The National Crane 400B Operator and Service Manual PDF (OEM ID 038-07) takes your 400B crane from warm-up and boom cable tensioning all the way to mounting on a truck frame, in 214 pages. Service work fills the biggest share of the book: wiring diagrams sit beside trouble diagnosis and procedures for the anti-two-block internal wire system, extend cylinder, rotation gearbox and jib load limiting device. Daily, weekly and monthly inspections, a lubrication chart, and installation guidance on PTO selection, counterweighting and stability checks round it out. Set anti-two-block wire tension at 15-25 lb (6-11 kg), and bring M8x1 Grade 8.8 fine-thread fasteners to 27-29 Nm. Guessing wrong costs you a cable and a second teardown. Bookmarked and text-searchable, this PDF helps you get the 400B lifting again.
What's Inside This National Crane 400B Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Boom Cable Tensioning Supplement | 1-12 | Tensioning Setup Procedure, Cable Tightening Sequence, Cable Balancing, Extend Cables, Retract Cables |
| Crane Warm-Up Procedures Supplement | 13-16 | Engine, Transmission, Hoist, Swing Drive and Turntable Bearing, Axles, Hydraulic Oil System |
| National Crane 400B Operator and Service Manual | 17-50 | - |
| Safety Information | 51-82 | Operational Aids, Crane Stability, Electrocution Hazard, Personnel Handling, Environmental Protection, Overload Inspection |
| Operation | 83-106 | Truck Cab Controls, Hoist System Operation, Anti-Two Block System, Hydraulic Capacity Alert System, Jib Load Limiting Device |
| Maintenance | 107-114 | Daily Inspections, Weekly Inspections, Monthly Inspections, Periodic Inspection, Wire Rope Inspection, Tire Load and Inflation |
| Lubrication | 115-124 | Lubricants, Hydraulic Oil, Lubrication Points, Wire Rope Lubrication, Lubrication Chart, Carwell Rust Inhibitor |
| Service | 125-174 | Cleanliness, Trouble Diagnosis, Anti-Two-Block Internal Wire System, Extend Cylinder, Rotation Gearbox, Jib Load Limiting Device |
| Specifications | 175-178 | Hydraulic System, Hoist System, Crane Operating Speeds, Center of Gravity, Load Moment |
| Crane Installation | 179-214 | Mounting Configurations, Truck Frame Strength, PTO Selection, Counterweighting, Stability Check, Outrigger Installation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Metric Fasteners, Fine Thread, Untreated (M8x1, Grade 8.8) | 27-29 Nm | p. 31 |
| Weld Stud Torque Values (#10) | 20 lb-in | p. 32 |
| O-Ring Face Seal B dimension (897063) | 0.07 inches (1,78 mm) | p. 126 |
| O-Ring Face Seal A dimension (897063) | 0.301 inches (7,64 mm) | p. 126 |
| Anti-two-block wire tension | 15-25 lb (6-11 kg) | p. 135 |
| Anti-two-block wire spring extension | 2 in (50 mm) | p. 136 |
| Rotation Gearbox Weight | 96 lbs | p. 159 |
| Rotation Gearbox Brake Torque | 800 in. lbs. | p. 159 |
| Hydraulic System Filtration | 10 Micron Return | p. 177 |
| Standard Hoist Wire Rope | 205 ft of 1/2 in dia. | p. 177 |
| Optional Hoist Wire Rope | 220 ft of 9/16 in dia. | p. 177 |
| Burst of Speed Maximum Pull | 3000 lb | p. 178 |
National Crane 400B Common Problems This Manual Covers
National Crane 400B anti-two block system shuts down when the weight is freely suspended
Check the anti-two-block internal wire tension against 15-25 lb (6-11 kg) using the service procedure on page 135. Verify spring extension reaches 2 in (50 mm) per page 136. Then work through the electrical and hydraulic trouble diagnosis charts in the Service section to isolate whether the fault sits in the wiring or hydraulic side.
Manual Section: Anti-two block trouble diagnosis - electricalHydraulic capacity alert system overload trips and will not reset, boom creeping down
Check the hydraulic capacity alert system step by step against its trouble diagnosis chart in the Service section before forcing a reset. Trace the related circuit on the hydraulic schematic on page 165. Once it resets, verify boom down speed from 80° to -15° runs 14 sec. ±2 sec. per page 178.
Manual Section: Hydraulic Capacity Alert System Trouble DiagnosisJib load limiting device in constant cut-out or cutting out too early or too late
Verify how the jib load limiting device is set up by reviewing its operating description in the Operation section. Then check each symptom (constant cut-out, early cut-out, late cut-out) against the jib load limiting device troubleshooting chart in the Service section, and inspect the device per the service procedure that follows before making adjustments.
Manual Section: Jib Load Limiting Device Troubleshooting p. 172Crane swing moves erratically or loosely, or will not turn at all
Check swing against the general trouble diagnosis chart on page 130 first. Time a full 375° turn against 36 sec. ±3 sec. per page 178. If the rotation gearbox needs to come out, plan for its 96 lbs weight (page 159) and verify brake torque against 800 in. lbs. before reinstalling.
Manual Section: General Trouble Diagnosis p. 130Poor hydraulic system performance with cylinders drifting and boom that will not extend
Check the hydraulic oil and 10 micron return filtration listed on page 177 before tearing into anything. Time boom up from -15° to 80° against 18 sec. ±2 sec. per page 178. Then work through the cylinder drift and boom extend entries in the general trouble diagnosis chart on page 130.
Manual Section: General Trouble Diagnosis p. 130Hoist will not lift or hold load, or hoist gearbox heats up
Check the hoist entries in the general trouble diagnosis chart on page 130. Confirm the line pull stays within the 3000 lb burst of speed maximum pull on page 178. Inspect the wire rope (standard is 205 ft of 1/2 in dia., page 177) and verify hoist lubrication in the Lubrication section starting on page 115.
Manual Section: General Trouble Diagnosis p. 130Frequently Asked Questions
How do I reset a National Crane 400B HCAS fault?
To reset an HCAS fault, you must first eliminate the overload condition. If the system remains tripped, turn the Hydraulic Capacity Alert key to the override position and momentarily press the HCA switch to bleed off trapped pressure with no load. If the system still does not reset, troubleshoot the electrical components as outlined in the Hydraulic Capacity Alert System Trouble Diagnosis flow chart on page 169. p. 169
What do error codes on a National Crane 400B jib load limiting device mean?
The jib load limiting device displays error codes on its single character display. A code of '0' indicates an invalid table number, while a code of '1' indicates that the load reading is higher than the limit. These codes appear in a 4-digit format where the first and last digits are blanks. p. 173
What are the torque specifications for National Crane 400B boom or outrigger bolts?
Torque specifications vary by bolt size and grade. For example, 1-inch 14 UNS studs for cross frame outrigger installation must be torqued to 450 lb-ft. For extend cylinder pistons, torque to 200 lb-ft (271 Nm), and for setscrews on the piston, torque to 8 lb-ft (11 N·m). Always refer to the specific torque tables in the Maintenance section for standard fasteners. p. 142
How do I calibrate the anti-two-block system on a National Crane 400B?
Calibration of the cylinder length sensor requires a laptop equipped with HED Conductor software and a USB cable connector (p/n 80009992). Contact your Manitowoc dealer for further assistance with this procedure. p. 43
What are the replacement specifications for the boom wear pads on the National Crane 400B?
Excessive wear for boom wear pads is defined as 3/16 inch (4.76 mm) from the original pad thickness. The top rear pad thickness is 0.75 inches (19.05 mm), the bottom front 1st section pad is 1 inch (25.4 mm), and the bottom front 2nd section pad is 0.50 inches (12.7 mm). Uneven pad wear of 3/32 inch (2.38 mm) from side to side is also considered excessive. p. 152
What exactly do I receive with this National Crane 400B manual?
This is a 214-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print a copy of this National Crane 400B manual for the shop?
Yes. No DRM, nothing blocks printing, so run off the pages you need on whatever printer you have.
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