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LOAD KING 80-160, Operator'S Manual

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LOAD KING 80-160 Operator'S Manual Download Page 66

66

80-160

Safety

Who must apply a lock & tag

•

Any person working on the equipment.

•

Foreman or other person responsible for the work being done.

•

If several people are working on a machine at the same time, each person must apply his or her

own lock and tag.

When can a lock and tag be removed

After performing these six steps:

1.

All safety 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 positioned for safe startup.

6.

The machine is ready for safe operation.

Who can remove a lock and tag

•

Only the person who applied a lock and tag is permitted to remove them.

The Lock Out & Tag Out rules laid out here are generic. To get instructions for your particular workplace, 

consult your employer’s Lock Out & Tag Out procedure.

Summary of Contents for 80-160

Page 1: ...OPERATORS MANUAL LOAD KING 80 160 REV B DECEMBER 2020...

Page 2: ...Page Intentionally 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: ...0 160 Safety Sign Locations 8 SafetyGuidelines 26 Personal Protection Equipment 27 Workplace Safety 28 Effects of Wind Conditions 37 LightningStorm 39 Temporary Interruption of Crane Operations 40 Res...

Page 6: ...spection 1 Suggested Hydraulic Crane Inspection Checklist 3 Daily Check 8 Hours 8 Weekly Check 40 Hours 9 MonthlyCheck 80hours 10 Quarterly Checks 250 Hours 11 Semiannual Checks 1000 Hours 12 Annual C...

Page 7: ...Operating Conditions 27 Initiating Operation 31 Arm and Hand Signals 32 Lifting the Load 33 Making a Typical Lift 34 Moving the Unit 39 Removable Counterweight 39 VehicularOperation 42 Traveling arou...

Page 8: ...oses 20 Filters and Maintenance 22 Diesel Exhaust Fluid Specification 24 TIRES 28 Tire Maintenance 30 Aluminum Decking Fender Maintenance Procedure 33 Swing Lock Maintenance 34 HVAC 35 Wire rope and r...

Page 9: ...5 11 Troubleshooting Introduction 1 General Procedure 3 Hydraulics General 4 Operator Controls 5 Siwng Circuit 6 Boom Hoist Circuit 7 Telescope Circuit 8 Winch Circuit 9 Outrigger Circuit 11 Swing Pum...

Page 10: ...pection of Rotation Bearing Clearance 20 Swing Reducer 22 ElectricalSystem 23 Fuse Block Operator s Cab 23 Relay FuseBlock Chassis 25 Electrical System Collector Ring 26 Maintenance Free Battery Testi...

Page 11: ...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 12: ...the meanings given whenever they are used 1 SUPERSTRUCTURE Supports swing mechanism operator s cab boom winch and hoist cylinders 2 BOOM The telescopic boom with hydraulic winch lift cylinder hook blo...

Page 13: ...ated 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 u...

Page 14: ...The information 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 wi...

Page 15: ...stions regarding product applications and safety Standards and regulations compliance information Questions regarding product modifications Current owner updates such as changes in machine ownership o...

Page 16: ...ete 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...

Page 17: ...NTY 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 ret...

Page 18: ...Page Intentionally Blank...

Page 19: ...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 8387 S...

Page 20: ...ous hazard that will likely be fatal WARNING Warning is used to alert readers about the potential for serious injury or death or serious damage to equipment CAUTION Caution is used to alert readers ab...

Page 21: ...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 22: ...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 ope...

Page 23: ...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 24: ...r 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 r...

Page 25: ...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 dam...

Page 26: ...26 80 160 Safety 80 160 Safety Sign Locations Right Hand Side View Left Hand Side View...

Page 27: ...27 Rear View Front View...

Page 28: ...28 80 160 Safety Upper Cab...

Page 29: ...jury Relieve pressure before disconnecting hydraulic lines Stay clear of leaks and pin holes Use a piece of cardboard or wood to search for leaks Do not use hand Fluid injected into skin must be surgi...

Page 30: ...30 80 160 Safety Fall Hazard Stay off crane boom jib load line and hook Falling can result in death or serious injury 4...

Page 31: ...extended point with finger in direction of swing of boom Clasp hands in front of body HOIST LOWER USE MAIN HOIST USE AUXILIARY HOIST Whipline RAISE BOOM LOWER BOOM MOVE SLOWLY RAISE BOOM AND LOWER BOO...

Page 32: ...ended thumb pointed up flex fingers in and out as long as load movement necessary B4 LOWER BOOM AND RAISE LOAD Arm extended thumb pointed down flex fingers in and out as long as load movement necessar...

Page 33: ...s manual before using or stowing jib Contact with falling lattice jib can result in death or serious injury Crush Hazard Keep clear of counterweight slabs while lowering Serious injury can result from...

Page 34: ...d Keep hands clear of moving winch load line Contact with moving load line can result in death or serious injury Electrocution Hazard Stay clear of machine Contact with electric power lines will resul...

Page 35: ...compliance with OSHA 1926 1431 and ANSI B30 23 Equipment Damage Hazard Damage to equipment can result if turbo charger is not fully lubricated before loading engine 1 Start engine and run at idle spee...

Page 36: ...eck ATB system after installation of each line and at start of every work shift Read and understand operator s manual Equipment Damage Hazard Damage to equipment can result if turbo charger is not all...

Page 37: ...ath or serious injury Crush Hazard Contact with moving outriggers can result in death or serious injury Stay clear of outrigger path during operation Turn machine off and remove key before servicing F...

Page 38: ...mes and sparks away Wear appropriate personal protective equipment including gloves face shield and long sleeve shirt Read manuals If you do not understand the information in the manuals consult your...

Page 39: ...g load can result in death or serious injury Unexpected machine response from improper operation of free swing or free float boom functions can result in death or serious injury Read and understand ma...

Page 40: ...es and sparks away Stop engine before adding fuel Fuel and fumes can explode and burn resulting in death or serious injury Crush Hazard Contact with falling load can result in death or serious injury...

Page 41: ...before driving this crane Electrocution Hazard Before operating the machine contact the electrical power line owner to disconnect move or insulate power lines Contact with electric power lines will r...

Page 42: ...on this machine can result in death or serious injury No riders Stay out of upper structure cab during machine travel Sudden or unwanted machine movement can result in death or serious injury Lift arm...

Page 43: ...43 26 Fall Hazard Falling can result in death or serious injury Use the provided access system 26...

Page 44: ...ty Safety Guidelines These are general safety rules that must be followed You are also required to read and understand the Operators Manual as there are instructions which are more detailed specific t...

Page 45: ...ty 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 loud noi...

Page 46: ...r can determine 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 m...

Page 47: ...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 feasible 18 Ke...

Page 48: ...ety responsibilities 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 member...

Page 49: ...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 perform...

Page 50: ...t of the 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 cap...

Page 51: ...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 Regulations...

Page 52: ...arance 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...

Page 53: ...A 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 to the...

Page 54: ...alent protection 5 When a boom length indicator is inoperative or malfunctioning the designated person responsible for supervising the lifting operations shall establish the boom length at which the l...

Page 55: ...20 mph 32 km h on a load surface of 11 7 ft 2 ton 1 1 m tonne Check the forecast and monitor wind speed conditions near the job site When wind speed exceeds 20 mph 32 km h derating of the cranes lift...

Page 56: ...Smoke 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 G...

Page 57: ...ures Getting into the operator s cab or attempting to get onto the carrier superstructure or boom assembly If on the machine do not try to get off the machine If you are in the operator s cab during a...

Page 58: ...are recharged 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...

Page 59: ...nd 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 values with...

Page 60: ...s 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 The crane may topple over The...

Page 61: ...on 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 Capacit...

Page 62: ...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 ignition ke...

Page 63: ...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 acoustical back...

Page 64: ...crane 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 prope...

Page 65: ...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 as intend...

Page 66: ...safety 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 po...

Page 67: ...crane where it is necessary for the operator to be when moving from the ground to the operator s cab or from the operator s cab to the ground Access egress to from areas of the crane not accessible t...

Page 68: ...68 80 160 Safety Operator s cab steps and grab handles with lower steps deployed NOTE Use 3 pts of contact when entering both cabs...

Page 69: ...69 4 NOTE Do not use item 4 Console Arm lift handle as a grab handle for entering or exiting the operator s cab...

Page 70: ...70 80 160 Safety Access Egress Rear...

Page 71: ...y 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 non slip...

Page 72: ...snug into place due to recoil assembly 3 Move LH RH arms down once belts is properly positioned 4 To release buckle and exit cab press release button within buckle assembly on RH side 5 For maintenanc...

Page 73: ...oom head wind speed indicator and or hazard light optional including bracket must be completely removed from the main boom head At a later point when the Jib is fitted the hazard light and the rotor o...

Page 74: ...section of tri fold ramp 1 2 5 Install the pin 2 after the folding section align with the middle folding section 2 6 Pull the T handle 3 and rotate to unlock the jib from the storage bracket 3 7 Exte...

Page 75: ...mounting holes of the Jib 5 9 Pull the lever 6 to disengage the secondary pivot pin 6 10 Use jib deployment cylinder 4 to push jib off the ramp Disengage the jib deployment cylinder hook by lifting t...

Page 76: ...th guide rope until the left side mounting holes of jib line up with the boom mounting holes Install lower left hand pin 6 6 12 Remove pin 7 from guide sheave kickstand 7 13 Flip up guide sheave 8 and...

Page 77: ...77 14 Reeve cable through guide sheave 8 and sheave 9 at end of jib base section 8 9 15 Install winch line and socket to jib base dead end 10 10...

Page 78: ...78 80 160 Assembly 16 Winch up using jib remote control until 4th pin comes into alignment and install 4th pin 11 11 17 Remove the guide rope...

Page 79: ...20 and 40 can be set based on the requirement of the operation The above Figure shows that the Jib at 0 offset angle position If need to change the offset angles refer to the below procedure Procedure...

Page 80: ...80 160 Assembly 5 Remove the jib offset pin 4 from the 0 offset hole 1 4 6 Install the offset pin 4 at the 20 offset hole 2 4 7 Refer to the Fig which shows that the jib is at 20 offset angle positio...

Page 81: ...offset pins 4 from the 20 offset hole 2 and keep the pin 4 in the toolbox 4 9 Refer to the Fig which shows that the jib is at 40 offset angle position 10 Reverse the above procedure to return the jib...

Page 82: ...d At a later point when the folding Jib is fitted the hazard light and the rotor of the wind speed indicator must be fitted on to the head of the folding Jib 1 Set the crane on fully extended outrigge...

Page 83: ...lattice sections of the jib 2 6 Swing the tubular section of jib with guide rope until the left side mounting holes line up with the left side mounting holes of lattice sections of the jib 7 Install t...

Page 84: ...84 80 160 Assembly 8 Remove the guide rope 9 Reeve the hoist line over the tubular jib sheave 3 3...

Page 85: ...e wear Deformed or outsized drum and excessive undercutting at the base of the flange also indicate that repair or replacement of the drum is necessary Check the bearings for excessive wear and play A...

Page 86: ...firmly on the free end of the cable to secure the wedge 5 Slowly rotate the drum ensuring the first layer of cable is evenly wound on the drum 6 Install the remainder of the cable as applicable The en...

Page 87: ...n installing wedge type sockets on wire rope Be certain the correct socket and wedge are used 1 Lead the rope 3 through the socket 1 form a large loop and draw the rope end 2 back through the socket A...

Page 88: ...avoid imposing shock loads on the rope until the wedge is firmly in place 5 After the wedge has been firmly seated a short length 6 inches of the cable should be secured to the free end of the wire ro...

Page 89: ...n the wire rope by braking the shipping reel and slowly operate the winch in the raise mode to wind the cable onto the winch drum As the spooling proceeds make sure that adjacent turns are tight again...

Page 90: ...the rope strands to adjust around it 3 Seat the wedge and loop just tightly enough to allow handling by attaching the socket to a strong support and engaging the winch to take a strain on the rope 4 F...

Page 91: ...e Reeving 1 2 8 9 10 4 5 6 7 3 1 Auxiliary Winch 7 Winch Dead End 2 Main Winch 8 Idler Sheave 3 5 Sheave 9 Load Sheave 4 4 Sheave 10 Block Sheave 5 Dead End for Even Parts of Line 6 Dead End for Odd P...

Page 92: ...rane incorporates a Quick Reeving boom head and block which do not require removal of the wedge and socket from the rope in order to change the reeving Removal of two pins in the boom head and three i...

Page 93: ...ifting the ATB weight The light and audible alarms should be actuated in the cab and the boom down boom extend and winch up controls should disconnect As shipped from the factory the crane has suffici...

Page 94: ...an the number of parts called for by the load rating chart The minimum required number of parts is determined by referring to the load rating chart This machine incorporates a Quick Reeving boom head...

Page 95: ...95 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 Method...

Page 96: ...ts on the deck of the crane in order to equalize the axle loading 1 Lower the outrigger jacks to support the weight of the crane 2 Rotate the upper to a position straight over the rear of the crane 3...

Page 97: ...press rocker switch to the UP position to raise the counterweight slabs tightly against the shell of the counterweight 7 Install horizontal pins item 2 and locking pins item 3 on each side to attach...

Page 98: ...98 80 160 Assembly...

Page 99: ...s Controls in the Cab Upper Control Switch Panel Rear Wall Upper Operator s Cab 1 Top Working Light press top part of switch to activate roof work lights 2 Front Working Light press top part of switch...

Page 100: ...se Knob to unlock door from the closed position for exiting cab or to move the door to the open position B Door Open Release Knob to unlock the door from the full open position so door can be closed 5...

Page 101: ...n 6 turns ON AC Mode When pressed it will turn on the selected mode an turn off the previous mode Press a button a second time will turn off the mode leaving on the fan running Fan Only Mode Selecting...

Page 102: ...Description Of Machine and Controls Cab Interior Controls 26 24 7 23 19 25 22 6 Upper Switch Panel A B C D E Upper Switch Panel A Cab Work Light B Roof Wiper C Roof Washer D Windscreen Wiper E Windscr...

Page 103: ...ts not only control direction but also flow They can be closed to direct air where needed most 8 Stereo Radio and CD Player Option 9 Dome Light 10 Storage Compartment 11 Beacon Rotary Light option Bea...

Page 104: ...Hold down lower part of switch to return tilt angle of cab to 0 Do not activate Cab Tilt Switch while swinging the upper structure Due to hydraulic circuit being shared between Cab Tilt and Swing cir...

Page 105: ...DURING CAB TILTING Keep hands and feet clear of exterior operator s cab area during tilting Sound horn before tilting cab to make personnel aware of cab movement 13 Outrigger Extend Retract switch Out...

Page 106: ...106 80 160 Description Of Machine and Controls 14 LH Control Lever Operator s Seat Controls 14 15 16...

Page 107: ...mrest must be in the UP position to prevent accidental manuevers Main Winch Two Speed Switch depressing the switch at the top will cause the winch speed to shift to HI SPEED mode and the red LED light...

Page 108: ...lized prevents damage to the cable when it is on the winch but not rigged over the boom head e g cable tied off to winch drum etch Depress switch to change Auxilary winch speed to HI LED red light wil...

Page 109: ...ake in and pay out speed will be in HIGH speed mode Push joystick forward MAIN WINCH DOWN to lower the load with the main winch The winch wire rope speed for lowering the load is proportional to the t...

Page 110: ...rdorbackward 16 Seat Controls see Operators Seat Controls topic DO NOT COMBINE OPPOSITE FUNCTIONS Example retracting one outrigger beam while simultaneously extending another or lowering one vertical...

Page 111: ...tch Lock Handle retain control of both raise lower handles when unlatching 19 until hatch is fully open Pull down on both handles when closing hatch and rotating 19 lock handles Keep head clear when p...

Page 112: ...tion Of Machine and Controls 18 Windscreen Lock HVAC Vent 18 Windscreen Lock 19 Emergency Stop Button Push to stop Engine operation Push in on red button and rotate clockwise to reset button prior to...

Page 113: ...charge level needle is in the Green zone B Release Latch lift latch to remove extinquisher from mount 21 Roof Sunshade Roof Sunshade 21 22 Swing Brake Pedal depress pedal to apply swing brake 23 Ignit...

Page 114: ...rm to rotate arm to UP position when entering or exiting the cab Warning Donotenterorexitthecabwiththearminthe DOWN orhorizontalposition joystick control is LIVE in this position when engine is runnin...

Page 115: ...nd arm will slide forward or rearward so joystick can be comfortably positioned to operator s preference Retight knob to lock into position 3 Backrest Angle Control Lever Lift lever to release backres...

Page 116: ...t running to prevent any battery drain 6 Lumbar Switch Press top part of rocker switch to inflate the seat backrest lumbar 7 Height Adjustment Press top part of rocker switch to Raise seat base height...

Page 117: ...117 Control Sreens This section is intended to familiarize the operator with the control screens provided for the operation of this machine Outrigger controls screen Home page screen...

Page 118: ...118 80 160 Description Of Machine and Controls Lifting controls screen Cab controls screen...

Page 119: ...sections of this manual have been covered Sections 1 and 3 are especially important with respect to machine operation Diagrams of the various carrier and upper controls are illustrated on the followin...

Page 120: ...60 Description Of Machine and Controls ELECTRICAL SYSTEM ON HEADLIGHTS WASHER IGNITION ON FAST ENGINE DIAGNOSTIC IGNITION SLOW INCR IDLE ADJ INCREASE AXLE DISENGAGE RANGE SHIFT INCR IDLE ADJ DECREASE...

Page 121: ...121 ENGINE STOP KEY OFF DIFF LOCK OFF HIGH SPEED REAR AXLE KEY ON KEY SWITCH LOW SPEED REAR AXLE KEY START PTO OUT DIFF LOCK ON PTO IN ENGINE WARN...

Page 122: ...122 80 160 Description Of Machine and Controls MIRROR HEAT SUSPENSION RAISE LOWER TAG AXLE LIFT ABS DIAGNOSTIC...

Page 123: ...ch on dash 4 Shift transmission into gear if necessary 5 Release parking brake if necessary Split Shaft Mounted Electric Clutch Shift PTO gearbox mounted in drive line Eaton Fuller Manual Transmission...

Page 124: ...124 80 160 Description Of Machine and Controls 1 1 PTO Engage Switch...

Page 125: ...is used to extend retract the jack 2 RETRACT SWITCH This switch is used to retract the outrigger When activated the backlight is BLUE 6 REAR LEFT JACK SWITCH This switch is used to extend retract the...

Page 126: ...126 80 160 Description Of Machine and Controls OUTRIGGER CONTROLS SCREEN Outrigger controls screen...

Page 127: ...ction and a tubular section Total Weight 2 400 lbs 1089 kg The optional jib extension is pinned directly to the ends of the sheave pins When not in use the jib can be unpinned from the boom head and s...

Page 128: ...128 80 160 Description Of Machine and Controls Before stowing the jib ensure that no personnel or obstacles are in the swing path of the jib...

Page 129: ...ck 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 Refer to the Gre...

Page 130: ...ted on the left side of the boom tip The switch is normally open During operation the switch is held closed by a counterweight suspended from the switch lever by a chain The closed limit switch allows...

Page 131: ...unit heater should be adequate for sustained operations LUBRICATION Perform the daily lubrication as required in the Lubrication Recommendations Lubricate cylinder mounting bushings and pins LINES AND...

Page 132: ...or proper tension and to insure that reel is free to rotate Verify visual and audible warning devices by lifting each of the counter weights This crane is equipped with a disconnect system on the cont...

Page 133: ...ODE 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 Damage D A...

Page 134: ...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 135: ...ADJUST 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 CLEAN...

Page 136: ...SSION 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 PE...

Page 137: ...137 REPAIRS ADJUSTMENTS REMARKS ITEM REQUIREMENT DATE...

Page 138: ...ulic 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 __ Drain Ai...

Page 139: ...stem 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 Align...

Page 140: ...ks __ Perform Monthly Lubrication __ Check Engine Belts __ Check Hydraulic Reservoir for Moisture __ Check all Slider Pads __ Have Hydraulic Oil sample Analyzed __ Clean Radiator Oil Cooler Exterior _...

Page 141: ...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 manufacture...

Page 142: ...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 143: ...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 144: ...ides 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 145: ...r box ends at the collar jack cylinder mounting tube and the beam welds Visually inspect all boom sections at least weekly or every fifty 50 hours whichever occurs first Preparatory to making the insp...

Page 146: ...146 80 160 Inspection If any indicator decals are missing or illegible either triangle markers or boom length numbers order the applicable items through your distributor...

Page 147: ...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 entire length of...

Page 148: ...148 80 160 Inspection 1 32 For rope diameters 3 8 through 1 2 3 64 For rope diameters 9 16 through 3 4 1 16 For rope diameters 7 8 through 1 1 8 REDUCTION OF WIRE ROPE DIAMETER...

Page 149: ...al for Criteria PLACE OF INSPECTION DATE DESCRIPTION OF CRANE Make Model Serial No Type and arrangement of attachments Date of Last Rope Inspection Hours and Time of Service Since Last Inspection Resu...

Page 150: ...alculation of the load 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 serv...

Page 151: ...g the safety equipment and can necessitate non destructive inspections such as magnetic particle or ultrasonic inspections Any malfunction or irregularity discovered during the inspection must be eval...

Page 152: ...dance with the safety factors from the product standards It is recommended to involve the crane manufacturer in such tests LoadTest Configurations If a load test is required by law the test conditions...

Page 153: ...end all outriggers to firm contact with solid level surface and level vehicle Raise the crane enough to lift the tires off the ground 6 Always pay out winch line before extending boom Failure to do so...

Page 154: ...SITIONS Position 1 Beam swing out cylinders are fully RETRACTED Inner beam extend cylinders are fully RETRACTED Jack cylinders are EXTENDED Outrigger pads are on ground and tires off ground Crane is l...

Page 155: ...155 OBSERVE CAUTION NOTES ON OUTRIGGER MOVEMENT WHENEVER SETTING UP OR STOWING OUTRIGGERS...

Page 156: ...e An ideal location is where the ground is firm level and dry The crane should be situated in close proximity to the work area The site should be free of overhead obstructions Maintain safe clearances...

Page 157: ...perature This can be accomplished by allowing the hydraulic pump to run under no load for ten minutes at low engine speed Next actuate all the controls slowly until controls move smoothly and easy In...

Page 158: ...nal Issues Ignition Switch Carrier Cab Upper Operator s Cab When moving from the carrier cab to the upper cab NOTE The carrier cab ignition switch must be in the OFF position for the upper craning cab...

Page 159: ...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 drum and sheav...

Page 160: ...PROPERLY SUPPORTED AND BLOCKED AN UNSUPPORTED BOOM CAN FALL UNCONTROLLED CAUSING DEATH OR SERIOUS INJURY OR PROPERTY DAMAGE EXTENSION CYLINDER HOLDING VALVES There are 2 boom extend cylinders and eac...

Page 161: ...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 162: ...AND PROPER OPERATING PROCEDURES RATED CAPACITY INDICATOR GREER VGA ELEMENT This system is designed to provide the operator with information on the load he she is lifting and also help prevent overload...

Page 163: ...adii 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 stoppin...

Page 164: ...ing radius 72 ft Operating boom length 105 ft Looking at the example load chart below the 72 ft operating radius is between the 70 and 75 ft radii We will therefore use the use the 75 ft chart radius...

Page 165: ...e of a dynamometer or scales Swinging of a suspended load can cause the load to drift away from the crane The drifting of the load away from the crane will increase the cranes operating radius The inc...

Page 166: ...166 80 160 Operating Instructions Operating Radius 1 2 3 1 1 Center Line of Bearing 3 Load Radius 2 Center Line of Load...

Page 167: ...167 Boom Angle Placards 0 1006843 10 20 30 40 5 0 6 0 7 0 8 0 10 CAUTION CAUTION Do not extend jib into this area unless boom is fully retracted...

Page 168: ...appear on the dash mounted panel and an audible signal will be heard when the switch is in the ON position RATED CAPACITY LIMITER The RCL will indicate an overload condition with an audible alarm All...

Page 169: ...169 LEGEND X Signals for drivers of the crane in the crane cab Y Signals for people in the crane s danger zone Z Execution speed of the crane movements...

Page 170: ...all crane functions including engine operation You must rotate the button clockwise and pull the button out before you can resume normal operation of the crane 3RDWRAP Winch down function wll be disab...

Page 171: ...ar with the controls and function of the Load King Boom Truck practice making some typical job applications As with any piece of equipment practice is required to develop the coordination and knowledg...

Page 172: ...On a negative grounded system connect both ends of one cable to positive terminals of each battery 5 Connect one end of the other cable to negative terminal of the booster battery 6 Connect other end...

Page 173: ...lene glycol Chromate base inhibitors reacting with ethylene glycol can produce chromium hydroxide commonly known as green slime This substance reduces the heat transfer rate and can cause serious engi...

Page 174: ...At the end of the work period or whenever the crane is to be left idle for extended periods prevent it from being frozen to the ground by parking it on a wood concrete asphalt or mat surface EXTREME H...

Page 175: ...increased frequency of lubrication and service discussed above should be determined by observations made at the work site Inspection will determine how long it takes for lubricants breathers and filte...

Page 176: ...ilable for combustion of the fuel Above 10 000 the engine fuel injectors may have to be changed to ensure proper performance Consult engine manufacturer should this problem arise Keeping the air clean...

Page 177: ...ger pads if terrain is soft or if outriggers tend to sink into ground Properly level the machine using the console mounted bubble level While operating the crane frequently check that proper level con...

Page 178: ...oad movement necessary Arm extended point with finger in direction of swing of boom Clasp hands in front of body HOIST LOWER USE MAIN HOIST USE AUXILIARY HOIST Whipline RAISE BOOM LOWER BOOM MOVE SLOW...

Page 179: ...dling devices such as slings yokes personnel platforms load blocks jib deducts etc 2 Consult the maximum load chart on your crane and determine the correct boom radius and parts of line required based...

Page 180: ...xtending the boom or lifting loads To achieve this condition the vertical jack cylinders should be extended until the tires are raised free of the supporting surface FULL extension of the vertical jac...

Page 181: ...wire rope remaining on the winch drum as specified in all applicable crane operating safety standards The intent of this caution is to prevent any possibility of either reverse winding of the rope on...

Page 182: ...w the swing by use of the swing lever First move the lever to the neutral position and then VERY SLOWLY into the opposite swing direction position as required to slow the swing Applytheswingbrake with...

Page 183: ...ontrolled by the LH Joystick LOWER the load by pushing the LH joystick FORWARD and RAISE the load by pulling the LH joystick BACK Improved control is obtained by operating the engine at low speed whil...

Page 184: ...GUIDED SOLELY BY THE APPROPRIATE MANUFACTURER S LOAD RATING CHART when considering load weight The manufacturer s rated loads must never be exceeded Cranes which are factory equipped with auxiliary w...

Page 185: ...n the crane is driven the counterweights slabs may need to be moved from the upper to the deck or removed from the crane to meet local weight restrictions and axle weight limits 1 Fully extend outrigg...

Page 186: ...ng move to a position on the decking facing the counterweight RAISE LOWER switch item 1 4 Remove the long horizontal pins item 2 and the locking pins item 3 that secure them from the top slabs to free...

Page 187: ...ghtly lower the side still pinned and pull the other side up tightly to remove the second pin 5 Withtheengineidlingslowly pressrockerswitchtothe Down positiontolowerthecounterweight slab to the trangu...

Page 188: ...k block up to the head when traveling or to secure it to the bumper ring will result in excessive swinging of the hook block and possible damage to machine Continuing to pull the block up after contac...

Page 189: ...operating off the road Holesandsoftorspongygroundsubjectthemachinetoexcessivestressesandshouldbeavoided HARD SURFACE OPERATION When operating on highways the machine is subjected to the same regulati...

Page 190: ...e the following rules as well as good common sense while moving a crane around a job site Carry the boom over the front only in the boom rack Lock the Swing Brake Switch friction and Swing Lock Switch...

Page 191: ...ades requires caution because the oil in the engine or transmission will move to one side of the engine or transmission As a result the engine or transmission may not be fully lubricated which could d...

Page 192: ...rigged Figure 2 SETUP CWT OFF ON JIB LOCATION BOOM LOCATION SWING LOCK OFF ON TRAVELING YES NO SPEED RESTRI CTION Setup 1 CWT ON Jib Stowed Boom Retracted in Boom Rack Swing Lock ON YES 2 MPH Setup 2...

Page 193: ...PENDED FROM LOAD LINE HOOK NEVER LEAVE THE WORK SITE OR REPOSITION THE TRUCK CRANE WITHOUT FIRST SECURING THE BOOM IN ROAD TRAVEL POSITION AND FULLY RETRACTING ALL OUTRIGGERS You should always know th...

Page 194: ...194 80 160 Operating Instructions Towing or Pushing Vehicle The engine cannot be started by pushing or towing...

Page 195: ...e dolly must be observed in the rear view mirror Depending on the construction of the dolly the driving behavior of the vehicle can be greatly influenced in a negative way The reduced axle loads repre...

Page 196: ...osition during dolly operation The float position must be set before beginning driving Be sure to follow the sequence of the handling steps described below Fitting the Dolly Risk of accidents due to t...

Page 197: ...onnect bypass hoses unless boom is fully supported on the boom rack or boom dolly Death or serious injury could result 10 Locate the Bypass Hose Assembly w Couplings A and B in the superstructure cent...

Page 198: ...ake Switch friction to open unlocked position and Swing Lock Switch gear to open unlocked position in the cranes operator s cab 13 Install Swing Lock Pin Block item 1 as indicated in graphic below Swi...

Page 199: ...er by lifting on the 2 rubber T handles at the top of cover to access the Swing circuit hydraulic valve handle and air valve knob 2 2 16 Pull the knob 1 to unlock the handle 2 Then rotate handle 2 clo...

Page 200: ...r local Load King service representative if indicator light can not be reset to GREEN and light RED light remains ON Carrier Cab Dolly Transport Indicator Lights Failure to immediately pull vehicle ov...

Page 201: ...e raising the main boom Only lift the main boom off the dolly when the Swing Brake and Swing Lock are functioning again and are applied Dolly Not Contained in the Delivery Scope of Crane Manufacturer...

Page 202: ...measurement 4 When a ATB device two blocking damage prevention or two block warning device is inoperable or malfunctioning the machine must be shutdown until the device is corrected and the device mu...

Page 203: ...on to prevent any inward creep It also provides support in the event of a ruptured line or hydraulic failure These holding cartridges should be maintained in a condition to hold a rated load suspended...

Page 204: ...ng loads in a static condition to prevent any downward creep It also provides support in the event of a ruptured line or hydraulic failure This holding cartridge should be maintained in a condition to...

Page 205: ...oom rest Attach a tag line to the boom 3 To release the friction swing brake and allow the vertical self alignment of the boom end over the load being lifted press the rocker switch item 45 in the upp...

Page 206: ...Page Intentionally Blank...

Page 207: ...Stowage 1 If the jib offset angle is other than 0 change its offset to 0 before do this procedure refer to the Changing the Jib Offset Angle section 2 Set the crane on fully extended outriggers in a...

Page 208: ...208 80 160 Disassembly 6 Remove the cable from the guide sheave 3 and sheave 4 at end of jib base section 3 4 7 Remove the pin 5 from the upper hole and flip down the guide sheave 6 6 5...

Page 209: ...209 8 Install the pin 5 in the guide sheave kickstand 5 9 Remove the lower left hand pin 7 7...

Page 210: ...ntil the jib come and rest on the tri fold ramp 11 Engage the jib deployment cylinder with the jib deployment cylinder hook Use jib deployment cylinder 8 to pull the jib inwards of the ramp 8 12 Push...

Page 211: ...ing holes 10 14 Retract the jib deployment cylinder 8 fully using the jib remote control Make sure that the jib should lock on the storage bracket 11 properly 11 15 Remove the pin 12 from the tri fold...

Page 212: ...to lock the 1st folding section with middle folding section of the ramp Remove pin 13 and fold the middle folding section of the ramp to clockwise 12 13 17 Install pin 13 on the locking hole to lock t...

Page 213: ...the crane is being transported Carry the boom over the front only Lock the swing brake and swing lock Secure the hook block or ball to the bumper loop or raise the hook block or ball close to the boo...

Page 214: ...llow the starting procedure below 1 Put the parking brake switch in the ON position 2 Turn the ignition switch to the ON position Wait to start light goes off 3 Turn the ignition switch to the START p...

Page 215: ...maintenance performed and serves as a tool detecting problem areas and reanalyzing maintenance requirements The items in each check interval on the check chart are grouped under their respective head...

Page 216: ...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 L...

Page 217: ...hieving operating temperature will help prevent the intake valves and exhaust valves from sticking The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdo...

Page 218: ...always run the engine until the coolant temperature is at least 82 C 180 F After the engine is warm proceed with warming up the other systems Start with the hydraulics Run the engine at less than 1 3...

Page 219: ...ations Make sure your tires that are inflated to the correct pressures for the cold temperatures If tires are below the recommended pressure they will have a shortened life A tire that is inflated to...

Page 220: ...66 68 70 72 73 75 78 80 65 70 72 73 75 77 79 82 84 86 70 75 77 79 81 83 85 88 90 92 75 80 82 84 87 89 91 94 96 99 80 86 88 90 92 95 97 100 102 105 85 91 93 96 98 100 103 106 108 111 90 96 99 101 104 1...

Page 221: ...authorized to do so Make sure all applicable instructions have been read and are understood thoroughly 8 DONOTcheckforhydraulicleakswithhands Oilunderpressurecanpenetratehumanskincausing serious injur...

Page 222: ...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 s...

Page 223: ...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 224: ...nspect each 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 equ...

Page 225: ...irt 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 Use tools t...

Page 226: ...stem Check in the engine compartment Belts for tension and wear Coolant level Oil level Transmission oil level Air cleaner sight gauge Air intake Muffler and exhaust DEF fluid level Check battery box...

Page 227: ...off This is an opportunity to ensure the outrigger holding cartridges are not leaking under load 3 Check the lights for proper operation 4 Check engine fluids Maintain oil and water levels above the...

Page 228: ...o not overgrease this bearing 2 Check for excessive movement in the rotation gear mechanism If over 4 of movement side to side isdetectedbymovingtheboomtipbackandforthwhenfullyretracted itwouldbeconsi...

Page 229: ...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 Deformation any visibly apparent bend or twist from the...

Page 230: ...n page 361 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 231: ...intenance Requirements ___ Drain Fuel Filters or Water Separator ___ Ensure Swing Brake is able to Hold Against Full Torque of Swing Motor ___Check DEF Urea Fluid Level in Reservoir ___Drain Water fro...

Page 232: ...ments ___ Check Brake Shoes for Wear Condition ___ Lubricate Valve Disconnects ___ Change Transmission Oil and Shift Air Filter ___ Clean and Wax all Exterior Painted Surfaces ___See Engine Maintenenc...

Page 233: ...checked by oil analysis ___ Perform Annual Lubrication ___ Drain and Refill the Winch Lubricant ___ Disassemble Winch and Inspect ___ Change Axle Oil ___ Drain and Clean Hydraulic Reservoir ___See Tra...

Page 234: ...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 pa...

Page 235: ...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 236: ...ease in the oil s oxidation rate As the oil oxidizes sludge and varnish forming materials will be deposited in the pumps valves cylinders and lines thus increasing the rate of wear on the components I...

Page 237: ...and is used the system should be flushed by cycling all cylinders at least once to their limits to insure that as much as possible of the old oil has been removed from the system NOTE Observe all oil...

Page 238: ...American Petroleum Institute API This would be indicated by a symbol on the container dispensing system showing adherence to the API Diesel Exhaust Fluid Certification Program The following are commo...

Page 239: ...portation containers The following conditions are ideal for maintaining DEF quality and shelf life during prolonged transportation and storage Storage temperature between 23 F and 77 F 5 C and 25 C St...

Page 240: ...ailure to clean the spilled Diesel Exhaust Fluid may result in an incorrectly diagnosed leak of the Diesel Exhaust Fluid Dosing system Before using containers funnels etc that will be used to dispense...

Page 241: ...to the Diesel Exhaust Fluid in an effort to prevent freezing If chemicals additives are added to the Diesel Exhaust Fluid the after treatment system may be damaged Diesel Exhaust Fluid will freeze aro...

Page 242: ...you must change a tire follow the step by step instructions detailed in a tire repair manual Should low pressures make it necessary to add air never stand beside the tire Instead use an extension hose...

Page 243: ...axle or the four smallest tires on the other driving axle Such tire mounting will cause an inter axle fight unusually high axle lubricant breakdown and possible costly axle service In addition to mat...

Page 244: ...S Instead slow down or stop until the tires cool Inflation pressure should be checked when tires are cool using an accurate tire pressure gauge Check pressures at regular intervals Bleeding the air fr...

Page 245: ...ed parts 3 Inflate tires in a safety cage 2 Don t re inflate a tire that has been run flat or seriously underinflated without first demounting and inspecting the tire and rim assembly 4 Inspect wheel...

Page 246: ...t protection when adding air Use of starting fluid ether or gasoline or any other flammable material to lubricate seal or seat the beads of a tubeless tire can cause the tire to explode or can cause t...

Page 247: ...aluminum and keep the coating maintained over time Preventing Salt Damage To prevent corrosion of aluminum from salts or other materials listed inspect the material regularly and repair any damage to...

Page 248: ...der 1 and pin engagement If cylinder stroke is not fully extending or retracting check air pressure to cylinder extend and retract port and electrical connector at cylinder See switch no 46 in the upp...

Page 249: ...t Exchanger Clean contaminated evaporator The cleaning is carried out by blow out or spraying do not use a high pressure cleaner Fins that were pushed down by external influences can be adjusted Check...

Page 250: ...oses if material is worn Fault Diagnostics Fault Cause Remedy Blower will not work Fuse defective or loose If the fuse correctly seated If necessary insert correctly Renew defective fuses If a new def...

Page 251: ...w to the clutch V belt loose or torn Adjust belt tension change belt V belt slides or does not turn on the v belt even though coupled Check repair change compressor Compressor clutch slides Repair clu...

Page 252: ...ely worn Increase tension of V belts or renew Clutch noisy Repair clutch Retainer of refrigerant compressor loose or inside parts defective Repair retainer renew refrigerant compressor Excessive wear...

Page 253: ...onnel lifting devices or ladder in order to inspect the ropes on the winches Refer to Wire Rope Users Manual section 9 and ANSI Standard B30 5 for guidelines covering the inspection maintenance repair...

Page 254: ...UBRICATION METHODS for wire rope lubricating procedures Before installing a new or replacement rope make certain the rope to be used is the proper type and size The wrong rope will not function proper...

Page 255: ...a guide which ensures that basic preventive maintenance requirements will be met under average operating conditions Conditions which impose greater wear loads or strain on the crane may dictate reduc...

Page 256: ...r proper function Cable and cable spooling on winch Cylinder pin connections for wear Check tires axles and drive lines for wear or damage Check in the cab for Instruments functioning properly Control...

Page 257: ...257 Master Lubrication Chart 13 14 5 4 3 2 2 8 12 9 7 6 15 10 11 BOOM BLOCK TOP VIEW...

Page 258: ...POSE GREASE OPEN GEAR GREASE GEAR LUBRICANT REGULAR GEAR LUBRICANT EP GEAR LUBRICANT EP HYDARULIC OIL MPG GG GL 1 GL 5 HO REFER TO OPERATORS S MANUAL FOR COMPLETE LISTING OF RECOMMENDED OILS FOR APPLI...

Page 259: ...l 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 the hydrau...

Page 260: ...r Under certain 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 C...

Page 261: ...IL 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 32 Nuto H...

Page 262: ...aintenance OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME Mobil Oil Corp 32 46 68 Nuto H 32 Nuto H 46 Nuto H 68 Texaco Inc USA 32 46 68 Rando Oil HD A2 5w 20 Rando Oil HD 32 Rando Oil HD 46 Ran...

Page 263: ...two complete revolutions while injecting grease When complete rotation is impractical inject grease through each fitting and rotate machine back and forth as far as possible as each fitting is grease...

Page 264: ...the manufacturer are MOBIL TEXACO SUNOCO AMOCO EXON RACE Mobilux EP1 Mutifak EP1 Prestige 742EP Amolith EP1 Beacon EP1 GEAR Mobilux EP1 Mutifak EP1 Prestige 742EP Amolith EP1 Beacon EP1 NOTE Other man...

Page 265: ...ed in the path of the wire rope and the rope is passed through the hot lubrication over sheaves and a center guide wheel Hot oils or greases have excellent penetrating qualities and upon cooling have...

Page 266: ...pe can be lubricated by opening a spigot Sheaves are the best location for lubricating operating wire ropes because the wires and strands open somewhat as they bend along the groove POURING Lubricant...

Page 267: ...operating routine SPRAYING A light lubricant containing solvents can be applied to a wire rope by a properly directed spray nozzle AEROSOL SPRAYING Installations requiring only small amounts of lubri...

Page 268: ...s 3 Using the grease compound as specified above lubricate the upper rear wear pads of the boom that ride on the inside top plate of the base section Use a grease gun with a flexible hose and insert t...

Page 269: ...the 2nd section 10 shots as shown 7 Repeat previous step for each access hole going forward in the second section as the 3rd section is extended Line up the zerk and apply the grease 8 With the 2nd se...

Page 270: ...ns 3 4 5 6 on surfaces similar to step 9 where wear pad contact can be seen DO NOT STICK HANDS OR TOOLS IN BOOM SECTIONS UNTIL THE ENGINE IS SHUT OFF AND THE PTO IS DISENGAGED SERIOUS INJURY WILL RESU...

Page 271: ...ction where you see thru each port hole that the wear pads have made contact with the metal surfaces as shown 13 No greasing of the 6th tip section is required Cycle boom in and out a few times to dis...

Page 272: ...SERIOUS INJURY MAY OCCUR IF ATTEMPTING LUBRICATION WITH THE ENGINE ON 15 To lubricate Boom Head Sheaves set outriggers retract and lower boom and place hook block on the ground Shut down engine All s...

Page 273: ...OF CRANE Make Model Serial Boom Length Jib Length DATE OF LAST BOOM LUBRICATION INSPECTION HOURS AND TIME OF SERVICE SINCE LAST INSPECTION RESULTS OF INSPECTION Wear Pads Location of Pads Conditions...

Page 274: ...or equivalent 2 Keep case breather item 2 clear of dirt and debris 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 w...

Page 275: ...h grease on areas of boom where wear pads contact is evident The inside of the top plate of all sections except the tip section also require grease This can be applied through the holes in the side pl...

Page 276: ...ditional torque is required after the first 8 or 40 hours then recheck each 8 or 40 hours until all bolts are found properly torqued Thereafter checks should be performed quarterly MODEL 4 1 TORQUE MU...

Page 277: ...tside must be checked This includes a total of sixtyfour 64 capscrews to be checked If ANY are found to have loosened ALL sixty four 64 must be retorqued Remember it is important to perform periodic c...

Page 278: ...HAT 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 TEMPERAT...

Page 279: ...erval 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 inyourma...

Page 280: ...pop when being lubed move the drive shaft laterally in all four directions and pull or push on the drive shaft in the direction opposite to the journal cross seal not relieving while lube gun pressure...

Page 281: ...Grade 1 has been adapted by the factory Relube spline at the intervals prescribed below Apply grease gun pressure to lubrication zerk 2 until lubricant appears at pressure relief hole 1 in welch plug...

Page 282: ...nd Grade 2 specifications are preferred The use of greases which tend to separate and cake should be avoided Lubrication cycles for drive shaft universal joints and slip splines will vary with service...

Page 283: ...cation of chassis components is required Grease should be supplied to the bracket until it begins to squirt out around the camshaft adjacent to the slack adjuster The slack adjuster should be filled u...

Page 284: ...e are listed in accordance with the MAINTENANCE CHECK LIST in Section 4 Consideration of severe working conditions may dictate a revision in scheduling periodic checks DAILY AIR TANKS There are four 4...

Page 285: ...ion in scheduling periodic checks DAILY HYDRAULIC FLUID LEVEL The hydraulic reservoir fluid level indicator and filler cap are on the right side of the machine Hydraulic Oil Fluid Level Gauge on right...

Page 286: ...OIR Drain any accumulated moisture from the hydraulic reservoir by parking the machine on a slight incline and loosen the pipe plug in the bottom of the reservoir HYDRAULIC OIL Visually check the cond...

Page 287: ...discarding the old filter element examine the type of material trapped in it This may indicate which if any hydraulic system components are deteriorating 1000 HOURS HYDRAULIC RESERVOIR Drain and clea...

Page 288: ...ilter is located inside the reservoir on the intake to the pump manifold Access to this filter is gained by removing the cover with the filter holding device from the top of the reservoir Remove the O...

Page 289: ...counterweight s A warning light should come on horn if in on position should sound and shut off system should disconnect controls Check entire length of cable and cable reel for evidence of damage Che...

Page 290: ...Adjustment is dependent on cable travel and the adjusted length of the clevis rods Adjustment is not required as long as the full range of engine rpm is available in response to control input INTERAXL...

Page 291: ...with multipurpose grease after removing any rust accumulations LONG TERM STORAGE 30 DAYS OR MORE Long term storage requires greater preparation than short term storage and must be undertaken with grea...

Page 292: ...escribed in the topic Engine Storage The TRANSMISSION should be prepared as prescribed in the topic Transmission Storage LONG TERM STORAGE 30 DAYS OR MORE Long term storage requires greater preparatio...

Page 293: ...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 it will be s...

Page 294: ...ive lubricants from all surfaces 2 Check all fluid levels adding or draining as required 3 Lubricate the machine according to Group 4 making certain that all points with grease fittings are lubricated...

Page 295: ...PREFORMED RIGHT REG LAY WIRE ROPE WEIGHT 1 04 LBS FT MINIMUM BREAKING STRENGTH 29 4 TONS OPT 3 4 ROTATION RESISTANT 34 X 7 COMPACTED STRAND GRADE 2160 WEIGHT 1 24 LBS FT MINIMUM BREAKING STRENGTH 36...

Page 296: ...336 0 336 0 336 0 B 55 0 55 0 55 0 C 55 0 55 0 55 0 D 474 9 474 9 474 9 E 68 0 68 0 68 0 F 42 0 42 0 42 0 G 77 0 77 0 77 0 H 237 3 Front 229 6 Rear 237 3 Front 229 6 Rear 237 3 Front 229 6 Rear J 312...

Page 297: ...297 DIM in FREIGHTLINER KENWORTH WESTERN STAR R 35 94 S 161 0 T 14 5 U 18 6 V 12 9 W 27 87 27 87 27 87...

Page 298: ...298 80 160 Specifications 156 0 312 0 199 93 310 82 580 7 153 306 NOTE For dimensions not listed contact Load King Engineering Department Boom Truck group...

Page 299: ...mp The following charts will allow you to accurately test the flow of the pump as well as determine what is the proper speed of the functions on the unit Oil temperature below 140 degrees F may result...

Page 300: ...Page Intentionally Blank...

Page 301: ...a guide which ensures that basic preventive maintenance requirements will be met under average operating conditions Conditions which impose greater wear loads or strain on the crane may dictate reduce...

Page 302: ...for proper function Cable and cable spooling on winch Cylinder pin connections for wear Check tires axles and drive lines for wear or damage Check in the cab for Instruments functioning properly Contr...

Page 303: ...ch are the most likely to cause the failure Consider the most obvious first 6 TEST YOUR CONCLUSION Test your conclusions in order of obviousness until the source of the failure is found The machine ca...

Page 304: ...nge the oil and oil filter at established intervals If in spite of these precautions improper operation does occur the cause can generally be traced to one of the following 1 Use of the wrong viscosit...

Page 305: ...valves are in 2 sectional valves one for the front outriggers and one for the rear outriggers To operate an outrigger cylinder the extend valve or the retract valve plus a function valve must shifted...

Page 306: ...bearing bearing Hose plugged or liner collapsed Replace hose Rotary manifold leaking internally Reseal rotary manifold Swing pump faulty See section on Pumps SWING MOTION SLUGGISH CAUSE REMEDY Main r...

Page 307: ...on packings damaged Replace packings Low oil level Add oil as required Hose plugged or liner collapsed Replace hose Air in cylinder Bleed cylinder BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED CAUS...

Page 308: ...ged Replace wear pads Wear pads shimmed to boom too tight Reshim wear pads Faulty counter balance valve Replace counter balance valve Loose chain system Adjust chains as required TELESCOPE CYLINDER EX...

Page 309: ...y chart WINCHWILL RAISE BUTWILL NOT LOWER CAUSE REMEDY The winch hold valve is mounted on the winch motor incorrectly Be certain that the winch is assembled properly The winch hold valve spool is stic...

Page 310: ...ATTERSWHEN LOWERING CAUSE REMEDY The winch hold valve is set wrong or is malfunctioning Check the hold valve setting If the winch continues to chatter the holding valve is sticking Inspect it for worn...

Page 311: ...ck cylinder not operating Repair or replace Line plugged or collapsed between outrigger valve and cylinder Replace hose Beam wedged in extended position Extend jack far enough to pick up end of beam a...

Page 312: ...y and repair NO PRESSURE IN SYSTEM CAUSE REMEDY Pumps not engaged Engage pumps Pump not delivering oil for any of the reasons listed previously Follow remedies given previously Relief valve not functi...

Page 313: ...ake suction filter plugged Clean filter Rag paper etc pulled into suction line or pump Remove Worn or broken parts Replace EXTERNAL OIL LEAKAGE AROUND PUMP CAUSE REMEDY Shaft seal worn causing oil to...

Page 314: ...ssive pressure above maximum pump rating Check relief valve setting Seizure due to lack of oil Check reservoir level oil filter and possibility of restriction in suction line more often Solid matter b...

Page 315: ...ap re center and re tighten Valve not at thermal equilibrium Let system warm up LEAKING SEALS CAUSE REMEDY Paint on or under seal Remove and clean Excessive back pressure Open or enlarge line to reser...

Page 316: ...FORMANCE OR FAILURE CAUSE REMEDY Dirt in relief valve Disassemble and clean Relief valve defective See section on Relief Valves Load too heavy Check line pressure Internal valve crack Replace valve Pl...

Page 317: ...USE REMEDY Poppet seal damaged Replace damaged parts Clean dirt and remove surface marks for free movement PRESSURE SETTING NOT CORRECT CAUSE REMEDY Wear due to dirt Lock nut adj screw loose See secti...

Page 318: ...l Rotary manifold leaking Reseal rotary manifold Worn pump Repair or replace pump Extremely high fluid temperatures causing pump and motor to slip temperature increases as pump and motor wear Add heat...

Page 319: ...Y CAUSE REMEDY Motor housing bolts loose Clean mating surfaces and tighten nuts to appropriate value Pinched O ring seal Replace LEAK AT OIL PORTS CAUSE REMEDY Damaged seal or O ring Replace O ring or...

Page 320: ...arts Tighten cylinder rod eyes if loose Check cylinder heads and tighten if loose Misalignment Check mounting pins and bushings Tighten rod eyes ERRATIC ACTION OF CYLINDERS CAUSE REMEDY Air in system...

Page 321: ...ot drifting or by replacement with a new cartridge Before installing the cartridge visually inspect the external O rings and backup washers Retest per the procedure above to determine if hold was defe...

Page 322: ...LINDER The suggested procedure for identifying the specific cause of leak down is similar to the boom lift cylinder procedure SET THE OUTRIGGERS ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE not completely e...

Page 323: ...orrect viscosity grade to be used Pumps assembled after overhaul may be assembled too tightly This reduces clearances and increases rubbing friction Follow instructions when reassembling Leaking relie...

Page 324: ...al or file hole larger Tripped circuit breakers Reset breaker Disconnected or broken wires Replace or repair Open circuit Check with test light Repair or replace Low voltage Check wires and grounds Po...

Page 325: ...and replace fuse 8 amp only Broken wire Check voltage in control panel between terminals 0 and 37 If 0 volts check between ignition post of ignition switch and ground If 12 volts available wire to con...

Page 326: ...Page Intentionally Blank...

Page 327: ...Once the cause of a problem or malfunction has been diagnosed take the corrective action specified in this manual Follow the procedures given for the specific problem If the difficulty is not covered...

Page 328: ...ects full beam swing out position Each sensor has an air gap to maintain to operate properly and send signals to the Rated Capacity Limiter RCL Visually inspect sensors for damage the condition of rel...

Page 329: ...329 1 Proximity Sensor Outrigger Swing Outrigger Beam Retracted 2 Proximity Sensor Outrigger Beam Extend...

Page 330: ...necting wires 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...

Page 331: ...331 Repairs Adjustments Remarks Log ITEM REQUIREMENT DATE...

Page 332: ...rque wrench extensions either commercially made or fabricated by the user When using an extension it must be remembered that the wrench torque the actual torque reading or setting of the wrench and th...

Page 333: ...333...

Page 334: ...f the weld Always have a fire extinguisher on hand in case of fire Adequate ventilation and dry area are necessary Protective clothing should be used and all persons in the welding area should have pr...

Page 335: ...ized when one is welding or cutting coated steel Use a power brush or grinding wheel to strip the coating from the steel in the vicinity where the cut or weld is to be made Remove the paint far enough...

Page 336: ...are conducted an a SEMI ANNUAL BASIS Check the relief valves and make the necessary adjustments by the following procedures The relief valves used on this hydraulic crane have a screw type adjustment...

Page 337: ...sure by the following procedure 2 Retract the boom completely and continue to retract over relief with the engine running at full governed rpm Initially set the retract port relief valve item 1 to obt...

Page 338: ...Boom Valve Tele Extend 241 3500 Limits Boom Extend Pressure Check pressure by fully extending boom until 2 tele cylinder is bottomed out Boom Valve Tele Retract 241 3500 Limits Boom Retract Pressure...

Page 339: ...ssure for port B Retract 3 Pump Pressure Gauge port to measure pump pressure 4 Pilot Pressure Set to 435 psi 30 bar requires installation of a pressure tap and only adjusted or checked by Load King Au...

Page 340: ...port item 15 of the SWING VALVE Fig 2 NOTE Test port item 15 is located on the Swing Relief Valve which is mounted inside the superstructure just to the left of the swing reduction unit The relief va...

Page 341: ...00 psi 200 bar 11 Swing A N A 12 Swing Brake A N A 13 Jib A N A 14 Cab Tilt Down N A 15 LS Port N A SWING MAXIMUM OPERATING PRESSURE ADJUSTMENT Relief pressure for the whole swing valve and all swing...

Page 342: ...ing pressure on the SWING VALVE Fig 2 item 2 is set at 2900 psi This pressure must be increased above 3500 psi to set the Main Relief 2 on the DIVERTER VALVE Fig 3 5 Move cab tilt up to read maximum p...

Page 343: ...ANUAL read all of the steps used in disassembly and all of the steps used in building up the unit It is important to airblast all parts and wipe them with a clean lintless cloth before assembly Dirt i...

Page 344: ...t to the 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 ta...

Page 345: ...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 346: ...ATION All swing drive gearboxes from Load King are shipped with an additive to the gear oil of 5 oz 148 ml of ethylene glycol for cold weather protection If the gear oil in the unit is changed Load Ki...

Page 347: ...ctrical System Fuse Block Operator s Cab LocatedabovetheRHconsoleisthecabfuseblockwhichrequiresperiodiccheckingforfusereplacement if issue is detected in one of the circuits listed below in chart desc...

Page 348: ...5 A ROOF WIPER 7 5A FRONT WASH PUMP 8 20 A FRONT CAB WORK LIGHTS 9 10 A DEFROST ACTUATOR 10 3 A DOME LIGHT 11 10 A RADIO 12 30 A HVAC BLOWER FAN 13 10 A CONTROLS 14 SPARE 15 25A FRONT WIPER LOW SPD 16...

Page 349: ...sue is detected in one of the circuits listed below in chart description ID AMP RATING Fuse DESCRIPTION R1 RELAY 12 VDC SENSOR POWER RELAY R2 RELAY 12 VDC DIVERTOR RELAY R3 RELAY 12 VDC COOLER CONTROL...

Page 350: ...nd washers at the top of the brush stud along with the outboard bearing This will allow the brush assemblies to be removed Carefully remove the brushes without over stretching the brush springs and ar...

Page 351: ...YELLOW CAN_12 CAN HIGH 15 GREEN CAN_12 CAN LOW RED CABLE 04 POTENTIOMETER V BLACK CABLE 04 POTENTIOMETER V WHITE CABLE 04 POTENTIOMETER SIGNAL A GREEN CABLE 04 POTENTIOMETER SIGNAL B SHIELD SHIELD POT...

Page 352: ...high beam head lamps or 15 amp load for 15 seconds Proceed to load test If there is an indicator and it shows low charge Charge then turn on high beam head lamps or 15 amp load for 15 seconds Proceed...

Page 353: ...21 C above 9 6 60 F 16 C 9 5 50 F 10 C 9 4 40 F 4 C 9 3 30 F 1 C 9 1 20 F 7 C 8 9 10 F 12 C 8 7 0 F 18 C 8 5 If water can be added to a battery a hydrometer reading of 1 225 80 F 27 C can be used inst...

Page 354: ...Page Intentionally Blank...

Page 355: ...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 356: ...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 2...

Page 357: ...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 358: ...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 fe...

Page 359: ...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 360: ...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 Granula...

Page 361: ...361 Torque Specs SAE Metric NOTE Refer to specific instructions for individual components super cede these values...

Page 362: ...362 80 160 Appendix...

Page 363: ...are known to the state of California to cause cancer birth defects and other reproductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known t...

Page 364: ...onstituents are known to the state of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accesories contain lead and lead compounds chemicals know...

Page 365: ...a Rated Capacity Limter RCL Element VGA system Completely read the attached manual in the Appendix section before attempting to operate the crane For Troubleshooting the system refer to your SHOP MAN...

Page 366: ...80 160 Notes...

Page 367: ...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 368: ...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 369: ...80 160 Operator Manual...

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