LOAD KING 80-160 User manual

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

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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.

4
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.

5
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

9
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

11
Introduction
Construction and Industrial Equipment Product Safety
It is the responsibility of the owner of the equipment to be knowledgeable about federal, state and local
regulations that effect the total usage of the equipment, and responsibility to working personnel and the
public. Since regulations are subject to change, and also differ from one locality to another, this manual
makes no attempt to provide such information.
Load King provides appropriate operation and maintenance manuals for various construction and
industrial equipment products that it manufactures and sells. In addition, where applicable, appropriate
national consensus standards, industry standards and safety related manuals are included with the
Load King manuals in the shipment of each product. It is company policy to provide this information for
the owner or user of the equipment. It is expected that the owner or user will utilize these manuals and
standards to provide the appropriate information and training to those people who are to operate,
maintain and supervise the use of equipment.
Construction and industrial equipment is designed and manufactured to perform heavy-duty work.
Under normal usage, the equipment will wear. For this reason it is essential that the owner/ user establish
and perform a periodic inspection of the equipment. The objective of inspection programs is to prevent
accidents, reduce downtime and 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 problem.
Proper training and inspection programs are essential to avoiding injury to persons, damage to property
and excessive maintenance costs.
Read and understand the manuals provided with this equipment. Assistance is available from the
distributors of your Load King product and from the Load King manufacturing facility.
When operating a hydraulic crane, the operator should realize that hydraulic and
structural competence, NOT TIPPING LOAD, is often the determinant of lifting capacity.
Therefore, THE OPERATOR MUST BE GUIDED SOLELY BY THE APPROPRIATE
MANUFACTURER’S LOAD RATING CHART when considering load weights. The
manufacturers rated loads must never be exceeded.
Follow the recommended operating and maintenance procedures and keep your machine operating
at MAXIMUM EFFICIENCY. Use the Suggested Inspection Check List provided. In addition, a
MAINTENANCE LOG should be kept in conjunction with all maintenance performed on the machine.
If you desire any special information regarding the care and operation of the machine, we will gladly
furnish it upon request. We ask that you include your machine model and serial number in all
correspondence so that we can provide the correct information.
The information, specifications, and illustrations in this publication are based on the information in effect
at the time of approval for printing. We reserve the right to make changes at any time without obligation.

12
80-160
Introduction
Nomenclature
This manual contains instructions and information on the operation, maintenance, lubrication and
adjustments of the Boom Truck. The operator should not attempt to operate the machine before he has
gained a thorough understanding of the material presented in the following pages. To aid in understanding
the contents of this manual, the following terms will always have 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
block assembly, and jib arrangement.
3. DECK The deck of the Boom Truck.
4. SUBFRAME The frame of the crane that is mounted to the truck chassis and
supports the deck and superstructure.
5. OUTRIGGERS The beams, cylinders, floats, boxes, hydraulic control system.
6. TRUCK The vehicle on which all boom and operator structures are
mounted.
7. ATB Anti-Two Block
8. RCI Rated Capacity Indicator
3 1
5
4
2
6

13
Intended Use
This mobile crane is designed to lift, lower, move, and position freely suspended loads within its rated
capacity while on firm, level ground. The crane is designed exclusively for assembly type, non-duty cycle
operations. Use of this product in any other way is prohibited and contrary to its intended use.
Other crane applications outside of the intended use statement above must be approved in writing by
Load King.

14
80-160
Introduction
Bulletin Distribution and Compliance
Safety of product users is of paramount importance to Load King. Various bulletins are used by
Load King to communicate important safety and product information to dealers and machine owners.
The information contained in bulletins is tied to specific machines using the machine model number and
PIN/serial number.
Distribution of bulletins is based on the most current owner of record along with their associated dealer,
so it is important to register your machine and keep your contact information up-to-date.
To ensure safety of personnel and the reliable continued operation of your machine, be sure to implement
the action indicated in a respective bulletin.

15
Contacting Manufacturer
At times it may be necessary to contact the manufacturer of this machine. When you do, be ready to
supply the model and PIN/serial number of your machine, along with your name and contact information.
At minimum, the manufacturer should be contacted for:
• Accident Reporting
• Questions regarding product applications and safety
• Standards and regulations compliance information
• Questions regarding product modifications
• Current owner updates, such as changes in machine ownership or changes in your contact
information (see Transfer of Machine Ownership, in this chapter, for more information).
Manufacturer contact information:
Custom Truck One Source
7701 Independence Ave, Kansas City, MO
64125
Parts: (816) 241- 8387
Service: [phone]
[e-mail]
https://store.loadkingmfg.com

16
80-160
Introduction
Transfer of Machine Ownership
Complete the New Owner Registration Form on the following page. The Model Name, Product
Identification Number (PIN), and serial number is located on a plate inside the operator’s cab. The six-
digit serial number is shown on a plate on the outside of the operator’s cab.

17
LOAD KING WARRANTY DATA RECORD
Warranty Form Submission Date
Date of Delivery
Model Number
S/N
Dealer
Address
Customer
Address
Record this informaon at the me that warranty registraon form is completed and returned to Load
King.

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19
Safety
Safety Introduction
Owners, Users, and Operators:
Load King appreciates your choice of our machine for your application. Our number one priority is user
safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety
if you, as the equipment users and operators:
1. Comply with OSHA, Federal, State, and Local Regulations.
2. Read, Understand, and Follow the instructions in this and other manuals supplied with this machine.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained and competent operators, directed by informed and knowledgeable supervision,
running the machine.
OSHA prohibits the alteration or modification of this crane without written
manufacturer’s approval. Use only factory-approved parts to service or repair this
unit.
If there is anything in this manual that is not clear or you believe should be added, please send your
comments to Load King Cranes, 7701 Independence Ave, Kansas City, MO 64125; or contact us by
telephone at Parts: (816) 241- 8387 Service: [phone].
Email: [email protected].
THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED! READ, UNDERSTAND,
AND FOLLOW ALL DANGER, WARNING, AND CAUTION DECALS ON YOUR
MACHINE.
Many aspects of crane operation and testing are discussed in standards published by the American
National Standards Institute. These Standards are updated on an annual basis with addenda, that are
sent by ASME to the original purchasers of the standard. Load King recommends you purchase and refer
to the following standards.
ANSI/ASME B30.5 - Mobile & Locomotive Crane (Latest Version)
These standards can be purchased from:
American Society of Mechanical Engineers
Two Park Avenue
New York, NY 10016-5990
800-843-2763 (U.S/Canada)
001-800-843-2763 (Mexico)
973-882-1170 (outside North America)
Email:
[email protected]g
www.ASME.ORG/SHIP/STANDARDS

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80-160
Safety
Product Safety Decals
Safety Denitions Used in this Manual
The following table describes text and symbols used to highlight important information.
Signal Word Symbol Explanation
DANGER Danger is used to alert readers about an immediate and serious 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 about the potential for anything from moderate
injury to serious equipment damage or destruction.
READ Read is used to alert readers of information to be read on machinery.
NOTE Note is used for a tip or suggestion to help readers carry out a procedure
successfully.