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CUSTOM TRUCK LOAD KING 10000 Operation, Service & Parts Manual

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

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  • Page 1 OPERATION, SERVICE, & PARTS MANUAL 10000 SERVICE CRANES Manual P/N BDY32344 For service and maintenance, reach out to the call & information center at 833-CT1S-911 (833-281-7911) or email CIC@CUSTOMTRUCK.COM.
  • Page 2 REVISION A...

  • Page 3: Table Of Contents

    2.0 Safety and Operations ........................15 2.1 Safety..............................15 2.2 Responsibilities of Owners, Users and Operators ................17 2.3 Features of the Load King 10000 Crane ....................17 3.0 Service .............................. 20 3.1 Inspection ............................20 3.2 Maintenance ............................. 21 Turret Assembly ............................
  • Page 5 REVISION A REVISION CONTENT REVISION DATE DESCRIPTION LOCATION 12/2019 INITIAL RELEASE...
  • Page 6 Load King 7701 Independence Ave, Kansas City, MO 64125 Toll Free: (605) 356-3301...
  • Page 7 Beginning in February of 2015, three family-owned and operated companies (Custom Truck & Equipment, Utility Fleet Sales and Forestry Equipment of VA) joined together to form what is now Custom Truck One Source. Shortly after its inception, UCO Equipment became a part of the CTOS family along with TNT Equipment six months later.
  • Page 8 REVISION A DEFINITIONS USED IN THIS MANUAL The following table describes text and symbols used to highlight important information. Signal Word Symbol Explanation Danger is used to alert readers about an immediate and serious hazard that will likely be DANGER fatal.

  • Page 9: Specifications

    Description Description The Load King 10000 Service Crane is hydraulically powered with proportional control The Load King 10000 Service Crane is hydraulically powered with proportional control for all functions. The crane is provided with remote control which utilizes a Canbus controller.
  • Page 10 REVISION A...

  • Page 11: Load Chart

    REVISION A 1.2 Load Chart...
  • Page 12 REVISION A...
  • Page 13 REVISION A...

  • Page 14: Dimensions

    REVISION A 1.3 Dimensions 1.4 Hydraulic Requirements ISO 32 hydraulic fluid, 15 gpm flow @ 3000 psi 1.5 Minimum Chassis Requirements Rated Bending Moment (RBM)- 1,200,000 in-# Gross Vehicle Weight Rating (GVWR)- 26,000 # (11,820 kg) Body- Load King Voyager II rated 72,500 FT-# (9.54 ton-m) 1.6 Detailed Crane Functions Described Rotation is 370 degrees non-continuous and is provided by a hydraulic motor driven worm gear slewing drive.

  • Page 15: Safety And Operations

    REVISION A 2.0 Safety and Operations 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 Locomotive Cranes, and OSHA 1910.180. If required by state or local standards you may need to become a certified operator before operating this crane.
  • Page 16 REVISION A WARNING Never alter hydraulic valve settings unless recommended by factory authorized personnel. To do so could result in equipment malfunction or failure and can result in serious personal injury or death. WARNING Never alter the Hydraulic Overload Protection (HOP) system. Its function is to protect the crane from overload.

  • Page 17: Responsibilities Of Owners, Users And Operators

    Failure to comply with these regulations 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 specific features designed to enhance safety and contribute to ease of...
  • Page 18 REVISION A Emergency Stop is activated by pushing down on the E-Stop button. Release the E-Stop by twisting clockwise. In the event of a transmitter or receiver failure the tether cable can connected to restore operations. Failing that the control valve is equipped with manual overrides. Press the Dump Valve and Flow Valve override plus the function desired to override and operate manually.
  • Page 19 REVISION A 2.3.4 Hook Stow Swing Arm A feature for hook stowing has been provided in the stow swing arm which allows connecting the hook to the stow about one foot lower than usual. This means less height to lift the load block and hook to the stow bracket.

  • Page 20: Service

    REVISION A 2.3.6 Planetary Hoist The hoist is intended to be used only for lift loads vertically. WARNING Do not drag loads sideways using the Hoist or Boom functions. Undo stresses may cause com- ponent or boom failure even for light loads resulting in serious injury personal injury or death. The hoist is planetary geared for speed and efficiency.

  • Page 21: Maintenance

    REVISION A 3.2 Maintenance WARNING If removal of the main pin is ever necessary secure the boom tip with a 2500# freight strap to the rear of the 1 Stage Boom as shown below. The booms can extend out or separate with the main pin removed.
  • Page 22 REVISION A 3.2.1 Lubrication Lubricate the crane at the lube points shown in the diagram below. Use High Pressure Grease such as Lubriplate Multi-Lube A or Shell Gadus S2. CAUTION: ALL grease zerks are to be topped off prior to first use and every month following.
  • Page 23 REVISION A ITEM DESCRIPTION LUBRICANT HOURS OF OPERATION SLEW DRIVE ROLLER BEARING MULTI-LUBE A SLEW DRIVE WORM THREAD MULTI-LUBE A BEARING 1ST STG BOOM MULTI-LUBE A EDTEND CYL. ROD END MULTI-LUBE A SLEW DRIVE BALL BEARINGS MULTI-LUBE A LIFT CYL. BASE END MULTI-LUBE A LIFT CYL.
  • Page 24 REVISION A...
  • Page 25 REVISION A ITEM DESCRIPTION LUBRICANT HOURS OF OPERATION SLEW DRIVE ROLLER BEARING MULTI-LUBE A SLEW DRIVE WORM THREAD MULTI-LUBE A BEARING 1ST STG BOOM MULTI-LUBE A EDTEND CYL. ROD END MULTI-LUBE A SLEW DRIVE BALL BEARINGS MULTI-LUBE A LIFT CYL. BASE END MULTI-LUBE A LIFT CYL.
  • Page 26 REVISION A...
  • Page 27 REVISION A ITEM DESCRIPTION LUBRICANT HOURS OF OPERATION SLEW DRIVE ROLLER BEARING MULTI-LUBE A SLEW DRIVE WORM THREAD MULTI-LUBE A BEARING 1ST STG BOOM MULTI-LUBE A EDTEND CYL. ROD END MULTI-LUBE A SLEW DRIVE BALL BEARINGS MULTI-LUBE A LIFT CYL. BASE END MULTI-LUBE A LIFT CYL.

  • Page 28: Turret Assembly

    REVISION A TURRET ASSEMBLY * TORQUE 159 FT-LBS • TORQUE 159 FT-LBS AT ANNUAL INSPECTION, REMOVE THE CRANE MOUNTING BOLTS TO THE BODY AND CHECK THE TORQUE OF THE LOWER SLEW DRIVE BOLTS. REPLACE ANY BOLTS FOUND TO NOT STILL BE AT PROPER TORQUE WITH NEW BOLTS.
  • Page 29 REVISION A TURRET ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY20025 TRANSDUCER 5000 PSI 4-20mA 3 PIN BDY20020-03 CANBUS CL-451-160-10 MASTER IO MODULE BDY20020-02 RECEIVER R170E BDY00132-01 WASHER 2 1/2" OD X 1/2 ID BDY00131 SHAFT WLDMT 2" X 12-3/16 BDY00126 LIFT CYLINDER LK10000 BDY00102...
  • Page 30 REVISION A TURRET ASSEMBLY (Cont.)
  • Page 31 REVISION A TURRET ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY20022-04 HOIST 5K PLANETARY A55 DX W/ 7/16" ROPE LWSHR-08-YZGR8 LOCK WASHER 1/2 DIA YZ GR8 HNUT-08-13-YZGR8 HEX NUT 1/2-13 YZ GR8 FWSHR-08-YZGR8 FLAT WASHER 1/2 DIA YZ GR8 HCS-08-13-20-YZGR8 HEX CAP SCREW 1/2-13 X 1-1/2 YZ GR8 9005-04-04 PORT ADAPTER -04 MJ X -04 M BSPP...
  • Page 32 REVISION A TURRET ASSEMBLY (Cont.)
  • Page 33 REVISION A TURRET ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY20016 CONTROL VALVE, CRANE BDY20014 SLEW DRIVE 17" LK10000 BDY20003-01 HYDR. GAUGE 0-5000 PSI BDY00155-01 ALARM W/ LIGHT BDY00152-30 BACK COVER BDY00152 VALVE COVER ASSY. FWSHR-06-SS FLAT WASHER 3/8" SS NNUT-06-16-SS 3/8-16 NYLOCK NUT SS 6600-12-12-12...
  • Page 34 REVISION A TURRET ASSEMBLY (Cont.)
  • Page 35 REVISION A TURRET ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY20017-24 CORD GRIP, STEEL, .38 TO .50 DIA 1/2" K.O. BDY20017-23 CORD GRIP, STEEL, .25 TO .38 DIA 1/2" K.O. BDY200018-125 O-Ring 3/32 DIA X 1..299 ID X 1..500 OD 70A BDY200018-121 O-Ring 3/32 DIA X 1.049 ID X 1.255 OD NNUT-04-20-YZGR8...
  • Page 36 REVISION A WINCH...
  • Page 37 REVISION A WINCH (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY32213 BASEMENT BDY32214 BALL BEARING 6210 TYPE A BDY32160 HOLE SNAP RING Ø90 BDY32215 SEAL RING 60X75X8 BASL BDY32216 FLANGE PROFILE BDY32217 ANTIROTATION FLANGE X WINCH A50/60 BDY32218 THICKNESS SHIM ADJUSTMENT 50X62X1 BDY32162 HEX SOCKET HEAD CAP SCREW M10X20 12.9 UNI 5931 BDY32219...

  • Page 38: Winch

    REVISION A WINCH (Cont.)
  • Page 39 REVISION A WINCH (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY32176 SOFT COPPER WASHER 3/8" UNI 6953 BDY32177 PLUG TCEI 3/8" GAS DIN908 (STEEL) BDY32232 HEX HEAD CAP SCREW M8X25 10.9 UNI 5739 BDY32233 OIL SEAL 70X85X8 BASL BDY32234 BALL BEARING 6012 TYPE B BDY32235 HOLE SNAP RING Ø95 BDY32236...
  • Page 40 REVISION A TURRET ASSEMBLY (Cont.)
  • Page 41 REVISION A TURRET ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY20019 SAFETY LIMIT SWITCH BDY00149-01 ROTATION STOP PLATE HCS-06-16-SS 3/8-16 X 3-1/2 HEX CAP SCREW SS FWSHR-06-SS FLAT WASHER 3/8" SS NNUT-10-11-YZGR8 NYLOCK NUT 5/8-11 YZ GR8 16MJ-16FJFB-LX LIVE SWIVEL GATES -16 12MJ-12FJFB-LX LIVE SWIVEL GATES -12...

  • Page 42: Winch Brake

    REVISION A WINCH BRAKE...
  • Page 43 REVISION A WINCH BRAKE (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY32245 FIXING FLANGE MOTOR A60-80/SE35AS2 BDY32246 SEAL ROTO-GLYD RING S 56131-0400-A42-N BDY32247 O-RING 2-049 BDY32248 BALL BEARING 16008 BDY32249 SHOULDER RING BR 90 FOR HOLE BDY32181 O-RING 2-008 BDY32250 CUP SPRING 90X46X3,5 DIN 2093 BDY32251 BRAKE PISTON S15 BDY32252...

  • Page 44: Valve Cover

    REVISION A VALVE COVER...
  • Page 45 REVISION A VALVE COVER (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY00152-20 VALVE COVER LFT ASSY. BDY00152-10 VALVE COVER RT ASSY. BDY00152-30 BACK COVER...

  • Page 46: Control Valve

    REVISION A CONTROL VALVE...
  • Page 47 REVISION A CONTROL VALVE (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY32116 CONTROL VALVE BDY20061 12V COIL BDY32111 RELIEF VALVE 2400 PSI BDY20055 RELIEF VALVE 3000 PSI BDY20054 FLOW CONTROL VALVE BDY32112 PILOT OP. THROTTLE VALVE BDY20060 12V COIL BDY20052 DUMP VALVE BDY32113 SEAL KIT BDY32114...

  • Page 48: Boom Assembly 10022

    REVISION A BOOM ASSEMBLY—10022 *GLUE IN WITH LOCTITE 680...
  • Page 49 REVISION A BOOM ASSEMBLY—10022 (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY00221-18 INTERNAL RETAINING RING BDY00150 BOOM ANGLE KIT BDY00143-02 PIN 1.25 DIA X 1.13 LG BDY00143-01 PIN 1.25 DIA X 1.156 LG BDY00142-01 GARMAX GM3438-032 2.00 ID X 2.25 OD X 2.00 LG BDY00307 EXTENSION CYLINDER LK10022 BDY00105...

  • Page 50: Boom Assembly 10022

    REVISION A BOOM ASSEMBLY—10026 *GLUE IN WITH LOCTITE 680...
  • Page 51 REVISION A BOOM ASSEMBLY—10026 (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY00221-18 INTERNAL RETAINING RING BDY00150 BOOM ANGLE KIT BDY00143-02 PIN 1.25 DIA X 1.13 LG BDY00143-01 PIN 1.25 DIA X 1.156 LG BDY00142-01 GARMAX GM3438-032 2.00 ID X 2.25 OD X 2.00 LG BDY00398 EXTENSION CYLINDER LK10026 BDY00105...

  • Page 52: Boom Assembly 10022

    REVISION A BOOM ASSEMBLY—10030 *GLUE IN WITH LOCTITE 680...
  • Page 53 REVISION A BOOM ASSEMBLY—10030 (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY00221-18 INTERNAL RETAINING RING BDY00150 BOOM ANGLE KIT BDY00143-02 PIN 1.25 DIA X 1.13 LG BDY00143-01 PIN 1.25 DIA X 1.156 LG BDY00142-01 GARMAX GM3438-032 2.00 ID X 2.25 OD X 2.00 LG BDY00107 EXTENSION CYLINDER LK10030 BDY00105...

  • Page 54: Boom Assembly (Cont.)

    REVISION A BOOM ASSEMBLY (Cont.)
  • Page 55 REVISION A BOOM ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY00048-06 RUB PAD 2.44 x 3.44 x 0.38 BDY00048-05 RUB PAD 1.94 x 2.94 x 0.38...
  • Page 56 REVISION A BOOM ASSEMBLY (Cont.)
  • Page 57 REVISION A BOOM ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY32069 LOOP CLAMP, VIB DAMPING, ZN PLD STEEL, 5/8" ID, 1 5/8" LG BDY32033 STEEL TUBING, SMLS, 5/8" OD, 0.049" WALL THKNS, 128" LG BDY32129 ROPE GUIDE BRACKET, 1ST STG HCS-06-16-64-YZGR8 3/8-16 X 8 HEX CAP SCREW YLW ZN GR8 FWSHR-06-YZGR8...
  • Page 58 REVISION A BOOM ASSEMBLY (Cont.)
  • Page 59 REVISION A BOOM ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY00147-01 LIGHTING STANDOFF BDY20001-08 SLEEVE BEARING 1/2 ID 3/4 OD 3/8 W BDY00147-02 LIGHT MTG. ARM FWSHR-08-YZGR8 FLAT WASHER 1/2 DIA YZ GR8 1003571 NYLOCK NUT 1/2-13 GR 5 ZN BDY20123 WORK LIGHT, LED, 2520 lm, 3.75in SQ, 10 - 30VDC NNUT-04-20-YZGR8...
  • Page 60 REVISION A BOOM ASSEMBLY (Cont.)
  • Page 61 REVISION A BOOM ASSEMBLY (Cont.) ITEM NO. PART NUMBER DESCRIPTION 1001350 ZERK, GREASE FITTING STRAIGHT STEEL 1/8 NPT BDY00131-01 SHAFT WLDMT 2" X 3 BDY00127 SHEAVE ASSEMBLY, 7/16" ROPE DIA, 8.7" OD, 1-1/2" WD BDY00144 ANTI-TWO BLOCK WLDMT. BDY00144-03 A2B TARGET BDY20019 SAFETY LIMIT SWITCH...

  • Page 62: Extension Cylinder

    REVISION A EXTENSION CYLINDER...
  • Page 63 REVISION A EXTENSION CYLINDER (Cont.) ITEM NO. PART NUMBER DESCRIPTION 1027506 WELDMENT,UPPER ROLLER BDY00382 WHEEL, EXTEND CYLINDER 1027502 WELDMENT, LOWER ROLLER 1027499 WEAR PAD, SADDLE BDY00107-05 CYLINDER PIN BDY20002-18 HAIR PIN 1-1/8" - 1-1/2" DIA X 1/4" WIRE DIA...

  • Page 64: Snatch Block

    REVISION A SNATCH BLOCK...
  • Page 65 REVISION A SNATCH BLOCK (Cont.) ITEM NO. PART NUMBER DESCRIPTION BDY00237-01 SNATCH BLOCK SIDE PLATE BDY00127 SHEAVE ASSEMBLY, 7/16" ROPE DIA, 8.7" OD, 1-1/2" WD BDY00238-01 MOD. CLEVIS PIN 1.50 DIA X 3 LG BDY20002-18 HAIR PIN 1-1/8" - 1-1/2" DIA X 1/4" WIRE DIA HCS-06-16-32-YZGR8 3/8-16 X 4 HEX CAP SCREW YLW ZN GR8 BDY32117...

  • Page 66: Load King 10000 Service Crane Labels

    REVISION A LOAD KING 10000 SERVICE CRANE LABELS...
  • Page 67 REVISION A...
  • Page 68 REVISION A...
  • Page 69 REVISION A...

  • Page 70: Warranty

    REVISION A LOAD KING WARRANTY Load King (herein after 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 time of shipment, for one (1) year from date of delivery.
  • Page 71 REVISION A LOAD KING WARRANTY DATA RECORD Service Crane Warranty Form Submission Date Date of Delivery Model Number Dealer Address Customer Address Record this information at the time that warranty registration form is completed and returned to Load King...
  • Page 72 REVISION A...
  • Page 73 REVISION A...

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