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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

__ Visually Inspect all Structural Members and Welds For Cracks, Alignment and Wear

__ Check Boom For Wear Cracked Welds, Alignment and Missing or Illegible Decals

__ Check Engine Manufacturer’s Manual for additional Maintenance Requirements

__ Clean Machine Weekly if Salt Covered to Prevent Rust and Corrosion

Summary of Contents for 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: ...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 To minimize exp...

Page 4: ...ruck cranes For more information please visit Load King s website www loadkingmfg com About Custom Truck One Source CustomTruckOneSourceisthefirsttruesingle sourceproviderofspecializedtruckandheavyequ...

Page 5: ...l Protection Equipment 24 Workplace Safety 25 Effects of Wind Conditions 34 Lightning Storm 36 Temporary Interruption of Crane Operations 37 Resuming Crane Operations 40 Ending Crane Operations 41 Tur...

Page 6: ...ection Record 92 Mobile Crane Load Test Inspection 93 6 Operating Instructions 97 Job Site 97 Job Site Setup Procedure 97 Outrigger Positioning 98 Work Site Position 99 Cold Weather Operation 100 Gene...

Page 7: ...ic Oil Requirements 138 90 Day Maintenance Items 142 Semi Annual Maintenance Items 143 Filters and Maintenance 144 Rotation System Maintenance and Troubleshooting 147 Swing System 147 Care and Mainten...

Page 8: ...Maintenance and Troubleshooting 185 Outrigger Position Sensors 185 Lift Cylinder 186 Outrigger Cylinder 189 Rotation Gear and Gearbox 196 Removal Installation of Rotation Gear and Gearbox 196 Inspecti...

Page 9: ...d keep the equipment working efficiently These inspection programs should be designed to discover worn cracked broken or deteriorated parts and loose or missing fasteners before they result in a probl...

Page 10: ...telescopic boom with hydraulic winch lift cylinder hook block assembly and jib arrangement 3 PEDESTAL The structure that supports the turret weldment outriggers and operator platforms on the truck 4 F...

Page 11: ...I ASME B30 5 Mobile Locomotive Crane Latest Version These standards may be purchased by Mail American Society of Mechanical Engineers Customer Service Department 22 Law Drive Fairfield New Jersey 0700...

Page 12: ...in 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 in...

Page 13: ...ation contained in bulletins is tied to specific machines using the machine model number and PIN serial number Distribution of bulletins is based on the most current owner of record along with their a...

Page 14: ...dent Reporting Questions regarding product applications and safety Standards and regulations compliance information Questions regarding product modifications Current owner updates such as changes in m...

Page 15: ...w 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...

Page 16: ...Y DATA RECORD Warranty Form Submission Date Date of Delivery Model Number S N Dealer Address Customer Address Record this information at the time that warranty registration form is completed and retur...

Page 17: ...ng in this manual that is not clear or you believe should be added please send your comments to Load King Cranes 7701 Independence Ave Kansas City MO 64125 or contact us by telephone at Parts 816 241...

Page 18: ...devices on decals and labels affixed to the machine to assist in hazard recognition and prevention 1 DANGER Indicates a hazardous situation that if not avoided will result in death or serious injury...

Page 19: ...Turret and Boom CRUSH HAZARD Death or Serious Injury can result from contact with moving machine Keep clear of moving machine Safety Alert Symbol Use personnel lift in compliance with OSHA and ANSI re...

Page 20: ...m fan and belt when engines running Stop engine before servicing Explosion Burn Hazard Will cause death burns or blindness due to ignition of explosive gases or contact with corrosive acid Keep all op...

Page 21: ...ow surfaces to cool before servicing Falling from height Use personnel lift or appropriate ladder to reach high places Maintain 3 Point Contact when using access system Two blocking the crane can caus...

Page 22: ...ar of Outriggers Electrical Shock Electrocution from Crane to Power Line Contact Stay Sufficient Distance From Electrical Power Lines These are general safety rules that must be followed You are also...

Page 23: ...nance 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...

Page 24: ...PPE Safety Glasses Impact resistant lenses offering limited protection for the user s eyes from flying debris Ear Plugs A device that is inserted into the ear canal to protect the user s hearing from...

Page 25: ...etermine what the crane can safely lift before attempting the actual lift 7 The operator must understand crane signals and take signals only from designated signal people However the operator must obe...

Page 26: ...ovements smoothly and swing at speeds that will keep the load under control 16 Keep at least two full wraps of wire rope on drum when operating 17 Use tag lines to keep loads under control when feasib...

Page 27: ...ponsibilities and be instructed to report any unsafe conditions to supervisor 6 Supply the weight and the characteristics of all loads to be lifted to the operator 7 Verify that all crew members are f...

Page 28: ...nt away from the work area 18 Position the machine to use shortest boom and radius possible OPERATOR PRELIFT CHECK 1 Check the machine log book to see if periodic maintenance and inspections have been...

Page 29: ...e hook and rigging the boom and or jib length parts of line and the work area 5 Use next lower rated capacity when working at boom lengths or radius between the figures on the rated lifting capacity c...

Page 30: ...WARNING INJURY CAN OCCUR POWER LINE SAFETY 1 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 Reg...

Page 31: ...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 25FT 7 6 m 500 TO 750 kV 35 FT 10 7 m 750 TO 1000 kV 45FT 1 37 m 1000 kV Refer...

Page 32: ...per OSHA regulation 1926 1408 and 1926 1409 TRAVEL 1 Care must be taken when cranes are driven traveled whether on or off the job site 2 Always pre plan the path of travel to determine the best route...

Page 33: ...ement 4 When an ATB device two blocking damage prevention or two block warning device is inoperative or malfunctioning the designated person responsible for supervising the lifting operations shall es...

Page 34: ...d capacity tables up to a wind speed of 20 mph 32 km h on a load surface of 11 7 ft 2 ton Check the forecast and monitor wind speed conditions near the job site When wind speed exceeds 20 mph 32 km h...

Page 35: ...rises vertically 1 Very Light 1 3 1 5 Wind direction indicated by the smoke and not by the banner 2 Light Breeze 4 7 6 11 The wind can be felt on the face the leaves rustle the banner moves 3 Gentle B...

Page 36: ...g procedures Getting into the operator s cab or attempting to get onto the carrier superstructure or boom assembly If on the machine do not try to get off the machine If you are in the operator s cab...

Page 37: ...harged The parking brake of the crane chassis shall be applied Transmission gear shall be set to neutral The wheels shall be secured with chocks the slew brake applied and the main boom secured If the...

Page 38: ...efore wind speeds exceed the permitted values This may not be possible depending on job site and crane setup If due to unforeseen weather conditions the wind speeds are in excess of the permitted valu...

Page 39: ...pinned 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 The crane may topple over The crane...

Page 40: ...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...

Page 41: ...telescopic boom all the way in 3 _________ Is work site crane boom all the way down and disassembled if necessary 4 _________ Is parking brake on crane chassis set 5 _________ Is crane engine off and...

Page 42: ...not have visual access to all the areas into which he will be travelling a guide who is in communication with the driver at all times must be used who can see those areas the driver cannot An acoustic...

Page 43: ...is parked The ground on which the crane is parked must be even and solid with sufficient load bearing capacity Mobile cranes can roll away if not properly prepared causing injury death or property dam...

Page 44: ...ock Out Tag Out is a procedure that s designed to prevent the unexpected or accidental startup of equipment and to alert all workers whenever it is unsafe to operate any piece of equipment When used a...

Page 45: ...guards are back in place 2 All work is complete and tools are put away 3 All workers are notified that a lock is being removed 4 All workers are positioned safely for startup 5 Controls are positione...

Page 46: ...n and dry Remove all oil grease mud ice and snow from walking surfaces 4 Store all tools rigging and other items in the tool box 5 Replace all broken ladders or other access system components 6 Keep n...

Page 47: ...nse thoroughly and dry in the shade 5 Do not bleach or re dye because such processing may severely weaken the assembly 6 Inspect the seat belt assembly frequently Anytime it does not operate properly...

Page 48: ...PAGE INTENTIONALLY LEFT BLANK...

Page 49: ...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...

Page 50: ...27 M Assembly Dead Ending Wire Rope in Socket Below are shown the three different ways to dead end wire rope 1 Loop Back Method 3 Special Clip Method 2 Extra Piece Same Size Rope Clipped to Main Rope...

Page 51: ...ightly BeforefittingtheJibassemblyonthemainboomhead windspeedindicatorand orhazardlight optional including bracket must be completely removed from the main boom head At a later point when the Jib is f...

Page 52: ...ottom 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 Arrow...

Page 53: ...wo 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 Insta...

Page 54: ...ot 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 C...

Page 55: ...EL 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 Do not remove pins until Step 7 has been...

Page 56: ...ult to get the top pin of the jib to the boom head installed Proceed with installing the lower curb side pin and retainer of the jib to boom head Retract the rear outrigger jack cylinders while the fr...

Page 57: ...d 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 ma...

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 1 Plug 3 Switch 2 Retaining P...

Page 59: ...of jib and install in open receptacle on boom head 1 Jib Base Receptacle 2 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 t...

Page 60: ...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 to ensur...

Page 61: ...t 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...

Page 62: ...62 35 127 M Assembly 12 Route cable through jib cable retainer and over jib sheave Install sheave pin and retainer 1 Cable Retainer 2 Pin 13 Attach ball or block to wire rope with pin and retainer...

Page 63: ...63 Description Of Machine and Controls Operator Controls 5 3 2 4 8 7 1 9 10 6...

Page 64: ...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 HAND...

Page 65: ...ng for manual transmissions 3 Engage PTO by Pulling Out knob on dash or by engaging PTO switch 4 There may be an indicator light on the dash depending on truck chassis model that will illuminate when...

Page 66: ...hine 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 inadverten...

Page 67: ...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: ...elief settings A SWING TEST PRESSURE PORT B WINCH TEST PRESSURE PORT C BOOM TEST PRESSURE PORT 6 OUTRIGGER EXTEND CONTROLS Push handle forward to lower pull handle back to raise A FRONT CURB SIDE B FR...

Page 69: ...g depress button on control knob while actuating control lever Release button to return to normal speed winching Frequent use of combined flow 2 speed winch will cause hydraulic oil to overheat Functi...

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 opti...

Page 71: ...city 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 manual located in back of this manu...

Page 72: ...periodically to make sure they are free turning and smooth Rough or sticking sheaves should be replaced as they could damage the ATB cable LIMIT SWITCH An ATB switch is mounted on the left side of the...

Page 73: ...nch up and boom down The 2 speed winch solenoid is also isolated to prevent interference with the boom functions The function of unloading oil is done by a pilot operated cartridge referred to as a po...

Page 74: ...74 35 127 M Description Of Machine and Controls 1 3 4 5 2 Boom Control Valve 1 Winch 4 Boom Control Valve 2 Winch Valve 5 Manifold 3 Function Cutt Off Valve...

Page 75: ...ION CODE SATISFACTORY ADJUST REPAIR VISUAL INSPECTION Complete Machine D Inspect OVERALL machine including carrier for cracks weld separation leaks damage and vandalism HYDRAULIC SYSTEM Leaks or Damag...

Page 76: ...D ATTACHMENT PIN BOLTS D MUFFLER EXHAUST SYSTEM D ALL CONTROL MECHANISMS D INSTRUMENT GAUGES D CLUTCHES BRAKES D WIRE ROPE SHEAVES GUARDS D TWO BLOCK DAMAGE PREVENTION SYSTEM D LOAD SUPPORTING COMPON...

Page 77: ...DJUST REPAIR HORN D PROPER CABLE SPOOLING D WEDGE SOCKETS D AXLE FLUID LEVEL W SWING REDUCER FLUID LEVEL W DRIVE SHAFTS U JOINTS W TIRE WHEEL CONDITION INFLATION PRESSURE W AIR REGULATORS W AIR CLEANE...

Page 78: ...ISSION FILTER P ENGINE OIL FILTER P ENGINE FUEL FILTER P SWING BEARING BOLT TORQUE P MACHINERY GUARDS P LOAD CHART SAFETY WARNINGS P INSPECTION CODE INTERVALS D DAILY W WEEKLY M MONTHLY A ANNUALLY P P...

Page 79: ...79 REPAIRS ADJUSTMENTS REMARKS ITEM REQUIREMENT DATE...

Page 80: ...brication as required in the Lubrication Recommendations Lubricate cylinder mounting bushings and pins LINES AND BLOCKS Inspect the hoist lines hoist block and ball hook and the crane attachment in ge...

Page 81: ...ble warning devices by lifting each of the counter weights This crane is equipped with a disconnect system on the control linkages A check of this system should be made prior to lifting Hoist the hook...

Page 82: ...Hydraulic Hose topic in Maintenance section of this manual __ Check Transmission Oil Level __ Drain Fuel Filters or Water Separator __ Check Boom Front Slider Pads __ Check Boom Chains And Ends __ Dr...

Page 83: ...tem Safety Valve __ Check Torque on Wheel Lug Nuts __ Check Hydraulic Cylinders and Rods __ Make Thorough Inspection of Wire Rope __ Visually Inspect all Structural Members and Welds For Cracks Alignm...

Page 84: ...cks __ 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: ...heck 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...

Page 86: ...ean 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 __ To...

Page 87: ...orm 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 __ Chang...

Page 88: ...lides Lubricate the main boom head Lubricate sliding surfaces EVERY 1000 HOURS Check the sheaves roller bearings or bushings and are properly lubricated EVERY 1500 HOURS Check wear pads shims wear pad...

Page 89: ...ually inspect all boom sections at least weekly or every fifty 50 hours whichever occurs first Preparatory to making the inspection set the outriggers and rotate the upper to an area where the boom ca...

Page 90: ...t any wire rope where failure might endanger personnel equipment or the load must be removed from service when any of the listed conditions are detected We recommend a daily visual inspection of the e...

Page 91: ...s 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 REDUCT...

Page 92: ...ser 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 Inspe...

Page 93: ...ad bearing structure of mobile cranes satisfies all applicable international standards EN ISO FEM etc and does not provide for continuous operation The cranes therefore have a service life which is de...

Page 94: ...s including the safety equipment and can necessitate non destructive inspections such as magnetic particle or ultrasonic inspections Any malfunction or irregularity discovered during the inspection mu...

Page 95: ...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 grea...

Page 96: ...PAGE INTENTIONALLY LEFT BLANK...

Page 97: ...se the crane enough to lift the tires off the ground 5 Always pay out winch line before extending boom Failure to do so will result in the load block contacting the ATB switch which will shut down the...

Page 98: ...DLING OVER SIDE OR REAR OF UNIT The main outriggers should be extended first then the auxiliary stabilizers Optional front bumper stabilizer if equipped must be extended last Raise the crane enough to...

Page 99: ...ion 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...

Page 100: ...ng 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 In extreme cold extra care must be taken to av...

Page 101: ...that three 3 full wraps of rope remain on winch drum at all times Maintain tension on the load line at all times to prevent rope from becoming twisted or kinked and to keep cable properly seated on d...

Page 102: ...OOM IS PROPERLY SUPPORTED AND BLOCKED AN UNSUPPORTED BOOM CAN FALL UNCONTROLLED CAUSING DEATH OR SERIOUS INJURY OR PROPERTY DAMAGE EXTENSION CYLINDER HOLDING VALVES A holding valve is mounted to the c...

Page 103: ...ance of their duties 4 Supervisors with a designated experienced person present Operators and trainees will meet the following qualifications 1 An operator shall be physically and mentally capable of...

Page 104: ...D PROPER OPERATING PROCEDURES RATED CAPACITY INDICATOR Greer Insight This system is designed to provide the operator with information on the load he she is lifting and also help prevent overloading of...

Page 105: ...always be metered when beginning or terminating movement to prevent sudden starting or stopping which imposes undue shock loads on the equipment This is especially true when handling heavy loads and i...

Page 106: ...n be lifted if that radius is maintained The following is an example of how to use the load chart Sample load chart on following page 1 Assume you have extended the boom until the orange stripe 86 Boo...

Page 107: ...s etc The weight of load handling equipment must be deducted from the maximum load rating to determine how much payload you can lift Swinging of a suspended load can cause the load to drift away from...

Page 108: ...108 35 127 M Operating Instructions Operating Radius 1 Center Line of Rotation 4 Read Operating Radius Here 2 Load Indicator 5 Weight suspended 3 Load Line...

Page 109: ...109 Boom Angle Placards CAUTION Do not extend jib into this area unless boom is fully retracted...

Page 110: ...ow 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: ...TIONAL FRONT BUMPER MOUNTED STABILIZER IT MUST BE EXTENDED LAST TO PREVENT STRUCTURAL DAMAGE While operating the crane frequently check that proper level condition is maintained NOTE Console mounted b...

Page 112: ...lace other hand motionless in front of hand giving the motion signal Hoist slowly shown as example Arm extended thumb pointed up flex fingers in and out as long as load movement necessary Arm extended...

Page 113: ...HOIST LOWER USE MAIN HOIST USE AUXILIARY HOIST Whipline RAISE BOOM LOWER BOOM MOVE SLOWLY RAISE BOOM AND LOWER BOOM AND SWING DOG EVERYTHING STOP EMERGENCY STOP LOWER LOAD RAISE LOAD Telescoping Boom...

Page 114: ...then use standard signals Arm extended fingers closed thumb pointed up Arm extended fingers closed thumb pointed down Use one hand to give any standard motion signal and place other hand motionless i...

Page 115: ...OAD RAISE LOAD Telescoping Boom EXTEND BOOM Telescoping Boom RETRACT BOOM Telescoping Boom EXTEND BOOM Telescoping Boom RETRACT BOOM One Hand Signal One fist in front of chest with thumb tapping chest...

Page 116: ...radius and parts of line required based upon your load weight 3 Check the configuration setting number for the Microguard 586 RCI It must match the actual crane configuration Including parts of line...

Page 117: ...om angle shall be determined by measurement 4 When an ATB device two blocking damage prevention or two block warning device is inoperative or malfunctioning the designated person responsible for super...

Page 118: ...you adjust this cartridge it may be used as an emergency retraction device in the case of ruptured lines or pump failure This may be accomplished with the following procedures 1 Have qualified operato...

Page 119: ...gh we DO NOT recommend that you adjust this cartridge it may be used as an emergency loweringdeviceinthecaseofrupturedlinesorpumpfailure Thismaybeaccomplishedwiththefollowing procedures 1 Have qualifi...

Page 120: ...m about 1 foot above the boom rest Attach a tag line to the boom 3 Plumb a PORT A POWER or other hydraulic source into the brake port on the rotation gearbox 4 Remove counterbalance valve cartridges f...

Page 121: ...aulic pump failure This may be accomplished with the following procedures 1 Have qualified operator per ANSI B30 5 hold the outrigger handle in the retract position 2 Loosen the jam nut on the extend...

Page 122: ...LEVATED OR LOAD SUSPENDED WHEN UNIT IS UNATTENDED 3 Fully retract all outriggers IF UNIT IS EQUIPPED WITH OPTIONAL FRONT BUMPER MOUNTED STABILIZER IT MUST BE EXTENDED LAST TO PREVENT STRUCTURAL DAMAGE...

Page 123: ...ed 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 t...

Page 124: ...PAGE INTENTIONALLY LEFT BLANK...

Page 125: ...procedure unless authorized to do so Make sure all applicable instructions have been read and are understood thoroughly 8 DONOTcheckforhydraulicleakswithhands Oilunderpressurecanpenetratehumanskincau...

Page 126: ...NOT weld or have open flame close to hydraulic lines and components without first placing a protective cover over them 12 DO NOT remove cylinders until working parts are resting on the ground or are...

Page 127: ...es hoses or tubes tag them for proper identification at reassembly 2 Before removing a component pump motor valve etc match mark its mounting position in relation to the adjacent component 3 Before di...

Page 128: ...old fluids refilling with recommended fluids or by applying recommended greases Use of improper fluids for ambient conditions can damage equipment COLD WEATHER PACKAGE COMPONENTS Description SPEC NO...

Page 129: ...ch component for damage that may have occurred during shipping Remove all shipping material from the ports of the components before installing them 4 Fittings hoses and tubes that are not equipped wit...

Page 130: ...o prevent dirt and water from entering 2 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 3...

Page 131: ...131 35 127 M Master Lube Chart 1 2 5 11 12 3 4 6 8 9 7...

Page 132: ...132 35 127 M Maintenance...

Page 133: ...st clear tires from ground and shut the engine off Move outrigger handles to unload any oil trapped in the hoses This is an opportunity to ensure the outrigger holding cartridges are not leaking under...

Page 134: ...t in the rotation gear mechanism If over 4 of movement side to side isdetectedbymovingtheboomtipbackandforthwhenfullyretracted itwouldbeconsidered excessive See Care and Maintenance of the Rotation Sy...

Page 135: ...Cover Screws 2 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 c...

Page 136: ...irregularities and 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 p...

Page 137: ...ement 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...

Page 138: ...ydraulic oil at the proper level to keep the hydraulic fluid clean see Hydraulic Maintenance section and to avoid overheating the oil The oil for the hydraulic system performs multiple functions While...

Page 139: ...rtain operating temperatures and conditions duty cycles it may be advisable to use another fluid in order to maintain the oil viscosity in the recommended range see Oil Viscosity Selection Chart on pa...

Page 140: ...lic Oils OIL COMPANY ISO BRAND NAME Conoco 32 46 68 Conoco DN 600 Arctic Conoco Super Hyd 5W 20 Multi Viscosity Conoco Super Hyd 32 Conoco Super Hyd 46 Conoco Super Hyd 68 Exxon Co USA 32 46 68 Nuto H...

Page 141: ...MPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME Mobil Oil Corp 32 46 68 DTE 24 DTE 13M DTE 25 DTE 15M DTE 26 DTE 16M Texaco Inc USA 32 46 68 Rando Oil HD A2 5w 20 Rando Oil HD 32 Rando Oil HD 46 Rando...

Page 142: ...eakage due to worn hoses or loose fittings Correct as necessary 4 Check the load block and the downhaul weight for signs of overloading spread side plates elongated holes bent tie bolts or cracks 5 An...

Page 143: ...n page 209 2 Check Hydraulic system pressures and adjust as necessary 3 Inspect all visible wear pads for excessive wear or looseness ALL MAINTENANCE AND INSPECTION INTERVALS ARE BASED ON NORMAL USE E...

Page 144: ...s cylinders and lines thus increasing the rate of wear on the components If the oil shows that water is present or if any other contaminates are suspected the oil should be changed Whenever the oil is...

Page 145: ...in regards to used oil and other fluids IMPROPER OR INADEQUATE MAINTENANCE OF THE HYDRAULIC OIL OR OIL FILTER WILL RESULT IN PREMATURE WEAR TO VALVES CYLINDERS MOTORS ETC SELECTING THE OIL When buying...

Page 146: ...il added is compatible with the oil already in the system When changing oil if a different brand is used the system should be flushed by cycling all cylinders at least once to their limits to insure t...

Page 147: ...g pilot pressure to release the parking brake At the same time this pilot pressure opens the counterbalance valve on the returnside allowingthemotortoswingtheboom Returnoilthenflowsthroughtheothercoun...

Page 148: ...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 SWING SYST...

Page 149: ...duce the longest possible life of the rotation bearing and rotation gearbox 1 Load King recommends that the torque be checked on the rotation gear hold down bolts every 90 days Thisinspectionshouldber...

Page 150: ...150 35 127 M Maintenance...

Page 151: ...2 be used Under normal operation the rotation bearing should be greased once a week The grease zerks are located at the streetside operator s console or driver s side by the inspection opening of the...

Page 152: ...ant like Shell S2 G 150 It is advisable to check this fluid level about once a month unless leakage around the gearbox is noted 3 All swing drive gearboxes from Load King are shipped with an additive...

Page 153: ...arbox Motor 1 Conditioning Box 7 Swing Sensor WAD 2 Brake Pressure 8 Oil Level Plug 3 Cartridge Valve 9 Breather Oil Fill Location 4 Motor Pressure Port 10 Grease Zerk 11 Oil Drain Port 6 Cartridge Va...

Page 154: ...e 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 Precheck procedure to verify Swing Work Area...

Page 155: ...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 Repeat steps 4 and 5 until the...

Page 156: ...is anything other than zero the WAD ISS is not functioning as intended Proceed to instructions for replacing the WAD sensor Part No T145537 Until unit passes the test procedure unit may only be opera...

Page 157: ...nsor 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 Unthread and disconnect the sensor from the swing d...

Page 158: ...ed end of the sensor into the sensor port of the swing drive see Fig 7 by hand thread it clockwise until the end of the sensor contact the gear inside the swing drive housing Do not force the sensor a...

Page 159: ...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...

Page 160: ...THAT EXCESSIVELY HEAVY OR THICK GEAR OIL MAY CONTRIBUTE TO INTERMITTENT BRAKE CLUTCH SLIPPAGE MAKE CERTAIN THAT THE GEAR OIL VISCOSITY USED IN YOUR HOIST IS CORRECT FOR YOUR PREVAILING AMBIENT TEMPERA...

Page 161: ...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 General guidelines are printed in your mainte...

Page 162: ...The TRANSMISSION should be prepared as prescribed in the topic Transmission Storage on page 168 LONG TERM STORAGE 30 DAYS OR MORE Long term storage requires greater preparation than short term storag...

Page 163: ...ve the MACHINE from storage via the following procedure 1 Remove preservative lubricants from all surfaces 2 Check all fluid levels adding or draining as required 3 Lubricate the machine according to...

Page 164: ...NOTE Do not drain the fuel system or the crankcase after this run 4 Check the air cleaner and service it if necessary as outlined under Air System 5 If freezing weather is expected during the storage...

Page 165: ...15 With an all purpose grease such as Shell Alvania No 2 or equivalent lubricate the clutch throwout bearing clutch pilot bearing drive shaft main bearing clutch release shaft and the outboard bearing...

Page 166: ...Covertheenginewithagoodweather resistanttarpaulinorothercoverifitmustbestoredoutdoors A clear plastic cover is recommended for indoor storage The stored engine should be inspected periodically If ther...

Page 167: ...specified under Diesel Fuel Oil Specifications 9 Close all of the drain cocks and fill the engine cooling system with clean soft water and a rust inhibitor If the engine is to be exposed to freezing t...

Page 168: ...viscosity rating for the prevailing ambient temperature i e a 10W20 should be used where a 10W monograde is used If a C 4 multigrade is used in place of J20 lubricant it is recommended that the visco...

Page 169: ...169 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: ...n if at all possible The steps outline below cover the procedures to be followed for Protecting New Equipment from corrosion if it must be stored in the extended position 1 Position the equipment as i...

Page 171: ...ve slow functions it is important to know the pump is receiving the proper RPM and how much flow to expect from the pump The following charts will allow you to accurately test the flow of the pump as...

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Page 173: ...e valve Brake locked sprage clutch defective Relief settings too low Gears damaged or locked in gear case Defective drive motor No response slow or erratic operation of swing function Swing brake lock...

Page 174: ...ease The sprag clutch connects the brake to the winch drum Being a special one way clutch it allows the winch to free wheel in the up direction and lock in the winch down direction 2 Counterbalance va...

Page 175: ...175 1 Hydraulic Tank 6 Winch Brake 2 Valve Section 7 Case Drain 3 Return Filter 8 Winch Motor 4 Counterbalance Valve 9 Winch Down Line 5 Winch Up Line...

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Page 177: ...ted to an enclosed function line the pressure of the pump will rise to meet the load requirement As long as the control valve handle is held open and the load is unchanged constant this working pressu...

Page 178: ...35 127 M Service Parts A Open Center Hydraulics Neutral B1 Filter A1 Filter B2 Open Center Valve A2 Open Center Valve B3 Load A3 Tank B4 Tank A4 Pump B5 Pump B Open Center Hydraulics Operate B6 Actua...

Page 179: ...CENTER CLOSED PORT 3500 PSI BOOM EXTEND CROSS PORT RELIEF PORT A 2700 PSI BOOM RETRACT CROSS PORT RELIEF PORT B 2250 PSI SWING OPEN CENTER OPEN PORT MOTOR 1800 PSI OUTRIGGER RELIEF IN DIVERTER VALVE...

Page 180: ...rooves Examine o rings and back up rings for any signs of damage Replace damaged or faulty parts All moving parts should slide freely with only seal friction present If possible remove minor nicks or...

Page 181: ...1 LS port 4 Retract boom Cross port relief B 2 Extend boom Cross port relief A 1 Install gauge in LS port 1 on boom valve Mid section of boom swing valve 2 Engine at full throttle Approx 1650 rpm dep...

Page 182: ...upward to relief pressure LEAVE ALL OTHER CONTROL LEVERS IN THE NEUTRAL POSITION 3 Check the reading on the test gauge See pressure table for proper settings NOTE Move the lever to the neutral positio...

Page 183: ...URE FOR ADJUSTING SWING VALVE 1 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...

Page 184: ...in the hydraulic system is warm or at operating temperature 1 WINCH VALVE 1 Install gauge in LS port 1 in winch valve 2 Disconnect brake release hoses 3 Operate winch DOWN and set pressure to 3000 ps...

Page 185: ...of each outrigger beam at mid and full extension Each sensor send signals to the RCI When both rear outrigger beam are at HALF extension a corresponding lift chart is provided When both rear outrigge...

Page 186: ...t off the ground Accurately measure and record the distance from the ground Shut off the engine and move the control levers to release the hydraulic pressure trapped in the hoses The load should not d...

Page 187: ...capped to prevent any fluid loss or slippery surfaces around the work area also to prevent contamination from entering the hydraulic system Plug the resulting open ports of the cylinder to prevent th...

Page 188: ...RETATINER RING 5 RETAINER PLATE BOLTS 10 RETAINER PLATE LIFT CYLINDER OVERHAUL PROCEDURE Contact Load King Service Department to receive overhaul information for the cylinder on the unit Have the cyl...

Page 189: ...rtridges are the same on Load King Boom Trucks DO NOT REMOVE CARTRIDGES WITHOUT SUPPORTING THE OUTRIGGERS IN AN UNLOADED CONDITION CARTRIDGES DO NOT BLEED OFF PRESSURE BY REMOVING SLOWLY THEY CAN EJEC...

Page 190: ...a means of externally trying to extend the cylinder Porta Power or Block Tackle 3 Disconnect retract port hose at valve If oil runs out of the cylinder retract pressure port The stow holding cartridge...

Page 191: ...pads for damage If pads are worn and have excessive clearance they should be shimmed or replaced 10 Move the cylinder to overhaul bench REASSEMBLY INSTALLATION OF MAIN OUTRIGGERS 1 Apply a thin film o...

Page 192: ...4 Thread Cap 9 Gland 5 Set Screw REMOVAL DISASSEMBLY OF AUXILIARY OUTRIGGERS 1 Either work with the rear outriggers over a pit or raise the rear of the truck so that there is at least 36 of clearance...

Page 193: ...loose and remove 4 Inspect slider pad for wear and or damage If worn to less than 3 8 thickness over 25 of surface replace with new pad 5 Use a heavy gun grease chassis lube applied to back flat side...

Page 194: ...s b Internal leaks bypassing within the cylinder or holding cartridge There are two things that must be checked in order to isolate the source of the leakage i Holding Cartridge ii Piston bypassing fr...

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...

Page 196: ...of bolts 5 Lift turret bearing assembly off mainframe and set aside where bearing can be removed from turret 6 Both the turret and mainframe bearing mounting surfaces must be carefully inspected for f...

Page 197: ...slots are provided in the turret for installing the bolts in the inner ring 11 Tighten the nuts for the inner ring to 100 ft lbs first then tighten the nuts to 610 ft lbs dry or 450 ft lbs lubed Use t...

Page 198: ...e table with clamps assuring that the inner raceway rotates freely after clamping it to the table As shown in the figure below attach a large C clamp in position 1 and tighten just enough to take all...

Page 199: ...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 whil...

Page 200: ...earbox installed 2 Be sure the high spot is aligned to the pinion turn the eccentric cam ring until the gears are in mesh and there is no clearance at all 3 Install a dial indicator as shown in the fo...

Page 201: ...201 Repairs Adjustments Remarks Log ITEM REQUIREMENT DATE...

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Page 203: ...94 2 778 1 8 0 1250 3 175 9 64 0 0406 3 572 5 32 0 1563 3 969 11 64 0 1719 4 366 3 16 0 1875 4 762 13 64 0 2031 5 159 7 32 0 2188 5 556 15 64 0 2344 5 953 1 4 0 2500 6 350 17 64 0 2656 6 747 9 32 0 28...

Page 204: ...6 16 272 21 32 0 6563 16 688 43 64 0 6719 17 085 11 16 0 6875 17 462 45 64 0 7031 17 859 23 32 0 7188 18 256 47 64 0 7344 18 653 3 4 0 7500 19 050 49 64 0 7656 19 447 25 32 0 7813 19 843 51 64 0 7969...

Page 205: ...tre 0 2642 gallon 1 litre 61 023 cu in 1 litre 2 202 lbs of water 62o F 1 cu foot 28 32 litres 1 gallon 3 785 litres 1 cu inch 0 0164 litre MEASURES OFWEIGHTS U S 16 ounces 1 pound 2000 pounds 1 short...

Page 206: ...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 f...

Page 207: ...Ready to Pour 2370 96 148 3996 Dolomite Crushed Fine 1521 90 95 2565 Dolomite Broken Lump 1521 90 95 2565 Earth Loamy Dry Loose 1201 50 75 2025 Earth Dry Packed 1521 90 95 2565 Earth Wet Mud 1762 20...

Page 208: ...5 Sand Wet Packed 1922 40 120 3240 Scale Rolling Mill Wet 2114 64 132 3564 Shale Broken 1361 70 85 2295 Slag Blast Furnace Broken 2210 76 138 3726 Slag Open Hearth Crushed 1682 10 105 2835 Slag Granul...

Page 209: ...209 Torque Specs SAE Metric...

Page 210: ...210 35 127 M Appendix...

Page 211: ...211 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...

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Page 213: ...Notes...

Page 214: ...ms 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 is not assi...

Page 215: ...www loadkingmfg com Load King 7701 Independence Ave Kansas City MO 64125 Parts 816 241 8387 Service 833 281 7911 Email info loadkingmfg com...

Page 216: ...35 127 M Operator Manual...

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