500E2 Service Manual

SERVICE MANUAL 1
This Manual has been prepared for and is considered part of -
500E2 Telescoping Crane

This Manual is Divided into the following Sections: 2
SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
3
SECTION 3 ELECTRICAL SYSTEM
SECTION 4 BOOM
SECTION 5 WINCH
SECTION 6 SWING
SECTION 7 LUBRICATION
SECTION 8 TROUBLESHOOTING
SECTION 9 CRANE INSTALLATION
SECTION 10 SCHEMATICS 4
NOTICE
The crane serial number is the only method your distributor or the factory has of providing you with correct parts and service
information. 5
The crane serial number is identified on the builder’s decal attached to the crane frame. Always furnish crane serial number
when ordering parts or communicating service problems with your distributor or the factory.
To prevent death or serious injury:

• Avoid unsafe operation and maintenance.
7
• This crane must be operated and maintained by trained and
experienced personnel. National Crane is not responsible for
qualifying these personnel.
• Do not operate or work on this crane without first reading and
understanding Operator’s Manual and Rating Plate supplied with
8
crane.
• If Operator’s Manual or Capacity Charts are missing from crane,
contact your distributor for new ones.
9
© 2010 Manitowoc
Published 03/24/10 Control # 112-01
10
To Contact Us:
Manitowoc Cranes, Inc.

2401 South 30th Street
Manitowoc, WI 54220
(920) 684-6621
(920) 683-6277 (fax)
Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)
National Crane Corporation

P.O. Box 21
(717) 597-8121
(717) 597-4062 (fax)
Grove Worldwide
P.O. Box 21
(717) 597-8121
(717) 597-4062 (fax)
Technical Field Parts Factory Training

Publications Service Service
TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Fatigue Of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Fasteners And Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Torque Wrenches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Using Torgue Wrench Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Adjustment And Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hydraulic System Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Label Parts When Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Oil Cooler Service & Maintenance (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Servicing The Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Disassembly And Reassembly Of Control Valves To Replace Seals . . . . . . . . . . . . . . . 2-3
Replacing Spool Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Unloader Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Control Valve Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System

Anti-two Block System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block Internal Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Three Section Boom ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Capacity Alert System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HCA Maintenance & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HCA System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
jib Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Single Character Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
TOC-1
Three Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Three Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Winch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Disassembly Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Additional Maintenance, Disassembled Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Three Section Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Three Section Top/Bottom Pad Replacement (Assembled Boom) . . . . . . . . . . . . . . . . . 4-6
Top Rear Pad Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Front Bottom Pad Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Inner Wear Pad Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Lift Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Extend Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Extend Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Extend Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Adding Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winch
Winch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Disassembly & Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tulsa Swing Drive Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Rotation Stop-mechanical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Rotation Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Arctic Conditions Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chassis Grease.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Extreme Pressure Multipurpose Gear Lubricant (EPGL) . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Open Gear Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chassis Grease Low Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Anti-wear Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Hydraulic OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Standard Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Intermediate Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Wide Range Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Arctic Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Surface Protection for Cylinder Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Inner Boom Pad Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Side and Bottom Boom Wear Pad Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
TOC-2
Winch Brake Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Winch Gearbox Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Winch Gearbox Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
SECTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting
Hydraulic System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Systematic Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HCA Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crane Installation

Crane to Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Minimum Truck Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Mounting Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Configuration 1 - 571E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Configuration 2 - 571E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Configuration 3 - 560E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Configuration 4 - 560E2 And Shorter Booms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Pto Horsepower Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Direct Mount Pump to Pto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Truck Frame Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Channel (Table A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Channel Reinforcement (Table A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Angle Reinforcement (Table B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Fish Plate Reinforcement (Table C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Angle Under Reinforcement (Table D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Requirements For Optional Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Truck Frame Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Positioning Crane On Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Reinforcing/after Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
After Frame Modification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Crane Mounting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Crane Component Installation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Torsion Box and ASH Stabilizer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Install Torsion Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Crane to Chassis Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
ASH to Torsion BoX Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Hydraulic Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Winch to Truck Cab Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Pin Bearing Inspection And Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Pin Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Trunnion Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
TOC-3
Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Counterweighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Counterweighting Determination Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Counterweighting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Concrete poured in the bed measures:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Boom Rest Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Initial Crane Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Stability Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
HCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Winch Speed and Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Crane Operating Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
SECTION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematics
TOC-4
500E2 SERVICE MANUAL INTRODUCTION
SECTION 1
1
INTRODUCTION
GENERAL factory assistance, please ask the dealer ’s service
management to coordinate the contact on your behalf.
This manual has been compiled to assist you in properly
operating and maintaining your Model 500E2 Series Supplemental Information
National Crane. Supplemental Information regarding Safety & Operation,
Before placing the crane in to service, all operators and Specifications, Service & Maintenance, Installation, and
persons working around the crane must thoroughly read and parts for options such as remote controls, augers, varying
understand the contents of the Operators Handbook control configurations, baskets, grapples, etc. is included in
pertaining to Safety, Operation and Maintenance. Before separate sections of this manual, if applicable.
moving a vehicle equipped with the crane, information Whenever a question arises regarding your National product
relating to transporting the vehicle must be read and or this publication, please consult your National Dealer for
observed. the latest information. Your National Dealer is equipped with
This manual must be retained with the machine for use by the proper tools, necessary National parts and trained
subsequent operating personnel. service personnel to properly maintain and service your
crane.
Information this manual does not replace federal, state or
local regulations, safety codes or insurance requirements
The National Crane has been designed for maximum
performance with minimum maintenance. With proper care, DANGER
years of trouble-free service can be expected. Failure to observe all the instructions contained in this
Constant improvement and engineering progress makes it manual could result in death or serious injury to the
necessary that we reserve the right to make specification operator or bystanders or damage to the equipment.
and equipment changes without notice.
Safety Information
National Crane and our Dealer Network want to ensure your
satisfaction with our products and customer support. Your A Safety Compact Disc (CD) which includes sections on
local dealer is the best equipped and most knowledgeable to Operation, Safety and Maintenance for National Crane
assist you for parts, service and warranty issues. They have operators and owners is supplied when the crane is
the facilities, parts, factory trained personnel, and the purchased new. Additional copies are available from your
information to assist you in a timely manner. We request that local distributor.
you first contact them for assistance. If you feel you need
Published 03/24/10 Control # 112-01 1-1

INTRODUCTION 500E2 SERVICE MANUAL
500E2 Series Major Components
Item Component Item Component

1 Winch 5 Stabilizers
2 Boom 6 Hydraulic Reservoir
3 Sheaves 7 Control Console
4 Boom Rest 8 Outriggers
GENERAL MAINTENANCE Cleanliness

The suggestions listed below are helpful in analyzing and Cleanliness is important in preserving the life of the machine.
correcting problems: Keep dirt out of working parts and compartments. Keep
filters and seals clean. Whenever hydraulic, fuel, lubricating
• Determine the problem. oil lines, or air lines are disconnected, clean the adjacent
• List possible causes. area as well as the point of disconnect. Cap and plug each
line or opening to prevent entry of foreign material.
• Devise checks.
Clean and inspect all parts. Be sure all passages and holes
• Conduct checks in a logical order to determine the are open. Cover all parts to keep them clean. Be sure parts
cause. are clean when they are installed. Leave new parts in their
• Consider the remaining service life of components containers until ready for assembly. Clean the rust
against the cost of parts and labor to replace them. preventive compound from all machined surfaces of new
parts before installing them.
• Make the repair.
• Test the equipment to ensure the problem is fixed.
Removal and Installation
NOTE: Safety is the number one consideration when Do not attempt to manually lift heavy parts that require
working around machines. Safety is a matter of hoisting equipment. Do not put heavy parts in an unstable
understanding the job to be done and the application position.
of good common sense. It is not just a list of do’s and
don’ts. Stay clear of all moving parts.
1-2 Published 03/24/10 Control # 112-01

When raising a portion or a complete crane, ensure the Use a steel flat washer between aluminum housings and
weight is supported by blocks rather than by lifting lock washers. 1
equipment.
Shims
When using hoisting equipment, follow the winch
manufacturers recommendations. Use lifting devices that When shims are removed, tie them together and identify
achieve the proper balance of the assemblies being lifted. them as to location. Keep shims clean and flat until they are
Unless otherwise specified, use an adjustable lifting reinstalled.
attachment for all removals requiring hoisting equipment.
Some removals require the use of lifting fixtures to obtain Bearings
proper balance.
Antifriction Bearings
All supporting members (chains and cables) need to be
parallel to each other and as near perpendicular as possible When an antifriction bearing is removed, cover it to keep out
to the top of the object being lifted. dirt and abrasives. Wash bearings in non-flammable
cleaning solution and allow them to drain dry. The bearing
CAUTION may be dried with compressed air BUT do not spin the
bearing. Discard the bearings if the races and balls or rollers
The capacity of an eyebolt diminishes as the angle
are pitted, scored, or burned. If the bearing is serviceable,
between the supporting members and the object
coat it with oil and wrap it in clean waxed paper. Do not
becomes less than 90°. Eyebolts and brackets should
unwrap new bearings until time of installation. The life of an
never be bent and should only have stress in tension.
antifriction bearing is shortened if not properly lubricated. Dirt
can cause an anitfriction bearing to lock and result in the
If a part resists removal, check to be sure all nuts and bolts
shaft turning in the inner race or the outer race turning within
have been removed and that an adjacent part is not
the cage.
interfering.
Double Row, Tapered Roller
Disassembly And Assembly
Double row, tapered roller bearings are precision fit during
Complete each step in turn when disassembling and manufacture and components are not interchangeable. The
assembling a component. Do not partially assemble one part cups, cones, and spacers are etched with the same serial
and start assembling some other part. Make all adjustments number and letter designator. If no letter designators are
as recommended. Always check the job after it is complete found, wire the components together to assure correct
to see that nothing has been overlooked. Recheck the installation. Reusable bearing components should be
various adjustments by operating the machine before installed in their original positions.
returning it to the job.
Heating Bearings
Pressing Parts
Bearings which require expansion for installation should be
When one part is pressed into another, use an anti-seize heated in oil not to exceed 121 °C (250 °F). When more than
compound or a molybdenum disulfide base compound to one part is heated to aid in assembly, they must be allowed
lubricate the mating surfaces. to cool and then pressed together again. Parts often
separate as they cool and contract.
Assemble tapered parts dry. Before assembling parts with
tapered splines, be sure the splines are clean, dry, and free Installation
from burrs. Position the parts together by hand to mesh the
splines before applying pressure. Lubricate new or used bearings before installation. Bearings
that are to be preloaded must have a film of oil over the entire
Parts which are fitted together with tapered splines are assembly to obtain accurate preloading. When installing a
always very tight. If they are not tight, inspect the tapered bearing, spacer, or washer against a shoulder on a shaft, be
splines and discard the part if the splines are worn. sure the chamfered side is toward the shoulder.
Locks When bearings are pressed into a retainer or bore, apply

pressure to the outer race uniformly. If the bearing is pressed
Lock washers, flat metal locks, or cotter pins are used to lock on the shaft, apply pressure on the inner race uniformly.
nuts and bolts. For flat metal locks, bend one end of the lock
around the edge of the part and the other end against one Preload
flat surface of the nut or bolt head.
Preload is an initial load placed on the bearing at the time of
Always use new locking devices on components which have a s s e m b l y. C o n s u l t t h e d i s a s s e m b l y a n d a s s e m b l y
moving parts. instructions to determine if the bearing can be preloaded.

Be careful in applying preload to bearings requiring end • Climate zones A and C with high ambient temperatures
clearance. Otherwise, bearing failure may result. and duty cycles after 4000 to 5000 hours of service.
Sleeve Bearings • Climate zones D and E after 4000 to 5000 hours of

service.
Do not install sleeve bearings with a hammer. Use a press
and be sure to apply the pressure directly in line with the Cleanliness
bore. If it is necessary to drive on a bearing, use a bearing
Contaminants in a hydraulic system affects operation and
driver or a bar with a smooth flat end. If a sleeve bearing has
results in serious damage to the system components.
an oil hole, align it with the oil hole in the mating part.
Keep The System Clean
Gaskets
When removing components of a hydraulic system, cover all
Be sure the holes in the gaskets correspond with the openings on both the component and the crane.
lubricant passages in the mating parts. If it is necessary to
make gaskets, select material of the proper type and If evidence of foreign particles is found in the hydraulic
thickness. Be sure to cut holes in the right places. Blank system, flush the system.
gaskets can cause serious damage.
Disassemble and assemble hydraulic components on a
Hydraulic Systems clean surface.
Clean all metal parts in a nonflammable cleaning fluid. Then
lubricate all components to aid in assembly.
! DANGER
Sealing Elements
Pressurized hydraulic fluid can cause serious injury.
Depressurize the hydraulic system before loosening Inspect all sealing elements (O-ring, gaskets, etc.) when
fittings. disassembling and assembling the hydraulic system
components. Installation of new elements is recommended.
Visual Inspection
Hydraulic Lines
Do a visual inspection daily on all hydraulic components for
missing hose clamps, shields, guards, excessive dirt build When disconnecting hoses, tag each one to ensure proper
up, and leaks. Do a monthly or 250 hour inspection for the identification during assembly.
items listed in the inspection procedure below. When installing metal tubes, tighten all bolts finger-tight.
Valves and Manifolds Then, in order, tighten the bolts at the rigid end, the
adjustable end, and the mounting brackets. After tubes are
Inspect valves and manifolds for leaking ports or sections. mounted, install the hoses. Connect both ends of the hose
with all bolts finger-tight. Position the hose so it does not rub
Hoses and Fittings
the machine or another hose and has a minimum of bending
Inspect all hoses and fittings for the following: and twisting. Tighten bolts in both couplings.
• Cut, kinked, crushed, flattened, or twisted hoses. Due to manufacturing methods there is a natural curvature to
a hydraulic hose. Reinstall the hose so any bend is with this
• Leaking hoses or fittings.
curvature.
• Cracked, blistered, or hoses charred by heat.
Electrical
• Damaged or corroded fittings.
• Fitting slippage on hoses. Batteries
Clean the batteries with a solution of baking soda and water.
If any the above conditions exist, evaluate and replace as Rinse with clear water and dry. Clean the battery terminals
necessary. with fine sandpaper and coat the terminals dielectric grease.
The climate in which the crane operates affects the service Do not use a non-dielectric grease.
life of the hydraulic components. The climate zones are Remove the batteries If the machine is not used for an
d e f i n e d i n t h e t a b l e o n p a g e 1 -5 . R e c o m m e n d e d extended period of time. Store the batteries in a warm, dry
replacement of hoses is as follows: place, preferably on wooden shelves. Never store on
• Climate zone C after 8,000 hours of service. concrete. A small charge should be introduced periodically to
keep the specific gravity rating at recommended level.

• Cracked or corroded connectors, battery terminals, and

CAUTION ground connections. 1
Disconnect batteries prior to working on the electrical
If any the above conditions exist, evaluate and replace as
system.
necessary.
When disconnecting wires, tag each one to ensure proper The climate in which the crane operates affects the service
identification during reassembly. life of the electrical components. The climate zones are
d e f i n e d i n t h e t a b l e o n p a g e 1 -5 . R e c o m m e n d e d
Connectors, Harnesses, Wires, and Connectors replacement of harness and cables is as follows:
Visually inspect all electrical harnesses, cables, and • Climate zone C after 10,000 hours of service.
connectors every month or 250 hours for the following:
• Climate zones A and C with high ambient temperatures
• Damaged, cut, blistered, or cracked insulation. and duty cycles after 8000 hours of service.
• Exposed bare wires. • Climate zones D and E after 10,000 hours of service.
• Kinked or crushed wires and cables. • Salt water conditions after 8,000 hours of service.
.
Climate Zone Classification
Zone Classification
A (Tropical Moist) Latitude 15° - 25° North and South (All months average above 64° F [18° C])
B (Dry or Arid) Latitude 20° - 35° North and South (Deficient of precipitation most of the year)
C (Moist Mid-Latitude) Latitude 30° - 50° North and South (Temperate with mild winters)
D (Moist Mid-Latitude) Latitude 50° - 70° North and South (Cold winters)
E (Polar) Latitude 60° - 75° North and South (Extremely cold winters and summers)
Fatigue Of Welded Structures Loctite

Highly stressed welded structures are subject to cracking
(fatigue) when repeatedly subjected to varying stresses
caused by twisting, shock, bending, and overloads. Inspect
! DANGER
equipment periodically for weld fatigue. The frequency of Loctite type adhesives contain chemicals that may be
inspections depends on the age of the equipment, the harmful if misused. Read and follow the instructions on
severity of the application, and the experience of the the container.
operators and the maintenance personnel. The following are
known high stress areas and should be inspected as part of Follow the directions on the Loctite container. There are
a preventive maintenance program: different Loctite types for different applications. The following
types of Loctite brand adhesives are available from the parts
• Hydraulic cylinder and boom pivot attaching points. department of the local National distributor.
• Outrigger pads, beams, boxes and attachment
Application of Medium Strength Loctite
structures.
NOTE: The fastener can be re-used and the adhesive can
• On the frame in the area of doubler plates and
be re-applied over cured adhesive residue.
crossmembers.
The following procedure covers the proper application and
• Turntable bearing connection (where bearing is welded
curing method for medium strength Loctite adhesive/sealant
to the crane turret).
(Loctite #242) and primer (Locquic Primer T7471).
• Counterweight support structures (were applicable).
Primer Application
• Hydraulic cylinder end connections.
NOTE: It is not necessary to bathe the threads in primer.
The above is provided only as a guide and your inspection
plan should not be limited to the areas listed. A visual Clean dirt and oil from the threaded surfaces, both male and
inspection of all weldments is good practice. female. Apply a light spray coating of primer to both surfaces
to clean and accelerate the curing process. Allow the part to
dry prior to adhesive/sealant application.

Adhesive/Sealant Application Use of proper torque values is extremely important. Improper

torquing can seriously affect performance and reliability.
Bead Application
Identification of fastener grade is always necessary. When
marked as a high strength bolt (grade 8, 5, etc.), the
mechanic must be aware that he is working with a highly
stressed component and the fastener should be torqued
accordingly.
If a fastener must be replaced and a similar grade is not
available, always use a higher grade torqued to the same
1. Apply a bead several threads wide in the approximate value as the original grade. As soon as available, the correct
area of threaded contact. grade fastener should be installed to avoid a future state of
confusion by the improper installation.
2. In a blind hole application, apply several drops of
adhesive in the bottom of the hole so that the adhesive is Special attention should be given to the existence of
forced up when the bolt is installed. lubricant, plating, or other factors that might require variation
from standard torque values.
3. After installation, fixturing occurs within five (5) minutes if
primed prior to engagement or up to 30 minutes on When maximum recommended torque values have been
unprimed parts. exceeded, the fastener should be replaced.
The time required to achieve full strength is 24 hours. NOTE: Temperature variation, vibration, and elasticity of
Maximum strength is achieved using no primer with this metals can result in the gradual reduction of bolt
specific threadlocking adhesive. torque. Bolts should be re-torqued as outlined in
the inspection and maintenance procedure.
FASTENERS AND TORQUE VALUES Torque values for bolts listed below are not affected with the
Use bolts of the correct length. A bolt which is too long may use of Loctite. Do not use Loctite on rotation bearing
bottom before the head is tight against the part it is to hold. If fasteners. Hardend washers should be used with Grade 8
a bolt is too short, there may not be enough threads engaged fasteners.
to hold the part securely. Threads can be damaged. Inspect Hex socket and Torx head fasteners are considered Grade 8
them and replace fasteners as necessary. unless otherwise specified. Use grade 8 tightening torques.
Torque values must correspond to the type bolts, studs, and Use grade 5 tightening torques for all wear pad fasteners.
nuts being used.
NOTE: For standard metric hex

bolts, the property, class,
and manufacturer ’s
identification appears on
the top of the head.

Torque Values for Unfinished Fasteners with No Special Lubrication - Coarse Threads 1
Bolt Diameter Inches
Torque Pounds-Foot
Coarse Thread
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
Capscrew
SAE Grade 1 5.5 11 20 31 47 69 97 156 210 312 493 685 919 1100
and Grade 2 5.0 9 18 29 43 63 89 144 194 288 455 633 849 1015
9.0 19 32 52 78 114 156 270 416 606 813 1141 1519 2028
SAE Grade 5
7.7 17 30 48 72 106 144 249 384 560 751 1053 1403 1865
12.5 26 48 73 120 161 234 385 615 929 1342 2043 2496 3276
SAE Grade 8
11.5 24 44 67 110 143 216 355 567 857 1234 1885 2296 3024
Socket 12.5 26 48 73 120 161 234 385 615 929 1342 2043 2496 3276
Capscrew 11.5 24 44 67 110 143 216 355 567 857 1234 1885 2296 3024
Socket 5 12 23 42 42 100 174 346
— — — — — —
Shoulder Screw 3 9 21 38 38 92 160 320
SAE 5.2
Serrated 12 25 45 72 110 220
— — — — — — — —
Flange Head 9 19 34 54 83 166
• Studs shall be torqued using capscrew figures when grade is known.
• Torque values for zinc plated fasteners are the same as for unfinished fasteners.
Torque Values for Unfinished Fasteners with No Special Lubrication - Fine Threads
Bolt Diameter Inches
Torque Pounds-Foot
Fine Thread
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
Capscrew
SAE Grade 1 6.3 12 22 34 52 76 108 172 230 340 535 751 1032 1221
and Grade 2 5.8 10 20 32 48 70 100 158 212 314 493 693 952 1127
10 21 36 57 88 126 182 312 458 658 882 1251 1704 2288
SAE Grade 5
9 19 34 53 81 116 167 287 421 606 814 1155 1572 2105
14.5 26 53 85 125 177 250 425 672 1009 1500 2092 2833 3640
SAE Grade 8
13.5 24 49 79 115 163 230 393 620 931 1380 1925 2605 3360
Socket 14.5 26 53 85 125 177 250 425 672 1009 1500 2092 2833 3640
Capscrew 13.5 24 49 79 115 163 230 393 620 931 1380 1925 2605 3360
SAE 5.2
Serrated 15 28 52 81 125 251 15 28
— — — — — —
Flange Head 11 21 39 61 94 189 11 21
• Studs shall be torqued using capscrew figures when grade is known.
• Torque values for zinc plated fasteners are the same as for unfinished fasteners.

Torque Values for Metric Fasteners (unfinished) with No Special Lubricating - Coarse Threads
Bolt Diameter Metric
Torque Newton-Meters
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Grade
0.157 0.197 0.236 0.276 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
3.1 6.5 11 19 27 53 93 148 230 391 447 608 774 1134 1538
8.8
2.8 5.9 10 17 25 49 85 136 212 294 413 562 714 1046 142
4.5 9.2 16 26 38 75 130 212 322 455 629 856 1089 1591 2163
10.9
4.1 8.5 14 24 35 69 120 195 298 418 581 790 1005 1469 1997
5.4 11 19 31 45 89 156 248 387 532 756 1029 1306 1910 2595
12.9
4.9 10 17 28 42 83 144 228 357 490 698 949 1206 1763 2395
Torque values for fine threads are 8% higher.
Torque Values for Metric Fasteners (unfinished) with No Special Lubricating - Coarse Threads
Bolt Diameter Metric
Torque Pounds-Foot
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Grade
0.157 0.197 0.236 0.276 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
2.3 4.8 8.1 14.0 20 39 69 109 170 235 329 448 548 836 1134
8.8
2.1 4.3 7.4 12.5 18 36 63 100 156 217 304 414 526 771 1047
3.3 6.8 11.8 19.0 29 55 96 156 237 335 464 631 803 1173 1594
10.9
3.0 6.3 10.3 17.6 26 51 88 144 220 308 428 582 741 1083 1472
4.0 8.1 14.0 23.0 33 66 115 183 285 392 557 758 963 1408 1913
12.9
3.6 7.4 12.5 20.6 31 61 106 168 263 361 514 699 889 1299 1765
Torque values for fine threads are 8% higher.
Torque Wrenches Torque values for bolts listed above are not
affected with the use of Loctite.
Torque wrenches are precision instruments and are to be
handled with care to ensure calibrated accuracy. Calibration Loctite should not be used on rotation bearing
checks should be made on a scheduled basis. Whenever fasteners. Hardend washers should be used with
the wrench might be either overstressed or damaged, it Grade 8 fasteners
should immediately be removed from service until re-
calibrated. An erratic or jerking motion of the wrench can Using Torgue Wrench Extensions
easily result in excessive torque. ALWAYS use a slow 1. Torque wrench extensions are designed to extend the
wrench movement and STOP when the predetermined value range or versatility of torque wrenches. Torque wrench
has been reached. scale readings or limit settings shall be computed with
NOTE: Torque values are in foot pounds (Nm). Torque the following formulas when an extension handle is
values apply to plain finish and zinc plated employed. The sketch below shows which formula is to
fasteners. Torque values specified are dry with as be used, adding “A” or subtracting “A” when calculating
received residual oils. Special lubricants are not the torque wrench setting.
recommended. 2. If the offset C/L is not in line with the torque wrench C/L,
then you must measure the distance from the C/L of the
torque wrench to the C/L of the offset by using a square.

Then apply this dimension to the torque wrench setting 3. If offset is positioned at right angles to the torque
formula. See sketch below. wrench, then the offset will not change the effective 1
length. Therefore, TW-wrench setting and Ta-applied
torque, will be the same value as if no offset were used.
Ta x L or Ta x L
TW =
L+A L-A
Ta = Torque required (specified) L = Length of torque wrench in inches (center of drive

tang to handle pivot pin or center of hand grip
TW = Wrench scale reading or limit setting of extension handles are considered part of wrench
torque wrench length, when used).
A = Length of adapter extensions in inches


500E2 SERVICE MANUAL HYDRAULIC SYSTEM
SECTION 2
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DESCRIPTION The standard swing gearbox is locked in place by an integrally
mounted spring applied brake and a dual counterbalance motor
The hydraulic system of this machine is an open center type holding valve. The swing brake and counterbalances are piloted
consisting of a fixed displacement three section high
pressure pump which supplies oil to a main control valve and
open and closed by operating swing left or right and are
automatically reapplied by ceasing the swing function.
2
a winch control valve. The main control valve is equipped Maximum swing speed can be limited using the swing speed
with a main inlet and a mid inlet. The main inlet supplies oil to adjustment valve.
the turn function, the mid inlet supplies the remainder of the
crane function requirements. The main control valves GENERAL ADJUSTMENT AND REPAIR
contain inlet section reliefs or port reliefs which limit pressure PROCEDURES
in the hydraulic system to acceptable levels and control
crane movements. See Specification Section for pressure Before adjustments and repairs are started on a crane, the
settings. following precautions shall be taken as applicable:
The large single section control valve supplies oil to winch up • Place a warning tag in a conspicuous place at the
and down. The inlet section contains a screw adjustable controls stating that the machine requires adjustment or
main relief. The first work section of the multi-section main repair before it can be operated.
control valve controls turn right and left.This work section is
• Park the crane it causes the least interference with other
supplied oil by the main inlet section which contains a screw
equipment or operations in the area.
adjustable relief valve. The remaining work sections are
boom telescope, boom lift, and outrigger functions in that • Place all controls at the off position and secure all
order. The oil to these sections is supplied by the mid inlet operating features from inadvertent motion by brakes or
section which also contains a main relief valve. The winch other means.
and the main circuits are all connected through shuttles to a
• Disable all methods used to start the truck's engine.
pressure gage located on the control console.
• Power plant stopped or disconnected at take-off.
The hydraulic oil is supplied by a truck frame mounted oil
reservoir, which is equipped with a replaceable canister type • Boom lowered to the ground or otherwise secured
return oil filter. The truck power take off driven hydraulic against dropping.
pump is sized to supply 34 GPM (129 Lpm) to the winch
circuit, 18 GPM (68 Lpm) to the boom lift and telescope • Load block lowered to ground or otherwise secured
circuits and 10 GPM (38 Lpm) to the turn function at 2400 against dropping.
rpm pump shaft speed. Higher pump speeds may result in • Relieve hydraulic oil pressure from all hydraulic circuits
excessive heat generation in the hydraulic system. The before loosening or removing hydraulic components.
pump is not bidirectional and can only be used when the
shaft rotates only in the proper direction. If you need to verify After adjustments and repairs have been made, the crane
or change pump rotation, contact your National distributor or shall not be returned to service until all guards have been
National Crane Product Support. reinstalled, trapped air removed from hydraulic system if
required, safety devices reactivated, and maintenance
The crane hydraulic system includes a hydraulic capacity equipment and all warning tags removed.
alert system. This system is a hydraulically operated,
maximum capacity sensing device that monitors lift cylinder Adjustments and repairs shall be done only by designated
pressure. As pressure in the lift cylinder approaches its personnel who are properly trained. Use only National
maximum predetermined level, which can be monitored on Crane supplied parts to repair the crane.
the console mounted range gages, a hydraulic pressure
switch activates an integral hydraulic dump circuit in the
Hydraulic System Maintenance Precautions
main control valve, disabling the crane functions which Contaminants in a hydraulic system affect operation and can
increase the over capacity condition. result in serious damage to the system components. If
All load bearing cylinders on this machine are protected from evidence of foreign particles is found in the hydraulic system,
inadvertent movement or collapse due to hose failure by pilot flush the system.
operated check valves or by pilot operated counterbalance Disassemble and assemble hydraulic components on a
valves if overhung loads must be controlled. clean surface. Clean all metal parts in a nonflammable
cleaning fluid. Lubricate all components to aid in assembly.

HYDRAULIC SYSTEM SERVICE MANUAL 500E2
Inspect all sealing elements (O-ring, gaskets, etc.) when

disassembling and assembling the hydraulic system
components. Installation of new sealing elements is always
recommended.
When installing metal hydraulic tubes, tighten all bolts finger
tight. Then, in order, tighten the bolts at the rigid end, the
adjustable end, and the mounting brackets. After tubes are
mounted, install the hoses. Connect both ends of the hose
with all bolts finger tight. Position the hose so it does not rub
the machine or another hose and has a minimum of bending
and twisting. Tighten bolts in both couplings.
Due to manufacturing methods, there is a natural curvature
to a hydraulic hose. The hose should be installed so any
bend is with this curvature.
In case of replacement hoses with angled stem reusable
fittings, the hose curvature must be taken into consideration
when assembling and positioning the angled stem.
Label Parts When Disassembling Hydraulic Filter

Return oil filtration has been designed to handle the
When removing or disconnecting a group of wires or cables,
maximum system flow and to protect the hydraulic system
tag each one to ensure proper identification during re-
components.
assembly.
The filter is mounted on the oil reservoir, and is a replaceable
When shims are removed, tie them together and identify
canister type return oil filter. The filter must be serviced with
them as to location. Keep shims clean and flat until they are
National Crane replacement elements at recommended
reinstalled.
intervals to assure the warranty remains in force.
Welding Precautions Oil Cooler Service & Maintenance (Optional)
Sensitive truck computer system and crane's jib load limiting
The heat exchanger must be kept clean to allow for efficient
device computer system components may be damaged by
operation of the cooler system. Frequent washing of the
welding on the truck or crane. The following precautions
heat exchanger core will eliminate oil film, road dirt and other
should be taken:
foreign object buildup on the heat exchanger fins which
• Disconnect truck battery cables (positive and negative) reduces cooling efficiency.
• Attach welding ground lead as close as possible to area Frequent inspection and tightening of hose clamp line
to be welded. connections will eliminate the possibility of end connection
failure due to back pressure from cold startup.
• Remove the jib from the crane before welding on the
crane or remove the jib sheave case assembly from the If cooler system fails to provide adequate performance,
jib before welding on the jib. reduced air or oil flow through the heat exchanger is the
probable cause. The cooling fan should be inspected for
Hydraulic Oil Reservoir proper operation. Any obstructions to air flow should be
corrected (cooler too close to other truck components,
The hydraulic oil reservoir has a sight gauge located on the
foreign matter in heat exchanger fins, etc.) All hydraulic lines
side of the reservoir. This sight gauge has a decal beside it
should be periodically checked for obstructions, hose kinks
that indicates a “full” level and an “add oil” level. The oil
or other flow restrictions.
required to bring it from the “add” line to the “full” line is 5
gallons. Do not fill the reservoir above the “full” line. The oil
level should be checked with the crane parked on a level
surface, in the transport condition (all cylinders retracted and
boom stowed) and the oil cold.

SERVICING THE CONTROL VALVES 8. When all valve sections are positioned on assembly
studs, replace stud nuts and tighten evenly to 32 ft-lb
Disassembly And Reassembly Of Control (43 N.m) torque for crane valve and 25 ft-lb (34 N.m)
Valves To Replace Seals torque for winch valve.
NOTE: If stud nuts are not tightened to the proper torque,
NOTE: For clarification, the inlet cover containing the main
valve spools may bind or stick, or cause section
relief is called the left side of the valve assembly.
1. Before disassembly, numerically mark each valve for
correct reassembly.
seals to extrude.
Replacing Spool Seals

2
2. Remove threestud nuts from the end section. Valve sections and covers are identified by numbers cast into
the body.
3. Remove valve sections by sliding from assembly studs.
1. Remove bonnet assembly parts from back of valves and
4. If valve sections are to be added or removed, use the
keep in order of disassembly.
proper length stud.
2. Remove all parts connected to the spool on the front of
NOTE: Use assembly nuts, three required, with all
the valve.
assembly studs. No lockwashers! All studs are
stress-proof material and should be replaced only NOTE: Do not remove the spool because the seals can be
with original equipment replacement parts. replaced externally. To prevent the spool from
turning, insert a screw driver through clevis slot. Do
5. Thoroughly clean o-ring counterbores and ground
not hold the spool with a wrench. This will destroy
surfaces of each section.
the finish.
6. Replace the four o-rings for crane valve, the three
3. Remove retainer plate, retainer plate washers, back-up
o-rings for the winch valve, and seals. There are two
washers, and spool seals.
seals per section. Buna-N seals are standard.
4. Thoroughly clean counterbore.
7. Replace the valve sections on assembly studs in the
same order in which they were removed. 5. Lightly oil new seals. Slide over valve spool and insert in
seal counterbore.
NOTE: Use care in replacing valve sections to avoid
dislodging o-rings from counterbores.
Backup Washers
Spool Seal
Bonnets
Assembly
Crane Valve Cover Retainer Plate
10 ft-lb (13.5 N.M)
Winch Valve Cover
5 ft-lb (6.7 N.M)
Work
Ports
Outlet
Cover
Crane Valve Cover
10 ft-lb (13.5 N.M) Spool Action
Winch Valve Cover Bonnets
5 ft-lb (6.7.8 N.M)
Inlet Cover
Outlet
Inlet
NOTE: Remove cap

to adjust main relief. Linkage End
Main Relief of Spool

Unloader Valve Service In the event that one of these three functions do not operate
or operates with a delay and the crane is not overloaded or
Refer to ATB System Diagnosis if an electrical problem has two-blocked, the following air purging procedure should be
occurred. followed. If no improvement is seen after completing the
This crane has three work sections equipped with unloader following procedure twice, follow the troubleshooting steps
(dump) valves. The functions connected to the unloader outlined for checking and inspecting the solenoid valve and
valves are winch up, boom down and boom extend. The unloaders in this hydraulic circuit outlined below.
purpose of these unloaders is to stop control oil from 1. Purposely trip the ATB switch to open the solenoid
reaching the functions in the event of a two-block occurrence (dump) valve.
or overload condition. Hydraulic lines extend between the
unloader valve on each of these sections to a single solenoid 2. Operate winch up, boom down and boom extend
(dump) valve. The hydraulic oil in these lines can drain out separately for about a minute, longer if the oil is cold.
over a period of time, when the pump is not engaged, or may 3. Operate all three functions simultaneously.
be lost during servicing the unit. Air may enter these lines at
such a time. If the unloader hydraulic lines have air in them, 4. Release the ATB switch.
these three functions may not operate or may exhibit a delay 5. Check the operation of each function.
in their operation.
6. Repeat procedure if necessary.
NOTE: Internal parts of the unloader valves are not
serviceable. In the event that one of these three functions will not operate
and the crane is not overloaded or two- blocked, the
following procedure is used to diagnose the problem.
Disconnect drain line from the

outlet end of the unloader valve.
Install cap fitting to the plug outlet

end of the unloader valve.
Operate the function.
Function operates correctly.
NO YES
Oil is passing through the check The poppet in the unloader is not
valve in another unloader. seated correctly. remove unloader and
flush to dislodge contamination.
Cap each of the other unloaders in

turn to identify the unloader with Reinstall, retest and replace unloader
the faulty check valve. if problem persists.
Flush to remove contamination

otherwise replace unloader valve.

CONTROL VALVE RELIEF ADJUSTMENT Some valve sections include work port reliefs. The work port
reliefs are shim adjustable. Adjustment is made by adding or
The control valves supplied on this crane are equipped with taking out shims. Adding a 0.010 shim will increase pressure
adjustable relief valves. After some time of use, it may be 100 psi (0.68 MPa). See “Specifications” section for correct
necessary to make some adjustment in pressure because of pressure settings.
spring weakening, etc. The relief valves are adjustable only
through a specific pressure range. Never set pressure above recommendations.
Both the inlet and mid-inlet of the main control valve and inlet
of the winch valve have screw adjustable main relief valves.
2
Turning the relief in increases pressure relief setting; turning WARNING
the relief out decreases pressure relief setting. If the machine does not perform properly at these
pressures, the problem is not the relief valve and no
The turn circuit pressure can be checked by plugging a port
attempt should be made to readjust the setting. It the relief
on the turn motor with a pressure gage. The pressure on the
valves are set to higher pressures than those listed
main control valve stack should be checked by booming the
above, the warranty on the machine is void. Also the
lift cylinder down against the end of the cylinder stroke. The
machine could operate in a manner such as to endanger
winch circuit pressure can be checked by plugging a port on
personnel safety.
the winch motor with a pressure gage.
O-RING FACE SEAL

O-RING BOSS
O-RING O-RING B
B
A FACE (REF) BOSS (REF)
A
O-RING FACE SEAL FITTING SIZE O-RING BOSS

MFGR
THREAD B inches A inches TUBE ’S A inches B inches THREAD
SIZE (mm) (mm) O. D. SIZE (mm) (mm) SIZE
CODE
9/16-18 0.07 (1.78) 0.301 (7.64) 0.250 4 0.351 (8.92) 0.072 (1.83) 7/16-20
11/16-16 0.07 (1.78) 0.364 (9.24) 0.375 6 0.458 (11.63) 0.078 (1.98) 9/16-18
13/16-16 0.07 (1.78) 0.489(12.42) 0.500 8 0.644 (16.36) 0.087 (2.21) 3/4-16
1-14 0.07 (1.78) 0.614 (15.60) 0.625 10 0.755 (19.18) 0.097 (2.46) 7/8-14
1 3/16-12 0.07 (1.78) 0.739 (18.77) 0.750 12 0.924 (23.47) 0.116 (2.95) 1 1/16-12
1 7/16-12 0.07 (1.78) 0.926 (23.52) 1.000 16 1.171 (29.74) 0.116 (2.95) 1 5/16-12
1 11/16-12 0.07 (1.78) 1.176 (29.87) 1.250 20 1.475 (37.46) 0.118 (3.00) 1 5/8-12
2-12 0.07 (1.78) 1.489 (37.82) 1.500 24 1.720 (43.69) 0.118 (3.00) 1 7/8-12
NOTE: Contact your National Crane Distributor or Manitowoc Crane Care for O-Ring boss seal kits.


500E2 SERVICE MANUAL ELECTRIC SYSTEM
SECTION 3
ELECTRIC SYSTEM
the 3rd section sheave case. The wire then loops around the
ANTI-TWO BLOCK SYSTEM DESCRIPTION clamp arrangement on the sheave case and routes through
access holes in the side plate of the boom. The wire
The anti-two-block system provided on your National Crane terminates at a quick connect three conductor plug designed
can help prevent cable damage by sensing the position of for anti-two-block switch or jib interface.
the winch cable end attachments with respect to the sheave
case and disabling the functions that can cause a two block
ANTI-TWO BLOCK INTERNAL WIRE REPAIR
condition.
In the event of a break in continuity of the anti-two-block wire
The anti-two-block system consists of normally open, work
routed internally in the boom, the anti-two-block hydraulic
port unloader valves in the main and winch control valves.
When the cartridge solenoid is energized, the crane
system will sense a problem and make certain crane 3
functions inoperative. Before repair or replacement of
functions normally, when de-energized, the oil to the boom
internal wire, check for continuity loss at the anti-two-block
extend, boom down, and winch up crane functions are
switch, damaged, missing, or corroded connectors and
diverted to tank. These solenoids are controlled by a limit
overall system condition. Due to the environmental
switch, which is attached to the boom or jib sheave case.
exposure of the system, a thorough check of the circuit
This switch is held in the closed position by a chain
should be performed.
suspended weight. The weight, which is looped around the
winch cable, causes the contacts to remain closed until the The procedure for removal and reinstallation of the anti-two-
winch cable end attachments contact the weight and release block wire can be accomplished using two different methods
the tension on the switch. At this point the contacts in the depending on the severity of the damage. Alternative #1
switch open, breaking electrical continuity through the circuit should be used if the wire has experienced a continuity
provided by the internal anti-two-block cord routed through failure in one or both of the conductors, but the rubber jacket
the boom. When this continuity is broken, the unloader of the wire is still intact. Alternative #2 is to be used if the wire
cartridges de-energize and divert the function oil to tank. An has been completely cut or either end of the wire is
indicator light is provided on the control console to alert the inaccessible.
operator when a two-block condition is detected.
On machines equipped with an optional Load Moment THREE SECTION BOOM ATB WIRE REPAIR
Indicator (LMI) System, the anti-two-block system is integral
with the LMI wiring and display. An audible, visual warning of
the two block condition is provided in the display console.
See LMI Operators Handbook for additional information. WARNING
Do not, under any circumstances, work at an elevated
Normal functioning is restored by winching down (or height without using proper fall protection as required by
retracting boom) until the weight is once again suspended local, state or federal regulations
freely. Occasionally if the winch up and boom extend
functions are operated at maximum speed in the dump
Alternative #1
mode, the back pressure induced in the circuit will cause the
winch up or boom extend functions to creep slightly (with no This procedure pulls the replacement wire through the boom,
load on the hook). Such a condition is not cause for alarm, as following the path of the defective wire.
the back pressure is not of sufficient magnitude to damage
the cable or end connections. Special tools or equipment:
• Two end-to-end electrical butt connectors
Anti-two Block Operation
• Shrink tube or electrical tape
The internal anti-two-block wire is routed from the control
console to the winch mount end of the boom, following the Proceed as Follows:
path of the extend cables to the rear of the 3rd section boom. 1. Retract boom completely.
This is the length of the wire that proportions in and out with
2. Loosen and remove capscrew and cable clamp
the boom length, similar to the route of the extend cables. At
arrangement from sheave case attachment point of anti-
this point at the rear of the 3rd section, the wire loops around two-block wire. Remove quick connect plug on anti-two-
and anchors at the anti-two-block cable clamp on the extend block wire by unscrewing base of plug and
cable anchor. The anti-two-block wire, now attached at the disconnecting individual wires from connections. Note
rear of the 3rd, runs the length of the section and attaches to

ELECTRIC SYSTEM 500E2 SERVICE MANUAL
pigtail length at this time and wire / terminal number 14. Visually inspect interior routing of anti-two-block wire for
location for proper reassembly. excess slack in wire, inaccurate routing of wire, etc.
correct any problems before boom operation.
3. Pull end of anti-two-block wire through side plates of 3rd
section boom to gain in-line wire path. Alternative #2
4. Attach replacement anti-two-block wire to damaged wire This procedure is to be used for anti-two-block wire
with a temporary splice, securing the conductors with replacement in the event of a complete separation of the
end to end butt connectors and shrink tube or electrical wire, or the inability to access one or both of the ends outside
tape. This connection must be secured well enough to the boom assembly. This procedure routes a new anti-two-
pull the new wire through the boom. block wire through the boom without having an existing wire
5. At the winch mount end, reach into the rear of the boom to pull it through (Alternative #1).
and loosen the capscrew on the anti-two-block cable
Special tools or equipment:
clamp enough to let the cable run around it with minimal
effort. This clamp is located on the extend cable anchor. • Electrical tape
6. Disassemble spade bolt anchor attaching anti-two-block • Installation tool
wire to the extend cable plate on the winch mount end of To route the wire the entire length of the boom, a long tube,
the boom. to be used as a installation tool, must be utilized to transport
7. Pull wire from winch mount end. Replacement wire the end of the anti-two-block wire from one end of the boom
temporary splice may need assistance reeving around assembly to the other. A telescopic grease applicator for the
anti-two-block cable clamp in rear of 3rd section. If boom, hydraulic tubing or electrical conduit are all
excessive force is needed to pull wire through, observe possibilities for an installation tool. The installation tool
wire routing and make adjustments as needed to avoid should be at a minimum 2’ (61cm) longer than the retracted
breaking temporary splice. If splice fails at this point, boom assembly.
wire routing Alternative #2 should be used. 1. Retract boom completely.
8. Pull wire through boom, leaving enough wire on sheave 2. Loosen and remove anti-two-block cable clamp
case end to properly attach and terminate wire. arrangements from sheave case and 3rd section extend
9. Tighten anti-two-block wire clamp located in rear of 3rd anchor. Remove spade bolt anchor from extend cable
section. anchor plate in the winch mount end of boom.
10. Route sheave case end of anti-two-block wire around 3. Remove quick disconnect plug on anti-two-block wire by
clamp in sheave case, and through holes in side plates. unscrewing base of plug and disconnecting individual
Pulling on this end will tension the static length of anti- wires from connections. Note pigtail length at this time,
and wire/terminal number location for proper
two-block wire clamped in the 3rd. Approximately 15-25 reassembly.
lb (6-11 kg) will be sufficient to provide proper operation.
Tighten sheave case anti-two-block wire clamp. 4. Pull anti-two-block wire out of boom assembly. Visually
inspect boom interior from both ends to verify all the
11. Reassemble quick disconnect plug to anti-two-block cable has been removed from the boom. Visually
wire. Proper wire attachment is critical for proper anti- inspect center sheave on extend cylinder for damage.
two-block system operation.Consult electrical schematic
in this book for proper connector wiring. 5. Start installation of replacement wire on the sheave case
end of the boom assembly. Using electrical tape, attach
12. Temporary splice should now be approximately 10 feet one end of replacement wire to the end of the installation
(3 m) past the winch mount end of the boom. Break tool.
splices and slide strain relief/cord grip onto wire, into
approximate position inside the boom. 6. Insert installation tool and wire into sheave case in the
center open area between the sheave case side plates.
13. Assemble spring and spade bolt to cord grip and Visually guide the wire and installation tool over the
reassemble anchor components to extend cable anchor center sheave on the extend cylinder sheave case.
plate on the winch mount. Slide cord grip up anti-two-
block wire into boom to increase spring tension on 7. Push installation tool and wire through boom until it
moving length of anti-two-block wire. Approximately 2" appears at the winch mount end, detach wire from
(50 mm) of spring extension tension should be adequate installation tool, route wire through open top of winch
for proper operation. mount and temporarily tie off to a convenient anchor
point. Pull installation tool out sheave case end of boom.

8. From sheave case end of boom, attach other end of block wire into boom to increase spring tension on
replacement wire to installation tool with electrical tape. moving length of anti-two-block wire. Approximately 2"
Insert installation tool and wire into the boom sheave (50 mm) of spring extension tension should be adequate
case, in the open area between the sheave case side for proper operation.
plates. Visually guide this end under the center sheave
20. Visually inspect interior routing of anti-two-block wire for
on the extend cylinder sheave case.
excess slack in wire, inaccurate routing of wire, etc.
9. Push installation tool and wire through boom until it Correct any problems before boom operation.
appears at the winch mount end. Do not detach wire
from installation tool. HYDRAULIC CAPACITY ALERT SYSTEM
10. From winch mount end of boom, locate installation tool This hydraulic capacity alert system uses the work port
and attached wire, and pull the wire out of the boom unloader solenoids in the anti-two-block system as the
section, removing the slack loop from the sheave case hydraulic system dump circuit.
end of the boom. This will place the wire close to, if not
on the center sheave of the extend cylinder. The hydraulic capacity alert system has an override switch
3
a n d b u t t o n l o c a t ed o n t h e o p e r a to r ’s c o n s o l e t h a t
11. Move to the sheave case end of the boom. Visually momentarily overrides the hydraulic capacity alert and anti-
determine if the wire has properly located itself onto the two-block systems and restores power to crane functions.
sheave. If not, manipulate the wire placement through
the end of the boom and place the wire on the sheave. A When trip pressure is reached, the pressure sensing switch
5' (1.50 m) long access tool (hook end) will simplify this breaks electrical continuity to the work port unloader
procedure greatly. solenoid in the main control valve.When power is removed
from this solenoid, the unloader valves allow the oil flowing to
12. From the winch mount end of the boom, assemble the winch up, telescope out and boom down to flow to tank. This
anti-two-block wire clamp on the extend cable anchor in path to tank will prevent further operation of these functions.
the rear of the 3rd section. Loop anti-two-block wire When the overload condition is corrected by winching down,
around clamp and lightly tighten capscrew holding retracting the boom, or raising the boom, the pressure
clamp together. Keeping a slight amount of tension on sensing switch allows the work port unloader solenoids to be
the wire at this point will keep the wire properly located powered thereby allowing the crane to function normally.
on the sheave.
HCA Maintenance & Repair
13. From the sheave case end, pull the installation tool and
wire end out of the boom. The route of the anti-two- The following step-by-step analysis will be helpful in isolating
block wire in the boom is now complete. and correcting almost every service problem if followed in a
step-by-step systematic manner. Use this information with
14. Pull wire at either end of boom to adjust length of wire on
the Hydraulic Schematic and the Illustrated Parts Catalog to
sheave case end to properly attach and terminate wire.
identify parts and follow flow paths. Start at top box and work
15. Tighten anti-two-block wire clamp located in rear of 3rd downward step by step. Do not try to start in the middle or
section. skip steps.
16. Route sheave case end of anti-two-block wire around

clamp in sheave case and through holes in side plates. 1. Refer to Hydraulic Schematic and System Description to
Pulling on this end will tension the static length of anti- gain a thorough understanding of the capacity alert
two-block wire clamped in the 3rd. Approximately 15-25 system before proceeding with any maintenance.
lb (7-11 kg) will be sufficient to provide proper operation. 2. System adjustment must be checked every three
Tighten sheave case anti-two-block wire clamp. months for accuracy. Refer to the preceding section on
17. Reassemble quick disconnect plug to anti-two-block System Adjustment.
wire. Proper wire attachment is critical for proper anti- 3. Always be sure the boom is adequately supported and
two-block system operation. Consult electrical no hydraulic pressure remains in the lines before the
schematic in this book for proper connector wiring pilot pressure line fittings are loosened.
18. From winch mount end of boom, slide strain relief/cord
grip onto wire, into approximately position inside the HCA System Adjustment
boom. The hydraulic capacity alert system should be checked for
19. Assemble spring and spade bolt to cord grip and proper adjustment during initial crane start-up and quarterly
reassemble anchor components to extend cable anchor thereafter. The procedure for proper adjustment should be
plate on the winch mount. Slide cord grip up anti-two- performed as follows:

NOTE: Trapped air must be bled from the system before .

adjustments are made.
1. Remove the console cover on the operators console. WARNING
. Before loosening any fittings, support the boom.
WARNING 9. When the pressure reaches capacity load pressure, the

overload system should activate and boom extension
Before loosening any fittings, support the boom.
will stop. This is defined as trip pressure. This point
should be at or very close to the red/yellow color change
2. Start the truck and set the crane up for operation as
on the load range gage.
prescribed in the Operators Manual.
10. Trip pressure should be reached as the boom extension
3. Select a test weight that is equal to crane capacity at an
reaches the chosen radius. If the overload system trips
intermediate boom length and radius.
before the chosen radius is reached or allows extension
4. Work with loads which have loaded boom angles near beyond the chosen radius, adjustment is required. If the
30. Starting with the boom at the chosen reference system is activated before trip pressure is reached,
angle and a radius less than the chosen radius, pick the lower the load and turn the knurled collar on the HCA
weight up with the winch and begin extending the boom. pressure switch clockwise to increase trip pressure.
5. As the boom is extending, lower the load with the winch
to keep the load near the ground.
6. Monitor the load range gage located in the console as Cover Operators
the boom is extending. The gage is plumbed directly into
Console
the lift cylinder pilot line and the pressure reading should
increase to what is defined as capacity load pressure as
the selected intermediate boom length and radius is
reached.
Relief
HCA pressure
Adjustment
switch
Knob
11. When the gage reaches trip pressure, turn the setscrew
counterclockwise until the system solenoid is
deactivated and tighten the locking nut.
7. The intermediate boom length is determined by a line 12. Retract the boom until the pilot pressure is reduced
and corresponding dimension decal on the side of the enough to reactivate the system solenoid. The hydraulic
second section boom. The chosen radius is measured capacity alert indicator light will go out when the solenoid
from the centerline of rotation to the loadline. is reactivated.
8. If the gage reading does not increase while extending, 13. Check the trip pressure setting by extending the load
lower the load to the ground and check the system until the chosen radius is reached. As the chosen radius
plumbing according to the hydraulic schematic. is reached, the system solenoid should be deactivated
Re-plumb the system according to the schematic and and the indicator light should come on. Readjust switch
illustrated parts page or replace faulty pressure gage. head if trip pressure is not correct.

14. Once proper adjustment is verified, return the boom to a • error codes
firmly supported position, stop the truck engine and
• current angle reading.
replace covers.
On power-up, the unit first displays the startup codes. The
JIB LOAD LIMITING DEVICE startup codes can be a sequence of up to four single digits,
but is usually be only one digit which is a "2". Each number is
The jib load limiting device is an electromechanical displayed for 1/2 second. The codes are:
maximum capacity sensing system that stops normal crane
functions which cause an overload condition when the • (1) Indicates the unit is being initialized. This only
maximum capacity of the jib is exceeded. In the event that an happens the first time the unit is powered up after it is
over capacity condition occurs, the jib load limiting device is programmed.
actuated by a load cell which causes the boom down, extend • (2) Indicates that the previously stored table is being
out, and winch up functions to become inoperative. On jibs erased. This is displayed when the unit is powered on
with a manually extendable section, a configuration switch
operated by the extension retaining pin distinguishes
and the switches are not set for the new table numbers. 3
between an extended jib and a retracted jib. This system • (3) This is displayed only before a new table number is
allows for continued operation of the winch down, boom up, stored. The “2” is displayed first.
and boom retract. This allows the operator to bring the load • (8) The switches are set up with the new table number
to a shorter operating radius or set the load down in order to and the old number is erased. On the next power on, the
eliminate an overload condition. Once the overload has been new table number is read in and stored.
reduced, normal operation can be resumed. This system
uses the work port unloader solenoid in the anti-two-block After the startup codes, the table number is displayed in the
system as the hydraulic system dump circuit. form of three sequential single digits. The first digit is always
zero. The digits are be displayed for about 1 second each.
When trip force is reached, the jib load limiting device breaks
electrical continuity to the work port unloader solenoid in the After the table number is displayed, the display starts to
main control valve. When power is removed from this sequence through the following information. After reaching
solenoid, the unloader valves allow the oil flowing to winch the end of the sequence, the display starts again at the
up, telescope out and boom down to flow to tank. This path to current load reading.
tank will prevent further operation of these functions. When • Current load reading (lbs.):
the overload condition is corrected by winching down,
retracting the boom, or raising the boom, the jib load limiting - 4 digits, decimal point on
device allows the work port unloader solenoid to be powered • Current limit value (lbs.):
thereby allowing the crane to function normally.
- 4 digits, decimal point flashing
During operation at near capacity loads, care must be taken
to operate the controls smoothly or the system may be • Error codes (only if an error exists):
shocked into the dump mode prematurely. - 4 digits, first and last digits are blanks.
Single Character Display - 0-invalid table number,
The electronics box of the jib load limiting devices equipped - 1-load readings higher than the limit.
with a single character display that provides the following
• Current angle reading:
information:
- 4 digits, decimal point off, displays in tenths of
• startup codes
degrees.
• table number selected
• current load reading
Jib Load Limiting Device Troubleshooting
• current limit value See chart in Section 8 of this manual.


500E2 SERVICE MANUAL BOOM
SECTION 4
BOOM
Item Component
Item Component
5 Extend Cable Anchor
1 Extend Cable Adjustment
6 RetractAnchor
2 Section 1
7 Section 2
3 Retract Cable
8 Section 3
4 Retract Cable Adjustment
9 Tip
THREE SECTION BOOM OPERATION section, therefore providing retraction of the 3 rd boom
section. This type of boom operation provides that the 2nd
A rod-fed, double-acting cylinder, attached to the 1st and 2nd
and 3 rd section booms extend and retract equally. Proper
boom sections, supports and propels the 2nd boom section.
service and maintenance is required to insure smooth and
The extend cables attach to the base end of the 1st boom proper operation.
section, are reeved around sheaves attached to the cylinder,
and attach to the base end of the 3rd boom section, providing Special Boom Inspection
support and extension the 3rd boom section. If the boom has not been disassembled and inspected in the
st
The retract cables attach to the tip end of the 1 boom last five years or 3,000 hours of use, the boom is to be
completely torn down to allow a thorough inspection of the
section, are reeved around sheaves attached to the 2 nd extend and retract cables, sheaves, and pins.
boom section, and attach to the base end of the 3 rd boom

BOOM 500E2 SERVICE MANUAL
THREE SECTION BOOM MAINTENANCE

Three Section Cable Tensioning
After boom reassembly or from time to time if interior
proportioning cables appear loose, cable tensioning may be
required. Tensioning must be done with the boom horizontal.
1. Slightly tighten all cables. Then cycle the boom
approximately 4 feet (120 cm) out and in a few times to
equalize the extend and retract cable/ boom section
sequence positioning.
2. Fully retract boom. Do not induce and hold hydraulic
pressure. At full retraction, observing through the winch
mount end of the boom, the second section should be
bottomed on the extend cylinder butt plate, and the third
section should be bottomed on the thick vertical side
plates welded to the inside of the second section.
NOTE: It is important to achieve these boom postitions

before torquing. Item Component
3. If the boom sections do not bottom out as specified 1 Winch
(boom is out of sequence), adjust cables to achieve
proper section positioning. 2 Boom
3 Capscrew (6 plcs)
4. Torque retract cables to 6 ft-lb (8.13 Nm). Cable
adjustment point is located at the sheave case end of 4 Hyd Hose 1
the boom, on the bottom of the 1st section. Use the flats
5 Winch Down Hose 2
at the front of the cable ends to keep the cables from
turning while torquing retainer nuts. 6 Winch Up Hose 3
5. Torque extend cables to 20 ft-lb (27.11 Nm). Cable 7 Winch Alignment Ears
adjustment point is located at the rear of the boom on
the cable anchor bar going through the winch mount. 3. Remove hook block or downhaul weight. Wind up rope
6. Repeat Steps 4 and 5. on winch drum and stow wedge socket on pegs provided
on 1st section. Shut down truck engine.
7. Torque the retract cables to 12 ft-lb (16.26 Nm).
4. Tag and remove the hydraulic hoses (the inside hose
8. Torque the extend cables to 30 ft-lb (40.67 Nm). “up” and the outside “down”). Cap all hoses.
9. Cycle the boom fully, check that all cables are torqued 5. Pull hydraulic hoses through the access hole towards
properly and that all sections are retracted completely, turret.
then add jam nuts to all cables. All threaded cable ends
must be equipped with retainer nuts and jam nuts.
WINCH REMOVAL
CAUTION
The combined weight of the winch and 325 ft. of wire rope
is 660 lbs (300 kg).
DANGER
Do not, under any circumstances, work at an elevated 6. Remove Rope Guard mesh and attach suitable lifting
height without using proper fall protection as required by device to winch and take up the slack.
local, state or federal regulations. 7. Remove 6 mounting capscrews and washers (3 on each
side).
1. Extend and set the outriggers.
8. Lift winch clear of boom and secure to a suitable holder.
2. Fully retract the boom and place in a horizontal position.

BOOM REMOVAL Boom Disassembly Alternative #1

1. Gaining access through rear of boom, loosen capscrews
Cg From Pivot
Boom Length Boom Weight retaining the extend cable anchor in the rear of the 3rd
Point
section as well as the capscrew on the anti-two-block
71 ft (21.6 m) 5145 lb (2334 kg) 140 in (3.56 m) wire clamp on the anchor assembly.
60 ft (18.2 m) 4660 lb (2113 kg) 19 in (3.02m) 2. Extend boom 24 inches (60 cm). Loosen and remove
the nuts which secure the extend cables to the cable
1. Extend and set machine outriggers. Boom must be
anchor plate. Remove nut from anti-two-block spade
completely retracted and stowed in the boom rest.
bolt. Tag and disconnect hydraulic lines to the extend
2. If equipped, remove swing around jib. See Section 4 cylinder.
Operator’s Handbook, Section 4.
3. Drape extend cables and anti-two-block cable inside
3. Remove hook block or downhaul weight. Wind up rope boom, and slide cable anchor plate out of the side of the
on winch drum and stow wedge socket on pegs provided winch mount if winch has been removed from boom.
on 1st section. Shut down truck engine.
4. Loosen and remove two capscrews, lockwashers and
4. Attach a lifting device to rod end of lift cylinder, remove spacers which anchor the extend cylinder rod butt plate
boom lift cylinder pin keeper and pin from bottom of the to the rear of the 1st section.
1st section boom. Lower lift cylinder to a suitable
5. Loosen and remove two capscrews and lockwashers
support.
securing spacer bar to the inside top of the front of the
5. Tag and disconnect extend cylinder lines and winch 1st section. Remove spacer bar.
hydraulic lines. Cap all open lines and ports.
6. Loosen and remove four capscrews securing wear pads
6. Attach a lifting device to provide even weight distribution to the bottom of the 1st section. Removal of side wear
and raise the boom until weight is removed from the
boom pivot pin. Remove boom pivot pin keeper and
pads is optional. Adequate clearance exists between
adjoining section side pads for boom disassembly. If
4
boom pivot pin. Lift boom free of turret. side pad removal is required, tag all pads, shims, and
corresponding locations for proper reassembly.
Boom Disassembly
7. Support 2nd 3rd assembly at the front with an appropriate
The 500E2 boom can be disassembled by using two different lifting method. Raise the 2nd 3rd assembly inside the 1st
methods. Alternative #1 disassembles the boom in the section to allow for front bottom pad removal. Remove
conventional manner. Alternative #2 removes the extend bottom wear pads.
cylinder from the rear of the boom, after removal of the
8. With the 2nd & 3rd assembly supported, slide assembly
winch. This feature facilitates cylinder service without
out of the 1st. Relocation of the sling point on the 2nd &
complete boom teardown.
3rd assembly will be necessary for proper balancing of
For reference, the front of the boom refers to the sheave the assembly as it slides out of the 1st section. Keep
case end, the rear of the boom is the winch mount end. Left tension on retract cables as the assembly is pulled out of
and right are viewed from front to rear. the 1st, to minimize the chance of retract cable damage.
If the boom is to be unpinned from the turret of the crane 9. Place 2nd & 3rd assembly on a suitable horizontal
structure, please refer to the Boom Removal Procedure surface. Take care not to pinch or crush retract cables
section in this book. If the required service procedure is to be while lifting or supporting assembly.
performed on the boom while still pinned to the turret, please
10. Remove top rear wear pads on the 2nd section. They will
follow these directions.
lift off the cam plates easily. Do not remove or loosen the
capscrews holding the cam plates to the section. This
will affect side clearance during re-assembly.
DANGER 11. Loosen and remove four capscrews securing the rear
Do not, under any circumstances, work at an elevated bottom wear pads on the 2nd section. This pad serves as
height without using proper fall protection as required by a bottom and side pad as well as the retract cable
local, state or federal regulations. keeper under the retract sheaves. Removal of this pad
will allow the retract cables to uncoil off the retract
sheaves. Place retract cable ends in a location to
minimize the possibility of damage.

12. Loosen and remove six capscrews securing retract 24. Loosen and remove all remaining capscrews and wear
sheave pin and retract sheaves to 2nd section. Remove pads from boom sections.
sheaves and pins.
13. Loosen and remove two capscrews functioning as upper BOOM DISASSEMBLY ALTERNATIVE #2
retract cable keepers. The 500E2 boom design allows for removal of the extend
14. Loosen and remove two capscrews securing lock bar to cylinder from the rear of the boom without complete
the extend cylinder collar. This bar constrains the disassembly of the boom sections. This procedure allows
vertical movement of the extend cylinder. Remove bar. quick access to the cylinder, retract cables, and various
internal boom components for service or replacement.
15. Loosen capscrews retaining extend cable anchor to
back of the 3rd section. Total removal of the capscrews
will allow the cable anchor to be completely
disassembled, backing capscrews out approximately DANGER
.50 inch (12 mm) will allow the anchor assembly to slide
Do not, under any circumstances, work at an elevated
rearward out of the section as the extend cylinder is
height without using proper fall protection as required by
removed.
local, state or federal regulations.
16. Support extend cylinder with an appropriate lifting
device and pull the extend cylinder out of the boom while 1. Remove winch. Please refer to the winch removal
keeping the extend cables and anti-two-block wire section in this book.
tensioned slightly by hand to minimize the possibility of
2. Gaining access through rear of boom, loosen capscrews
damage to the cables. Pull cylinder to within 3 feet (91
retaining the extend cable anchor in the rear of the 3rd
cm) of complete removal from the boom sections.
section as well as the anti-two-block wire clamp on the
17. Reach into the rear of the 3rd section and loosen and anchor assembly. Loosen and remove two capscrews
remove the anti-two-block cable clamp on the extend retaining lock bar to extend cylinder. Remove lock bar
cable anchor. Pull the extend cable anchor out from its
3. Extend boom 24 inches (61 cm). Loosen and remove
retaining pocket on the bottom of the 3rd section. A slight
the nuts which secure the extend cables to the cable
angle applied to the anchor as it is being pulled to the
anchor plate. Remove nut from anti-two-block spade
rear will permit easier removal through the 2nd section.
bolt.
18. Remove the extend cylinder from the boom.
4. Drape extend cables and anti-two-block wire inside
a. Do not allow sheaves to fall off the pin on th end of boom, and slide cable anchor plate out of the side of the
th extend cylinder. winch mount.
b. Remove extend cables. Place cylinder and cables in 5. Loosen and remove two capscrews, lockwashers and
suitable area to prevent possible damage. spacers which anchor the extend cylinder rod butt plate
to the rear of the 1st section.
19. Remove retract cables from the back of the 3rd section
by manipulating cable end through the slot in the anchor. 6. Using appropriate lifting device, lift extend cylinder up
Place cables in location to prevent possible damage. and out of retaining slot on rear of 2nd section.
Retracting cylinder with an external hydraulic power
20. Anti-two-block wire can be removed if necessary by source during this step may be necessary.
disassembly of the clamp arrangement at the sheave
case and pulling wire through boom. 7. Pull cylinder out through rear of boom assembly
approximately one-half the length of the cylinder.
21. Loosen and remove two capscrews, cable guide, wear Turning of the butt plate and rod 90 degrees may aid in
pad and spacer bar from the front top of the second sliding cylinder through winch mount area. Keep extend
section. cables tight to minimize the possibility of damage.
22. Loosen and remove four capscrews attaching the 8. Lift extend cylinder up until it contacts inside of boom
bottom pad plate to the second section. Slightly lift third section. Remove anti-two-block wire clamp from extend
section, and remove pad plate. cable anchor. Remove anchor by pulling anchor and
23. Slide 3rd section out of 2nd section. Removal of side cables out rear of boom. A slight angle applied to the
pads is optional, as the side pads have adequate anchor as it is being pulled to the rear will permit easier
clearance for boom disassembly. If removal of side pads removal.
is required, tag all shims, pads and corresponding 9. Continue to pull extend cylinder and cables out of rear of
locations for proper re-assembly. boom. Remove extend cables and store in an area to
minimize the possibility of damage.

Additional Maintenance, Disassembled 6. Install front side wear pads with appropriate shims,
Boom between 3rd and 2nd sections. If boom has been
disassembled, and no sections have been replaced, use
1. Clean all boom sections and inspect for wear, dents, same shim quantity and location as was previously
bent or bowed boom sections, gouged metal, broken used.
welds or any abnormal conditions. Repair or replace as
7. Route anti-two-block wire through 3rd section, keeping
required.
bulk of wire at the rear of the boom sections. Routing
2. Inspect all sheaves for excessive groove wear or can be accomplished using an installation tool, such as
abnormal rim wear. Replace as required. a telescopic boom grease applicator, electrical conduit,
or hydraulic tubing. Route anti-two-block wire between
3. Inspect all sheave bearings for excessive wear or cut
sheave case side plates. If locations are in question,
liner material. If installed bearing diameter is .015 inch
refer to Shim Calibration Section in this manual.
(.38 mm) larger than the pin diameter, bearing must be
replaced. Any cut or gouge which causes the bearing 8. Uncoil retract cable assemblies, and insert button end
liner to be distorted is cause for bearing replacement. into anchors in back of the 3rd section. Place uncoiled
cable in area that will minimize the potential for damage.
4. Clean and inspect all cable assemblies according to the
wire rope inspection procedures in this section. Pay 9. Assemble retract sheaves and retract sheave pins in
particular attention to any wire breakage within 6 feet rear of 2nd section. Coat surfaces of bearings with
(180 cm) of the end connections. Replace cable grease before assembly.
assemblies as required. Lubricate all cable assemblies
10. Place retract cables over top of retract sheaves. Install
before reinstalling them in the boom.
keeper capscrew above sheave to hold retract cables in
5. Inspect all sheave pins for nicks, gouges or pitting due to place.
rust in the bearing surface area. Replace if any damage
11. Reeve cables over retract sheave and install keeper/
6.
is evident.
Inspect anti-two-block wire full length for damage, check
wear pad to bottom rear of 2nd section. This pad acts as
a side pad, bottom pad, and a cable retainer.
4
for electrical continuity.
12. Assemble exterior extend cylinder components. Install
and center sheave pin into butt plate of extend cylinder.
THREE SECTION BOOM ASSEMBLY Install bearings into extend cable sheaves. Coat surface
NOTE: Do not use Loctite on any cable threaded ends. of bearings with grease and assemble extend sheaves
Always use the locknut and nut provided. on sheave pin.
When initially assembling threaded ends of cables, 13. Wrap approximately 10 feet (300 cm) of each 5/8 inch
thread the first nut on past the flat in the cables so (15.88 mm) diameter extend cable around extend
adjustment can be made later. sheaves and install extend cable anchor. Do not tighten
capscrews clamping anchor together completely. These
Refer to Inner Wear Pad Calibration on page 4-7 of capscrews if tightened completely will not allow cable
this section to determine Wear Pad shim thickness. anchor to install into 3rd section. Route anti-two-block
cable over center sheave on extend cylinder.
1. Assemble sheaves into 3rd section sheave case. Top
sheave is to be installed to the left hand side of the boom 14. Install wear pad over extend cylinder sheave side plates.
with the spacer to the right hand side. This serves as a wear pad to keep the end of the extend
cylinder centered in the boom, as well as an extend
2. Attach rear wear pads on bottom of 3rd section. Using
cable retainer.
Loctite 242 blue, Loctite all wear pad mounting
capscrews. 15. Slide extend cylinder /extend cables into 2nd/3rd boom
assembly enough to assemble extend cable anchor into
3. Install 3rd section boom into 2nd section. Slide together
bottom rear of 3rd section. Route anti-two-block cable
approximately 5 feet (150 cm).
over extend cable anchor as anchor slides into 3rd
4. Assemble bottom front wear pads for 2nd section and section. Be aware of extend and anti-two-block cable
Teflon plugs. Attach pads to pad plate. location when inserting cylinder into boom sections,
inadvertent crushing or other damage to cables will
5. Using appropriate lifting device, lift 3rd section to allow
warrant replacement.
for wear pad/pad plate installation in front of 2nd. Install
wear pad/pad plate assembly. Slide sections together 16. Tighten capscrews clamping extend anchor together.
within 12 inches (30 cm) of full retraction. These capscrews will protrude through the 3rd section
bottom plate, locking the anchor in position.

17. Loop anti-two-block cable at the extend cable anchor in cables through holes in anchor and assemble hex nuts
the 3rd and install anti-two-block cable clamp. Do not onto threaded ends.
completely tighten clamp capscrew.
31. Assemble top/rear wear pads to the top of the 2nd and
18. Assemble anti-two-block clamp in the sheave case. 3rd boom sections with the cam plates.. Wear pads can
Reeve anti-two-block cable around anchor and through be inserted from the winch mount end of the boom.
holes in side plate of sheave case. Pull approximately 2 Install capscrews through holes in outer boom sections.
feet (60 cm) of cable out the end of the boom for proper
32. The wear pad on each side at the top/rear of the boom
routing and termination.
can be adjusted over a range of 3/16" (4.8 mm) by
19. Tighten anti-two-block clamp on the extend cable anchor rotating, end for end, the wear pad and plate or the wear
in the rear of the boom. Tension anti-two-block cable pads and plate independently. This is possible because
from the sheave case end of the boom, and tighten anti- the holes in these parts are offset from the center. The
two-block clamp located in sheave case. holes are .06" (1.5 mm) off center in the plate and .03"
(.8 mm) off center in the wear pad. Various combinations
20. Visually verify that the extend and anti-two-block cables
of rotation of these parts allow the adjustment.
are properly routed on their sheaves and continue to
slide the extend cylinder and cables into the boom a. Adjust pads until they are within .03” (.8mm) off
sections. Keep extend and anti-two-block cables center in the were pad. Various combinations of
supported and slightly tensioned during insertion of rotation of these parts allows the adjustment.
cylinder, to maintain proper cable placement.
b. Torque retainer capscrews to 110 ft-lb (149 N-m).
21. As the extend cylinder keeper plate nears the 2nd Failure to properly torque capscrews will cause loss
section, adjust the height of the cylinder to allow the of preload and cause excessive side clearance
cylinder to access the cylinder keeper cutouts in the between sections.
doubler plates on the sides of the 2nd section.
33. Approximately 10 feet (300 cm) of anti-two-block cable
22. Drop the cylinder down into the vertical cutouts in the will be available on the winch mount end of the boom to
doubler plates on the sides of the 2nd section. route and hookup to the control console wiring. Find the
end of this cable and slide the cord grip/strain relief
23. Install lock bar and capscrews to the extend cylinder.
hookup onto it and slide it up the cable into approximate
24. Position 2nd/3rd/ cylinder assembly in position to be position inside the boom.
inserted into 1st section. Lay retract cables out under
34. Assemble the extension spring and spade bolt to the
2nd/3rd/ cylinder to allow easy installation as the booms
cord grip. Assemble the spade bolt through the extend
are assembled.
cylinder anchor with a hex nut. Adjust tension on anti-
25. Slide 2nd/3rd/ cylinder assembly into 1st section boom two-block cable by sliding cord grip down cable into the
approximately 2 feet (60 cm). Use caution during this boom. Approximately 2 inches (5 cm) of spring
step to keep retract cables straight and on the correct extension should be adequate for proper boom
side of the boom assembly as the sections are operation.
assembled.
35. Visually check each end of boom for proper extend,
26. Continue to slide 2nd/3rd/ cylinder assembly into 1st until retract and anti-two-block cable routing and placement.
it is approximately halfway into 1st. Make certain anti-two-block cable is correctly on
sheave. Inspect from sheave case end.
27. Assemble bottom front wear pads in 1st section, trapping
ends of retract cables in slots on bottom of 1st section. 36. Adjust slack out of extend and retract cables at hex nut
Lift 2nd/3rd/cylinder assembly up to ease installation. adjustment points. Slowly cycle boom in and out several
times. Torque cables per procedure located elsewhere
28. Slide boom together to within 12 inches (30 cm) of
in this book.
complete retraction. Install upper front spacer bar in 1st
section and upper front wear bar and cable guide Three Section Top/Bottom Pad Replacement
assembly to 2nd.
(Assembled Boom)
29. Retract boom completely, using proper hardware and
spacers, connect extend cylinder butt plate to the winch NOTE: Refer to Inner Wear Pad Calibration on page 4-7 of
mount. Hydraulic power source can be utilized at this this section to determine Wear Pad shim thickness.
time if slight cylinder length adjustment is necessary. Inspect top and bottom wear pads periodically for signs of
30. Slide extend cable anchor into position in winch mount. abrasion or excessive wear. Excessive is defined as:
Push threaded ends of 5/8 inch (15.88 mm) extend - 3/16 of an inch (4.76 mm) from the original pad
thickness.

- Top rear pad thickness 0.75 inch (19.05 mm). 3. Loosen and remove the four capscrews holding the pad
doubler plate in between the 3rd and 2nd sections,
- Bottom front 1st section 1 inch (25.4 mm). remove plate, remove pads from this plate. Note all pad
locations and tag accordingly.
- Bottom front 2nd section 0.50 inch (12.7 mm).
4. Loosen and remove the four capscrews holding the
- Uneven pad wear of 3/32 inch (2.38 mm) from side
bottom front wear pads to the 1st section, remove pads.
to side on the wear pad.
Retract cable adjustment ends may have to be loosened
If any of these conditions exist, the top and bottom pads can during this step. Note all pad locations and tag
be replaced without complete disassembly of the boom. accordingly.
Top Rear Pad Replacement 5. If disassembly of cables was required:

- Replace all wear pads.
NOTE: Refer to Inner Wear Pad Calibration on page 4-7 of
this section to determine Wear Pad shim thickness. - Wear pad plate.
1. Retract boom completely. - Re-torque retract cables.
2. Remove capscrews through access holes on top rear of
sections. INNER WEAR PAD CALIBRATION
3. Remove wear pads and cam plates from the rear of the 1. With a pair of inside/outside calipers, measure the inside
boom through open winch mount end. width of the outer section (Wi) at the front and back of
the boom and record the smallest measurement. If the
4. Note all pad locations and tag accordingly. section has cylinder anchor bars, take a measurement
5. Inspect pads for wear using previously mentioned directly in front of these bars
inspection criteria.
6. Assemble top/rear wear pads to the top of the 2nd and 4
3rd boom sections with the cam plates.. Wear pads can
be inserted from the winch mount end of the boom. Wi
Install capscrews through holes in outer boom sections. CYLINDER
ANCHOR BARS
7. The wear pad on each side at the top/rear of the boom
can be adjusted over a range of 3/16" (4.8 mm) by OUTER
rotating, end for end, the wear pad and plate or the wear SECTION
pads and plate independently. This is possible because
the holes in these parts are offset from the center. The
holes are .06" (1.5 mm) off center in the plate and .03"
(.8 mm) off center in the wear pad. Various combinations 2. With the inside/outside calipers, measure the outside
of rotation of these parts allow the adjustment. width of the inner section (W0) at each side pad location.
Record the largest measurement.
a. Adjust pads until they are within .03” (.8mm) off
center in the were pad. Various combinations of
rotation of these parts allows the adjustment.
Wo 2 PLCS
b. Torque retainer capscrews to 110 ft-lb (149 N-m).
TOP
Failure to properly torque capscrews will cause loss
of preload and cause excessive side clearance
between sections.
Wo 1 PLC
BOTTOM
Front Bottom Pad Replacement
NOTE: Refer to Inner Wear Pad Calibration on page 4-7 of
this section to determine Wear Pad shim thickness. INNER SECTION
1. Extend boom approximately 4 feet (120 cm) out.

2. Using an appropriate lifting device, sling around the 3rd
section boom and lift it up until weight is removed from
the bottom pads in the front of the 2nd and 1st boom twp twp
sections.

3. Measure the thickness of the wear pads and record 4. Subtract the largest outside width (W0) of the inner
(twp). section and the thickness of the two pads (twp) from the
inside width of the outer section (Wi). Add shims as
required [each shim is .03 inches (.8 mm) thick) to
tighten the pads so that there is .03 inch -.09 inch (.8 mm
- 2.3 mm) clearance between the widest part of the inner
boom and the most narrow part of the outer boom when
shims and pads are installed. In some cases it will be
necessary to have an unequal number of shims behind
the pads at the top and bottom side pad locations. See
example.
Shim Calculation for Wear Pads (Example)
Wi = 12.12 (308mm) at front

12.06 (306) at backnear
cylinder anchor bars
twp =.52 (13mm)
Wo = 10.94 (278mm) at
top rear pad location
Wo = 11.00 (279mm) at twp =.52 (13mm)

top forward pad location
Wo = 10.94 (287mm) at
bottom rear pad location
Top Rear Bottom Rear

Wi = 12.06 (306 mm) 12.06 (306) mm
-Wo = -10.94 (-278 mm) -10.94 (-278 mm)
-twp = -0.52 (-13 mm) -0.52 (-13 mm)
-twp = -0.52 (-13 mm) -0.52 (-13 mm)
Clearance Before Shims = 0.008 (2 mm) 0.08 (2 mm)
Left Side Shim = -0.03 (-0.8 mm) -0.03 (-0.8mm)
Final Clearance = 0.05 (1.2 mm) 0.05 (1.2 mm)

LIFT CYLINDER REPAIR 5. Using a special drive tool, drive the packing gland into
the barrel assembly to expose the round cross section
Lift Cylinder Disassembly retaining ring. Then use a small needle nose locking
plier to clamp the round cross section retaining ring to
1. Disconnect shaft end of cylinder from machine. prevent it from rotating in the groove. Use two straight
2. Retract cylinder shaft with oil from the hydraulic system blade screw drivers: one to pry the end of the ring out of
until about 12 inches (30 cm) of shaft is extended. The the groove and the other to pry the ring out of the barrel
barrel must be filled with oil to prevent a compressed air assembly.
chamber being formed which could result in injury at 6. Attach a porta-power hand pump or hydraulic line from
disassembly. crane circuit valve to the shaft end of the cylinder. De-
3. Remove the cylinder from the machine and place on burr ring groove edge. Failure to do so will damage
supports with an oil pan directly beneath the cylinder barrel or packing gland.
head area. 7. Operate hand pump or crane circuit valve, preferably the
4. Using the proper size of external snap ring pliers, boom telescope circuit, to force packing gland out of
expand the snap ring completely and remove from barrel.
groove. Slide large washer forward to gain access to the 8. Remove holding valve from cylinder to allow removal of
packing gland. shaft and piston assembly. Remove the shaft and piston
assembly by hand.
Pressure line from a porta-power

or hydraulic line from the crane
circuit valve. Read step 5 and 6 4
before performing this step.
Cylinder Barrel
Retaining Ring
Washer
Snap Ring
Shaft extended
about 12 inches
9. Disassemble the piston set by removing nut, replace 12. Reassemble shaft and piston set assembly in the proper
worn or damaged parts. Note: Loctite 680 is used during order with external snap ring, large washer, internal
original assembly to secure nut to shaft. If necessary, round section ring, assembled packing gland, stop tube,
heat nut to 400-500° F (204-260°C) to facilitate removal. piston to shaft O.-ring, assembled piston, and locknut.
If heat is necessary for removal, discard nut and replace Loctite locknut onto shaft using type 680 according to
with new equivalent nut as well as worn or damaged Loctite recommendations. Torque locknut to 600 ft-lbs
parts. (813 Nm).
10. Wipe and inspect all cylinder internal and external 13. Grease piston assembly and install the shaft assembly
surfaces for damage. with piston, O.-ring, stop tube, packing gland, internal
round ring, large washer, and external snap ring into
11. Remove seals and bearings from packing gland and
barrel assembly.
piston. Replace all seals and bearings.

14. Using special drive tool, drive the packing gland into the 5. Plug retract port in the cylinder butt plate with SAE #8
barrel assembly. O.-Ring boss plug and pull on the rod assembly to force
packing gland out of the barrel assembly.
15. Insert one end of round ring into groove in barrel
assembly and spiral the ring into groove with straight 6. If step 5 fails to break packing gland loose from the
blade screw driver. barrel assembly, remove the plug from the retract port
and plug the extend port in the cylinder butt plate (SAE
16. Slide large washer into position on end of packing gland
#8 O.-Ring boss). Apply retract pressure to cylinder to
and retain with the external snap ring being sure that
break packing gland loose. Remove holding valve and
snap ring contracts completely and properly into the
extend and retract plugs from butt plate and pull packing
snap ring gland groove.
gland out by hand.
EXTEND CYLINDER REPAIR 7. As soon as the packing gland is sufficiently loosened,

properly support the rod assembly and carefully remove
it by hand. Place rod assembly on supports. Exersize
caution in the support and removal of the rod assembly
as damage to the chrome surface requires rod assembly
Boom Extend
replacement.
8. Disassemble the piston set by removing nut, replace
worn or damaged parts.
NOTE: Note: Loctite 680 is used during original assembly
to secure nut to shaft.
9. If necessary, heat nut to 400-500° F (204-260°C) to
facilitate removal. If heat is necessary for removal,
Boom Retract discard nut and replace with new equivalent nut as well
as worn or damaged parts.
10. Wipe and inspect all cylinder internal and external
surfaces for damage.
Extend Cylinder Disassembly 11. Remove seals and bearings from packing gland and
piston. Replace all seals and bearings.
1. After cylinder has been removed from boom, place on
supports and place drain pan under holding valve and 12. Inspect wear pad on barrel assembly and replace as
cylinder head area. required.
2. Retract cylinder shaft with oil from the hydraulic system
Extend Cylinder Assembly
until about 12 inches (30 cm) of shaft is extended. The
barrel must be filled with oil to prevent a compressed air 1. Reassemble shaft and piston set assembly in the proper
chamber being formed which could result in injury at order with internal round section ring, assembled
disassembly. Relieve any trapped hydraulic pressure packing gland, stop tube, piston to shaft o-rings,
which might remain in the cylinder. assembled piston, and locknut. Loctite locknut onto
shaft using type 680 according to Loctite
3. Remove any plug or fitting that is in the retract port in the
recommendations. Torque locknut to 300 ft-lbs (407Nm).
cylinder butt plate. Using a special drive tool, drive the
packing gland into the barrel assembly to expose the 2. De-burr ring groove edge in barrel assembly and inspect
round cross section retaining ring. Then use a small all internal and external surfaces for damage.. Failure to
needle nose locking plier to clamp the round cross do so will damage packing gland and or barrel assembly
section retaining ring to prevent it from rotating in the when packing gland is installed.
groove. Use two straight blade screw drivers: one to pry
3. Grease piston assembly and install the shaft assembly
the end of the ring out of the groove and the other to pry
with piston, o-ring, stop tube, packing gland, internal
the ring out of the barrel assembly.
round ring into barrel assembly.
4. De-burr ring groove edge after removing round ring.
4. Using special drive tool, drive the packing gland into the
Failure to do so will damage packing gland and or barrel
barrel assembly.
assembly when packing gland is removed.
5. Insert one end of round ring into groove in barrel
assembly and spiral the ring into groove with straight
blade screw driver.

6. Cycle test cylinder to ensure no leaks exist. Support end

of cylinder as it extends and retracts.
JIB INSTALLATION AND ADJUSTMENT

1. Loosely bolt the two ear assemblies with shims and bars
as shown to the side of the first boom section.
NOTE: Note: All measurements are in inches (mm).
3/4” Grade 5
(Typ 4 Plcs) 0.38 (10) Bar
0.06 (1.6)
0.38 (10) Shims
Bar 5. With jib pinned to the sheave head, swing the jib parallel
to the boom and install the pin which keeps the jib from
swinging (the pin is attached by cable to the end of the
jib).
.
0.06 (1.6)
Shims Shims
0.38 (10) Upper Support

Bar
Jib Ears
4
2. Loosely bolt the hook assembly to the side of the first
boom section.
Lower Support
6. Slowly retract the boom until the jib ears are within 0.50
inch (13 mm) of the ear assemblies on the first section.
Observe the vertical alignment of the jib ears and ear
Typ 4 Plcs
assemblies and add or remove shims until the jib is
supported by the jib ears. The jib will typically rest only
on the upper support.
Alignment Pin
3. Extend the boom approximately one foot (300 mm).

7. Observe the horizontal alignment of the slot in the ear
4. Using an overhead hoist, lift the jib assembly and align
assemblies and the alignment pin in the jib. Horizontal
and pin the jib to the boom sheave head.
adjustment of the stow ears is provided by oversize bolt
holes in the stow ear. Move the ears in or out to achieve
proper alignment. Position the top ear so it holds the top
of the jib in toward the boom and the bottom ear so that it
holds the bottom of the jib away from the bottom of the
boom.
8. Retract the boom slowly. Observe the stow hook and
side stow bracket assembly alignment as the boom is
retracted (View AA and BB below).

Ramp Side Stow

Bracket on Jib
Stow Hook CAUTION
on Boom
Make sure ramp slides up to the stow hook and does not
hit the end of the ramp.
Alignment 9. When the boom is fully retracted, the jib must be

Pin bottomed out securely in the ear assemblies. If the
alignment pins are not aligned properly, the hook
Stow Pin
assembly and front bars will have to be positioned as
shown so the jib cannot slide forward or backward as the
boom is elevated.
10. Try to remove the jib pins. If the pins are too tight, the
stow hook assembly or front bars will have to be
adjusted.
Front Bar Not
(Top & Bottom Acceptable 11. Torque all capscrews to their specified torque value (see
“Fasteners and Torque Values Table in Section 2. Install
stow pin in lock assembly and remove the jib pins.
12. Extend and retract boom to insure proper alignment of
jib pins.
13. Install jib pins and remove the stow pins.
Acceptable
14. Extend and retract the boom and jib to ensure proper
alignment of jib stow brackets.
15. Install jib stow pins and remove jib pins.
Always save shims to allow future adjustment of jib stow if required
Hook Assembly
Stow Pin
Alignment
Pin in Slot

JIB JACK SERVICE AND MAINTENANCE 3. Lay the jack on its side and drain the oil into a suitable
drain pin. The oil will run slowly because air must enter
Important: Use only a good grade hydraulic jack oil, as oil drains out.
transmission oil, or turbine oil. Avoid mixing types of oil. Do
not use brake fluid, alcohol, glycerin, detergent motor oil, or 4. Be careful to prevent dirt or foreign matter from entering
dirty oil. Improper fluid can cause serious Internal damage to the system.
the jack rendering it inoperative. 5. Replace with proper oil as described above.
Adding Oil Lubrication
1. With saddle fully lowered and piston depressed, set jack Add proper lubrication oil to all pivoting sections every three
in upright level position and remove oil filler plug. months.
2. Fill until oil is level with filler plug hole.
Rust Prevention
Changing Oil Check ram every three months for any sign of rust or
1. For best performance and longest life, replace the corrosion. Clean as needed and wipe with an oil saturated
complete oil supply at least once a year. cloth.
2. To drain the oil, remove the filler plug. NOTE: When the jack is not in use, always leave the
saddle and ram all the way down.


500E2 SERVICE MANUAL WINCH
SECTION 5
WINCH
WINCH REMOVAL 4. Remove and cap hydraulic hoses.
NOTE: Tag hydraulic hoses to avoid confusion during
re-assembly (the inside hose “up” and the outside
is “down”).
CAUTION
The combined weight of the winch and 325 ft. of wire rope
is 660 lbs (300 kg).
5. Remove rope Mesh Guard.
6. Attach suitable lifting device to winch and take up the

slack.
7. Remove 6 mounting capscrews and washers (3 on each
side).
8. Lift which clear of boom and secure to a suitable holder
Item Component WINCH INSTALLATION 5

1 Winch 1. Remove rope Mesh Gaurd from winch.
2 Boom
2. Lift winch with suitable lifting device.
3 Capscrew (6 plcs)
3. Lower winch onto the alignment ears.
4 Case Drain
4. Install Mesh Gaurd.
5 Winch Down Hose
5. Install 6 capscrews and washers. Torque capscrews to
6 Winch Up Hose 22020ft lb (300 ± 30 N.m.
7 Winch Alignment Ears 6. Inspect hydraulic hoses and anti chafing sleeve for wear
or damage. Replace as required.
7. Route hoses with anti chafing sleeve installed through
1. Extend and set the outriggers. access hole in turret assembly.
2. Fully retract the boom and place in a horizontal position. 8. Install winch up hydraulic hose to lower inside fitting on
3. Remove hook block or downhaul weight.Shut down which motor.
truck engine. 9. Install winch down hydraulic hose to outside fitting on
winch motor.

WINCH 500E2 SERVICE MANUAL

500E2 SERVICE MANUAL SWING
SECTION 6
SWING
SWING GEARBOX AND BRAKE 0.080

( 2.03
in mm
(
0.085 2.16
Disassembly & Assembly Instructions
This section describes the disassembly and assembly Replace if the
procedures for the swing gearbox. Item numbers shown in thickness is below
0.070 in (1.78 mm)
parentheses throughout this procedure, refer to the exploded
parts breakdown drawing.
Swing Drive Disassembly

1. Remove drive from vehicle and drain gearbox lubricant
by removing the drain plug (26).
2. Remove the motor from the motor adapter (3).
3. Remove the brake assembly from the gear housing Friction Disc
assembly (1) by removing six socket head No Wear
capscrews (27).
NOTE: The position of the brake port in conjunction with
the drain and fill holes in the housing for
reassembly.
4. Separate the motor adapter assembly (3) from the brake 10. Inspect the piston 0-rings (20 &21)and the back up rings
housing (2) by removing six capscrews (28). (19 & 22) for damage, replace if necessary.
NOTE: Notice the position of the motor mounting hole in
relation to the brake release port for reassembly.
O-Rings
CAUTION Back-up Ring 6

The motor adapter is spring loaded and the capscrews Back-up Ring
Piston
should be loosened in a sequence that will allow an even
load distribution on the motor adapter.
5. Inspect the motor adapter o-ring (24) for wear. Re place

if necessary.
6. Remove the six springs (15) and the brake driver (8)
from the brake housing (2).
7. Remove retaining ring (37) from the brake piston (5).
8. Remove the stator plates (16) and friction discs (17)
from the brake piston (5). Inspect stator plates for
excessive grooving or burn spots. Also, inspect friction
discs for wear. Replace as required.
11. Inspect the thrust plate (9) for excessive grooving and
9. Remove the piston (5) from the brake housing (2). replace if necessary by removing snap ring (36).
NOTE: Notice the position of the dowel pin hole in piston 12. Remove the brass thrust washer (34) and sun gear (41).
with the brake release port for reassembly.
13. Remove input planet set (3, part of gear set 4) from gear
A port-a-power can be used to assist in removal of piston by housing (1) by pulling straight up and out of the housing.
slowly pressurizing the brake release port until piston clears
the top of the housing.

SWING 500E2 SERVICE MANUAL
29
28
39
3
34
41
24
43
8
11 44 50 15
18
42 51
1 5
52
45 50 22
48
53 21
43 20
4
46 19
49
26
50 37
12
24 47 54 17
7
35 32 55
10 48 54
56
6
16
57 27
36
23
Grease Fitting
Breather/Oil Fill
Oil Drain Plug
Brake Release Port

Item Component Item Component Item Component

1 Gear Housing 16 Stator Plates 36 Snap Ring
2 Brake Housing 17 Friction Plates 37 Retaining Ring
3 Motor Adapter 19 Back-up Ring 41 Sun Gear
4 Gear Set 20 O-ring 43 Retaining Ring
5 Brake Piston 21 O-ring 44 Input Carrier
6 Pinion Shaft 22 Back-up Ring 45 Sun Gear
7 Outboard Bearing 23 O-ring 46 Locking Bolt
8 Brake Driver 24 Fill Plug 47 Output Planet Carrier
9 Thrust Plate 26 Drain Plug 48 Retaining Rings
10 Seal 27 Socket Head Capscrew 49 Pinion Bolt
11 Inboard Bearing 28 Socket Head Capscrew 51 Planet Gear
12 Bearing Cup 32 Breather 52 Needle Bearings
15 Spring 34 Thrust Washer 53 Planet Pin
35 Grease Fitting
14. Remove the retaining ring (43) from the input carrier 18. Remove the inboard bearing (11) and inspect for wear.
(44), remove the output sun gear (45), and inspect for
19. Remove the pinion shaft (6) from the housing (1) and
wear and replace as necessary.
inspect the pinion shaft, seal, and bearing for wear.
15. Remove retaining rings (48), press out the planet pin
20. Remove outboard bearing (7) and seal (10). Inspect for
(53), remove the planet gear (51), and needle bearings
wear and replace if necessary.
(52), inspect for unusual wear. Replace as required.
16. Remove the pinion locking bolt (46) from the out put
planet carrier (47). Loosen the pinion bolt (49).
Tulsa Swing Drive Assembly Procedure
6
1. Press the inboard and outboard bearing cup (12) into the
gear housing (1) if replaced.
2. Grease pack the bearing cones items (7) with EP 2
Pinion Locking Bolt
before installation.
3. Install the outboard cone (7) into the outboard cup (12).
Press the seal (10) into the gear housing(1) from the
outboard side.
4. Slide the output pinion (6) into the housing (1) from the
outside.
5. Install the inboard bearing cone (11).
6. Separate the gear set (4) into sections.
7. Apply Loctite to the threads of the pinion bolt (49). Install
Pinion Bolt the output carrier (47) into the gear housing (1).
a. Tighten the pinion bolt halfway, check the alignment
of the output carrier (47) with the spline on the
pinion shaft (6), and then tighten the pinion bolt the
17. Remove the retaining rings (48). Lift output planet set rest of the way.
out of the housing (1). Press out the planet pin (57);
remove the planet gear (55) and needle bearings (54). b. Torque the pinion bolt to 50 ft-lb (68 Nm), loosen
and re-torque until the pinion locking bolt aligns with
Inspect for unusual wear. Replace as required.

the slot on the nut portion of the pinion bolt at 25 ft-lb NOTE: Soak friction disk in EP-90 for 24 hrs. before
(34 Nm) If the pinion bolt is between slots always installation.
tighten to the next slot.
16. Reinstall the retaining ring (37) into the piston.
NOTE: Install a 1/2-13 bolt into the end of the pinion shaft
17. Install six springs (15) into the holes in the motor adapter
on the outboard side and check the rolling torque.
(3).
Preload of the bearing rolling torque should be 35-
50 ft-lb (47-68 Nm). Apply Loctite to the pinion 18. Mount the motor adapter (3) to the brake housing (2)
locking bolt (46) and torque to 20 ft-lb (27 Nm). with six cap screws (28) checking to make sure the roll
pin (18) is in line with the dowel hole in piston (5).
8. Install the input carrier section (44) with Sun gear (45)
attached with retaining ring (43). NOTE: Notice the position of the motor mounting hole in
relation to the brake release port for correct
9. Install the sun gear (41) and thrust washer (34)
reassembly.
10. Assemble the brake section by first installing the 0-ring
19. Fill the gearbox to desired level with EP-90 gear lube.
(23) on the brake housing (2). Install six caps crews (27)
to the brake housing (2) and torque to 10 ft-lb (13 Nm).
Notice the position of the brake port in conjunction with ROTATION STOP-MECHANICAL
the drain and fill holes in the housing.
The rotation stop system is designed to stop crane rotation
11. Install the 0-ring (20) and back-up ring (19) on the small beyond 375 degrees in the clockwise or counterclockwise
step of the piston (5). directions. This is accomplished by mechanically returning
the control valve to the centered position as full rotation is
12. Install one back-up ring (22) and one 0-ring (21) on the
approached. The operator will feel the control lever begin to
large step of the piston (5). Apply a slight film of oil on
pull in the opposite direction as full rotation is approached.
the 0-rings and back-up rings before installing.
The operator should not resist this counteracting force, but
13. Carefully press the assembled piston (5) into the brake
permit the rotation stop system to return the lever to neutral.
housing (2), taking care not to damage the rings.
If a load cannot be reached or placed due to the available
NOTE: The position of the dowel pinhole in piston with the
rotation, the crane must be re-positioned.
brake release port for correct assembly.
Pinion Locking Bolt DANGER

.Attempting to over ride the rotation stop system will result
in damage to the crane and possible injury to the operator.
Rotation Stop Adjustment

There are two methods that can be used for adjusting the
rotation stop system.
Method 1
1. From inside of the frame, rotate the flag rod until it is
centered between the two stop pins on either side of the
flag.
Pinion Bolt
2. Make certain that the turn lever is vertically aligned. If
not, adjust the lever at the clevis connecting it to the
control valve.
14. Insert the brake driver (8) into the assembled brake 3. With the turn lever vertically adjusted, verify that the
housing (2) and piston (5). spacer is centered in the turn control rod tab.
15. Install the stator plates (16) and friction disks (17) 4. If it is not centered, loosen the two nuts, one on either
starting with one stator plate and alternating between side of the spacer. Turn the nuts in the same direction
friction disk and stator plate until six stator plates and until the spacer is centered. Tighten the nuts against the
five friction disks are used. ends of the spacer to secure it in place.
5. Verify that the flag is sill centered between the stop pins.

4. Rotate the crane clockwise, or counterclockwise until

the rotation stop system centers the control lever.
5. Again make a mark at the crane frame aligned with the
center of the lift cylinder.
Method 2 6. Now rotate the crane in the opposite direction until the
1. Follow the crane set-up procedures in this manual to set rotation stop system centers the control lever.
outriggers and stabilizers and level the ma chine. 7. Make another mark on the crane frame aligned with the
2. With the crane properly set-up, raise the boom to near center of the lift cylinder.
full boom angle (75-80 degrees). This must be done with 8. If the rotation stop system is properly adjusted, the
the boom fully retracted and with no load attached to the distance should be the same from the first mark made to
loadline. the second mark, as it is from the first mark to the third
mark.
6
3. Slowly rotate the boom until is directly over the front of
the truck (behind cab mounting). With the boom directly 9. If not, loosen the nut on either side of the spacer on the
over the front, place a mark at the top of the frame flag rod actuator rod and adjust the position of the
aligned with the center of the lift cylinder. spacer. Tighten the two nuts and repeat steps 3 thru 7
above until proper adjustment is achieved.


500E2 SERVICE MANUAL LUBRICATION
SECTION 7
LUBRICATION
GENERAL Extreme Pressure Multipurpose Gear
Lubricant (EPGL)
Following a designated lubrication procedure is important to
ensure a maximum crane life. The procedures and This gear lubricant is compounded to achieve high load
lubrication charts in this section include information on the carrying capacity and meet the requirements of either API-
types of lubricants used, the location of the lubrication points, GL-5 or MIL-L-2105C. Unless otherwise specified,
the frequency of lubrication, and other information. This SAE 80W-90 viscosity may be used for year round service.
section does not include lubrication requirements for the Low temperature usage is restricted as follows:
truck chassis. Refer to truck service manual for this
information. SAE Viscosity Minimum Ambient Temperature
Number F (C)
The service intervals specified are for normal operation
where moderate temperature, humidity, and atmospheric 75W -40 (-40)
conditions prevail. In areas of extreme conditions, the
80W -15 (-26)
service periods and lubrication specifications should be
altered to meet existing conditions. For information on 85 +10 (-12)
extreme condition lubrication, contact your local National 90 +20 (-7)
Crane Distributor or Manitowoc Crane Care.
140 +40 (+5)
Lubricants 250 +50 (+10)
Specific recommendations of brand and grade of lubricants
are not made here due to regional availability, operating Open Gear Lubricant
conditions, and the continual development of improved This is a special high-graphite adhesive lubricant that helps
products. Where questions arise, contact your National to eliminate fretting corrosion, is water resistant, and forms a
Crane Distributor or Manitowoc Crane Care. dry lubrication film which does not attract dust. Lubricant
meets NLGI Class 1-2 specifications.
Arctic Conditions Below -18°C (0°F)
In general, petroleum based fluids developed especially for Chassis Grease Low Temp
low temperature service may be used with satisfactory This special grease for low temperature remains plastic at
results. However, certain fluids, such as halogenated -60°F (-51°C) with melting point of 280°F (138°C). The
hydrocarbons, nitro hydrocarbons, and phosphate ester grease is a heavy duty extreme pressure type lubricant
hydraulic fluids, might not be compatible with hydraulic (Lubricate Low Temp or equal).
system seals and wear bands. If you are in doubt about the
suitability of a specific fluid, check with your authorized Anti-wear Additives 7
Manitowoc distributor or Manitowoc Crane Care.
Excessive wear in the system may cause a loss in volumetric
NOTE: All fluids and lubricants may be purchased by efficiency, and may cause shutdowns for maintenance. An
contacting the Manitowoc Crane Care Parts efficient anti-wear oil protects the components against
Department. rusting, resists oxidation and helps prevent wear.
Regardless of temperature and oil viscosity, always use
suitable start-up procedures to ensure adequate lubrication Hydraulic OIL
during system warm-up. Oil in a hydraulic system serves as the power transmission
medium, system lubricant and coolant. Selection of the
Chassis Grease. proper oil is essential to ensure satisfactory system
Lubricating grease of proper consistency is to be applied performance and life. The most important factors in selecting
periodically at relatively frequent intervals with grease guns an oil for hydraulic service are viscosity and anti-wear
through grease fittings. Minimum apparent viscosity of 300 additives.
SUS (Saybolt Universal Seconds) at 100° F (38° C) is
recommended.

LUBRICATION 500E2 SERVICE MANUAL
All oil levels are to be checked with the crane parked on a

level surface in transport position, and while the oil is cold,
CAUTION
unless otherwise specified. On plug type check points, the oil
Operation of the crane with incorrect hydraulic oil in sub levels are to be at the bottom edge of the fill port.
freezing temperature (below 32°F, 0°C) can cause
damage to the extend cylinder. Over lubrication of non-sealed fittings will not harm the
fittings or components, but under lubrication shortens
Standard Hydraulic Oil lifetime.
Worn grease fittings that do not hold a grease gun, or those
Above 10°F (-12°C)
that have a stuck check ball, must be replaced.
The factory fill standard hydraulic oil is SAE grade 10W-20
When wear pads or rotation bearings are lubricated, cycle
Hydraulic Oil. This fluid is acceptable for operating
the components and lubricate again to ensure complete
temperatures above -12°C (10°F).
lubrication of the entire wear area.
Intermediate Hydraulic Oil
CAUTION
(-10°F to 80°F) (-23°C to 27°C)
Lubrication intervals (page 7-2) are to be used only as a
For colder operating environments, the standard fluid may be guide. Actual intervals should be formulated by the
replaced with a Low Service Temperature Multi Viscosity operator to correspond accordingly to conditions such as
Hydraulic Oil with High Viscosity index 175+. continuous duty cycles and/or hazardous environments.
Wide Range Intermediate Hydraulic Oil. Surface Protection for Cylinder Rods
(-30°F to 80°F) (-34°C to 27°C) Steel cylinder rods include a thin layer of chrome plating on
their surfaces to protect them from corroding. However,
For even colder operating conditions, the standard fluid may
chrome plating inherently has cracks in its structure which
be replaced with a petroleum based fluid developed
can allow moisture to corrode the underlying steel. At typical
especially for colder environments.
ambient temperatures, hydraulic oil is too thick to penetrate
these cracks. Normal machine operating temperatures will
Arctic Hydraulic Oil.
allow hydraulic oil to warm sufficiently to penetrate these
(-10°F and below) (-23°C and below) cracks and if machines are operated daily, protect the rods.
Machines that are stored, transported, or used in a corrosive
In general, petroleum based fluids developed especially for environment (high moisture, rain, snow, or coastline
low temperature service may be used with satisfactory conditions) need to have the exposed rods protected more
results. However, certain fluids, such as halogenated frequently by applying a protectant. Unless the machine is
hydrocarbons, nitro hydrocabons and phosphate ester operated daily, exposed rod surfaces will corrode. Some
hydraulic fluids might not be compatible with hydraulic cylinders will have rods exposed even when completely
system seals and wear bands. Arctic hydraulic oil is not retracted. Assume all cylinders have exposed rods, as
recommended for service in ambient temperatures above corrosion on the end of the rod can ruin the cylinder.
32°F (0°C).
It is recommended that all exposed cylinder rods be
If you are in doubt about the suitability of a specific fluid, protected using Boeshield® T-9 Premium Metal Protectant.
check with your authorized National Crane distributor or Manitowoc CraneCARE has Boeshield T-9 Premium Metal
Manitowoc Crane Care. Protectant available in 12 oz. cans that can be ordered
NOTE: All fluids and lubricants may be purchased by through the Parts Department.
contacting the Manitowoc Crane Care Parts NOTE: Cylinder operation and inclement weather will
Department. r e m o v e t h e B o e s h i e l d p r o t e c ta n t . I n s p e c t
machines once a week and reapply Boeshield to
LUBRICATION POINTS unprotected rods.
A regular frequency of lubrication must be established based The following describe the lubrication points and gives the
on component operating time. The most efficient method of lube type, lube interval, lube amount, and application of
keeping track of lube requirements is to maintain a job log of each. Each lubrication point is numbered, and this number
crane usage. corresponds to the index number shown on the Lubrication
Chart. Lube description and symbols are found in tables
below.

Symbol Description Manitowoc Lube Specification

EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. A6-829-003477
EP-3MG Extreme Pressure Moly Grease A6-829-015304
GL-5 Extended Service Interval Gear Lubricant - SAE Grade 80W-90 A6-829-012964
AFC - 50/50 50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941, ASTM D6210 A6-829-101130
HYDO Hydraulic Oil - Must meet ISO 4406 cleanliness level 17/14 A6-829-006444
EO-15W/40 Engine Oil - SAE 15W-40, API Service Classification CI-4 or better A6-829-003483
EP-OGL Open Gear Lubricant, CEPLATTYN 300 Spray, NLGI Grade 1-2 A6-829-102971
AGMA EP-4 Extreme Pressure Gear Lubricant. A6-829-100213
WRL Wire Rope Lubricant A6-829-015236
LTG Low Temperature Grease, NLGI Grade 1 A6-829-225828
13
18
Oil Fill/Breather
Oil Drain
14 12
5
18 16 19 4
10a 20
10b
6
7
7
23
19
20
11
2 3
15
9a
9b 22
1
NOTE: Torque diffuser to
51 lb-ft (69 Nm). Openings
must face bottom of tank.
21

Recommended
Item Application Procedure Frequency
Lubricant
1 Hydraulic oil reservoir HYDO Check fill change Weekly, semi-annually, as required
After first 40 hrs. as indicated by
2 Oil filter, magnetic plug, hydraulic oil reservoir Change or clean
gauge thereafter.
3 Breather, hydraulic oil reservoir Clean Monthly
4 Sheave pins: boom (3 plcs), jib (1 pl) EP-MPG Grease gun Weekly
5 Wire rope (loadline) EP-OGL Brush or spray Semi-Annually
6 Boom pivot pin EP-MPG Grease gun Monthly
7 Lift cylinder pins - 2 ea. EP-MPG Grease gun Monthly
8 Swing bearing (turret) (Not Shown) EP-MPG Grease gun Weekly
9a Pump drive U-Joint 2 ea. EP-MPG Grease gun Monthly
Remove pump and apply to
9b Pump spline shaft (direct mount) EP-MPG Semi-Annually
shaft or grease gun
10a Winch gearbox. SAE 90 EP Change/check & fill Every 1000 hours or 6 months
10b Winch brake HYDO Change/check & fill Every 1000 hours or 6 months
11 Control linkage EO-15W/40 Oil Can As Required
After first 50 hours. Every 500 hours
12 Swing drive gearbox GL-5 Change
thereafter. 1.5 pts (0.7 liters)
13 Swing gear teeth EP-OGL Spray Can Monthly
14 Boom extension LTG Brush, roller or grease gun Monthly or as required
15 Outrigger beams, bottom, sides LTG Brush or roller Monthly or as required
Any time boom is disassembled or
16 Extension cables (not shown) WRL Spray or brush
5 years
17 Boom Wear Pads (not shown) EP-MPG Brush or roller Monthly or as required
18 Swing Motor Pinion Bearing EP-MPG Grease gun Sparingly every 50 hours
19 Extend Sheaves EP-3MG Grease gun Weekly
Retract Sheaves: Extend the boom until the
20 retract sheave grease holes are visible through EP-3MG Grease gun Weekly
the access holes along side of boom.
21 Diffuser strainer, Hydraulic oil reservoir Clean Semi-Annually with oil change
22 Magnetic plug, hydraulic oil reservoir Clean At oil filter service interval
23 Continuous rotation swivel (optional) EP-MPG Grease gun Monthly
Internal Cable Sheave Lubrication NOTE 1: To determine the amount of grease required,
visually inspect the sheaves. From the front of
the boom, look back through the sheave case at
the extend sheaves. From the back of the boom,
DANGER look up through the winch mount at the retract
Do not, under any circumstances, work at an elevated sheaves. A small amount of grease extrusion
height without using proper fall protection as required by around the pin is adequate.
local, state or federal regulations The extend sheaves are located on the boom tip end of the
extend cylinder, and the retract sheaves are located on the
The lubrication points on the internal sheaves require a
inside rear of the 2nd section. Lubrication is as follows:
grease gun adapter because there are no grease fittings on
the sheaves. 1. Extend boom until grease access hole (Item 19 on the
Lubrication Points diagram) becomes visible on side of
Special Tools:
2nd section.
Nozzle or needle grease gun fitting:
2. Check alignment between the 2nd section access hole
- 0.25 inch (6.35 mm) diameter nozzle grease gun tip
(National P/N 955047). and the 3rd section access holes. When these holes
become aligned, the end of the extend cable sheave pin
- Contact the Crane Care to obtain this nozzle tip. is visible and accessible for lubrication.
3. This boom position also aligns the access holes at the
rear of the 1st section for lubrication of the retract
sheaves.

Inner Boom Pad Lubrication 5. Extend and retract the boom several times until the
grease is evenly spread.
1. With the boom fully retracted, apply grease to the wear
pads on the top of second boom section with a small 6. Repeat steps 1-3 as necessary to ensure the boom is
paint brush or a grease gun. fully lubricated.
2. Extend boom to position the wear pad access holes Winch Brake Oil
directly above the wear pads on the third boom section,
apply grease to the pads using the brush or gun. To check the winch brake oil, remove the vent/fill plug and
visually inspect the level. The fluid should be level with the
3. Extend boom to position the wear pad access holes bottom of the vent/fill hole. If more fluid is needed, use
directly above the wear pads on the fourth boom section, National Crane hydraulic oil.
apply grease to the pads using the brush or gun. .
4. After grease is applied to all wear pads raise the boom to

the maximum angle and slowly extend the boom to full ! DANGER
extension and slowly retract completely.
Do not use EP type gear lubes in the brake section. This
5. Repeat steps 1 - 4 three times to ensure the boom is may prevent proper operation and cause the load to fall
fully lubricated. resulting in serious injury or death.
Side and Bottom Boom Wear Pad

Lubrication
3
1
Brake Oil
Vent/Fill Plug
Oil Brake Drain Plug 7

Item Component Winch Gearbox Oil Level Check
1 First Section of Boom To check the winch gearbox oil level:
2 Wear Pad Access Holes • Rotate the drum until the oil fill/drain plug is level with the
3 Third Section Wear Pads oil level/fill inspection hole.
• Remove the oil fill/drain plug and visually inspect the
level. The oil should be level with the bottom of the
1. Fully extend and set the outriggers. inspection hole. If more oil is needed, add SAE 90 EP
gear lube.
2. Lower the boom to horizontal.
NOTE: Winch gear and brake lubricants are satisfactory
3. Fully extend the boom and apply grease to the side and for operation in temperatures from -10°F to +110°F
bottom of the 2nd and 3rd sections with a brush. (-23°C to 43°C). For operation outside this range,
4. Raise the boom to about 75° and retract the boom contact Manitowoc Crane Care for
recommendations.

Winch Gearbox Oil Change HYDRAULIC OIL RESERVOIR LEVEL

Oil Drain The hydraulic oil reservoir has a sight gauge located on the
side of the reservoir. This sight gauge has a decal beside it
1. Rotate the drum until the oil/fill plug is level with the drain that indicates a "full" level and an "low oil" level. The oil
hole. required to bring it from the "low" line to the "full" line is 5
2. Screw a 1” black pipe nipple into the drain hole so that gallons. Do not fill the reservoir above the "full" line. The oil
the oil can be drained into an approved container. level should be checked with the crane parked on a level
surface in the transport condition (all cylinders retracted and
3. Remove the drain/fill plug with a 3/8” hex wrench. boom stowed) and the oil cold.
4. Remove the breather.
Oil Fill Hydraulic Oil Level
1. Remove the 1” pipe nipple from the drain hole.

2. Rotate the drum until the drain/fill hole is level with the fill
hole.
3. Install a 1” pipe nipple with elbow in the drain/fill hole.
4. Fill the gearbox with 1.5 quarts of new gear lube. The
lube should be level with the bottom of the fill hole.
5. Remove the fill pipe.
6. Check that the breather is not frozen. Replace if
necessary.
7. Install the drain/fill plug and breather.
.
Sight Gauge
WIRE ROPE LUBRICATION

A wire rope cannot be lubricated sufficiently during
manufacture to last it’s entire life. Therefore, new lubricant
must be added throughout the life of a rope to replace factory
lubricant which is used or lost. It is important that lubricant
applied as part of a maintenance program shall be
compatible with the original lubricant, and to this end, the
1” Fill Pipe
rope manufacturer should be consulted. Lubricant applied
Breather
shall be of the type which does not hinder visual inspection.
Gearbox Those sections of rope which are located over sheaves or
Drain Hole otherwise hidden during inspection and maintenance
procedures require special attention when lubricating rope.
The object of rope lubrication is to reduce internal friction and
Gearbox to prevent corrosion.
Level/Fill Hole
During fabrication, ropes receive lubrication; the kind and
amount depends on the rope’s size, type, and anticipated
1” Pipe use. This in-process treatment will provide the finished rope
Nipple Fill/Drain
Plug with ample protection for a reasonable time if it is stored
under proper conditions. But, when the rope is put into
service, the initial lubrication may be less than needed for the
full useful life of the rope. Because of this possibility, periodic
applications of a suitable rope lubricant are necessary.

The following are important characteristics of a good wire Before applying lubrication, accumulations of dirt or other
rope lubricant: abrasive material should be removed from the rope.
Cleaning can be accomplished by using a stiff wire brush and
1. It should be free from acids and alkalis.
solvent, compressed air, or live steam. Immediately after the
2. It should have sufficient adhesive strength to remain on wire rope is cleaned, it should be lubricated. Many
the ropes. techniques may be used; bath, dripping, pouring, swabbing,
painting, pressure spray.
3. It should be of a viscosity capable of penetrating the
interstices between wires and strands. Whenever possible, the lubricant should be applied at the
top of a bend in the rope, because at that point the strands
4. It should not be soluble in the medium surrounding it
are spread by bending and are more easily penetrated.
under the actual operating conditions (i.e. Water).
There should be no load on the rope while it is being
5. It should have a high film strength. lubricated. It should be noted, the service life of wire rope will
be directly proportional to the effectiveness of the method
6. It should resist oxidation. used and amount of lubricant reaching the working parts of
the rope.


500E2 SERVICE MANUAL TROUBLESHOOTING
SECTION 8
TROUBLESHOOTING
HYDRAULIC SYSTEM TROUBLESHOOTING CHART
Condition Possible Cause Possible Solution
Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings.
Torque to manufacturers specifications. Replace oil
Oil seal rings deteriorated by excess heat. seal rings by disassembling Pump unit.
(a) Loosen then tighten single bolt to torque
Bolt loose or its sealing area deteriorated specification.
Oil Leakage by corrosion.
(b) Replace bolt.
Remove seal carrier from pump. - Remove
damaged seal from seal carrier.
Shaft seal worn or damaged.
If shaft is worn, install new seal in the inner position.
Reinstall seal carrier.
Check proper drive rotation. Make sure pump shaft
is turning (i.e. drive coupling is engaged). Check for
Pump not installed correctly.
sources of suction leaks, inlet flange tight? Pinched
o-rings?
No Flow from Pump (If
pump does not prime in Pump not getting oil. Make sure reservoir is full of oil.
30 seconds STOP!) Can't Build Any Pressure
Is it an open circuit to the reservoir.
Flow has an unrestricted path.
Internal leakage in cylinders, valves,
Repair component.
motors or pumps.
Insure overload system is working properly and Anti-
Overload system inoperative.
Two-Block/Overload solenoid is powered.
Load too heavy. Check Capacity Chart.
PTO not engaged. Engage PTO.
Low hydraulic fluid supply. Check and fill as required.
No response to control
Suction line blocked. Drain tank and hose and remove blockage.
Broken hydraulic pressure line. Replace as required.
Defective hydraulic pump. See Pump Service Manual.
Incorrect relief valve setting. Adjust relief.
Relief valve sticking. Clean relief. 8

TROUBLESHOOTING 500E2 SERVICE MANUAL

Check PTO ratio, pump size and engine speed for
Pump not operating at proper speed.
proper oil flow
Low hydraulic fluid supply. Check and fill as required.
Relief valve sticking. Remove and clean.
Relief setting too low. Readjust to proper setting.
Worn pump, motor or cylinder. Replace bad part.
Plugged filter. Change filter.
Poor hydraulic system
Valve spools not fully open. Adjust linkage so valve has full throw.
performance
Boom holding valves out of adjustment. Adjust or clean as required.
Reduce engine speed, slow cycle time to cool oil or
Oil temperature too high.
add oil cooler option.
Hydraulic oil too cold or dirty. Warm oil or use less viscous oil.
Line restricted. Check lines; clean and repair as necessary.
Internal control valve crack. Replace valve.
Load too heavy. Check Capacity Chart and reduce load.
Loose turntable bearing. Torque bearing mounting bolts.
Loose swing gearbox mounting bolts. Tighten bolts.
Worn gears or bearing. Replace worn parts or adjust gearbox spacing.
Operator control of lever too erratic. Operate controls smoothly.
Motor counterbalance valves dirty or not Clean or replace counterbalance valves not set at
Swing moves erratic or set properly. 600 psi.
loosely (Standard
Replace worn brake parts or shim brake to proper
system)
torque.
Brake not holding properly.
Replace worn brake parts or shim brake to proper
torque
Bleed air from brake with bleed screw on side of
Brake releasing at wrong time or erratically.
brake.
Swing speed adjustment set too low. Adjust valve on turn motor.
Turn circuit relief valves sticking. Clean and check circuit pressure.
Turntable bearing drag. Lubricate thoroughly as rotating boom.
Swing will not turn Check for 200 + PSI brake pilot pressure. Clean pilot
(Standard System) Brake not releasing properly. line or adjust motor counterbalance valves.
Adjust or clean brake for proper release.
Swing speed adjustment set too low. Adjust valve on turn motor.


Excessive pump speed. Adjust foot throttle or check for too high PTO ratio.
Low oil temperature. Allow unit to warm up.
Low hydraulic oil supply. Check and fill.
Suction line kinked, collapsed or blocked. Clear blockage.
Excessive pump noise
Pump Cavitation Check for loose clamps.
during operation
Hydraulic oil too thick. Warm oil or use oil more applicable to environment.
Relief valve chattering. Dirt in relief valve or damaged relief.
Hydraulic tubing vibration. Check for loose tubing.
Tank breather plugged. Clean breather.
Not getting oil to cylinders. Clean and replace as required.
Worn or damaged piston seals. Replace as required.
Cylinders drift Air in hydraulic oil. Cycle operate crane cylinder to remove air.
Loose holding valve. Tighten valve.
Dirt in holding or check valve. Clean valve.
Check load and change to applicable multipart
Load too heavy.
reeving.
Relief valve setting too low. Check and adjust if required.
Winch will not lift or hold Motor worn excessively. Replace motor.
load
Counterbalance valve defective or leaking. Clean and replace as necessary.
Anti-two-block system defective. Repair anti-two-block system.
Brake worn out. Repair or replace brake.
Gearbox grease low. Check and fill as required.
Winch gearbox heats
Duty cycle too high. Reduce cycle time or speed of winch.
Boom sections need lubrication. Grease boom.
Boom chatters during Wear pads not shimmed correctly. Re-shim as described in boom assembly section.
extension/retraction or
Worn wear pads. Replace pads.
doesn't proportion
properly Extension cables out of adjustment. Readjust cables and tension properly.
Extend or retract cables broken. Disassemble and inspect and replace cables.
Boom will not extend

Proportioning cables not attached.
Anti-two-block system shut down.
Reconnect, replace and/or adjust cables.
Lower hook, and extend load.
8
Defective anti-two-block system Check anti-two-block system; repair if defective.


JIB LOAD LIMITING DEVICE TROUBLESHOOTING
Carefully check the integrity of all circuits external to
Loose or incorrect wiring. the electronics box, from the jib tip to the console.
Compare to electrical schematic.
Check fuse at crane console. Replace if necessary.
Remove electronics box from jib, remove electronics
Blown fuse.
from housing, and check a fuse on board. Replace if
necessary.
ATB switch open. Ensure that ATB switch is closed.
Set the unit for the proper table.
No table selected. • Power down the unit, set the DIP switch to
System is in a state of Crane Table Switch Settings: 10101010, and power up the unit.
constant cut-out • 560E2 = 00101000 • Power down the unit and set the DIP switch for
• 571E2 = 10101000 the appropriate table.
Power up the unit.
Load cell not calibrated To set the zero point, remove all force from the load
cell. Power down the unit. Set switch position 8 to
DIP Switch Positions ON. Power the system. Do not turn off power until
both the zero point and the gain have been set. To
8 7 6 5 4 3 2 1 set the zero point, press the button on the board. To
set the gain, set switch position 8 to OFF. Set the
switch to the correct code that matches the load cell
Closed (ON) = 1 Open (OFF) = O gain. This code can be found on the tag that
accompanies the load cell. Press the button.
Wrong table selected. See no table selected above.
Ensure that the electronics box is tightly mounted to
the jib. Zero the angle sensor using the following
procedure:
• Place the level indicator on the jib over the
Angle sensor not zeroed. electronics box and level the jib.
• Power up the unit, unplug the connector to the
ATB switch, and jump pin 1 to ground.
• Remove the jumper wire, re-connect the ATB
connector, and power down the unit.
System cuts out too
early or too late Configuration switch must be closed when the jib is
Configuration switch stuck open or closed
retracted and open when the jib is extended. Adjust
(two section jibs only).
or replace switch As necessary.
Ensure that pivot pin is free, well lubricated, and
Pivot pin not free to move. allows the jib head to pivot freely. Inspect and
replace bearings in jib head assembly as required.
Foreign object stuck between jib head Remove any foreign objects which interfere with jib
assembly and jib. The only contacts head assembly operation.
between the jib head assembly and the jib
are to be the load cell and the pivot pin.


JIB JACK TROUBLESHOOTING
No oil in system Add oil to reservoir tank through oil filler hole
Does not lift load
Release valve not closed Turn handle clockwise tightly
Lifts load only part way Oil level low Add oil to reservoir tank through oil filler hole
The following valve or valves leaking
a. Suction valve
Lifts load but does not Replace jack
b. Delivery valve
hold
c. Release valve
Packings worn or damaged Replace jack
Release valve stuck, probably dirt or Transfer load then replace dirty oil, flush oil reservoir
Jack does not lower
foreign matter with kerosene
Dirty oil Change hydraulic oil
Poor lifting
Air in hydraulic system Purge air from system
Poor pumping action Oil seal for pump unit worn out or damaged Replace jack
Systematic Troubleshooting the Hydraulic Schematic and the Illustrated Parts Catalog to
identify parts and flow paths. Start at the top box and work
The following step-by-step analysis will be helpful in isolating downward step-by-step. Do not try to start in the middle or
and correcting almost every service problem if followed in a skip steps.
step by step systematic manner. Use this information with
Boom creeping down
Control Valve Centered
Yes No
Cap sensing line between

the counterbalance valve Control valve in
and the compensating meter in position.
pressure switch.
Still creeps Stops creep

Yes No 8
Center valve Control valve in
Incorrect counterbalance Replace compensating down position
setting, bad counterbalance pressure switch normal operation
valve, leaking cylinder seals

HCA TROUBLESHOOTING FLOW CHART
Overload trips and does not reset
No
Has overload been eliminated?
Yes
Downhaul weight lifting the

Eliminate overload
anti-two-block weight
No
Yes
Lower downhaul weight
Crane booms down, Yes

telescopes out, winches up? Problem solved
No
Boom lift cylinder

fully extended?
Yes No
Press HCA override switch and

boom down 5° with no load.
Crane booms down, No 12 V across

telescopes out, pressure switch?
winches up?
Yes
Yes No
Problem Solved Fuse OK 12 V to solenoid?
No No Yes
Yes
Replace fuse Troubleshoot Resistance across
12 V across wiring solenoid?
pressure switch?
Functions operate
No Sticking spool 12 ohm Replace

Replace No
clean or replace solenoid valve
Yes wiring
Yes
Problem Solved
Not all functions work
Valves sticking?
Clean or replace

500E2 SERVICE MANUAL CRANE INSTALLATION
SECTION 9
CRANE INSTALLATION
CRANE TO TRUCK INSTALLATION platform length of the particular unit. Match the platform
length to the retracted boom length so that the boom
The installation section contains information for mounting doesn't overhang the rear of the bed by more than that
and initial check out of the crane. Proper mounting is required by legal regulations where the unit will be
required for long lasting crane performance. Improper operated. The truck cab-to-axle dimension is then
mounting can cause permanent damage to the truck, i.e. determined by the length of the bed (the bed should be
frame or transmission, and the crane, i.e. pump or approximately centered over the rear axle) and the
nonstability. Also Federal Department of Transportation mounting space that the crane frame takes up between
Laws relating to vehicle manufacture and modification such the cab and the bed.
as lights, brakes and axle loads must be met as well as State
vehicle laws relating to weights and dimensional restrictions • Truck Frame - Try to select a truck frame that will
such as overall length, overhang, etc. minimize or eliminate frame reinforcement or extension
of the after frame (AF). Many frames are available that
This section is organized by first presenting detailed have the necessary after frame (AF) section modulus
information relating to truck requirements and mounting (S.M.) and resistance to bending moment (RBM) so that
configurations followed by a step-by-step installation reinforcing is not required. The front hydraulic jack is
procedure including PTO selection, Pump rotation selection, used for a 360 degree working range around the truck.
reinforcement, crane and stabilizer installation, The frame under the cab through the front suspension
counterweighting, boom rests and stability testing. must have the minimum S.M. and RBM because
The final manufacturer of the vehicle must certify that the reinforcing through the front suspension is often difficult
axle ratings have not been exceeded with all permanently because of engine, radiator mounts and steering
attached equipment including a full load of fuel and men [at mechanics. See "Truck Requirements" and "Frame
200 lb (90 kg) each]. Strength" pages for the necessary section modulus and
resistance to bending moment values.
National Cranes need to meet ASME/ANSI B30.5 (latest)
when completed as cranes and ASME/ANSI B30.23 (latest) • Additional Equipment - In addition to the axle ratings,
when completed as a personnel lifting system. These wheelbase, cab-to-axle requirements and frame, it is
standards require welds to meet AWS D14.3 or AWS D1.1 recommended that the truck is equipped with electronic
respectively. Any work done in mounting must be done in engine control, increased cooling and a transmission
compliance with these codes. with a PTO opening available with an extra heavy duty
PTO. See "PTO Selection" pages. A conventional cab
NOTE: Before installation, verify that the serial number on truck should be used for standard crane mounts.
the plates located on the major components match
the main serial number on the crane frame. If the • Neutral Start Switch - If equipped with optional remote
serial numbers do not match, contact the factory controls, the chassis must be equipped with a switch
before proceeding. Matching the serial numbers that prevents operation of the engine starter when the
insure that accurate warranty information is transmission is in gear.
recorded at the factory and aids in dispensing
service bulletins and other pertinent information. MOUNTING CONFIGURATIONS
The National Crane is a versatile machine and its versatility
MINIMUM TRUCK REQUIREMENTS can be enhanced by the manner in which it is mounted.
Many factors must be considered in the selection of a proper Following is a brief description of the mounting
truck for a boom truck crane. Items which must be configurations and the advantages of each. The minimum
considered are: weights listed below the front and rear axles for each
configuration are estimated minimum front and rear axle
• Axle Rating - Axle ratings are determined by the axles, weights for an 85% stability factor before the crane,
tires, rims, springs, brakes, steering and frame strength
9
stabilizers and sub-base, if required, are installed on the
of the truck. If any one of these components is below the chassis. The minimum weights listed below the front and rear
required rating, the gross axle rating is reduced to its axles for the New York City approved configurations are
weakest component value. estimated front and rear axle weights for 75% stability factor
• Wheelbase, Cab-to-Axle (CA) - The wheelbase and before the crane stabilizers and sub-base are installed on the
CA required are in part determined by the mounting chassis.
configuration but also by the boom length and the

CRANE INSTALLATION 500E2 SERVICE MANUAL
NOTE: These weights include the permanently attached sub-base for 20 ft bed. In most cases, the chassis will not
equipment on the chassis, such as pumps, PTO's, require reinforcing and the amount of counterweight required
reinforcing, chassis mounted options, bed and as minimized increasing payload capabilities.
counterweight.
Requires 12,000 (5443 kg) GAWRF, 21,000 (9525 kg)
Before placing this unit in service, a final stability check as GAWRR, 33,000 (14,968 kg) GVWR, ASH rear stabilizers
outlined in this section must be performed. and sub-base for 20 ft bed.
The maximum weights listed below the front and rear axles Full capacity work area is rear 180 of vehicle from outrigger
for each configuration are estimated maximum front and rear to outrigger.
axle weights for not exceeding axle capacities before the
Tandem axle trucks may be used for hauling larger payloads.
crane, stabilizers, and sub-base, if required, are installed on
the chassis. Truck frame must have or be capable of being reinforced to
15.9 in3 S.M. (261cm3) and 1,749,000 in-lb (197,610 N-m)
CONFIGURATION 1 - 571E2 RBM under the crane, spring hanger to spring hanger.
This configuration allows the installation of the Series 571E

on a chassis with a small frame by using the standard
Ash
3 (7.6) Min
69 (175.2) Min 168 (426.6) Min

*6900 lb *7000 lb
(3130) kg (3175) kg
Min Min
* Actual scale weights Note: All dimensions inch (cm)

prior to installation of
crane, sub-base, and
stabilizers
180° Full Capacity

Work Area

Configuration 2 - 571E2 between the crane and the ASH. Counterweighting in this
manner reduces the loading induced on the front stabilizer
This mount requires front stabilizer and additional when lifting over the front. Truck must have 15.9 in3 (261
counterweight in the underside of the bed for full capacity cm3 ) section modulus and 1,749,000 in-lb (197,610 N-m)
360× around the truck. Front stabilizer gives the machine a RBM or be capable of being reinforced to this strength under
solid base helping the operator control loads. the crane frame through to the front suspension. Normally a
Requires 12,000 pound (5443 kg) GAWRF, 21,000 tapered frame cannot be reinforced to this requirement. The
(9,525 kg) GAWRR, 33,000 (14,968 kg) GVWR, standard frame strength requirements for the remainder of the truck
sub-base for 20 ft bed, SFO and ASH rear stabilizers and frame are the same as in Configuration 1. Tandem axle
usually requires concrete counterweight in the torsion box trucks may be used for hauling larger payloads.
SFO
3 (7.6) Min
69 (175.2) Min 168 (426.6) Min

*7000 lb
*6900 lb Note: All dimensions inch (cm)
(3175) kg
(3130 kg)
Min
Min
* Actual scale weights
Counter Weight
stabilizers
360° Full Capacity

Work Area 9

Configuration 3 - 560E2 Requires 12,000 (5443 kg) GAWRF, 21,000 (9525 kg)
GAWRR, 33,000 (14,968 kg) GVWR, ASH rear stabilizers
This configuration allows the installation of the Series 560E and sub-base for 18' bed. Full capacity work area is rear
on a chassis with a small frame by using the standard sub- 180× of vehicle from outrigger to outrigger. Tandem axle
base for 18' bed. In most cases, the chassis will not require trucks may be used for hauling larger payloads. Truck frame
reinforcing and the amount of counterweight required as must have or be capable of being reinforced to 15.9 in.3 S.M.
minimized increasing payload capabilities. (218 cm3) and 1,749,000 in-lb (197,610 N-m) RBM under the
crane, spring hanger to spring hanger.
Ash
3 (7.6) Min
69 (175.2) Min 154 (391.1) Min

*6800 lb *5500 lb
(3084) kg (2494) kg
Min Min
* Actual scale weights prior to

installation of crane, sub-base, Note: All dimensions inch (cm)
and stabilizers
180° Full Capacity

Work Area

Configuration 4 - 560E2 And Shorter Booms the crane and the ASH. Counterweighting in this manner
reduces the loading induced on the front stabilizer when
This mount requires front stabilizer and additional lifting over the front. Truck must have 15.9 in.3 (261 cm3)
counterweight in the underside of the bed for full capacity section modulus and 1,749,000 in-lb (197,610 N-m) RBM or
360around the truck. Front stabilizer gives the machine a be capable of being reinforced to this strength under the
solid base helping the operator control loads. crane frame through to the front suspension. Normally a
Requires 12,000 pound (5443 kg) GAWRF, 21,000 (9,525 tapered frame cannot be reinforced to this requirement. The
kg) GAWRR, 33,000 (14,968 kg) GVWR, standard sub-base frame strength requirements for the remainder of the truck
for 18' bed, Single Front Outrigger (SFO) and Angle frame are the same as in Configuration 3. Tandem axle
Stabilizer Hydraulic (ASH) rear stabilizers and usually trucks may be used for hauling larger payloads.
requires concrete counterweight in the torsion box between
SFO
3 (7.6) Min
69 (175.2) Min 154 (391.1) Min
*6800 lb *7000 lb
(3084 kg) (3175) kg
Min Min Note: All dimensions inch (cm)
* Actual scale weights

Counter Weight
stabilizers
360° Full Capacity

Work Area
9

PTO HORSEPOWER REQUIREMENTS Do not confuse engine crankshaft rotation with power take
off rotation. If the power take off shaft rotates opposite the
The unit is equipped with a three section pump that supplies engine crankshaft, it is turning in a clockwise (cw) direction
34 GPM (129 LPM) to the winch, 18 GPM (68 LPM) to the when viewed from the rear of the truck and if the power take
boom and outriggers, and 10 GPM (38 LPM) to the swing off shaft rotates the same as the engine crankshaft it is
(turn) circuit. To provide these flows, the pump shaft must turning counter-clockwise (ccw).
turn at 2400 RPM. The PTO requirement is a torque rating of
at least 200 ft-lb (271 Nm) or 40 HP (30 KW) per 1000 RPM Operating speeds and performance of the crane are based
of PTO shaft speed. on proper pump outputs to the winch, lift, telescope and
swing circuits. A triple pump system is standard equipment
Direct Mount Pump to Pto on the 600D. This pump supplies 34 (129), 18 (68) and 10
(38) GPM (LPM) to the appropriate crane circuits when
Most pump installations can be direct mounted to the PTO operating at 2400 RPM.
using adapter assemblies available from the PTO supplier. If
the pump is direct mounted, its weight should be supported The speeds shown below are optimum operating speeds.
by a strap between the pump and the transmission. The The engine must be operated at a speed such that the
splined shaft coupling in a direct mount pump installation horsepower developed is adequate to pull the pumps under
requires lubrication. #200S Silver Streak Special Multi-Lube pressure.
(Medium) needs to be applied to the shaft during original See pump rotation section to determine correct pump for
installation and re-applied to the shaft or zerk provided on your application.
PTO housing shaft semi-annually thereafter.
Pump Rotation
ENGINE SPEED PTO RATIO
It is imperative that the three section hydraulic pump
(RPM) 2400 RPM PUMP
installed in a 500E2 application be the correct pump rotation
configuration for the truck drive train/power take off rotation 2900 82%
direction. Make certain which direction the power take off 2800 85%
Gasoline Engine
output shaft rotates before selecting a clockwise (cw) or
Optimum Speed 2600 92%
counter-clockwise (ccw) rotation hydraulic pump. Either cw
Range 2400 100%
or ccw rotation pumps are available, and are marked clearly
with a directional arrow on the pump housing. 2200 109%
Diesel Engine 2000 120%
Optimum Speed 1800 133%
CAUTION Range
1600 150%
To avoid pump failure, do not turn the pump in the
opposite direction of the indicating arrow on the pump 1500 160%
housing.
Engine CCW
Engine CCW
PTO CCW PTO CW

TRUCK FRAME STRENGTH (1197,610 N-m) RBM and 15.9 in3 (261 cm3) S.M. under the
crane frame between the front and rear springs with
In order for a truck frame to be suitable for accepting a Series 1,430,000 in-lb (161,590 N-m) RBM and 13 in3 (213 cm3)
500E2 size crane, the truck frame must have a requirement S.M. through suspension to rear stabilizers on each truck
for rigidity so as not to allow excessive boom movement due frame rail. For 360° stability, the truck frame must have a
to truck frame deflection, and it must be strong enough to 15.9 in 3 (261 cm 3 ) section modulus [1,749,000 in-lb
resist the loading induced by the crane so as not to (197,610 N-m) RBM] minimum at the crane frame between
permanently bend or deform. Section Modulus (S.M.) is a the front and rear springs with 1,430,000 in-lb (161,590 N-m)
measurement of the area of the truck frame and determines RBM and 13 in.3 (213 cm3) S.M. through suspension to rear
the rigidity of the frame. Resistance to bending moment stabilizers on each truck frame rail. Listed below is a table
(RBM) is a measurement of strength and is determined by showing the commonly used truck frame and reinforcing
multiplying the section modulus of each frame rail by the materials and the section modulus required for each material
yield strength of the rail material. to ensure adequate strength and rigidity. In all cases, the
For a standard, behind-the-cab mount, 180° stability, the minimum requirements for section modulus and RBM must
Series 500E2 crane requires a minimum of 1,749,000 in-lb be met.
REQUIRED FRAME STRENGTH

Minimum Section
Truck Frame or Minimum
Modulus RBM Under Rmb Through
Reinforcing Section Modulus
Through Rear Crane Suspension
Material Under Crane
Suspension
110,000 PSI 1,749,000 in-lb 1463,000 in-lb

15.9 in3 (261 cm3) 13.3 in3 (218 cm3)
(758 MPa) (197,637 Nm) (161,570 Nm)
360° Stability
50,000 PSI 1,650,000 in-lb 850,000 in-lb
33.0 in3 (541 cm3) 18.0 in3 (295 cm3)
(345 MPa) (186,425 Nm) (96,050 N-rn)
110,000 PSI 1,749,000 in-lb 1,463,000 in-lb

15.9 in3 (261 cm3) 13.3 in3 (218cm3)
(758 MPa) (197,637 Nm) (161,570 Nm)
180° Stability
50,000 PSI 1,650,000 in-lb 850,000 in-lb
33.0 in3 (541 cm3) 18.0 in3 (295 cm3)
(345 MPa) (186,425 Nm) (96,050 N-m)
SECTION MODULUS TABLES Channel Reinforcement (Table A)

The following tables will determine the section modulus of In order to provide more strength, a channel of suitable
the truck frame. Always measure the truck frame and check thickness can be added to the existing frame. The depth and
the tables to be sure that any truck factory listed section flange width of this channel should be chosen so it fits over
modulus is correct. the existing frame. The section modulus of the needed
channel is obtained from Table A and should be added to the
Channel (Table A). section modulus obtained from the truck frame.
Table A provides the section modulus of channel frames in Angle Reinforcement (Table B)
thicknesses of 3/16 inch (4.76 mm), 1/4 inch (6.35 mm), 5/16
inch (7.94 mm), and 3/8 inch (9.52 mm) with each grouping a If the truck is reinforced with an angle, refer to Table B for the
flange width and web depth column. When the depth of data on the added strength provided by the angle.
frame channel and flange width is known, the point at which
Add this to the section modulus of the channel obtained from
these two lines intersect is the section modulus from that
Table A.
particular channel.
If the section modulus of the channel does not meet the
requirements, the channel should be reinforced in the most
Fish Plate Reinforcement (Table C)
The frame can be strengthened by adding a fish plate of
9
applicable method following.
suitable thickness and depth equal to the frame. The section
modulus of the fish plate can be obtained from Table C and
this must be added to the section modulus of the frame to
obtain the total section modulus.

Angle Under Reinforcement (Table D) Welding. Two rows of 1 inch (25.4 mm) diameter plug welds
are to be placed in a staggered pattern of the web; the rows
This table lists the section modulus of an angle with the to be spaced 5 inches (127 mm) apart with welds at an
flange under the truck frame that is added to a frame with an interval of 4 inches (102 mm). Do not weld on the flanges.
angle reinforcement already added. Add the section
modulus from Table D to the section modulus obtained from Where thickness, depth or flange width vary, interpolation
tables A and B to determine total section modulus. between tables or variables within a given table will provide
the strength for the section.
The edges of the reinforcing angles or channels are to be
flush with the edges of the frame. If you have any questions concerning frame strength or
reinforcing, contact National Crane before proceeding.
W
TABLE A
Section Modulus in3 (cm3)
D
Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm)
W in. (mm) W in. (mm)
D in. (mm) D in. (mm)
2.5 (64) 3 (76) 3.5 (89) 4 (102) 2.5 (64) 3 (76) 3.5 (89) 4 (102)
8 (203) 5.3 (87) 6.0 (98) 6.7 (110) 7.5 (123) 8 (203) 6.9 (113) 7.8 (128) 8.8 (144) 9.7 (159)
9 (229) 6.3 (103) 7.1 (116) 7.9 (130) 8.7 (143) 9 (229) 8.2 (134) 9.2 (151) 10.3 (169) 11.4 (187)
10 (254) 7.3 (120) 8.2 (134) 9.1 (149) 10.0 (164) 10 (254) 9.5 (156) 10.7 (175) 11.9 (195) 13.1 (215)
in3 (cm3)
in3 (cm3)
11 (279) 8.4 (138) 9.4 (154) 10.4 (170) 11.4 (187) 11 (279) 11.0 (180) 12.3 (202) 13.6 (223) 14.9 (244)
12 (305) 9.5 (156) 10.6 (174) 11.7 (192) 12.8 (210) 12 (305) 12.5 (205) 13.9 (228) 15.3 (251) 16.8 (275)
13 (330) 10.8 (177) 11.9 (195) 13.1 (215) 14.3 (234) 13 (330) 14.1 (231) 15.6 (256) 17.2 (282) 18.8 (308)
14 (356) 12.0 (197) 13.3 (218) 14.6 (239) 15.9 (261) 14 (356) 15.8 (259) 17.5 (287) 19.1 (313) 20.8 (341)
15 (381) 13.4 (220) 14.7 (241) 16.1 (264) 17.5 (287) 15 (381) 17.5 (287) 19.3 (316) 21.2 (348) 23.0 (377)
2.5 (64) 3 (76) 3.5 (89) 4 (102) 2.5 (64) 3 (76) 3.5 (89) 4 (102)
8 (203) 8.4 (138) 9.5 (156) 10.7 (175) 11.9 (195) 8 (203) 9.8 (161) 11.2 (184) 12.5 (205) 13.9 (228)
9 (229) 10.0 (164) 11.3 (185) 12.6 (206) 13.9 (228) 9 (229) 11.7 (192) 13.2 (216) 14.8 (243) 16.3 (267)
10 (254) 11.6 (190) 13.1 (215) 14.6 (239) 16.0 (262) 10 (254) 13.6 (223) 15.4 (252) 17.1 (280) 18.8 (308)
in3 (cm3)
11 (279) 13.4 (220) 15.0 (246) 16.6 (272) 18.3 (300) 11 (279) 15.7 (257) 17.7 (290) 19.6 (321) 21.5 (352) in3 (cm3)
12 (305) 15.3 (251) 17.1 (280) 18.8 (308) 20.6 (338) 12 (305) 18.0 (295) 20.1 (329) 22.2 (364) 24.3 (398)
13 (330) 17.3 (284) 19.2 (315) 21.1 (346) 23.1 (379) 13 (330) 20.3 (333) 22.6 (370) 24.9 (408) 27.2 (446)
14 (356) 19.4 (318) 21.4 (351) 23.5 (385) 25.6 (420) 14 (356) 22.8 (374) 25.3 (415) 27.8 (456) 30.3 (497)
15 (381) 21.6 (354) 23.8 (390) 26.0 (426) 28.3 (464) 15(381) 25.4 (416) 28.1 (461) 30.8 (505) 35.5 (582)

W
TABLE B
D
2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108)
7.5 (191) 2.2 (36) 2.3 (38) 2.3 (38) 2.4 (39) 7.5 (191) 2.9 (48) 3.0 (49) 3.1 (51) 3.2 (52)
8.5 (216) 2.8 (46) 2.9 (48) 3.0 (49) 3.0 (49) 8.5 (216) 3.7 (61) 3.8 (62) 3.9 (64) 4.0 (66)
9.5 (241) 3.4 (56) 3.5 (57) 3.6 (59) 3.7 (61) 9.5 (241) 4.5 (74) 4.7 (77) 4.8 (79) 5.0 (82)
in3 (cm3)
in3 (cm3)
10.5 (267) 4.1 (67) 4.3 (70) 4.4 (72) 4.5 (74) 10.5 (267) 5.5 (90) 5.7 (93) 5.8 (95) 6.0 (98)
11.5 (292) 4.9 (80) 5.1 (84) 5.2 (85) 5.4 (88) 11.5 (292) 6.5 (106) 6.7 (110) 6.9 (113) 7.1 (116)
12.5 (318) 5.8 (95) 6.0 (98) 6.1 (100) 6.3 (103) 12.5 (318) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136)
13.5 (343) 6.7 (110) 6.9 (113) 7.1 (116) 7.3 (120) 13.5 (343) 8.8 (144) 9.1 (149) 9.4 (154) 9.6 (157)
14.5 (368) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136) 14.5 (368) 10.1 (166) 10.5 (172) 10.7 (175) 11.0 (180)
2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108)
7.5 (191) 3.6 (59) 3.7 (61) 3.9 (64) 4.0 (66) 7.5 (191) 4.3 (70) 4.5 (74) 4.6 (75) 4.8 (79)
8.5 (216) 4.6 (75) 4.7 (77) 4.9 (80) 5.0 (82) 8.5 (216) 5.5 (90) 5.7 (93) 5.9 (97) 6.0 (98)
9.5 (241) 5.6 (92) 5.8 (95) 6.0 (98) 6.2 (102) 9.5 (241) 6.7 (110) 7.0 (115) 7.2 (118) 7.4 (121)
in3 (cm3)
in3 (cm3)
10.5 (267) 6.8 (111) 7.1 (116) 7.3 (120) 7.5 (123) 10.5 (267) 8.1 (133) 8.4 (138) 8.7 (143) 8.9 (146)
11.5 (292) 8.1 (133) 8.4 (138) 8.6 (141) 8.9 (146) 11.5 (292) 9.7 (159) 10.0 (164) 10.3 (169) 10.6 (174)
12.5 (318) 9.5 (156) 9.8 (161) 10.1 (166) 10.4 (170) 12.5 (318) 11.3 (185) 11.7 (192) 12.1 (198) 12.4 (203)
13.5 (343) 11.0 (180) 11.4 (187) 11.7 (192) 12.0 (197) 13.5 (343) 13.1 (215) 13.6 (223) 14.0 (229) 14.3 (234)
14.5 (368) 12.6 (206) 13.0 (213) 13.4 (220) 13.7 (224) 14.5 (368) 15.1 (247) 15.5 (254) 16.0 (262) 16.4 (269)
TABLE C
D Section Modulus in3 (cm3)
TH
D in. (mm)
TH in. (mm)
8 (203) 9 (229) 10 (254) 11 (279) 12 (305) 13 (330) 14 (356) 15 (381) 16 (406)
3/16 (4.76) 2.0 (33) 2.51 (41) 3.10 (51) 3.75 (61) 4.46 (73) 5.24 (86) 6.08 (100) 6.98 (114) 7.94 (130)
1/4 (6.35) 2.66 (44) 3.37 (55) 4.16 (68) 5.03 (82) 5.99 (98) 7.03 (115) 8.15 (134) 9.36 (153) 10.5 (172) 9
in3 (cm3)
5/16 (7.94) 3.33 (55) 4.21 (69) 5.20 (85) 6.29 (103) 7.49 (123) 8.79 (144) 10.19 (167) 11.7 (192) 13.31 (218)
3/8 (9.52) 4.0 (66) 5.06 (83) 6.25 (102) 7.56 (124) 9.00 (148) 10.56 (173) 12.25 (201) 14.06 (230) 16.0 (262)
7/16 (11.11) 4.67 (76) 5.9 (97) 7.29 (119) 8.82 (144) 10.5 (172) 12.32 (202) 14.29 (234) 16.4 (269) 18.66 (306)

W
TABLE D
D
3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89) 4 (102) 4.5 (114)
8.5 (216) 5.7 (93) 6.4 (105) 7.0 (115) 7.7 (126) 8.5 (216) 7.7 (126) 8.6 (141) 9.4 (154) 10.3 (169)
9.5 (241) 6.7 (110) 7.4 (121) 8.1 (133) 8.9 (146) 9.5 (241) 9.1 (149) 10.0 (164) 10.9 (179) 11.9 (195)
10.5 (267) 7.7 (126) 8.5 (139) 9.3 (152) 10.1 (166) 10.5 (267) 10.5 (172) 11.5 (188) 12.5 (205) 13.6 (223)
in3 (cm3)
in3 (cm3)
11.5 (292) 8.8 (144) 9.7 (159) 10.6 (174) 11.4 (187) 11.5 (292) 11.9 (195) 13.1 (215) 14.2 (233) 15.4 (252)
12.5 (318) 10.0 (164) 10.9 (179) 11.9 (195) 12.8 (210) 12.5 (318) 13.5 (221) 14.7 (241) 16.0 (262) 17.2 (282)
13.5 (343) 11.2 (184) 12.2 (200) 13.2 (216) 14.3 (234) 13.5 (343) 15.2 (249) 16.5 (270) 17.8 (292) 19.2 (315)
14.5 (368) 12.5 (205) 13.6 (223) 14.6 (239) 15.7 (257) 14.5 (368) 16.9 (277) 18.3 (300) 19.7 (323) 21.2 (347)
15.5 (394) 13.8 (226) 15.0 (246) 16.1 (264) 17.3 (284) 15.5 (394) 18.7 (306) 20.2 (331) 21.7 (356) 23.3 (382)
3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89) 4 (102) 4.5 (114)
8.5 (216) 9.8 (161) 10.8 (177) 11.9 (195) 12.9 (211) 8.5 (216) 11.9 (195) 13.2 (216) 14.4 (236) 15.6 (256)
9.5 (241) 11.5 (188) 12.6 (206) 13.8 (226) 15.0 (246) 9.5 (241) 14.0 (229) 15.3 (251) 16.7 (274) 18.1 (297)
10.5 (267) 13.3 (218) 14.5 (238) 15.8 (259) 17.1 (280) 10.5 (267) 16.2 (266) 17.7 (290) 19.2 (315) 20.7 (339)
in3 (cm3)
in3 (cm3)
11.5 (292) 15.1 (247) 16.5 (271) 18.0 (295) 19.4 (318) 11.5 (292) 18.4 (302) 20.1 (329) 21.8 (357) 23.5 (385)
12.5 (318) 17.1 (280) 18.6 (305) 20.2 (331) 21.7 (356) 12.5 (318) 20.9 (342) 22.6 (370) 24.5 (402) 26.3 (431)
13.5 (343) 19.2 (315) 20.8 (341) 22.5 (369) 24.2 (397) 13.5 (343) 23.4 (384) 25.3 (415) 27.3 (447) 29.3 (480)
14.5 (368) 21.4 (351) 23.1 (379) 24.9 (408) 26.7 (438) 14.5 (368) 26.0 (426) 28.1 (461) 30.2 (495) 32.4 (531)
15.5 (394) 23.7 (388) 25.5 (418) 27.4 (449) 29.4 (482) 15.5 (394) 28.8 (472) 31.0 (508) 33.3 (546) 35.6 (583)

Example:
A truck frame of 110,000 psi (758 MPa) yield strength steel has the following dimensions: 3/8 in. 3.00
(76.2)
(9.65 mm) thick, 3 in. (76.2 mm) flanges and is 10.25 in. (260 mm) deep. To find the frame
section modulus:
10.25
1. From Table A, 3/8 in. (9.65 mm) thickness, (260)
• W (width) = 3 in. (76.2 mm),

• D (depth) = 10 in. (254 mm)
Inch 0.375
• section modulus = 15.4 in.3 (252 cm3. (mm) (9.65)
2. From Table A, 3/8 in. (9.65 mm) thickness,
• W = 3 in. (76.2 mm),
• D = 11 in. (279 mm),
• Section Modulus = 17.7 in.3 (290 cm3).
3. Interpolating between the two values:
• 10 in. (254 mm) deep channel = 15.4 in.3 (252 cm3)
• 10.5 in. (267 mm) deep channel
15.4 in.3 ÷ 17.7 in.3
= = 16.55 in.3
2
252 cm3 ÷ 290 cm3
=
2 = 271 cm3
4. Now interpolate between a 10 in. (254 mm) deep channel and a 10.5 in. (267 mm) deep channel
to get the section modulus of a 10.25 in. (260 mm) deep channel.
• 10.5 in. (267 mm) deep channel = 16.55 in.3 (271 cm3)
15.4 in.3 ÷ 16.55 in.3
= = 15.98 in.3
2
252 cm3 ÷ 271 cm3
=
2 = 262 cm3
5. A 3/8 in. (9.65 mm) x 3 in. (76.2 mm) x 10.25 in. (260 mm) truck frame has a 15.98 in.3 (262 cm3)
Section Modulus and RBM of 110,000 psi x 15.98 in.3 = 1,757,800 in. lbs. (758 MPa x 262 cm3 =
198,596 N.m)
• 10.5 in. (267 mm) deep channel = 16.55 in.3 (271 cm3)
• 10.25 in. (260 mm) deep channel l
15.4 in.3 ÷ 16.55 in.3
= = 15.98 in.3
2
252 cm3 ÷ 271 cm3
=
2 = 262 cm3 9
6. 15.98 in.3 (262 cm3) Section Modulus, 110,000 psi (758 MPa) steel is adequate for a standard
mount with a torsion box.

REQUIREMENTS FOR OPTIONAL FRONT required. The bracket must be capable of supporting 0.50
STABILIZER inch (12.7 mm) DIA. Grade 8 bolts to their nominal breaking
strength. Torque the mounting bolts supplied with the front
The truck frame must have adequate strength from under the stabilizer to 110 ft-lb (149 N·m).
crane frame through the front suspension to the bumper
Do not use spacers between the bumper bracket and the
assembly for front stabilizer installation. A truck frame yield
front stabilizer bumper assembly.
strength of 110,000 psi (758 MPa) is required.
If the bumper bracket and front of the truck frame do not
The following diagram shows the required section modulus
meet these specifications, an extended frame truck must be
at various stations along the front end of the truck frame for a
used. Contact factory for details. Details for mounting a
standard behind-the-cab mount with torsion box.
stabilizer on an extended frame truck are included in that
In order to safely mount a front stabilizer in place of the installation instruction. However, the Section Modulus
normal front bumper, a minimum bolt pattern as shown is requirements outlined below do apply.
Front
Axle
Front of
CL
T-Box
2.0 in3 11.0 in3 15.9 in3

(33 cm3) 7.5 in3 (180 cm3) (261 cm3)
(123 cm3)
Section Modulus per Truck
Frame Rail (Frame Rail Yield
Stress = 110,000 psi (785 MPa)
Bumper
4.50 in (11.4 cm) Min

TRUCK FRAME SECTION MODULUS Angle (Table F). Use Table F for an angle section such as
TABLES when a flange and part of the web of a truck frame channel is
removed.
Use Table E and Table F below along with Tables A through
Where thickness, depth or flange width vary, interpolation
D in the preceding section of this manual for determining the
between tables or variables within a given table will provide
section modulus of the truck frame.
Always measure the truck frame and check the tables to be
If you have any questions concerning frame strength or
sure that any truck factory listed section modulus is correct. It
reinforcing, contact National Crane before proceeding.
is also necessary to measure the frame and check the
section modulus wherever the depth and/or flange width Where thickness, depth or flange width vary, interpolation
changes. between tables or variables within a given table will provide
Channel (Table E). Table E supplements Table A for
narrower truck frame flanges. Use the width of the narrow If you have any questions concerning frame strength or
flanges for "W" to find the section modulus from Table E. reinforcing, contact National crane before proceeding.
TABLE E
D Section Modulus in3 (cm3)
1 (25) 1.53 (38) 2 (51) 1 (25) 1.53 (38) 2 (51)
8 (203) 3.2 (52) 3.9 (64) 4.6 (75) 8 (203) 4.1 (67) 5.0 (82) 5.9 (97)
9 (229) 3.8 (62) 4.7 (77) 5.5 (90) 9 (229) 5.0 (82) 6.0 (98) 7.1 (116)
10 (254) 4.6 (75) 5.5 (90) 6.4 (105) 10 (254) 5.9 (97) 7.1 (116) 8.3 (136)
in3 (cm3)
in3 (cm3)
11 (279) 5.4 (88) 6.4 (105) 7.4 (121) 11 (279) 7.0 (115) 8.3 (136) 9.6 (157)
12 (305) 6.3 (103) 7.4 (121) 8.5 (139) 12 (305) 8.2 (134) 9.6 (157) 11.0 (180)
13 (330) 7.2 (118) 8.4 (138) 9.6 (157) 13 (330) 9.4 (154) 10.9 (179) 12.5 (205)
14 (356) 8.2 (134) 9.5 (156) 10.8 (177) 14 (356) 10.7 (175) 12.4 (203) 14.1 (231)
15 (381) 9.3 (152) 10.6 (174) 12.0 (197) 15 (381) 12.1 (198) 13.9 (228) 15.7 (257)
Thickness 5/16 in. (7.94 mm)

Thickness 3/8 in. (9.52 mm)
W in. (mm)
D in. (mm) W in. (mm)
1 (25) 1.53 (38) 2 (51) D in. (mm)
1 (25) 1.53 (38) 2 (51)
8 (203) 4.9 (80) 6.1 (100) 7.2 (118)
8 (203) 5.7 (93) 7.1 (116) 8.4 (138)
9 (229) 6.0 (98) 7.3 (120) 8.6 (141)
9 (229) 7.0 (115) 8.6 (141) 10.1 (166)
10 (254) 7.2 (118) 8.7 (142) 10.1 (166)
10 (254) 8.4 (138) 10.2 (167) 12.0 (197)
in3 (cm3)
11 (279) 8.5 (139) 10.1 (166) 11.8 (193)

in3 (cm3)
11 (279) 10.0 (164) 11.9 (195) 13.8 (226)

12 (305) 9.9 (162) 11.7 (192) 13.5 (221)
12 (305) 11.6 (190) 13.8 (226) 15.9 (261)
13 (330) 11.5 (188) 13.4 (220) 15.3 (251)
14 (356)
15 (381)
13.1 (215) 15.2 (249) 17.3 (284)
14.8 (242) 17.1 (280) 19.3 (316)
13 (330)
14 (356)
13.4 (220) 15.7 (257) 18.0 (295)
15.4 (252) 17.8 (292) 20.3 (333) 9
15 (381) 17.4 (285) 20.1 (329) 22.8 (374)

TABLE F
D
2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108)
3.5 (89) 0.6 (10) 0.6 (10) 0.6 (10) 0.6 (10) 3.5 (89) 0.8 (13) 0.8 (13) 0.8 (13) 0.8 (13)
4.5 (114) 0.9 (15) 1.0 (16) 1.0 (16) 1.0 (16) 4.5 (114) 1.2 (20) 1.3 (21) 1.3 (21) 1.3 (21)
5.5 (140) 1.4 (23) 1.4 (23) 1.4 (23) 1.5 (25) 5.5 (140) 1.8 (30) 1.8 (30) 1.9 (31) 1.9 (31)
6.5 (165) 1.8 (30) 1.9 (31) 2.0 (33) 2.0 (33) 6.5 (165) 2.4 (39) 2.5 (41) 2.6 (43) 2.6 (43)
7.5 (191) 2.2 (36) 2.3 (38) 2.3 (38) 2.4 (39) 7.5 (191) 2.9 (48) 3.0 (49) 3.1 (51) 3.2 (52)
in3 (cm3)
in3 (cm3)
8.5 (216) 2.8 (46) 2.9 (48) 3.0 (49) 3.0 (49) 8.5 (216) 3.7 (61) 3.8 (62) 3.9 (64) 4.0 (66)
9.5 (241) 3.4 (56) 3.5 (57) 3.6 (59) 3.7 (61) 9.5 (241) 4.5 (74) 4.7 (77) 4.8 (79) 5.0 (82)
10.5 (267) 4.1 (67) 4.3 (70) 4.4 (72) 4.5 (74) 10.5 (267) 5.5 (90) 5.7 (93) 5.8 (95) 6.0 (98)
11.5 (292) 4.9 (80) 5.1 (84) 5.2 (85) 5.4 (88) 11.5 (292) 6.5 (106) 6.7 (110) 6.9 (113) 7.1 (116)
12.5 (318) 5.8 (95) 6.0 (98) 6.1 (100) 6.3 (103) 12.5 (318) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136)
13.5 (343) 6.7 (110) 6.9 (113) 7.1 (116) 7.3 (120) 13.5 (343) 8.8 (144) 9.1 (149) 9.4 (154) 9.6 (157)
14.5 (368) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136) 14.5 (368) 10.1 (166) 10.5 (172) 10.7 (175) 11.0 (180)
2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108)
3.5 (89) 0.9 (15) 1.0 (16) 1.0 (16) 1.0 (16) 3.5 (89) 1.1 (18) 1.1 (18) 1.1 (18) 1.2 (20)
4.5 (114) 1.5 (25) 1.5 (25) 1.6 (26) 1.6 (26) 4.5 (114) 1.8 (30) 1.8 (30) 1.9 (31) 1.9 (31)
5.5 (140) 2.2 (36) 2.3 (38) 2.3 (38) 2.4 (39) 5.5 (140) 2.6 (43) 2.7 (44) 2.7 (44) 2.8 (46)
6.5 (165) 3.0 (49) 3.1 (51) 3.2 (52) 3.2 (52) 6.5 (165) 3.5 (57) 3.7 (61) 3.8 (62) 3.8 (62)
7.5 (191) 3.6 (59) 3.7 (61) 3.9 (64) 4.0 (66) 7.5 (191) 4.3 (70) 4.5 (74) 4.6 (75) 4.8 (79)
in3 (cm3)
in3 (cm3)
8.5 (216) 4.6 (75) 4.7 (77) 4.9 (80) 5.0 (82) 8.5 (216) 5.5 (90) 5.7 (93) 5.9 (97) 6.0 (98)
9.5 (241) 5.6 (92) 5.8 (95) 6.0 (98) 6.2 (102) 9.5 (241) 6.7 (110) 7.0 (115) 7.2 (118) 7.4 (121)
10.5 (267) 6.8 (111) 7.1 (116) 7.3 (120) 7.5 (123) 10.5 (267) 8.1 (133) 8.4 (138) 8.7 (143) 8.9 (146)
11.5 (292) 8.1 (133) 8.4 (138) 8.6 (141) 8.9(146) 11.5 (292) 9.7 (159) 10.0 (164) 10.3 (169) 10.6 (174)
12.5 (318) 9.5 (156) 9.8 (161) 10.1 (166) 10.4 (170) 12.5 (318) 11.3 (185) 11.7 (192) 12.1 (198) 12.4 (203)
13.5 (343) 11.0 (180) 11.4 (187) 11.7 (192) 12.0 (197) 13.5 (343) 13.1 (215) 13.6 (223) 14.0 (229) 14.3 (234)
14.5 (368) 12.6 (206) 13.0 (213) 13.4 (220) 13.7 (224) 14.5 (368) 15.1 (247) 15.5 (254) 16.0 (262) 16.4 (269)

Example:
Refer to the sample truck frame cross sections in Table E. Truck frame yield strength is I I 0,000 psi (758 MPa) with
the following dimensions at the front axle location: 3/8 in. (9.65 mm) thick, 1.50 in. (38.1 mm) top flange, 3 in. (76.2
mm) bottom flange, 10.25 in. (260 mm) deep. To find the frame section modulus:
1. Use a channel with 1.50 (38.1 mm) flanges since I.50 in. (38.1 mm) is the smaller flange width.
2. From Table E, 3/8 in. (9.65 mm) thickness:
• W (width) = 1.50 in. (38.1 mm)
• D (depth) = 10.0 in. (254 mm)
• Section Modulus = 10.2 in3 (167 cm3)
3. From Table E, 3/8 in. (9.65 mm) thickness
• W = 1.50 in. (38.1 mm),
• D = 11.0 in. (279 mm)
• Section Modulus = I I.9 in.3 (195 cm3)
4. Interpolate between the two values:
• 10 in.(254mm) deep channel = 10.2 in.3 (167cm3)
• 11 in.(279mm) deep channel = 11.9 in.3 (195cm3)
• 10.5 in.(267 mm) deep channel
10.2 in.3 + 11.9 in.3

= = 11.0 in.3
2
167 cm3 + 195 cm3

= = 181 cm3
2
5. Now interpolate between a 10.0 in. (254 mm) deep channel and a 10.5 in. (267 mm) deep channel to get the
section modulus of a 10.25 in. (260 mm) deep channel.
• 10.0 in. (254 mm) deep channel = 10.2 in.3 (167cm3)
• 10.5 in. (267 mm) deep channel = 11.0 in.3 (181cm3)
10.2 in.3 + 11.0 in.3

= = 10.6 in.3
2
167 cm3 + 181 cm3

= = 174 cm3
2
1.50
(38.1)
Frame Section Modulus at the front axle location is 10.6 in.3 (174 cm3). This is greater
10.25
than the 7.5 in.3 (123 in.3) required so the truck frame is strong enough at this location. (260)
9
3.0 0.375
(76.2) (9.65)
Inch
(mm)

TRUCK PREPARATION PTO INSTALLATION

Plan installation completely before any work is done. Plan Select the PTO according to the PTO Selection pages shown
the location of the crane for the final front and rear axle earlier in this section. PTO's are not furnished by the factory.
weights and boom overhang. Check final weight (see
Counterweighting Section to verify that final truck weight with Hydraulic Pump Installation
crane, reinforcement, counterweight and options such as jib,
1. Install the PTO and PTO shifting mechanism according
etc. complies with the appropriate laws).
to the PTO manufacturer's instructions. If PTO has a
Welding Precautions reverse gear, it must be blocked out. Pump must not run
backwards.
- Sensitive truck computer system and crane's LMI or
jib load limiting device computer system
CAUTION
components may be damaged by welding on the
truck or crane. The following precautions should be To avoid pump failure, do not turn the pump in the
taken: opposite direction of the indicating arrow on the pump
housing.
- Disconnect truck battery cables (positive and
negative) 2. If PTO integral mount flanges are to be used, the pump
- Attach welding ground lead as close as possible to can be mounted directly to the PTO. Be sure adequate
area to be welded. clearance exists for this type of pump mount.
Sometimes the pump is powered through a drive line
- Remove the jib from the crane before welding on the with the pump located no more than 42 inches (107 cm)
crane or remove the jib sheave case assembly from from the PTO. The drive line should not exceed a 7°
the jib before welding on the jib. angle. The drive line U-joint yokes on both ends of the
drive shaft must be parallel with each other. Drive lines
POSITIONING CRANE ON TRUCK should be sized so they can safely carry the maximum
pump horsepower requirements. See "PTO Selection"
The final user of the crane must be aware of all state axle
pages. Drive lines are not furnished by the factory.
and length laws in force at the time of crane mounting and
position the crane on the truck accordingly. Following are 3. Plan the location of the pump mounting bracket and
items which must be considered. drive line, if used, so that ample clearance is maintained
between pump and truck drive shaft or exhaust system.
1. Overall Length: Most states have a maximum straight
Pump should be situated so that hydraulic lines can be
truck length limit of 40 feet (12.19 m). Using too long a
connected without sharp bends especially the large
WB truck could cause the unit to exceed this limit.
suction line from the reservoir. Pump mounting brackets
2. Axle Weights: All states allow 20,000 lb (9072 kg) single may be attached to existing frame crossmembers or a 6
axle weight and 34,000 lb (15,422 kg) tandem axle inch (15 cm) channel crossmember can be made and
weights on primary roads, however, some states restrict installed.
axle weight to less on secondary roads or at certain
4. Install pump mounting bracket (driveline driven pumps
times throughout the year. Be aware of your state's axle
only) securely to the truck frame. Attach pump to pump
laws and the roads the machine will operate on for
mounting plate or directly to the PTO using capscrews
weight restrictions due to secondary roads, bridges,
provided.
winter driving conditions, etc.
a. Install the pump support bar at the rear of the pump
3. Overhang: The most restrictive overhang laws call for a
and bolt or weld the upper end to a crossmember if
maximum of 3 feet (.91 m) in front of the truck. Many
the pump is driven by a driveline.
states have a maximum of 4 feet (122 cm) overhang in
back of the truck. Check on your state requirements. b. For a direct mounted PTO bolt to transmission.
4. Federal Bridge Law: The Federal Bridge Law in effect c. The rear of the pump must be supported regardless
currently states that in order to carry 54,000 pounds of the mounting method.
(24,494 kg) on a three axle truck, the extremes of any
5. The splines of the pump shaft and the drive coupling
group of axles must be at least 23.5 feet (7.16 m) apart.
need Lubrication. If the gearbox is a wet drive then no
This equates to a truck with a wheelbase of at least 258
grease is required because the gearbox oil will lubricate
inches (655 cm) with a minimum length of 24 inches
the splines. If the gearbox coupling is sealed then the
(60.96 cm) from the center of tandems to the center of
splines needs to be greased with Heavy Lithium Grease
the rear axle.
covering all the Splines

6. For a wet mount, a gasket is required for the mounting NOTE: An arrow is cast into the rear of the pump
flange to PTO gearbox interface. Dry mount does not housing to identify rotation. Make sure the
require a gasket. rotation is correct.
7. Torque the mounting flange nuts to 50 ft. lbs (222 Nm). Rotate the pump in the direction as the PTO. Rotate the
pump in the mounting bracket so suction side is toward
NOTE: Some of the pipe fittings used are sealed by means
the reservoir suction port.
of two threaded tapered sections, one male and
one female. When these two tapers meet, you will
note a sudden increase in the force required to REINFORCING/AFTER FRAME EXTENSION
screw the fittings together. This is true of all tapered 1. Refer to "Truck Frame Strength" and "Section Modulus"
pipe threads. Further tightening will not only fail to tables. Determine section modulus by actual
increase the pressure tightness of the joint, but measurement of the truck frame. If reinforcing is
may ruin the connections and make correct required, always use at least 100,000 psi (758 MPa)
assembly impossible. steel to minimize the amount of reinforcing required. Use
Other fittings are of the o-ring boss type. These are Grade 90 weld material for any welding to be done.
installed by first screwing the lock nut flush to the 2. Strip the frame of obstructions in the area to be
upper thread land and installing fitting into port until reinforced or extended, one side at a time. If the truck
the nut contacts the surface of the port. Adjust frame cross members are bolted in, remove the bolts.
fitting to desired direction. Tighten locknut. Do not attempt to remove any rivets.
Most pressure fittings are the O-ring face seal 3. Place the reinforcing on the truck frame and clamp in
types. A small O-ring is compressed between the place. Mark the location of any rivets by striking the
male and the female fittings of the joint. Be sure the outside of the reinforcing over the rivet area so that the
O-ring is present on the fitting and seated properly rivets make an impression on the inside of the
in its groove before the fittings are tightened. reinforcing. Mark the approximate location of the crane
8. Remove the dust covers from the pump inlet and outlet mounting anchors so that no obstructions exist. Remove
and make sure that the suction and pressure sides of the the reinforcing and drill or torch cut clearance holes for
pump are correct. bolts or rivets. See Figure A.
Remove bolts, clamp on

reinforcing, and mark the Plan the location of the crane
bolt hole location from mounting anchors so they don’t
the inside of the frame interfere with the bolts, etc.
(Ref) Truck frame
The bolt hole clearance is

1/16 (1.52) to 1/8 (3.17) in
diameter larger than the
bolt shank
(Ref) Reinforcing
Do not remove the rivets.
The rivet hole clearance
Clamp on reinforcing and strike
9
is 1/2 (12.7) in diameter
NOTE: All dimensions the reinforcing in this area to
larger than the rivet head
are inches (millimeters) mark the location of rivets
Figure A

4. If reinforcing is to be welded on, torch cut hole pattern in place, install any crossmember bolts that were previously
reinforcing being careful to clear crane mounting removed, then drill through reinforcing and truck frame being
anchors. Install reinforcing, clamp in place, install any careful to clear crane mounting anchors and bolt reinforcing
crossmember bolts that were previously removed and in place. See Figure C for recommended drilling and bolting
weld to truck frame as shown in Figure B. procedure. Use 5/8, Grade 8 bolts, drill holes to 39/64
diameter, drive fit bolts and torque according to "Torque
In some cases, because of customer stipulation or truck
Values For Grade 5 and 8 Bolts" table in Section 2.
manufacturer voiding their warranty, bolt-on reinforcing is
required. In these cases, install the reinforcing, clamp in
2 (51)
1 (25.4) diameter
5 (127) holes for plug welds
Planned location of mounting

2 (51)
plate. Plug weld locations can
4 (101) be shifted to clear plate.
4 (101)
8 (203)
Crossmember bolt holes

plug weld. Holes can be
shifted slightly to clear.
Clearance holes for rivets on weld or

on reinforcement. Can be filet welded
around to eliminate plug weld holes.
Figure B
2 (51) Min
2 (51) Min
4 (101) 8 (203) Typ
NOTE: All dimensions are inches (millimeters) Figure C

5. If the frame through the rear suspension doesn't meet as in Figure B. Slide the reinforcing angle up from the
minimum specifications for RBM and section modulus bottom, butt it to existing forward reinforcing and weld
as shown on "Truck Frame Strength" table, it can be rear suspension reinforcing to forward reinforcing.
reinforced by adding an angle type of reinforcing as in Replace as much of the spring hanger cut out areas as
Figure D. See "Section Modulus tables, Table B for the possible and butt weld these pieces in.
required size of reinforcing. Strip all easily removable
If reinforcing angle is to be bolted on, drill hole pattern and
equipment from the frame through the suspension such
install bolts according to Figure C. Reinforce spring hanger
as spring stops, etc. Butt the reinforcing angle up
cut outs and the weld area, suspension reinforcing to forward
against the reinforcing forward of the suspension and
reinforcing by adding bars under these areas. The bars
mark the areas that will require cutting so that the angle
should be of the same thickness, width and yield strength as
will slide up around the spring hangers and against the
the reinforcing angle lip, and should be long enough to
existing truck frame and forward reinforcing. Torch out
extend at least 6 inches (152 mm) beyond either side of the
the marked areas in the long leg of the angle deep
weld or cut out areas. Weld these reinforcing bars to the
enough so that the lip of the angle can be slid up from
underside of the reinforcing with length-wise welds. Do Not
the underneath the frame to contact either existing truck
Weld Across The Flanges. Replace any equipment that
frame or spring hanger brackets (if they extend down
had been removed.
below the existing truck frame). If reinforcing angle is to
be welded to truck frame, cut out plug weld hole pattern
Reinforcing under crane
Cut outs Replace as much

material as possible. Butt weld
Butt weld
Overload spring stop.
S k it h a bo
Remove and replace.
w ong
ip lte th
w e r n ed
al
ld at e ge
al
Weld 6 (152)
l b we
ar ld
Skip 6 (152)
s
Weld 6 (152)
s
Skip 6 (152)
Weld 12 (304)
Truck frame (REF)
6 (152)
6 (152)
6 (152)
NOTE: All dimensions are
inches (millimeters) 9
6 (152)
Figure D
Reinforcing (REF)

AFTER FRAME MODIFICATION 7. Install Boom
If additional suspension reinforcing is required, as may be 8. Install winch cable

the case with a truck frame that tapers down to 9. Fill hydraulic reservoir
approximately 6 inches (15.24 cm) deep through the
suspension, a channel may be fabricated through the Torsion Box and ASH Stabilizer Installation
suspension for additional strength. To do this, install the
angle as described in the previous step, making sure that the 1. Determine installation position for the crane considering
long leg of the angle extends to the top of the truck frame. A the operating area of the crane, space for saddle tanks,
bar of the same material strength, thickness, length and truck frame crossmembers, or anything that might affect
flange width as the reinforcing angle is then added to the top installation and be sure the frame is clear of any
of the truck frame. The bar is butt welded to the top of the obstructions that might interfere with proper installation.
forward reinforcing, then skip-welded with 6 inches (15.24 2. Center the subbase on chassis at the proper location.
cm) of weld, 6 inches (15.24 cm) no weld, etc., along both
edges of the bar, front to back. Length of after frame (AF) 3. If subbase does not fit tightly on truck frame at all
may have to be modified for crane installation. If AF is too locations, do not force them together to remove gaps
long, cut off excess and remove any crossmembers from since they will not affect the units stiffness or strength.
back of truck frame. If AF is too short, the frame will have to Add spacers as required to level truck bed before
be lengthened. Use channels fabricated from 100,000 psi attaching it to the torsion box.
(758 MPa) yield material that are the same size as the truck
frame. Weld these channels to the ends of the existing truck Install Torsion Box
frame channels. Bevel the ends of the channels to get 100% Install outriggers on crane frame as shown in illustrated parts
weld joints with Grade 90 weld material. Fabricate an inner pages. Attach the appropriate hoses to the outrigger
channel of the same thickness as the truck frame channels cylinders. Cycle the outriggers to fill with oil completely and
to span the weld joint for at least 12 inches (30 cm) on each install the latch plate to hold outriggers in place during travel.
side of joint. Plug weld this channel to the inside of the truck
frame, then skip weld the inside edge of the top and bottom Crane to Chassis Mounting
flanges to the truck frame flanges
1. Center crane frame on chassis at designated distance.
CRANE MOUNTING PROCEDURE 2. The standard supplied stud is 32.5" long. For most
The following is a suggested sequence of steps required to applications, the stud will be required to be cut to a more
successfully mount the crane on the truck. This is only one of appropriate length per application. If studs must be
several possible ways to mount the crane and is offered as shortened, cut off stud on long thread end of stud.
an aid to planning the mounting of the crane. Following is the recommend method to determine the
required length.
Crane Component Installation Sequence Depth of frame + 17.5" = Required stud length
• Position Torsion Box and mark frame locations for NOTE: Do not use a cutting torch to shorten the mounting
Hydraulic Reservoir and ASH studs. If studs must be shortened, they must be cut
• Remove Torsion Box off with a saw.
• Install hydraulic pump 3. Run lock nut on short 2.75" threaded end of each stud
until one thread sticks out of the lock nut. The lock nut
• Locate and drill holes for Hydraulic Reservoir end of the stud will always be on the bottom side of the
• Install Hydraulic Reservoir stud when installed.
• Install pump lines to Reservoir 4. Insert stud to be used on internal side of truck frame into
hardened washer, bottom clamp plate and then the
• Position Torsion Box restraint tabs on proper frame spacers. Insert internal
stud into crane frame and frame spacer into truck frame.
• Install ASH
Install hardened washer and nut on top end of stud.
• Install Truck Bed
5. From the bottom, insert outside stud into hardened
• Install Frame Assembly washer, bottom clamp plate, up along the outside of the
truck frame rails into the crane frame bottom plate with
• Install Outriggers
2.75" short threaded end at bottom.
6. Route and connect hydraulic hoses to Reservoir and
Main Control Valve

6. Install hardened washer and first nut on top and tighten 11. Apply the final torque to the bottom lock nuts in the
both inside and outside stud nuts on top. (Note long sequence (following the above diagram) to the specified
thread end of stud is to the top.) torque of 1120 ±112 ft-lb.
7. Install 2nd nut on top and tighten the two nuts until they To keep the stud from turning, use a wrench to hold the
are locked. top nut.
NOTE: The jam nut is not to be secured using a pneumatic NOTE: Alternate between studs at each corner during the
impact tool. The jam nut should be hand tighten tightening process to insure studs are straight and
until snug against the 1st nut. Then, a ratchet bottom clamp plate is kept parallel with truck frame.
should be used to tighten the jam nut against the Failure to keep clamp plate parallel with truck
1st nut (applying a slight torque to secure nut). The frame will cause uneven edge loading and cause
bottom (lock nut) will secure stud appropriately. premature stud failure.
8. Use impact tool or ratchet to tighten (snug) the locknut
located on the bottom of the frame.
9. Torque bottom lock nut to specified torque of 1120 ±112
ft-lb.
CAUTION
Do not allow the nuts to bottom out on the threads on
To keep the stud from turning, use a wrench to hold the top
either end of the studs
nut.
NOTE: The following diagram illustrates the star pattern
tightening sequence that should be followed when
securing the bottom lock nut
10. Initially torque all nuts to approximately 600 ft-lbs in
WARNING
sequence (following the sequence below). When tightening bottom nuts keep the plate parallel to
truck frame. Failure to do so causes uneven edge loading
and stud failure.
Assembly
Sequence
Tighten
Second
Tighten
Fourth
Tighten
Third
Tighten
First
9
Plate must be parallel to truck
frame or stud failure will result

ASH TO TORSION BOX MOUNTING
CAUTION
Do not allow the nuts to bottom out on the
threads on either end of the studs
Torsion Box
(Ref)
Stabilizer Assy
(Ref)
Truck Frame
(Ref)
Plate must be parallel to

truck frame. Uneven loading
causes stud failure.
Tube Assy
(Ref)
Typical Both Sides

Typical Both Sides
Custom BOM for
Appropriate ASH
Spacer Kit (Ref)

Hydraulic Reservoir Installation 3. Install the return line from the crane frame to the filter on
the side of the reservoir.
1. Find a location for and install hydraulic oil reservoir.
Mounting brackets may be bolted to the truck frame. NOTE: The weight of suction and return hose and
Before placing reservoir in service, remove cleanout plumbing must be supported to prevent damage to
cover and inspect to ensure proper installation of the reservoir. Install support brackets and clamp or
diffuser. tie hoses up to eliminate strain on reservoir
connections.
2. Connect manifod return, winch drain, and pump suction
to couplings on reservoir before filling with oil.
Torsion Box (Ref)
(6 Plcs)
To Winch
Drain
To Return
Manifold
To Pump

BOOM INSTALLATION 4. Support outer end of boom securely and use the
overhead hoist to position the lift cylinder with the control
Lift Cylinder Installation valve to pin the cylinder to the boom ears. Torque pin
keeper capscrews to proper torque.
NOTE: Before attempting to assemble the boom and lift
cylinder to the frame, see Pin Bearing Inspection 5. Grease the three pin joints with gun grease and operate
the boom and lift cylinder through several complete
and Installation pages in this section. Before
cycles before placing machine in operation.
connecting hoses, boom must be opposite (180)
the rotation stop to minimize hose twist. 6. Route the 1/2 inch R12 telescope hoses over the turret
back plate and to the back side of the boom. Connect
1. Pin lift cylinder barrel in position in the turret.
the telescope cylinder connections at the back of the
2. Pin boom pivot to turret. (It will be necessary to use an boom.
overhead hoist for lifting boom and lift cylinder.)
7. Route the 3/4 inch R12 winch hoses and the 1/4 inch R1
3. Connect the 1/2 inch R12 hoses to the lift cylinder. winch drain hose through the turret then through the
holes in the side of the winch side plates and connect to
the winch fittings.

Wire Rope Installation the cable against the preceding wrap with a rubber
mallet until at least half of the drum is full. The remaining
1. Unspool approximately 15 feet (8 m) of cable and route half of the drum should wrap tightly because the fleet
the cable through the boom cable guides from the front angle of the cable will tend to pull the cable to the center
of the boom to the winch. of the drum thus wrapping tightly.
2. Install one end of the loadline cable into the winch drum 6. Continue winding the cable on the second, third and
using the wedge socket provided. fourth layer of the drum. Keep the cable paying in
3. Remove the cable keeper T-handle pin from the sheave straight to the boom to avoid side loading the boom. The
case and lay the cable over the top sheave. Replace the preceding layers will wrap smoothly guided by the first
top cable keeper pin. layer wrapping.
4. Unspool the remainder of the cable out from the back of 7. After cable is completely wrapped on drum, replace
the truck being sure the cable is straight and without remaining cable keeper bolts on the sheave case. Attach
kinks. Attach downhaul weight, wedge socket, hook and wedge socket and cable clip to end of cable per
cable clamp to the end of cable as shown in Loadline illustration in Loadline Section of parts manual and
Section. Torque cable clamp (clip) to 95 ft-lb (128 N·m). torque cable clip bolts to 95 ft-lb (128 N·m) for 9/16 inch
This torque must be rechecked after initial operation of cable.
the crane. Be sure cable clamp is attached to the free
end of the cable only. If equipped with optional 2/3 part Wedge Socket
Live
block, omit downhaul weight and assemble as shown in Dead
End Live End is
Loadline Section. Special care should be taken to reeve End Dead
End Entering
the cable through the wedge socket as shown below. Wrong Side
5. Spool the loadline onto the winch drum while
maintaining approximately 500 pounds (250 kg) of
tension on the cable (attaching a small vehicle to the end
of the loadline with another person lightly riding the
vehicle brakes while the cable is spooling on the drum 20 x Cable Dia
will accomplish this). While the first half of the winch Minimum
bare drum is filling, it will be necessary to force the cable
to wrap tightly against the preceding wrap by pounding RIGHT WRONG
Terminator Wedge Socket
Torque Value Table

Cable Size (inches) 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4
9
Torque ft/lbs 45 65 65 95 95 130 225 225 225 360
Torque values shown are based upon clean dry threads free of lubrication.

Winch to Truck Cab Clearance remaining four bearings are to be installed in the lift
cylinder, two at each side of the rod end of the cylinder
Check for winch mount tail swing clearance at top of cab. and two at each side of the butt end of the cylinder.
Any equipment that extends above the truck cab such as
exhaust stacks or air horns may interfere with the winch 2. The bearings should be started in their respective bores
mount when the boom is elevated and rotated. Shorten by rotating the bearing while applying inward pressure
exhaust stacks or move air horns, etc. to ensure clearance. with the hand. Once the bearing has been started
squarely into its bore, it can be driven to its full
Painting counterbored depth by tapping lightly with a rubber
mallet. The head diameter of the mallet should exceed
If crane is to be repainted, mask all decals prior to final paint the outside diameter of the bearing to ensure that the
or install all new decals in accordance with location drawings bearing is not damaged during assembly into the bore.
and illustrated parts catalog over final paint.
3. If the bearing appears to be loose in the bore (if it can be
PIN BEARING INSPECTION AND pushed in with hand pressure alone), it is permissible to
tighten the bearing by center punching the bore
INSTALLATION PROCEDURE diameter in approximately 50 places around and
throughout the 2 inch (51mm) deep bored area. Center
Pin Inspection punching will raise the metal around the edge of the
1. Remove the protective covering from pins and inspect punch mark and this raised metal will hold the bearing
each pin for nicks, gouges or deep wide scratches. A firmly in place during machine operation.
small nick or gouge up to 1/8 inch (3 mm) diameter can 4. After all bearings have been installed and before
be repaired by dressing the edges of the imperfection attempting to assemble the machine, insert the pins
with a file so that no metal protrudes above the circular through both bearings in each end of the lift cylinder and
surface of the pin. through the boom pivot bearings to insure alignment and
2. A circular scratch of up to 1/16 inch (1.5 mm) wide or fit are correct. Also check the two sets of pin holes in the
deep can be repaired as in 1 above. turret and the pin holes in the boom ears to ensure that
the pins will slide freely through the leading hole and
3. A lengthwise scratch on the pin of up to 1/32 inch start in the opposite hole. If a pin starts to bind through
(0.8 mm) wide or deep can be repaired as in 1 above. the leading hole, do not force the pin any further to avoid
4. Pins with defects larger than those listed in 1, 2 or 3 damaging the pin surface finish. Remove the pin and
should be replaced. clean any corrosion of burrs out of the holes with a round
file or emery cloth.
Bearing Installation 5. When pinning the boom to the turret, and the lift cylinder
1. The bearings furnished with this machine are made up to the turret and boom, use a round smooth bar of
of a tough epoxy impregnated wound glass backing approximately 1-1/2 inch (38 mm) diameter as a pry bar
shell with a thin inner layer of filament wound bearing to align the pin holes. A pry bar with a sharp edge, such
material. The outer bearing material should be visually as a crowbar, can gouge or cut bearing and this may
checked for imperfections. Bearings with cracks or lead to premature bearing failure.
gouges larger than 1/4 inch (6 mm) diameter on the
outside diameter should be replaced. COUNTERWEIGHTING
2. Inspect the inner diameter surface of the bearing. any Refer to Mounting Configuration pages in this section. The
scratches, cut or gouges which have penetrated through amount of counterweight and its location is dependent upon
the inner liner may cause premature failure of the the stability working area (180 x behind the truck or 360 x
bearing. The bearing should be replaced. around the truck), the weight of the truck and all permanently
attached equipment. Permanently attached equipment which
Trunnion Inspection can be considered as counterweight includes the bed,
reinforcing, PTO and pumps, tool boxes, etc. The torsion
The trunnion bore should either have a machined step or resisting subbase and rear stabilizers are considered part of
have a spring spacer installed to prevent inward movement this crane and not part of the counterweight. Additional
of the bearing. If equipped with a spring spacer, check to counterweight is usually added to the underside of the bed
make sure the opening is positioned over the grease hole. and/or to the torsion resisting subbase. On some trucks, a
heavy front bumper may also be required for stability around
Bearing Inspection the rear.
1. Two bearings are to be installed in the boom pivot
trunnion located directly below the winch and the

The 85% tipping factor as outlined in OSHA and ANSI In order to determine the amount of counterweight required,
specifications means that when lifting the full capacity loads it is necessary to add up the weight that each permanently
most likely to cause the truck (with outriggers and stabilizer attached piece of equipment will place on the front and rear
set) to overturn, the unit is at 85% of tipping over. Increasing axles of the truck along with the initial truck chassis weight
this full capacity load by 117.6% (overloading) will cause the and then compare the total front and rear axle weights with
unit to tip over. the weights listed on the “Mounting Configuration”
(Installation Section) pages to determine the amount and
location of counterweight required.
68 in 52 in Counterweighting Determination Example

(170 cm) (132 cm)
0 in 232 in
60 in (589 cm) 248 in
7500 lb (3402 kg) (152 cm) (630 cm)
Initial Chassis 8800 lb (3992 kg)
Weight Initial Chassis 1200 lb (544 kg)
150 lb (68 kg)
Weight Bed Weight
Pump and PTO Weight
(Wt) x (Dist from Front Axle)

= Rear Axle Wt Wt - Rear Axle Wt = Front Axle Wt
Wheel Base
Rear Front
Rear Axle Weight Front Axle Weight
Initial Front Axle Weight
(7500) x 0 (3402) x 0
= 0 lb = 0 kg 7500 - 0 = 7500 lb 3402 - 0 = 3402 kg
232 589
(150) x 60 (68) x 152
Pump and PTO Weight = 39 lb = 18 kg
232 589 150 - 39 = 111 lb 68 - 18 = 50 kg
(8800) x 232
Initial Rear Axle Weight = 8800 lb (3922) x 589 = 3922 kg 8800 - 8800 = 0 lb 3922 - 3922 = 0 kg
232 589
(1200) x 248
Bed Weight = 1283 lb (544) x 630 = 582 kg 1200 - 1283 = -83 lb 544 - 582 = -38 kg
232 589
Add the front and rear axle 10122 lb 4592 kg 7528 lb 3414 kg
weights
Compare with weight required
for this type of mount from
Mounting Configuration 1 10500 lb 4763 kg 8000 lb 3629 kg
9
Difference 378 lb 171 kg 472 lb 215 kg

Counterweighting Methods 2350 pounds (1066 kg) of concrete poured in the front of the
bed. See “Counterweighting for 180° Stability” in this section
Two methods of counterweighting may be used:
Determine axle weights added by the counterweight by using
a. a heavy front bumper and concrete in the bed or the same method as used before. Figure the center of the
b. concrete in the bed only. counterweight to determine where the weight acts. If the
counterweight is oddly shaped, figure the center and weight
The easiest and most economical method is usually of each regular shape. Weights ahead of the front axle
concrete in bed only. The amount of counterweight required require using a negative (-) distance in calculations.
will be 1132 + 918 = 2050 pounds (513 + 417 = 930 kg). Use
69 in 53.8 in
(175 cm) (137 cm)
20 in
(51 cm)
142 in (363 cm) 237 in (602 cm)

2350 lb (1060 kg)
0 in Concrete
(2350) x 142.8 (2350) - 1416 = 934 lb

= 1416 lb
237
1150 lb (520 kg) Bed Concrete
(1066) x 363 (1066) - 643 = 423 lb
= 634 kg
602
1132 lb 918 lb
Required Counterweight
513 kg 417 kg
Difference 284 lb 16 lb
130 kg 6 kg
The rear axle weight is 284 lbs (130 kg) heavier than required and the front axle weight is 16 lbs (6 kg) heavier than required.

Check the final weight of the unit with crane installed. See per man) to ensure that the axle ratings have not been
“Specifications Section” for weight of 571E and center of exceeded so that DOT certifications requirements can be
gravity. Note that this weight does not include weight of rear met.
ASH stabilizers [830 pounds (377 kg)]. Use 4” set back (Cab
After the unit is completely assembled, the stability test must
to Torsion Box).
be run in accordance with the Stability Test Procedure at the
Check the final unit weight with a full load of diesel (7.3 lbs end of this section to verify crane stability.
per gal) (0.87 kg per liter) and men (200 lbs per man) (90 kg
69 in
(179 cm)
21 in
(53 cm)
21 in
174 in (696 cm)
0 in (53 cm)
169.5 in (431 cm) 830 lb (377 kg)
15316 lb (6947 kg) Rear Stabilizer Wt
571E Crane Wt
4968 lb 5982 lb
Base Unit
2254 kg 2713 kg
1416 lb 934 lb
Counterweight 643 kg 423 kg
(15136) x 169.5
= 10954 lb (15136) - 10954 = 4326 lb
237
Add Crane Weight
(6947) x 431
= 4974 kg (6947) - 14974 = 1973 kg
602
(830) x 274
= 960 lb (830) - 960 = -130 lb
237
Rear Stabilizer Weight
(377) x 696
602
= 436 kg (377 - 436 = -59 kg
9
18298 lb 11148 lb
Total 8307 kg 5050 kg

The method shown below can be used to shift more weight Example
to the front of the crane than the previous methods. When
using this method, check for interference with hydraulic Concrete poured in the bed measures:
reservoir and truck tires. Bed attachment to truck should be • 4 inches (10.16 cm) deep
planned in advance. If the bed is attached to the torsion box
by bolting through the slots in torsion box, leave an open • 86 inches (218.44 cm) wide
area in concrete counterweight for hardware access. The • 70 inches (177.80 cm) long.
weight of the concrete can be determined by multiplying the
volume in cubic inches by 0.083 lb per cubic inch. The weight of the concrete is 4 x 86 x 70 x0.083 = 2000 lb.
(907 kg). The center of this weight is in the center of the
concrete slab.
8 in (20.3 cm)
44 in
111.8 cm)

BOOM REST REQUIREMENTS tie down point low enough to allow room for anti-two-block
weight. Do not shorten chain.
Before the mounting of a crane is complete, a boom rest
must be installed. A rest must be supplied for transport to The boom rest should be positioned to support the 1 st
reduce vibratory stress on the crane and truck and protect section boom. Be careful to avoid contacting the boom at or
rotation system from transient damage. near the end where the retract cables are located. Contact
with these cables will result in costly repairs.
Below are shown typical configuration designed to meet
boom support requirements. These Boom Rests are The boom rest saddle provided is designed to support the 1st
available at your National distributor. section boom. It will be necessary to modify the saddle to
make it narrower and reposition the support cushions under
The loadline shall be hooked to some point on the bed, truck the boom side plates if the boom is extended to reach the
frame, etc. to secure the hook weight during transport. Install boom rest.
Horizontal or Removable Mount

for Greater Load Space.
Bed Box

INITIAL CRANE RUN IN PROCEDURE The stability test load will be 1.18 times the load chosen from
the load rating area of the capacity chart.
1. Engage the PTO and run the truck engine at idle to
activate the pump (approximately 600 rpm). Turn the Example for 571E2
crane power switch on and operate the crane and
• Boom Length: 71' (21.64 m)
outriggers though all of their functions at least six (6)
times to purge cylinders of air. Operate the control • Loaded Radius: 60' (18.29 m)
valves slowly with the truck engine at idle and cycle each
• Load Rating: 2200 lb (998 kg)
cylinder through its complete stroke each time. Check to
see that movement of outriggers and boom correspond • Stability Test Load: 1.18 x 2200 lb (998 kg) = 2596 lb
with direction indicated on switches and levers. Refer to (1178 kg) (Includes weights of slings and downhaul
hydraulic or electrical schematic and parts pages to blocks.)
correct any problems.
Be sure the stability test weight is accurate. A 1% increase in
NOTE: Add oil to reservoir as required to keep air from stability test weight will mean up to a 10% increase in
reentering the system. counterweight. Extend the boom to the maximum boom
length and winch the stability load off the ground. Slowly
2. Set throttle according to engine RPM and PTO ratio to
boom the load down so the load will swing out, until the
get 2400 RPM pump shaft speed.
loaded radius is reached. As the boom is lowered keep
3. When all cylinders have operated through complete winching the load up to keep it about 6 inches off the ground.
cycles, stow crane and place the outriggers in the up
NOTE: Do not exceed loaded radius
position. The oil level should be visible near the top of
the sight gage. Lift and stability test must now be Slowly rotate the boom throughout the work area. As the
performed on the unit. Winch and crane tests should be boom is rotated, the boom will have to be raised and/or
conducted to insure proper performance. lowered to maintain the loaded radius because of subbase
flexure.
4. After testing is completed, the mounting bolts and all
cable clamp bolts should be re-torqued to specifications. On units not equipped with front stabilizers, tipping from
stabilizer support to front wheel support will occur as the load
5. Upon completion, overall height of crane vehicle
or boom is swung around the front. Do not attempt to lift
combination must be measured and posted inside of cab
rated loads around the front of the truck unless the unit is
informing driver of overall height.
equipped with a front stabilizer.
STABILITY CHECK NOTE: Weights of accessories installed on the boom or
loadline (including downhaul weight) must be
The chassis weight, before the crane is mounted, is intended deducted from the calculated load when checking
for use only as a guideline in determining the total weight stability.
required for the unit to be stable with an 85% tipping factor
(i.e. when lifting capacity load, the unit is at 85% of tipping or 4. If slight tipping occurs, but load can be kept from coming
less). in contact with ground by winching the load up, unit is
stable. If not, counterweighting will have to be added to
In order to ensure the stability of the unit with an 85% tipping get unit in a stable condition or decal must be added to
factor, a live load stability test must be performed on each define areas of full stability and areas of reduced
completed unit. Proceed as follows: capacity because of stability. If the unit is equipped with
1. Test the unit for stability on a firm level surface. a jib, the stability test should be repeated. Use the fully
extended jib capacity multiplied times 1.18 at the lowest
2. A Series 500E2 crane requires rear stabilizers for angle that the jib is rated fully extended.
stability. With the boom stowed, set the unit up level on
the outriggers and stabilizers. 5. When adding counterweight to the vehicle, it is usually
most effective when added as close to the crane as
3. When stability testing this unit, select the load from the possible. After adding counterweight, the above
capacity chart that is listed at the longest boom procedure must be repeated to insure the added
extension and approximately 30 of boom elevation. counterweight is adequate.
Boom Loaded Loaded

Model
Length Angle Radius
560E2 60' (18.28 m) 34.5° 50' (15.24 m)
571E2 71' (21.64 m) 32 60' (18.29 m)

SPECIFICATIONS
Hydraulic Pump
Displacements:
Section P1 ..................................................................... 34 GPM (128.7 LPM) at 2400 RPM
Section P2 .................................................................... 18 GPM (68.1 LPM) at 2400 RPM
Section P3 ..................................................................... 10 GPM (45.4 LPM) at 2400 RPM
Hydraulic System
Requirements:
Boom and Outrigger System ......................................... 18 GPM (68 LPM), 3900 psi +100/-000 (26.89 MPa)
Boom Extend ................................................................ 18 GPM (68 LPM), 2800 psi +50/50 (19.31 MPa)
Boom Retract ................................................................ 18 GPM (68 LPM), 2900 psi +100/-000 (20.00 MPa)
Winch System ............................................................... 34 GPM (129 LPM), 3300 psi +100/-000 (22.75 MPa)
Turn ............................................................................... 10 GPM (38 LPM), 2350 psi +100/-000 (16.20 MPa)
Reservoir
Capacity ........................................................................ 66 Gallons (250 L)
Filtration ........................................................................ 10 Micron Return
Flow rates listed are at free flow condition (approx. 100 psi/ 1 MPa)
HCA
Load charts are based on 2650 psi (18.27 MPa) Constant Pressure (2800 psi (19.31 MPa) Trip Pressure on HCA)
Winch System Wire Rope.............................................. Standard 325 ft (99 m) of 9/16 “(14.3 mm) diameter,
Rotation Resistant Nominal Breaking Strength ............. 38,500 lb (17,463 kg) 325 ft (99 m) of 9/16 “(14.3 mm)
diameter
Rotation Resistant Nominal Breaking Strength ............. 38,500 lb (17,463 kg)
Winch Speed and Pull

Winch Pull Winch Speed BOS Winch Speed Rope Capacity
Layer
lbs (kg) fpm (mpm) fpm (mpm) ft (m)
1 10,200 (4627) 111 (34) 157 (48) 64 19
2 9,200 (4173) 123 (38) 173 (53) 136 41
3 8,400 (3810) 135 (42) 191 (59) 215 65
4 7,700 (3493) 147 (45) 207 (64) 301 91
5 7,100 (3221) 159 (49) 220 (68) 394 120
NOTE: All ratings based on 34 GPM at 3300 psi (128.7 LPM at 22.75 MPa)- Burst of Speed maximum pull = 3000 lb (1361 kg)
Crane Operating Speeds

Rotation 375° 35 ± 5 sec
27-71 Extend 50+/-6 fpm (53 +/-6 sec)
27-21 Retract 50+/-6 fpm (50 +/-6 sec)
23-60 Extend 49+/- 6 fpm (45 +/-5 sec)
23-60 Retract 51+/- 6 fpm (44+/-5 sec)
27-90 Extend 44+/- 6 fpm (85 +/-12 sec)
27-90 Retract 27 +/-6 fpm (140+/-30 sec) 9


500E2 SERVICE MANUAL SCHEMATICS
SECTION 10
SCHEMATICS
For your convenience, the latest version of schematics

available at the time of printing are placed in this section.
10
SCHEMATICS 500E2 SERVICE MANUAL

500E2 SERVICE MANUAL ALPHABETICAL INDEX
ALPHABETICAL INDEX
jib Load Limiting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
After Frame Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Anti-two Block Internal Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ASH to Torsion BoX Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Rest Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Concrete poured in the bed measures: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Configuration 1 - 571E2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Control Valve Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Counterweighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Crane Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Crane Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Crane to Truck Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Extend Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Fasteners And Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General Adjustment And Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
HCA Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hydraulic System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Crane Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Inner Wear Pad Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Minimum Truck Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Mounting Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Pin Bearing Inspection And Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Positioning Crane On Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Pto Horsepower Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Reinforcing/after Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Requirements For Optional Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Rotation Stop-mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Servicing The Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Stability Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
APL-1
ALPHABETICAL INDEX SERVICE MANUAL 500E2
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Three Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Three Section Boom ATB Wire Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Three Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Truck Frame Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Truck Frame Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
APL-2

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SERVICE MANUAL 1

This Manual has been prepared for and is considered part of -

500E2 Telescoping Crane

To prevent death or serious injury:

Manitowoc Cranes, Inc.

National Crane Corporation

Technical Field Parts Factory Training

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System

SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crane Installation

Published 03/24/10 Control # 112-01 1-1

500E2 Series Major Components

Item Component Item Component

GENERAL MAINTENANCE Cleanliness

1-2 Published 03/24/10 Control # 112-01

Locks When bearings are pressed into a retainer or bore, apply

Published 03/24/10 Control # 112-01 1-3

Sleeve Bearings • Climate zones D and E after 4000 to 5000 hours of

1-4 Published 03/24/10 Control # 112-01

• Cracked or corroded connectors, battery terminals, and

Fatigue Of Welded Structures Loctite

Published 03/24/10 Control # 112-01 1-5

Adhesive/Sealant Application Use of proper torque values is extremely important. Improper

NOTE: For standard metric hex

1-6 Published 03/24/10 Control # 112-01

Published 03/24/10 Control # 112-01 1-7

1-8 Published 03/24/10 Control # 112-01

Ta = Torque required (specified) L = Length of torque wrench in inches (center of drive

Published 03/24/10 Control # 112-01 1-9

1-10 Published 03/24/10 Control # 112-01

Published 03/24/10 Control # 112-01 2-1

Inspect all sealing elements (O-ring, gaskets, etc.) when

Label Parts When Disassembling Hydraulic Filter

2-2 Published 03/24/10 Control # 112-01

Replacing Spool Seals

NOTE: Remove cap

Published 03/24/10 Control # 112-01 2-3

Disconnect drain line from the

Install cap fitting to the plug outlet

Operate the function.

Function operates correctly.

Cap each of the other unloaders in

Flush to remove contamination

2-4 Published 03/24/10 Control # 112-01

O-RING FACE SEAL

O-RING FACE SEAL FITTING SIZE O-RING BOSS

Published 03/24/10 Control # 112-01 2-5

2-6 Published 03/24/10 Control # 112-01

Published 03/24/10 Control # 112-01 3-1

3-2 Published 03/24/10 Control # 112-01

16. Route sheave case end of anti-two-block wire around

Published 03/24/10 Control # 112-01 3-3

NOTE: Trapped air must be bled from the system before .

WARNING 9. When the pressure reaches capacity load pressure, the

3-4 Published 03/24/10 Control # 112-01

Published 03/24/10 Control # 112-01 3-5

3-6 Published 03/24/10 Control # 112-01

Published 03/24/10 Control # 112-01 4-1

THREE SECTION BOOM MAINTENANCE

NOTE: It is important to achieve these boom postitions