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National Crane 800D
Manitowoc National Crane 800D User Manual
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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
Fo
r
Reference
Only
113
115
Table of Contents
Table of Contents
5
Safety Messages
11
General
11
Safety Alert Symbol
12
Signal Words
12
General
12
Accidents
12
Operator Information
12
Operator Qualifications
13
Operational Aids
14
Rated Capacity Limiter (RCL) Systems (if Equipped)
14
Anti-Two-Blocking Device
14
Working Area Limiter (if Equipped)
15
Crane Stability/Structural Strength
15
Load Charts
16
Work Site
16
Wind Forces
16
Wind Speeds
17
Lifting Operations
30
Counterweight
31
Outrigger Lift off
31
Multiple Crane Lifts
31
Tilt-Up Panel Lifting
31
Pile Driving and Extracting
32
Crane Equipment
32
Crane Inspection
32
Electrocution Hazard
33
Set-Up and Operation
34
Electrocution Hazard Devices
34
Electrical Contact
35
Special Operating Conditions and Equipment
35
Grounding the Crane
35
Personnel Handling
36
Environmental Protection
37
Maintenance
37
Service and Repairs
37
Lubrication
38
Tires
39
Hoist Rope
39
Synthetic Hoist Rope
39
Wire Rope
39
Sheaves
40
Batteries
41
Engine
41
Transporting the Crane
41
Travel Operation
42
Work Practices
43
Personal Considerations
43
Crane Access
43
Job Preparation
43
Working
43
Lifting
44
Hand Signals
45
Boom Extension
47
Parking and Securing
47
Shut-Down
47
Cold Weather Operation
47
Temperature Effects on Hook Blocks
48
Temperature Effects on Hydraulic Cylinders
48
Overload Inspection
49
Operation
57
Truck Cab Controls
57
Power Take-Off (PTO)
57
Park Brake
58
Crane Controls
58
Control Functions
58
Hydraulic Capacity Alert (HCA) System (if Equipped)
59
Rated Capacity Limiter (RCL) (if Equipped)
60
Crane Nomenclature
62
Operating Procedures
63
Equipment Familiarization
63
Equipment Checks
63
Cold Weather Operation
63
Crane Warm-Up Procedures
63
Engine
63
Transmission
64
Hoist
64
Swing Drive and Turntable Bearing
64
Axles
64
Hydraulic Oil System
64
Pre-Operation Inspection and Calibration Verification
64
Work Site Position
65
Before Leaving the Cab
66
Proper Leveling of the Crane
66
Bubble Level Adjustment
66
Crane Set up
66
Before Making the Lift
67
Reading and Understanding the Load Charts
67
Hoist System Operation
73
Using Multiple Part Lines
73
General Rules When Operating Hoist
73
Lifting the Load
73
Shutting down and Preparing for Road Travel
74
Optional HOIST Burst of Speed Operation
74
Outrigger Monitoring System (OMS) (Optional-Standard in North America)
75
Operation
75
Maintenance
76
Anti-Two Block System
78
Description/Operation
78
Anti-Two-Block Weight Installation
79
Hydraulic Capacity Alert System (Optional)
80
System Description
80
System Operation
80
JIB Safety and Operation
83
Safety Tips for Jib Operation
84
Side Folding-Swing Around Jib Operation
84
Jib Maintenance
86
Jib Jack
86
Adjustable Swing Speed Valve
87
Standard Hand Signals for Controlling Crane Operations
88
Maintenance
89
Inspection and Maintenance
89
Inspection
89
Daily Inspections
89
Weekly Inspections
90
Monthly Inspections
90
Periodic Inspection
90
Other
91
Hoist Cable Inspection and Maintenance
91
Keeping Records
91
Environmental Conditions
91
Dynamic Shock Loads
91
Precautions and Recommendations During Inspection
91
Inspection
92
Wire Rope Replacement
92
Adjustments and Repairs
93
Seizing Wire Rope
93
Care of Wire Rope
94
Tire Load and Inflation Table
95
Lubrication
100
Hydraulic Oil
100
Lubrication Points
100
Wire Rope Lubrication
101
Lubrication Chart
102
Hydraulic Oil Reservoir Level
103
Carwell© Rust Inhibitor
103
Protecting Cranes from Corrosion
103
Cleaning Procedures
103
Inspection and Repair
104
Application
104
Areas of Application
105
Service
107
Service and Repair
107
Environmental Protection
108
Cleanliness
108
Hydraulic Systems
108
Label Parts When Disassembling
109
Hydraulic Oil Recommendations
109
Draining and Flushing
109
Removing Air from the Hydraulic System
110
Welding Precautions
110
National Crane Fitting O-Ring Part Numbers
110
Loctite
112
Fasteners and Torque Values
112
Trouble Diagnosis
133
Electrical
137
Hydraulic
137
Anti-Two-Block Internal Wire System/Four
139
Section Boom (Cable on Top of Sections)
139
Operation
139
Maintenance
139
1/2 Stage Anti-Two Block Wire Replacement
139
Disassembly of 1/2 Stage
139
2/3/4 Stage Anti-Two Block Wire Replacement
141
Replacement of Proportioning Cable for 1/2 Stage of Anti-Two Block Wire
143
Operation
143
Maintenance
143
Anti-Two-Block Internal Wire System/Three
146
Operation
146
Maintenance
146
Anti-Two-Block Wire with External Reel
148
Operation
148
Maintenance
148
Cylinder Disassembly and Repair
152
Telescope Cylinder Disassembly
153
Telescope Cylinder Assembly
153
Three Section Boom Operation
154
Boom Illustrations
154
Boom Extended
154
Boom Retracted
154
Three Section Boom Maintenance
155
Internal Cable Sheave Lubrication
155
Three Section Cable Tensioning
155
Three Section Boom Service
156
Boom Disassembly
156
Three Section Top/Bottom Pad Replacement
159
Four Section Cable Tensioning
161
Four Section Boom Service
161
Boom Removal
161
Boom Disassembly
161
Four Section Boom Assembly
163
Four Section Top/Bottom Pad Replacement
165
Top Rear Pad Replacement
165
Front Bottom Pad Replacement
166
Boom Cable Tensioning
166
Cable Tensioning
167
Cable Tension Sequence
167
4- Section Boom W/ 2 Stage Cylinder Cable Positioning
168
4- Section Boom W/ 1 Stage Cylinder Cable Positioning
169
3- Section Boom W/ 1 Stage Cylinder Cable Positioning
170
Cable Retention
171
Top/Rear Side Pad Adjustment
174
Inner Boom Pad Lubrication
175
Jib Installation and Adjustment
176
Jib Jack Service & Maintenance
177
Adding Oil
178
Changing Oil
178
Lubrication
178
Rust Prevention
178
Troubleshooting
178
(Optional) Oil Cooler Service & Maintenance
178
Adjustment Procedure
182
Servicing the Control Valves
183
Disassembly and Reassembly of Control
183
Valves to Replace Seals
183
Replacing Spool Seals
183
Unloader Valve Service
184
Control Valve Relief Adjustment
185
MID-Inlet Relief Adjustment
185
Unloader Dump Valve - Air Purging
186
Instruction
186
Hydraulic System Description
186
Optional Hydraulic Capacity Alert System
187
System Adjustment
187
Troubleshooting
188
Maintenance & Repair
190
Minimum Truck Requirements
197
Mounting Configurations
198
Configuration 1 - 8100D
198
Configuration 2 - 8100D
198
Configuration 3 - 800D
199
Than 8100D)
199
Configuration 4 - 800D
200
Than 8100D)
200
Configuration 5 - Rear Mount
200
PTO Horsepower Requirements
201
Direct Mount Pump to PTO
201
Pump Rotation
201
Auger System
201
PTO Selection
202
Truck Frame Strength
202
Section Modulus Tables
203
Truck Frame Requirements for Optional Front Stabilizer
206
Truck Preparation
210
Welding Precautions
210
Positioning Crane on Truck
210
PTO, Pump, Reservoir
210
Reinforcing/After Frame Extension
211
After Frame Modification
215
Introduction and Theory of Operation
235
Hydraulic Schematic
236
Maintenance and Service
237
Maintenance Scheduling
237
Oil Level Maintenance
237
Oil Change Interval
237
Hoist Brake Oil
237
Hoist Gearbox Oil
238
Recommended Oil
238
Disassembly
239
Assembly
239
Installing Cable on the Hoist
240
Wedge Socket Installation
240
Dead-End Rigging
241
Servicing the Motor
242
Servicing the Brake
243
Servicing the Planetary Sets
244
Troubleshooting
246
Hoist Won't Hold Load
246
Hoist Unable to Lift Load
246
Hoist Unable to Lower Load
246
Oil Leaks from Motor-Side Vent
246
Hoist Torque Specifications Chart
247
Bill of Material
248
Exploded Isometric Assembly Drawing
250
4
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Manitowoc National Crane 800D Specifications
General
Brand
Manitowoc
Model
National Crane 800D
Category
Construction Equipment
Language
English
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