CUSTOM TRUCK LOAD KING 25-92 User manual
INSTALLATION MANUAL
LOAD KING
25-92
MARCH 16, 2020
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LOAD KING WARRANTY
Load King (herein aer referred to as the COMPANY) warrants all products manufactured by it and
purchased by you to be free from defects in material and manufacture at the me of shipment, for one
(1) year from date of delivery. The COMPANY will furnish replacements for such parts as the COMPANY nds
to have been defecve at the me of delivery or, at the COMPANY’s opon, will make or authorize repairs to
such parts, provided that, upon request, such parts are returned, transportaon is prepaid to the factory from
which they were shipped.
This warranty shall not apply to any Product which has been subjected to misuse, misapplicaon,
overloading, neglect (including but not limited to use of unauthorized parts or aachments), adjustments or
repair. Engines, motor, res, wheels, suspensions, axles, etc. and any accessories furnished with or used in the
COMPANY’s products, but which are not manufactured by the COMPANY, are not warranted by the COMPANY
but are sold only with the express warranty, if any, or the manufacturers thereof. This warranted is limited to
the rst purchaser/user and is not transferable.
THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED (INCLUDING,
WITHOUT LIMITATIONS, OF MERCHANTABILITY AND FITNESS OF ANY PRODUCT FOR A PARTICULAR
PURPOSE), AND OF ANY OTHER OBLIGATION OR LIABILITY ON THE PART OF THE COMPANY. THERE ARE NO
WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE FACE THEREOF.
LIMITATION OF LIABILITY
It is expressly understood and agreed by you that the COMPANY’s liability for its products, whether due to
breach of warranty, or otherwise is limited to the furnishing of such replacement parts, F.O.B.
factory, and the COMPANY will not be liable for any other injury, loss, damage, or expense, whether direct or
consequenal, including but not limited to loss of use, income, prot, or producon, injury to person or
increase in cost of operaon, spoilage of or damage to material, arising out of or in connecon with the sale,
installaon, use or inability to use, or the repair or replacement of the COMPANY’s products.
All used vehicles and/or bodies are sold in the “AS IS” condion and no expressed or implied warranty is
made.
All of COMPANY’S Products are of high quality and are manufactured in conformity with the best commercial
pracces in the various lines. The COMPANY guarantees all Products manufactured by it to be free from
defects in material and manufactured at the me of shipment, for one (1) year from date of delivery. In
addion, the COMPANY guarantees the poron of the product to be considered structural for one (1) year
from date of manufacture.
While Load King, LLC. designs and manufactures its specic equipment conguraons to industry standards, it
is ulmate responsibility of the buyer/operator to assure that all loads are properly loaded and distributed.
All loads must comply with the applicable state and federal load limits.
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TABLE OF CONTENTS
25-92
PAGE TITLE
SECTION 1 - Safety
1-1 Introduction / Warranty Registration Information
1-2 Specific Points of Safety
1-3 Symbols
SECTION 2 - Installation Requirements
2-1 Sequence of Assembly / Applicable Standards
2-2 Installer Responsibilities
2-3 Chassis Requirements
2-4 Chassis Preparation
2-5 PTO Selection
2-7 Typical State Restrictions
2-8 Calculating Axle Loading
2-9 Axle Loading Calculation Procedure
2-11 Axle Loading Calculation Worksheet
2-12 Axle Loading Calculation Example
2-13 C.G. Measurement Diagram
2A-1 Component Weight Reference Table
SECTION 3 - Installation
3-1 Hydraulic Pump Installation
3-2 Frame Stiffener Installation
3-3 Main Outrigger Leg Installation
3-6 Wiring and Hose Routing
3-7 Crane Installation
3-10 Boom Installation
3-13 Electrical Wiring
3-14 Pre-Start Inspection
3-15 RCI / ATB Installation / Winch Cable Installation
3-16 Winch Cable Installation
3-17 Front Bumper Stabilizer Installation
I
TABLE OF CONTENTS
25-92
PAGE TITLE
3-18 Lift Capacity Chart Check
3-19 Stability Test Preparation
3-20Stability Test Parameters
3-21Stability Test Criteria
3-22Stability Test Procedure
3-23 Erecting the Jib
3-24 Changing the Offset of the Jib
3-25 Extending and Retracting the Jib Pullout Section
3-26 Stowing the Jib
SECTION 4 - Documentation
4-1 Stability Test Record
4-2 Truck Weights and Dimensions
4-3 Crane Information
SECTION 5 - Post Installation
5-1 Validation of Relief Valve Pressures
5-2 Adjustment of Relief Valve Pressures
SECTION 6 - Reference
6-1 Torque Chart for Installation Hardware
6-2 Chassis Nomenclature
6-4 Crane Nomenclature
SECTION 7 - RCI Operation/Setup Manual
SECTION 8 - Prints
II
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SAFETY
INTRODUCTION
K
NOTE:
Comply
Read, Understand, and Follow
Use Good, Safe Work Practices.
Only have trained operators
WARRANTY REGISTRATION INFORMATION
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: (833) 281-7911
Email: [email protected].
SAFETY
SPECIFIC POINTS OF SAFETY
Page 1 - 2
SAFETY
SYMBOLS
Page 1 - 3
The symbols below are used to inform the operator of important information con-
cerning the operation of this unit.
Safety Definitions 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.
L
K
lh
51
INSTALLATION REQUIREMENTS
Page 2 - 2
The installer is the first party to operate the complete machine. Installers are responsible for
validation of the machine and that it operates properly. While Load King cycles the boom and
main-frame assemblies at the factory,some additional work may be required once the
machine is operational.
During PTO and pump installation it is critical that the installer makes sure they have the right
rotation components to match the chassis. Incorrect rotation of the pump will result in little or no
oil flow and will likely cause pump failure. For detailed information on proper PTO and pump
installation see Section 2-5: PTO Selection, and Section 3-1: Hydraulic Pump Installation.
Once the boom has been cycled on the machine the boom assembly will require additional
adjustments which include but are not limited to:
• extend and retract cable adjustments
• pad alignment adjustments
For machines with jib options: the jib must be adjusted on a completed machine after the boom
has been cycled and the machine tested to ensure that all air is removed from the boom
extend cylinder. This adjustment will include the jib brackets and boom cables to get the jib to
pin to the boom head and stow properly. For detailed information on jib installation, see Section
3-28: Erecting the Jib, and Section 3-31: Stowing the Jib.
Relief valve pressures have been factory preset. The installer should do quick pressure checks
on the machine. Section 5has good information on pressures, both validation and adjustment.
If you have any questions with installation or need help please contact Load King at
855-548-2336.
INSTALLER RESPONSIBILITIES
K
5-
(MIN VALUES)
°
°
Bare Chassis Weights
Suspension Capacities
°
°
3
INSTALLATION REQUIREMENTS
CHASSIS PREPARATION
1.
material x
I
i!
x
T
Page 2 -4
Before the crane is mounted, Load King Cranes recommends that
instal-lation personnel give the truck a thorough inspection to
ensure that everything is up to expectations. We expect the
installer/dealer to inspect the truck for the items listed in Steps 1
through 3. These checks will make sure the truck is what you
ordered and is in condi-tion to accept the crane package. Trucks
not in proper working order, or not to specification, make for
unreliable and sometimes even dangerous crane operation.
INSTALLATION REQUIREMENTS
PTO SELECTION
IT IS HIGHLY RECOMMENDED THAT
THE PTO BE SPECIFIED WITH AN EXTER
NAL LUBE PROVISION (greese zerk) FOR
THE OUTPUT SHAF
L
K
9
2300 rpm x 100 _ 1811
127% -rpm
5
INSTALLATION REQUIREMENTS
PTO SELECTION
PTO ROTATION:
PUMP ROTATION:
EXAMPLE:
Page 2 -6
CONTACT WITH A ROTATING
DRIVELINE COMPONENT WILL CAUSE
SERIOUS INJURY OR DEATH
KEEP CLEAR OF ROTATING DRIVE
SHAFT
NEVER WORK ON AN INSTALLED
POWER TAKE-OFF WITH THE
ENGINE RUNNING
Note: Keep the protective covers
on the pump inlet and outlets until
the hoses are ready to be installed to
keep dirt out!
INSTALLATION REQUIREMEN TS
TYPICAL STATE RESTRICTIONS
Page 2 -7
A note on NON-CDL truck requirements:
Under the Commercial Motor Vehicle Safety Act of 1986, Operators of vehicles
having a GVWR of 26,001 lbs or more, must have a Commercial Driver’s License
(CDL). States may establish standards that are above and beyond the Federal
Standards, check with you individual State for their exact CDL requirements
To ensure that the final, assembled configuration of the boom truck is road legal, it
is important that the assembler understand the user’s state laws as well as the
weight distribution of the components to be assembled on the truck chassis. Before
beginning installation, AXLE WEIGHT CALCULATIONS should be done to ensure
the legality of your finished crane.
INSTALLATION REQUIREMENTS
CALCULATING AXLE LOADING
Axle Loading Calculations
AXLE LOADING CALCULATION NOTES
8
INSTALLATION REQUIREMENT S
AXLE LOADING CALCULATION PROCEDURE
a
9
Note: components that are located in
front of the front axle should be calculated
using a negative distance. This will result in a
negative weight on the rear axle for that
component. This is correct and the value
should be sub-tracted when totaling the rear
axle weight. You will also get a negative front
axle weight for items located behind the rear
axle
CAB TO SUBFRAME DISTANCE 25-92: 15"
INSTALLATION REQUIREMENT S
AXLE LOADING CALCULATION PROCEDURE
10
The final axle weight values should be compared to local, state, and federal laws to help
ensure legality of your completed crane. Also, make sure the values match your own
expectations. If you experience issues with your calculations, contact Load King
service for assistance.
Table of contents
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