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

Page: 164 / 256

REPAIR 800D
6-14
Published 5-27-2018 Control # 039-06
12. Reeve cables over retract sheave and install keeper/
wear pad to bottom rear of 3rd section. This pad acts as
a side pad, bottom pad, and a cable retainer. Loctite®
rear wear pad hardware on bottom of 3rd section with
Loctite® 243 blue. Loctite® all wear pad mounting
capscrews.
13. Loop the 1/2/3 extend cable in half and place it on the
top of the 3rd section, with the loop end towards the
sheave case end and the threaded and button end
towards the rear of the section.
14. Install clamp plate and capscrews with the button end of
the cable installed in the anchor slot on the rear top of
the 3rd section.
15. Place sheave pin and sheave for the 1/2/3 extend cable
in position on the sheave case end of the boom, inside
the loop of cable
16. Install 3rd and 4th section boom assembly into 2nd
section. Slide together approximately 5 ft (150 cm). Use
caution as retract cables and upper extend cable
attached to the 4th-3rd section assembly slide into the
2nd section to prevent damage or crossing of cables.
17. Assemble bottom front wear pads for 2nd section and
Teflon plugs. Attach pads to pad plate.
18. Using appropriate lifting device, lift 3rd and 4th section
assembly 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.
19. Install cable guide and spacer to top of 2nd section
20. 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. Slide sections fully
together
21. Assemble new wear pads with the cam plates and install
through the hoist mount end of the boom. Install
capscrews through holes in outer boom sections.
The wear pad on each side at the top/rear of the boom
can be adjusted over a range of 3/16 in (4.8 mm) by
rotating, end for end, the wear pad and plate or the wear
pads and plate independently. This is possible because
the holes in these parts are offset from the center. The
holes are 0.06 in (1.5 mm) off center in the plate and
0.03 in (0.8 mm) off center in the wear pad. Various
combinations of rotation of these parts allow the
adjustment.
22. Position sheave and sheave pin located in cable loop on
top of 3rd to allow capscrew installation, through top
plate of 2nd. Install capscrews and torque to
specification, clamping sheave pin and sheave to the
bottom of the 2nd section top plate.
23. Assemble retract sheaves, retract sheave pins and
cable keeper plates in rear of 2nd section. Coat surfaces
of bearings with grease before assembly.
24. Place retract cables anchored to 3rd over top of retract
sheaves attached to rear of 2nd. Install keeper capscrew
above sheave to hold retract cables in place.
25. 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.
26. Assemble exterior telescope cylinder components.
Install and center sheave pin into sheave case end of
telescope cylinder. Install bearings into extend cable
sheaves. Make sure spacers and sheave are in place for
anti-two-block wire if equipped. Coat surface of bearings
with grease and assemble extend sheaves on sheave
pin. Install snap rings.
27. Wrap approximately 10 ft (300 cm) of each 3/4 in (19.0
mm) diameter 2/3/4 extend cable around extend
sheaves and install 4th section extend cable anchor
around cables at button end. Do not tighten capscrews
clamping anchor together completely. These capscrews
if tightened completely will not allow cable anchor to
install into 4th section.
28. 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.
29. Slide telescope cylinder/extend cables into 2nd/ 3rd/4th
boom assembly enough to assemble extend cable
anchor into bottom rear of 4th section. Be aware of
extend cable location when inserting cylinder into boom
sections, inadvertent crushing or other damage to
cables will warrant replacement.
30. Tighten capscrews clamping extend cable anchor
together. This will also lock anchor in place in the anchor
cutouts in the 4th section.
31. Visually verify that the extend cables are properly routed
on their sheaves and continue to slide with the telescope
cylinder and cables into the boom sections. Keep extend
cables supported and slightly tensioned during insertion
of cylinder to maintain proper cable placement.
32. As the telescope cylinder nears complete insertion into
the 2nd/3rd/4th section assembly, adjust the height of
the cylinder to allow the cylinder anchor collars to
access the cylinder keeper cutouts in the doubler plates
on the sides of the 2nd and 3rd sections.
33. Drop the cylinder down into the vertical cutouts in the
doubler plates on the sides of the 2nd and 3rd sections.
Cylinder length or boom section placement may have to
be adjusted to allow cylinder collars to drop into their
proper position.
34. Install lock bar and capscrews to the telescope cylinder
collar in the 3rd section.
Fo
r
Reference
Only