CUSTOM TRUCK LOAD KING 10000 Guide

Manual P/N BDY32344
OPERATION, SERVICE,
& PARTS MANUAL
for
10000 SERVICE CRANES
For service and maintenance, reach out to the call & information center at
833-CT1S-911 (833-281-7911) or email [e-mail].

REVISION A
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REVISION A
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Table of Contents
1.0 Specicaons......................................................................................................................................9
1.1 General Specicaons .........................................................................................................................9
1.2 Load Chart.........................................................................................................................................11
1.3 Dimensions....................................................................................................................................... 14
1.4 Hydraulic Requirements ....................................................................................................................14
1.5 Minimum Chassis Requirements........................................................................................................14
1.6 Detailed Crane Funcons Described...................................................................................................14
2.0 Safety and Operaons.......................................................................................................................15
2.1 Safety................................................................................................................................................15
2.2 Responsibilies of Owners, Users and Operators...............................................................................17
2.3 Features of the Load King 10000 Crane ..............................................................................................17
3.0 Service ..............................................................................................................................................20
3.1 Inspecon .........................................................................................................................................20
3.2 Maintenance.....................................................................................................................................21
Turret Assembly......................................................................................................................................28
Winch.....................................................................................................................................................38
Winch Brake ...........................................................................................................................................42
Valve Cover ............................................................................................................................................44
Control valve ..........................................................................................................................................46
Boom Assembly 10022............................................................................................................................48
Boom Assembly 10022............................................................................................................................50
Boom Assembly 10022............................................................................................................................52
Boom Assembly (Cont.)...........................................................................................................................54
Extension Cylinder ..................................................................................................................................62
Snatch Block ...........................................................................................................................................64
Load King 10000 Service Crane Labels .....................................................................................................66
Warranty................................................................................................................................................70

REVISION A
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REVISION DATE DESCRIPTION LOCATION
A12/2019 INITIAL RELEASE
REVISION CONTENT

Load King
7701 Independence Ave, Kansas City, MO 64125
Toll Free: [phone]

INTRODUCTION
7
Company
Load King has been producing quality trailers since 1956. We are located in Elk Point, South Dakota.
Although the trailer industry is an ever-changing environment and we’ve seen many changes over the years,
we have remained commied to the simple philosophy that we will make a reasonable prot through the
designing, manufacturing, and markeng of top quality products that we can always be proud to call Load
King. We have not, and will not, compromise in this area.
Quality shows in all facets of an operaon, from the moment you make your rst phone call for a product
inquiry to the me you sell your used equipment and realize you’ve received top dollar on your sale. We
connue to strive for excellence in every area and never quit trying to improve. We have earned our
reputaon believing that quality is value and value sells products.
Through our shared Engineering, Markeng and Sales teams, Load King and Custom Truck One Source bring
that tradion of quality and value to another market with the Load King 10000 Service Crane.
About Custom Truck One Source
Beginning in February of 2015, three family-owned and operated companies (Custom Truck & Equipment,
Ulity Fleet Sales and Forestry Equipment of VA) joined together to form what is now Custom Truck One
Source. Shortly aer its incepon, UCO Equipment became a part of the CTOS family along with TNT
Equipment six months later. In December 2015, CTOS welcomed its sixth company under its brand, Load King,
a leading manufacturer of high-quality and customizable trailers.
The announcement of the partnership represented the plaorm’s collecve commitment to the connued
growth and dominance of each legacy company’s individual oerings, now compounded to leverage the
experse of the team and, ulmately, beer serve loyal CTOS customers all over the world. CTOS will build
upon the market posions of each legacy company, while serving as a single source supplier of specialty
equipment and services for the ulity and heavy equipment industries. The ulity and heavy equipment
plaorm collecvely oers sales, rentals, parts and aer market services, remanufacturing, customized
equipment and transportaon.

REVISION A
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DEFINITIONS USED IN THIS MANUAL
The following table describes text and symbols used to highlight important informaon.
Table—1
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 potenal for serious injury or death or serious
damage to equipment.
CAUTION
Cauon is used to alert readers about the potenal for anything from moderate injury to
serious equipment damage or destrucon.
READ Read is used to alert readers of informaon to be read on machinery
NOTE Note is used for a p or suggeson to help readers carry out a procedure successfully.

REVISION A
9
1.0 Specicaons
Descripon The Load King 10000 Service Crane is hydraulically powered with proporonal control
for all funcons. The crane is provided with remote control which ulizes a Canbus controller.
Maximum reach is 30 feet and boom elevaon varies from -15 to +80 degrees. Loads can be
controlled at angles below level as well as above level. Rotaon is 380 degrees total. With boom p
lighng the unit also serves as a mobile work light.
1.1 General Specicaons
1.0 Specicaons
Descripon The Load King 10000 Service Crane is hydraulically powered with proporonal control
for all funcons. The crane is provided with remote control which ulizes a Canbus controller.
Maximum reach is 30 feet and boom elevaon varies from -15 to +80 degrees. Loads can be
controlled at angles below level as well as above level. Rotaon is 380 degrees total. With boom p
lighng the unit also serves as a mobile work light.
1.1 General Specicaons
10030 Crane Specicaons
Crane Rang 72500 FT-# (10.81 ton-m)
*FT-# is the horizontal distance from the center of rotaon to the load line x the weight of the load
Horizontal Reach 30'-0" (9.84 m)
Hydraulic Extend 204" (5.58 m)
Crane Weight 2450# (1110kg)
Center of Gravity 39.5” (1 m) Forward of Centerline
Load Line 7/16” IWRC x 1230 FT (11.1 mm X 39.4 M)
Storage Height 40 3/4” (1.04M)
Storage Length 16’ -1/4” (5.25 m)
Mounng Plate 1 1/4" Thick (31.8mm)
Bolt Paern 14.75” x 18.75” (375 mm x 476 mm)

REVISION A
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REVISION A
11
1.2 Load Chart

REVISION A
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REVISION A
13

REVISION A
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1.3 Dimensions
1.4 Hydraulic Requirements
ISO 32 hydraulic uid, 15 gpm ow @ 3000 psi
1.5 Minimum Chassis Requirements
Rated Bending Moment (RBM)- 1,200,000 in-#
Gross Vehicle Weight Rang (GVWR)- 26,000 # (11,820 kg)
Body- Load King Voyager II rated 72,500 FT-# (9.54 ton-m)
1.6 Detailed Crane Funcons Described
Rotaon is 370 degrees non-connuous and is provided by a hydraulic motor driven worm gear
slewing drive. Patented hourglass worm technology provides increased gear strength, and the drive is
rated IP55 for dust and water incursion.
Boom Extend is provided by two double acng cylinders in a piggyback arrangement. The rst cylinder
extends/retracts the 2nd stage boom, the second cylinder extends/retracts the 3rd stage boom. The
cylinders have a dual counterbalance valve to hold the boom extension above and below level.
Hoist Up and Down is provided by a hydraulic motor connected to a planetary gear box and cable
drum with holding brake.
Boom Up and Down is provided by a double acng cylinder with a single counterbalance valve on the
base end of the cylinder.

REVISION A
15
2.0 Safety and Operaons
2.1 Safety
It is your responsibility to safely operate and maintain this crane, and adhere to all applicable
standards. Be aware of and observe all federal, state, local, and employer safety standards including
ASME B30.5 Mobile and Locomove Cranes, and OSHA 1910.180. If required by state or local
standards you may need to become a cered operator before operang this crane.
Prior to operang this unit every person working with a Load King crane should have read and
understand all material in this manual. Safe operaon requires that the crane not be overloaded,
misused or altered, all of which may void the warranty. Operators must understand the li
capacity rangs as shown on the Load Chart. Look at the horizontal distance from the center of
rotaon and the angle of boom elevaon to determine the correct load rang.
For the operator’s protecon, there are warning labels and safety devices on the Load King Crane
that are NOT to be tampered with or removed. It is important for the operator to read all warning
labels before operang the Load King Crane . It is the owner’s responsibility to ensure that the
operator and workers on and around the Crane understand all of the safety warnings herein and
axed to the machine. Do not operate Crane if safety labels are missing or damaged.
WARNING
This crane is not electrically insulated. It must never be used near energized power lines.
Load King cranes, load lines, and the load handled must always maintain a safe minimum distance
from electrically energized power lines. See ASME B30.5 for safe minimum distances and your
employer’s work rules.
WARNING
This crane must be well maintained and regularly inspected for safe and ecient operaon.
Failure to operate and maintain this crane in accordance with the instrucons of this manual can
result in serious injury personal injury or death.

REVISION A
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WARNING
Never alter hydraulic valve sengs unless recommended by factory authorized personnel. To
do so could result in equipment malfuncon or failure and can result in serious personal injury or
death.
WARNING
Never alter the Hydraulic Overload Protecon (HOP) system. Its funcon is to protect the
crane from overload.
WARNING
Never alter the An-Two Block (A2B). Its funcon is to prevent contact between the load
block and boom p sheave. The load may be suddenly dropped should contact occur resulng in se-
rious injury personal injury or death.

REVISION A
17
2.2 Responsibilies of Owners, Users, and Operators
NOTICE
Your Load King 10000 crane is designed for material handling and specically for hoisng loads
within the range of the Load Chart provided.
Owners, users, and operators have specic responsibilies as designated by OSHA 1910.180 and
ASME B30.5 and state or local requirements. Failure to comply with these regulaons can result in
citaons and nes.
WARNING
Failure to comply with these regulaons may result in equipment damage, property damage, and can
result in serious personal injury or death.
This manual will primarily be concerned with equipment features and use of the Load King 10000
crane.
2.3 Features of the Load King 10000 Crane
2.3.1 Your Load King crane has specic features designed to enhance safety and contribute to ease of
operaon.
2.3.2 Remote controls and proporonal control of all funcons are provided. A pistol grip radio
transmier sends commands to the turret mounted receiver. The transmier is linked only to its receiver by
transmied identy codes. The remote system complies with J1939. The overload protecon system controls
are programmed into the receiver.
To begin operaons, push the E-Stop clockwise unl it pops up. Hold the Engine Start switch for a few
seconds unl the TX and RX lights are ashing. This indicates the remote and receiver are linked up. The
remote will me out aer 15 minutes of inacvity. To restart engage the Engine Start switch again.
The pistol grip index nger lever movement corresponds to the speed at which the funcons operate. To
operate the Rotate, Boom Extend, Winch, or Boom Elevaon rst move the nger lever the desired amount
for starng speed. Then select a funcon or funcons with one of the toggle switches. The funcon or
funcons will then move at speeds according to the posion of the nger lever.
Remote indicator lights

REVISION A
18
Emergency Stop is acvated by pushing down on the E-Stop buon. Release the E-Stop by twisng
clockwise.
In the event of a transmier or receiver failure the tether cable can connected to restore operaons.
Failing that the control valve is equipped with manual overrides. Press the Dump Valve and Flow Valve
override plus the funcon desired to override and operate manually.
2.3.3 An-Two Block (A2B) feature prevents contact between the load block and boom p sheave.
WARNING
The load may be suddenly dropped should contact occur resulng in serious injury personal
injury or death.
The A2B is acve at all mes unl disengaged by releasing the A2B switch. Adjust the A2B frame bracket
to disengage the switch at contact. When the A2B has made contact The following funcons are disabled:
Hoist Up and Boom Extend. To exit the A2B acve condion reverse travel by Hoisng Down or Retracng
Boom.
Your A2B feature also assists in stowing the hook for travel. The A2B will stop Hoist UP as the load line is
ghtened to prevent stowing damage and relieve the load line of tension when stowed. Check the
adjustment of the A2B frame bracket to disengage the A2B switch just before the load block meets the stow
bumper.

REVISION A
19
2.3.4 Hook Stow Swing Arm
A feature for hook stowing has been provided in the stow swing arm which allows connecng the hook to
the stow about one foot lower than usual. This means less height to li the load block and hook to the stow
bracket. Once hooked rotate the stow swing arm up unl the pawl latches in. Tighten up the load line unl the
block nears the stow posion, the A2B when properly adjusted will shut o the Hoist Up.
2.3.5 Hydraulic Overload Protecon (HOP) is acve at all mes to help prevent overload situaons. The
pressure transducer located on the Li cylinder sends a pressure signal to the controller module. If the hy-
draulic pressure is above 3050 psi the HOP alarms the following funcons are disabled: Hoist Up, Boom Ex-
tend, and Boom Down. To exit the HOP acve condion Retract the boom a short distance to request HOP
exit. Then do any movement that reduces the load on the boom Hoist Down (to ground), Boom Retract, or
Boom Up unl the alarm is silent.
If the HOP condion was entered by topping the Boom all the way up to the Li cylinder’s end of stroke
(and subsequent high pressure), retract the boom a short distance to request HOP exit. The controller will al-
low 2 seconds of Boom Down to relieve the condion.

REVISION A
20
2.3.6 Planetary Hoist
The hoist is intended to be used only for li loads vercally.
WARNING
Do not drag loads sideways using the Hoist or Boom funcons. Undo stresses may cause com-
ponent or boom failure even for light loads resulng in serious injury personal injury or death.
The hoist is planetary geared for speed and eciency. It is equipped with a spring applied hy-
draulically released brake. Hoist speed is 90 FPM (feet per minute) single parted.
The Load Block BDY00236 enables the crane load line to be two parted. The end of the load
line is snatched back to the boom p instead of connected to the hook.
2.3.7 Boom Elevaon
The Li Cylinder raises and lowers the boom. It has a single counterbalance on the base end. None is re-
quired for the rod end.
3.0 Service
This unit must be regularly maintained and inspected for safe and ecient performance. See Secon 3.2
for Maintenance Schedule.
3.1 Inspecon
Inspect the unit daily if in daily if used or periodically if in occasional use. Determine the inspecon inter-
vals according to Ch. 5 Inspecon, Tesng, and Maintenance Requirements of ASME B30.5
Checklist-
• Check for loose or worn parts, missing safety related parts, and damaged parts.
• Check the load line for crushed strands and broken strands.
• Inspect that all lubricated items have been lubricated.
• Check the Transmier that all funcons are operable. Check the E-Stop.
• Check the An-Two Block (A2B) switch by liing the A2B frame to disengage the switch. The Hoist
should not raise with the A2B system disengaged.
• Check for hydraulic leaks.
• Test the Hydraulic Overload Protecon (HOP) annually. The transducer should cause the HOP to dis-
engage at 3050 psi. The HOP stops the following Hoist Raise, Boom Extend, and Boom Lower unl the
system pressure is less than 3050 psi. Exing the HOP alarm mode can be accomplished by Lowering
the load to the ground, retracng the boom (most eecve), or raising the boom.