Manitowoc National Crane 800D Operator & Service Manual – PDF DOWNLOAD

Description

Manitowoc National Crane 800D Operator & Service Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc National Crane 800D Operator & Service Manual – PDF DOWNLOAD

Language : English
Pages : 256
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc National Crane 800D Operator & Service Manual – PDF DOWNLOAD

SECTION 1 11
Safety Information 11
Safety Messages 11
General 11
Safety Alert Symbol 12
Signal Words 12
General 12
Accidents 12
Operator Information 12
Operator Qualifications 13
Operational Aids 14
Rated Capacity Limiter (RCL) Systems (If Equipped) 14
Anti-Two-Blocking Device 14
Working Area Limiter (If Equipped) 15
Crane Stability/Structural Strength 15
Load Charts 16
Work Site 16
Wind Forces 16
Wind Speeds 17
Lifting Operations 30
Counterweight 31
Outrigger Lift Off 31
Multiple Crane Lifts 31
Tilt-Up Panel Lifting 31
Pile Driving and Extracting 32
Crane Equipment 32
Crane Inspection 32
Electrocution Hazard 33
Set-Up and Operation 34
Electrocution Hazard Devices 34
Electrical Contact 35
Special Operating Conditions and Equipment 35
Grounding the Crane 35
Personnel Handling 36
Environmental Protection 37
Maintenance 37
Service and Repairs 37
Lubrication 38
Tires 39
Hoist Rope 39
Synthetic Hoist Rope 39
Wire Rope 39
Sheaves 40
Batteries 41
Engine 41
Transporting the Crane 41
Travel Operation 42
Work Practices 43
Personal Considerations 43
Crane Access 43
Job Preparation 43
Working 43
Lifting 44
Hand Signals 45
Boom Extension 47
Parking and Securing 47
Shut-Down 47
Cold Weather Operation 47
Temperature Effects on Hook Blocks 48
Temperature Effects on Hydraulic Cylinders 48
Overload Inspection 49
SECTION 2 57
Operation 57
Truck Cab Controls 57
Power Take-Off (PTO) 57
Park Brake 58
Crane Controls 58
Control Functions 58
Hydraulic Capacity Alert (HCA) System (if Equipped) 59
Rated Capacity Limiter (RCL) (If Equipped) 60
Operating Procedures 63
Equipment Familiarization 63
Equipment Checks 63
Cold Weather Operation 63
Crane Warm-up Procedures 63
Engine 63
Transmission 64
Hoist 64
Swing Drive and Turntable Bearing 64
Axles 64
Hydraulic Oil System 64
Pre-Operation Inspection and Calibration Verification 64
Work Site Position 65
Before Leaving The Cab 66
Proper Leveling of the Crane 66
Bubble Level Adjustment 66
Crane Set Up 66
Before Making The Lift 67
Reading and Understanding the Load Charts 67
Hoist System Operation 73
Using Multiple Part Lines 73
General Rules When Operating Hoist 73
Lifting the Load 73
Shutting Down and Preparing for Road Travel 74
Optional HOIST Burst of Speed Operation 74
Operation 75
Maintenance 76
Description/Operation 78
Anti-two-block Weight Installation 79
System Description 80
System Operation 80
Safety Tips For Jib Operation 84
Side Folding-swing Around Jib Operation 84
Jib Maintenance 86
Jib Jack 86
Standard Hand Signals For Controlling Crane Operations 88
SECTION 3 89
Maintenance 89
Inspection and Maintenance 89
Inspection 89
Daily Inspections 89
Weekly Inspections 90
Periodic Inspection 90
Other 91
Hoist Cable Inspection and Maintenance 91
Keeping Records 91
Environmental Conditions 91
Dynamic Shock Loads 91
Precautions and Recommendations During Inspection 91
Inspection 92
Wire Rope Replacement 92
Adjustments and Repairs 93
Seizing Wire Rope 93
Care of Wire Rope 94
Tire Load and Inflation Table 95
SECTION 4 99
Lubrication 99
Lubrication Procedures And Charts 99
Lubricants 99
Hydraulic Oil 100
Lubrication Points 100
Wire Rope Lubrication 101
Lubrication Chart 102
Hydraulic Oil Reservoir Level 103
Carwell© Rust Inhibitor 103
Protecting Cranes From Corrosion 103
Cleaning Procedures 103
Inspection and Repair 104
Application 104
Areas of Application 105
SECTION 5 107
Service 107
Service and Repair 107
Environmental Protection 108
Cleanliness 108
Hydraulic Systems 108
Hydraulic Oil Recommendations 109
Draining and Flushing 109
Removing Air From the Hydraulic System 110
Welding Precautions 110
National Crane Fitting O-ring Part Numbers 110
Loctite® 112
Fasteners and Torque Values 112
Weld Studs 131
Using Torque Wrench Extensions 131
Trouble Diagnosis 132
Anti-two Block Trouble Diagnosis — Electrical 135
Anti-two Block Trouble Diagnosis — Hydraulic 137
Anti-two-block Internal Wire System/Four Section Boom (Cable On Top Of Sections) 139
Operation 139
Maintenance 139
1/2 Stage Anti-two Block Wire Replacement 139
Disassembly Of 1/2 Stage 139
Replacement Of Proportioning Cable For 1/2 Stage Of Anti-two Block Wire 143
Operation 143
Maintenance 143
Anti-two-block Internal Wire System/three Section Boom 146
Operation 146
Maintenance 146
Anti-two-block Wire With External Reel 148
Operation 148
Maintenance 148
SECTION 6 151
Repair 151
Cylinder Disassembly and Repair 152
Telescope Cylinder 153
Telescope Cylinder Disassembly 153
Telescope Cylinder Assembly 153
Three Section Boom Operation 154
Boom Illustrations 154
Boom Extended 154
Boom Retracted 154
Three Section Boom Maintenance 155
Internal Cable Sheave Lubrication 155
Three Section Cable Tensioning 155
Three Section Boom Service 156
Boom Removal 156
Boom Disassembly 156
Additional Maintenance, Disassembled Boom 157
Three Section Boom Assembly 158
Three Section Top/bottom Pad Replacement Assembled Boom 159
Top Rear Pad Replacement 159
Front Bottom Pad Replacement 160
Four Section Boom Maintenance 160
Internal Cable Sheave Lubrication 160
Four Section Cable Tensioning 161
Four Section Boom Service 161
Boom Removal 161
Boom Disassembly 161
Four Section Boom Assembly 163
Four Section Top/bottom Pad Replacement Assembled Boom 165
Top Rear Pad Replacement 165
Front Bottom Pad Replacement 166
Boom Cable Tensioning 166
Cable Tensioning 166
Cable Tension Sequence 167
4- Section Boom w/ 2 Stage Cylinder Cable Positioning 168
4- Section Boom w/ 1 Stage Cylinder Cable Positioning 169
3- Section Boom w/ 1 Stage Cylinder Cable Positioning 170
Cable Retention 171
SECTION 7 173
Side Shimming Of Boom Sections 173
Top/rear Side Pad Adjustment 174
Inner Boom Pad Lubrication 175
Jib Installation And Adjustment 176
Jib Jack Service & Maintenance 177
Adding Oil 178
Changing Oil 178
Lubrication 178
Rust Prevention 178
Troubleshooting 178
(Optional) Oil Cooler Service & Maintenance 178
Swing Drive Service 180
Lubrication and Maintenance 180
Oil Capacities 180
Disassembly Procedure 180
Assembly Procedure 181
Rotation Stop-mechanical 182
Adjustment Procedure 182
Servicing The Control Valves 183
Disassembly and Reassembly of Control Valves to Replace Seals 183
Replacing Spool Seals 183
Unloader Valve Service 184
Control Valve Relief Adjustment 185
Mid-inlet Relief Adjustment 185
Unloader Dump Valve – Air Purging Instruction 186
Hydraulic System Description 186
Optional Hydraulic Capacity Alert System 187
System Adjustment 187
Troubleshooting 188
Maintenance & Repair 190
SECTION 8 191
Specifications 191
SECTION 9 195
Installation 195
Configuration 1 — 8100D 198
Configuration 2 — 8100D 198
Configuration 3 — 800D (all booms other than 8100D) 199
Configuration 4 — 800D (all booms other than 8100D) 200
Configuration 5 — Rear Mount 200
Direct Mount Pump To PTO 201
Pump Rotation 201
Auger System 201
Welding Precautions 210
Positioning Crane on Truck 210
PTO, Pump, Reservoir 210
Reinforcing/After Frame Extension 211
SECTION 10 217
Crane Installation 217
Pin Inspection 221
Bearing Inspection 221
Trunnion Inspection 221
Installation 221
Stability Check 231
SECTION 11 233
Hoist 233
Maintenance and Service 237
Maintenance Scheduling 237
Oil Level Maintenance 237
Oil Change Interval 237
Hoist Brake Oil 237
Hoist Gearbox Oil 238
Recommended Oil 238
Disassembly 239
Assembly 239
Installing Cable On The Hoist 240
Wedge Socket Installation 240
Dead-end Rigging 241
Servicing the Motor 242
Servicing the Brake 243
Servicing the Planetary Sets 244
Hoist won’t hold load 246
Hoist unable to lift load 246
Hoist unable to lower load 246
Oil leaks from motor-side vent 246
SECTION 12 251
Schematics 251

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