National Crane Published 10-30-2014 Control # 040-09 5-33
1400H OPERATOR AND SERVICE MANUAL SERVICE
17. Install a nut on the threaded ends of the 5/4/3 retract
cables, to keep the cable ends from pulling thru the
anchor as the sections are pushed together.
18. Push the 4th-5th section inside the 3rd section, until it is
within 36 in (90 cm) of full insertion.
19. Install side wear pads with appropriate shims on front
inside of the 3rd section boom. Install upper spacer bar
and cable guide with wear pad and related hardware on
the top to the 3rd section. Shim according to calibration
instructions, or as pads were originally removed and
tagged.
20. Slide 4th-5th section inside 3rd until the end of the 4th
section hits against the doubler bars in the 3rd section.
Use caution as the 5/4/3 retract cable threaded end gets
close to the grooves in the lower front pad plate, adjust
as necessary to allow proper placement. A scribe mark
on the 4th section at full retraction will aid in cable
tensioning for proper boom sequence later.
21. Assemble top rear wear pads with the cam plates to the
top of the 4th section. See step #11 for pad installation
detail.
22. Uncoil 4/3/2 retract cables out of the 5th section,
assemble 3rd section retract sheaves and pins into the
inside of the 3rd section rear, using proper hardware and
loctite 243, reeve cable over sheave installing upper
keeper capscrew and lower rear pad, this pad serves as
a cable keeper, lower pad and side pad for the rear of the
section.
23. Pull threaded end of 4/3/2 retract cables, now under the
3rd section, towards front of boom.
24. Assembly step 22 completes the 5/4/3 boom section
stage, at this point the Hydraulic extension cylinder and
related cables and components are inserted into the 3rd-
4th-5th section assembly starting with step 24
25. Support extension cylinder in a workable location and
install the 3 extend sheaves in the sheave case end of
the cylinder, orientate the pin so that the bearing grease
holes are on the unloaded side of the pin (towards
cylinder butt plate). Slide pin in thru round area of
keyway shaped slot, installing sheaves one at a time, as
the pin is slide thru the sheave case. Align slots in pin
with square keyway side plate cutouts and push pin/
sheaves rearward (towards cylinder butt plate) into slot.
26. Install 3 2/3/4 extend cables over sheaves by placing
button end thru opening between the sheave and the
front double tapered plate on the cylinder. After the
cables are in place, install the plastic tapered cylinder
pads on the top and bottom shelves of the cylinder
sheave case, these pads when secured in place act as
cable retainers as well as wear pads, again apply loctite
and jam nuts in these locations.
27. Pull the 3 button ends thru the extend cylinder sheave
case until there is enough slack to install the 2/3/4
extend cable anchor, install cable anchor on extend
cables, keep capscrews clamping the two halves of the
anchor together just tight enough to not let the cables
escape from their positions, this will allow easier
assembly into the 4th section anchor point.
28. Drape 2/3/4 extend cables that come off the top of the
sheaves in an area to avoid damage, preferably on the
top of the extend cylinder, this will put them in their
approximate location as the cylinder is installed into the
5th/4th/3rd boom assembly.
29. Slide extend cylinder into the 3rd-4th-5th boom
assembly approximately 36 inches (90cm) Raise
cylinder up at an angle slightly to allow easier access to
the 2/3/4 extend cable anchor in the rear of the 4th
section. Install 2/3/4 extend cable anchor and cable
ends into the anchor point. Install keeper plates over the
retract cable ends, these keepers are shaped to retain
the 2/3/4 anchor as well as the retract cable ends.
Tighten capscrews holding the two halves of the 2/3/4
anchor assembly together.
30. Lower extend cylinder to a position parallel with the 3rd-
4th-5th boom assembly and slowly push the cylinder into
the 3rd-4th-5th boom assembly until the cylinder collar
makes contact with the 3rd section rear vertical doubler
plates. Monitor 2/3/4 extend cable location as cylinder
slides into boom sections to avoid damaging cables.
31. Raise extend cylinder up to allow cylinder collar to slide
thru and align with the anchor pocket on the back of the
3rd, lower cylinder, collar will move down into cylinder
anchor pocket, if properly positioned over pocket.
Assemble lock bar and proper hardware to the cylinder
collar, this will retain the cylinder into the anchor pocket.
32. Attach button end of 1/2/3 small extend cables into
anchor point on the rear top plate of the 3rd section, a
thin plate on the bottom and a thicker anchor plate on
the top of the 3rd section top are required for proper
cable retention, assemble with proper hardware and
Loctite 243.
33. Lay 1/2/3 extend cables on the top of the 3rd section
with the proper sheaves and pins that eventually will
attach to the top plate of the 2nd section. Arrange cables
per illustration (see figure 1).
34. The 3rd-4th-5th and cylinder assembly is now ready to
assemble into the 2nd section boom.
35. Slide 3rd-4th-5th and cylinder assembly into the 2nd
section boom approx. 36 in (90 cm) keep the 3rd-4th-5th
and cylinder assembly suspended to avoid damage to
the 4/3/2 retract cables.
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