Manitowoc National Crane 800D

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SERVICE 800D

5-8

Published 5-27-2018 Control # 039-06

SAE Grade 1

and Grade 2

HHCS

SAE Grade 5

HHCS

SAE Grade 7

HHCS

SAE Grade 8

HHCS

Serrated Flange

Head

Socket Head

Shoulder Screw

Socket Head

Capscrew

FIGURE 5-2

Reference

Only

Main Page

Table of Contents5
Safety Messages11
General11
Safety Alert Symbol12
Signal Words12
General12
Accidents12
Operator Information12
Operator Qualifications13
Operational Aids14
Rated Capacity Limiter (RCL) Systems (if Equipped)14
Anti-Two-Blocking Device14
Working Area Limiter (if Equipped)15
Crane Stability/Structural Strength15
Load Charts16
Work Site16
Wind Forces16
Wind Speeds17
Lifting Operations30
Counterweight31
Outrigger Lift off31
Multiple Crane Lifts31
Tilt-Up Panel Lifting31
Pile Driving and Extracting32
Crane Equipment32
Crane Inspection32
Electrocution Hazard33
Set-Up and Operation34
Electrocution Hazard Devices34
Electrical Contact35
Special Operating Conditions and Equipment35
Grounding the Crane35
Personnel Handling36
Environmental Protection37
Maintenance37
Service and Repairs37
Lubrication38
Tires39
Hoist Rope39
Synthetic Hoist Rope39
Wire Rope39
Sheaves40
Batteries41
Engine41
Transporting the Crane41
Travel Operation42
Work Practices43
Personal Considerations43
Crane Access43
Job Preparation43
Working43
Lifting44
Hand Signals45
Boom Extension47
Parking and Securing47
Shut-Down47
Cold Weather Operation47
Temperature Effects on Hook Blocks48
Temperature Effects on Hydraulic Cylinders48
Overload Inspection49
Operation57
Truck Cab Controls57
Power Take-Off (PTO)57
Park Brake58
Crane Controls58
Control Functions58
Hydraulic Capacity Alert (HCA) System (if Equipped)59
Rated Capacity Limiter (RCL) (if Equipped)60
Crane Nomenclature62
Operating Procedures63
Equipment Familiarization63
Equipment Checks63
Cold Weather Operation63
Crane Warm-Up Procedures63
Engine63
Transmission64
Hoist64
Swing Drive and Turntable Bearing64
Axles64
Hydraulic Oil System64
Pre-Operation Inspection and Calibration Verification64
Work Site Position65
Before Leaving the Cab66
Proper Leveling of the Crane66
Bubble Level Adjustment66
Crane Set up66
Before Making the Lift67
Reading and Understanding the Load Charts67
Hoist System Operation73
Using Multiple Part Lines73
General Rules When Operating Hoist73
Lifting the Load73
Shutting down and Preparing for Road Travel74
Optional HOIST Burst of Speed Operation74
Outrigger Monitoring System (OMS) (Optional-Standard in North America)75
Operation75
Maintenance76
Anti-Two Block System78
Description/Operation78
Anti-Two-Block Weight Installation79
Hydraulic Capacity Alert System (Optional)80
System Description80
System Operation80
JIB Safety and Operation83
Safety Tips for Jib Operation84
Side Folding-Swing Around Jib Operation84
Jib Maintenance86
Jib Jack86
Adjustable Swing Speed Valve87
Standard Hand Signals for Controlling Crane Operations88
Maintenance89
Inspection and Maintenance89
Inspection89
Daily Inspections89
Weekly Inspections90
Monthly Inspections90
Periodic Inspection90
Other91
Hoist Cable Inspection and Maintenance91
Keeping Records91
Environmental Conditions91
Dynamic Shock Loads91
Precautions and Recommendations During Inspection91
Inspection92
Wire Rope Replacement92
Adjustments and Repairs93
Seizing Wire Rope93
Care of Wire Rope94
Tire Load and Inflation Table95
Lubrication100
Hydraulic Oil100
Lubrication Points100
Wire Rope Lubrication101
Lubrication Chart102
Hydraulic Oil Reservoir Level103
Protecting Cranes from Corrosion103
Cleaning Procedures103
Inspection and Repair104
Application104
Areas of Application105
Service107
Service and Repair107
Environmental Protection108
Cleanliness108
Hydraulic Systems108
Label Parts When Disassembling109
Hydraulic Oil Recommendations109
Draining and Flushing109
Removing Air from the Hydraulic System110
Welding Precautions110
National Crane Fitting O-Ring Part Numbers110
Loctite112
Fasteners and Torque Values112
Trouble Diagnosis133
Electrical137
Hydraulic137
Anti-Two-Block Internal Wire System/Four139
Section Boom (Cable on Top of Sections)139
Operation139
Maintenance139
1/2 Stage Anti-Two Block Wire Replacement139
Disassembly of 1/2 Stage139
2/3/4 Stage Anti-Two Block Wire Replacement141
Replacement of Proportioning Cable for 1/2 Stage of Anti-Two Block Wire143
Operation143
Maintenance143
Anti-Two-Block Internal Wire System/Three146
Operation146
Maintenance146
Anti-Two-Block Wire with External Reel148
Operation148
Maintenance148
Cylinder Disassembly and Repair152
Telescope Cylinder Disassembly153
Telescope Cylinder Assembly153
Three Section Boom Operation154
Boom Illustrations154
Boom Extended154
Boom Retracted154
Three Section Boom Maintenance155
Internal Cable Sheave Lubrication155
Three Section Cable Tensioning155
Three Section Boom Service156
Boom Disassembly156
Three Section Top/Bottom Pad Replacement159
Four Section Cable Tensioning161
Four Section Boom Service161
Boom Removal161
Boom Disassembly161
Four Section Boom Assembly163
Four Section Top/Bottom Pad Replacement165
Top Rear Pad Replacement165
Front Bottom Pad Replacement166
Boom Cable Tensioning166
Cable Tensioning167
Cable Tension Sequence167
4- Section Boom W/ 2 Stage Cylinder Cable Positioning168
4- Section Boom W/ 1 Stage Cylinder Cable Positioning169
3- Section Boom W/ 1 Stage Cylinder Cable Positioning170
Cable Retention171
Top/Rear Side Pad Adjustment174
Inner Boom Pad Lubrication175
Jib Installation and Adjustment176
Jib Jack Service & Maintenance177
Adding Oil178
Changing Oil178
Lubrication178
Rust Prevention178
Troubleshooting178
(Optional) Oil Cooler Service & Maintenance178
Adjustment Procedure182
Servicing the Control Valves183
Disassembly and Reassembly of Control183
Valves to Replace Seals183
Replacing Spool Seals183
Unloader Valve Service184
Control Valve Relief Adjustment185
MID-Inlet Relief Adjustment185
Unloader Dump Valve - Air Purging186
Instruction186
Hydraulic System Description186
Optional Hydraulic Capacity Alert System187
System Adjustment187
Troubleshooting188
Maintenance & Repair190
Minimum Truck Requirements197
Mounting Configurations198
Configuration 1 - 8100D198
Configuration 2 - 8100D198
Configuration 3 - 800D199
Than 8100D)199
Configuration 4 - 800D200
Than 8100D)200
Configuration 5 - Rear Mount200
PTO Horsepower Requirements201
Direct Mount Pump to PTO201
Pump Rotation201
Auger System201
PTO Selection202
Truck Frame Strength202
Section Modulus Tables203
Truck Frame Requirements for Optional Front Stabilizer206
Truck Preparation210
Welding Precautions210
Positioning Crane on Truck210
PTO, Pump, Reservoir210
Reinforcing/After Frame Extension211
After Frame Modification215
Introduction and Theory of Operation235
Hydraulic Schematic236
Maintenance and Service237
Maintenance Scheduling237
Oil Level Maintenance237
Oil Change Interval237
Hoist Brake Oil237
Hoist Gearbox Oil238
Recommended Oil238
Disassembly239
Assembly239
Installing Cable on the Hoist240
Wedge Socket Installation240
Dead-End Rigging241
Servicing the Motor242
Servicing the Brake243
Servicing the Planetary Sets244
Troubleshooting246
Hoist Won't Hold Load246
Hoist Unable to Lift Load246
Hoist Unable to Lower Load246
Oil Leaks from Motor-Side Vent246
Hoist Torque Specifications Chart247
Bill of Material248
Exploded Isometric Assembly Drawing250

Manitowoc National Crane 800D - Page 114

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