National Crane Published 08/16/19 Control # 112-05 4-7
500E2 SERVICE MANUAL BOOM
15. Slide extend cylinder /extend cables into 2
nd
/3
rd
boom
assembly enough to assemble extend cable anchor into
bottom rear of 3
rd
section. Route anti-two-block cable
over extend cable anchor as anchor slides into 3
rd
section. Be aware of extend and anti-two-block cable
location when inserting cylinder into boom sections,
inadvertent crushing or other damage to cables will
warrant replacement.
16. Tighten capscrews clamping extend anchor together.
These capscrews will protrude through the 3
rd
section
bottom plate, locking the anchor in position.
17. Loop anti-two-block cable at the extend cable anchor in
the 3
rd
and install anti-two-block cable clamp. Do not
completely tighten clamp capscrew.
18. Assemble anti-two-block clamp in the sheave case.
Reeve anti-two-block cable around anchor and through
holes in side plate of sheave case. Pull approximately 2
feet (60 cm) of cable out the end of the boom for proper
routing and termination.
19. Tighten anti-two-block clamp on the extend cable anchor
in the rear of the boom. Tension anti-two-block cable
from the sheave case end of the boom, and tighten anti-
two-block clamp located in sheave case.
20. Visually verify that the extend and anti-two-block cables
are properly routed on their sheaves and continue to
slide the extend cylinder and cables into the boom
sections. Keep extend and anti-two-block cables
supported and slightly tensioned during insertion of
cylinder, to maintain proper cable placement.
21. As the extend cylinder keeper plate nears the 2
nd
section, adjust the height of the cylinder to allow the
cylinder to access the cylinder keeper cutouts in the
doubler plates on the sides of the 2
nd
section.
22. Drop the cylinder down into the vertical cutouts in the
doubler plates on the sides of the 2
nd
section.
23. Install lock bar and capscrews to the extend cylinder.
24. Position 2
nd
/3
rd
/ cylinder assembly in position to be
inserted into 1
st
section. Lay retract cables out under
2
nd
/3
rd
/ cylinder to allow easy installation as the booms
are assembled.
25. Slide 2
nd
/3
rd
/ cylinder assembly into 1
st
section boom
approximately 2 feet (60 cm). Use caution during this
step to keep retract cables straight and on the correct
side of the boom assembly as the sections are
assembled.
26. Continue to slide 2
nd
/3
rd
/cylinder assembly into 1
st
until
it is approximately halfway into 1
st
.
27. Assemble bottom front wear pads in 1
st
section, trapping
ends of retract cables in slots on bottom of 1
st
section.
Lift 2
nd
/3
rd
/cylinder assembly up to ease installation.
28. Slide boom together to within 12 inches (30 cm) of
complete retraction. Install upper front spacer bar in 1
st
section and upper front wear bar and cable guide
assembly to 2
nd.
29. Retract boom completely, using proper hardware and
spacers, connect extend cylinder butt plate to the winch
mount. Hydraulic power source can be utilized at this
time if slight cylinder length adjustment is necessary.
30. Slide extend cable anchor into position in winch mount.
Push threaded ends of 5/8 inch (15.88 mm) extend
cables through holes in anchor and assemble hex nuts
onto threaded ends.
31. Assemble top/rear wear pads to the top of the 2
nd
and
3
rd
boom sections with the cam plates.. Wear pads can
be inserted from the winch mount end of the boom.
Install capscrews through holes in outer boom sections.
32. 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
rotating, end for end, the wear pad and plate or the wear
pads and plate independently. This is possible because
the holes in these parts are offset from the center. The
holes are 0.06" (1.5 mm) off center in the plate and 0.03"
(0.8 mm) off center in the wear pad. Various
combinations of rotation of these parts allow the
adjustment.
a. Adjust pads until they are within 0.03” (0.8mm) off
center in the were pad. Various combinations of
rotation of these parts allows the adjustment.
b. Torque retainer capscrews to 110 ft-lb (149 N-m).
Failure to properly torque capscrews will cause loss
of preload and cause excessive side clearance
between sections.
33. Approximately 10 feet (300 cm) of anti-two-block cable
will be available on the winch mount end of the boom to
route and hookup to the control console wiring. Find the
end of this cable and slide the cord grip/strain relief
hookup onto it and slide it up the cable into approximate
position inside the boom.
34. Assemble the extension spring and spade bolt to the
cord grip. Assemble the spade bolt through the extend
cylinder anchor with a hex nut. Adjust tension on anti-
two-block cable by sliding cord grip down cable into the
boom. Approximately 2 inches (5 cm) of spring
extension should be adequate for proper boom
operation.
35. Visually check each end of boom for proper extend,
retract and anti-two-block cable routing and placement.
To Next Page
Loading...
Need help?
General
