National Crane Published 5-27-2018 Control # 039-06 11-7
800D HOIST
WARNING
Do not use EP type gear lubes in the brake section of this
hoist. EP lubes may prevent the clutch from locking up,
which, in turn causes the load to fall, resulting in property
damage, personal injury, or death.
The hydraulic system should use only high quality hydraulic
fluid from reputable suppliers. These oils should contain
additives to prevent foaming and oxidation in the system. All
hoist hydraulic systems should be equipped with a return line
filter capable of filtering 10 micron particles from the system.
Hoists are shipped from the factory with SAE 90 Extreme
Pressure (EP) gear lube in the gearbox and lightweight non-
EP oil in the brake section. This oil and gear lube should be
satisfactory for operation in ambient temperatures from -
10°F (-23°C) to +130°F (+55°C).
DISASSEMBLY
1. Drain the oil from the gearbox and brake sections using
the instructions in Hoist Brake Oil, page 11-5 and Hoist
Gearbox Oil, page 11-6.
2. Stand the hoist on its end with the motor pointing up.
3. Disconnect the hose (46) connected to the brake
housing (21). Remove the motor and counterbalance
valve assembly from the hoist by removing two
capscrews (51) and washers (52). See Servicing the
Motor, page 11-10 for motor and counterbalance valve
disassembly.
4. Remove the brake subassembly from the hoist by
removing eight capscrews (9) holding the brake housing
to the side plate (1). Reinstall two of these capscrews
into the two extra tapped holes and tighten them evenly
until the brake housing comes loose from the side plate.
See Servicing the Brake, page 11-11 for brake repair.
5. Remove the side plate (1) by removing four capscrews
(2).
6. Lift the bearing carrier (26) out of the drum (5). Inspect
the bearing (28) for signs of pitting or spalling and if
necessary, replace the bearing and seal (7-4).
7. Remove the thrust washer (6) and input sun gear (8)
from the input planet gearset (36). Inspect for damage
and replace if needed.
8. Remove the input planet gearset (36) from the drum.
Inspect the gearset for wear and repair as needed. See
Servicing the Planetary Sets, page 11-12 for
disassembly and repair.
9. Remove the thrust washer (6) and output sun gear (16).
Inspect for damage and replace if needed.
10. Remove the output planet gearset (4) from the drum (5).
Inspect the gearset for wear and repair as needed. See
Servicing the Planetary Sets, page 11-12 for
disassembly and repair.
11. Remove the drum (5) by lifting straight up and off of the
output shaft (32). Inspect the gear teeth for excessive
wear and replace if necessary. Inspect the bearing (28)
for signs of spalling or pitting and, if necessary, replace
the bearing and seal (7-4).
12. Inspect the retaining ring (3) on the output shaft to
ensure that it is still in the groove and is not bent, and
replace if necessary.
13. Inspect the output shaft (32) for wear or damage and, if
necessary, remove it from the side plate (50) by
removing six capscrews (9).
ASSEMBLY
1. Thoroughly clean all parts. Replace those that show
wear or damage.
2. Inspect the drum (5) for structural integrity and the gear
teeth for excessive wear, then replace if necessary.
3. Attach the output shaft (32) to the side plate (50) with six
capscrews (9), making sure the vent (30) is oriented
properly, then torque them to specification (see Hoist
Torque Specifications Chart, page 11-15).
4. Install the retaining ring (3) onto the output shaft (32).
5. Attach the rods (43) to the side plate (50) with four
capscrews (2). Torque to specification (see Hoist Torque
Specifications Chart, page 11-15).
6. If necessary, install a new bearing (28) and oil seal (7-4)
into the drum.
7. Lay the unit down so that the rods (43) are pointing up.
Set the drum (5) onto the output shaft (32) being careful
not to damage the seal (7-4), seating the drum on the
bearing (28).
8. Install the output planet gearset (4) into the drum (5),
making sure it's installed correctly onto the output shaft
(32).
9. Put a light coating of grease on the thrust washer (6) to
keep it in place. Install the thrust washer into the output
gearset (4), and then insert the output sun gear (16).
The slot in the sun gear must be installed facing the
output shaft.
OIL CAPACITY
GEARBOX 1.42 liter (1.50 qt)
BRAKE 0.23liter (0.25 qt)
Fo
r
Reference
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