National Crane Published 08/16/19 Control # 112-05 9-29
500E2 SERVICE MANUAL CRANE INSTALLATION
Hoist to Truck Cab Clearance
Check for hoist mount tail swing clearance at top of cab. Any
equipment that extends above the truck cab such as exhaust
stacks or air horns may interfere with the hoist mount when
the boom is elevated and rotated. Shorten exhaust stacks or
move air horns, etc. to ensure clearance.
Painting
If crane is to be repainted, mask all decals prior to final paint
or install all new decals in accordance with location drawings
and illustrated parts catalog over final paint.
PIN BEARING INSPECTION AND
INSTALLATION PROCEDURE
Pin Inspection
1. Remove the protective covering from pins and inspect
each pin for nicks, gouges or deep wide scratches. A
small nick or gouge up to 1/8 inch (3 mm) diameter can
be repaired by dressing the edges of the imperfection
with a file so that no metal protrudes above the circular
surface of the pin.
2. A circular scratch of up to 1/16 inch (1.5 mm) wide or
deep can be repaired as in 1 above.
3. A lengthwise scratch on the pin of up to 1/32 inch
(0.8 mm) wide or deep can be repaired as in 1 above.
4. Pins with defects larger than those listed in 1, 2 or 3
should be replaced.
Bearing Installation
1. The bearings furnished with this machine are made up
of a tough epoxy impregnated wound glass backing
shell with a thin inner layer of filament wound bearing
material. The outer bearing material should be visually
checked for imperfections. Bearings with cracks or
gouges larger than 1/4 inch (6 mm) diameter on the
outside diameter should be replaced.
2. Inspect the inner diameter surface of the bearing. any
scratches, cut or gouges which have penetrated through
the inner liner may cause premature failure of the
bearing. The bearing should be replaced.
Trunnion Inspection
The trunnion bore should either have a machined step or
have a spring spacer installed to prevent inward movement
of the bearing. If equipped with a spring spacer, check to
make sure the opening is positioned over the grease hole.
Bearing Inspection
1. Two bearings are to be installed in the boom pivot
trunnion located directly below the hoist and the
remaining four bearings are to be installed in the lift
cylinder, two at each side of the rod end of the cylinder
and two at each side of the butt end of the cylinder.
2. The bearings should be started in their respective bores
by rotating the bearing while applying inward pressure
with the hand. Once the bearing has been started
squarely into its bore, it can be driven to its full
counterbored depth by tapping lightly with a rubber
mallet. The head diameter of the mallet should exceed
the outside diameter of the bearing to ensure that the
bearing is not damaged during assembly into the bore.
3. If the bearing appears to be loose in the bore (if it can be
pushed in with hand pressure alone), it is permissible to
tighten the bearing by center punching the bore
diameter in approximately 50 places around and
throughout the 2 inch (51mm) deep bored area. Center
punching will raise the metal around the edge of the
punch mark and this raised metal will hold the bearing
firmly in place during machine operation.
4. After all bearings have been installed and before
attempting to assemble the machine, insert the pins
through both bearings in each end of the lift cylinder and
through the boom pivot bearings to insure alignment and
fit are correct. Also check the two sets of pin holes in the
turret and the pin holes in the boom ears to ensure that
the pins will slide freely through the leading hole and
start in the opposite hole. If a pin starts to bind through
the leading hole, do not force the pin any further to avoid
damaging the pin surface finish. Remove the pin and
clean any corrosion of burrs out of the holes with a round
file or emery cloth.
5. When pinning the boom to the turret, and the lift cylinder
to the turret and boom, use a round smooth bar of
approximately 1-1/2 inch (38 mm) diameter as a pry bar
to align the pin holes. A pry bar with a sharp edge, such
as a crowbar, can gouge or cut bearing and this may
lead to premature bearing failure.
COUNTERWEIGHTING
Refer to Mounting Configuration pages in this section. The
amount of counterweight and its location is dependent upon
the stability working area (180 x behind the truck or 360 x
around the truck), the weight of the truck and all permanently
attached equipment. Permanently attached equipment which
can be considered as counterweight includes the bed,
reinforcing, PTO and pumps, tool boxes, etc. The torsion
resisting subbase and rear stabilizers are considered part of
this crane and not part of the counterweight. Additional
counterweight is usually added to the underside of the bed
and/or to the torsion resisting subbase. On some trucks, a
heavy front bumper may also be required for stability around
the rear.
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