National Crane Published 08/16/19 Control # 112-05 6-5
500E2 SERVICE MANUAL SWING
the slot on the nut portion of the pinion bolt at 25 ft-lb
(34 Nm) If the pinion bolt is between slots always
tighten to the next slot.
NOTE: Install a 1/2-13 bolt into the end of the pinion shaft
on the outboard side and check the rolling torque.
Preload of the bearing rolling torque should be 35-
50 ft-lb (47-68 Nm). Apply Loctite to the pinion
locking bolt (46) and torque to 20 ft-lb (27 Nm).
8. Install the input carrier section (44) with Sun gear (45)
attached with retaining ring (43).
9. Install the sun gear (41) and thrust washer (34)
10. Assemble the brake section by first installing the O-ring
(23) on the brake housing (2). Install six capscrews (27)
to the brake housing (2) and torque to 10 ft-lb (13 Nm).
Notice the position of the brake port in conjunction with
the drain and fill holes in the housing.
11. Install the O-ring (20) and back-up ring (19) on the small
step of the piston (5).
12. Install one back-up ring (22) and one 0-ring (21) on the
large step of the piston (5). Apply a slight film of oil on
the O-rings and back-up rings before installing.
13. Carefully press the assembled piston (5) into the brake
housing (2), taking care not to damage the rings.
NOTE: The position of the dowel pinhole in piston with the
brake release port for correct assembly.
14. Insert the brake driver (8) into the assembled brake
housing (2) and piston (5).
15. Install the stator plates (16) and friction disks (17)
starting with one stator plate and alternating between
friction disk and stator plate until six stator plates and
five friction disks are used.
NOTE: Soak friction disk in EP-90 for 24 hrs. before
installation.
16. Reinstall the retaining ring (37) into the piston.
17. Install six springs (15) into the holes in the motor adapter
(3).
18. Mount the motor adapter (3) to the brake housing (2)
with six capscrews (28) checking to make sure the roll
pin (18) is in line with the dowel hole in piston (5).
NOTE: Notice the position of the motor mounting hole in
relation to the brake release port for correct
reassembly.
19. Fill the gearbox to desired level with EP-90 gear lube.
ROTATION STOP-MECHANICAL
The rotation stop system is designed to stop crane rotation
beyond 375 degrees in the clockwise or counterclockwise
directions. This is accomplished by mechanically returning
the control valve to the centered position as full rotation is
approached. The operator will feel the control lever begin to
pull in the opposite direction as full rotation is approached.
The operator should not resist this counteracting force, but
permit the rotation stop system to return the lever to neutral.
If a load cannot be reached or placed due to the available
rotation, the crane must be re-positioned.
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.
2. Make certain that the turn lever is vertically aligned. If
not, adjust the lever at the clevis connecting it to the
control valve.
3. With the turn lever vertically adjusted, verify that the
spacer is centered in the turn control rod tab.
4. If it is not centered, loosen the two nuts, one on either
side of the spacer. Turn the nuts in the same direction
until the spacer is centered. Tighten the nuts against the
ends of the spacer to secure it in place.
5. Verify that the flag is sill centered between the stop pins.
Pinion Locking Bolt
Pinion Bolt
DANGER
Attempting to override the rotation stop system will result
in damage to the crane and possible injury to the operator.
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