day before start-up and the start of operations. 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 80 10-47 Inspection AIR TANKS Open the air tank drain cocks to blow out moisture and sediment. FUEL FILTER Water and sediment should be drained from the fuel filter by opening the drain cock at the bottom of each. ATB SYSTEM Inspect all ATB switches found on boom, jib, and auxiliary sheave heads for damage.

  • Page 81: 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 82 10-47 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 LOAD SUPPORTING COMPONENTS CONDITION...
  • Page 83 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 84 10-47 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 85 REPAIRS - ADJUSTMENTS - REMARKS ITEM REQUIREMENT DATE...

  • Page 86: Daily Check (8 Hours)

    10-47 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 87: 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 88: Monthly Check (80 Hours)

    10-47 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 __ Check Engine Manufacturer’s Manual For Additional Maintenance Requirements...

  • Page 89: 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 90: Semiannual Checks (1000 Hours)

    10-47 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 __ Change Power Steering Filter Element __ Check Hydraulic Relief Valve Pressure Settings __ Torque Swing Bearing Bolts...

  • Page 91: 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 92: Crane Boom

    10-47 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 DAILY •...
  • Page 93 NOTE: 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. WEEKLY: STRUCTURAL MEMBERS AND WELDS Visually inspect all structural members and welds including (but not limited to) the extended boom for straightness, roller (or pad) adjustment,...
  • Page 94 Page Intentionally Blank...

  • Page 95: Wire Rope Inspection

    Wire Rope Inspection Safe operation of your Load King Cranes 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 96 10-47 Inspection 1/64” For rope diameters up to and including 5/16” 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” 3/32” For rope diameters 1 1/4” through 1 1/2” REDUCTION OF WIRE ROPE DIAMETER...

  • Page 97: 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 Conditions Noted...

  • Page 98: Mobile Crane Load Test Inspection

    10-47 Inspection Mobile Crane Load Test Inspection General As a worldwide crane manufacturer, Load King Cranes does not recommend carrying out a regular overload test on mobile cranes. An overload test after every change of location or crane reconfiguration is not a reliable and safe inspection method and can cause premature material fatigue.
  • Page 99 Operational planning: Higher floor loading than provided for, difficult handling of the additional test load, ban on carrying out any overload tests on-site in some fields of industry (e.g. petrochemical plants). Operational safety: Anyone in the vicinity of the crane must be warned of the test procedure and must leave the area during the test.
  • Page 100 10-47 Inspection Load tests may be required by law. after assembling the crane or after changes in location. The conditions listed above do not apply after reconfiguration or repairs to load- bearing crane parts. In this case, the load test factor can be higher (in accordance with the safety factors from the product standards).

  • Page 101: 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. Engage pump PTO. Allow hydraulic oil to warm up by circulating to prevent pump damage. NEVER DRIVE VEHICLE WITH PUMP PTO ENGAGED. Check hydraulic system filter indicator to confirm that filter is functioning properly.

  • Page 102: Outrigger Positioning

    10-47 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 103: Work Site Position

    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. The site should be free of overhead obstructions. Maintain safe clearances from electrical power lines and apparatus.

  • Page 104: Cold Weather Operation

    10-47 Operating Instructions Cold Weather Operation During cold weather operation the operator must allow the oil to warm up to operating temperature. This can be accomplished by allowing the hydraulic pump to run under no load for ten minutes at low engine speed. Next, actuate all the controls slowly until controls move smoothly and easy.

  • Page 105: General Operational Issues

    General Operational Issues General Rules Always operate controls to lower the load line while extending the boom. This will maintain clearance between boom tip and downhaul weight. Make certain load line is not twisted or kinked, and that load line is properly seated on drum and in sheaves.
  • Page 106 10-47 Operating Instructions Load Line Three Wraps Minimum Drum Wedge...

  • Page 107: Safety Devices

    Safety Devices The safety devices on your Load King Cranes 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 108: Training And Operator Qualifications

    10-47 Operating Instructions 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 109: Operator Aids

    Operator Aids 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. A warning horn will sound to alert the operator to the two-block condition.

  • Page 110: Load Handling Operations

    10-47 Operating Instructions 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 111: Max. Load And Boom Angle Charts

    Max. Load and Boom Angle Charts Using the Maximum Load Chart 360° operation requires the use of the optional front bumper outrigger. The maximum load charts shown are located on the side of the pedestal. Their purpose is to show you the load capacities at various radii and boom angles. The boom lengths are color coded to match the colored stripe on the sides and bottom of the second stage boom.
  • Page 112 10-47 Operating Instructions 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. The maximum load chart shows the maximum lifted load. Maximum load is the weight of the material being handled plus such load handling equipment as slings, buckets, downhaul weights, etc.

  • Page 113: Operating Radius

    Operating Radius Center Line of Rotation Read Operating Radius Here Load Indicator Weight (suspended) Load Line...

  • Page 114: Boom Angle Placards

    10-47 Operating Instructions Boom Angle Placards CAUTION - Do not extend jib into this area unless boom is fully retracted.

  • Page 115: Operating The Unit

    Operating the Unit Operating the Unit Now that you are familiar with the controls and function of the Load King Cranes 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 116: Initiating Operation

    10-47 Operating Instructions 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 103). However, strict observance of load weight, radius and maximum load rating must always be complied with.

  • Page 117: Arm And Hand Signals

    Arm and Hand Signals Hand Signals Graphic Operation Action STOP Arm extended, palm down, move arm back and forth horizontally. LOWER With arm extended downward, forefinger pointing down, move hand in small horizontal circle. USE MAIN Tap fist on head; then use regular signals. HOIST Tap elbow with one hand, then use regular WHIPLINE...
  • Page 118 10-47 Operating Instructions RAISE BOOM Arm extended, fingers closed, thumb pointing upward. LOWER BOOM Arm extended, fingers closed, thumb pointing downward. MOVE Use one hand to give any motion signal and SLOWLY place other hand motionless in front of hand giving the motion signal.
  • Page 119 TRAVEL Arm extended forward, hand open and slightly raised, make a pushing motion in direction of travel. Clasp hands in front of body. EVERYTHING TRAVEL (Both Use both fists in front of body, making a Tracks) circular motion about each other, indicating direction of travel, forward and backward.
  • Page 120 10-47 Operating Instructions EXTEND Both fists in front of body with thumbs BOOM pointing outward. (Telescope Boom) RETRACT Both fists in front of body with thumbs BOOM pointing toward each other. (Telescoping Boom) STOP Arm extended, palm down, move arm back and forth horizontally.

  • Page 121: 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.

  • Page 122: Emergency Procedures

    10-47 Operating Instructions Emergency Procedures 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 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 123: 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 124: Emergency Lowering Of Boom

    10-47 Operating Instructions Emergency Lowering of Boom The Load King Boom Truck is equipped with a pilot operated holding cartridge in the base of the topping cylinder. This cartridge provides a means of supporting loads in a static condition to prevent any downward creep. It also provides support in the event of a ruptured line, or hydraulic failure.

  • Page 125: Emergency Rotation

    Emergency Rotation The Load King Boom Truck is equipped with a spring applied, pressure released rotation brake. This brake will only allow rotation if there is sufficient hydraulic pressure. In case of hydraulic failure this brake will have to be HYDRAULICALLY released. This may be accomplished with the following procedures: Use emergency retraction procedures to fully retract the boom.

  • Page 126: Emergency Retraction Of Outriggers

    10-47 Operating Instructions Emergency Retraction of Outriggers The Load King Boom Truck is equipped with pilot operated holding cartridges in both parts of the outrigger cylinder. The extend cartridges provide a means of supporting loads in a static condition to prevent any upward creep of the outrigger legs. They also provide support in the event of a ruptured line, or hydraulic failure.

  • Page 127: Roading The Unit

    Roading the Unit Before leaving the work site or repositioning the crane at the work site, always: Retract boom. Stow boom on the boom rest. Always use the boom rest. Using D-Ring on rear of truck, attach load line hook and hoist in until slack is taken up. On tractor mount models, always use boom rest for securing the boom and tie off load line hook to attachment provided NEVER LEAVE BOOM ELEVATED OR LOAD SUSPENDED WHEN UNIT IS...
  • Page 128 10-47 Operating Instructions ALWAYS KNOW YOUR MAXIMUM ROAD HEIGHT AND OBSERVE ALL OVERHEAD OBSTRUCTIONS. FAILURE TO DO SO MAY RESULT IN SEVERE DAMAGE TO THE CRANE/VEHICLE AND/OR DEATH OR SERIOUS INJURY TO OPERATING PERSONNEL.

  • Page 129: Maintenance

    Maintenance Safety Practices ALWAYS apply the parking brake on the truck before undertaking any repairs to the crane. 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.
  • Page 130 10-47 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. 10.

  • Page 131: 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.

  • Page 132: Cold Weather Package Specification

    10-47 Maintenance Cold Weather Package Specification The Load King Stinger Boom Trucks 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 133: Storing Components

    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 134: Cleanliness

    10-47 Maintenance 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 135: 10-47 Master Lube Chart

    10-47 Master Lube Chart...
  • Page 136 10-47 Maintenance SWING DRIVE GREASE FITTING - LUBE @ 150 HRS. OR MONTHLY SWING DRIVE FILL PLUG - CHECK @ 450 HRS.- DRAIN AND REFILL @ 900 HRS. OR SIX MONTHS SWING GEAR TEETH - LUBE @ 40 HRS. OR WEEKLY SHEAVE PINS - LUBE @ 40 HRS.
  • Page 137 LOAD BALL PIVOT - LUBE @ 40 HRS. OR WEEKLY SWING BEARING GREASE FITTINGS - LUBE @ 150 HRS OR MONTHLY OIL BREATHER - CHANGE FILTER @ 450 HRS. OR THREE MONTHS 10. HYDRAULIC SYSTEM RESERVOIR - CHECK EVERY 8 HRS OR DAILY 11.

  • Page 138: Maintenance Checks And Lubrication

    10-47 Maintenance Maintenance Checks and Lubrication The following are the recommended maintenance instructions for the Load King Cranes Boom Truck. The unit is equipped with special Teflon bushings at the topping cylinder and boom hinge pin points that do not require lubrication. The outrigger hinge points do not require lubrication either.
  • Page 139 Check to make certain that the load line is properly spooled on the winch drum and that it is not damaged. Check all Operator Aids for proper operation (ATB, Load Moment Sensing System and Holding Valves). Do daily lubrication. Check that the downhaul weight (load block or ball) is properly secured to the loadline and the hook safety latch is in proper operating condition.
  • Page 140 10-47 Maintenance Lubricate PTO with multi-purpose grease Shaft Cover Screws Grease Zerk PTO Lubrication Instructions: Remove Shaft cover Screws (1) and remove cover. Using grease gun, apply 2-3 pumps of multipurpose grease through grease zerk (2). Replace shaft cover and tighten screws. Change hydraulic oil filter.

  • Page 141: Hydraulic Hoses

    Hydraulic Hoses The service life of a hose used on a mobile crane may significantly vary from the indicated lifetime of the hose from the manufacturer. The service life is influenced by a number of factors such as environment (temperature, humidity, corrosive air...) and use, duty cycles, bending cycles, abrasion, fluid etc.
  • Page 142 10-47 Maintenance 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 143: Hydraulic Oil Requirements

    Hydraulic Oil Requirements hydraulic system filled with Shell Tellus S2 V 46 premium hydraulic oil. This hydraulic is recommended broad range of operating temperatures but the end user is ultimately responsible determining if the appropriate for their specific operating conditions or if another hydraulic oil is required.
  • Page 144 10-47 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 145 Check the oil cooler for plugs or restricted air flow. 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.
  • Page 146 10-47 Maintenance OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME Rando Oil HD A2 DTE 24/DTE-13M (5w-20) Texaco Inc. DTE 25/DTE-15M Rando Oil HD 32 Mobil Oil Corp. (USA) DTE 26/DTE-16M Rando Oil HD 46 Rando Oil HD 68...

  • Page 147: 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. (See Backlash Adjustment on page 229.) Torque rotation gear mounting bolts. (See Torque Specs-SAE &...

  • Page 148: Semi-Annual Maintenance Items

    10-47 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 and rear outrigger mounting bolts. (SeeTorque Specs-SAE & Metric on page 241.) Check Hydraulic system pressures and adjust as necessary. Inspect all visible wear pads for excessive wear or looseness.

  • Page 149: Filters And Maintenance

    Filters and Maintenance DETERMINING THE CONDITION OF THE OIL The only definite way to assure that all accumulated contaminants which will wear the pump, motors, and cylinders are removed from the hydraulic system is to drain the old oil and replace it with new. If oil did not break down or could be kept lean permanently, changing would not be necessary.
  • Page 150 10-47 Maintenance NOTE: Bypass with cold oil is normal and acceptable. The unit should always be allowed to gradually warm up (oil temperature above 60° F) before checking the filter bypass gauge. The oil filter is mounted to the front of the control console. To change the return filter, shut off the power supply to the pump and unscrew the filter canister.
  • Page 151 RECOMMENDED OIL AMBIENT TEMPERATURE VISCOSITY INDEX Shell Tellus S2 V 46 ABOVE 32° Shell Tellus S2 V 32 BELOW 32° Shell Tellus S2 V 22 BELOW 0° Your Load King Stinger Boom Truck will have been filled with Shell Tellus S2 V 46 hydraulic oil unless otherwise specified.

  • Page 152: Rotation System Maintenance And Troubleshooting

    10-47 Maintenance Rotation System Maintenance and Troubleshooting Swing System The swing system is equipped with a counterbalancing motor control. There are some basic reasons to have this system as follows: To insure that the swing brake is used only as a parking brake instead of a service type brake.
  • Page 153 If pressure is lost for any reason while swinging, the counterbalance valve will fully close and the swing brake will spring apply to stop the swing motion. This is why it is important to smoothly meter the application and release of the swing control handle. The schematic on the next page will aid in following the descriptive operation of the swing system.

  • Page 154: Care And Maintenance Of The Rotation System

    10-47 Maintenance Care and Maintenance of the Rotation System See the SHOP-CD in your manual package for swing gearbox and rotation bearing maintenance information. The following steps will produce the longest possible life of the rotation bearing and rotation gearbox: Load King recommends that the torque be checked on the rotation gear hold-down bolts every 90 days.
  • Page 156 10-47 Maintenance Access Holes Inner Bolt Circle 1-8NC Nut Outer Bolt Circle 1-8NC Socket Head Bolt Turret Assembly Turret Base Plate Swing Stop Bolt Fitting in Rotation Gear (2ea - 180 degrees apart) Turret Base Plate Rotation Gear Rotation Bearing Grease Tubes Hardened Flat Washer Zerk "A"...

  • Page 157: Rotation Gearbox And Gear Teeth

    Rotation Gearbox and Gear Teeth The teeth of the rotation gear as well as the rotation gearbox pinion should be lubricated regularly with a good open coat lubricant (Texaco Texclad #2 or spray equivalent). The grease is purged from these teeth by the very nature of the application so close attention will produce longer tooth life.
  • Page 158 10-47 Maintenance Swing Drive Gearbox & Motor Conditioning Box Swing Sensor (WAD) Brake Pressure Oil Level Plug Cartridge Valve Breather & Oil Fill Location Motor Pressure Port Grease Zerk Motor Pressure Port Oil Drain Port Cartridge Valve...

  • Page 159: Swing (Wad/Iss) Sensor Check & Replacement Procedure

    Swing (WAD/ISS) Sensor Check & Replacement Procedure Swing Gearbox & Motor Swing (WAD) Sensor Conditioning Box Operation into an unintended work zone may result if the Operator Programmable Alarms do not function as programmed and an operator is relying on them to alert him/her when approaching the unintended work zone.
  • Page 160 10-47 Maintenance Raise the boom until the boom angle is approximately 40°. Rotate the boom slowly and smoothly to the 90° position as shown in Fig. 2. Swing the boom counterclockwise approximately 20° and stop abruptly. Pause appoximately 5 seconds. Repeat steps 4 and 5 until the boom is at the 270°...
  • Page 161 Repeat Steps 3 thru 6 nine times, for a total of ten cycles. Set the boom in the boom rest and align to the zero location as shown in Fig. 1. Record the CURRENT SWING ANGLE displayed on the RCI display. If the CURRENT SWING ANGLE readings recorded in Steps 1 or 8 are zero, The WAD/ ISS is functioning as intended.
  • Page 162 10-47 Maintenance Remove covers to gain access to swing-drive and pinion using a socket wrench. Manually unthread and disconnect the sensor cable from the conditioning box as shown in Fig. 5. Conditioning Box & Swing Sensor Loosen the sensor retaining nut using a 3/4" open-end wrench. Unthread and disconnect the sensor from the swing drive housing using a 3/4"...
  • Page 163 Dial Indicator & Bell Type Indicator Tip Re-power the crane. 10. Raise boom out of boom rest to approximately 40°. 11. Rotate swing drive at least one full revolution of the output pinion gear while watching dial indicator to determine lowest reading on indicator. Note the lowest reading. 12.
  • Page 164 10-47 Maintenance 18. Manually insert the sensor cable into the conditioning box and thread clockwise. 19. Replace covers for swing-drive and pinion using socket wrench. 20. Calibrate per Swing Sensor Setup instructions in the RCI manual. 21. Repeat the Precheck procedure Steps 1 thru 8.

  • Page 165: Winch Lubrication

    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. The information below is intended to assist in determining which lubricant is best suited to your application.

  • Page 166: Wire Rope Lubrication

    10-47 Maintenance 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 167: 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 168 10-47 Maintenance Coat exposed cylinder rods with grease. The ENGINE should be prepared as prescribed in the topic “Engine Storage” on page 170. The TRANSMISSION should be prepared as prescribed in the topic “Transmission Storage” on page 174.

  • Page 169: Restoration To Service

    Restoration to Service Refer to “Restoring Engine to Service” on page 173, and “Restoring Transmission to Service” on page 175, for the procedures required to restore these components 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.

  • Page 170: Engine Storage

    10-47 Maintenance Engine Storage PREPARING ENGINE FOR STORAGE When an engine is to be stored or removed from operation for a period of time, special precautions should be taken to protect the interior and exterior of the engine, transmission, and other parts from rust accumulation and corrosion. The parts requiring attention and the recommended preparations are given below.
  • Page 171 Add a rust inhibitor to the cooling system (refer to Group 4, “Corrosion Inhibitor”). Remove, check and recondition the injectors, if necessary, to make sure they will be ready to operate when the engine is restored to service. Reinstall the injectors in the engine, time them, and adjust the valve clearance. Circulate the coolant through the entire system by operating the engine until normal operating temperature is reached (160°...
  • Page 172 10-47 Maintenance 22. Seal all of the openings in the engine, including the exhaust outlet, with moisture resistant tape. Use cardboard, plywood or metal covers where practical. 23. Clean and dry the exterior painted surfaces of the engine. Spray the surfaces with a suitable liquid automobile body wax, a synthetic resin varnish or a rust preventive compound.

  • Page 173: Restoring Engine To Service

    Restoring Engine to Service Remove the valve rocker cover(s) and pour at least one-half gallon of oil, of the same grade as used in the crankcase, over the rocker arms and push rods. Reinstall the valve rocker cover(s). Remove the covers and tape from all of the openings of the engine, fuel tank, and electrical equipment.

  • Page 174: Transmission Storage

    10-47 Maintenance Transmission storage PRESERVATIVE SELECTION It is recommended that the highest viscosity monograde lubricant available be used for the anticipated ambient temperature. Typically this will be a Cat TO-4 qualified lubricant. When large swings in ambient temperature are probable J20 C, D multigrades are recommended. Multigrade lubricants should be applied at the lower viscosity rating for the prevailing ambient temperature i.e.

  • Page 175: Restoring Transmission To Service

    Restoring Transmission to Service Drain oil. Install a new oil filter element(s). Refill transmission with hydraulic transmission fluid to proper level.

  • Page 176: Chrome Cylinder Rod Storage

    10-47 Maintenance 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 177 NOTE: Caution must be used when cleaning equipment in service with high pressure washes. Soaps or chemicals containing chlorines or other corrosive elements should be avoided. Cylinders should be cleaned in a retracted position as not to expose rods to the chemicals. Cylinders should be cycled immediately following the wash.
  • Page 178 Page Intentionally Blank...

  • Page 179: Troubleshooting

    Troubleshooting Troubleshooting CONDITION POSSIBLE CAUSE No response to any control PTO not engaged Low hydraulic oil supply Broken hydraulic pressure line Defective pump Slow operation Pump not operating at proper speed Low hydraulic oil supply Relief setting too low Worn pump, motor, or cylinder Plugged filter Valve spools not fully opening Cold oil...

  • Page 180: Winch System Maintenance And Troubleshooting

    10-47 Troubleshooting Winch System Maintenance and Troubleshooting Winch Maintenance and Repair The Load King Boom Truck is equipped with a power drum type winch. It is equipped with a spring-applied, pressure-released brake. Operation this system requires a counterbalance valve to insure that the brake is totally released when winching down, with or without a load.
  • Page 181 Hydraulic Tank Winch Brake Valve Section Case Drain Return Filter Winch Motor Counterbalance Valve Winch Down Line Winch Up Line...

  • Page 182: Two-Speed Winch Function

    10-47 Troubleshooting Burst of Speed Winch Function The Load King Boom Truck is equipped with a burst of speed winch system as standard equipment. This is controlled by a push button on the winch control at each operator’s console. When the high speed button is pushed to the down position, oil from the 20 GPM side of the pump is pushed into the mainstream of the winch oil.
  • Page 183 Check all electrical connections to make sure power is getting to the winch unloader valve solenoid. If the solenoid coil is getting power, check with a screwdriver on the end of the solenoid to see if it is energized. (The metal screwdriver should be magnetically attracted to the end of the solenoid shaft if the coil is working properly.) If the coil is working, the solenoid may be stuck and should be cleaned or replaced.
  • Page 184 Page Intentionally Blank...

  • Page 185: Service / Parts

    Service / Parts Hydraulic System Description The hydraulic system on the Boom Truck is an open center system. The open-center" means that any time the hydraulic pump is running and the control valves are in the neutral" position, oil is going into the inlet of the control valves and through the open center of the" valve and back to the tank.
  • Page 186 10-47 Service / Parts Open Center Hydraulics/Neutral Filter Filter Open Center Valve Open Center Valve Load Tank Tank Pump Pump Open Center Hydraulics/Operate Actuator...

  • Page 187: Control Valves And Pressures

    Control Valves and Pressures The relief pressure settings on the Boom Truck are very important for the following reasons: They protect the pump from being overpressured by allowing oil above the main relief setting to be vented to the tank. If this does not happen on a fixed displacement system, it could cause serious damage to hoses, pumps, and other components in the system.
  • Page 188 10-47 Service / Parts Oil Inlet Orifice Piston Poppet Relief Piston Pilot Poppet Acorn Nut Adjustment Screw The reliefs are factory set and should not be tampered with unless poor performance is experienced. Any relief which has been removed for inspection, cleaning, or replacement must be adjusted after installation.
  • Page 189 PROCEDURE FOR ADJUSTING SYSTEM RELIEFS The system reliefs should be set only when the oil in the hydraulic system is warm or at operating temperature. The unit must be run from the driver’s side (or street side) console to be able to observe the gauge mounted on the operator’s console. See Page 6 - 4 for gauge and relief location.
  • Page 190 10-47 Service / Parts Rotation Gearbox Brake Release Hose Brake Release Fitting Rear Of Truck 0-3000 PSI Gauge On units equipped with a triple pump, the independent swing circuit pressure is not connected to the control pressure gauge. Stop the engine, remove the brake release hose at the rotation gearbox and attach a 0 - 3,000 PSI pressure gauge at the end of the hose.
  • Page 191 Swing Relief 1800 PSI Console Gauge (Streetside) Boom Relief Shuttle Winch Relief With control levers in neutral position, raise pump RPM to 2,300. With either the winch engaged in a deadman pull, or the winch-up workport capped and plugged, move the winch handle to the up direction. Hold the handle until the system goes over relief.

  • Page 192: Pumps And Flow Speeds

    10-47 Service / Parts Pumps and Flow Speeds The pumps used on the Load King Series Boom Truck are fixed/positive displacement of the rotary vane type. To produce the proper amount of flow to run the functions at full speed, the pump shaft must be turning at 2,000 RPM.

  • Page 193: Outrigger And Cylinder Maintenance And Troubleshooting

    Outrigger and Cylinder Maintenance and Troubleshooting Topping Cylinder HOW TO ANALYZE TOPPING PERFORMANCE The topping cylinder should hold up the boom and load with a minimal amount of drop-off. The cylinder is equipped with a counterbalance type holding cartridge in the base of the cylinder.
  • Page 194 10-47 Service / Parts clean the cartridge. Boom must be unloaded and supported before cartridge is removed. Piston bypassing from base side to rod side If oil comes out of the boom-down hose while still engaged in the same test, the cylinder is bypassing internally and will require internal repairs.
  • Page 195 CARTRIDGE PISTON NUT PISTON BARREL END GLAND BYPASS ORIFICE RETATINER RING RETAINER PLATE BOLTS RETAINER PLATE TOPPING CYLINDER OVERHAUL PROCEDURE Contact Load King Service Department to receive overhaul information for the cylinder on the unit. Have the cylinder part number, located on the barrel, available at time of call and the information will be sent to you.

  • Page 196: Outrigger Cylinder

    10-47 Service / Parts Outrigger Cylinder OUTRIGGER TWO-WAY CHECK SYSTEM Outrigger Holding Cartridge - LOAD Extend Tube Manual Release Retract Tube Outrigger Holding Cartridge - STOW Side Tube OUTRIGGER TWO-WAY PILOT TO OPEN CHECK SYSTEM LOCATED: On each outrigger cylinder. FUNCTION: Locks outrigger in up position for roading, and down for crane or operation.
  • Page 197 Welds (Base to cylinder barrel). End gland of cylinder. Cartridge O-Ring. Internal leaks are more difficult to find and almost without exception require cylinder removal. Three items must be checked to isolate the leak: The load holding cartridge. Stop engine. Activate outrigger control handle to relieve trapped pressure. Disconnect extend port hose at valve.
  • Page 198 10-47 Service / Parts Attach a choker strap on the lower side of the link pin boss. Drive a wedge between the inner and outer legs to help hold the inner leg in place when the upper pivot pin is removed.
  • Page 199 Using the choker strap and hoist, pin the upper leg to the mainframe bracket. Lower the leg until the links align with the hole in the outrigger leg boss. Install the pin through the links and outrigger boss and install the snap rings. Connect the outrigger hoses.
  • Page 200 10-47 Service / Parts Align rod end with holes in inner leg and install pin and snap rings. Apply a thin coat of anti-seize lubricant to pin before installation. If slider pad is still inside outer housing (located under doubler strap at lower end of housing), pry it loose and remove.

  • Page 201: Extension Cylinder

    Extension Cylinder HYDRAULIC ASSIST EXTENSION SYSTEM The extension system on the extends and retracts by means of a hydraulic cylinder and a series of cables. The picture below describes the cylinder mounting. The cylinder mounts into the boom by a series of mounting trunnions shown in the illustrations below Extension Cylinder Assembly Cartridge 2nd Stage Trunion...
  • Page 202 10-47 Service / Parts Base Mount Base End of Boom Extension Cylinder Extension Cable Adjustment Second Stage Mount Extension Cylinder Mount Boom Mount The extension cylinder is equipped with a counterbalance cartridge to hold the rated load suspended. The system is designed so that when the extension handle is pushed to extend, the oil is allowed to free-flow through the counterbalance and into a hollow porting tube in the center of the cylinder rod and into the cylinder’s base.
  • Page 203 When the handle is pulled to retract, the oil is routed directly into the rod side of the cylinder. As pressure is applied, the oil gets into the pilot portion of the counterbalance and pilots it open, allowing the base oil to be exhausted back to tank. See the following illustration: Pilot Port Retract Line Counterbalance...
  • Page 204 10-47 Service / Parts WHEN LOOSENING FITTINGS, HIGH PRESSURE OIL COULD BE PRESENT IF COUNTERBALANCE VALVE IS STUCK OPEN OR IF INTERNAL LEAKAGE IS SEVERE. BOOM SHOULD ONLY BE SLIGHTLY EXTENDED SO THAT SUDDEN MOVEMENT DOES NOT CAUSE INJURY OR PROPERTY DAMAGE Extend boom 3-4”...

  • Page 205: Boom Maintenance, Adjustment And Repair

    Boom Maintenance, Adjustment and Repair Wear Pad Adjustment and Replacement Front View (left) and Rear View (right) The following notes will apply anytime replacement or removal of any wear pads are involved. Use shims under the pads to attain proper clearances between boom sections. See dimension notes on above illustration for clarification.
  • Page 206 10-47 Service / Parts Apply a thin film of brush-type anti-seize lubricant on the base, 2nd, and 3rd stage boom sections where pads make contact, on inside surfaces. On outer boom tip surfaces use lithium based grease. The width and length of lubrication needs to be full wear pad contact area.
  • Page 207 DO NOT STICK HANDS OR TOOLS IN BOOM SECTIONS UNTIL THE ENGINE IS SHUT OFF AND PTO IS DISENGAGED. SERIOUS INJURY WILL RESULT IF BOOM IS TELESCOPED WHILE HANDS OR TOOLS ARE IN HOLES REAR TOP WEAR PADS fully retract the boom so the top rear wear pads on the 2nd stage are accessible through the holes in the top of the base section.
  • Page 208 10-47 Service / Parts PART NUMBER DESCRIPTION THICKNESS 787-00238 SHIM 0.04 *787-00308 787-00239 SHIM 0.063 *787-00309 787-00240 SHIM 0.10 * 787-00310 NOTE: * These shims used with wear pad # 729-02640 top rear 2nd stage boom. Securely tighten the mounting screws after the shims are installed. Use Loctite 242 on all bolts.
  • Page 209 NOTE: Mounting screws for the side wear pads must not rub against the adjacent section. If necessary, add washers behind the head of the mounting screws so screws fully engage the nuts in the wear pads but not rub against the section.
  • Page 210 10-47 Service / Parts of holding approximately 10,000 lbs. Stands or blocking must be installed close to both ends of the base boom to provide a sturdy support. The boom should be secured to these stands to prevent any unexpected movement. It is best if the stands are shaped in such a way that the keel shape of the boom is matched so it will not tilt or fall over during servicing.
  • Page 211 Lift the cylinder and extend tube assembly as high as possible, and remove the 3rd stage retract cable sheave pins, sheaves, and cable guides. Remove the 3rd stage retraction cables and inspect for rust, kinks, and any signs of damage. Carefully remove the 3rd and 4th stage assemblies from the 2nd stage boom.

  • Page 212: Boom Reassembly

    10-47 Service / Parts Boom Reassembly BOOM ASSEMBLY PROCEDURE These instructions assume that the boom is in a completely disassembled condition. The re- assembly will be carried out in several stages of sub-assembly starting with the 4th stage boom first. Rear, Side and Top Wear Pads Retract Cable Spacer Plate...
  • Page 213 Extend Tube Assembly Snap Rings Extend Cables Grease Zerks Wear Pads Sheave Pin Sheaves Assemble the extend tube assembly as follows: Assemble sheaves, bearings, pin, grease zerks, and snap rings to tip of extend tube assembly. Grease roller bearings through grease zerks with EP multipurpose grease. Install the extend cables into the sheave grooves and install the retaining bolts, nuts, and spacers.
  • Page 214 10-47 Service / Parts Extend Cables Grease Zerk Cable Retainer Bolts Wear Pads - Install with Beveled Corner to the Outside Cylinder Anchor Bolts 1" Bolts (torque to 480 ft-lbs. - 4 ea.) Backup Bar 4 Grooves Extend Sheave Cable Anchor Sheave Bearings Critical Dimension Lift extend tube assembly as high as possible and install cable anchor and support bar...
  • Page 215 Install bolts, washers, spacers, and lock nuts through sheave tip to retain cables. Grease roller bearings through grease zerks installed in each end of the sheave pin. Be sure to use a multipurpose EP type of grease. Assemble rear, side, and top wear pads to the 3rd stage boom. 10.
  • Page 216 10-47 Service / Parts 4th Stage Retract Cable Extension Cylinder Assembly Cable Clamp Cable Retainer Extend Cables Extend/Retract Bracket Wear Pads Retract Sheave & Guide 3rd Stage 2nd Stage Retract Cables Assembly 4th Stage...
  • Page 217 4th Stage Retract Cable Sheave Retainer Pin Sheave Guard Cable Clamp Block Bushing Extend/Retract Cable Anchor Bearing Buckeye 3rd Stage Retract Cable Sheave Pin 15. Assemble the front side of the bottom wear pads into the front of the 3rd stage boom, shimming as required to achieve the clearances called out in the boom shimming chart.
  • Page 218 10-47 Service / Parts 21. Slide the extend tube assembly into the 4th stage boom until the holes in the extend/ retract anchor line up with the holes in the 3rd stage boom. Raise the extend tube assembly and extension cylinder assembly to align the holes. 22.
  • Page 219 NOTE: Failure to do this could result in serious damage to cylinder and weldments. 27. Assemble front side and bottom wear pads to 2nd stage boom. See section on shimming for proper shimming procedures. Also install retract cable blocks. 28. Apply FS White Lithium Grease 12 to boom sides that contact wear pads and wear pad surfaces.
  • Page 220 10-47 Service / Parts 34. Remove the cartridge block from the extension cylinder and manually pull the cylinder rod out approximately 24”. Take precautions to prevent dirt from getting into the cylinder ports. 35. Assemble the top and side rear wear pads to the 2nd stage boom. Adjust clearance in accordance with the wear pad clearance section of this manual.
  • Page 221 BOOM INSTALLATION SHUT OFF ENGINE AND DISENGAGE PTO. DO NOT STICK HANDS OR TOOLS IN BOOM SECTIONS UNTIL THE ENGINE IS SHUT OFF AND PTO IS DISENGAGED. FAILURE TO DO THIS MAY RESULT IN SEVERE PERSONAL INJURY, INCLUDING LOSS OF HANDS OR FINGERS! Lift the boom into position at the turret and install the boom hinge pin.

  • Page 222: Boom Cable Adjustment Procedure

    10-47 Service / Parts Boom Cable Adjustment Procedure SHUT OFF ENGINE AND DISENGAGE PTO. DO NOT STICK HANDS OR TOOLS IN BOOM SECTIONS UNTIL THE ENGINE IS SHUT OFF AND PTO IS DISENGAGED. FAILURE TO DO THIS MAY RESULT IN SEVERE PERSONAL INJURY, INCLUDING LOSS OF HANDS OR FINGERS! 2nd Stage Boom 3rd &...
  • Page 223 cables by hand. Tighten the adjusting nut on the loosest cable until the two cables are equally tensioned. Tighten the adjusting nuts on the 4th stage retract cables to 25 ft.lbs. Fully extend the boom and check tension of the 4th stage extend cables. Tighten the adjusting nut on the loosest cable until the cables are equally tensioned.
  • Page 224 10-47 Service / Parts Measure the remaining stroke between match mark A on the 2nd stage boom section and the base boom. If the 2nd stage stopped first: Measure the remaining stroke between match mark B on the 3rd stage and the end of the 2nd stage.

  • Page 225: Rotation Gear And Gearbox

    Rotation Gear and Gearbox Removal/Installation of Rotation Gear and Gearbox NOTE: The following instructions assume the boom has been removed from the turret. Thoroughly steam clean unit in rotation gear area. Remove the rotation gearbox from its mounting and lay it on the control console. It is not necessary to disconnect the hydraulic lines when performing this step.
  • Page 226 10-47 Service / Parts TORQUING SEQUENCE FOR ROTATION GEAR Lift the turret and rotation gear into position over the mainframe. Mounting surfaces must be clean and flat. Position the inner ring so the loading plug is 180° to the left of the rotation gearbox. NOTE: Left corresponds to the operator’s left side when standing at the controls.

  • Page 227: Inspection Of Rotation Bearing Clearance

    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. A bearing may cause a problem in the operation of the Boom Truck or the confidence of the operator long before it would be deemed structurally unsafe.
  • Page 228 10-47 Service / Parts Radial Clearance Check Procedure Clamp Position #1 Rotation Gear Clamp Position #2 Dial Indicator "C"Clamp 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 229: Backlash Adjustment

    Backlash Adjustment The rotation mechanism should be checked periodically for any signs of looseness or excess lash between the gears. The procedure for setting backlash is as follows: Locate the high spot on the rotation gear. This spot is marked with yellow paint at the time of manufacture of the bearing.
  • Page 230 10-47 Service / Parts Coat rotation gearbox pilot and mainframe pilot bore with anti-seize compound to prevent rust and binding of the eccentric ring.

  • Page 231: Internal Rci Cable Repair

    Internal RCI Cable Repair EXTERNAL CABLE BREAK In the case that the RCI cable breaks outside of the boom, DO NOT EXTEND BOOM. Attach replacement cable to broken cable. Pull new cable through boom assembly by pulling broken cable from boom head. INTERNAL CABLE BREAK In the case that the RCI cable breaks inside of the boom, follow the procedure below.
  • Page 232 10-47 Service / Parts EXTEND CYLINDER SHEAVE CABLE GUIDE 2 BRACKET CABLE GUIDE 1 After the rod is through Cable Guide 1 it may be necessary to lift the rod up or down to align with Cable Guide 2 After routing the rod through guide 2, feed it all the way to the rear of the tip section. (Approximately 25’) Extend boom until access holes align in top of boom sections.
  • Page 233 TOP VIEW Cable Eyelet Loosen left-most extend cable so that you can access the rod on the bottom plate of the boom with your hand. Make sure that the rod is fed straight through. Do not allow the rod to be wrapped by any extend cables. Feed the rod through cable eyelet mounted to the inner left side of the boom and then through cable hole at the base of the boom.
  • Page 234 10-47 Service / Parts ATB PLUG THIMBLE RETAINING SCREW Place thimble onto retaining screw. Access inner end of screw by reaching through the hole in the front of the boom head. Attach fender washer and hex nut. If using a replacement washer, make sure that it is a fender washer with a large enough diameter to hold the cable thimble.

  • Page 235: 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 236 10-47 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 16.688 43/64...
  • Page 237 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 238 10-47 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 or 4 rods or 1 chain 80 chains...

  • Page 239: Average Weight Of Materials

    Average Weight of Materials KG/CU. MATERIAL 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 240 10-47 Appendix KG/CU. MATERIAL 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 1566 Sand - Dry, Loose 1521.90...

  • Page 241: Torque Specs -Sae & Metric

    Torque Specs -SAE & Metric...
  • Page 242 10-47 Appendix...

  • Page 243: Personnel Platform Installation & Operation Manual

    Personnel Platform Installation & Operation Manual...

  • Page 244: Greer Insight Operation's Manual

    10-47 Appendix Greer Insight Operation's Manual Your crane is set up with a Greer Insight Rated Capacity Indicator (RCI) system. Completely read the attached manual in the Appendix section and view the Setup & Operations Video DVD (Part No. 12261-644) supplied in your crane manual pack before attempting to operate the crane.
  • Page 245 10-47 Notes...
  • Page 246 LOAD KING WARRANTY Load King (herein after referred to as the COMPANY) warrants all products manufactured by it and purchased by you to be free from defects in material and manufacture at the time of shipment, for one (1) year from date of delivery. The COMPANY will furnish replacements for such parts as the COMPANY finds to have been defective at the time of delivery or, at the COMPANY’s option, will make or authorize repairs to such parts, provided that, upon request, such parts are returned, transportation is prepaid to the factory from which they were shipped.
  • Page 247 Page Intentionally Blank...
  • Page 248 www.loadkingmfg.com Load King 7701 Independence Ave, Kansas City, MO 64125 Parts: (816) 241- 8387 Service: (833) 281-7911 Email: info@loadkingmfg.com...

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