Manitowoc National Crane 800D Operator's And Service Manual
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Manitowoc National Crane 800D Operator's And Service Manual

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Operator and Service Manual

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  • Page 1 National Crane 800D Operator and Service Manual...
  • Page 2 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside.
  • Page 3 OPERATOR AND SERVICE MANUAL This Manual has been prepared for and is considered part of - 800D This Manual is Divided into the following Sections: INTRO INTRODUCTION AND TABLE OF CONTENTS SECTION 1 SAFETY INFORMATION SECTION 2 OPERATION SECTION 3 MAINTENANCE SECTION 4 LUBRICATION...

  • Page 5: Table Of Contents

    Safety Information ..........1-1 Safety Messages .
  • Page 6 Temperature Effects on Hook Blocks ........1-38 Temperature Effects on Hydraulic Cylinders .
  • Page 7 Maintenance ........... 3-1 Inspection and Maintenance .
  • Page 8 Maintenance ........... . . 5-33 1/2 Stage Anti-two Block Wire Replacement .
  • Page 9 Jib Jack Service & Maintenance ......... . . 7-5 Adding Oil .
  • Page 10 Pin Bearing Inspection And Installation Procedure ......10-5 Pin Inspection ........... . 10-5 Bearing Inspection .

  • Page 11: Safety Messages

    800D SAFETY INFORMATION SECTION 1 SAFETY INFORMATION SECTION CONTENTS Safety Messages......1-1 Grounding the Crane ..... . 1-25 General .

  • Page 12: Safety Alert Symbol

    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.

  • Page 13: Operator Qualifications

    800D SAFETY INFORMATION No personnel shall be allowed to climb onto the crane or Refer to the Parts Manual for this crane for the locations of all enter the crane cab or operator’s station unless performance safety decals. of their duties require them to do so, and then only with You must be familiar with the regulations and standards knowledge of the operator or other qualified person.

  • Page 14: Operational Aids

    SAFETY INFORMATION 800D As operator of this crane, you are granted the authority to supported personnel platforms. Personnel shall not be stop and refuse to lift loads until safety is assured. lifted when anti-two-block devices are not functioning properly. OPERATIONAL AIDS •...

  • Page 15: Working Area Limiter (If Equipped)

    800D SAFETY INFORMATION b o o m e x t e n s i o n n o s e r e s p e c t i v e l y. A n o p e r a t o r, block conditions.

  • Page 16: Load Charts

    SAFETY INFORMATION 800D Use adequate cribbing under outrigger floats to distribute weight over a greater area. Check frequently for settling. Read and follow the following safety decal for cranes with center front stabilizers. KEEP THE BOOM SHORT. Swinging loads with a long line can create an unstable condition and possible structural failure of the boom.

  • Page 17: Wind Speeds

    800D SAFETY INFORMATION provided to assist in determining safe operation in windy decreased backward stability, wind on the side of the boom conditions. can result in structural damages, etc.) Always use extreme caution when windy conditions exist. Wind forces can exert extreme dynamic loads. National NEVER exceed the rated capacity shown on the Load Chart.
  • Page 18 SAFETY INFORMATION 800D NOTE: This condition is limited to operation with the main In both cases a) and b) above, the lift may also be limited by boom on fully extended outriggers only. the projected wind area of the load Ap and by the wind drag coefficient Cd: This limit can be determined by comparing c) If V(z) is >...
  • Page 19 800D SAFETY INFORMATION Simplified Method to Determine Maximum Permissible Wind Speed Determine 3-Second Gust 0.14 V(z) = [(z/10) + 0.4]v [m/s] Wind Speed at boom tip, 0.14 V(z) = [(z/33) + 0.4]v [mph] V(z) 13.4 m/s < V(z) < 20.1 m/s V(z) >...
  • Page 20 SAFETY INFORMATION 800D Determination of 3-second wind gust speed at boom Size and Shape of the load: tip height: These rated capacities are also based on the assumption that the Wind Resistance Area of load, Awr is not more The following example illustrates how to calculate 3-second (load) wind gust speed at boom tip height based on mean wind than 0.0012 square meters per kilogram (0.0059 sq.ft per...
  • Page 21 800D SAFETY INFORMATION Calculation of Projected Wind Area (Ap) Wind Wind = 8 m = 24 m 25 ft 25 ft Wind Wind 10 ft 3 ft = 75 ft = 250 ft 10 ft 3 ft 8384-1 FIGURE 1-2 Determining Wind Drag Coefficient (Cd) If the exact Wind Drag Coefficient of a shape is not known, use the maximum value of the shape’s range...
  • Page 22 SAFETY INFORMATION 800D Table 1-2 Wind Drag Coefficient Maximum Permissible Wind Speed If the wind resistant area of the load Awr is greater than (load) Shape the allowable wind resistant area Awr , the ratio can be (allow) used to determine a permissible wind speed V(z) for the load 1.1 to 2.0 using Table 1-3.
  • Page 23 800D SAFETY INFORMATION Rated Load Chart Example - Metric 8383-1 FIGURE 1-3 National Crane Published 5-27-2018 Control # 039-06 1-13...
  • Page 24 SAFETY INFORMATION 800D 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 extension) For wind speed V(z) (3-second gust speed at boom tip height) V(z) > 13.4 m/s ≤ 20.1 m/s, the Reduced Capacity shall be calculated by multiplying the Published Rated Capacity by the following factors: Main Boom Length in Meters Wind Speed...
  • Page 25 800D SAFETY INFORMATION At wind speeds greater than 13.4 m/s, it is not permissible to Load example 1.3a: lift a load greater than 12,040 kg, even if the wind resistance With large wind resistance area of the load Awr (load) area of the load is less than 14.45 m •...
  • Page 26 SAFETY INFORMATION 800D • Is the load to be lifted less than allowable load? Ratio = 1.37 8,000 kg ≤ 12,040 kg • Is Awr less than Awr (load) (allow) From Table 1-5, the maximum permissible wind speed at 19.83 m ≤...
  • Page 27 800D SAFETY INFORMATION Rated Load Chart Example - Non-metric 8382-1 FIGURE 1-4 National Crane Published 5-27-2018 Control # 039-06 1-17...
  • Page 28 SAFETY INFORMATION 800D Table 1-6 Example-Capacity Reduction Factors for Wind Speed V(z) Greater than 30 mph - Non-metric (Only for lifting with main boom on fully extended outriggers, with or without stowed extension) For wind speed Vz (3-second gust speed at boom tip height) is greater > 30> mph ≤ 45 mph, the Reduced Capacity shall be calculated by multiplying the Published Rated Capacity by the following factors: Main Boom Length in Feet Wind Speed...
  • Page 29 800D SAFETY INFORMATION • Is Awr less than Awr (load) (allow) 108 ft ≤ 119 ft L i f t i n g L i m i t s a t w i n d s p e e d V ( z ) > 3 0 m p h Conclusion: This load is permissible to lift in wind speed up and ≤...

  • Page 30: Lifting Operations

    SAFETY INFORMATION 800D Refer to the above Lifting Limits at wind speed V(z) injury could result from the crane tipping over or failing > 30 mph and ≤ 45 mph. Comparing the load and wind structurally from overload. resistant area to the allowable: The crane can tip over or fail structurally if: •...

  • Page 31: Counterweight

    800D SAFETY INFORMATION Counterweight • Maintain communication between all parties throughout the entire operation. If possible, provide approved radio On cranes equipped with removable counterweights, ensure equipment for voice communication between all parties the appropriate counterweight sections are properly installed engaged in the lift.

  • Page 32: Pile Driving And Extracting

    SAFETY INFORMATION 800D • The panel shall be lifted so that the hoist lines are in line • The pile driver and piling shall be suspended from a with the crane. hoist cable with sufficient line speed to meet or exceed the rate of descent of the driver and piling to preclude •...

  • Page 33: Electrocution Hazard

    800D SAFETY INFORMATION ELECTROCUTION HAZARD 29CFR1926.1408 and ASME B30.5 American National Standard. Thoroughly read, understand, and abide by all applicable federal, state, and local regulations regarding operation of cranes near electric power lines or equipment. United States federal law prohibits the use of WARNING cranes closer than 6 m (20 ft) to power sources up to 350 kV and greater distances for higher...

  • Page 34: Set-Up And Operation

    SAFETY INFORMATION 800D The rules in this Operator Manual must be followed at all or load moves near a power source. This person shall have times, even if the electrical power lines or equipment have no other duties while the crane is working. been de-energized.

  • Page 35: Electrical Contact

    Should the distributor not be immediately • If a thunder storm is forecast available, contact Manitowoc Crane Care. The crane must not be returned to service until it is thoroughly inspected for Use electrically conducting material for grounding.

  • Page 36: Personnel Handling

    SAFETY INFORMATION 800D Connect the free end of the cable with a clamp (1) to a General requirements. The use of a crane or der- rick to hoist employees on a personnel platform is good electrically conductive location on the frame. prohibited, except when the erection, use, and dis- mantling of conventional means of reaching the worksite, such as a personnel hoist, ladder, stair-...

  • Page 37: Environmental Protection

    800D SAFETY INFORMATION The platform is properly attached and secured to the • Always drain waste fluids into leak proof containers that load hook. are clearly marked with what they contain. • For boom mounted platforms: • Always fill or add fluids with a funnel or a filling pump. On cranes equipped with a boom mounted •...

  • Page 38: Lubrication

    Do not attempt to repair or tighten any hydraulic hose or • Consult with Manitowoc Crane Care to determine if load fitting while the engine is running, or when the hydraulic testing is required after a structural repair is performed.

  • Page 39: Tires

    K100™ Synthetic Crane Hoist Line Manual P/N • Core deterioration, usually observed as a rapid 9828100734 available by contacting Manitowoc Crane Care. reduction in rope diameter, is cause for immediate removal of the rope. During installation and setup, care must be taken to avoid overlap and crossing of wire rope and synthetic hoist ropes.

  • Page 40: Sheaves

    SAFETY INFORMATION 800D • Never “shock load” a rope. A sudden application of force Evidence of abuse or contact with another object. or load can cause both visible external and internal Heat damage. damage. There is no practical way to estimate the force applied by shock loading a rope.

  • Page 41: Batteries

    800D SAFETY INFORMATION Engine Ensure sheaves carrying ropes that can be momentarily unloaded are equipped with close fitting guards or other Fuel the crane only with the engine turned off. Do not smoke devices to guide the rope back into the groove when the load while fueling the crane.

  • Page 42: Travel Operation

    SAFETY INFORMATION 800D exercised anytime any crane function is being performed Watch clearances when traveling. Do not take a chance of while the cable is hooked into the hookblock tie down. running into overhead or side obstructions. When moving in tight quarters, post a signal person to help TRAVEL OPERATION guard against collisions or bumping structures.

  • Page 43: Work Practices

    Operator Manual when extending or retracting the system that have not been evaluated and approved by outriggers. Death or serious injury could result from improper Manitowoc Crane Care. crane set up on outriggers. Do not step on surfaces on the crane that are not approved Be familiar with surface conditions and the presence of or suitable for walking and working.

  • Page 44: Lifting

    SAFETY INFORMATION 800D Sparks from the crane’s electrical system and/or engine exhaust can cause an explosion. Do not operate this crane in an area with flammable dust or vapors, unless good ventilation has removed the hazard. Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area.

  • Page 45: Hand Signals

    800D SAFETY INFORMATION Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the brake is working correctly before continuing the lift.
  • Page 46 SAFETY INFORMATION 800D 8496-1 Reprinted from ASME B30.5-2014, by permission of The American Society of Mechanical Engineers. All Rights Reserved. FIGURE 1-6 1-36 Published 5-27-2018 Control # 039-06...

  • Page 47: Boom Extension

    800D SAFETY INFORMATION BOOM EXTENSION that certain jobsite conditions may not permit the boom and boom extension of a crane to be fully lowered to the ground. To avoid death or serious injury, follow the procedures in this When a qualified person at a jobsite determines that it is not manual during erection, stowage, and use of the boom practical to lower the boom to the ground, we recommend extension.

  • Page 48: Temperature Effects On Hook Blocks

    SAFETY INFORMATION 800D If applicable to your crane, frequently check all air tanks for would retract approximately 196 mm (7 3/4 in) [see Table 1- water in freezing weather. 8]. A cylinder extended 1.5 m (5 ft) in which the oil cools 15.5°C (60°F) would only retract approximately 38 mm (1 1/ Never store flammable materials on the crane.

  • Page 49: Overload Inspection

    800D SAFETY INFORMATION Table 1-8: Boom Drift Chart (Cylinder length change in inches) Coeff. = 0.00043 (in / °F) STROKE Temperature Change (°F) (FT.) 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64...
  • Page 50 • Perform the inspections outlined in this publication for after the actual event. overloads up to 50%. • Stop operating the crane and contact Manitowoc Crane Care immediately for overloads of 50% and higher. 1-40 Published 5-27-2018 Control # 039-06...
  • Page 51 800D SAFETY INFORMATION Boom Inspection 9455 Illustration for reference only. Your crane may be different. National Crane Published 5-27-2018 Control # 039-06 1-41...
  • Page 52 SAFETY INFORMATION 800D NOTE: The following checklist includes all features that can be found on National Cranes. Your crane may not have some features. Overload less than 25% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect for damage. Retainers Overload from 25% to 49% Sheaves,...
  • Page 53 800D SAFETY INFORMATION Superstructure Inspection 9456 Illustration for reference only. Your crane may be different. National Crane Published 5-27-2018 Control # 039-06 1-43...
  • Page 54 SAFETY INFORMATION 800D NOTE: The following checklist includes all features that can be found on National Cranes. Your crane may not have some features. Overload less than 25% Lift Cylinder Inspect for leaking. See topic in Introduction section of Wire Rope Inspect all for damage.
  • Page 55 800D SAFETY INFORMATION Carrier Inspection 9457 Illustration for reference only. Your crane may be different. National Crane Published 5-27-2018 Control # 039-06 1-45...
  • Page 56 SAFETY INFORMATION 800D NOTE: The following checklist includes all features that can be found on National Cranes. Your crane may not have some features. Overload less than 25% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% Stabilizer...

  • Page 57: Operation

    800D OPERATION SECTION 2 OPERATION SECTION CONTENTS Truck Cab Controls ......2-1 Reading and Understanding the Load Power Take-Off (PTO) .

  • Page 58: Park Brake

    OPERATION 800D Power Shift Control – If the vehicle is equipped with automatic transmission, the power take-off must be engaged with the engine at idle. Refer to transmission manufacturer’s instructions for special procedures. Payout loadline before extending boom. Failure to do so may cause the loadline to break or damage the crane.

  • Page 59: Hydraulic Capacity Alert (Hca) System (If Equipped)

    800D OPERATION 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.

  • Page 60: Rated Capacity Limiter (Rcl) (If Equipped)

    If operating limits are met, the RCL when bleeding air from the hydraulic hoses when calibrating will stop aggravating crane movements, like hoist up or the transducers. Contact Manitowoc Crane Care for more telescope out. information about calibrating RCL sensors.
  • Page 61 800D OPERATION Override Switches – The 800D features two RCL override not use override to continue lifting operations in an overload switches for RCL/ATB lockout conditions: or two blocked condition. • On/Off Key Switch The override push button (Figure 2-2) is located on the bulkhead between the crane’s two operator positions.

  • Page 62: Crane Nomenclature

    OPERATION 800D CRANE NOMENCLATURE BOOM HOIST TELESCOPING TURN TURN PRESSURE O/R THIS SIDE GAUGE O/R OTHER SIDE O/R OTHER SIDE O/R THIS SIDE STABILIZER STABILIZER FUSE ENGINE EMERGENCY STOP SWITCH HORN BOOM HOIST  TELESCOPING HCA LOAD  TURN RANGE GAUGE ...

  • Page 63: Operating Procedures

    Lubrication on page 4-1, by contacting your local National • Check the loadline cable for kinks, broken strands or Crane distributor, or by contacting Manitowoc Crane Care other damage in accordance with instructions in the directly). “Lubrication & Maintenance” section.

  • Page 64: Transmission

    OPERATION 800D Upon startup, allow the engine to idle for 3 to 5 minutes Ensure the boom is fully retracted and near maximum lift before operating with a load. angle with no load applied. Cold Engine Startup: After allowing the engine to warm Rotate the superstructure at a speed of less than one- by idling it for 3 to 5 minutes, slowly increase the engine half RPM for at least two complete revolutions in one...

  • Page 65: Work Site Position

    800D OPERATION If the operator cannot see the load handling device Operation approaching the boom nose, he shall have an assistant After being properly checked, the RCL is operational. The (signal person) watch the load handling device. The operator operator shall be thoroughly familiar with all controls of the shall be prepared to stop the machine immediately should RCL and he shall properly set the reeving (parts of line) the RCL (or optional HCA system) not function properly.

  • Page 66: Before Leaving The Cab

    OPERATION 800D It is best to select a location on the site such that most of the lifting can be done over the outrigger support or rear of the truck. CRANE SET UP BEFORE LEAVING THE CAB Position the truck so that the outriggers can be extended without encountering obstructions.

  • Page 67: Before Making The Lift

    800D OPERATION When Lifting Over the Front of the Truck and the Vehicle particularly important after the unit has been serviced or is Equipped with a Front Stabilizer repaired. If any abnormal operations are detected, correct the condition before continuing. During all operations, the controls should be metered when beginning or terminating a movement to prevent sudden starting or stopping which imposes undue shock...
  • Page 68 OPERATION 800D The weight of load handling devices is considered as a Set-Up part of the load being lifted. Inspect vehicle and crane including crane operation The correct loadline reeving is used for the load to be prior to use each day. lifted.
  • Page 69 800D OPERATION (side) loads, experience of personnel, two machine lifts, or other hazardous conditions for safe operation. When boom length or radius or both are between points listed on capacity chart, the smallest load shown at either the next larger radius or boom length shall be used.
  • Page 70 OPERATION 800D Example 1 • Allowable load for single part line is 7700 lb (3492 kg) well above the 6300 lb (2858 kg) to be lifted. A load is to be lifted from the ground and weighs 6120 lb (2776 kg) at a radius of 35 ft (10.7 m). It will be placed on the Operator should now proceed to lift the load as smoothly as roof of a building at a radius of 25 ft (7.62 m) and a height of possible.
  • Page 71 800D OPERATION Example 3 Starting Point: With the 25 ft (7.62 m) jib deployed and the boom fully extended, the capacity is 3900 lb (1769 kg) at a A load of 2500 lb (1134 kg) is to be lifted from the roof of a 30 ft (9.14 m) radius and boom angle of 78°.
  • Page 72 OPERATION 800D NATIONAL CRANE CORPORATION NOTE: SERIES 8100D Operate with jib by radius when main boom is fully extended. If necessary 2ND JIB WITH increase boom angle to maintain loaded radius. 44FT 44FT JIB Operate with jib by boom angle when main boom is not fully extended. Do 1ST JIB not exceed rated jib capacities at any reduced boom lengths.

  • Page 73: Hoist System Operation

    800D OPERATION HOIST SYSTEM OPERATION USING MULTIPLE PART LINES The hoist is mounted at the rear of the first section boom. It The hoist load rating chart on each machine provides the has capacities totally independent of the rest of the crane information for pull limitations on the hoist with various and can normally pull more than the crane itself can applicable part reevings.

  • Page 74: Shutting Down And Preparing For Road Travel

    OPERATION 800D OPTIONAL HOIST BURST OF SPEED can also be aided by carefully coordinating the throttle control. OPERATION Lower loadline and attach load. The “Burst of Speed” will increase hoist line speed 60% over normal operation by diverting oil from the multibank control Control load by use of a non-conductive tag line.

  • Page 75: Outrigger Monitoring System (Oms) (Optional-Standard In North America)

    800D OPERATION OUTRIGGER MONITORING SYSTEM (OMS) on cranes equipped with Rear Stabilizer Out and Down (RSOD)), the Outrigger Status Indicator illuminates constant (OPTIONAL—STANDARD IN NORTH GREEN, indicating a lift can be made. If power is on and one AMERICA) or more outrigger or stabilizer beams are not extended to a position which provides maximum stability, the Outrigger Operation Status Indicator flashes RED, indicating a lift should not be...

  • Page 76: Maintenance

    OPERATION 800D Maintenance Connect electrical connector (1) to sensor. Calibrate sensor. Refer to Calibrate, page 20. Outrigger Cylinder Length Sensor (Version Calibrate Calibrating the cylinder length sensor requires a laptop equipped with the HED Conductor software and a USB cable connector (p/n 80009992).
  • Page 77 800D OPERATION turns from constant red to constant green when the outrigger is fully extended. 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.

  • Page 78: Anti-Two Block System

    OPERATION 800D ANTI-TWO BLOCK SYSTEM With power on and stabilizer beam fully extended, ensure LED (6, Figure 2-9) on proximity switch Description/Operation illuminates. Retract stabilizer beam and ensure LED is not illuminated. With untrained or inexperienced or distracted operators, two blocking the hoist cable is a very real possibility.

  • Page 79: Anti-Two-Block Weight Installation

    800D OPERATION ATB Switch Lanyard PROPER ATB Upper Quicklink WEIGHT RIGGING Load Line Chain 16 in. long (40 cm) Lower Quick Link ATB Weight 9367 ANTI-TWO-BLOCK WEIGHT INSTALLATION To prevent the hoist cable from slipping out of the ant-two- Upper Link block weight, rig the weight as shown in Figure 2-11.

  • Page 80: Hydraulic Capacity Alert System (Optional)

    OPERATION 800D HYDRAULIC CAPACITY ALERT SYSTEM Red - Overload. The gauge is plumbed directly to the lift cylinder and the indicator position can be used as an aid in (OPTIONAL) determining the load condition of the crane. The lift control lever must be moved from boom up position to the neutral System Description position to get the most accurate reading when using load...
  • Page 81 800D OPERATION FIGURE 2-13 FIGURE 2-12 9473 9472 The load range gauge is provided to aid the operator when operating near the rated capacity of the crane. The 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.
  • Page 82 OPERATION 800D The RCL or (optional) Hydraulic Capacity Alert Systems are intended to be used as aids to prevent most overload conditions. Do not use the RCL or (optional) Hydraulic Capacity Alert System as substitutes for safe operating practices as outlined in the “Safety Information” section of this manual. Do not expect the RCL or (optional) Hydraulic Capacity Alert System to detect all possible overload conditions.

  • Page 83: Jib Safety And Operation

    800D OPERATION JIB SAFETY AND OPERATION C (4 PLCS) STOW LOOP 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 RIGHT SIDE LEFT SIDE SIDE...

  • Page 84: Safety Tips For Jib Operation

    OPERATION 800D Safety Tips For Jib Operation 17. When the jib is stowed, the boom can not be fully retracted if a boom tip attachment option is installed. The anti-two-block switch weight and cord must be CAUTION attached to the jib when deployed. •...
  • Page 85 800D OPERATION 10. Using tag line, swing jib into deployed position. Disconnect twist lock anti-two-block wire connector at rear of 1st section jib. Connect twist lock connector to 11. Remove cable keeper pins from boom sheave case and anti-two-block switch connector on boom tip. Move anti- jib.

  • Page 86: Jib Maintenance

    OPERATION 800D device has been designed to line up the bottom jib pin hole on the left side of the crane. To use the device, follow the proper procedure outlined in the Owner’s Manual to install both jib pins on the right side of Visually check all pin positions to assure jib is fully retracted into stow brackets, jib stow attachment is crane and the top pin on the left side.

  • Page 87: Adjustable Swing Speed Valve

    800D OPERATION ADJUSTABLE SWING SPEED VALVE The Series 800D is equipped with an adjustable swing speed valve. This valve allows the operator to limit the maximum swing speed of the machine to suit operator preference or varying applications. An adjustment dial is located on the swing holding valve mounted on the swing motor inside the crane frame.

  • Page 88: Standard Hand Signals For Controlling Crane Operations

    OPERATION 800D STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS 9371 SWING. Arm extended, point with STOP. Arm extended, palm EMERGENCY STOP. Both arms HOIST. With forearm vertical, LOWER. With arm extended finger in direction of swing of down, move arm back and forth extended, palms down, move forefinger pointing up, move hand downward, forefinger pointing...

  • Page 89: Maintenance

    800D MAINTENANCE SECTION 3 MAINTENANCE SECTION CONTENTS Inspection and Maintenance ....3-1 Environmental Conditions ....3-3 Inspection .

  • Page 90: Weekly Inspections

    MAINTENANCE 800D 16. All securing hardware such as cotter pins, snap Torque of cable clip bolts above wedge socket at rings, hairpins, pin keepers and capscrews for end of loadline should be 95 ft-lb (129 Nm). proper installations. All boom wear pad retaining bolts. 17.

  • Page 91: Other

    • Measure the rope’s diameter across crowns of the strands when determining if rope has become damaged, NOTE: Wire rope may be purchased through Manitowoc refer to Figure 3-1. Crane Care. National Crane Published 5-27-2018 Control # 039-06...

  • Page 92: Inspection

    MAINTENANCE 800D Daily Inspections All cable in continuous service must be inspected at the beginning of each work day. Inspect the eye end and length of cable that is used in daily operation. The end should be inspected for abrasion, corrosion, broken wires, and loose or broken servings.

  • Page 93: Adjustments And Repairs

    800D MAINTENANCE Wire rope shall be taken out of service when any of the Boom lowered to the ground or otherwise secured following conditions exist: against dropping. Load block lowered to ground or otherwise secured • In rotation resistant ropes: two randomly distributed against dropping.

  • Page 94: Care Of Wire Rope

    MAINTENANCE 800D Method 2 7204 FIGURE 3-4 Care of Wire Rope FIGURE 3-3 Handle wire rope with care to prevent damage to the Wind a length of soft annealed wire Figure 3-3 around the individual wires which affect the overall strength and wire rope at least seven times.

  • Page 95: Tire Load And Inflation Table

    800D MAINTENANCE TIRE LOAD AND INFLATION TABLE Definite tire inflation pressures are established for each tire size depending upon the load imposed on the tires. For greater stability, riding comfort and prolonged tire life, tires should be inflated for the loads carried. The “Load and Inflation Table”...
  • Page 96 MAINTENANCE 800D WIDE BASE RADIAL TIRES FOR TRUCKS IN NORMAL HIGHWAY SERVICE (TIRES USED AS SINGLES) TIRE LOAD LIMITS, LB (kg), AT VARIOUS COLD INFLATION PRESSURES, PSI (kPa) TIRE SIZE DESIGNATION (483) (517) (552) (586) (621) (655) (690) (724) (758) (793) (827) 445/65R19.5...
  • Page 97 800D MAINTENANCE TIRES FOR TRUCKS IN NORMAL HIGHWAY SERVICE (TIRES MOUNTED ON 15° DROP CENTER RIMS) TIRE LOAD LIMITS, LB (kg), AT VARIOUS COLD INFLATION PRESSURES, PSI (kPa) TIRE SIZE RADIAL PLY USAGE DESIGNATION (448) (483) (517) (552) (586) (621) (655) (690) (724)
  • Page 98 MAINTENANCE 800D THIS PAGE BLANK 3-10 Published 5-27-2018 Control # 039-06...
  • Page 99 800D LUBRICATION SECTION 4 LUBRICATION SECTION CONTENTS Lubrication Procedures And Charts ... 4-1 Carwell© Rust Inhibitor..... . 4-5 Lubricants .

  • Page 100: Lubrication

    If you are in doubt about the suitability of a specific fluid, The following oil viscosity characteristics are recommended: check with your authorized National Crane distributor or • 80 to 180 SUS optimum at system operating Manitowoc Crane Care. temperature. Lubrication Points • 60 SUS minimum at system operating temperature.

  • Page 101: Wire Rope Lubrication

    800D LUBRICATION Over lubrication of non-sealed fittings will not harm the The surface of some ropes may become covered with dirt, fittings or components, but under lubrication will definitely rock dust, or other material during their operation. This lead to a shorter lifetime. covering can prevent field applied lubricants from properly penetrating into the rope.

  • Page 102: Lubrication Chart

    LUBRICATION 800D Lubrication Chart 9376 RECOMMENDED APPLICATION PROCEDURE FREQUENCY LUBRICANT 1. Hydraulic Oil Reservoir Hydraulic Oil Check & Fill Weekly Change (See “Hydraulic Oil Semi-Annually Reservoir Level” on page 4-5) 2. Oil Filter, Magnetic Plug Change or Clean After First 40 Hours then Quarterly 3.

  • Page 103: Hydraulic Oil Reservoir Level

    To help protect against corrosion of National Crane, application. This red tint will turn clear on its own within Manitowoc Crane Care recommends washing the crane at approximately 24 hours after application. National Crane...

  • Page 104: Inspection And Repair

    To the extent any damage is structural in nature, corrosion, but will also improve the ability to identify Manitowoc Crane Care must be contacted and consulted potential issues before they grow into larger problems. as to what repairs may be required.

  • Page 105: Areas Of Application

    / hook block pins and fasteners. necessary. • All hardware, clips, pins, hose connections not painted Please contact Manitowoc Crane Care should you have any © will have Carwell applied. questions.
  • Page 106 LUBRICATION 800D 9379 Item Description Item Description Hook Block/Headache Ball Hoist Plumbing Connections O/R Hose Connections All Hardware, Clips, Pins, Hose Connections O/R Pins, Clips not painted O/R Pins, Clips Power Train Hardware Pivot Shaft Entire underside of unit Hose Connections Turntable Bearing Fasteners, Pins Mirror Mounting Hardware Valve Bank, Hose Connections...

  • Page 107: Service

    If at any time you cannot find or Make the necessary repair. correct the problem, contact your National Crane distributor or Manitowoc Crane Care. Be sure you have your parts Recheck to ensure that nothing has been and service book, model number and serial number at overlooked.

  • Page 108: Environmental Protection

    SERVICE 800D sense. It is not just a matter of “Do's” and “Don'ts”. Stay covering apply when access covers or inspection plates are clear of all moving parts. removed. Clean and inspect all parts. Be sure all passages and holes Environmental Protection are open.

  • Page 109: Label Parts When Disassembling

    800D SERVICE Label Parts When Disassembling When removing or disconnecting a group of wires or cables, CAUTION tag each one to ensure proper identification during re- When draining the outrigger cylinders, always operate assembly. either both front or both rear cylinders together to prevent When shims are removed, tie them together and identify twisting the crane.

  • Page 110: Removing Air From The Hydraulic System

    SERVICE 800D Fill the reservoir to the full mark on the reservoir sight gauge. • To remove entrapped air from telescope cylinders, lower After the reservoir is filled, operate all circuits and recheck the boom to below horizontal and fully telescope the the reservoir sight gauge.
  • Page 111 800D SERVICE O-RING FACE SEAL FITTING SIZE O-RING BOSS NATIONAL MFGR'S NATIONAL THREAD B inch A inch TUBE A inch B inch THREAD CRANE SIZE CRANE SIZE (mm) (mm) O.D. (mm) (mm) SIZE PART NO. CODE PART NO. **897063 9/16-18 0.07 0.301 0.250...

  • Page 112: Loctite

    SERVICE 800D Fatigue of Welded Structures available from the Parts Department of the local National Crane distributor. Experience has shown that highly stressed welded structures when repeatedly subjected to varying stresses Application of Medium Strength Loctite® caused by twisting, shock, bending, and intentional and/or NOTE: The fastener may be re-used;...
  • Page 113 800D SERVICE The torque tables are provided by National Crane for NOTE: If multipliers and/or special tools are used to reach reference when performing maintenance. hard to get at areas, ensure torque readings are accurate. Use of proper torque values is extremely important. Improper torquing can seriously affect performance and reliability.
  • Page 114 SERVICE 800D SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8 and Grade 2 HHCS HHCS HHCS HHCS Socket Head Socket Head Serrated Flange Capscrew Shoulder Screw Head FIGURE 5-2 Published 5-27-2018 Control # 039-06...
  • Page 115 800D SERVICE Table 5-1 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-20 UNC 13.5 13.2 12.8 5/16-18 UNC 19.1 18.6 18.1 24.0 23.4 22.8 3/8-16 UNC 33.9...
  • Page 116 SERVICE 800D Table 5-2 Inch Series with Fine Threads (UNF) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-28 UNF 10.6 10.4 10.1 15.0 14.6 14.2 5/16-24 UNF 21.1 20.6 20.1 27.2 26.5...
  • Page 117 800D SERVICE Table 5-3 Metric Series with Coarse Threads – Zinc Flake Coated Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 10.9 M4x0.7 12.9 10.9 M5x0.8 12.9 M6x1.0 10.9 12.2 11.9 11.6 12.9 14.3 13.9 13.6...
  • Page 118 SERVICE 800D Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 881.6 859.6 837.5 M27x3 10.9 1255.7 1224.3 1192.9 12.9 1469.4 1432.7 1395.9 1195.3 1165.5 1135.6 M30x3.5 10.9 1702.5 1659.9 1617.3 12.9 1992.3 1942.4 1892.6 2089.8 2037.6...
  • Page 119 800D SERVICE Table 5-4 Metric Series with Fine Threads – Zinc Flake Coated Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 21.6 21.1 20.5 M8x1.0 10.9 31.7 30.9 30.1 12.9 37.1 36.2 35.3 46.8 45.6 44.4...
  • Page 120 SERVICE 800D Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 655.8 639.4 623.0 M24x2 10.9 934.0 910.6 887.3 12.9 1092.9 1065.6 1038.3 951.4 927.6 903.8 M27x2 10.9 1355.0 1321.1 1287.2 12.9 1585.6 1546.0 1506.3 1369.2 1334.9...
  • Page 121 800D SERVICE Table 5-5 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads Size Torque (Nm) M2.5x0.45 M3x0.5 M4x0.7 M5x0.8 M6x1 M8x1.25 M10x1.5 Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength. Stainless steel fasteners tend to gall while being tightened.
  • Page 122 SERVICE 800D Table 5-6 Inch Series Screws of STAINLESS STEEL 300 (18-8) with Coarse Threads Torque Size lb-in lb-ft #5-40 (0.125) #6-32 (0.138) #8-32 (0.164) #10-24 (0.190) 1/4-20 5/16-18 3/8-16 17.5 Torque Values for fasteners with lubrication these torque and Stainless steel fasteners tend to gall while being tightened.
  • Page 123 800D SERVICE Table 5-7 Inch Series Bearing Bolts – Untreated (black finish) Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 5/8-11 UNC 5/8-18 UNF 3/4-10 UNC 7/8-9 UNC 1-8 UNC 1 1/4-7 UNC 2043 1964 1885 National Crane...
  • Page 124 SERVICE 800D Table 5-8 Metric Series Bearing Bolts– Untreated (black finish) Nominal Size, Threads per Torque (Nm) Inch, and Series Grade Maximum Nominal Minimum Designation M20X2.5 12.9 M24X3 10.9 1089 1047 1005 M24X3 12.9 1306 1256 1206 M27X3 10.9 1591 1530 1469 5-18...
  • Page 125 800D SERVICE Table 5-9 Inch Series with Coarse Threads (UNC) – Untreated (black finish) Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-20 12.5 11.5 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 259.5 3/4-10 7/8-9 1 1/8-7 1342 1288 1234 1141 1097 1053 1 1/4-7 2043...
  • Page 126 SERVICE 800D Inch Series with Fine Threads (UNF) – Untreated (black finish) Table 5-10 Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-28 14.5 13.5 5/16-24 3/8-24 7/16-20 84.5 1/2-20 9/16-18 174.5 5/8-18 299.5 3/4-16 439.5 7/8-14 1-12 1009 644.5 1-14 908.5 1 1/8-12 1500...
  • Page 127 800D SERVICE Table 5-11 Metric Series with Coarse Threads – Untreated (black finish) Torque (Nm) Property Size Class Maximum Nominal Minimum M4x0.7 10.9 12.9 M5x0.8 10.9 12.9 10.5 10.5 M6x1 10.9 12.9 M8x1.25 10.9 36.5 12.9 43.5 M10x1.5 10.9 12.9 M12x1.75 10.9 12.9...
  • Page 128 SERVICE 800D Torque (Nm) Property Size Class Maximum Nominal Minimum 1134 1090 1046 M27x3 10.9 1591 1530 1469 12.9 1910 1836.5 1763 1538 1479 1420 M30x3.5 10.9 2163 2080 1997 12.9 2595 2495 2395 2681 2578.5 2476 M36x4 10.9 3964 3812 3660 12.9...
  • Page 129 800D SERVICE Table 5-12 Metric Series with Fine Threads – Untreated (black finish) Torque (Nm) Property Size Class Maximum Nominal Minimum M8x1 10.9 39.5 12.9 M10x0.75 10.9 12.9 M10x1.25 10.9 12.9 97.5 M12x1 10.9 12.9 M12X1.25 10.9 141.5 12.9 165.5 M12x1.5* 10.9 12.9...
  • Page 130 SERVICE 800D Torque (Nm) Property Size Class Maximum Nominal Minimum 803.5 M24x2 10.9 1176 1130.5 1085 12.9 1410 1356 1302 1225 1171.5 1130 M27x2 10.9 1718 1652.5 1587 12.9 2063 1983.5 1904 1530 1471.5 1413 M30x1.5 10.9 2253 2166.5 2080 12.9 2637 2536...
  • Page 131 800D SERVICE Weld Studs Unless otherwise specified the following grade 2 torque values (± 10%) apply. Table 5-13: Weld Stud Torque Values Stud Size Torque No. 10 20 lb-in 1/4 in 4 lb-ft 5/16 in - 18 9 lb-ft 5/16 in - 24 10 lb-ft 3/8 in 14 lb-ft...
  • Page 132 SERVICE 800D TROUBLE DIAGNOSIS inclusive but are designed to help isolate the problem and should be checked before calling the factory Service The following chart lists malfunctions which may occur Department. during equipment operation, followed immediately by possible cause and possible solution. These are not all CONDITION POSSIBLE CAUSE POSSIBLE SOLUTION...

  • Page 133: Trouble Diagnosis

    800D SERVICE TROUBLE DIAGNOSIS (continued) CONDITION POSSIBLE CAUSE POSSIBLE SOLUTION Swing will not • Attempting to swing up too much of incline. • Level machine. turn • Turn circuit relief valves sticking. • Clean and check circuit pressure. • Turntable bearing drag. •...
  • Page 134 SERVICE 800D TROUBLE DIAGNOSIS (continued) CONDITION POSSIBLE CAUSE POSSIBLE SOLUTION Boom chatters • Boom sections need lubrication. • Grease boom. during • Wear pads not shimmed correctly. • Reshim as described in boom assembly section. extension/ • Worn wear pads. •...
  • Page 135 800D SERVICE Anti-two Block Trouble Diagnosis — Electrical Anti-Two Blocking System fails to shut down, hoist up and boom extend Check for voltage across leads of limit switch with weight supported Check limit switch or actuator arm for sticking - Repair or Fuse blown replace switch Test HCA &...
  • Page 136 SERVICE 800D Anti-two Block Trouble Diagnosis – Electrical (Continued) Anti-Two Blocking System shuts down crane functions when weight is freely suspended 12 volts at limit switch Fuse blown Test HCA & ATB relays for Replace fuse proper operation (see Schematic) NORMAL FAULTY RELAY OPERATION...

  • Page 137: Electrical

    800D SERVICE Anti-two Block Trouble Diagnosis — Hydraulic Anti-Two Blocking System fails to shut down hoist up, boom down and boom extend HYDRAULIC ELECTRICAL Check to ensure ATB Do all three functions fail to electrical system is working shut down properly.
  • Page 138 SERVICE 800D ANTI-TWO BLOCK TROUBLE DIAGNOSIS - HYDRAULIC (CONTINUED) Anti-Two Blocking System shuts down crane functions when ATB weight is freely suspended Purge air from unloader circuits. See procedure in this manual Functions operate correctly? Problem solved Are all three functions shut down? Examine solenoid valve Work with individual...

  • Page 139: Anti-Two-Block Internal Wire System/Four

    800D SERVICE ANTI-TWO-BLOCK INTERNAL WIRE block. The maintenance of this wire can be accomplished with the boom fully assembled but would be simplified if the SYSTEM/FOUR SECTION BOOM (CABLE 2/3/4 boom assembly was removed from the first section. ON TOP OF SECTIONS) Do not, under any circumstances, work at an elevated Operation height without using proper fall protection as required...
  • Page 140 SERVICE 800D 12. Install a jumper across the terminals of one of the 10. Insert the hooked end of the two “tools” into the space connectors and check for continuity at the opposite between the tops of the first and second sections and connector.

  • Page 141: 2/3/4 Stage Anti-Two Block Wire Replacement

    800D SERVICE 22. Install a jumper across the terminals of one of the 25. Make all wire connections, reattach the wire to the connectors and check for continuity at the opposite cushion clamp on the bottom of the boom and check connector.
  • Page 142 SERVICE 800D the bottom back end of the fourth section. If excessive boom assembly to the other. A telescopic grease applicator force is needed to pull the wire through, observe the for the boom, hydraulic tubing or electrical conduit are all routing for obstructions and make adjustments to avoid possibilities for use as an installation tool.

  • Page 143: Replacement Of Proportioning Cable For 1/2 Stage Of Anti-Two Block Wire

    800D SERVICE 15. The routing of the new wire is now complete and the tool sure the Weather-Pack connector is on the end that will can be detached from the wire. Visually inspect the wire attach to the 1/2 wire. routing to make sure that it is correctly routed.
  • Page 144 SERVICE 800D plate of the second section with the 5/16-18NC grade 5 capscrew that was removed earlier. 055.00 At the sheave case end of the boom, install the spacer and capscrews in the top front of the first section. Make 1.00 sure that the new anti-two-block wire is routed through the slot in the spacer bar.
  • Page 145 800D SERVICE Extend the boom completely. 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 Use a piece of No. 9 wire as an installation tool. Make a original location.

  • Page 146: Anti-Two-Block Internal Wire System/Three

    SERVICE 800D 11.5 in PROPORTIONING CABLE (29 cm) BOOM EXTENDED TRAVELING BLOCK BOOM RETRACTED 2ND SECTION BOOM TOP PLATE 1/2 WIRE ROUTING 9393 ANTI-TWO-BLOCK INTERNAL WIRE should be used if the wire has experienced a continuity failure in one or both of the conductors, but the rubber jacket SYSTEM/THREE SECTION BOOM of the wire is still intact.
  • Page 147 800D SERVICE At the hoist mount end, reach into the rear of the boom •Electrical tape and loosen the capscrew on the anti-two-block cable •Installation tool clamp enough to let the cable run around it with minimal To route the wire the entire length of the boom, a long tube, effort.

  • Page 148: Anti-Two-Block Wire With External Reel

    SERVICE 800D 11. Move to the sheave case end of the boom. Visually Pulling on this end will tension the static length of anti- determine if the wire has properly located itself onto the two-block wire clamped in the 3rd. Approximately 15-25 sheave.
  • Page 149 800D SERVICE a thorough check of the circuit should be performed. If the in opposite directions and that the loop in the cord is at wire on the reel is determined to be faulty, replace the wire. the top of the anchor. Tighten the capscrew until it bottoms out in the threads.
  • Page 150 SERVICE 800D conduit. This will still leave the anti- two-block wire in opposite directions and that the loop in the cord is at routed through the roller guides. the top of the anchor. Tighten the capscrew until it bottoms out in the threads. 13.
  • Page 151 800D REPAIR SECTION 6 REPAIR SECTION CONTENTS Cylinder Disassembly and Repair... . . 6-2 Four Section Boom Maintenance... . . 6-10 Internal Cable Sheave Lubrication.

  • Page 152: Cylinder Disassembly And Repair

    REPAIR 800D CYLINDER DISASSEMBLY AND REPAIR PRESSURE LINE FROM PORTA- POWER OR HYDRAULIC LINE FROM CRANE CIRCUIT VALVE READ PARAGRAPH 5 & 6 BEFORE PERFORMING THIS STEP SNAP RING WASHER SNAP RING CYLINDER BARREL SHAFT EXTENDED Disconnect shaft end of cylinder from machine. during original assembly to secure nut to shaft.

  • Page 153: Telescope Cylinder Disassembly

    800D REPAIR TELESCOPE CYLINDER Boom Retract Boom Extend 9396 Telescope Cylinder Disassembly Remove the two locking setscrews from piston. Using proper spanner wrench loosen and remove After cylinder has been removed from boom, place on threaded piston. supports and place drain pan under holding valve and cylinder head area.

  • Page 154: Three Section Boom Operation

    REPAIR 800D THREE SECTION BOOM OPERATION The boom service and maintenance section of this manual includes both the three and four section boom information. Use appropriate information for your particular boom length. EXTEND CABLE BASE 3RD SECTION 1ST SECTION 2ND SECTION RETRACT CABLE 9397 A rod-fed, double-acting cylinder, attached to the 1st and 2nd...

  • Page 155: Three Section Boom Maintenance

    800D REPAIR THREE SECTION BOOM MAINTENANCE fully retracted. Access to the grease holes on either end of the pin is through holes in the boom side plates. Do not, under any circumstances, work at an elevated Three Section Cable Tensioning height without using proper fall protection as required by local, state or federal regulations.

  • Page 156: Three Section Boom Service

    REPAIR 800D THREE SECTION BOOM SERVICE remove keeper plates. Loosen capscrew on the anti- two-block wire clamp on the anchor assembly. Boom Removal Extend boom 24 in (61 cm). Loosen and remove the nuts which secure the extend cables to the cable anchor Boom Length Boom Weight CG from pivot point...
  • Page 157 800D REPAIR vertical movement of the telescope cylinder. Remove Remove hoist. bar. Gaining access through rear of boom, loosen and 15. Loosen capscrews retaining extend cable anchor to remove capscrews retaining the keeper plates holding back of the 3rd section. Total removal of the capscrews the extend cable anchor in the rear of the 3rd section as will allow the cable anchor to be completely well as the anti-two-block wire clamp on the anchor...
  • Page 158 REPAIR 800D as required. Lubricate all cable assemblies before 10. Place retract cables overtop of retract sheaves. Install reinstalling them in the boom. keeper capscrew above sheave to hold retract cables in place. Inspect all sheave pins for nicks, gouges or pitting due to rust in the bearing surface area.

  • Page 159: Three Section Top/Bottom Pad Replacement

    800D REPAIR 21. As the telescope cylinder keeper plate nears the 2nd extension should be adequate for proper boom section, adjust the height of the cylinder to allow the operation. cylinder to access the cylinder keeper cutouts in the 34. Visually check each end of boom for proper extend, doubler plates on the sides of the 2nd section.
  • Page 160 REPAIR 800D Front Bottom Pad Replacement Retract cable adjustment ends may have to be loosened during this step. Note all pad locations and tag Extend boom approximately 4 feet (120 cm) out. accordingly. Using an appropriate lifting device, sling around the 3rd Replace all wear pads, wear pad plate and retorque section boom and lift it up until weight is removed from retract cables if disassembly of cables was required.

  • Page 161: Four Section Cable Tensioning

    800D REPAIR and the extend cable sheave attached to the bottom of the Torque large extend cables to 20 lb-ft (27 Nm). Cable adjustment point is located at the rear of the boom on top plate of the second section at the sheave case end of the the cable anchor located in the rear of the 2nd section boom, are accomplished as follows: Torque 3-2-1 retract cables to 14 lb-ft (19 Nm) Cable...
  • Page 162 REPAIR 800D conventional manner. Alternative #2 removes the telescope section. Keep tension on retract cables as the assembly is pulled out of the 1st to minimize the chance of retract cylinder from the rear of the boom, after removal of the hoist. cable damage.

  • Page 163: Four Section Boom Assembly

    800D REPAIR 20. Loosen and remove six capscrews attaching the bottom When initially assembling threaded ends of cables, thread pad plate to the second section. Slightly lift third section, the first on past the flat in the cables so adjustment can be and remove pad plate.
  • Page 164 REPAIR 800D 12. Reeve cables over retract sheave and install keeper/ 23. Assemble retract sheaves, retract sheave pins and wear pad to bottom rear of 3rd section. This pad acts as cable keeper plates in rear of 2nd section. Coat surfaces a side pad, bottom pad, and a cable retainer.

  • Page 165: Four Section Top/Bottom Pad Replacement

    800D REPAIR 35. Install large extend cable anchor into anchor cutouts in 46. Slightly tighten all cables. Cycle boom slowly to assure the doubler plates in the rear of the 2nd by routing the 3/ proper operation before torquing cables. Refer to the 4 in (19.0 mm) extend cables through the anchor and the “Four Section Cable Tensioning”...

  • Page 166: Front Bottom Pad Replacement

    REPAIR 800D Front Bottom Pad Replacement A dual stage cylinder will control second extendable section. Timing sequence of cables will depend on number of Extend boom approximately 4 ft (120 cm) out. sections and the extend cylinder construction. Remove cable guides and upper spacer bars from front Design intent of the cable tensioning is to balance the of boom sections preload of extend and retract cables for each extendable...

  • Page 167: Cable Tensioning

    800D REPAIR 8860-5 8860-6 FIGURE 6-1 Cable Tension Sequence 234 extend cables 432 retract cables. Five section boom with two stage cylinder. Four section boom with one stage cylinder. Cable tensioning (See Figure 6-2) to be in the following order: Cable tensioning to be in the following order: 321 retract cables 123 extend cables.

  • Page 168: 4- Section Boom W/ 2 Stage Cylinder Cable Positioning

    REPAIR 800D 4- Section Boom w/ 2 Stage Cylinder Cable Positioning 1/2/3 EXTEND 2/3/4 EXTEND 1ST STAGE BASE 2ND STAGE 3RD STAGE 4th STAGE 8860-2 4/3/2 RETRACT 3/2/1 RETRACT FIGURE 6-2 Cable Tightening Sequence 4 Section Boom Retraction with Two Stage Extend Cylinder Measure the retraction gaps between the first and second section and the second and third section.

  • Page 169: 4- Section Boom W/ 1 Stage Cylinder Cable Positioning

    800D REPAIR The fourth section should have moved out. Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap Tightening until the extension gap between the third and measurements. fourth section is equal to the extension gap between the Extend and retract the boom a few times and then second and third section.

  • Page 170: 3- Section Boom W/ 1 Stage Cylinder Cable Positioning

    REPAIR 800D At this time the second and first extendable sections should Retraction extend and retract equally and bottom out against the stops Measure the retraction gaps between the second and simultaneously. third section and the third and fourth section. 234 and 432 cable balancing If the retraction gap is greater between the third and fourth section than the retraction gap between the second and third...

  • Page 171: Cable Retention

    800D REPAIR Extend and retract the boom a few times and then Tighten the 321 retract cable located at the front bottom repeat measuring the extension gaps. of the base section the difference in the retraction gap measurements. The third section should have moved out. Extend and retract the boom a few times and then Tightening until the extension gap between the first and repeat measuring the retraction gaps.
  • Page 172 REPAIR 800D Third (positive lock) nut installation is to be placed on each of Metric Series with Coarse Threads the extend cables. The retract cables do not require the third (positive lock) nut. Minimum Cable end TORQUE The third nut should be hand tightened until the tapped hole Nut Type Thread Size Property...
  • Page 173 800D SIDE SHIMMING OF BOOM SECTIONS SECTION 7 SIDE SHIMMING OF BOOM SECTIONS SECTION CONTENTS Top/rear Side Pad Adjustment ....7-2 Adjustment Procedure ..... 7-10 Servicing The Control Valves.

  • Page 174: Top/Rear Side Pad Adjustment

    SIDE SHIMMING OF BOOM SECTIONS 800D TOP/REAR SIDE PAD ADJUSTMENT 0.03 in (0.8 mm) off center in the wear pad. Various combinations of rotation of these parts allow the With the inner boom section fully retracted, center the inner adjustment. boom in the outer boom by prying the inner boom section Once the boom is located, the wear pad and plate from side to side.

  • Page 175: Inner Boom Pad Lubrication

    800D SIDE SHIMMING OF BOOM SECTIONS INNER BOOM PAD LUBRICATION Using a 1/4 in diameter nozzle grease gun adapter, fill pad retention pockets with grease. With the boom fully retracted, fill upper rear pad Retract boom. This should apply grease to the pad retention pockets (pad retainers) with grease.

  • Page 176: Jib Installation And Adjustment

    SIDE SHIMMING OF BOOM SECTIONS 800D JIB INSTALLATION AND ADJUSTMENT Using an overhead hoist, lift the jib assembly and align and pin the jib to the boom sheave head. Loosely bolt the two ear assemblies with shims and bars 2 PLCS as shown to the side of the first boom section.

  • Page 177: Jib Jack Service & Maintenance

    800D SIDE SHIMMING OF BOOM SECTIONS holes in the stow ear. Move the ears in or out to achieve When the boom is fully retracted, the jib stow pins must proper alignment. Position the top ear so it holds the top be bottomed out securely in the ear assemblies.

  • Page 178: Adding Oil

    SIDE SHIMMING OF BOOM SECTIONS 800D Adding Oil Be careful to prevent dirt or foreign matter from entering the system. With saddle fully lowered and piston depressed, set jack Replace with proper oil as described above. in its upright level position and remove oil filler plug. Fill until oil is level with filler plug hole.
  • Page 179 800D SIDE SHIMMING OF BOOM SECTIONS Rotation Gearbox and Brake 9414 FIGURE 7-1 National Crane Published 5-27-2018 Control # 039-06...
  • Page 180 SIDE SHIMMING OF BOOM SECTIONS 800D SWING DRIVE SERVICE Remove stator plates (19) and friction discs (20) from the brake housing (15). Inspect stator plates for Lubrication and Maintenance excessive grooving or burn spots. Also, inspect friction discs for wear. Replace as required. (Ref. Figure 7-2). Manufacturer recommends changing oil after first 50 hours of operation.
  • Page 181 800D SIDE SHIMMING OF BOOM SECTIONS 10. Remove race (12) from input planet set (13). 20 lb-ft. If the locknut is between tabs on the lockwasher always tighten until tabs align with slots in locknut. 11. Remove input planet set (13) from gear housing (7) by Secure locknut by bending tabs on lockwasher so that it pulling straight up and out of the housing.

  • Page 182: Adjustment Procedure

    SIDE SHIMMING OF BOOM SECTIONS 800D ROTATION STOP-MECHANICAL If it is not centered, loosen the two nuts, one on either side of the spacer. Turn the nuts in the same direction The rotation stop system is designed to stop crane rotation until the spacer is centered.

  • Page 183: Servicing The Control Valves

    800D SIDE SHIMMING OF BOOM SECTIONS SERVICING THE CONTROL VALVES Replacing Spool Seals Valve sections and covers are identified by numbers cast into Disassembly and Reassembly of Control the body. Valves to Replace Seals Remove bonnet assembly parts from back of valves and NOTE: For clarification, we shall call the inlet cover keep in order of disassembly.

  • Page 184: Unloader Valve Service

    SIDE SHIMMING OF BOOM SECTIONS 800D CRANE VALVE SPOOL ACTION BONNETS OUTLETCOVER WORKPORTS INLETCOVER OUTLET INLET TURN RELIEF LOOSEN NUT TO LINKAGE END ADJUST RELIEF OF SPOOL DUAL PRESSURE MAIN RELIEF 9420 UNLOADER VALVE SERVICE following procedure twice, follow the troubleshooting steps outlined for checking and inspecting the solenoid valve and Refer to ATB System Diagnosis if an electrical problem has unloaders in this hydraulic circuit outlined below.

  • Page 185: Control Valve Relief Adjustment

    800D SIDE SHIMMING OF BOOM SECTIONS Disconnect Drain Line from Outlet End of Unloader Valve Install Cap Fitting to Plug Outlet End of Unloader Valve Operate Function Function Operates Correctly The Poppet in the Unloader is Not Oil is Passing Through the Seated Correctly.

  • Page 186: Unloader Dump Valve - Air Purging

    SIDE SHIMMING OF BOOM SECTIONS 800D Disconnect the hose from one of the outrigger sections and plug the port. This function can be used to test the system pressure without the hoses or cylinder seeing the higher pressure. .31 in (7.9 mm) Remove the fitting from the relief valve at C.

  • Page 187: Optional Hydraulic Capacity Alert System

    National Crane boom length and radius is reached. The intermediate distributor or Manitowoc Crane Care. boom length is determined by a line and corresponding dimension decal on the side of the second section The crane hydraulic system includes a Rated Capacity boom.

  • Page 188: Troubleshooting

    SIDE SHIMMING OF BOOM SECTIONS 800D before the chosen radius is reached or allows extension be deactivated and the indicator light should come on. beyond the chosen radius, adjustment is required. If the Readjust switch head if trip pressure is not correct. system is activated before trip pressure is reached, Once proper adjustment is verified, return the boom to a lower the load, remove acorn nut and loosen the locking...
  • Page 189 800D SIDE SHIMMING OF BOOM SECTIONS Overload Trips and will not Reset Has Overload Condition been Eliminated Loadline Downhaul Weight Eliminate Overload Lifting Anti-Two-Block Weight Lower Loadline Weight Do Crane Functions Boom Down, Telescope Out, Hoist up work Boom Lift Cylinder Problem Solved Fully Extended Actuate Momentary Key Switch...

  • Page 190: Maintenance & Repair

    SIDE SHIMMING OF BOOM SECTIONS 800D MAINTENANCE & REPAIR Refer to Hydraulic Schematic and System Description to gain a thorough understanding of the capacity alert system before proceeding with any maintenance. System adjustment must be checked every three months for accuracy. Refer to the preceding section on System Adjustment.
  • Page 191 800D SPECIFICATIONS 93.30 [2370 mm] 43.12 [1095 mm] 72.02 [1829 mm] 66.85 [1698 mm] 84.68 [2151 mm] 91.55 [2325 mm] 119.42 [3033 mm] 9425 National Crane Published 5-27-2018 Control # 039-06...
  • Page 192 SPECIFICATIONS 800D SPECIFICATIONS Hydraulic Pump Pump Speed ........2500 RPM Displacements Section Pl .
  • Page 193 800D SPECIFICATIONS Crane Operating speeds Rotation, 375°.........45 sec., ± 7 sec. Lift Up, (-10°...
  • Page 194 SPECIFICATIONS 800D THIS PAGE BLANK Published 5-27-2018 Control # 039-06...
  • Page 195 800D INSTALLATION SECTION 9 INSTALLATION SECTION CONTENTS Typical Locations / Serial Number Auger System ......9-7 Identification .
  • Page 196 INSTALLATION 800D TYPICAL LOCATIONS / SERIAL NUMBER IDENTIFICATION 1ST SECTION BOOM CYLINDER MID SECTIONS BOOM TURRET SHEAVE SECTION BOOM FRAME STABILIZER 9426 Published 5-27-2018 Control # 039-06...

  • Page 197: Minimum Truck Requirements

    800D INSTALLATION MINIMUM TRUCK REQUIREMENTS Many factors must be considered in the selection of a proper have the necessary after frame (AF) section modulus truck for a 800D series crane. Items which must be (S.M.) and resistance to bending moment (RBM) so that considered are: reinforcing is not required.

  • Page 198: Mounting Configurations

    INSTALLATION 800D MOUNTING CONFIGURATIONS The Series 800D is a versatile machine and its versatility can be enhanced by the manner in which it is mounted. Following is a brief description of the mounting configurations and the advantages of each. The minimum weights listed below the front and rear axles for each configuration are estimated minimum front and rear axle weights for an 85% stability factor before the crane, stabilizers and subbase, if required,...

  • Page 199: Configuration 3 - 800D

    800D INSTALLATION 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.

  • Page 200: Configuration 4 - 800D

    INSTALLATION 800D Configuration 4 — 800D (all booms other *Actual axle scale weights prior to installation of crane, torsion box and stabilizers. than 8100D) Configuration 5 — Rear Mount This mount requires front stabilizer for full capacity 360° around the truck. Front stabilizer gives the machine a solid This configuration allows the rear mount installation of base helping the operator control loads.

  • Page 201: Pto Horsepower Requirements

    800D INSTALLATION PTO HORSEPOWER REQUIREMENTS A three pump hydraulic system is furnished with this crane. output shaft rotates before selecting a clockwise (cw) or The unit is equipped with a three section pump that will counter-clockwise (ccw) rotation hydraulic pump. Either cw supply 34 gpm (128 l/min) to the hoist, 18 gpm (68 l/min) to or ccw rotation pumps are available, and are marked clearly the boom and outriggers and 10 gpm (37 l/min) to the swing...

  • Page 202: Pto Selection

    INSTALLATION 800D PTO SELECTION Operating speeds and performance of the crane are based on proper pump outputs to the hoist, lift, telescope and swing circuits. A triple pump system is standard equipment on the ENGINE SPEED (RPM) 800D. This pump supplies 34 (128), 18 (68) and 10 (37) gpm FOR 2500 RPM PUMP (l/min) to the appropriate crane circuits when operating at SHAFT SPEED...

  • Page 203: Section Modulus Tables

    800D INSTALLATION SECTION MODULUS TABLES The following tables will determine the section modulus of Fish Plate Reinforcement (Table C). The frame can be the truck frame. Always measure the truck frame and check strengthened by adding a fish plate of suitable thickness the tables to be sure that any truck factory listed section and depth equal to the frame.
  • Page 204 INSTALLATION 800D W in (mm) W in (mm) 2½ (64) 3 (76) 3½ (89) 4 (102) 2½ (64) 3 (76) 3½ (89) 4 (102) D in (mm) D in (mm) 8 (203) 8.4 (138) 9.5 (156) 10.7 (175) 11.9 (195) 8 (203) 9.8 (161) 11.2 (184)
  • Page 205 800D INSTALLATION 9437 TABLE D Section Modulus in THICKNESS 3/16 in (4.76 mm) THICKNESS 1/4 in (6.35 mm) W in (mm) W in (mm) 3 (76) 3½ (89) 4 (102) 4½ (114) 3 (76) 3½ (89) 4 (102) 4½ (114) D in (mm) D in (mm) 8½...

  • Page 206: Truck Frame Requirements For Optional Front Stabilizer

    INSTALLATION 800D Truck Frame Requirements For Optional Front required. The bracket must be capable of supporting 0.50 in (12.7 mm) DIA. Grade 8 bolts to their nominal breaking Stabilizer strength. Torque the mounting bolts supplied with the front The truck frame must have adequate strength from under the stabilizer to 110 lb-ft (149 Nm).
  • Page 207 800D INSTALLATION Section Modulus Tables Angle (Table F). Use Table F for an angle section such as when a flange and part of the web of a truck frame Use Table E and Table F below along with Tables A through channel is removed.
  • Page 208 INSTALLATION 800D 3½ (89) 0.6 (10) 0.6 (10) 0.6 (10) 0.6 (10) 3½ (89) 0.8 (13) 0.8 (13) 0.8 (13) 0.8 (13) 4½ (114) 0.9 (15) 1.0 (16) 1.0 (16) 1.0 (16) 4½ (114) 1.2 (20) 1.3 (21) 1.3 (21) 1.3 (21) 5½...
  • Page 209 800D INSTALLATION EXAMPLE: Now interpolate between a 10.0 in (254 mm) deep channel and a 10.5 in (267 mm) deep channel to get the Refer to the sample truck frame cross sections in Table E. section modulus of a 10.25 in (260 mm) deep channel Truck frame yield strength is 110,000 psi (758 MPa) with the following dimensions at the front axle location: 3/8 in (9.65 10.0 in (254 mm) deep channel...

  • Page 210: Truck Preparation

    INSTALLATION 800D TRUCK PREPARATION Plan installation completely before any work is done. Plan If PTO integral mount flanges are to be used, the pump the location of the crane for the final front and rear axle can be mounted directly to the PTO. Direct mount weights and boom overhang.

  • Page 211: Reinforcing/After Frame Extension

    800D INSTALLATION bracket so suction side is toward the reservoir suction steel to minimize the amount of reinforcing required. Use port. An arrow is cast into the rear pump housing to Grade 90 weld material for any welding to be done. identify rotation.
  • Page 212 INSTALLATION 800D If reinforcing is to be welded on, torch cut hole pattern in previously removed, then drill through reinforcing and reinforcing being careful to clear crane mounting truck frame being careful to clear crane mounting anchors. Install reinforcing, clamp in place, install any anchors and bolt reinforcing in place.
  • Page 213 800D INSTALLATION 51 mm 2 in 5 in 1 in (25 mm) DIAMETER HOLES FOR PLUG WELDS (127 mm) 2 in PLANNED LOCATION OF MOUNTING (51 mm) PLATE. PLUG WELD LOCATIONS CAN 4 in BE SHIFTED TO CLEAR PLATE (102 mm) 4 in (102 mm) 8 in...
  • Page 214 INSTALLATION 800D If the frame through the rear suspension doesn’t meet bottom, butt it to existing forward reinforcing and weld minimum specifications for RBM and section modulus rear suspension reinforcing to forward reinforcing. as shown on “Truck Frame Strength” table, it can be Replace as much of the spring hanger cut out areas as reinforced by adding an angle type of reinforcing as in possible and butt weld these pieces in.

  • Page 215: After Frame Modification

    800D INSTALLATION AFTER FRAME MODIFICATION If additional suspension reinforcing is required, as may remove any cross members from back of truck frame. If AF is be the case with a truck frame that tapers down to too short, the frame will have to be lengthened. Use approximately 6 in (15.24 cm) deep through the suspension, channels fabricated from 100,000 psi (758 MPa) yield a channel may be fabricated through the suspension for...
  • Page 216 INSTALLATION 800D THIS PAGE BLANK 9-22 Published 5-27-2018 Control # 039-06...
  • Page 217 800D CRANE INSTALLATION SECTION 10 CRANE INSTALLATION SECTION CONTENTS Pin Bearing Inspection And Installation Counterweighting Methods For Stability Procedure ....... 10-5 Around The Rear 180°...
  • Page 218 CRANE INSTALLATION 800D MOUNT ANCHOR ASSEMBLY RSOD MOUNTING SUB-ASSEMBLY FOR 9446 RSOD STABILIZER Loosely assemble flex plate and two anchor ears as Raise and locate the RSOD frame to the RSOD shown. Locate flex plate anchor ears to torsion box and mounting subassembly and weld (E70).
  • Page 219 800D CRANE INSTALLATION Find a location for and install hydraulic oil reservoir. 12. Route the 1/2 inch R12 telescope hoses over the turret Mounting brackets may be bolted to the truck frame. back plate and to the back side of the boom. Connect Before placing reservoir in service, remove cleanout the telescope cylinder connections at the back of the cover and inspect to ensure proper installation of...
  • Page 220 CRANE INSTALLATION 800D Terminator Type Wedge Installation 20 × Rope Diameter 11.25 In (292 mm) Minimum “No-Go” WRONG WRONG WRONG “Go” RIGHT Rope Wedge Tail Clipped 9448 Backward Backward to live Line Rope size 7/16 9/16 1-1/8 1-1/4 *Torque lb-ft (Nm) 45 (61) 65 (88) 65 (88)
  • Page 221 800D CRANE INSTALLATION PIN BEARING INSPECTION AND INSTALLATION PROCEDURE Pin Inspection remaining four bearings are to be installed in the lift cylinder, two at each side of the rod end of the cylinder Remove the protective covering from pins and inspect and two at each side of the butt end of the cylinder.
  • Page 222 CRANE INSTALLATION 800D COUNTERWEIGHTING Refer to “Mounting Configuration” pages in this section. loads most likely to cause the truck (with outriggers and The amount of counterweight and its location is stabilizer set) to overturn, the unit is at 85% of tipping dependent upon the stability working area (180°...
  • Page 223 800D CRANE INSTALLATION REAR Front (Weight) × (Distance From Front Axle) Rear Axle Front Axle Rear Axle ----------------------------------------------------------------------------------------------------- - Weight – Weight Weight Weight Wheel Base Rear Axle Weight Front Axle Weight (8000) × 0 (3628) × 0 --------------------------- - --------------------------- - 1.
  • Page 224 CRANE INSTALLATION 800D Rear Axle Weight Front Axle Weight 79 in 19.5 in (495 mm) (2010 mm) 8534 lb 8072 lb Base Unit 3870 kg 3661 kg Subbase 22 ft 3445 lb (1563 kg) 245.25 in Counterweight 696 lb 454 lb (6229 mm) 315 kg 205 kg...
  • Page 225 800D CRANE INSTALLATION COUNTERWEIGHTING METHODS FOR STABILITY AROUND THE REAR 180° CENTER OF BED CWT HEAVY BUMPER HEAVY BUMPER 1100 LB (498 kg) 800 LB (362 kg) 500 LB (227 kg) WEIGHTED AREA TRUCK BED BOTTOM VIEW BED COUNTERWEIGHTING BED COUNTERWEIGHTING BED COUNTERWEIGHTING FOR 1150 LB (520 kg) FOR 2000 LB (910 kg)
  • Page 226 CRANE INSTALLATION 800D 8 in (203) 44 in (1118 mm) 9453 The method shown above can be use do shift more weight to Example the front of the crane than the previous methods will. When Concrete poured in the bed measures 4 in (10.16 cm) deep using this method check for interference with hydraulic by 86 in (218.44 cm) wide by 70 in (177.80 cm) long.
  • Page 227 800D CRANE INSTALLATION ANTI-TWO-BLOCK RATED CAPACITY LIMITER INSTALLATION AND FUNCTION VERIFICATION 800D model cranes equipped with DS160 RCL systems Route the two conductor cord to a convenient location in have the RCL reel length cable routed inside the boom. the truck cab. Install the RCL power switch and indicator The cable has been installed and pretensioned at the light.
  • Page 228 CRANE INSTALLATION 800D inclinometer (measures to within 0.1°, Example: varies slightly from length indicated on Load Chart (see SMARTTOOL DIGITAL LEVEL) adjust boom angle to 0° table below). (range -0.5° - +0.5°) and mechanically adjust the angle After pressing “OK”, the system will request the length sensor so that the system reads the angle to ±0.0 deg.
  • Page 229 800D CRANE INSTALLATION INITIAL CRANE RUN IN PROCEDURE With the unit in an open area for testing that will permit Set throttle according to engine RPM and PTO ratio to full operation of all its functions, engage the PTO and run get 2500 RPM pump shaft speed.
  • Page 230 CRANE INSTALLATION 800D BOOM RESTS Before the mounting of a crane is complete, a boom rest The boom rest should be positioned to support the 1st must be installed. A rest must be supplied for transport to section boom. Be careful to avoid contacting the boom at or reduce vibratory stress on the crane and truck and protect near the end where the retract cables are located.
  • Page 231 800D CRANE INSTALLATION STABILITY CHECK The chassis weight, before the crane is mounted, is intended Be sure the stability test weight is accurate. A 1% increase in for use only as a guideline in determining the total weight stability test weight will mean up to a 10% increase in required for the unit to be stable with an 85% tipping factor counterweight.
  • Page 232 CRANE INSTALLATION 800D THIS PAGE BLANK 10-16 Published 5-27-2018 Control # 039-06...
  • Page 233 800D HOIST SECTION 11 HOIST SECTION CONTENTS Introduction and Theory of Operation ..11-3 Dead-end Rigging ......11-9 Servicing the Motor .
  • Page 234 HOIST 800D • Cable 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 WARNING doesn't come loose. Failure to heed the following warnings may result in serious •...

  • Page 235: Introduction And Theory Of Operation

    800D HOIST INTRODUCTION AND THEORY OF OPERATION 9459 The planetary hoist is designed to utilize a geroler, gear, or During payout, a brake valve is used to prevent the load from piston motor, driving through a multiple-disc oil brake, moving faster than desired. This brake valve partially blocks through a pair of planetary gearsets to the cable drum.

  • Page 236: Hydraulic Schematic

    HOIST 800D HYDRAULIC SCHEMATIC HYDRAULIC FLUID FROM CONTROL VALVE CB VALVE HYDRAULIC FLUID TO CONTROL VALVE HYDRAULIC MOTOR RAISE HIGH PRESSURE HYDRAULIC FLUID TO LOW PRESSURE CONTROL VALVE CB VALVE HYDRAULIC FLUID FROM CONTROL VALVE HYDRAULIC MOTOR LOWER 9460 11-4 Published 5-27-2018 Control # 039-06...

  • Page 237: Maintenance And Service

    800D HOIST MAINTENANCE AND SERVICE Check Hoist Brake Oil For safe and consistent operation of this hoist a regular CAUTION program of preventive maintenance is strongly The maximum fill capacity for the hoist brake is 0.23 liter recommended. Regular oil changes with the correct oil for (0.25 quart).

  • Page 238: Hoist Gearbox Oil

    HOIST 800D Hoist Gearbox Oil Rotate the drum so that the port is visible through the upper hole 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 Hoist Gearbox Oil Change with 1.42 liters (1.50 quarts) of EP-90 oil.

  • Page 239: Disassembly

    800D HOIST Remove the input planet gearset (36) from the drum. Inspect the gearset for wear and repair as needed. See OIL CAPACITY Servicing the Planetary Sets, page 11-12 for disassembly and repair. GEARBOX 1.42 liter (1.50 qt) Remove the thrust washer (6) and output sun gear (16). BRAKE 0.23liter (0.25 qt) Inspect for damage and replace if needed.

  • Page 240: Installing Cable On The Hoist

    HOIST 800D 10. Install the input planet gearset (36) into the drum (5), making sure it's installed correctly onto the output sun gear (16). 11. Put a light coating of grease on the thrust washer (6) to keep it in place. Install the thrust washer into the input gearset (36), and then insert the input sun gear (8).

  • Page 241: Dead-End Rigging

    800D HOIST the rope will bend as it leaves the socket, and the edge Of the methods shown below, National Crane prefers that of the socket will wear into the rope causing damage to method A or F be used, i.e., clipping a short piece of wire the rope and eventual failure.

  • Page 242: Servicing The Motor

    HOIST 800D Specialty Clip Specialty Wedge Wedge Socket FIGURE 11-6 side of the valve to make sure it is not obstructed. Also, inspect the o-rings for damage and replace if necessary. SERVICING THE MOTOR Motors and counterbalance valves are not serviceable in the field.

  • Page 243: Servicing The Brake

    800D HOIST SERVICING THE BRAKE the markings facing the proper direction in order for the hoist to function properly. Inspect the surface on the Evenly remove the four capscrews (11, Figure 11-8) input and brake drivers (13 & 38) where the clutch (34) holding the brake cover (20) in place.

  • Page 244: Servicing The Planetary Sets

    HOIST 800D 9465 FIGURE 11-8 SERVICING THE PLANETARY SETS Before reassembly, be sure to insert the thrust plate into the carrier. Remove the retaining rings from the planet pins. To reassemble, be careful to line up the planet pins with Remove the pins from the carrier by carefully tapping the washers and bearings then press the knurled part of them out.
  • Page 245 800D HOIST INPUT GEARSET (36) OUTPUT GEARSET 9466 FIGURE 11-9 National Crane Published 5-27-2018 Control # 039-06 11-13...

  • Page 246: Troubleshooting

    HOIST 800D TROUBLESHOOTING Hoist won't hold load Possible Solutions: There is excessive back pressure in the hydraulic system. Check the system for line restrictions and reduce the back pressure. The brake discs are worn. Replace the brake discs. Friction discs should measure no less than 0.055 in thick and the stator plates should measure at least 0.068 in thick.

  • Page 247: Hoist Torque Specifications Chart

    800D HOIST HOIST TORQUE SPECIFICATIONS CHART Plated Lubricated Plated Lubricated SAE Grade 5 SAE Grade 5 SAE Grade 5 SAE Grade 8 SAE Grade 8 SAE Grade 8 Torque Torque Torque Torque Torque Torque Nominal Size *(lb-ft) *(lb-ft) *(lb-ft) *(lb-ft) *(lb-ft) *(lb-ft) 5/16...

  • Page 248: Bill Of Material

    HOIST 800D BILL OF MATERIAL DESCRIPTION SIDE PLATE CAPSCREW RETAINING RING OUTPUT GEARSET CARRIER OUTPUT PLANET GEAR PLANET PIN RETAINING RING THRUST PLATE BEARING SPACER WASHER DRUM RACE SEAL KIT O-RING O-RING O-RING OIL SEAL OIL SEAL O-RING BACKUP RING BACKUP RING O-RING 7-10...
  • Page 249 800D HOIST DESCRIPTION BREATHER O-RING PLUG SHAFT O-RING PLUG CAM CLUTCH INPUT GEARSET 36-1 CARRIER 36-2 PLANET GEAR 36-3 PLANET PIN 36-4 RETAINING RING 36-5 THRUST PLATE 36-6 BEARING 36-7 WASHER INPUT DRIVER BUSHING O-RING PLUG COUNTERBALANCE BLOCK SUPPORT ROD HYDRAULIC MOTOR STRAIGHT ADAPTER HOSE ASSEMBLY...

  • Page 250: Exploded Isometric Assembly Drawing

    HOIST 800D EXPLODED ISOMETRIC ASSEMBLY DRAWING 9467 11-18 Published 5-27-2018 Control # 039-06...
  • Page 251 800D SCHEMATICS SECTION 12 SCHEMATICS For your convenience, the latest version of schematics available at the time of printing are placed in this section. National Crane Published 5-27-2018 Control # 039-06...
  • Page 252 SCHEMATICS 800D Published 5-27-2018 Control # 039-06...
  • Page 253 800D ALPHABETICAL INDEX Alphabetical Index (Optional) Oil Cooler Service & Maintenance ....... . . 7-6 1/2 Stage Anti-two Block Wire Replacement .
  • Page 254 ALPHABETICAL INDEX 800D Maintenance ............3-1 Operation .

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