LOAD KING 80-160 User manual

OPERATORS MANUAL
LOAD KING
80-160
REV B
DECEMBER, 2020

Page Intentionally Blank

For more informationgotowww.P65warnings.ca.gov/diesel.
•Always start andoperate theengine in awell-ventilated area.
•If in an enclosed area,ventthe exhausttothe outside.
•Donot modify or tamper with theexhaust system.
•Donot idle the engine except as necessary.
WARNING Operating, servicingand maintainingthis equipmentcan expose you
to chemicals including engine exhaust, carbon monoxide, phthalates, and lead,which
are knowntothe Stateof California to causecancer andbirth defects or other
reproductive harm.These chemicals canbeemitted from or contained in other various
parts and systems, fluids and some componentwear by-products. To minimize
exposure,avoid breathing exhaust, do not idlethe engine except as necessary, service
your equipmentand vehicle in awell-ventilated area andwear gloves or wash your
hands frequently when servicingyour equipmentor vehicleand afteroperation. For
more informationgotowww.P65Warnings.ca.gov/passenger-vehicle.
Breathingdiesel engine exhaustexposes youto chemicals knowntothe Stateof
Californiato cause cancer andbirth defectsorother reproductive harm.

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Company
Load King has been producing rst-class heavy equipment since 1956. Cung-edge innovaon and
engineering excellence make us the market leader. Load King is a key part of the Custom Truck One Source
family of brands, oering standard and custom trailers, vocaonal equipment, and a full line of Boom
Trucks and truck cranes. For more informaon, please visit Load King’s website: www.loadkingmfg.com.
About Custom Truck One Source
Custom Truck One Source is the rst true single-source provider of specialized truck and heavy equipment
soluons. With sales, rentals, aermarket parts and service, equipment customizaon, remanufacturing,
nancing soluons, and asset disposal, our team of experts, vast equipment breadth and integrated
network of locaons across North America oer superior service and unmatched eciency for our
customers.

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Table of Contents
1. Introduction
Construction and Industrial Equipment Product Safety.........................................1
Nomenclature........................................................................................................2
Intended Use.........................................................................................................3
Bulletin Distribution and Compliance....................................................................4
Contacting Manufacturer.......................................................................................5
Transfer of Machine Ownership.............................................................................6
2. Safety
Safety Introduction.................................................................................................1
Product Safety Decals............................................................................................2
Safety Definitions Used in this Manual...................................................................2
General Safety........................................................................................................7
Safety Sign Maintenance..................................................................................7
80-160 Safety Sign Locations...........................................................................8
Safety Guidelines............................................................................................26
Personal Protection Equipment............................................................................27
Workplace Safety.................................................................................................28
Effects of Wind Conditions..................................................................................37
Lightning Storm....................................................................................................39
Temporary Interruption of Crane Operations........................................................40
Resuming Crane Operations................................................................................43
Ending Crane Operations.....................................................................................44
Turning/Driving in Reverse...................................................................................45
Parking the Vehicle...............................................................................................46
Lock Out & Tag Out...............................................................................................47
Access/Egress.....................................................................................................49
PersonalSafety.....................................................................................................56
Seat Belts.............................................................................................................57
3. Assembly
Erecting the Jib......................................................................................................1
Changing the Offset of the Jib................................................................................3
Spooling Wire Rope on Drums ...............................................................................5
Cable Sockets........................................................................................................9
Hoist-Line Reeving...............................................................................................12
Cable Reeving......................................................................................................15
Dead Ending Wire Rope in Socket........................................................................16

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Contents
Extending and Retracting the Jib Pull-out Section...............................................17
Counterweight Installation ..................................................................................19
4. Description Of Machine and Controls
Controls in the Cab.................................................................................................1
Upper Controls and Instruments.........................................................................16
Universal Symbol Identification...........................................................................19
Power Take-Off....................................................................................................23
Carrier Controls and Instruments........................................................................25
Side-Stow Jib......................................................................................................26
Rated Capacity Indicator and ATB.......................................................................28
Rated Capacity Indicator System...................................................................28
ATB Components...........................................................................................29
5. Inspection
Pre-Start Inspection..............................................................................................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 Check (1500 - 2000 Hours).......................................................................13
Crane Boom.........................................................................................................14
Wire Rope Inspection...........................................................................................17
Wire Rope Inspection Record...............................................................................19
Mobile Crane Load Test Inspection......................................................................20
6. Operating Instructions
Job-Site..................................................................................................................1
Job Site Setup Procedure.................................................................................1
Outrigger Positioning........................................................................................2
Work Site Position.............................................................................................4
Cold Weather Operation...................................................................................5
General Operational Issues....................................................................................6
Ignition Switch-Carrier Cab & Upper Operator’s Cab .......................................6
General Rules...................................................................................................7
Safety Devices..................................................................................................8
Training and Operator Qualifications.................................................................9

7
Operator Aids......................................................................................................10
Load Handling Operations ..................................................................................11
Max. Load and Boom Angle Charts.....................................................................12
Using the Maximum Load Chart.....................................................................12
Load Rating Chart Interpretation....................................................................14
Operating Radius...........................................................................................20
Boom Angle Placards.....................................................................................21
Operating the Unit................................................................................................22
Operator Shutoff Devices...............................................................................22
Operating the Unit..........................................................................................25
Jump Starting an Engine- Booster Cable Instructions....................................26
Unusual Operating Conditions.......................................................................27
Initiating Operation.........................................................................................31
Arm and Hand Signals....................................................................................32
Lifting the Load...............................................................................................33
Making a Typical Lift........................................................................................34
Moving the Unit....................................................................................................39
Removable Counterweight.............................................................................39
VehicularOperation.........................................................................................42
Traveling around the Jobsite...........................................................................44
Roading the Unit.............................................................................................47
Towing or Pushing Vehicle...............................................................................48
Dolly................................................................................................................49
Emergency Procedures........................................................................................57
Emergency Procedures..................................................................................57
Emergency Boom Retraction..........................................................................58
Emergency Lowering of Boom.......................................................................59
Emergency Rotation.......................................................................................60
7. Disassembly
Side Stow Jib Stowage..........................................................................................1
8. Transportation
Transporting the Crane..........................................................................................1
Instructions for Loading and Unloading ................................................................2

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Contents
9. Maintenance
Maintenance Introduction......................................................................................1
Cold Weather Package Specification.....................................................................2
Cold Weather Package Recommendations...........................................................3
Safety Practices.....................................................................................................7
General Work Practices..........................................................................................9
Storing Components............................................................................................10
Cleanliness...........................................................................................................11
Operator Observation..........................................................................................12
Maintenance Checks and Lubrication..................................................................13
90-Day Maintenance Items...................................................................................15
Semi-Annual Maintenance Items ........................................................................16
Machine Maintenance Checklist..........................................................................17
Hydraulic Hoses..................................................................................................20
Filters and Maintenance......................................................................................22
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 reeving..........................................................................................39
Lubrication...........................................................................................................41
LubricationIntroduction..................................................................................41
Master Lubrication Chart................................................................................43
Hydraulic Oil Requirements............................................................................45
Turntable and Swing Pinion............................................................................49
Cable Lubrication Methods............................................................................51
BoomLubrication............................................................................................54
Boom Lubrication and Wear Pads Inspection Record...................................60
Swing Reducers.............................................................................................61
Slider Pads.....................................................................................................62
Swing System Maintenance.................................................................................63
Swing Bearing Bolting Procedure...................................................................63
Winch Lubrication................................................................................................65
Wire Rope Lubrication..........................................................................................66

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Drive Shaft Maintenance......................................................................................67
Brake System Maintenance.................................................................................70
Air System Maintenance......................................................................................71
Hydraulic System Maintenance...........................................................................72
ATB System..........................................................................................................76
Storage.................................................................................................................78
Machine Storage............................................................................................79
Chrome Cylinder Rod Storage........................................................................80
Restoration to Service.....................................................................................81
10. Specications
Wire Rope Specifications.......................................................................................1
Vehicle Dimensions................................................................................................2
Pumps and Function Speeds.................................................................................5
11. Troubleshooting
Introduction..............................................................................................................1
General Procedure.................................................................................................3
Hydraulics - General..............................................................................................4
Operator Controls..................................................................................................5
Siwng Circuit..........................................................................................................6
Boom Hoist Circuit.................................................................................................7
Telescope Circuit....................................................................................................8
Winch Circuit..........................................................................................................9
Outrigger Circuit...................................................................................................11
Swing Pumps Circuit............................................................................................12
Swing Circuit Control Valves................................................................................15
Swing Circuit Control Valves................................................................................17
Fluid Motor...........................................................................................................18
Cylinders..............................................................................................................20
Cylinder Leakage.................................................................................................21
Excessive Heating of Oil In System......................................................................23
Electrical Controls................................................................................................24
Two-Block System...............................................................................................25
12. Service / Parts
General Service Information...................................................................................1
Outrigger Position Sensors.....................................................................................2
General Work Practices..........................................................................................4

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Contents
Repairs-Adjustments-Remarks Log.......................................................................5
Torque Wrench Extensions.....................................................................................6
Welding Instructions...............................................................................................8
Hydraulic System.................................................................................................10
Pressure Settings-Pumps & Valves................................................................10
Pumps............................................................................................................17
Rotary Manifold..............................................................................................18
Rotation System...................................................................................................20
Inspection of Rotation Bearing Clearance......................................................20
Swing Reducer...............................................................................................22
Electrical System..................................................................................................23
Fuse Block-Operator’s Cab............................................................................23
Relay & Fuse Block-Chassis............................................................................25
Electrical System Collector Ring....................................................................26
Maintenance -Free Battery Testing................................................................28
13. Appendix
Conversion Tables..................................................................................................1
Average Weight of Materials...................................................................................5
Torque Specs -SAE & Metric..................................................................................7
California Proposition 65 Warning..........................................................................9
Lead Warning - State of California........................................................................10
Greer Element VGA Operator’s Manual................................................................11