LOAD KING 35-127 M Operator's Manual

Table of Contents

Quick Links

Download this manual

OPERATORS MANUAL

LOAD KING

35-127 M

C1046093 - REV A

FEBRUARY 09, 2022

Table of Contents

Troubleshooting

Summary of Contents for LOAD KING 35-127 M

Page 1 OPERATORS MANUAL LOAD KING 35-127 M C1046093 - REV A FEBRUARY 09, 2022...
Page 2 PAGE INTENTIONALLY LEFT 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
Table of Contents Introduction ..................9 Construction and Industrial Equipment Product Safety �� 9 35-127 M Nomenclature �� 10 Standards �� 11 Intended Use �� 12 Bulletin Distribution and Compliance �� 13 Contacting Manufacturer �� 14 Transfer of Machine Ownership �� 15 Safety ....................
Page 6 35-127 H Contents Rated Capacity Indicator System �� 71 ATB Components �� 72 Inspection ..................75 Suggested Hydraulic Crane Inspection Checklist �� 75 Pre-Start Inspection �� 80 Daily Check (8 Hours) �� 82 Weekly Check (40 Hours) �� 83 Monthly Check (80 hours) �� 84 Quarterly Checks (250 Hours) ��...
Page 7 General Work Practices �� 127 Cold Weather Package Specification �� 128 Storing Components�� 129 Cleanliness �� 130 35-127 M Master Lube Chart �� 131 Maintenance Checks and Lubrication �� 133 Hydraulic Hoses�� 136 Hydraulic Oil Requirements �� 138 90-Day Maintenance Items �� 142 Semi-Annual Maintenance Items ��...
Page 8 35-127 H Contents Troubleshooting ................173 Troubleshooting �� 173 Winch System Maintenance and Troubleshooting �� 174 Winch Maintenance and Repair �� 174 10. Service / Parts ................177 Hydraulic System Description�� 177 Control Valves and Pressures �� 179 Outrigger and Cylinder Maintenance and Troubleshooting �� 185 Outrigger Position Sensors ��...
Page 9: 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 10: 35-127 M Nomenclature
35-127 M Introduction 35-127 M 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”...
Page 11: Standards
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� Load King recommends that you purchase and refer to the following standards: ANSI/ASME B30�5 – Mobile & Locomotive Crane (Latest Version)
Page 12: Intended Use
35-127 M 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
35-127 M 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�...
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 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
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 18: Product Safety Decals
35-127 M Safety Product Safety Decals ANSI HAZARD CLASSIFICATION SYSTEM A multi-tier hazard classification system is used on machine safety signs to communicate potential personal injury hazards� The following signal words used with the safety alert symbol indicate a specific level of severity of the hazard�...
Page 19 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 20 35-127 M 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 21 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 22 35-127 M 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 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
35-127 M 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�...
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 1� Safe operation must always be the operator’s most important concern� 2�...
Page 26 35-127 M Safety OPERATOR’S RESPONSIBILITIES 9� 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�...
Page 27 RESPONSIBILITIES OF ALL CREW MEMBERS 1� Unsafe conditions and/or practices must be corrected� 2� Obey all warning signs� 3� Watch out for your safety and the safety of others� 4� Know and understand proper machine erection and rigging procedures� 5� Alert operator and signal person of hazards, such as power lines, unstable ground, etc�...
Page 28 35-127 M Safety 10� Determine how the load will be rigged� 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�...
Page 29 OPERATOR AIDS CHECK Ensure that the listed items are in place and operational� 1� Boom angle indicator� 2� Backup Alarms� 3� ATB devices� 4� Overload Protection, Load Indicators, Rated Capacity Indicator� OPERATION OVERLOAD PROTECTION 1� Know the weight and characteristics of all loads to be lifted� 2�...
Page 30 35-127 M Safety OPERATION SETUP 1� Be sure the load bearing surface is strong enough to support the machine with lifted load� 2� Be sure the crane is level� Check frequently and re-level when necessary� 3� Stay away from rotating cranes� Erect barricades to keep people away� Make sure these areas are clear before swinging�...
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 50 kV 10 FT ( 3�0 M) 500 TO 200 kV 15 FT (4�6 m) 2000 TO 350 kV 20FT (6�1 m) 350 TO 500 kV...
Page 32 35-127 M Safety POWER LINE SAFETY 4� If contact occurs, stay on crane until the boom is cleared or until the electrical current is turned off� 5� 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 operational aids are inoperative or malfunctioning, the following requirements shall apply for continued use or shutdown of the crane� 1� 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 34: Effects Of Wind Conditions
35-127 M 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 km/h) on a load surface of 11�7 ft^2/ton�...
Page 35 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 Consequences Scale Terms Described km/h...
Page 36: Lightning Storm
35-127 M 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�...
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 35-127 M Safety • 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 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
35-127 M 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...
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
35-127 M 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�...
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
35-127 M 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: Personal Safety
35-127 M Safety Personal Safety SLIP AND FALL PREVENTION 1� Always wait until machine has stopped before getting on and off the equipment� 2� Do not use controls or steering wheel as hand holds� 3� Keep the machine clean and dry� Remove all oil, grease, mud, ice and snow from walking surfaces�...
Page 47: Seat Belts
Seat Belts SOME SUGGESTED USAGE AND MAINTENANCE INSTRUCTIONS FOR SEAT BELTS: 1� Wear your lap belt low and snug� 2� Manually adjustable lap belts and shoulder harnesses are adjusted by pulling the loose end of the webbing through the buckle or adjuster� 3�...
Page 48 PAGE INTENTIONALLY LEFT BLANK...
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: Dead Ending Wire Rope In Socket
35-127 M Assembly 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 51: Jib Mounting
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 52 35-127 M Assembly 3� Remove bottom and top retainers and guide pins from sheave head� Arrow indicates PIN to be removed Arrow indicates PIN to be removed 4� Reinstall top and bottom guide pins and retainers in the sheave head�...
Page 53 5� Remove load line from boom head sheave and allow it to hang off the side of the boom� 6� Remove two pins and retainers from outer pin stow bracket� 7� 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�...
Page 54 35-127 M Assembly 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. 8� 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 55 10� DO NOT REMOVE PIN SECURING JIB TO THE BOOM, AT JIB STOW BRACKET UNTIL STEP 7 HAS BEEN PERFORMED, OTHERWISE JIB WILL FALL OFF THE BOOM CAUSING SERIOUS INJURY TO PERSONNEL AND PROPERTY DAMAGE� 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�...
Page 56 35-127 M Assembly 12� Swing jib away from boom with tag line� Control movement of the jib at all times to prevent injury and/or equipment damage� 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�...
Page 57 WOOD BLOCK SUPPORT 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 58 35-127 M Assembly EXTENDING SECOND JIB STAGE 1� Unstow ATB cable from jib base section� 2� Remove ATB switch, retaining pin, and plug from the boom head� Reinstall on jib head� Plug Switch Retaining Pin...
Page 59 3� Remove ATB plug from base of jib and install in open receptacle on boom head� Jib Base Receptacle Plug 4� Raise boom to angle high enough to allow the jib to be extended without contacting the ground� 5� Fasten a tag line to the anchor point on the jib head�...
Page 60 35-127 M Assembly 6� Remove lock pin and retainer from rear of jib� 7� Pull second stage jib out until it contacts jib stop pin� 8� Insert jib lock pin into extend position and secure with retaining pin� Push back on second stage...
Page 61 9� 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� Install guide pin and retainer�...
Page 62 35-127 M Assembly 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 63: Description Of Machine And Controls
Description Of Machine and Controls Operator Controls...
Page 64 35-127 M Description Of Machine and Controls 1� WINCH CONTROL LINKAGE KEY 2� SWING CONTROL HANDLE 3� B TELE CONTROL HANDLE 4� BOOM HOIST CONTROL HANDLE 5� WINCH CONTROL HANDLE 6� CONSOLE WELDMENT 7� BUBBLE LEVEL 8� KNOB, CONTROL (BLACK) 9�...
Page 65: Power Take-Off
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� Transmission Mounted, Shiftable PTO’s To Engage PTO 1�...
Page 66: Outrigger Stow Pins
35-127 M 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�...
Page 67 Disengage pin at end of each beam before extending� Damage to pin and horizontal beam housing may occur if beams are extended without first releasing the stow pin� DISENGAGED...
Page 68: Outrigger Controls
35-127 M 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� 1� SIGNAL DEVICE - Push button to sound truck horn as an audible signal to warn other personnel in the area�...
Page 69: Boom And Winch Controls
Boom and Winch Controls BOOM AND WINCH CONTROLS 1� SWING - Push lever to rotate boom counterclockwise, pull lever to rotate boom clockwise� 2� BOOM TELESCOPE - Push lever to extend boom, pull to retract boom� 3� WINCH (COMBINED FLOW 2-SPEED) - Push lever to lower loadline, pull lever to raise loadline� For high speed winching, depress button on control knob while actuating control lever�...
Page 70 35-127 M Description Of Machine and Controls Front Stabilizer Front stabilizer must be used when working off the front of the truck crane� This outrigger is only used with the continuous rotation option�...
Page 71: Rated Capacity Indicator And Atb
Rated Capacity Indicator and ATB Rated Capacity Indicator System The Load King RS 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 72: Atb Components
35-127 M 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� The cable reel has slip rings which allow electric current to flow even while the reel is turning�...
Page 73 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 74 35-127 M Description Of Machine and Controls Boom Control Valve 1 Winch 4 Boom Control Valve 2 Winch Valve 5 Manifold 3 Function Cutt Off Valve...
Page 75: Inspection
Inspection 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...
Page 76 35-127 M 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...
Page 77 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 78 35-127 M 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 79 REPAIRS - ADJUSTMENTS - REMARKS ITEM REQUIREMENT DATE...
Page 80: Pre-Start Inspection
35-127 M 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�...
Page 81 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� Check the freedom of counterweight attached to these switches;...
Page 82: Daily Check (8 Hours)
35-127 M 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 83: 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 84: Monthly Check (80 Hours)
35-127 M 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 85: 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 86: Semiannual Checks (1000 Hours)
35-127 M 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 87: 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 88: Crane Boom
35-127 M 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 89 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.
Page 90: Wire Rope Inspection
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�...
Page 91 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 92: Wire Rope Inspection Record
35-127 M Inspection 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...
Page 93: Mobile Crane Load Test 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 94 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 95 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 moment)�...
Page 96 PAGE INTENTIONALLY LEFT BLANK...
Page 97: Operating Instructions
Operating Instructions Job-Site Job Site Setup Procedure 1� Position vehicle on solid level ground, fully set parking brake, and place transmission in neutral� 2� Engage pump PTO� Allow hydraulic oil to warm up by circulating to prevent pump damage� NEVER DRIVE VEHICLE WITH PUMP PTO ENGAGED� 3�...
Page 98: Outrigger Positioning
35-127 M 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 99: 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�...
Page 100: Cold Weather Operation
35-127 M 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�...
Page 101: General Operational Issues
MAINTAIN (3) FULL WRAPS ON WINCH DRUM� 7� 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 102: Safety Devices
Operating Instructions 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 103: 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: 1�...
Page 104: Operator Aids
35-127 M Operating Instructions 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�...
Page 105: 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 106: Max. Load And Boom Angle Charts
35-127 M Operating Instructions 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�...
Page 107 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 108: Operating Radius
35-127 M Operating Instructions Operating Radius Center Line of Rotation Read Operating Radius Here Load Indicator Weight (suspended) Load Line...
Page 109: Boom Angle Placards
Boom Angle Placards CAUTION - Do not extend jib into this area unless boom is fully retracted�...
Page 110: 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...
Page 111: Initiating Operation
Initiating Operation 1� 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 99)� However, strict observance of load weight, radius and maximum load rating must always be complied with� 2�...
Page 112: Arm And Hand Signals
35-127 M Operating Instructions Arm and Hand Signals Hand Signals Graphic Operation Action STOP Arm extended, palm down, move arm back and forth horizontally� HOIST LOWER USE MAIN HOIST RAISE BOOM USE AUXILIARY HOIST LOWER With arm extended downward, forefinger...
Page 113 STOP EMERGENCY STOP Do not deface or remove this label from the machine. use standard signals. Order replacement labels from your Load King dealer. GNALS Arm extended, palm down, move Both arms extended, palms down, move arms arm back and forth horizontally.
Page 114 EMERGENCY STOP Do not deface or remove this label from the machine. use standard signals. 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 115 Both fists in front of body with thumbs pointing outward. thumbs pointing toward each other. Do not deface or remove this label from the machine. Order replacement labels from your Load King dealer. G EVERYTHING EXTEND BOOM RETRACT BOOM 1006862 REV A...
Page 116: Lifting The Load
Rotate the boom tip until it is directly over the material to be lifted� Unless continuous rotation is specified, Load King Boom Trucks are equipped with 370° rotation stops� It is important that you be aware of the position of the stops before lifting in order to assure maximum rotation and prevent excess handling of the load�...
Page 117: Emergency Procedures
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� 1� 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 118: Emergency Boom Retraction
Operating Instructions 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 119: Emergency Lowering Of Boom
Emergency Lowering of Boom The Load King Boom Truck is equipped with a pilot operated 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� It also provides support in the event of a ruptured line, or hydraulic failure�...
Page 120: Emergency Rotation
Operating Instructions 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: 1�...
Page 121: Emergency Retraction Of Outriggers
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 122: Roading The Unit
Secure any load or lifting attachments (steel platforms, roofer’s package) to the flatbed� 6� The Load King Cranes 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�...
Page 123 You should always know the maximum road height of your crane when repositioning at the job site or preparing for road travel� A placard like the one shown above, which shows the height of your crane as manufactured and installed is attached to the dash board inside the truck cab� Severe personal injury, as well as damage to the crane and truck, can result from failure to observe overhead obstructions during repositioning at the job site or during road travel�...
Page 124 PAGE INTENTIONALLY LEFT BLANK...
Page 125: Maintenance
Maintenance Safety Practices 1� ALWAYS apply the parking brake on the truck before undertaking any repairs to the crane� 2� Lower all loads to the ground so load line is slack� 3� Move all controls to neutral position� 4� Disengage the PTO and turn off ENGINE 5�...
Page 126 35-127 M Maintenance DO NOT SPILL OR DUMP OIL 1� Keep open flame away� 2� Injury could result if not cleaned up� 3� Oil is a regulated/hazardous waste� 4� Capture oil when repairing or draining systems� 5� Disposal must conform to state/federal regulations�...
Page 127: 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� 1� Before disconnecting wires, hoses or tubes, tag them for proper identification at reassembly� 2�...
Page 128: 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 129: Storing Components
Storing Components 1� Store new components (valves, pumps, motors, cylinders, hoses, tubes, fittings) in a clean, dry indoor location� 2� DO NOT unpack components or remove port plugs until the components are needed� 3� Once unpacked, carefully inspect each component for damage that may have occurred during shipping�...
Page 130: Cleanliness
35-127 M Maintenance Cleanliness 1� 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�...
Page 131: 35-127 M Master Lube Chart
35-127 M Master Lube Chart...
Page 132 35-127 M Maintenance...
Page 133: Maintenance Checks And Lubrication
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 lift cylinder and boom hinge pin points that do not require lubrication� The outrigger hinge points do not require lubrication either� It is recommended that an EP (Extreme Pressure) type grease be used where greasing is indicated�...
Page 134 35-127 M Maintenance WEEKLY CHECKS The following weekly checks should be performed in addition to the daily checks: 1� Check mechanical linkages for signs of wear or binding� Lubricate as necessary with 10 weight motor oil� 2� 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 135 8� Lubricate PTO with multi-purpose grease Shaft Cover Screws Grease Zerk PTO Lubrication Instructions: 1� Remove Shaft cover Screws (1) and remove cover� 2� Using grease gun, apply 2-3 pumps of multipurpose grease through grease zerk (2)� 3� Replace shaft cover and tighten screws� 9�...
Page 136: 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 137 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 138: Hydraulic Oil Requirements
35-127 M Maintenance 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 139 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 140 4� Check pressure settings – Is a pump failing or a relief set to low? 5� Reduce the duty cycle of the machine� Consult an Authorized Load King Dealer� 6� The following hydraulic oils are not recommended: ● Engine Oils ●...
Page 141 OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME Rando Oil HD A2 (5w-20) DTE 24/DTE-13M Rando Oil HD 32 Mobil Oil Corp� DTE 25/DTE-15M Texaco Inc� (USA) Rando Oil HD 46 DTE 26/DTE-16M Rando Oil HD 68...
Page 142: 90-Day Maintenance Items
35-127 M Maintenance 90-Day Maintenance Items The following maintenance procedures should be done every 90 days in addition to the daily, weekly, and monthly checks: 1� Check and reset the rotation gear backlash� (See Backlash Adjustment on page 200�) 2�...
Page 143: Semi-Annual Maintenance Items
Semi-Annual Maintenance Items The following checks should be done semi-annually in addition to the daily, weekly, and monthly checks: 1� Torque the mainframe and rear outrigger mounting bolts� (See Torque Specs-SAE & Metric on page 209�) 2� Check Hydraulic system pressures and adjust as necessary� 3�...
Page 144: Filters And Maintenance
Adequate protection against oil contamination has been given to the system through filtration� The Load King Stinger Boom Truck is equipped with a 10 micron spin on type filter to strain out particles down to 10 microns in size� (40 microns is as small as the eye can see)�...
Page 145 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 146 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� 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 147: Rotation System Maintenance And Troubleshooting
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: 1� To insure that the swing brake is used only as a parking brake instead of a service type brake� The brake system is not designed to slow the rotation of the unit as some people believe�...
Page 148 35-127 M Maintenance 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�...
Page 149: Care And Maintenance Of The Rotation System
Care and Maintenance of the Rotation System Contact Load King Service Parts Department to receive overhaul information for the gearbox on the unit� Have the serial number available at time of call and the information will be sent to you�...
Page 150 35-127 M Maintenance...
Page 151 Access Holes Inner Bolt Circle 1-8NC Nut Outer Bolt Circle 1-8NC Socket Head Bolt Turret Assembly Turret Base Plate Swing Stop Bolt C2 Fitting in Rotation Gear (2ea - 180 degrees apart Turret Base Plate Rotation Gear Rotation Bearting Grease Tubes Hardened Flat Washer Zerk “A”...
Page 152: Rotation Gearbox And Gear Teeth
3� 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 153 Swing Drive Gearbox & Motor Conditioning Box Swing Sensor (WAD) Brake Pressure Oil Level Plug Cartridge Valve Breather & Oil Fill Location Motor Pressure Port 10 Grease Zerk 11 Oil Drain Port Cartridge Valve...
Page 154: Swing (Wad/Iss) Sensor Check & Replacement Procedure
35-127 M Maintenance Swing (WAD/ISS) Sensor Check & Replacement Procedure Swing Gearbox & Motor 1� Swing (WAD) Sensor 2� 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 155 2� Raise the boom until the boom angle is approximately 40°� 3� Rotate the boom slowly and smoothly to the 90° position as shown in Fig� 2� 4� Swing the boom counterclockwise approximately 20° and stop abruptly� 5� Pause appoximately 5 seconds� 6�...
Page 156 35-127 M Maintenance 7� Repeat Steps 3 thru 6 nine times, for a total of ten cycles� 8� 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�...
Page 157 4� Remove covers to gain access to swing-drive and pinion using a socket wrench� 5� Manually unthread and disconnect the sensor cable from the conditioning box as shown in Fig� 5� Conditioning Box & Swing Sensor 6� Loosen the sensor retaining nut using a 3/4” open-end wrench� 7�...
Page 158 35-127 M Maintenance Dial Indicator & Bell Type Indicator Tip 9� 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�...
Page 159 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 160: Winch Lubrication
35-127 M 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 161: 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 162: Storage
35-127 M Maintenance 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 163: Restoration To Service
Restoration to Service Refer to “Restoring Engine to Service” on page 167, and “Restoring Transmission to Service” on page 169, for the procedures required to restore these components to service� Remove the MACHINE from storage via the following procedure: 1� Remove preservative lubricants from all surfaces�...
Page 164: Engine Storage
35-127 M 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�...
Page 165 5� Reinstall the injectors in the engine, time them, and adjust the valve clearance� 6� Circulate the coolant through the entire system by operating the engine until normal operating temperature is reached (160° F� to 185° F)� 7� Stop the engine� 8�...
Page 166 35-127 M Maintenance 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� 24� Cover the engine with a good weather-resistant tarpaulin or other cover if it must be stored outdoors�...
Page 167: Restoring Engine To Service
Restoring Engine to Service 1� 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� 2� Reinstall the valve rocker cover(s)� 3�...
Page 168: Transmission Storage
35-127 M 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 169: Restoring Transmission To Service
Restoring Transmission to Service 1� Drain oil� 2� Install a new oil filter element(s)� 3� Refill transmission with hydraulic transmission fluid to proper level�...
Page 170: Chrome Cylinder Rod Storage
35-127 M 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 171: Specifications
Pumps and Function 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 2,300 RPM�...
Page 172 PAGE INTENTIONALLY BLANK...
Page 173: Troubleshooting
This Manual does not contain any information for the truck� Please adhere to the following safety practices and information when performing any maintenance or repair on the Load King Cranes Truck Crane� If in doubt, contact your local Load King Cranes dealer for assistance�...
Page 174: Winch System Maintenance And 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 of this system requires a counterbalance valve to insure that the brake is totally released when winching down, with or without a load�...
Page 175 Hydraulic Tank Winch Brake Valve Section Case Drain Return Filter Winch Motor Winch Down Line Counterbalance Valve Winch Up Line...
Page 176 PAGE INTENTIONALLY LEFT BLANK...
Page 177: 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 178 35-127 M Service / Parts Open Center Hydraulics/Neutral Filter A1 Filter Open Center Valve A2 Open Center Valve Load A3 Tank Tank A4 Pump Pump Open Center Hydraulics/Operate Actuator...
Page 179: Control Valves And Pressures
Control Valves and Pressures The relief pressure settings on the RS Boom Truck are very important� They protect the system components 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 180 35-127 M 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 181 PROCEDURE FOR ADJUSTING BOOM VALVE ADJUSTMENTS The system reliefs should be set only when the oil in the hydraulic system is warm or at operating temperature� BOOM VALVE CROSS PORT RELIEF LS port Retract boom - Cross port relief (B) Extend boom - Cross port relief (A) 1�...
Page 182 35-127 M Service / Parts PROCEDURE FOR ADJUSTING OUTRIGGER RELIEFS The system reliefs should be set only when the oil in the hydraulic system is warm or at operating temperature� OUTRIGGER RELIEFS DIVERTER VALVE Outriggger Test Outrigger Jack Adjust Outrigger Extend Adjust MLS Port 1�...
Page 183 PROCEDURE FOR ADJUSTING SWING VALVE 1� Install gauge in LS port (1) in swing valve (swing inlet section of boom/swing valve)� 2� Disconnect brake release line from swing drive� 3� Operate swing and set pressure to 1800 psi�...
Page 184 35-127 M Service / Parts PROCEDURE FOR ADJUSTING THE WINCH VALVE The system relief should be set only when the oil in the hydraulic system is warm or at operating temperature� WINCH VALVE 1� Install gauge in LS port (1) in winch valve�...
Page 185: Outrigger And Cylinder Maintenance And Troubleshooting
Outrigger and Cylinder Maintenance and Troubleshooting Outrigger Position Sensors If your crane is equipped with Outrigger Position Sensors-the rear outrigger box will contain (2) two string tape type sensors for determining the location of each outrigger beam at mid and full extension� Each sensor send signals to the RCI�...
Page 186: Lift Cylinder
35-127 M Service / Parts Lift Cylinder HOW TO ANALYZE TOPPING PERFORMANCE The lift 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 187 LIFT CYLINDER REMOVAL Perform the following steps to remove the lift cylinder: 1� Fully retract and lower the boom onto the boom rest� Disengage the PTO and stop engine� Actuate topping lever in both directions to release trapped pressure� 2� Tag and disconnect the hydraulic lines from the lift cylinder�...
Page 188 10 RETAINER PLATE LIFT 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...
Page 189: Outrigger Cylinder
FUNCTION: Locks outrigger in up position for roading, and down for crane or operation� Requires internal pilot pressure to operate in either direction� INFORMATION: All outrigger cartridges are the same on Load King Boom Trucks� DO NOT REMOVE CARTRIDGES WITHOUT SUPPORTING THE OUTRIGGERS IN AN UNLOADED CONDITION�...
Page 190 35-127 M Service / Parts Some things to check might be: 1� Steel lines and fittings� 2� Welds (Base to cylinder barrel)� 3� End gland of cylinder� 4� 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: 1�...
Page 191 4� 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� DO NOT DRIVE THE WEDGE TO THE POINT OF BOWING THE METAL IN THE LEG� Take up the slack in the strap with a hoist�...
Page 192 35-127 M Service / Parts 6� 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� 7� Install the pin through the links and outrigger boss and install the snap rings�...
Page 193 REASSEMBLY & INSTALLATION OF AUXILIARY OUTRIGGERS 1� Extend cylinder 1”-2” and insert into inner leg� Cylinder must be oriented so that ports are to outside when inner leg is installed� 2� 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�...
Page 194 35-127 M Service / Parts CHECKING LOAD HOLDING To test the cylinder for holding, the following procedures should be used: 1� Raise boom to maximum angle and extend the boom approximately 3’� Attach a live load, as used in the topping test, to the load line and lift rated load� Raise the load 4”-5” off the ground� Shut off the engine and move the control lever to release hydraulic pressure trapped in the hose�...
Page 195 For removal of the extension cylinder assembly see Boom Disassembly Procedure� Contact Load King Service Parts 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...
Page 196: Rotation Gear And Gearbox
35-127 M Service / Parts Rotation Gear and Gearbox Removal/Installation of Rotation Gear and Gearbox NOTE: The following instructions assume the boom has been removed from the turret. 1� Thoroughly steam clean unit in rotation gear area� 2� 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 197 TORQUING SEQUENCE FOR ROTATION GEAR 8� Lift the turret and rotation gear into position over the mainframe� Mounting surfaces must be clean and flat� 9� 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 198: Inspection Of Rotation Bearing Clearance
35-127 M Service / Parts Inspection of Rotation Bearing Clearance 1� 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 199 Dial Indicator "C" Clamp 1� Any new bearing being installed on a Load King Boom Truck should not have more than � 004 - �007 radial clearance� 2� Any bearing taken off a unit which has �030 - �050 radial clearance should be screened carefully for roughness while rotating�...
Page 200: Backlash Adjustment
35-127 M Service / Parts 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: 1� Locate the high spot on the rotation gear� This spot is marked with yellow paint at the time of manufacture of the bearing�...
Page 201: Repairs-Adjustments-Remarks Log
Repairs-Adjustments-Remarks Log ITEM REQUIREMENT DATE...
Page 202 PAGE INTENTIONALLY LEFT BLANK...
Page 203: 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 204 35-127 M 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 205 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 206 35-127 M 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 207: 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 208 35-127 M 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 209: Torque Specs -Sae & Metric
Torque Specs -SAE & Metric...
Page 210 35-127 M Appendix...
Page 211: Greer Insight Operation's Manual
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 (242)�...
Page 212 PAGE INTENTIONALLY LEFT BLANK...
Page 213: Notes & Warranty
Notes...
Page 214 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 215 Load King 7701 Independence Ave, Kansas City, MO 64125 Parts: (816) 241- 8387 Service: (833) 281-7911 Email: info@loadkingmfg.com...

LOAD KING 35-127 M Operator's Manual

Quick Links

Troubleshooting

Related Manuals for LOAD KING 35-127 M

Summary of Contents for LOAD KING 35-127 M

Table of Contents