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

Page: 158 / 256

REPAIR 800D
6-8
Published 5-27-2018 Control # 039-06
as required. Lubricate all cable assemblies before
reinstalling them in the boom.
5. Inspect all sheave pins for nicks, gouges or pitting due to
rust in the bearing surface area. Replace if any damage
is evident.
6. Inspect anti-two-block wire full length for damage, check
for electrical continuity.
THREE SECTION BOOM ASSEMBLY
This procedure includes assembling internal anti-two-block
wire
Note: Do not use Loctite® on any cable threaded ends.
Always use the locknut and nut provided.
When initially assembling threaded ends of cables, thread
the first on past the flat in the cables so adjustment can be
made later.
1. Assemble sheaves into 3rd section sheave case. Top
sheave is to be installed to the left hand side of the boom
with the spacer to the right hand side.
2. Attach rear wear pads on bottom of 3rd section. Using
Loctite® 243 blue, Loctite® all wear pad mounting
capscrews.
3. Install 3rd section boom into 2nd section. Slide together
approximately 5 ft (150 cm).
4. Assemble bottom front wear pads for 2nd section and
Teflon™ plugs. Attach pads to pad plate.
5. Using appropriate lifting device, lift 3rd section to allow
for wear pad/pad plate installation in front of 2nd. Install
wear pad/pad plate assembly. Slide sections together
within 12 in (30 cm) of full retraction.
6. Install front side wear pads with appropriate shims,
between 3rd and 2nd sections. If boom has been
disassembled, and no sections have been replaced, use
same shim quantity and location as was previously
used. If locations are in question, refer to shim
calibration section in this book.
7. Route anti-two-block wire through 3rd section, keeping
bulk of wire at the rear of the boom sections. Routing
can be accomplished using an installation tool, such as
a telescopic boom grease applicator, electrical conduit,
or hydraulic tubing. Route anti-two-block wire between
sheave case side plates.
8. Uncoil retract cable assemblies, and insert button end
into anchors in back of the 3rd section. Place uncoiled
cable in area that will minimize the potential for damage.
9. Assemble retract sheaves and retract sheave pins in
rear of 2nd section. Coat surfaces of bearings with
grease before assembly.
10. Place retract cables overtop of retract sheaves. Install
keeper capscrew above sheave to hold retract cables in
place.
11. Reeve cables over retract sheave and install keeper/
wear pad to bottom rear of 2nd section. This pad acts as
a side pad, bottom pad, and a cable retainer.
12. Assemble exterior telescope cylinder components.
Install and center sheave pin in sheave case end of
telescope cylinder. If boom is equipped with internal anti-
two-block wire routing make sure the sheave and spacer
are installed on pin. Install bearings into extend cable
sheaves. Coat surface of bearings with grease and
assemble extend sheaves on sheave pin. Install snap
rings.
13. Wrap approximately 10 ft (300 cm) of each 3/4 in (19.0
mm) diameter extend cable around extend sheaves and
install extend cable anchor. Do not tighten capscrews
clamping anchor together completely. These capscrews
if tightened completely will not allow cable anchor to
install into 3rd section. Route anti-two-block cable over
center sheave on telescope cylinder.
14. Install wear pad over telescope cylinder sheave side
plates. This serves as a wear pad to keep the end of the
telescope cylinder centered in the boom, as well as an
extend cable retainer.
15. Slide telescope cylinder /extend cables into 2nd-3rd
boom assembly enough to assemble extend cable
anchor into bottom rear of 3rd section. Route anti-two-
block cable over extend cable anchor as anchor slides
into 3rd section. Be aware of extend and anti-two-block
cable location when inserting cylinder into boom
sections, inadvertent crushing or other damage to
cables will warrant replacement.
16. Tighten capscrews clamping extend anchor together.
Install keeper plates to retain the extend cable anchor
and retract cables into the rear of the 3rd section.
17. Loop anti-two-block cable at the extend cable anchor in
the 3rd and install anti-two-block cable clamp. Do not
completely tighten clamp capscrew.
18. Assemble anti-two-block clamp in the sheave case.
Reeve anti-two-block cable around anchor and through
holes in side plate of sheave case. Pull approx. 2 ft (60
cm) of cable out the end of the boom for proper routing
and termination.
19. Tighten anti-two-block clamp on the extend cable anchor
in the rear of the boom. Tension anti-two-block cable
from the sheave case end of the boom, and tighten anti-
two-block clamp located in sheave case.
20. Visually verify that the extend and anti-two-block cables
are properly routed on their sheaves and continue to
slide the telescope cylinder and cables into the boom
sections. Keep extend and anti-two-block cables
supported and slightly tensioned during insertion of
cylinder, to maintain proper cable placement.
Fo
r
Reference
Only