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

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Manitowoc National Crane 800D Operator'S And Service Manual Download Page 7

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Daily Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Weekly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Monthly Inspections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hoist Cable Inspection and Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Keeping Records  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Dynamic Shock Loads  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Precautions and Recommendations During Inspection  . . . . . . . . . . . . . . . . . . . . . . 3-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Wire Rope Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Adjustments and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Seizing Wire Rope  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Care of Wire Rope  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Tire Load and Inflation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Lubrication Procedures And Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Wire Rope Lubrication  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Lubrication Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Hydraulic Oil Reservoir Level  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Carwell© Rust Inhibitor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Protecting Cranes From Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cleaning Procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Application  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Areas of Application  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Service  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Service and Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Systems  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Label Parts When Disassembling   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Removing Air From the Hydraulic System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
National Crane Fitting O-ring Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Loctite®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fasteners and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Using Torque Wrench Extensions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Anti-two Block Trouble Diagnosis — Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Anti-two Block Trouble Diagnosis — Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Anti-two-block Internal Wire System/Four Section Boom (Cable On 

Top Of Sections) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

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Summary of Contents for National Crane 800D

Page 1: ...Operator and Service Manual National Crane 800D F o r R e f e r e n c e O n l y ...

Page 2: ...more information go to www P65warnings ca gov diesel Batteries battery posts terminals and related accessories can expose you to chemicals including lead and lead compounds which are known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling For more information go to www P65warnings ca gov California Spark Arrestor Operation of this equ...

Page 3: ...e builder s decal attached to the crane frame Always furnish crane serial number when ordering parts or communicating service problems with your distributor or the factory An untrained operator subjects himself and others to death or serious injury Do not operate this crane unless You are trained in the safe operation of this crane National Crane is not responsible for qualifying personnel You rea...

Page 4: ...F o r R e f e r e n c e O n l y ...

Page 5: ...and Extracting 1 22 Crane Equipment 1 22 Crane Inspection 1 22 Electrocution Hazard 1 23 Set Up and Operation 1 24 Electrocution Hazard Devices 1 24 Electrical Contact 1 25 Special Operating Conditions and Equipment 1 25 Grounding the Crane 1 25 Personnel Handling 1 26 Environmental Protection 1 27 Maintenance 1 27 Service and Repairs 1 27 Lubrication 1 28 Tires 1 29 Hoist Rope 1 29 Synthetic Hois...

Page 6: ...g of the Crane 2 10 Bubble Level Adjustment 2 10 Crane Set Up 2 10 Before Making The Lift 2 11 Reading and Understanding the Load Charts 2 11 Hoist System Operation 2 17 Using Multiple Part Lines 2 17 General Rules When Operating Hoist 2 17 Lifting the Load 2 17 Shutting Down and Preparing for Road Travel 2 18 Optional HOIST Burst of Speed Operation 2 18 Outrigger Monitoring System OMS Optional St...

Page 7: ...t 4 4 Hydraulic Oil Reservoir Level 4 5 Carwell Rust Inhibitor 4 5 Protecting Cranes From Corrosion 4 5 Cleaning Procedures 4 5 Inspection and Repair 4 6 Application 4 6 Areas of Application 4 7 Service 5 1 Service and Repair 5 1 Environmental Protection 5 2 Cleanliness 5 2 Hydraulic Systems 5 2 Label Parts When Disassembling 5 3 Hydraulic Oil Recommendations 5 3 Draining and Flushing 5 3 Removing...

Page 8: ...sassembly 6 6 Additional Maintenance Disassembled Boom 6 7 Three Section Boom Assembly 6 8 Three Section Top bottom Pad Replacement Assembled Boom 6 9 Top Rear Pad Replacement 6 9 Front Bottom Pad Replacement 6 10 Four Section Boom Operation 6 10 Four Section Boom Maintenance 6 10 Internal Cable Sheave Lubrication 6 10 Four Section Cable Tensioning 6 11 Four Section Boom Service 6 11 Boom Removal ...

Page 9: ...tem 7 15 System Adjustment 7 15 Troubleshooting 7 16 Maintenance Repair 7 18 Specifications 8 1 Specifications 8 2 Installation 9 1 Typical Locations Serial Number Identification 9 2 Minimum Truck Requirements 9 3 Mounting Configurations 9 4 Configuration 1 8100D 9 4 Configuration 2 8100D 9 4 Configuration 3 800D all booms other than 8100D 9 5 Configuration 4 800D all booms other than 8100D 9 6 Co...

Page 10: ...nance and Service 11 5 Maintenance Scheduling 11 5 Oil Level Maintenance 11 5 Oil Change Interval 11 5 Hoist Brake Oil 11 5 Hoist Gearbox Oil 11 6 Recommended Oil 11 6 Disassembly 11 7 Assembly 11 7 Installing Cable On The Hoist 11 8 Wedge Socket Installation 11 8 Dead end Rigging 11 9 Servicing the Motor 11 10 Servicing the Brake 11 11 Servicing the Planetary Sets 11 12 Troubleshooting 11 14 Hois...

Page 11: ...Protection 1 27 Maintenance 1 27 Service and Repairs 1 27 Lubrication 1 28 Tires 1 29 Hoist Rope 1 29 Synthetic Hoist Rope 1 29 Wire Rope 1 29 Sheaves 1 30 Batteries 1 31 Engine 1 31 Transporting the Crane 1 31 Travel Operation 1 32 Work Practices 1 33 Personal Considerations 1 33 Crane Access 1 33 Job Preparation 1 33 Working 1 33 Lifting 1 34 Hand Signals 1 35 Boom Extension 1 37 Parking and Sec...

Page 12: ...immediately advised of the incident and consulted on necessary inspections and repairs Should the distributor not be immediately available contact should be made directly with Manitowoc Product Safety at the address below The crane must not be returned to service until it is thoroughly inspected for any evidence of damage All damaged parts must be repaired or replaced as authorized by your Nationa...

Page 13: ...nings and must be read prior to any operational or maintenance function Refer to the Parts Manual for this crane for the locations of all safety decals You must be familiar with the regulations and standards governing cranes and its operation Work practice requirements may vary slightly between government regulations industry standards and employer policies so a thorough knowledge of all such rele...

Page 14: ...ning Device is inoperative or malfunctioning the designated person responsible for supervising the lifting operations shall establish procedures such as assigning an additional signal person to furnish equivalent protection This does not apply when lifting personnel in load line supported personnel platforms Personnel shall not be lifted when anti two block devices are not functioning properly Whe...

Page 15: ...onditions It is not a replacement for operator awareness and competence Never interfere with the proper functioning of operational aids or warning devices Working Area Limiter If Equipped This crane may be equipped with a working area limiter as part of the RCL system designated as either Work Area Definition System WADS or Working Range Limiter WRL You must read and understand the operator manual...

Page 16: ...ders plus center front stabilizer if equipped must be properly extended and set to provide precise leveling of the crane Tires must be clear of the ground before lifting on outriggers KEEP THE BOOM SHORT Swinging loads with a long line can create an unstable condition and possible structural failure of the boom Load Charts Load Charts represent the absolute maximum allowable loads which are based ...

Page 17: ...peed V z may be calculated based on mean wind speed reported at http www windfinder com Super Forecast This 3 second wind gust is assumed to act on the entire crane and the load The wind effect on the load can be conservatively estimated as a If V z is 13 4 m s 30 mph then the allowable load is the published rated capacity from the Load Chart b If V z is 13 4 m s 30 mph and is 20 1 m s 45 mph the ...

Page 18: ...e lifting operations and lower and retract the boom In both cases a and b above the lift may also be limited by the projected wind area of the load Ap and by the wind drag coefficient Cd This limit can be determined by comparing the Actual wind resistance area with the Allowable wind resistance area Refer to Figure 1 1 for a simplified calculation method to determine permissible wind speed F o r R...

Page 19: ...ate Awr load Ap X Cd Determine Cd of Load Ap maximum height X maximum length See Figure 1 2 Lifting is not permitted Cease Lifting Operations V z 20 1 m s 45 mph 13 4 m s V z 20 1 m s 30 mph V z 45 mph Use Main Boom on Fully Extended Outriggers ONLY V z 13 4 m s 30 mph Main Boom Allowable load Published Rated Capacity Allowable Load Published Rated Capacity X Capacity Reduction Factor from Load Ch...

Page 20: ... Shape of the load These rated capacities are also based on the assumption that the Wind Resistance Area of load Awr load is not more than 0 0012 square meters per kilogram 0 0059 sq ft per pound of load See below Formulas 2 4 and 2 5 The load capacities shall be reduced to account for the larger wind resistance area of load and 3 second wind gust speed at boom tip height Use tag lines when the wi...

Page 21: ... Drag Coefficient Cd values If the exact Wind Drag Coefficient of a shape is not known use the maximum value of the shape s range Table 1 2 If the wind drag coefficient of the load cannot be estimated or determined it shall be assumed that Cd 2 4 Ap 24 m2 Ap 8 m2 Wind Wind 8 m 1 m 3 m 8 m 1 m 3 m Ap 250 ft2 Ap 75 ft2 Wind Wind 25 ft 3 ft 10 ft 25 ft 3 ft 10 ft 8384 1 FIGURE 1 2 F o r R e f e r e n...

Page 22: ...ng Table 1 3 Table 1 3 Awr Ratio and Permissible Wind Speed V z Non metric 8384 2 Shape Cd 1 1 to 2 0 0 3 to 0 4 0 6 to 1 0 0 8 to 1 2 0 2 to 0 3 0 05 to 0 1 Approximately 1 6 Turbine Blade or Complete Rotor Note Permissible and rated wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph For Rated Capacity at 30 mp...

Page 23: ...National Crane Published 5 27 2018 Control 039 06 1 13 800D SAFETY INFORMATION Rated Load Chart Example Metric FIGURE 1 3 8383 1 F o r R e f e r e n c e O n l y ...

Page 24: ... second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed m s For Rated Capacity at 13 4 m s 12 2 11 4 10 6 10 0 9 5 For Allowable Capacity at 20 1 m s 18 3 17 0 15 9 15 0 14 2 Table 1 4 Example Capacity Reduction Factors for Wind Speed V z Greater than 13 4 m s Metric Only for lifting with main boom on fully extended outriggers with or without stowed exten...

Page 25: ... Conclusion This load is permissible to lift in wind speed up to 20 1 m s Load example 1 3a With large wind resistance area of the load Awr load Load to be lifted of 14 000 kg Projected Wind Area Ap 21 85 m2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap X Cd 21 85 x 1 2 26 22 m2 Refer to the above Lifting Limits at wind speed V z 13 4 m s and 20 1 m ...

Page 26: ...NO Conclusion This load is NOT permissible to lift in wind speed up to 20 1 m s but permitted to lift at a reduced wind speed calculated as follows Ratio 1 37 From Table 1 5 the maximum permissible wind speed at ratio of 1 37 rounded to next higher table value of 1 4 is 17 0 m s Conclusion This load is permissible to lift in wind speed up to 17 0 m s only F o r R e f e r e n c e O n l y ...

Page 27: ...National Crane Published 5 27 2018 Control 039 06 1 17 800D SAFETY INFORMATION Rated Load Chart Example Non metric FIGURE 1 4 8382 1 F o r R e f e r e n c e O n l y ...

Page 28: ...low 0 0059 x 20 160 119 ft2 Note Permissible and rated wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph For Rated Capacity 30 mph 27 4 25 4 23 7 22 4 21 2 For Allowable Capacity 45 mph 41 1 38 0 35 6 33 5 31 8 Table 1 6 Example Capacity Reduction Factors for Wind Speed V z Greater than 30 mph Non metric Only f...

Page 29: ...onclusion This load is permissible to lift in wind speed up to 45 mph Load example 2 3a With large wind resistance area of the load Awr load Load to be lifted of 22 000 lb Projected Wind Area Ap 180 ft2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap x Cd 180 x 1 2 216 ft2 Refer to the above Lifting Limits at wind speed V z 30 mph and 45 mph Comparing ...

Page 30: ...to the crane and as close to the ground as possible Do not overload the crane by exceeding the capacities shown on the appropriate Load Chart Death or serious injury could result from the crane tipping over or failing structurally from overload The crane can tip over or fail structurally if The load and crane s configuration is not within the capacity as shown on the applicable Load Chart and note...

Page 31: ...person to direct the operation Make sure all signals are coordinated through the lift director or person in charge of the lift Coordinate lifting plans with the operators designated person and signal person prior to beginning the lift Maintain communication between all parties throughout the entire operation If possible provide approved radio equipment for voice communication between all parties e...

Page 32: ... ground The combined weight of the driver or extractor piling leads attachments etc shall not exceed 80 of the published load chart values for on outriggers operation The pile driver or pile extractor and attachments shall be kept clear of the boom nose at all times The pile driver and piling shall be suspended from a hoist cable with sufficient line speed to meet or exceed the rate of descent of ...

Page 33: ...on and prudent judgement Operate slowly and cautiously when in the vicinity of power lines Before operating this crane in the vicinity of electrical power lines or equipment notify the power utility company Obtain positive and absolute assurance that the power has been turned off This crane is not insulated Always consider all parts of the load and the crane including the wire rope hoist cable pen...

Page 34: ...Electrocution Hazard Devices The use of insulated links insulated boom cages guards proximity warning devices or mechanical limit stops does not assure that electrical contact will not occur Even if codes or regulations require the use of such devices failure to follow the rules listed here may result in serious injury or death You should be aware that such devices have limitations and you should ...

Page 35: ...evidence of damage and all damaged parts are repaired or replaced as authorized by your National Crane distributor or Manitowoc Crane Care Special Operating Conditions and Equipment Never operate the crane during an electrical thunderstorm When operating near transmitter communication towers where an electrical charge can be induced into the crane or load The transmitter shall be deenergized OR Te...

Page 36: ...itions Additional requirements for crane operations are stated in ASME B30 5 Mobile and Locomotive Cranes ASME B30 8 Floating Cranes and Floating Derricks and in OSHA regulations 29CFRI910 180 for General Industry and 29CFRI926 1431 for Construction Use of a National crane to handle personnel is acceptable provided The requirements of the applicable national state and local regulations and safety ...

Page 37: ...into leak proof containers that are clearly marked with what they contain Always fill or add fluids with a funnel or a filling pump Immediately clean up any spills MAINTENANCE The crane must be inspected prior to use on each work shift The owner user and operator must ensure that routine maintenance and lubrication are being dutifully performed Never operate a damaged or poorly maintained crane Na...

Page 38: ...arts Amputation of a body part may result Turn off the engine and wait until the fan and belts stop moving before servicing crane Pinch points which result from relative motion between mechanical parts are areas of the machine that can cause personal injury or death Do not place limbs or your body in contact with pinch points either on or around the machine Care must be taken to prevent motion bet...

Page 39: ...iameter For running ropes other than rotation resistant six 6 broken wires in one rope lay or three 3 broken wires in one strand One valley break where the wire fractures between strands in a running rope is cause for removal Abrasion of the rope resulting in a 5 reduction in the original wire diameter Any kinking bird caging crushing corrosion or other damage resulting in distortion of the rope s...

Page 40: ... a wire rope Lack of lubrication can significantly shorten the useful life of a wire rope Contact with electrical wires and resulting arcing will damage a wire rope An inspection should include verification that none of the specified removal criteria for this usage are met by checking for such things as Surface wear nominal and unusual Broken wires number and location Reduction in diameter Rope st...

Page 41: ... well ventilated area that is free of flame smoking sparks and fire Engine Fuel the crane only with the engine turned off Do not smoke while fueling the crane Do not store flammable materials on the crane Be familiar with the location and use of the nearest fire extinguisher Be careful when checking the engine coolant level The fluid may be hot and under pressure Shut down the engine and allow the...

Page 42: ...inst collisions or bumping structures Before traveling a crane check suitability of proposed route with regard to crane height width and length Never back up without the aid of a signal person to verify the area behind the crane is clear of obstructions and or personnel On cranes equipped with air operated brakes do not attempt to move the crane until brake system air pressure is at operating leve...

Page 43: ...n the crane This practice will prevent ground personnel from being crushed or electrocuted when they attempt to access personal belongings stored on the crane Job Preparation Before crane use Barricade the entire area where the crane is working and keep all unnecessary personnel out of the work area Ensure that the crane is properly equipped including access steps covers doors guards and controls ...

Page 44: ... operator s control station Do not reach in a window or door to operate any controls Operate the crane slowly and cautiously looking carefully in the direction of movement A good practice is to make a dry run without a load before making the first lift Become familiar with all factors peculiar to the job site Ensure the rope is properly routed on the hook block and boom nose and that all rope guar...

Page 45: ... lower the boom into the carrier cab if applicable Never push or pull loads with the crane s boom never drag a load Do not subject crane to side loading A side load can tip the crane or cause it to fail structurally If the boom should contact an object stop immediately and inspect the boom Remove the crane from service if the boom is damaged When lifting a load the boom may deflect causing the loa...

Page 46: ...MATION 800D 1 36 Published 5 27 2018 Control 039 06 8496 1 FIGURE 1 6 Reprinted from ASME B30 5 2014 by permission of The American Society of Mechanical Engineers All Rights Reserved F o r R e f e r e n c e O n l y ...

Page 47: ...oad on the hook or in erection mode or in wind conditions in excess of allowed values The boom should be retracted as far as is practical the crane configured in as stable a configuration as possible boom angle superstructure orientation boom extension angle etc In high winds the boom and boom extensions should be lowered or secured Changing weather conditions including but not limited to wind ice...

Page 48: ...ded 1 5 m 5 ft in which the oil cools 15 5 C 60 F would only retract approximately 38 mm 1 1 2 in The rate at which the oil cools depends on many factors and will be more noticeable with a larger difference in oil temperature verses the ambient temperature Thermal contraction coupled with improper lubrication or improper wear pad adjustments may under certain conditions cause a stick slip conditio...

Page 49: ...6 6 45 7 74 9 03 10 32 11 61 12 90 30 1 55 3 10 4 64 6 19 7 74 9 29 10 84 12 38 13 93 15 48 35 1 81 3 61 5 42 7 22 9 03 10 84 12 64 14 45 16 25 18 06 40 2 06 4 13 6 19 8 26 10 32 12 38 14 45 16 51 18 58 20 64 45 2 32 4 64 6 97 9 29 11 61 13 93 16 25 18 58 20 90 23 22 50 2 58 5 16 7 74 10 32 12 90 15 48 18 06 20 64 23 22 25 80 55 2 84 5 68 8 51 11 35 14 19 17 03 19 87 22 70 25 54 28 38 60 3 10 6 19...

Page 50: ...ion for overloads up to 50 Stop operating the crane and contact Manitowoc Crane Care immediately for overloads of 50 and higher NOTE If your crane is equipped with CraneSTAR an overload warning will be posted to the web site for review by the crane owner Overload warnings do NOT indicate real time events Warnings could be sent 24 hours or more after the actual event F o r R e f e r e n c e O n l y...

Page 51: ...National Crane Published 5 27 2018 Control 039 06 1 41 800D SAFETY INFORMATION Boom Inspection Illustration for reference only Your crane may be different 9455 F o r R e f e r e n c e O n l y ...

Page 52: ...r damage 2 Collar Wear Pads Pad Retainers Inspect all for damage 3 Collar welds Inspect all for damage 4 Pinning Areas Inspect all for cracks 5 Telescopic Sections Inspect for bent or twisted sections Check the boom for straightness 6 Lift Cylinder Head Area Inspect for bends or cracked welds 7 Turret Base Section Inspect for cracked welds 8 Jib Section Inspect for bent or twisted section Check fo...

Page 53: ...National Crane Published 5 27 2018 Control 039 06 1 43 800D SAFETY INFORMATION Superstructure Inspection Illustration for reference only Your crane may be different 9456 F o r R e f e r e n c e O n l y ...

Page 54: ...nder Inspect for leaking 2 Wire Rope Inspect all for damage See topic in Introduction section of Service Manual 3 Turntable Bearing Check bolts for proper torque See topic in Swing section of Service Manual 4 Hoist Drums Inspect each for damage 5 Hoist Brakes Brakes must hold rated line pull 6 Bearing Main Boom Pivot Pin Inspect for deformation cracked welds 7 Lift Cylinder Lower Mount Inspect pin...

Page 55: ...National Crane Published 5 27 2018 Control 039 06 1 45 800D SAFETY INFORMATION Carrier Inspection Illustration for reference only Your crane may be different 9457 F o r R e f e r e n c e O n l y ...

Page 56: ...2 Outrigger Pads Inspect for deformation and cracked welds Overload from 25 to 49 1 Stabilizer Cylinders Inspect for leaking 2 Outrigger Pads Inspect for deformation and cracked welds 3 Outrigger Beams Inspect for deformation and cracked welds 4 Outrigger Boxes Inspect for deformation and cracked welds 5 Welds Inspect for cracks 6 Paint Inspect for cracked paint which could indicate twisted stretc...

Page 57: ...n Operation 2 22 Anti two block Weight Installation 2 23 Hydraulic Capacity Alert System Optional 2 24 System Description 2 24 System Operation 2 24 JIB Safety and Operation 2 27 Safety Tips For Jib Operation 2 28 Side Folding swing Around Jib Operation 2 28 Jib Maintenance 2 30 Jib Jack 2 30 Adjustable Swing Speed Valve 2 31 Standard Hand Signals For Controlling Crane Operations 2 32 TRUCK CAB CO...

Page 58: ...om Operate the lever to IN to retract the boom Hoist Operate the lever to DOWN to payout and lower the loadline Operate the lever to UP to reel in and raise the loadline Refer to hoist system operation section for additional information Payout loadline before extending boom Failure to do so may cause the loadline to break or damage the crane Stabilizers Up Down Operate the lever to DOWN to lower a...

Page 59: ...een OK 2 Yellow Caution and 3 Red Overload Do not use the Load Range Gauge with a jib Refer to Hydraulic Capacity Alert System for more information HCA Overload Light Indicator light illuminates when HCA detects crane overload and boom down extend out and hoist up functions disabled ATB Light Indicator light illuminates when a two block condition is detected Override Key Switch The Override Key Sw...

Page 60: ...e gusset under the turret QScale Operator Console The QScale operator console displays data about the crane the operator needs to operate the crane effectively and safely including the status of the outriggers boom status and load chart information The monitor is mounted on a swing arm on the front assembly and can be adjusted for use on either operator platform For more information about the cons...

Page 61: ...ill override the RCL ATB continuously until the key is turned to the OFF position Do not use override to continue lifting operations in an overload or two blocked condition The override push button Figure 2 2 is located on the bulkhead between the crane s two operator positions Push down the button to temporarily override the RCL ATB system When the button is released the RCL ATB system is no long...

Page 62: ...TOP SWITCH HORN PRESSURE GAUGE HCA LOAD RANGE GAUGE OVERLOAD LIGHT OVERRIDE BUTTON ATB LIGHT HCA LOAD RANGE GAUGE OPTIONAL HCA SYSTEM BOOM ANGLE INDICATOR RCL CENTRAL PROCESSING UNIT RCL DISPLAY CONSOLE CAPACITY CHART LEVEL INDICATOR SWING ADJUSTMENT KNOB FOOT THROTTLE COVER OVERRIDE KEY SWITCH OPTIONAL HCA RCL SYSTEM BOOM LENGTH INDICATOR Illustration for reference only Your crane may be differen...

Page 63: ...e hydraulic oil lubricants and other auxiliary items required for operation in very cold temperatures Operate individual crane functions to ensure they are sufficiently warmed prior to performing a lift Operation of cranes at full rated capacities in temperatures between 9 C 15 F and 40 C 40 F or lower should be accomplished only by competent operators who possess the skill experience and dexterit...

Page 64: ... than one RPM for at least one complete revolution in the opposite direction Warm up Procedures for Temperatures Below 7 C 20 F 1 Ensure the boom is fully retracted and near maximum lift angle with no load applied 2 Rotate the superstructure at a speed of less than one half RPM for at least two complete revolutions in one direction then rotate the superstructure at a speed of less than one half RP...

Page 65: ...rees with the actual boom angles Check that the display of the operating radius of the crane agrees with the actual radius Check the load display by lifting a load of known weight The accuracy of the load indication shall be within the tolerance of SAE J159 Operation After being properly checked the RCL is operational The operator shall be thoroughly familiar with all controls of the RCL and he sh...

Page 66: ...rm level surface 2 Extend and set the outriggers Level the crane as indicated by the bubble level indicator using the outriggers 3 Place a miracle pointer level carpenter level or similar type device on a machined surface such as the turntable bearing or bearing mounting surfaces 4 Using the outriggers level the crane as indicated on the leveling device used in step 3 5 Using the bubble level indi...

Page 67: ...ontrols should be metered when beginning or terminating a movement to prevent sudden starting or stopping which imposes undue shock loads on the equipment This metering can be performed by metering the control lever and the foot throttle 3 Check the operating area for electric powerlines READING AND UNDERSTANDING THE LOAD CHARTS The structures and components of your unit are designed to provide sa...

Page 68: ...ine or use of equipment that is not factory specified or approved can be hazardous Refer to capacity deduction chart for weights which must be deducted from rated loads when accessories are attached to boom or loadline Set Up 1 Inspect vehicle and crane including crane operation prior to use each day 2 Load ratings shown on the chart are maximum allowable loads with the crane mounted on a factory ...

Page 69: ...ore loading should be greater to account for deflections The loaded boom angle combined with the boom length give only an approximation of the operating radius 3 Working Area Area measured in a circular arc above the center line of rotation as shown on the Working Area diagram If no decal is present the work area is 360 4 Freely Suspended Load Load hanging free with no direct external force applie...

Page 70: ...e Allowable load for single part line is 7700 lb 3492 kg well above the 6300 lb 2858 kg to be lifted Operator should now proceed to lift the load as smoothly as possible Example 2 Assume a load of 9000 lb 4082 kg at 10 ft 3 04 m radius on the ground beside the truck to be picked up swung over and placed on the truck bed at an 8 ft 2 43 m radius from the crane Crane is reeved for single part Step 1...

Page 71: ...m jib deployed and the boom fully extended the capacity is 3900 lb 1769 kg at a 30 ft 9 14 m radius and boom angle of 78 Ending Point With the main boom still fully extended the capacity is 2800 lb 1270 kg at a radius of 40 ft 12 19 m and boom angle of 73 Note The capacity of the jib remains the same even with the main boom retracted Operate with jib by radius when main boom is fully extended and ...

Page 72: ... 600 46 5 100 56 5 4 750 63 4 400 67 5 4 250 80 51 5 400 58 600 45 38 4 250 51 5 4 050 59 5 3 800 64 5 3 650 85 55 5 450 50 28 5 3 400 46 3 450 55 3 250 61 3 150 55 14 2 200 40 2 900 51 2 800 57 5 2 650 60 33 2 350 46 5 2 400 54 2 300 65 24 1 800 41 2 000 50 1 850 70 6 5 700 35 5 1 600 46 1 650 75 29 1 250 42 1 350 80 20 800 37 1 050 85 32 800 90 25 500 0 5 100 0 2 300 0 950 0 150 ADD TO CAPACITIE...

Page 73: ...to neutral to determine if the brake is working properly 6 Do not drag loads in any direction with the hoist 7 Never attempt to lift loads which are not loose and free i e frozen down material or poles out of ground 8 Maintain tension on the loadline at all times to prevent the cable from becoming twisted or kinked or improperly seated on the hoist drum or sheaves LIFTING THE LOAD After the vehicl...

Page 74: ... any loads or lifting devices on truck bed or body 6 Disengage Power Take Off PTO 7 Release park brake before moving truck 8 When traveling on the road check all underpasses to be sure there is sufficient clearance for the unit OPTIONAL HOIST BURST OF SPEED OPERATION The Burst of Speed will increase hoist line speed 60 over normal operation by diverting oil from the multibank control valve to the ...

Page 75: ...ty stabilizers beams shall be fully extended on cranes equipped with Rear Stabilizer Out and Down RSOD the Outrigger Status Indicator illuminates constant GREEN indicating a lift can be made If power is on and one or more outrigger or stabilizer beams are not extended to a position which provides maximum stability the Outrigger Status Indicator flashes RED indicating a lift should not be made If t...

Page 76: ...or 1 to sensor 5 Calibrate sensor Refer to Calibrate page 20 Calibrate Calibrating the cylinder length sensor requires a laptop equipped with the HED Conductor software and a USB cable connector p n 80009992 Contact your National Crane distributor for further assistance Outrigger Proximity Switch Version 2 On newer versions of the 800D the OMS and RCL use proximity switches to determine if the out...

Page 77: ... turns from constant red to constant green when the outrigger is fully extended or If equipped with an RCL and OMS systems outrigger status is shown on the QScale monitor Make sure all outrigger status symbols turn from red to green when the outriggers are fully extended Stabilizer Proximity Switch version 1 The following procedures describe maintenance of the proximity switches on the stabilizers...

Page 78: ...s When the cartridge solenoid is energized the crane functions normally when de energized the oil to the boom extend boom down and hoist up crane functions are diverted to tank These solenoids are controlled by a limit switch which is attached to the boom or jib sheave case This switch is held in the closed position by a chain suspended weight The weight which is looped around the hoist cable caus...

Page 79: ...hown in Figure 2 11 ATB Switch Lanyard Upper Quicklink Chain 16 in long 40 cm Load Line Lower Quick Link ATB Weight PROPER ATB WEIGHT RIGGING 9367 FIGURE 2 11 The anti two block chain must be installed between the slot in the weight and the hoist cable Anti two block Weight hoist Cable Slot Chain Length 16 inches 40 cm Do not shorten the chain Upper Link Lower Link F o r R e f e r e n c e O n l y ...

Page 80: ...n Section Once an over capacity condition is reached the system will not allow the operator to move the load to a greater radius The truck may have to be repositioned closer to the load in order to set the load at the desired location When trip pressure is reached the pressure sensing switch breaks electrical continuity to the work port unloader solenoid in the main control valve When power is rem...

Page 81: ...e gauge only provides accurate indication when the lift control lever is in neutral The gauge movement is not proportional to the load on the hook It is not unusual for the indicator to be in the red area at less than rated load condition when operating the lift control especially during boom down operation FIGURE 2 12 9472 FIGURE 2 13 9473 9368 F o r R e f e r e n c e O n l y ...

Page 82: ...ll capacity 5 Extending the boom without first paying out the loadline which can result in deadheading two blocking the loadline against the boom tip 6 Loads in excess of capacity when operating with a jib deployed 7 Loads with lift cylinder fully retracted 8 Excessive induced loading during auger system operation 9 Operation without outriggers and stabilizers fully deployed or inadequate footing ...

Page 83: ...ION C 4 PLCS B JIB IN OPERATING POSITION IMPROPER STOWED JIB WILL RESULT IN DEATH OR SERIOUS INJURY Storage lock pin must be in stow bracket NOT here when jib is stowed E F F A B C1 C2 LEFT SIDE RIGHT SIDE SIDE STOW BRACKET JIB IN STOW POSITION D STOW LOOP 9369 F o r R e f e r e n c e O n l y ...

Page 84: ...ut spring clips in pins to ensure that they will stay in place 17 When the jib is stowed the boom can not be fully retracted if a boom tip attachment option is installed Also on manually extendable jib options 1 Extension retaining pin E must always be installed when operating 2 All swing around stow and unstowing operations shall be done with jib retracted and pinned 3 Extendable section may slid...

Page 85: ... function until the 2nd section is fully retracted 3 Reinstall extension retention pin through the 1st and 2nd section jib assembly and install spring clip 4 Remove loadline from jib sheave case Place loadline in area to avoid possible damage from stow procedure 5 Disconnect twist lock anti two block wire connector at rear of 1st section jib Connect twist lock connector to anti two block switch co...

Page 86: ...Next remove jack handle and using the flattened end close jack release valve by turning handle clockwise until it is firmly closed Insert the round end of the handle into the handle sleeve and pump jack until ram contacts boom sheave case Continue to pump slowly until jib pin hole is exactly aligned with hole in boom ear At this time the final jib pin can be easily tapped into position If hole ali...

Page 87: ...ed on the swing motor inside the crane frame The valve has an adjustment screw with a lock collar Loosen the lock collar when adjusting the speed then tighten the lock collar to maintain swing speed limit setting Turning the knob counter clockwise reduces the rotation speed The adjustment dial allows the maximum swing speed to be reduced as follows Number of Turns Approximate Max Swing Speed 375 R...

Page 88: ... Tap elbow with one hand then use regular signals RAISE BOOM Arm extended fingers closed thumb pointing upward LOWER BOOM Arm extended fingers closed thumb pointing downward TRAVEL One Track Lock the track on side indicated by raised fist Travel opposite track in direction indicated by circular motion of other fist rotated vertically in front of body For land cranes only RETRACT BOOM Telescoping B...

Page 89: ...ld be visually inspected each day by the operator prior to using the unit Weekly Inspections These items should be visually inspected weekly by the operator Monthly Inspections These inspections are to be performed monthly by the personnel responsible for maintenance and service of the crane Periodic Inspections This inspection is a thorough inspection conducted at least every three months and inc...

Page 90: ... and capacity placards for readability and secure attachment 8 Torque of cable clip bolts above wedge socket at end of loadline should be 95 ft lb 129 Nm 9 All boom wear pad retaining bolts 10 Boom extension cables for proper tension or evidence of abnormal wear 11 Sheaves and cable drums for wear and cracks 12 Unspool loadline and check according to rope maintenance procedure Periodic Inspection ...

Page 91: ...ire rope inspection program include reports on the examination of wire rope removed from service This information can be used to establish a relationship between visual inspection and the rope s actual internal condition at the time of removal from service Environmental Conditions The life expectancy of wire rope may vary due to the degree of environmental hostility and other conditions to which t...

Page 92: ...onthly Inspections Inspect the eye end and length of cable normally used in daily operations Examine the rest of the cable for kinked crushed or otherwise damaged points Periodic Inspections Wire rope should be inspected periodically annually or at a shorter time interval if necessitated by environmental or other adverse conditions and shall cover the entire length of the wire rope Periodic inspec...

Page 93: ...on by brakes or other means 4 All methods used to start the truck s engine rendered inoperative 5 Power plant stopped or disconnected at take off 6 Boom lowered to the ground or otherwise secured against dropping 7 Load block lowered to ground or otherwise secured against dropping 8 Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components After a...

Page 94: ...This distortion and wire displacement cannot be corrected even under high tension and a permanent weak point remains in the rope Displaced or raised wires indicate a previous kink but does not show the damaged condition of the inner rope wires Never pull wire rope over a non rotating support such as a spindle bar a pin or an inoperative sheave This practice causes severe abrasion to the outer stra...

Page 95: ...G 10 22 5 DUAL SINGLE 3510 1592 3560 1615 3690 1674 3770 1710 3870 1755 4000 1814 4040 E 1833 E 4210 1910 4200 1905 4410 2000 4360 1978 4610 E 2091 E 4520 F 2050 F 4790 2173 4670 2118 4970 2254 4820 2186 5150 F 2336 F 4970 G 2254 G 5320 2413 5490 2490 5670 G 2572 G 11 22 5 DUAL SINGLE 4380 1987 4530 2055 4580 2077 4770 2164 4760 F 2159 F 4990 2263 4950 2245 5220 2368 5120 2322 5430 F 2463 F 5300 G...

Page 96: ...60 2114 4820 2186 4870 2209 5070 2300 5070 F 2300 F 5310 2409 5260 2386 5550 2517 5450 2472 5780 F 2622 F 5640 G 2558 G 6000 2722 5820 2640 6210 2817 6000 2722 6430 G 2917 G 6170 H 2799 H 6630 3007 6840 3103 7030 H 3189 H 11 00 20 DUAL SINGLE 4780 2168 4940 2241 4990 2263 5200 2359 5190 F 2354 F 5450 2472 5390 2445 5690 2581 5590 2536 5920 F 2685 F 5780 G 2622 G 6140 2785 5960 2703 6370 2889 6150 ...

Page 97: ...5 DUAL SINGLE 3750 1701 3970 1801 3930 1783 4180 1896 4095 1857 4355 1975 4300 1950 4540 2059 4405 1998 4685 2125 4415 2003 4850 2200 4675 G 2121 G 5070 G 2300 G 305 70R19 5 DUAL SINGLE 4540 2059 4940 2241 4670 2118 5130 2327 4860 2204 5340 2422 5070 2300 5510 2499 5230 2372 5745 2606 5410 2454 5945 2697 5675 H 2574 H 6175 H 2801 H 5770 2617 6340 2876 6005 J 2724 J 6610 J 2998 J 255 70R22 5 DUAL S...

Page 98: ...MAINTENANCE 800D 3 10 Published 5 27 2018 Control 039 06 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 99: ...uestions arise refer to the component manufacturer s manual and a reliable supplier Chassis Grease Lubricating grease of proper consistency is to be applied periodically at relatively frequent intervals with grease guns through grease fittings Minimum apparent viscosity of 300 SUS Saybolt Universal Seconds at 100 F 38 C is recommended Extreme Pressure Multipurpose Gear Lubricant EPGL This gear lub...

Page 100: ...s Excessive wear in the system may cause a loss in volumetric efficiency and may cause shutdowns for maintenance An efficient antiwear oil protects the components against rusting resists oxidation and helps prevent wear Standard Hydraulic Oil 32 F to 100 F 0 C to 38 C The factory fill standard hydraulic oil is Exxon Mobil 424 10W 30 This fluid is acceptable for operating temperatures above 9 C 15 ...

Page 101: ...d or lost The surface of some ropes may become covered with dirt rock dust or other material during their operation This covering can prevent field applied lubricants from properly penetrating into the rope Therefore these ropes should be cleaned before being lubricated The lubricant applied should be light bodied enough to penetrate to the core of the rope Lubricant may be applied effectively by ...

Page 102: ...e Gun Remove Pump and Apply to Shaft or Zerk Provided on PTO Housing Shaft Monthly Semi Annually 10 Hoist Drive Refer to Hoist Manual for Oil Recommendation on Hoist Check Fill Change Weekly Semi Annually 11 Control Linkage SAE 10W Oil Can Quarterly 12 Swing Drive Gearbox Swing Gearbox Upper Bearing EPGL Chassis Grease Change Check Fill Change Grease Gun After First 50 Operating Hours Weekly Semi ...

Page 103: ...ing fades could initially be mistaken for a hydraulic oil leak While the product is not harmful to painted surfaces glass plastic or rubber it must be removed using standard steam cleaning techniques Carwell works in various ways 1 it eliminates the moisture containing salt dirt and other pollutants by lifting and removing them from the metal surface 2 the film creates a barrier to repel further m...

Page 104: ...r outward from the mark to blend the repair into the original surface Body putty may be applied as necessary to hide the defect then sand smooth Cover all bare metal with a primer that is compatible with the original paint finish and allow to dry thoroughly Prepare the surface prior to applying the finish coat of paint Apply a finish coat paint using accepted blending techniques Use of original pa...

Page 105: ...e any questions Areas of Application The underside of the unit will have full coverage of the rust inhibitor These are the only areas that a full coat of the rust inhibitor is acceptable on the painted surfaces Areas include Valves hose end and fittings Swivel pumps axles drive lines transmission all interior surfaces of the frame Frame application areas are hose ends and fittings all unpainted fa...

Page 106: ...ed O R Pins Clips 3 Pivot Shaft 4 Hose Connections 5 Mirror Mounting Hardware 6 Wire Rope 7 Boom Nose Pins Clips 8 Hook Block Headache Ball 9 O R Hose Connections 10 O R Pins Clips 11 Power Train Hardware 12 Entire underside of unit 13 Turntable Bearing Fasteners Pins 14 Valve Bank Hose Connections 15 Clips for Optional Jib 16 Hanger Hardware for Optional Jib Item Description F o r R e f e r e n c...

Page 107: ... and general maintenance information are found in two previous sections of this manual Before attempting to perform any service work the machine must be shut down as outlined under Maintenance Procedure in the Maintenance section of this book Generally a study of the hydraulic schematics in conjunction with a systematic procedure to locate and correct the problem will enable a skilled mechanic to ...

Page 108: ...eaning and covering apply when access covers or inspection plates are removed Clean and inspect all parts Be sure all passages and holes are open Cover all parts to keep them clean Be sure parts are clean when they are installed Leave new parts in their containers until ready for assembly Hydraulic Systems Contaminants in a hydraulic system affect operation and will result in serious damage to the...

Page 109: ...remaining outriggers 10 Disconnect the return lines from a pair of outrigger jack cylinders and activate the cylinders to their maximum down positions 11 Connect the return lines and raise the outrigger jack cylinders to the stowed position Replenish the reservoir hydraulic oil level as necessary 12 Repeat Steps 10 and 11 for the remaining two outrigger cylinders 13 Disconnect the return line from...

Page 110: ...telescope cylinders lower the boom to below horizontal and fully telescope the boom in and out several times If the air is not readily removed lower the boom to below horizontal extend the telescope cylinders as far as practicable and allow the boom to remain in this position overnight This should allow entrapped air to find its way to the holding valve so that telescoping the boom IN the next mor...

Page 111: ...0 07 1 78 0 07 1 78 0 07 1 78 0 07 1 78 0 301 7 64 0 364 9 24 0 489 12 42 0 614 15 60 0 739 18 77 0 926 23 52 1 176 29 87 1 489 37 82 0 250 0 375 0 500 0 625 0 750 1 000 1 250 1 500 4 6 8 10 12 16 20 24 0 351 8 92 0 458 11 63 0 644 16 36 0 755 19 18 0 924 23 47 1 171 29 74 1 475 37 46 1 720 43 69 0 072 1 83 0 078 1 98 0 087 2 21 0 097 2 46 0 116 2 95 0 116 2 95 0 118 3 00 0 118 3 00 7 16 20 9 16 1...

Page 112: ...ional Crane distributor Loctite Always follow the directions on the Loctite container as not all Loctite types are suitable for all applications Various types of Loctite are specified throughout the Service Manual The following types of Loctite brand adhesives are available from the Parts Department of the local National Crane distributor Application of Medium Strength Loctite NOTE The fastener ma...

Page 113: ...ices that can be pre set to required values eliminate dial readings and provide more reliable less variable readings NOTE If multipliers and or special tools are used to reach hard to get at areas ensure torque readings are accurate Torque wrenches are precision instruments and must be handled with care To ensure accuracy calibrations must be made on a scheduled basis Whenever there is a possibili...

Page 114: ...ished 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 F o r R e f e r e n c e O n l y ...

Page 115: ...37 4 36 5 8 54 3 52 9 51 5 1 2 13 UNC 5 58 6 57 1 55 7 8 82 8 80 7 78 6 9 16 12 UNC 5 84 5 82 4 80 3 8 119 4 116 5 113 5 5 8 11 UNC 5 116 6 113 7 110 8 8 164 8 160 7 156 6 3 4 10 UNC 5 206 8 201 7 196 5 8 292 3 284 9 277 6 7 8 9 UNC 5 333 8 325 4 317 1 8 471 6 459 8 448 0 1 8 UNC 5 500 3 487 8 475 3 8 707 0 689 3 671 6 1 1 8 7 UNC 5 624 0 608 4 592 8 8 1001 4 976 4 951 4 1 1 4 7 UNC 5 880 5 858 5 ...

Page 116: ...8 60 6 59 1 57 6 1 2 20 UNF 5 66 0 64 4 62 7 8 93 3 90 9 88 6 9 16 18 UNF 5 94 3 91 9 89 6 8 133 2 129 9 126 6 5 8 18 UNF 5 132 1 128 8 125 5 8 186 7 182 0 177 3 3 4 16 UNF 5 231 0 225 2 219 4 8 326 4 318 2 310 1 7 8 14 UNF 5 367 7 358 5 349 3 8 519 6 506 6 493 6 1 12 UNF 5 547 4 533 7 520 0 8 773 5 754 2 734 8 1 1 8 12 UNF 5 700 0 682 5 665 0 8 1123 5 1095 4 1067 3 1 1 4 12 UNF 5 975 0 950 6 926 ...

Page 117: ...7 33 8 33 0 M10x1 5 8 8 40 0 39 0 38 0 10 9 58 7 57 2 55 8 12 9 68 7 67 0 65 3 M12x1 75 8 8 69 7 68 0 66 2 10 9 102 4 99 8 97 2 12 9 119 8 116 8 113 8 M14x2 8 8 111 4 108 6 105 8 10 9 163 6 159 5 155 4 12 9 191 5 186 7 181 9 M16x2 8 8 172 8 168 5 164 1 10 9 253 8 247 4 241 1 12 9 296 9 289 5 282 1 M18x2 5 8 8 246 2 240 1 233 9 10 9 350 7 341 9 333 2 12 9 410 4 400 1 389 9 M20x2 5 8 8 348 0 339 3 3...

Page 118: ... 4 1432 7 1395 9 M30x3 5 8 8 1195 3 1165 5 1135 6 10 9 1702 5 1659 9 1617 3 12 9 1992 3 1942 4 1892 6 M36x4 8 8 2089 8 2037 6 1985 3 10 9 2976 4 2902 0 2827 6 12 9 3483 0 3395 9 3308 9 Nominal Size Threads per Inch and Series Designation Property Class Torque Nm Maximum Nominal Minimum F o r R e f e r e n c e O n l y ...

Page 119: ...7 113 8 110 9 12 9 136 6 133 2 129 8 M12x1 25 8 8 76 2 74 2 72 3 10 9 111 8 109 0 106 3 12 9 130 9 127 6 124 3 M12x1 5 8 8 72 9 71 1 69 2 10 9 107 1 104 4 101 7 12 9 125 3 122 1 119 0 M14x1 5 8 8 120 2 117 2 114 2 10 9 176 5 172 1 167 7 12 9 206 6 201 4 196 2 M16x1 5 8 8 184 4 179 8 175 2 10 9 270 9 264 1 257 3 12 9 317 0 309 1 301 2 M18x1 5 8 8 276 6 269 7 262 8 10 9 394 0 384 2 374 3 12 9 461 1 ...

Page 120: ...00 7 10 9 1950 0 1901 3 1852 5 12 9 2281 9 2224 9 2167 8 M30x2 8 8 1324 6 1291 5 1258 4 10 9 1886 6 1839 4 1792 2 12 9 2207 7 2152 5 2097 3 M33x2 8 8 1784 5 1739 9 1695 3 10 9 2541 6 2478 0 2414 5 12 9 2974 2 2899 8 2825 4 M36x2 8 8 2340 1 2281 6 2223 1 10 9 3332 8 3249 5 3166 2 12 9 3900 2 3802 6 3705 1 Nominal Size Threads per Inch and Series Designation Property Class Torque Nm Maximum Nominal ...

Page 121: ...orque values result in an 80 utilization of the yield strength Stainless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads and torque at low speeds without interruptions Do not use excessive pressure Impact wrenches are not recommended Size Torque Nm M2 5x0 45 0 4 M3x0 5 0 9 M4x0 7 1 5 M5x0 8 3 1 M6x1 5 3 M8x1 25 13 M10x1 5 27 F o r R e f e r e n c e O n ...

Page 122: ...t in an 80 utilization of the yield strength Stainless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads and torque at low speeds without interruptions Do not use excessive pressure Impact wrenches are not recommended Size Torque lb in lb ft 5 40 0 125 6 9 6 32 0 138 9 8 32 0 164 18 10 24 0 190 21 1 4 20 68 5 16 18 120 10 3 8 16 210 17 5 F o r R e f e r e...

Page 123: ...ts Untreated black finish Nominal Size Threads per Inch and Series Designation Grade Torque ft lb Maximum Nominal Minimum 5 8 11 UNC 8 234 225 216 5 8 18 UNF 8 250 240 230 3 4 10 UNC 8 385 370 355 7 8 9 UNC 8 615 591 567 1 8 UNC 8 929 893 857 1 1 4 7 UNC 8 2043 1964 1885 F o r R e f e r e n c e O n l y ...

Page 124: ...Series Bearing Bolts Untreated black finish Nominal Size Threads per Inch and Series Designation Grade Torque Nm Maximum Nominal Minimum M20X2 5 12 9 756 727 698 M24X3 10 9 1089 1047 1005 M24X3 12 9 1306 1256 1206 M27X3 10 9 1591 1530 1469 F o r R e f e r e n c e O n l y ...

Page 125: ...6 5 32 31 30 8 48 46 44 7 16 14 5 52 50 48 8 73 70 67 1 2 13 5 78 75 72 8 120 115 110 9 16 12 5 114 110 106 8 161 152 143 5 8 11 5 156 150 144 8 234 225 216 3 4 10 5 270 259 5 249 8 385 370 355 7 8 9 5 416 400 384 8 615 591 567 1 8 5 606 583 560 8 929 893 857 1 1 8 7 5 813 782 751 8 1342 1288 1234 1 1 4 7 5 1141 1097 1053 8 2043 1964 1885 1 3 8 6 5 1519 1461 1403 8 2496 2396 2296 1 1 2 6 5 2028 19...

Page 126: ... 55 53 8 85 82 79 1 2 20 5 88 84 5 81 8 125 120 115 9 16 18 5 126 121 116 8 177 170 163 5 8 18 5 182 174 5 167 8 250 240 230 3 4 16 5 312 299 5 287 8 425 409 393 7 8 14 5 458 439 5 421 8 672 646 620 1 12 5 658 632 606 8 1009 970 931 1 14 5 670 644 5 619 8 945 908 5 872 1 1 8 12 5 882 848 814 8 1500 1440 1380 1 1 4 12 5 1251 1203 1155 8 2092 2008 5 1925 1 3 8 12 5 1704 1638 1572 8 2833 2719 2605 1 ...

Page 127: ... 17 M8x1 25 8 8 27 26 25 10 9 38 36 5 35 12 9 45 43 5 42 M10x1 5 8 8 53 51 49 10 9 75 72 69 12 9 89 86 83 M12x1 75 8 8 93 89 85 10 9 130 125 120 12 9 156 150 144 M14x2 8 8 148 142 136 10 9 212 203 5 195 12 9 248 238 228 M16x2 8 8 230 221 212 10 9 322 310 298 12 9 387 372 357 M18x2 5 8 8 319 306 5 294 10 9 455 436 5 418 12 9 532 511 490 M20x2 5 8 8 447 430 413 10 9 629 605 581 12 9 756 727 698 M22x...

Page 128: ...090 1046 10 9 1591 1530 1469 12 9 1910 1836 5 1763 M30x3 5 8 8 1538 1479 1420 10 9 2163 2080 1997 12 9 2595 2495 2395 M36x4 8 8 2681 2578 5 2476 10 9 3964 3812 3660 12 9 4639 4461 4283 Size Property Class Torque Nm Maximum Nominal Minimum F o r R e f e r e n c e O n l y ...

Page 129: ...97 5 94 10 9 150 144 138 12 9 175 168 161 M12X1 25 8 8 100 96 92 10 9 147 141 5 136 12 9 172 165 5 159 M12x1 5 8 8 100 96 92 10 9 140 135 130 12 9 168 162 156 M14x1 5 8 8 160 153 5 147 10 9 229 220 211 12 9 268 257 246 M16x1 5 8 8 248 238 5 229 10 9 348 335 322 12 9 418 402 386 M18x1 5 8 8 345 331 5 318 10 9 491 471 451 12 9 575 552 529 M20X1 8 8 471 453 435 10 9 694 667 5 641 12 9 812 781 750 M20...

Page 130: ...2063 1983 5 1904 M30x1 5 8 8 1530 1471 5 1413 10 9 2253 2166 5 2080 12 9 2637 2536 2435 M30x2 8 8 1661 1597 5 1534 10 9 2336 2246 5 2157 12 9 2800 2695 2590 M33x2 8 8 2141 2059 1977 10 9 3155 3034 2913 12 9 3692 3550 5 3409 M36x2 8 8 2795 2688 2581 10 9 4118 3960 3802 12 9 4818 4634 4450 Size Property Class Torque Nm Maximum Nominal Minimum F o r R e f e r e n c e O n l y ...

Page 131: ...rive tang to handle pivot pin or center of hand grip extension handles are considered part of wrench length when used A Length of adapter extensions in inches 2 If the offset C L is not in line with the torque wrench C L then you must measure the distance from the C L of the torque wrench to the C L of the offset by using a square Then apply this dimension to the torque wrench setting formula See ...

Page 132: ...f adjustment Oil temperature too high Hydraulic oil too cold or dirty Line restricted Internal control valve crack Load too heavy Check PTO ratio pump size and engine speed for proper oil flow Check and fill as required Remove and clean Readjust to proper setting Replace bad part Change filter Adjust linkage so valve has full throw Adjust or clean as required Reduce engine speed slow cycle time to...

Page 133: ...e oil more applicable to environment Dirt in relief valve or damaged relief Check for loose tubing Clean breather Cylinders drift Not getting oil to cylinders Worn or damaged piston seals Air in hydraulic oil Loose holding valve Dirt in holding or check valve Clean and replace as required Replace as required Cycle operate crane cylinder to remove air Tighten valve Clean valve Hoist will not lift o...

Page 134: ...tension cables out of adjustment Extend or retract cables broken Grease boom Reshim as described in boom assembly section Replace pads Readjust cables and tension properly Disassemble and inspect and replace cables Boom will not extend Proportioning cables not attached Anti two block system shut down Defective anti two block system Reconnect replace and or adjust cables Lower hook and extend load ...

Page 135: ...e across leads of limit switch with weight supported Check limit switch or actuator arm for sticking Repair or replace switch Fuse blown Test HCA ATB relays for proper operation see Schematic Examine solenoid valve for sticking spool due to corrosion burrs contamination etc Replace relay Replace fuse YES NO NO YES NORMAL RELAY OPERATION FAULTY RELAY OPERATION 9386 F o r R e f e r e n c e O n l y ...

Page 136: ...ontacts closed with weight suspended Replace relay Replace fuse YES NO NO YES NORMAL RELAY OPERATION FAULTY RELAY OPERATION YES NO YES NO NO YES FAULTY RELAY OPERATION NORMAL RELAY OPERATION Test HCA ATB relays for proper operation see Schematic Continuity check lead wires Replace relay Check for 12 volts at solenoid valve Replace limit switch or check actuator arm for free movement Check continui...

Page 137: ...g properly Refer to ATB electrical diagnosis Work with individual section which fails to shut down Examine solenoid valve for sticking spool due to corrosion burrs contamination etc HYDRAULIC ELECTRICAL NO YES Disconnect drain line from outlet end of unloader valve Operate function at low engine RPM Oil flow from open port in unloader valve YES NO Poppet is not shifting Remove unloader and flush t...

Page 138: ...il is passing through the check valve in another unloader Install cap fitting to plug outlet end of unloader valve Functions operate correctly YES NO YES NO Flush to remove contamination otherwise replace unloader valve The poppet in the unloader is not seated Remove unloader and flush to dislodge contamination Cap each of other unloaders in turn to identify the unloader with the faulty check valv...

Page 139: ... contains the fault refer to the following procedures for replacement 1 2 STAGE ANTI TWO BLOCK WIRE REPLACEMENT The 1 2 stage anti two block wire is located between the top plates of the 1st and 2nd boom sections riding on a traveling block The maintenance of this wire can be accomplished with the boom fully assembled but would be simplified if the 2 3 4 boom assembly was removed from the first se...

Page 140: ...etween the tops of the first and second sections and run them back until the tools hook over the top plate of the second section 11 Run the replacement wire through the open sheave one sheave will have the steel cable routed through it already of the traveling block and temporarily attach each end of the new wire to the two tools You have now made a big loop with the two tools and the new wire rou...

Page 141: ... or federal regulations Alternative No 1 This procedure pulls the replacement wire through the boom following the path of the defective wire Special tools or equipment Two end to end butt connectors Shrink tube or electrical tape 1 Retract boom completely 2 Loosen and remove capscrew and cable clamp from sheave case attachment point Remove connector from wire measure and record pigtail length from...

Page 142: ...transport the end of the new anti two block wire from one end of the boom assembly to the other A telescopic grease applicator for the boom hydraulic tubing or electrical conduit are all possibilities for use as an installation tool The installation tool should be at a minimum 2 ft 0 5 m longer than the retracted boom length 1 Retract the boom completely 2 2 Loosen and remove the anti two block cl...

Page 143: ...sually inspect routing and anchors for correct assembly excessive slack and or capscrew torque etc Verify continuity of new anti two block wire REPLACEMENT OF PROPORTIONING CABLE FOR 1 2 STAGE OF ANTI TWO BLOCK WIRE Operation The 1 2 stage of the anti two block wire is driven by a small diameter steel proportioning cable This cable drives the traveling block which carries the live wire of the syst...

Page 144: ...eated in the sheave grooves 10 Cut off the excess wire from the new wire that is sticking out of the first section leaving a length to 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 11 Slide the cable stop onto the end of the wire sticking out of the end of the firs...

Page 145: ...aveling 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 ...

Page 146: ...and reinstallation of the anti two block wire can be accomplished using two different methods depending on the severity of the damage Alternative No 1 should be used if the wire has experienced a continuity failure in one or both of the conductors but the rubber jacket of the wire is still intact Alternative No 2 is to be used if the wire has been completely cut or either end of the wire is inacce...

Page 147: ...e through the boom without having an existing wire to pull it through Alternative No 1 Special tools or equipment Electrical tape Installation tool To route the wire the entire length of the boom a long tube to be used as an installation tool must be utilized to transport the end of the anti two block wire from one end of the boom assembly to the other A telescopic grease applicator for the boom h...

Page 148: ...ion Consult electrical schematic in this book for proper connector wiring 18 From hoist mount end of boom slide strain relief cord grip onto wire into approximately position inside the boom 19 Assemble spring and spade bolt to cord grip and reassemble anchor components to extend cable anchor plate on the hoist mount Slide cord grip up anti two block wire into boom to increase spring tension on mov...

Page 149: ...s 14 Allow the reel to retract the two thimbles back into the boom 15 At the hoist end of the boom attach the two thimbles to the 4th boom section making sure that the thimbles point in opposite directions and that the loop in the cord is at the top of the anchor Tighten the capscrew until it bottoms out in the threads 16 At the sheave case end of the boom attach the thimble in the slot and pull i...

Page 150: ...e threads 17 At the sheave case end of the boom attach the thimble in the slot and pull it towards the open end of the boom to tension the anti two block wire 18 Attach the electrical connector and connect to the switch 19 Slowly operate the boom to make sure that the anti two block wire runs freely in the boom and that the cable reel runs properly 20 Test the anti two block circuit for proper ope...

Page 151: ...tion Top bottom Pad Replacement Assembled Boom 6 9 Top Rear Pad Replacement 6 9 Front Bottom Pad Replacement 6 10 Four Section Boom Operation 6 10 Four Section Boom Maintenance 6 10 Internal Cable Sheave Lubrication 6 10 Four Section Cable Tensioning 6 11 Four Section Boom Service 6 11 Boom Removal 6 11 Boom Disassembly 6 11 Four Section Boom Assembly 6 13 Four Section Top bottom Pad Replacement A...

Page 152: ...e worn or damaged parts Note Loctite 680 is used during original assembly to secure nut to shaft If necessary heat nut to 400 500 F 204 260 C to facilitate removal If heat is necessary for removal discard nut and replace with new equivalent nut as well as worn or damaged parts 9 Wipe and inspect cylinder barrel for internal damage 10 Wipe and inspect cylinder shaft for damage 11 Remove shaft packi...

Page 153: ... by hand 7 As soon as the packing gland is sufficiently loosened properly support the rod assembly and carefully remove it Place rod assembly on supports Caution must be exercised in the support and removal of the rod assembly as damage to the chrome surface will necessitate rod assembly replacement 8 Remove the two locking setscrews from piston 9 Using proper spanner wrench loosen and remove thre...

Page 154: ...refore providing support and extension of the 3rd boom section The retract cables attach to the tip end of the 1st boom section are reeved around sheaves attached to the 2nd boom section and attach to the base end of the 3rd boom section therefore providing retraction of the 3rd boom section This type of boom operation provides that the 2nd and 3rd section booms extend and retract equally Proper s...

Page 155: ...elescope cylinder can be greased while the boom is fully retracted Access to the grease holes on either end of the pin is through holes in the boom side plates Three Section Cable Tensioning After boom reassembly or from time to time if interior proportioning cables appear loose cable tensioning may be required Tensioning must be done with the boom horizontal 1 Slightly tighten all cables Then cyc...

Page 156: ...nd remove the nuts which secure the extend cables to the cable anchor plate Remove nut from anti two block spade bolt Tag and disconnect hydraulic lines to the telescope cylinder 3 Drape extend cables and anti two block cable inside boom and slide cable anchor plate out of the side of the hoist mount if hoist has been removed from boom 4 Loosen and remove two capscrews lockwashers and spacers whic...

Page 157: ...oper fall protection as required by local state or federal regulations 1 Remove hoist 2 Gaining access through rear of boom loosen and remove capscrews retaining the keeper plates holding the extend cable anchor in the rear of the 3rd section as well as the anti two block wire clamp on the anchor assembly Loosen and remove two capscrews retaining lock bar to telescope cylinder Remove lock bar 3 Ex...

Page 158: ...t 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 s...

Page 159: ... it and slide it up the cable into approximate position inside the boom 33 Assemble the extension spring and spade bolt to the cord grip Assemble the spade bolt through the telescope cylinder anchor with a hex nut Adjust tension on anti two block cable by sliding cord grip down cable into the boom Approximately 2 in 5 cm of spring extension should be adequate for proper boom operation 34 Visually ...

Page 160: ...the 3rd boom section The 4th section retract cables attach to the tip end of the 2nd boom section are reeved around sheaves attached to the 3rd boom section and attach to the base end of the 4th boom section therefore providing retraction of the 4th boom section A proportioning cable attached to the rear of the 1st section reeved around a sheave at the tip of the 2nd section and anchored to the re...

Page 161: ...ul during the tensioning process 4 Torque 4 3 2 retract cables to 8 lb ft 11 Nm Cable adjustment point is located at the sheave case end of the boom on the bottom of the 2nd section Use the flats at the front of the cable ends to keep the cables from turning while torquing retainer nuts 5 Torque large extend cables to 20 lb ft 27 Nm Cable adjustment point is located at the rear of the boom on the ...

Page 162: ...ancing of the assembly as it slides out of the 1st section Keep tension on retract cables as the assembly is pulled out of the 1st to minimize the chance of retract cable damage 9 Place 2nd 3rd 4th assembly on a suitable horizontal surface Take care not to pinch or crush retract cables while lifting or supporting assembly 10 Remove top rear wear pads on the 2nd section They will lift off the cam p...

Page 163: ... 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 4th 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 o...

Page 164: ...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 ...

Page 165: ...m extend cable and serves as the upper hoist attachment point Hold this bar up in its slot with a spacer on each side This will facilitate easier assembly 45 Install the threaded end of the 3 8 in 9 53 mm extend cable through hole in center of the hoist attachment bar 46 Slightly tighten all cables Cycle boom slowly to assure proper operation before torquing cables Refer to the Four Section Cable ...

Page 166: ...l dictate which extendable section will be the driver that the other extend sections will need to be adjusted to utilizing cable adjustment A single stage cylinder will control first extendable section A dual stage cylinder will control second extendable section Timing sequence of cables will depend on number of sections and the extend cylinder construction Design intent of the cable tensioning is...

Page 167: ... section boom with two stage cylinder Cable tensioning to be in the following order 1 321 retract cables 2 123 extend synchronizing cables 3 234 extend cables 4 432 retract cables Four section boom with one stage cylinder Cable tensioning to be in the following order 1 123 extend cables 2 321 retract cables 3 234 extend cables 4 432 retract cables Three section boom with one stage cylinder Cable t...

Page 168: ...he base section may need to be loosened Retraction 1 Measure the retraction gaps between the first and second section and the second and third section If the retraction gap is greater between the first and second section than the retraction gap between the second and third section 2 Tighten the 123 synchronizing cable located at the back of the base section the difference in the retraction gap mea...

Page 169: ...fully bottomed out and do not spring back Reference Tensioning Setup Procedure 321 and 123 cable balancing Extension 1 Measure the extension gaps between the first and second section and the second and third section If the extension gap between second and third section is less than the extension gap between the first and second section 2 Tighten 123 extend cable located at the back top of the base...

Page 170: ...m of the second section the difference in the retraction gap measurements 3 Extend and retract the boom a few times and then repeat measuring the retraction gaps The fourth section should have moved in 4 Tightening until the retraction gap between the third and fourth section is equal to the retraction gap between the second and third section At this time the all extendable sections should extend ...

Page 171: ...cond and the third are equal At this time the all extendable sections should extend and retract equally and bottom out against the stops simultaneously Cable Retention Cable Retention Hardware Nut configuration see Figure 6 5 will be First Nut ADJUSTMENT and Second Nut TORQUED NOTE OPTION 2 method used ONLY when space constraints prevent OPTION 1 usage When tightening loosening the first adjustmen...

Page 172: ...space constraints prevent OPTION 1 usage see Figure 6 5 TORQUE VALUES for Second Nut Inch Series with Coarse Threads UNC Metric Series with Coarse Threads Cable end Thread Size Minimum Nut Strength GRADE Nut Type TORQUE ft lb 1 2 13 SAE 2 Hex Jam HALF 12 5 8 11 SAE 2 Hex Jam HALF 31 3 4 10 SAE 2 Hex Jam HALF 47 7 8 9 SAE 2 Hex Jam HALF 63 1 8 SAE 2 Hex Jam HALF 199 1 7 SAE 2 Hex Jam HALF 203 1 6 S...

Page 173: ...inlet Relief Adjustment 7 13 Unloader Dump Valve Air Purging Instruction 7 14 Hydraulic System Description 7 14 Optional Hydraulic Capacity Alert System 7 15 System Adjustment 7 15 Troubleshooting 7 16 Maintenance Repair 7 18 Center inner boom section in outer boom section X1 X2 Calculate shims required Gaps X1 X2 0 56 in 14 3 mm Wear pad thickness twp 0 44 in 11 1 mm Add shims as required each sh...

Page 174: ...ns of rotation of these parts allow the adjustment Once the boom is located the wear pad and plate combinations can be inserted into the space between the boom sections and aligned over the holes in the sections If the holes in the plate are not centered over the holes in the sections the wear pads and plates have to be removed and adjusted either towards or away from the side plate of the next la...

Page 175: ...n pockets will be under the 1 4 in grease access holes in the butterfly plates on the top of the boom sections 3 Using a 1 4 in diameter nozzle grease gun adapter fill pad retention pockets with grease 4 Retract boom This should apply grease to the pad bearing area of the top plates of the boom sections 5 These steps can be repeated as many times as necessary if unacceptable boom noise or chatter ...

Page 176: ... which keeps the jib from swinging the pin is welded to a chain on the end of the jib 6 Slowly retract the boom until the jib ears are within 0 50 in 13 mm of the ear assemblies on the first section Observe the vertical alignment of the jib ears and ear assemblies and add or remove shims until the jib is supported by the jib ears The jib will typically rest only on the upper support 7 Observe the ...

Page 177: ...are too tight the stow hook assembly or front bars will have to be adjusted 11 Torque all capscrews to their specified torque value see table in Service Maintenance Section Install stow pin in lock assembly and remove the jib pins 12 Extend and retract boom to insure proper alignment of jib pins 13 Install jib pins and remove the stow pins 14 Extend and retract the boom and jib to ensure proper al...

Page 178: ... cooling efficiency Frequent inspection and tightening of hose clamp line connections will eliminate the possibility of end connection failure due to back pressure from cold startup If cooler system fails to provide adequate performance reduced air or oil flow through the heat exchanger is the probable cause The cooling fan should be inspected for proper operation see Specifications Any obstructio...

Page 179: ...National Crane Published 5 27 2018 Control 039 06 7 7 800D SIDE SHIMMING OF BOOM SECTIONS Rotation Gearbox and Brake FIGURE 7 1 9414 F o r R e f e r e n c e O n l y ...

Page 180: ...ed and the capscrews should be loosened in a sequence that will allow an even load distribution on the motor adapter 5 Inspect the motor adapter o ring 29 for damage Replace if necessary 6 Remove the six springs 33 piston 25 and brake driver 27 from brake housing 15 NOTE Notice the position of the dowel pin hole in piston with respect to the brake release port for re assembly NOTE A port a power c...

Page 181: ...ckwasher always tighten until tabs align with slots in locknut Secure locknut by bending tabs on lockwasher so that it engages locknut to prevent locknut from backing off NOTE Install a 5 8 11 bolt into the end of the pinion shaft on the outboard side and check the rolling torque Preload of the bearing torque should be 50 75 lb in 8 Install the output carrier 10 into the gear housing 7 Install sun...

Page 182: ... the nuts in the same direction until the spacer is centered Tighten the nuts against the ends of the spacer to secure it in place 5 Verify that the flag is still centered between the stop pins Method 2 1 Follow the crane set up procedures in this manual to set outriggers and stabilizers and level the machine See Proper Leveling of the Crane on page 10 2 With the crane properly set up raise the bo...

Page 183: ...lodging o rings from counterbores 8 When all valve sections are positioned on assembly studs replace stud nuts and tighten evenly to 32 lb ft 43 Nm torque for crane valve and 25 lb ft 34 Nm torque for hoist valve NOTE If stud nuts are not tightened to the proper torque valve spools may bind or stick or cause section seals to extrude Replacing Spool Seals Valve sections and covers are identified by...

Page 184: ...of the unloader valves are serviceable In the event that one of these three functions will not operate or operates with a delay and the crane is not overloaded or two blocked the following air purging procedure should be followed If no improvement is seen after completing the following procedure twice follow the troubleshooting steps outlined for checking and inspecting the solenoid valve and unlo...

Page 185: ...ion for correct standard pressure setting Adjusting the relief valve for the standard pressure setting 1 Remove the fitting from the relief valve at C 2 Loosen jam nut A1 and with a wrench on the body at A2 either screw the body in or out Screwing the body in increases the pressure setting Screwing the body out reduces the pressure setting The pressure can be read on the gauge on the console durin...

Page 186: ...an those listed above the warranty on the machine is void Also the machine could operate in a manner such as to endanger personnel safety UNLOADER DUMP VALVE AIR PURGING INSTRUCTION When a crane sits for a long period the oil can drain back to the reservoir and air could get into the pilot lines of the unloader dump valves This is likely to be more of a problem in colder weather as the oil will no...

Page 187: ...lot operated check valves or by pilot operated counterbalance valves if overhung loads must be controlled The standard swing gearbox is locked in place by an integrally mounted spring applied brake and a dual counterbalance motor holding valve The swing brake and counterbalances are piloted open and closed by operating swing left or right and are automatically reapplied by ceasing the swing functi...

Page 188: ...m solenoid should be deactivated and the indicator light should come on Readjust switch head if trip pressure is not correct 6 Once proper adjustment is verified return the boom to a firmly supported position stop the truck engine and replace covers TROUBLESHOOTING The following step by step analysis will be helpful in isolating and correcting almost every service problem if followed in a step by ...

Page 189: ... Out Hoist up work Problem Solved Boom Lift Cylinder Fully Extended Actuate Momentary Key Switch and Boom Down 5 with No Load Crane Functions Boom Down Telescope Out Hoist up work Problem Solved 12v Across Compensating Pressure Switch Fuse OK 12v to Solenoid Trouble Shoot Wiring 12v to Compensating Pressure Switch Replace Fuse Functions Operate Problem Solved Replace Wiring ResistanceAcross Soleno...

Page 190: ...anding of the capacity alert system before proceeding with any maintenance 2 System adjustment must be checked every three months for accuracy Refer to the preceding section on System Adjustment 3 Always be sure the boom is adequately supported and no hydraulic pressure remains in the lines before the pilot pressure line fittings are loosened F o r R e f e r e n c e O n l y ...

Page 191: ... mm 3 81 97 mm 47 49 1206 mm 43 28 1099 mm 38 49 978 mm 14 56 370 mm 48 47 1231 mm 40 00 1016 mm GROUND LEVEL 8 47 215 mm 9 00 229 mm 18 00 457 mm 126 0 3200 mm 19 5 495 mm BOTTOM VIEW SOME COMPONENTS REMOVED FOR CLARITY G DRY WEIGHT W OIL WEIGHT 851D 860D 869D 880D 890D 8100D 28 in 71 cm 46 in 117 cm 63 in 160 cm 56 in 142 cm 68 in 173 cm 79 in 201 cm 13 700 lb 6214 kg 14 270 lb 6472 kg 14 830 lb...

Page 192: ...st System 34 gpm 128 l min 3300 psi 100 000 22 75 MPa Turn 10 gpm 38 l min 2600 psi 100 000 15 17 MPa Reservoir Capacity 66 gal 249 l System Capacity 88 gal 333 l Filtration 10 Micron Return Flow rates listed are at free flow condition approx 100 psi 1 MPa Hoist System Wire Rope Standard 325 ft 99 1 m of 9 16 in 14 3 mm dia Rotation Resistant Nominal Breaking Strength 38 500 lb 17 463 kg Hoist Per...

Page 193: ... Up 10 to 80 33 sec 5 sec Lift Down 10 to 80 24 sec 5 sec Telescope Extend 3 Section 31 ft min 5 ft min 9 45 m min 1 5 m min 4 Section 33 ft min 5 ft min 10 06 m min 1 5 m min Telescope Retract 3 Section 39 ft min 6 ft min 11 89 m min 1 83 m min 4 Section 40 ft min 6 ft min 12 19 m min 1 83 m min F o r R e f e r e n c e O n l y ...

Page 194: ...SPECIFICATIONS 800D 8 4 Published 5 27 2018 Control 039 06 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 195: ... relating to weights and dimensional restrictions such as overall length overhang etc This section is organized by first presenting detailed information relating to truck requirements and mounting configurations followed by a step by step installation procedure including PTO selection Pump rotation selection reinforcement crane and stabilizer installation counterweighting boom rests and stability ...

Page 196: ...0D 9 2 Published 5 27 2018 Control 039 06 TYPICAL LOCATIONS SERIAL NUMBER IDENTIFICATION 1ST SECTION BOOM MID SECTIONS BOOM SHEAVE SECTION BOOM JIB STABILIZER FRAME TURRET CYLINDER 9426 F o r R e f e r e n c e O n l y ...

Page 197: ...ct a truck frame that will minimize or eliminate frame reinforcement or extension of the after frame AF Many frames are available that have the necessary after frame AF section modulus S M and resistance to bending moment RBM so that reinforcing is not required The front hydraulic jack is used for a 360 degree working range around the truck The frame under the cab through the front suspension must...

Page 198: ...on the chassis Configuration 1 8100D This configuration allows the installation of the Series 8100D on a chassis by using the sub base for a 22 ft bed In most cases the chassis will not require reinforcing Requires 16 000 lb 7257 kg GAWRF 34 000 lb 15 422 kg GAWRR 50 000 lb 22 679 kg GVWR RSOD rear stabilizers and sub base for 22 ft bed Full capacity work area is rear 180 of vehicle from outrigger...

Page 199: ...n some states it is legal to be more than 40 ft 12 19 m in length and some states allow overlength permits Configuration 3 800D all booms other than 8100D This configuration allows the installation of the Series 800D on a chassis with a sub base and bed combination which best fits the boom length Depending on the boom length the bed can be 18 ft 20 ft or 22 ft Not all bed lengths can be used with ...

Page 200: ...tabilizers Configuration 5 Rear Mount This configuration allows the rear mount installation of the Series 800D This configuration is 360 stable and allows the effective use of close working area to lift the heavier capacity loads Requires a 16 000 lb 7257 kg GAWRF 40 000 lb 18 143 kg GAWRR and 56 000 lb 25 401 kg GVWR overframe outriggers rear stabilizer and heavy duty rear mount sub base The maxi...

Page 201: ... rotation direction Make certain which direction the power take off output shaft rotates before selecting a clockwise cw or counter clockwise ccw rotation hydraulic pump Either cw or ccw rotation pumps are available and are marked clearly with a directional arrow on the pump housing Do not attempt to turn pump in the opposite direction of the indicating arrow on the pump housing Pump failure will ...

Page 202: ...ies 800D crane requires a minimum of 1 749 000 lb in 197 610 Nm RBM and 15 9 in3 260 cm3 S M under the crane frame between the front and rear springs with 1 430 000 lb in 161 568 Nm RBM and 13 0 in3 213 cm3 S M through suspension to rear stabilizers on each truck frame rail For 360 stability the truck frame must have a 20 0 in3 327 cm3 section modulus 2 200 000 lb in 248 566 Nm RBM minimum under t...

Page 203: ...us of the frame to obtain the total section modulus 5 Angle Under Reinforcement Table D This table lists the section modulus of an angle with the flange under the truck frame that is added to a frame with an angle reinforcement already added Add the section modulus from Table D to the section modulus obtained from tables A and B to determine total section modulus The edges of the reinforcing angle...

Page 204: ...3 8 62 4 7 77 5 7 93 6 7 110 7 9 129 9 1 149 10 5 172 3 1 51 3 9 64 4 8 79 5 8 95 6 9 113 8 1 133 9 4 154 10 7 175 3 2 52 4 0 66 5 0 82 6 0 98 7 1 116 8 3 136 9 6 157 11 0 180 THICKNESS 5 16 in 7 94 mm THICKNESS 3 8 in 9 52 mm 2 70 3 83 3 95 4 108 2 70 3 83 3 95 4 108 7 191 8 216 9 241 10 267 11 292 12 318 13 343 14 368 3 6 59 4 6 75 5 6 92 6 8 111 8 1 133 9 5 156 11 0 180 12 6 206 3 7 61 4 7 77 5...

Page 205: ...4 11 2 184 12 5 205 13 8 226 6 4 105 7 4 121 8 5 139 9 7 159 10 9 179 12 2 200 13 6 223 15 0 246 7 0 115 8 1 133 9 3 152 10 6 174 11 9 195 13 2 216 14 6 239 16 1 264 7 7 126 8 9 146 10 1 166 11 4 187 12 8 210 14 3 234 15 7 257 17 3 284 8 216 9 241 10 267 11 292 12 318 13 343 14 368 15 394 7 7 126 9 1 149 10 5 172 11 9 195 13 5 221 15 2 249 16 9 277 18 7 306 8 6 141 10 0 164 11 5 188 13 1 215 14 7 ...

Page 206: ... supporting 0 50 in 12 7 mm DIA Grade 8 bolts to their nominal breaking strength Torque the mounting bolts supplied with the front stabilizer to 110 lb ft 149 Nm Do not use spacers between the bumper bracket and the front stabilizer bumper assembly If the bumper bracket and front of the truck frame do not meet these specifications an extended frame truck must be used Contact factory for details De...

Page 207: ...e proceeding TABLE E Section Modulus in3 cm3 THICKNESS 3 16 in 4 76 mm THICKNESS 1 4 in 6 35 mm 1 25 1 38 2 51 1 25 1 38 2 51 8 203 9 229 10 254 11 279 12 305 13 330 14 356 15 381 3 2 52 3 8 62 4 6 75 5 4 88 6 3 103 7 2 118 8 2 134 9 3 152 3 9 64 4 7 77 5 5 90 6 4 105 7 4 121 8 4 138 9 5 156 10 6 174 4 6 75 5 5 90 6 4 105 7 4 121 8 5 139 9 6 157 10 8 177 12 0 197 8 203 9 229 10 254 11 279 12 305 1...

Page 208: ... 1 116 8 3 136 9 6 157 11 0 180 THICKNESS 5 16 in 7 94 mm THICKNESS 3 8 in 9 52 mm 2 70 3 83 3 95 4 108 2 70 3 83 3 95 4 108 3 89 4 114 5 140 6 165 7 191 8 216 9 241 10 267 11 292 12 318 13 343 14 368 0 9 15 1 5 25 2 2 36 3 0 49 3 6 59 4 6 75 5 6 92 6 8 111 8 1 133 9 5 156 11 0 180 12 6 206 1 0 16 1 5 25 2 3 38 3 1 51 3 7 61 4 7 77 5 8 95 7 1 116 8 4 138 9 8 161 11 4 187 13 0 213 1 0 16 1 6 26 2 3...

Page 209: ...79 mm Section Modulus 11 9 in3 195 cm3 4 Interpolate between the two values 10 in 254 mm deep channel 10 2 in3 167 cm3 11 in 279 mm deep channel 11 9 in3 195 cm3 10 5 in 267 mm deep channel 5 Now interpolate between a 10 0 in 254 mm deep channel and a 10 5 in 267 mm deep channel to get the section modulus of a 10 25 in 260 mm deep channel 10 0 in 254 mm deep channel 10 2 in3 167 cm3 10 5 in 267 mm...

Page 210: ...o be used the pump can be mounted directly to the PTO Direct mount pumps require lubrication of the spline shaft coupling See Service and Maintenance Section for lubrication information Be sure adequate clearance exists for this type of pump mount Sometimes the pump is powered through a drive line with the pump located no more than 42 in 107 cm from the PTO The drive line should not exceed a 15 an...

Page 211: ...red Use Grade 90 weld material for any welding to be done 2 Strip the frame of obstructions in the area to be reinforced or extended one side at a time If the truck frame crossmembers are bolted in remove the bolts Do not attempt to remove any rivets 3 Place the reinforcing on the truck frame and clamp in place Mark the location of any rivets by striking the outside of the reinforcing over the riv...

Page 212: ...mer stipulation or truck manufacturer voiding their warranty bolt on reinforcing is required In these cases install the reinforcing clamp in place install any crossmember bolts that were previously removed then drill through reinforcing and truck frame being careful to clear crane mounting anchors and bolt reinforcing in place See Figure C for recommended drilling and bolting procedure Use 5 8 Gra...

Page 213: ...T WELDED AROUDED TO ELIMINATE PLUG WELD HOLES CROSSMETER BOLT HOLES PLUG WELD HOLES CAN BE SHIFTED SLIGHTLY TO CLEAR 5 in 127 mm 2 in 51 mm 4 in 102 mm 4 in 102 mm 8 in 203 mm PLANNED LOCATION OF MOUNTING PLATE PLUG WELD LOCATIONS CAN BE SHIFTED TO CLEAR PLATE FIGURE B 51 mm 2 in MIN 203 mm 8 in TYP 4 in 102 mm 2 in MIN 51 mm 8 in TYP 203 mm FIGURE C 9444 F o r R e f e r e n c e O n l y ...

Page 214: ...in Figure B Slide the reinforcing angle up from the bottom butt it to existing forward reinforcing and weld rear suspension reinforcing to forward reinforcing Replace as much of the spring hanger cut out areas as possible and butt weld these pieces in If reinforcing angle is to be bolted on drill hole pattern and install bolts according to Figure C Reinforce spring hanger cut outs and the weld are...

Page 215: ...lded with 6 in 15 24 cm of weld 6 in 15 24 cm no weld etc along both edges of the bar front to back Length of after frame AF may have to be modified for crane installation If AF is too long cut off excess and remove any cross members from back of truck frame If AF is too short the frame will have to be lengthened Use channels fabricated from 100 000 psi 758 MPa yield material that are the same siz...

Page 216: ...INSTALLATION 800D 9 22 Published 5 27 2018 Control 039 06 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 217: ...t s stiffness or strength Add spacers as required to level truck bed before attaching it to the torsion box 4 Drill four 3 4 in diameter holes through the truck frame at each mounting plate using the holes in the mount anchor assembly as pilot holes Install 3 4 in diameter Grade 8 bolts washers and nuts in mounting plates 5 With RSOD stabilizers retracted determine the distance from the top of the...

Page 218: ... with six 5 8 in Grade 8 bolts washers and nuts Tighten to proper torque Repeat flex plate installation procedure on other side Raise and locate the RSOD frame to the RSOD mounting subassembly and weld E70 7 Set the crane frame on the subbase and install the three 1 1 8 in diameter Grade 8 mounting bolts at each corner Bolt the crane to mounting anchors through tubes in the subbase and mounting an...

Page 219: ...proper torque Grease the three pin joints with gun grease and operate the boom and lift cylinder through several complete cycles before placing machine in operation 12 Route the 1 2 inch R12 telescope hoses over the turret back plate and to the back side of the boom Connect the telescope cylinder connections at the back of the boom 13 Route the 3 4 inch R12 hoist hoses and the 1 4 in R1 hoist drai...

Page 220: ...n accordance with location drawings and illustrated parts catalog over final paint 23 After installation check all oil and lubricant levels and lubricate unit according to Lubrication Chart on page 4 in Service and Maintenance Section Rope size 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 Torque lb ft Nm 45 61 65 88 65 88 95 128 8 95 128 8 130 176 225 305 225 305 225 305 360 488 The tightening torq...

Page 221: ...each side of the rod end of the cylinder and two at each side of the butt end of the cylinder 2 The bearings should be started in their respective bores by rotating the bearing while applying inward pressure with the hand Once the bearing has been started squarely into its bore it can be driven to its full counterbored depth by tapping lightly with a rubber mallet The head diameter of the mallet s...

Page 222: ...h outriggers and stabilizer set to overturn the unit is at 85 of tipping over Increasing this full capacity load by 117 6 overloading will cause the unit to tip over 3 In order to determine the amount of counterweight required it is necessary to add up the weight that each permanently attached piece of equipment will place on the front and rear axles of the truck along with the initial truck chass...

Page 223: ... Section for weight of 8100D and center of gravity Note that this weight does not include weight of RSOD stabilizers 1300 pounds 590 kg REAR Front Rear Axle Weight Front Axle Weight 1 Initial front axle wt 0 lb 0 kg 8000 0 8000 lb 3628 0 3628 kg 2 Pump PTO s 34 lb 15 kg 150 34 116 lb 68 15 53 kg 3 Initial rear axle wt 7000 lb 3175 kg 7000 7000 0 lb 3175 3175 0 kg 4 Bed wt 1500 lb 680 kg 1456 1500 ...

Page 224: ...in 495 mm 79 in 2010 mm Subbase 22 ft 3445 lb 1563 kg 245 25 in 6229 mm 261 in 6629 mm 33 in 838 mm 0 in 69 in 1752 mm 328 in 8331 mm 1300 lb 590 kg Rear Stabilizer Wt 161 5 in 4102 mm 17 710 lb 8033 kg 8100D Crane Wt 9451 Rear Axle Weight Front Axle Weight Base Unit 8534 lb 8072 lb 3870 kg 3661 kg Counterweight 696 lb 454 lb 315 kg 205 kg Add Crane Weight 10 958 lb 17 710 10 958 6752 lb 4970 kg 8...

Page 225: ...00 LB 227 kg WEIGHTED AREA TRUCK BED BOTTOM VIEW BED COUNTERWEIGHTING FOR 1150 LB 520 kg BED COUNTERWEIGHTING FOR 2000 LB 910 kg BED COUNTERWEIGHTING FOR 3000 LB 1360 kg 86 in 2184 mm 86 in 2184 mm 86 in 2184 mm 40 in 1016 mm 70 in 1778 mm 105 in 2667 mm 4 in 102 mm 20 in 508 mm CG 52 5 in 1334 mm CG NOTE SHADED AREAS INDICATE CONCRETE 35 in 889 mm CG 4 in 102 mm 4 in 102 mm 9452 F o r R e f e r e...

Page 226: ...ached to torsion box by bolting through slots in torsion box leave open area in concrete counterweight for hardware access The weight of the concrete can be determined by multiplying the volume in cubic inches by 0 083 Ib per cubic inch Example Concrete poured in the bed measures 4 in 10 16 cm deep by 86 in 218 44 cm wide by 70 in 177 80 cm long The weight of the concrete is 4 86 70 0 083 2000 Ib ...

Page 227: ...oom rest loosen bleeder on bulkhead fitting rod side transducer and install clear plastic hose and route to catch pan Slowly actuate boom down lever generating flow and permitting air to escape and when air ceases to escape tighten bleeder 6 Route the two conductor cord to a convenient location in the truck cab Install the RCL power switch and indicator light A mounting plate is provided or the sw...

Page 228: ...ength sensor calibration be saved Selected YES then press OK to confirm calibration Press EXIT to leave calibration Verify length and angle indication are accurate and replace cable reel cover 13 Load indicating accuracy is verified by lifting known loads Select one or more known test loads that will load the crane to full capacity preferably a load that can fully load the crane at more than one r...

Page 229: ...and levers Refer to hydraulic or electrical schematic and parts pages to correct any problems Note Add oil to reservoir as required to keep air from reentering the system 2 Set throttle according to engine RPM and PTO ratio to get 2500 RPM pump shaft speed 3 When all cylinders have operated through complete cycles stow crane and place the outriggers in the up position The oil level should be visib...

Page 230: ... during transport Install tie down point low enough to allow room for anti two block weight Do not shorten chain The boom rest should be positioned to support the 1st section boom Be careful to avoid contacting the boom at or near the end where the retract cables are located Contact with these cables will result in costly repairs The boom rest saddle provided is designed to support the 1st section...

Page 231: ...eed loaded radius Slowly rotate the boom throughout the work area As the boom is rotated the boom will have to be raised and or lowered to maintain the loaded radius because of subbase flexure On Front Mounted Cranes that are not equipped with front stabilizers tipping from stabilizer support to front wheel support will occur as the load or boom is swung around the front Do not attempt to lift rat...

Page 232: ...CRANE INSTALLATION 800D 10 16 Published 5 27 2018 Control 039 06 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 233: ... 6 Recommended Oil 11 6 Disassembly 11 7 Assembly 11 7 Installing Cable On The Hoist 11 8 Wedge Socket Installation 11 8 Dead end Rigging 11 9 Servicing the Motor 11 10 Servicing the Brake 11 11 Servicing the Planetary Sets 11 12 Troubleshooting 11 14 Hoist won t hold load 11 14 Hoist unable to lift load 11 14 Hoist unable to lower load 11 14 Oil leaks from motor side vent 11 14 Hoist Torque Speci...

Page 234: ...anchors on hoists are not designed to hold the rated load of the hoist You must keep at least five 5 wraps of cable on the drum to ensure that the cable doesn t come loose Stay clear of suspended loads and of cable under tension A broken cable or dropped load can cause serious injury or death Avoid shock loads This type of load imposes a strain on the hoist many times the actual weight of the load...

Page 235: ...ch bypassing the brake When the load comes to a stop the cam clutch locks up and the brake prevents the load from moving During payout a brake valve is used to prevent the load from moving faster than desired This brake valve partially blocks the main line from the motor back to the directional control valve allowing only a limited amount of hydraulic fluid through the motor The brake valve is the...

Page 236: ...MATIC CB VALVE HYDRAULIC FLUID FROM CONTROL VALVE HYDRAULIC FLUID TO CONTROL VALVE HYDRAULIC MOTOR HIGH PRESSURE LOW PRESSURE CB VALVE HYDRAULIC FLUID TO CONTROL VALVE HYDRAULIC FLUID FROM CONTROL VALVE HYDRAULIC MOTOR RAISE LOWER 9460 F o r R e f e r e n c e O n l y ...

Page 237: ...or oil leakage is detected during an inspection maintenance should be performed to correct any problems Oil Change Interval The oil in the gearbox and brake sections is recommended to be changed after first 50 hours of operation and every 1000 hours or 6 months of usage Hoist Brake Oil Check Hoist Brake Oil To check the hoist brake oil remove the vent and fill plug Figure 11 1 and visually inspect...

Page 238: ... in the side plate Install a 1 in pipe with elbow into the upper hole in the side plate See view 3 Fill the gearbox with 1 42 liters 1 50 quarts of EP 90 oil Remove the pipe and elbow then replace the plug 33 For information about changing hoist brake oil see Drain Add New Hoist Brake Oil page 11 5 See Recommended Oil page 11 6 for recommended oil type and grade for your application RECOMMENDED OI...

Page 239: ...6 from the drum Inspect the gearset for wear and repair as needed See Servicing the Planetary Sets page 11 12 for disassembly and repair 9 Remove the thrust washer 6 and output sun gear 16 Inspect for damage and replace if needed 10 Remove the output planet gearset 4 from the drum 5 Inspect the gearset for wear and repair as needed See Servicing the Planetary Sets page 11 12 for disassembly and re...

Page 240: ...LING CABLE ON THE HOIST NOTE The cable should preferably be straightened before installation on the hoist drum Install cable on the hoist drum in accordance with the following procedure 1 Position the cable over the boom nose sheave and route to the hoist drum 2 Position the hoist drum with the cable anchor slot on top 3 Insert the cable through the slot and position around the anchor wedge 1 Figu...

Page 241: ... F be used i e clipping a short piece of wire rope to the dead end or using a commercially available specialty wedge Typically it is recommended that the tail length of the dead end should be a minimum of 6 rope diameters but not less that 6 in 15 2 cm for standard 6 to 8 strand ropes and 20 rope diameters but not less than 6 in 15 2 cm for rotation resistant wire ropes When using method A place a...

Page 242: ...d inspect the small metering hole located on the side of the valve to make sure it is not obstructed Also inspect the o rings for damage and replace if necessary 3 Motors and counterbalance valves are not serviceable in the field Return them to an authorized National Crane distributor for service FIGURE 11 6 Wedge Socket Specialty Clip Specialty Wedge METERING HOLE FIGURE 11 7 9464 F o r R e f e r...

Page 243: ...de in which the markings on the clutch 34 are facing The clutch assembly must be re assembled with the markings facing the proper direction in order for the hoist to function properly Inspect the surface on the input and brake drivers 13 38 where the clutch 34 runs If there is any pitting or spalling on the drivers then both it and the clutch must be replaced 10 Re assemble the driver clutch assem...

Page 244: ...ar and replace if necessary 5 On output planet gearsets note that two bearings with a spacer between them are used 6 Before reassembly be sure to insert the thrust plate into the carrier 7 To reassemble be careful to line up the planet pins with the washers and bearings then press the knurled part of the pin into the carrier If the pins are not lined up properly the washers can be shattered during...

Page 245: ...National Crane Published 5 27 2018 Control 039 06 11 13 800D HOIST INPUT GEARSET 36 OUTPUT GEARSET 4 FIGURE 11 9 9466 F o r R e f e r e n c e O n l y ...

Page 246: ...Possible Solutions 1 The relief valve setting may be too low to allow proper lifting Increase the relief pressure setting 2 The load being lifted may be more than the hoists rating Verify weight and reduce the load or re rig it to increase mechanical advantage Hoist unable to lower load Possible Solutions 1 The counterbalance valve cartridge may have a plugged metering hole see Figure 11 7 for loc...

Page 247: ...4 28 10 7 6 14 10 8 5 16 18 17 13 10 25 18 15 5 16 24 19 14 11 27 20 16 3 8 16 31 23 19 44 33 26 3 8 24 35 26 21 49 37 30 7 16 14 49 37 30 70 53 42 7 16 20 55 41 33 78 58 47 1 2 13 76 57 45 106 80 64 1 2 20 85 64 51 120 90 72 9 16 12 109 82 65 153 115 92 9 16 18 122 91 73 172 129 103 5 8 11 150 113 90 212 159 127 5 8 18 170 128 102 240 180 144 3 4 10 266 200 160 376 282 226 3 4 16 297 223 178 420 ...

Page 248: ...ASHER 5 1 DRUM 6 2 RACE 7 1 SEAL KIT 7 1 1 O RING 7 2 1 O RING 7 3 1 O RING 7 4 2 OIL SEAL 7 5 1 OIL SEAL 7 6 1 O RING 7 7 1 BACKUP RING 7 8 1 BACKUP RING 7 9 2 O RING 7 10 1 O RING 8 1 INPUT SUN GEAR 9 14 CAPSCREW 10 1 BRAKE PISTON 11 4 CAPSCREW 13 1 BRAKE DRIVER 14 2 RACE 15 2 RETAINING RING 16 1 OUTPUT SUN GEAR 17 2 BUSHING 18 7 FRICTION DISC 19 8 STATOR PLATE 20 1 BRAKE COVER 21 1 BRAKE HOUSIN...

Page 249: ...ANET PIN 36 4 3 RETAINING RING 36 5 1 THRUST PLATE 36 6 3 BEARING 36 7 6 WASHER 38 1 INPUT DRIVER 39 1 BUSHING 40 1 O RING PLUG 42 1 COUNTERBALANCE BLOCK 43 4 SUPPORT ROD 44 1 HYDRAULIC MOTOR 45 2 STRAIGHT ADAPTER 46 1 HOSE ASSEMBLY 49 1 90 DEGREE ADAPTER 50 1 SIDE PLATE 51 2 CAPSCREW 52 2 LOCKWASHER 55 3 CAPSCREW 57 1 BUSHING 58 1 COUNTERBALANCE VALVE SEQ QTY DESCRIPTION F o r R e f e r e n c e O...

Page 250: ...HOIST 800D 11 18 Published 5 27 2018 Control 039 06 EXPLODED ISOMETRIC ASSEMBLY DRAWING 9467 F o r R e f e r e n c e O n l y ...

Page 251: ...blished 5 27 2018 Control 039 06 1 800D SCHEMATICS SECTION 12 SCHEMATICS For your convenience the latest version of schematics available at the time of printing are placed in this section F o r R e f e r e n c e O n l y ...

Page 252: ...SCHEMATICS 800D 2 Published 5 27 2018 Control 039 06 F o r R e f e r e n c e O n l y ...

Page 253: ...s 2 7 Cylinder Disassembly and Repair 6 2 Disassembly 11 7 Electrocution Hazard 1 23 Environmental Protection 1 27 Equipment Checks 2 7 Equipment Familiarization 2 7 Fasteners and Torque Values 5 6 Four Section Boom Assembly 6 13 Four Section Boom Maintenance 6 10 Four Section Boom Service 6 11 Four Section Top bottom Pad Replacement Assembled Boom 6 15 General Rules When Operating Hoist 2 17 Gene...

Page 254: ... 10 Servicing the Planetary Sets 11 12 Shut Down 1 37 Shutting Down and Preparing for Road Travel 2 18 Side Shimming Of Boom Sections 7 1 Specifications 8 1 Standard Hand Signals For Controlling Crane Operations 2 32 Swing Drive Service 7 8 Telescope Cylinder 6 3 Temperature Effects on Hook Blocks 1 38 Temperature Effects on Hydraulic Cylinders 1 38 Three Section Boom Assembly 6 8 Three Section Bo...

Page 255: ...F o r R e f e r e n c e O n l y ...

Page 256: ...F o r R e f e r e n c e O n l y ...

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