Manitowoc National Crane 800D, Operator'S And Service Manual

Page: 145 / 256

National Crane
Published 5-27-2018 Control # 039-06 5-39
800D SERVICE
6. Extend the boom completely.
7. Use a piece of No. 9 wire as an installation tool. Make a
hook with an opening of about 1/2 in (13 mm) on one
end. With the other end of the No. 9 wire, run the wire
through the eyelet on the new wire and bend the wire
over to make a hook. Tape the No. 9 wire and new
proportioning cable to make sure these parts stay
together as the cable is installed. The new wire is now
attached to the installation tool.
8. Insert the tool into the space between the top plates of
the first and second sections and hook it over the back of
the top plate on the second section.
9. Slowly retract the boom while maintaining tension on the
new steel cable.
10. When the boom is fully retracted, reach into the boom
and pull the tool on out of the back of the boom. Detach
the tool from the new proportioning cable. Route the end
of the new wire around the sheave at the back of the first
section and align the eyelet of the cable with the hole in
the top plate of the second section. Loosely install the
5/16-18 NC capscrew.
11. On the power circuit side of the anti-two-block system,
disconnect the connectors in the turret and remove the
cushion clamp at the bottom of the boom. Loosen the
cable clamp on the top hoist end of the first section.
Loosening this wire will allow the traveling block to be
drawn out of the front end of the boom assembly.
12. While the new steel proportioning cable is being held
and guided to prevent damage, extend the boom until it
is fully extended.
13. Again using the No. 9 wire, reach into the space
between the first and second sections and hook and pull
the traveling block out of the boom assembly. Inspect
the traveling block for damage.
14. Route the proportioning cable around the sheave
mounted to the top plate of the first section. Then run the
new steel cable through the open sheave of the traveling
block. Visually inspect to ensure the wire is routed
correctly.
15. At the hoist end of the boom, slowly pull the circuit wire
back out of the back of the boom until it reaches its
original location. A crimped area on the jacket of the wire
should be visible and line up with the clamp plate.
Loosely tighten the retaining plate capscrews.
16. If the parts are properly aligned, the center pin of the
sheave on the sheave case end of the traveling block
should be about 11-1/2 in (29 cm) behind the center of
the sheave bolted to the top plate of the first section. If
the traveling block is not located correctly, it will be
damaged during boom extension or retraction.
17. Tighten the 5/16-18NC capscrew at the top hoist end of
the second section. Tighten the capscrews in the
retaining plate at the hoist end of the first section.
18. At the sheave case end of the boom, install the spacer
and capscrews in the top front of the first section. Make
sure that the new anti-two-block proportioning cable is
routed through the slot in the spacer bar.
19. Visually inspect the routing of the proportioning cable to
make sure that it is properly seated in the sheave
grooves.
20. Cut off the excess wire from the new wire that is sticking
out of the first section leaving a length of about 24 in (61
cm). This will allow a short amount of wire to use to apply
tension and for the installation of the cable stop and
shrink tube without dealing with a lot of extra wire.
21. Slide the cable stop onto the end of the wire sticking out
of the end of the first section and run it up against the
spacer bar. While pulling on the steel cable with a
tension of about 15-25 lb (7-11 kg), tighten the screw in
the cable stop.
22. Slide a new piece of shrink tube onto the end of the wire,
run it up against the cable stop, and apply heat to shrink
the tube. This will prevent the end of the wire from
fraying.
23. Cut off the excess wire leaving about 1 in (25 mm) of
wire with shrink tube sticking out of the cable stop.
24. Slowly operate the boom to make sure the sheaves turn
and the cable runs correctly.
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Reference
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