Manitowoc Grove National Crane 800D OPERATOR AND SERVICE MANUAL 039-05

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Manitowoc Grove National Crane 800D OPERATOR AND SERVICE MANUAL 039-05 – PDF DOWNLOAD

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The Manitowoc Grove National Crane 800D Operator and Service Manual (039-05) is an essential PDF guide. Download for detailed insights into 800D operation and service, ensuring safe and efficient crane use with comprehensive instructions.

Manitowoc Grove National Crane 800D OPERATOR AND SERVICE MANUAL 039-05 – PDF DOWNLOAD

Language : English
Pages :232
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove National Crane 800D OPERATOR AND SERVICE MANUAL 039-05 – PDF DOWNLOAD

Supplement a
Outrigger Monitoring System (OMS) (Optional—Standard in North America c
Operation c
Maintenance d
Side Folding Swing-Around Jib Operation e
Safety Information
Safety Messages 1-1
General 1-1
Safety Alert Symbol 1-1
Signal Words 1-1
General 1-1
Accidents 1-1
Operator’s Information 1-2
Operator’s Qualifications 1-2
Operational Aids 1-3
Load Moment Indication (LMI) Systems (If Equipped) 1-3
Anti-Two-Block Device 1-3
Work Area Definition System (WADS) (If Equipped) 1-4
Crane Stability/Structural Strength 1-4
Load Charts 1-5
Work Site 1-5
Wind Forces 1-5
Lifting Operation 1-6
Counterweight 1-7
Outrigger Lift Off 1-7
Multiple Crane Lifts 1-7
Electrocution Hazard 1-8
Set-Up and Operation 1-9
Electrocution Hazard Devices 1-9
Electrical Contact 1-10
Special Operating Conditions and Equipment 1-10
Personnel Handling 1-10
Environmental Protection 1-11
Maintenance 1-11
Service and Repairs 1-12
Lubrication 1-12
Tires 1-13
Wire Rope 1-13
Sheaves 1-14
Batteries 1-15
Engine 1-15
Transporting the Crane 1-15
Travel Operation 1-15
Work Practices 1-17
Personal Considerations 1-17
Crane Access 1-17
Job Preparation 1-17
Working 1-17
Lifting 1-18
Hand Signals 1-19
Boom Extension 1-21
Parking and Securing 1-21
Shut-Down 1-21
Cold Weather Operation 1-21
Temperature Effects on Hydraulic Cylinders 1-22
Overload Inspection 1-23
Boom Inspection 1-24
Superstructure Inspection 1-26
Carrier Inspection 1-28
Operation
Controls 2-1
Truck Cab Controls 2-1
Crane Controls 2-1
Optional Hydraulic Capacity Alert System 2-2
Crane Nomenclature 2-3
Operating Procedures 2-4
Equipment Familiarization 2-4
Equipment Checks 2-4
Work Site Position 2-5
Before Leaving the Cab 2-5
Crane Set Up 2-5
Before Making the Lift 2-6
Reading and Understanding the Capacity Chart 2-7
Winch System Operation 2-12
Using Multiple Part Lines 2-12
General Rules when Operating the Winch 2-12
Lifting the Load 2-12
Shutting Down and Preparing for Road Travel 2-13
Optional Winch Burst of Speed Operation 2-13
Anti-Two-Block System 2-14
Description/Operation 2-14
ATB Weight Rigging 2-14
Optional Hydraulic Capacity Alert System 2-15
System Description 2-15
System Operation 2-15
Jib Safety and Operation 2-16
Safety Tips for Jib Operation 2-18
Side Folding Swing-Around Jib Operation 2-18
Jib Maintenance 2-19
Jib Jack 2-20
Operation 2-20
Adjustable Swing Speed Valve 2-21
Standard Hand Signals for Controlling Crane Operations 2-22
Optional Hydraulic Capacity Alert System 2-28
System Adjustment 2-28
Troubleshooting 2-29
Maintenance & Repair 2-30
Maintenance, Lubrication & Service
Maintenance
Inspection and Maintenance 3-1
Inspection 3-1
Daily Inspections 3-1
Weekly Inspections 3-1
Monthly Inspections 3-2
Periodic Inspections 3-2
Other 3-2
Wire Rope Inspection and Maintenance 3-3
Inspection 3-3
Rope Replacement 3-3
Care of the Wire Rope 3-4
Rope Construction 3-4
Adjustments and Repairs 3-4
Tire Load and Inflation Table 3-5
Lubrication
Lubrication Procedures and Charts 4-1
Lubricants 4-1
Hydraulic Oil 4-1
Lubrication Points 4-2
Wire Rope Lubrication 4-2
Lubrication Chart 4-3
Hydraulic Oil Reservoir Level 4-4
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 4-6
Service
Service and Repair 5-1
Cleanliness 5-1
Hydraulic Systems 5-1
Label Parts When Disassembling 5-2
Welding Precautions 5-2
National Crane Fitting O-Ring Part Numbers 5-2
Fatigue of Welded Structures 5-3
Loctite 5-3
Fasteners and Torque Values 5-3
Torque Wrenches 5-4
Torque Values 5-4
Weld Studs 5-7
Using Torque Wrench Extensions 5-8
Winch Oil Level 5-9
Brake Oil Level 5-9
Trouble Diagnosis 5-10
Anti-Two Block Trouble Diagnosis – Electrical 5-13
Anti-Two Block Trouble Diagnosis – Hydraulic 5-15
Cylinder Disassembly and Repair 6-1
Single-Stage Extend Cylinder Disassembly and Repair 6-2
Cylinder Disassembly 6-2
Cylinder Reassembly 6-2
Four Section Boom Operation 6-12
Four Section Boom Maintenance 6-13
Internal Cable Sheave Lubrication 6-13
Four Section Cable Tensioning 6-13
Four Section Boom Service 6-14
Boom Removal 6-14
Boom Disassembly 6-14
Additional Maintenance/Disassembled Boom 6-14
Four Section Boom Assembly 6-16
Four Section Top/Bottom Pad Replacement, Assembled Boom 6-19
Top Rear Pad Replacement 6-19
Front Bottom Pad Replacement 6-19
Three Section Boom Operation 6-3
Boom Illustrations 6-4
Three Section Boom Maintenance 6-5
Internal Cable Sheave Lubrication 6-5
Three Section Cable Tensioning 6-5
Three Section Boom Service 6-6
Boom Removal 6-6
Boom Disassembly 6-6
Additional Maintenance/Disassembled Boom 6-8
Three Section Boom Assembly 6-9
Three Section Top/Bottom Pad Replacement, Assembled Boom 6-11
Top Rear Pad Replacement 6-11
Front Bottom Pad Replacement 6-11
Inner Wear Pad Calibration 7-1
Inner side Pads 7-1
Inner Boom Pad Lubrication 7-3
Jib Installation and Adjustment 7-4
Jib Jack Service and Maintenance 7-7
Adding Oil 7-7
Changing Oil 7-7
Lubrication 7-7
Rust Prevention 7-7
Trouble Shooting 7-7
(Optional) Oil Cooler Service and Maintenance 7-8
Rotation Gearbox and Brake Illustration 7-9
Swing Drive Service 7-10
Lubrication and Maintenance 7-10
Oil Capacities 7-10
Disassembly Procedure 7-10
Assembly Procedure 7-11
Servicing the Control Valves 7-13
Disassembly and Reassembly of Control Valves to Replace Seals 7-13
Replacing Spool Seals 7-13
Control Valve Relief Adjustment 7-15
Unloader Dump Valve – Air Purging Instructions 7-16
Hydraulic System Description 7-17
Service Manual for Pump
Service Manual for Load Moment Indicator
Specifications
Dimensional Specification 8-1
Dimensional Specification Tractor Mount 8-2
Specifications 8-3
Installation
Installation 9-1
Typical Locations/Serial Number Identification 9-2
Minimum Truck Requirements 9-3
Mounting Configurations 9-4
Configuration 1 – 8100D 9-5
Configuration 2 – 8100D 9-5
Configuration 3 – 8100D 9-6
Configuration 4 – 800D 9-6
PTO Horsepower Requirements 9-8
Direct Mount Pump to PTO 9-8
Pump Rotation 9-8
Auger System 9-8
PTO Selection 9-9
Truck Frame Strength 9-10
Section Modulus Tables 9-11
Truck Frame and Mounting Bolt Requirements for Front Stabilizer 9-14
Section Modulus Tables 9-15
Truck Preparation 9-19
Welding Precautions 9-19
Positioning Crane on Truck 9-19
PTO, Pump, Reservoir 9-19
Reinforcing/After Frame Extension 9-20
After Frame Modification 9-23
Crane Installation 10-1
Pin Bearing Inspection and Installation Procedure 10-5
Pin Inspection 10-5
Bearing Inspection 10-5
Trunnion Inspection 10-5
Installation 10-5
Counterweighting 10-6
Counterweighting Methods for Stability Around the Rear 180° 10-9
Anti-Two-Block Load Moment Indicator Installation and Function Verification 10-11
Initial Crane Run-In Procedure 10-13
Boom Rests 10-14
Stability Check 10-15

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