9-28 Published 08/16/19 Control # 112-05
CRANE INSTALLATION 500E2 SERVICE MANUAL
Wire Rope Installation
1. Unspool approximately 15 feet (8 m) of cable and route
the cable through the boom cable guides from the front
of the boom to the hoist.
2. Install one end of the loadline cable into the hoist drum
using the wedge socket provided.
3. Remove the cable keeper T-handle pin from the sheave
case and lay the cable over the top sheave. Replace the
top cable keeper pin.
4. Unspool the remainder of the cable out from the back of
the truck being sure the cable is straight and without
kinks. Attach downhaul weight, wedge socket, hook and
cable clamp to the end of cable as shown in Loadline
Section. Torque cable clamp (clip) to 95 ft-lb (128 N·m).
This torque must be rechecked after initial operation of
the crane. Be sure cable clamp is attached to the free
end of the cable only. If equipped with optional 2/3 part
block, omit downhaul weight and assemble as shown in
Loadline Section. Special care should be taken to reeve
the cable through the wedge socket as shown below.
5. Spool the loadline onto the hoist 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 will accomplish
this). While the first half of the hoist bare drum is filling, it
will be necessary to force the cable to wrap tightly
against the preceding wrap by pounding the cable
against the preceding wrap with a rubber mallet until at
least half of the drum is full. The remaining half of the
drum should wrap tightly because the fleet angle of the
cable will tend to pull the cable to the center of the drum
thus wrapping tightly.
6. Continue winding the cable on the second, third and
fourth layer of the drum. Keep the cable paying in
straight to the boom to avoid side loading the boom. The
preceding layers will wrap smoothly guided by the first
layer wrapping.
7. After cable is completely wrapped on drum, replace
remaining cable keeper bolts on the sheave case. Attach
wedge socket and cable clip to end of cable per
illustration in Loadline Section of parts manual and
torque cable clip bolts to 95 ft-lb (128 N·m) for 9/16 inch
cable.
Dead
End
Dead
End
Live End is
Entering
Wrong Side
Live
End
20 x Cable Dia
Minimum
RIGHT
WRONG
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
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.
Terminator Wedge Socket
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