Manitowoc Grove National Crane 800DU Operator & Service Manual

Description

Manitowoc Grove National Crane 800DU Operator & Service Manual  – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove National Crane 800DU Operator & Service Manual  – PDF DOWNLOAD

Language : English
Pages : 238
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc Grove National Crane 800DU Operator & Service Manual  – 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
Proper Leveling of the Crane 2-22
Installing Cable on the Hoist 2-22
Wedge Socket Installation 2-22
Unattended Crane 2-24
Maintenance, Lubrication & Service
Maintenance Checklist
Crane Inspection and Maintenance 3-1
Inspection 3-1
Daily Inspections 3-1
Weekly Inspections 3-2
Monthly Inspections 3-2
Periodic Inspections 3-2
Other 3-2
Stability 3-3
Wire Rope Inspection and Maintenance 3-3
Inspection 3-3
Rope Replacement 3-5
Care of the Wire Rope 3-5
Rope Construction 3-4
Crane Adjustments and Repairs 3-6
Tire Load and Inflation Table 3-10
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
Telescope Cylinder Disassembly 6-2
Telescope Cylinder Assembly 6-2
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
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
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
Rotational Stop-Mechanical 7-12
Servicing the Control Valves 7-13
Disassembly and Reassembly of Control Valves to Replace Seals 7-13
Replacing Spool Seals 7-13
Unloader Valve Service 7-14
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 Rear Mount 8-2
Specifications Turret Control 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
Configuration 5 -Rear Mount 9-7
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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