Manitowoc National Crane 500E2 Service Manual
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Manitowoc National Crane 500E2 Service Manual

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National Crane 500E2
Service Manual
9869

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  • Page 1 National Crane 500E2 Service Manual 9869...
  • Page 2 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside.
  • Page 3 SERVICE MANUAL This Manual has been prepared for and is considered part of - 500E2 This Manual is Divided into the following Sections: SECTION 1 INTRODUCTION SECTION 2 HYDRAULIC SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION 4 BOOM SECTION 5 HOIST SECTION 6 SWING SECTION 7...
  • Page 4 THIS PAGE BLANK...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1 ..........Introduction General .
  • Page 6 Parts Replacement............2-4 Maintenance Records .
  • Page 7 Boom Disassembly Alternative #2 ......... . 4-5 Additional Maintenance, Disassembled Boom.
  • Page 8 Arctic Conditions Below -9°C (15°F) ........7-2 Chassis Grease .
  • Page 9 Angle Under Reinforcement (Table D)........9-9 Requirements For Optional Single Front Outrigger .
  • Page 10 THIS PAGE BLANK TOC-vi...

  • Page 11: Section 1

    500E2 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Fatigue Of Welded Structures .

  • Page 12: New Owner

    If you are the new owner of a National crane, please register Crane distributor for the latest information. Your National it with Manitowoc Crane Care so we have the ability to Crane distributor is equipped with the proper tools, contact you if the need arises.

  • Page 13: Cleanliness

    500E2 SERVICE MANUAL INTRODUCTION NOTE: Safety is the number as recommended. Always check the job after it is complete one consideration when working around machines. Safety is a matter of to see that nothing has been overlooked. Recheck the understanding the job to be done and the application various adjustments by operating the machine before of good common sense.

  • Page 14: Gaskets

    INTRODUCTION 500E2 SERVICE MANUAL number and letter designator. If no letter designators are Visual Inspection found, wire the components together to assure correct Do a visual inspection daily on all hydraulic components for installation. Reusable bearing components should be missing hose clamps, shields, guards, excessive dirt build installed in their original positions.

  • Page 15: Electrical

    500E2 SERVICE MANUAL INTRODUCTION Hydraulic Lines This crane has multiple computer systems (crane control, RCL, engine & transmission control) that are highly When disconnecting hoses, tag each one to ensure proper susceptible to voltage/amperage surges in the electrical identification during assembly.

  • Page 16: Dielectric Grease

    INTRODUCTION 500E2 SERVICE MANUAL Climate Zone Classification Zone Classification A (Tropical Moist) Latitude 15° - 25° North and South (All months average above 64° F [18° C]) B (Dry or Arid) Latitude 20° - 35° North and South (Deficient of precipitation most of the year) C (Moist Mid-Latitude) Latitude 30°...

  • Page 17: Loctite

    500E2 SERVICE MANUAL INTRODUCTION inspections depends on the age of the equipment, the severity of the application, and the experience of the Bead Application operators and the maintenance personnel. The following are known high stress areas and should be inspected as part of a preventive maintenance program: •...
  • Page 18 INTRODUCTION 500E2 SERVICE MANUAL Special attention should be given to the existence of damaged, it should immediately be removed from service lubricant, plating, or other factors that might require variation until recalibrated. When using a torque wrench, any erratic or from standard torque values.
  • Page 19 500E2 SERVICE MANUAL INTRODUCTION Table 1-1 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-20 UNC 13.5 13.2 12.8 5/16-18 UNC 19.1 18.6 18.1 24.0 23.4 22.8...
  • Page 20 INTRODUCTION 500E2 SERVICE MANUAL Table 1-2 Inch Series with Fine Threads (UNF) – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 15.0 14.6 14.2 5/16-24 UNF 21.1 20.6 20.1 27.2 26.5 25.8 3/8-24 UNF...
  • Page 21 500E2 SERVICE MANUAL INTRODUCTION Table 1-3 Metric Series with Coarse Threads – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (Nm) Property millimeter, and Series Class Maximum Nominal Minimum Designation M6x1.0 10.9 12.2 11.9 11.6 12.9 14.3 13.9 13.6 20.2 19.7 19.2...
  • Page 22 INTRODUCTION 500E2 SERVICE MANUAL Table 1-3 Metric Series with Coarse Threads – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (Nm) Property millimeter, and Series Class Maximum Nominal Minimum Designation 2089.8 2037.6 1985.3 M36x4 10.9 2976.4 2902.0 2827.6 12.9 3483.0 3395.9 3308.9...
  • Page 23 500E2 SERVICE MANUAL INTRODUCTION Table 1-4 Metric Series with Fine Threads – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (Nm) Property millimeter, and Series Class Maximum Nominal Minimum Designation 405.7 395.5 385.4 M20x1 10.9 577.8 563.3 548.9 12.9 676.1 659.2 642.3...
  • Page 24 INTRODUCTION 500E2 SERVICE MANUAL Table 1-5 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads (Continued) Size Torque (Nm) M8x1.25 M10x1.5 Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength. Stainless steel fasteners tend to gall while being tightened.
  • Page 25 500E2 SERVICE MANUAL INTRODUCTION Inch Series with Coarse Threads (UNC) – Untreated (black finish) Table 1-9 Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-20 12.5 11.5 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 259.5 3/4-10 7/8-9 1 1/8-7 1342 1288 1234 1141 1097 1053...
  • Page 26 INTRODUCTION 500E2 SERVICE MANUAL Table 1-10 Inch Series with Fine Threads (UNF) – Untreated (black finish) (Continued) Torque (ft/lb) Size Grade Maximum Nominal Minimum 5/16-24 3/8-24 7/16-20 84.5 1/2-20 9/16-18 174.5 5/8-18 299.5 3/4-16 439.5 7/8-14 1-12 1009 644.5 1-14 908.5 1 1/8-12 1500...
  • Page 27 500E2 SERVICE MANUAL INTRODUCTION Table 1-11 Metric Series with Coarse Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum M5x0.8 10.9 12.9 10.5 10.5 M6x1 10.9 12.9 M8x1.25 10.9 36.5 12.9 43.5 M10x1.5 10.9 12.9 M12x1.75 10.9 12.9...
  • Page 28 INTRODUCTION 500E2 SERVICE MANUAL Table 1-11 Metric Series with Coarse Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum 1538 1479 1420 M30x3.5 10.9 2163 2080 1997 12.9 2595 2495 2395 2681 2578.5 2476 M36x4 10.9 3964 3812...
  • Page 29 500E2 SERVICE MANUAL INTRODUCTION Table 1-12 Metric Series with Fine Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum 331.5 M18x1.5 10.9 12.9 M20X1 10.9 667.5 12.9 464.5 M20x1.5 10.9 12.9 M22x1.5 10.9 888.5 12.9 1111 1068 1025...

  • Page 30: Weld Studs

    INTRODUCTION 500E2 SERVICE MANUAL WELD STUDS received residual oils. Special lubricants are not recommended. Unless otherwise specified the following grade 2 torque Torque values for bolts listed above are not values (+/- 10%) apply. affected with the use of Loctite. Table 1-13: Weld Stud Torque Values Loctite should not be used on rotation bearing fasteners.

  • Page 31: Wire Rope

    500E2 SERVICE MANUAL INTRODUCTION Ta x L Ta x L TW = L + A L - A = Length of torque wrench in inches (center of drive Ta = Torque required (specified) tang to handle pivot pin or center of hand grip TW = Wrench scale reading or limit setting of extension handles are considered part of wrench torque wrench...

  • Page 32: Environmental Conditions

    INTRODUCTION 500E2 SERVICE MANUAL Environmental Conditions over sheaves or otherwise hidden during inspection require special attention when lubricating rope. The life expectancy of wire rope may vary due to the degree During fabrication, ropes receive lubrication which provides of environmental hostility. Variation in temperature, the rope with protection for a reasonable time if stored under continuous excessive moisture levels, exposure to corrosive proper conditions.

  • Page 33: Inspection

    500E2 SERVICE MANUAL INTRODUCTION Daily Inspections All cable in continuous service must be inspected at the beginning of each work day. Inspect the eye end and length of cable that is used in daily operation. The end should be inspected for abrasion, corrosion, broken wires, and loose or broken servings.

  • Page 34: Care Of Wire Rope

    INTRODUCTION 500E2 SERVICE MANUAL Wire rope shall be taken out of service when any of the Never pull wire rope over a non-rotating support such as a following conditions exist: spindle bar, a pin, or an inoperative sheave. This practice causes severe abrasion to the outer strand wires.

  • Page 35: Wire Rope Replacement (All Wire Rope)

    Consensus Standard as referenced by Federal Government non-preformed styles of wire rope need to be seized prior to Agencies and Manitowoc Crane Care recommendations to cutting. Seizings must be placed on both sides of the point help determine when wire rope needs to be replaced. Wire where the wire rope is to be cut.
  • Page 36 INTRODUCTION 500E2 SERVICE MANUAL PREFORMED Before Cutting After Cutting NON-PREFORMED Before Cutting 6 Rope After Cutting Diameters FIGURE 1-9 FIGURE 1-8 NOTE: Non-preformed wire rope should have two seizings located on each side of the cut (Figure 1-9). 1-26 Published 08/16/19 Control # 112-05...

  • Page 37: Hydraulic System Description

    500E2 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Hydraulic System Description....2-1 Maintenance Records ..... . 2-4 Hydraulic Oil Reservoir .

  • Page 38: Hydraulic System Maintenance Precautions

    HYDRAULIC SYSTEM 500E2 SERVICE MANUAL Label Parts When Disassembling • Park the crane it causes the least interference with other equipment or operations in the area. When removing or disconnecting a group of wires or cables, • Place all controls at the off position and secure all tag each one to ensure proper identification during re- operating features from inadvertent motion by brakes or assembly.

  • Page 39: Removing Air From The Hydraulic System

    500E2 SERVICE MANUAL HYDRAULIC SYSTEM Connect the cylinder return line and lower the boom to and forward. Replenish the reservoir hydraulic oil level its stowed position. Replenish the reservoir hydraulic oil as necessary. level as required. Disconnect the return line from an outrigger extension CAUTION cylinder and fully extend the outrigger.

  • Page 40: Parts Replacement

    HYDRAULIC SYSTEM 500E2 SERVICE MANUAL records must be kept where they can be easily obtained and reviewed. Hydraulic Oil Reservoir CAUTION Always locate the machine on a firm supporting surface, The hydraulic oil reservoir has a sight gauge located on the extend the outriggers and level the machine and position side of the reservoir.

  • Page 41: Servicing The Control Valves

    500E2 SERVICE MANUAL HYDRAULIC SYSTEM corrected (cooler too close to other truck components, Replace the valve sections on assembly studs in the foreign matter in heat exchanger fins, etc.). All hydraulic lines same order in which they were removed. should be periodically checked for obstructions, hose kinks NOTE: Use care in replacing valve sections to avoid or other flow restrictions.

  • Page 42: Unloader Valve Service

    HYDRAULIC SYSTEM 500E2 SERVICE MANUAL Backup Washers Spool Seal Bonnets Assembly Crane Valve Cover Retainer Plate 10 ft-lb (13.5 N.M) Winch Valve Cover 5 ft-lb (6.7 N.M) Work Ports Outlet Cover Crane Valve Cover Spool Action 10 ft-lb (13.5 N.M) Bonnets Winch Valve Cover 5 ft-lb (6.7.8 N.M)

  • Page 43: Control Valve Relief Adjustment

    500E2 SERVICE MANUAL HYDRAULIC SYSTEM Disconnect drain line from the outlet end of the unloader valve. Install cap fitting to the plug outlet end of the unloader valve. Operate the function. Function operates correctly. The poppet in the unloader is not Oil is passing through the check seated correctly.
  • Page 44 1.176 (29.87) 1.250 1.475 (37.46) 0.118 (3.00) 1 5/8-12 2-12 0.07 (1.78) 1.489 (37.82) 1.500 1.720 (43.69) 0.118 (3.00) 1 7/8-12 NOTE: Contact your National Crane Distributor or Manitowoc Crane Care for O-Ring boss seal kits. Published 08/16/19 Control # 112-05...

  • Page 45: Anti-Two Block System Description

    500E2 SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS Anti-two Block System Description ... 3-1 Remote Control ......3-9 Anti-two Block Operation .

  • Page 46: Anti-Two Block Internal Wire Repair

    ELECTRIC SYSTEM 500E2 SERVICE MANUAL the 3 section sheave case. The wire then loops around the Pull end of anti-two-block wire through side plates of 3 clamp arrangement on the sheave case and routes through section boom to gain in-line wire path. access holes in the side plate of the boom.

  • Page 47: Alternative #2

    500E2 SERVICE MANUAL ELECTRIC SYSTEM Alternative #2 plates. Visually guide this end under the center sheave on the extend cylinder sheave case. This procedure is to be used for anti-two-block wire Push installation tool and wire through boom until it replacement in the event of a complete separation of the appears at the hoist mount end.

  • Page 48: Hydraulic Capacity Alert System

    ELECTRIC SYSTEM 500E2 SERVICE MANUAL 20. Visually inspect interior routing of anti-two-block wire for Remove the console cover on the operators console. excess slack in wire, inaccurate routing of wire, etc. Correct any problems before boom operation. WARNING HYDRAULIC CAPACITY ALERT SYSTEM Before loosening any fittings, support the boom.

  • Page 49: Jib Load Limiting Device

    500E2 SERVICE MANUAL ELECTRIC SYSTEM 14. Once proper adjustment is verified, return the boom to a firmly supported position, stop the truck engine and replace covers. WARNING JIB LOAD LIMITING DEVICE Before loosening any fittings, support the boom. The jib load limiting device is an electromechanical When the pressure reaches capacity load pressure, the maximum capacity sensing system that stops normal crane overload system should activate and boom extension...

  • Page 50: Jib Load Limiting Device Troubleshooting

    ELECTRIC SYSTEM 500E2 SERVICE MANUAL Maintenance • (1) Indicates the unit is being initialized. This only happens the first time the unit is powered up after it is programmed. Outrigger Cylinder Length Sensor (Version 1) • (2) Indicates that the previously stored table is being erased.
  • Page 51 500E2 SERVICE MANUAL ELECTRIC SYSTEM Outrigger Proximity Switch (Version 2) On newer versions of the crane, the OMS and RCL use proximity switches to determine if the outriggers are fully extended. The switches are located between the operator’s cab and A-frame outriggers. The proximity switch (1, Figure 3-2) uses a tab (2) on the outrigger arm to determine when the outrigger is fully extended.
  • Page 52 ELECTRIC SYSTEM 500E2 SERVICE MANUAL constant red to constant green when the outrigger is Tighten jam nut (3, Figure 3-4) on switch. fully extended. Connect electrical connector (1, Figure 3-4) to switch. With power on and stabilizer beam fully extended, If equipped with an RCL and OMS systems, ensure LED (6, Figure 3-4) on proximity switch outrigger status is shown on the QScale monitor.

  • Page 53: Remote Control

    500E2 SERVICE MANUAL ELECTRIC SYSTEM REMOTE CONTROL DANGER Safety Starting truck engine with drive train engaged will cause death or serious injury. DANGER Do not start truck engine unless drive train is in neutral. This crane is not insulated. The remote control provides Before attempting to start truck with remote control make no protection against the electrocution hazard.

  • Page 54: Hydraulic System Description

    ELECTRIC SYSTEM 500E2 SERVICE MANUAL Service and Maintenance 16. Disconnect hand control and store in truck, (If equipped with hard wire remotes). Follow t he p roce dure s o utline d in t he Se rvice and 17. Start truck from inside of cab. Maintenance Section of the Owner Manual to maintain proper crane operation.

  • Page 55: Installation

    500E2 SERVICE MANUAL ELECTRIC SYSTEM Installation engines. Never resume operation until the problem has been corrected! Install the crane on the truck by following the procedures in the Installation Section of this manual. DANGER The Electrical and Hydraulic Schematics show the typical connections of the remote control system.

  • Page 56: Quick Test For Receiver Antenna And Cable

    ELECTRIC SYSTEM 500E2 SERVICE MANUAL switches are industrial grade, self-cleaning, environmental b. With power to the receiver, the Power Indicator LED sealed switches. To remove dirt, grease, oil, etc., wipe with a will be on. Turn transmitter power on. At this time the cloth soaked with soap and water.

  • Page 57: Specifications

    500E2 SERVICE MANUAL ELECTRIC SYSTEM Remove faceplate from transmitter. Make sure Transmitter Description that leads to each lead screw on toggles are Antenna External 6: (Rubber Ducky) secure and will not be at an angle where it would be touching anything when replacing the Operating Temperature -20°C to +50°C (-4°F to +122°F) faceplate.
  • Page 58 ELECTRIC SYSTEM 500E2 SERVICE MANUAL screwdriver. Release the screwdriver and the connection is When power is supplied to the receiver the Power complete. This connector will accept wire sizes from 14 Indicator LED will come on. If not, verify correct polarity gauge to 22 gauge wire.
  • Page 59 500E2 SERVICE MANUAL ELECTRIC SYSTEM 5 Conductor NCC Cord Wire Description Output Label Cord Wire Color Color Output 10 Output 9 Tele Retract Output 8 Tele Extend Output 7 Hoist Up Output 6 Hoist Down Output 5 Output 4 Throttle Output 3 Red/Blu Start...
  • Page 60 ELECTRIC SYSTEM 500E2 SERVICE MANUAL • High End Proportional — 0 Highest Trigger Setting, F until a noticeable decrease in function speed is Least Trigger Setting n o t i c e d . N o w b a c k u p t h e H i g h E n d Proportional hex switch 1 to 2 settings.
  • Page 61 500E2 SERVICE MANUAL ELECTRIC SYSTEM FIGURE 3-9 National Crane 3-17 Published 08/16/19 Control # 112-05...
  • Page 62 ELECTRIC SYSTEM 500E2 SERVICE MANUAL FIGURE 3-9 continued 3-18 Published 08/16/19 Control # 112-05...
  • Page 63 500E2 SERVICE MANUAL ELECTRIC SYSTEM FIGURE 3-10 National Crane 3-19 Published 08/16/19 Control # 112-05...
  • Page 64 ELECTRIC SYSTEM 500E2 SERVICE MANUAL FIGURE 3-11 3-20 Published 08/16/19 Control # 112-05...

  • Page 65: Section 4

    500E2 SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Three Section Boom Operation....4-2 Cable Tensioning......4-10 Special Boom Inspection .

  • Page 66: Three Section Boom Operation

    BOOM 500E2 SERVICE MANUAL Item Component Item Component Extend Cable Adjustment Extend Cable Anchor Section 1 Retract Anchor Retract Cable Section 2 Retract Cable Adjustment Section 3 THREE SECTION BOOM OPERATION service and maintenance is required to insure smooth and proper operation.

  • Page 67: Hoist Removal

    500E2 SERVICE MANUAL BOOM Slightly tighten all cables. Then cycle the boom approximately 4 feet (120 cm) out and in a few times to equalize the extend and retract cable/ boom section sequence positioning. Fully retract boom. Do not induce and hold hydraulic pressure.

  • Page 68: Boom Removal

    BOOM 500E2 SERVICE MANUAL BOOM REMOVAL Boom Disassembly Alternative #1 Gaining access through rear of boom, loosen capscrews Cg From Pivot Boom Length Boom Weight retaining the extend cable anchor in the rear of the 3 Point section as well as the capscrew on the anti-two-block 71 ft (21.6 m) 5145 lb (2334 kg) 140 in (3.56 m)

  • Page 69: Boom Disassembly Alternative #2

    500E2 SERVICE MANUAL BOOM sheaves. Place retract cable ends in a location to clearance for boom disassembly. If removal of side pads minimize the possibility of damage. is required, tag all shims, pads and corresponding locations for proper re-assembly. 12. Loosen and remove six capscrews securing retract 24.

  • Page 70: Additional Maintenance, Disassembled Boom

    BOOM 500E2 SERVICE MANUAL anchor as it is being pulled to the rear will permit easier Install 3 section boom into 2 section. Slide together removal. approximately 5 feet (150 cm). Continue to pull extend cylinder and cables out of rear of Assemble bottom front wear pads for 2 section and boom.
  • Page 71 500E2 SERVICE MANUAL BOOM 15. Slide extend cylinder /extend cables into 2 boom 27. Assemble bottom front wear pads in 1 section, trapping assembly enough to assemble extend cable anchor into ends of retract cables in slots on bottom of 1 section.

  • Page 72: Three Section Top/Bottom Pad Replacement (Assembled Boom)

    BOOM 500E2 SERVICE MANUAL Make certain anti-two-block cable is correctly on Adjust pads until they are within 0.03” (.8mm) off sheave. Inspect from sheave case end. center in the were pad. Various combinations of rotation of these parts allows the adjustment. 36.
  • Page 73 500E2 SERVICE MANUAL BOOM With the inside/outside calipers, measure the outside width of the inner section (W0) at each side pad location. Record the largest measurement. 2 PLCS 1 PLC BOTTOM Subtract the largest outside width (W0) of the inner section and the thickness of the two pads (t ) from the INNER SECTION...

  • Page 74: Cable Tensioning

    BOOM 500E2 SERVICE MANUAL CABLE TENSIONING When tightening/loosening the first (adjustment) nuts on cables, secure cable using the wrench flats at the front of the A boom assembly is considered properly timed when cable ends to prevent cable twist. Excess twisting of cables telescoping sections extend equally relative to each other can cause premature failure.

  • Page 75: 3- Section Boom W/ 1 Stage Cylinder Cable Positioning

    500E2 SERVICE MANUAL BOOM 3- Section Boom w/ 1 Stage Cylinder Cable Positioning EXTEND CABLE BASE 3RD SECTION 1ST SECTION 2ND SECTION 8860-4 RETRACT CABLE FIGURE 4-2 Cable Tightening Sequence 3 Section Boom with (1) Tightening until the extension gap between the first and Stage Extend Cylinder second section and the extension gap between the second and the third are equal.

  • Page 76: Cable Retention

    BOOM 500E2 SERVICE MANUAL OPTION 1 OPTION 2 8859-1 8859-2 FIGURE 4-3 Cable Retention After the cable adjustment procedure is completed for the entire boom assembly. The second (torqued) nut must be Cable Retention Hardware installed on all retract and extend cables. The second nut should be hand tightened until it comes in Item Description...

  • Page 77: Lift Cylinder Repair

    500E2 SERVICE MANUAL BOOM TORQUE VALUES for Second Nut: Remove the cylinder from the machine and place on supports with an oil pan directly beneath the cylinder Inch Series with Coarse Threads (UNC) head area. Minimum Using the proper size of external snap ring pliers, Cable end TORQUE expand the snap ring completely and remove from...

  • Page 78: Extend Cylinder Repair

    BOOM 500E2 SERVICE MANUAL Pressure line from a porta-power or hydraulic line from the crane circuit valve. Read step 5 and 6 before performing this step. Cylinder Barrel Retaining Ring Washer Snap Ring Shaft extended about 12 inches Extend Cylinder Disassembly 14.

  • Page 79: Extend Cylinder Assembly

    500E2 SERVICE MANUAL BOOM break packing gland loose. Remove holding valve and NOTE: Note: All measurements are in inches (mm). extend and retract plugs from butt plate and pull packing gland out by hand. 3/4” Grade 5 As soon as the packing gland is sufficiently loosened, 0.38 (10) Bar (Typ 4 Plcs) properly support the rod assembly and carefully remove...
  • Page 80 BOOM 500E2 SERVICE MANUAL swinging (the pin is attached by cable to the end of the jib). Front Bar Acceptable (Top & Bottom Shims Upper Support Jib Ears Acceptable Lower Support Slowly retract the boom until the jib ears are within 0.50 inch (13 mm) of the ear assemblies on the first section.

  • Page 81: Jib Jack Service And Maintenance

    500E2 SERVICE MANUAL BOOM Hook Assembly Stow Pin Alignment Pin in Slot JIB JACK SERVICE AND MAINTENANCE Lay the jack on its side and drain the oil into a suitable drain pin. The oil will run slowly because air must enter Important: Use only a good grade hydraulic jack oil, as oil drains out.
  • Page 82 BOOM 500E2 SERVICE MANUAL THIS PAGE BLANK 4-18 Published 08/16/19 Control # 112-05...

  • Page 83: Section 5

    500E2 SERVICE MANUAL HOIST SECTION 5 HOIST SECTION CONTENTS Hoist Removal......5-1 Hoist Installation .
  • Page 84 HOIST 500E2 SERVICE MANUAL THIS PAGE BLANK Published 08/16/19 Control # 112-05...

  • Page 85: Section 6

    500E2 SERVICE MANUAL SWING SECTION 6 SWING SECTION CONTENTS Swing Gearbox And Brake....6-1 General ....... . . 6-6 Disassembly &...
  • Page 86 SWING 500E2 SERVICE MANUAL 0.080 2.03 0.085 O-Rings 2.16 Back-up Ring Replace if the Back-up Ring Piston thickness is below 0.070 in (1.78 mm) Friction Disc No Wear 11. Inspect the thrust plate (9) for excessive grooving and replace if necessary by removing snap ring (36). 12.
  • Page 87 500E2 SERVICE MANUAL SWING Grease Fitting Breather/Oil Fill Oil Drain Plug Brake Release Port National Crane Published 08/16/19 Control # 112-05...

  • Page 88: Tulsa Swing Drive Assembly Procedure

    SWING 500E2 SERVICE MANUAL Item Component Item Component Item Component Stator Plates Gear Housing Snap Ring Friction Plates Brake Housing Retaining Ring Back-up Ring Motor Adapter Sun Gear O-ring Gear Set Retaining Ring O-ring Brake Piston Input Carrier Back-up Ring Pinion Shaft Sun Gear O-ring...

  • Page 89: Rotation Stop-Mechanical

    500E2 SERVICE MANUAL SWING the slot on the nut portion of the pinion bolt at 25 ft-lb NOTE: Soak friction disk in EP-90 for 24 hrs. before (34 Nm) If the pinion bolt is between slots always installation. tighten to the next slot. 16.

  • Page 90: Maintenance

    SWING 500E2 SERVICE MANUAL Now rotate the crane in the opposite direction until the rotation stop system centers the control lever. Make another mark on the crane frame aligned with the center of the lift cylinder. If the rotation stop system is properly adjusted, the distance should be the same from the first mark made to the second mark, as it is from the first mark to the third mark.

  • Page 91: Swing Bearing Bolts

    500E2 SERVICE MANUAL SWING plating that will cause variation from dry torque values. When If it is reported by the crane operator or suspected that the a high strength bolt is removed, or un-torqued, the bolt must crane has been overloaded beyond the capacities specified be replaced with a new bolt of the same classification.
  • Page 92 SWING 500E2 SERVICE MANUAL FRONT REAR 9828 FIGURE 6-1 Inner Race Outer Race FIGURE 6-2 Published 08/16/19 Control # 112-05...

  • Page 93: Torque Values

    500E2 SERVICE MANUAL SWING Torque Values • increased drive power required • noise Torque all swing bearing bolts to a final torque. Refer to “Fasteners and Torque Values” on page 1-7. • rough operation Inner Race Torquing • acceleration in the increase in bearing clearance Measure the internal clearance of the swing bearing to The inner race bearing bolts are located on top of the inner determine if it needs to be replaced.
  • Page 94 SWING 500E2 SERVICE MANUAL Top of Swing Bearing Magnetic Base Dial Indicator Top of Frame FIGURE 6-3 FIGURE 6-4 6-10 Published 08/16/19 Control # 112-05...

  • Page 95: Bearing Replacement

    500E2 SERVICE MANUAL SWING BEARING REPLACEMENT Installation Removal DANGER Fully extend and set the outriggers enough to take up the slack in the pads. Do not reuse the swing bearing bolts. The swing bearing is torqued to the applied torque of the grade 8 bolts. New NOTE: Do not raise the machine on the outriggers.

  • Page 96: Testing

    SWING 500E2 SERVICE MANUAL NOTE: If a new bearing is installed, a new pinion gear Install the boom and lift cylinder following the procedures must also be used. outlined in Section 4- BOOM. Install the swing drive pinion so that the high point Reconnect the batteries.

  • Page 97: Section 7

    For information on • Immediately clean up any spills. extreme condition lubrication, contact your local National Crane Distributor or Manitowoc Crane Care. Lubricants ENVIRONMENTAL PROTECTION Specific recommendations of brand and grade of lubricants are not made here due to regional availability, operating...

  • Page 98: Arctic Conditions Below -9°C (15°F)

    If you are in doubt about the +10°C (+50°F) suitability of a specific fluid, check with your authorized National Crane distributor or Manitowoc Crane Care. Open Gear Lubricant NOTE: All fluids and lubricants may be purchased by...

  • Page 99: Arctic Hydraulic Oil

    For colder operating conditions, the standard fluid may be level and must meet John Deere Standard JDM J20C. replaced with a petroleum based fluid developed especially Contact your National Crane distributor or Manitowoc Crane for colder environments. Care if you have any questions.
  • Page 100 LUBRICATION 500E2 SERVICE MANUAL Worn grease fittings that do not hold a grease gun, or those that have a stuck check ball, must be replaced. DANGER When wear pads or rotation bearings are lubricated, cycle Do not, under any circumstances, work at an elevated the components and lubricate again to ensure complete height without using proper fall protection as required by lubrication of the entire wear area.

  • Page 101: Lubrication Chart

    500E2 SERVICE MANUAL LUBRICATION LUBRICATION CHART Oil Fill/Breather Oil Fill-Level NOTE: Torque diffuser to 51 lb-ft (69 Nm). Openings must face bottom of tank. Recommended Item Application Procedure Frequency Lubricant Check and Fill: Weekly, Fill as Check and Fill required Hydraulic oil reservoir HYDO Change...

  • Page 102: Internal Cable Sheave Lubrication

    Continuous rotation swivel (optional) EP-MPG Grease gun Monthly Internal Cable Sheave Lubrication • Contact the Manitowoc Crane Care to obtain this nozzle tip. NOTE: To determine the amount of grease required, visually inspect the sheaves. From the front of the DANGER boom, look back through the sheave case at the extend sheaves.

  • Page 103: Inner Boom Pad Lubrication

    500E2 SERVICE MANUAL LUBRICATION Lower the boom to horizontal. Check alignment between the 2 section access hole and the 3 section access holes. When these holes Fully extend the boom and apply grease to the side and become aligned, the end of the extend cable sheave pin bottom of the 2 and 3 sections with a brush.

  • Page 104: Hoist Brake Oil

    LUBRICATION 500E2 SERVICE MANUAL 1.42 liters (1.50 quarts) of oil. Remove the pipe and elbow, Chart” on page 7-5 for recommended oil type and grade for then replace the plug. your application. For information about changing hoist brake oil, see “Drain / Add New Hoist Brake Oil”...

  • Page 105: Swing Gearbox And Brake Oil

    -23° C to 82° C (-10° F to +180° F). For under proper conditions. But, when the rope is put into operation outside this range, contact Manitowoc Crane Care service, the initial lubrication may be less than needed for the for recommendations.

  • Page 106: Carwell© Rust Inhibitor

    To help protect against corrosion of National Cranes, In addition to the factory-applied Carwell coating, National Manitowoc Crane Care recommends washing the crane at Crane owners must provide proper maintenance and care to least monthly to remove all foreign matter. More frequent...

  • Page 107: Inspection And Repair

    To the extent any damage is structural in nature, Manitowoc Crane Care must be contacted and consulted as to what repairs may be required. CAUTION •...

  • Page 108: Areas Of Application

    • Boom applications areas are; pivot pins, hose end and Please contact Manitowoc Crane Care should you have any fittings, jib pins and shafts, all bare metal surfaces, questions. downhaul weight / hook block pins and fasteners.
  • Page 109 500E2 SERVICE MANUAL LUBRICATION 7650-43 7650-42 National Crane 7-13 Published 08/16/19 Control # 112-05...
  • Page 110 LUBRICATION 500E2 SERVICE MANUAL Item Description O/R Pins, Clips Item Description Power Train Hardware Boom Nose Pins, Clips Valve Bank, Hose Connections Inside Wire Rope Turntable All Hardware, Clips, Pi ns, Hose Connections Entire underside of unit not painted O/R Pins, Clips Hook Block/Downhaul Weight Pivot Shaft Turntable Bearing Fasteners...

  • Page 111: Hydraulic System Troubleshooting Chart

    500E2 SERVICE MANUAL TROUBLESHOOTING SECTION 8 TROUBLESHOOTING SECTION CONTENTS Hydraulic System Troubleshooting Chart ..8-1 Jib Jack Troubleshooting ....8-5 Systematic Troubleshooting .
  • Page 112 TROUBLESHOOTING 500E2 SERVICE MANUAL HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution Check PTO ratio, pump size and engine speed for Pump not operating at proper speed. proper oil flow Low hydraulic fluid supply. Check and fill as required. Relief valve sticking.
  • Page 113 500E2 SERVICE MANUAL TROUBLESHOOTING HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution Excessive pump speed. Adjust foot throttle or check for too high PTO ratio. Low oil temperature. Allow unit to warm up. Low hydraulic oil supply. Check and fill. Suction line kinked, collapsed or blocked.

  • Page 114: Jib Load Limiting Device Troubleshooting

    TROUBLESHOOTING 500E2 SERVICE MANUAL HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution JIB LOAD LIMITING DEVICE TROUBLESHOOTING Carefully check the integrity of all circuits external to the electronics box, from the jib tip to the Loose or incorrect wiring. console.

  • Page 115: Jib Jack Troubleshooting

    500E2 SERVICE MANUAL TROUBLESHOOTING HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution JIB JACK TROUBLESHOOTING No oil in system Add oil to reservoir tank through oil filler hole Does not lift load Release valve not closed Turn handle clockwise tightly Lifts load only part way Oil level low Add oil to reservoir tank through oil filler hole...

  • Page 116: Hca Troubleshooting Flow Chart

    TROUBLESHOOTING 500E2 SERVICE MANUAL HCA TROUBLESHOOTING FLOW CHART Overload trips and does not reset Has overload been eliminated? Downhaul weight lifting the Eliminate overload anti-two-block weight Lower downhaul weight Crane booms down, Problem solved telescopes out, hoists up? Boom lift cylinder fully extended? Press HCA override switch and boom down 5°...

  • Page 117: Crane To Truck Installation

    500E2 SERVICE MANUAL CRANE INSTALLATION SECTION 9 CRANE INSTALLATION SECTION CONTENTS Crane to Truck Installation ....9-1 Torsion Box Mounting ..... 9-23 Mount the Outrigger Box .

  • Page 118: Minimum Truck Requirements

    CRANE INSTALLATION 500E2 SERVICE MANUAL vehicle laws relating to weights and dimensional restrictions of the after frame (AF). Many frames are available that such as overall length, overhang, etc. have the necessary after frame (AF) section modulus (S.M.) and resistance to bending moment (RBM) so that This section is organized by first presenting detailed reinforcing is not required.

  • Page 119: Configuration 1 - 571E2

    500E2 SERVICE MANUAL CRANE INSTALLATION Configuration 1 - 571E2 Full capacity work area is rear 180° of vehicle from outrigger to outrigger. This configuration allows the installation of the Series 571E Tandem axle trucks may be used for hauling larger payloads. on a chassis with a small frame by using the standard sub-base for 20 ft bed.

  • Page 120: Configuration 2 - 571E2

    CRANE INSTALLATION 500E2 SERVICE MANUAL Configuration 2 - 571E2 between the crane and the ASH. Counterweighting in this manner reduces the loading induced on the SFO when lifting This mount requires single front outrigger (SFO) and over the front. Truck must have 15.9 in (261 cm ) section additional counterweight in the underside of the bed for full...

  • Page 121: Configuration 3 - 560E2

    500E2 SERVICE MANUAL CRANE INSTALLATION Configuration 3 - 560E2 Requires 12,000 (5443 kg) GAWRF, 21,000 (9525 kg) GAWRR, 33,000 (14,968 kg) GVWR, ASH rear stabilizers This configuration allows the installation of the Series 560E and sub-base for 18' bed. Full capacity work area is rear on a chassis with a small frame by using the standard sub- 180×...

  • Page 122: Configuration 4 - 560E2 And Shorter Booms

    CRANE INSTALLATION 500E2 SERVICE MANUAL Configuration 4 - 560E2 And Shorter Booms the crane and the ASH. Counterweighting in this manner reduces the loading induced on the SFO when lifting over the This mount requires single front outrigger (SFO) and front.

  • Page 123: Pto Horsepower Requirements

    500E2 SERVICE MANUAL CRANE INSTALLATION PTO HORSEPOWER REQUIREMENTS Do not confuse engine crankshaft rotation with power take off rotation. If the power take off shaft rotates opposite the The unit is equipped with a three section pump that supplies engine crankshaft, it is turning in a clockwise (cw) direction 34 GPM (129 LPM) to the hoist, 18 GPM (68 LPM) to the when viewed from the rear of the truck and if the power take boom and outriggers, and 10 GPM (38 LPM) to the swing...

  • Page 124: Truck Frame Strength

    CRANE INSTALLATION 500E2 SERVICE MANUAL Engine CCW Engine CCW PTO CCW PTO CW TRUCK FRAME STRENGTH 1,749,000 in-lb (1197,610 N-m) RBM and 15.9 in (261 cm S.M. under the crane frame between the front and rear In order for a truck frame to be suitable for accepting a Series springs with 1,430,000 in-lb (161,590 N-m) RBM and 13 in 500E2 Service Manual size crane, the truck frame must have (213 cm3) S.M.

  • Page 125: Section Modulus Tables

    500E2 SERVICE MANUAL CRANE INSTALLATION SECTION MODULUS TABLES Add this to the section modulus of the channel obtained from Table A. The following tables will determine the section modulus of the truck frame. Always measure the truck frame and check Fish Plate Reinforcement (Table C) the tables to be sure that any truck factory listed section The frame can be strengthened by adding a fish plate of...
  • Page 126 CRANE INSTALLATION 500E2 SERVICE MANUAL TABLE A Section Modulus in Thickness 1/4 in. (6.35 mm) Thickness 3/16 in. (4.76 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 2.5 (64) 3 (76) 3.5 (89) 4 (102) 2.5 (64) 3 (76) 3.5 (89)
  • Page 127 500E2 SERVICE MANUAL CRANE INSTALLATION TABLE B Section Modulus in Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95)
  • Page 128 CRANE INSTALLATION 500E2 SERVICE MANUAL TABLE D Section Modulus in Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89) 4 (102)
  • Page 129 500E2 SERVICE MANUAL CRANE INSTALLATION Example: 3.00 A truck frame of 110,000 psi (758 MPa) yield strength steel has the following dimensions: 3/8 in. (76.2) (9.52 mm) thick, 3 in. (76.2 mm) flanges and is 10.25 in. (260 mm) deep. To find the frame section modulus: 10.25 (260)

  • Page 130: Requirements For Optional Single Front Outrigger

    CRANE INSTALLATION 500E2 SERVICE MANUAL REQUIREMENTS FOR OPTIONAL SINGLE bracket must be capable of supporting 0.50 inch (12.7 mm) DIA. Grade 8 bolts to their nominal breaking strength. Torque FRONT OUTRIGGER the mounting bolts supplied with the SFO to 110 ft-lb (149 The truck frame must have adequate strength from under the N·m).

  • Page 131: Truck Frame Section Modulus Tables

    500E2 SERVICE MANUAL CRANE INSTALLATION TRUCK FRAME SECTION MODULUS Angle (Table F). Use Table F for an angle section such as when a flange and part of the web of a truck frame channel is TABLES removed. Use Table E and Table F below along with Tables A through Where thickness, depth or flange width vary, interpolation D in the preceding section of this manual for determining the between tables or variables within a given table will provide...
  • Page 132 CRANE INSTALLATION 500E2 SERVICE MANUAL TABLE F Section Modulus in Thickness 1/4 in. (6.35 mm) Thickness 3/16 in. (4.76 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95)
  • Page 133 500E2 SERVICE MANUAL CRANE INSTALLATION Example: Refer to the sample truck frame cross sections in Table E. Truck frame yield strength is I I 0,000 psi (758 MPa) with the following dimensions at the front axle location: 3/8 in. (9.52 mm) thick, 1.50 in. (38.1 mm) top flange, 3 in. (76.2 mm) bottom flange, 10.25 in.

  • Page 134: Truck Preparation

    CRANE INSTALLATION 500E2 SERVICE MANUAL TRUCK PREPARATION PTO INSTALLATION Plan installation completely before any work is done. Plan Select the PTO according to the PTO Selection pages shown the location of the crane for the final front and rear axle earlier in this section.

  • Page 135: Reinforcing/After Frame Extension

    500E2 SERVICE MANUAL CRANE INSTALLATION For a wet mount, a gasket is required for the mounting NOTE: An arrow is cast into the rear of the pump housing flange to PTO gearbox interface. Dry mount does not to identify rotation. Make sure the rotation is require a gasket.
  • Page 136 CRANE INSTALLATION 500E2 SERVICE MANUAL If reinforcing is to be welded on, torch cut hole pattern in place, install any crossmember bolts that were previously reinforcing being careful to clear crane mounting removed, then drill through reinforcing and truck frame being anchors.
  • Page 137 500E2 SERVICE MANUAL CRANE INSTALLATION If the frame through the rear suspension doesn't meet as in Figure B. Slide the reinforcing angle up from the minimum specifications for RBM and section modulus bottom, butt it to existing forward reinforcing and weld as shown on “Truck Frame Strength”...

  • Page 138: After Frame Modification

    CRANE INSTALLATION 500E2 SERVICE MANUAL AFTER FRAME MODIFICATION • Install Boom • Install hoist cable If additional suspension reinforcing is required, as may be t h e c a s e w i t h a t r u c k f r a m e t h a t t a p e r s d o w n t o •...

  • Page 139: Torsion Box Mounting

    500E2 SERVICE MANUAL CRANE INSTALLATION Assemble and install the bolt and washer assembly through the holes in plate (5) and install plate on outer WARNING surface of the truck chassis. Crushing Hazard! Install crush plate (6) to the inside of chassis frame It is mandatory that T-box attaching bolts be inspected channel.

  • Page 140: Mount The Outrigger Box

    CRANE INSTALLATION 500E2 SERVICE MANUAL Machine plate as necessary to anchor and fit inside the truck frame Apply molding to both holes. Cut to proper length. Truck Frame Plate must be parallel to truck frame or bolt failure will result 9136 8552-3 FIGURE 9-1...

  • Page 141: Ash To Torsion Box Mounting

    500E2 SERVICE MANUAL CRANE INSTALLATION ASH TO TORSION BOX MOUNTING Torsion Box (Ref) Stabilizer Assy (Ref) Truck Frame (Ref) Tube Assy (Ref) Typical Both Sides Typical Both Sides Reference Custom BOM for Appropriate ASH Spacer Kit Torque mounting studs to 540 ±...

  • Page 142: Assemble The Outriggers

    CRANE INSTALLATION 500E2 SERVICE MANUAL Assemble the Outriggers Before placing reservoir in service, remove cleanout cover and inspect to ensure proper installation of Assemble the outriggers as shown in the parts manual diffuser. and connect the hydraulics as per hydraulic schematics. Connect manifold return, hoist drain, and pump suction Connect the solenoids to the outrigger selector switch to couplings on reservoir before filling with oil.

  • Page 143: Boom Installation

    500E2 SERVICE MANUAL CRANE INSTALLATION BOOM INSTALLATION Support outer end of boom securely and use the overhead hoist to position the lift cylinder with the control Lift Cylinder Installation valve to pin the cylinder to the boom ears. Torque pin keeper capscrews to proper torque.

  • Page 144: Wire Rope Installation

    CRANE INSTALLATION 500E2 SERVICE MANUAL Wire Rope Installation against the preceding wrap with a rubber mallet until at least half of the drum is full. The remaining half of the Unspool approximately 15 feet (8 m) of cable and route drum should wrap tightly because the fleet angle of the the cable through the boom cable guides from the front cable will tend to pull the cable to the center of the drum...

  • Page 145: Hoist To Truck Cab Clearance

    500E2 SERVICE MANUAL CRANE INSTALLATION Hoist to Truck Cab Clearance remaining four bearings are to be installed in the lift cylinder, two at each side of the rod end of the cylinder Check for hoist mount tail swing clearance at top of cab. Any and two at each side of the butt end of the cylinder.

  • Page 146: Counterweighting Determination Example

    CRANE INSTALLATION 500E2 SERVICE MANUAL The 85% tipping factor as outlined in OSHA and ANSI In order to determine the amount of counterweight required, specifications means that when lifting the full capacity loads it is necessary to add up the weight that each permanently most likely to cause the truck (with outriggers and stabilizer attached piece of equipment will place on the front and rear set) to overturn, the unit is at 85% of tipping over.

  • Page 147: Counterweighting Methods

    500E2 SERVICE MANUAL CRANE INSTALLATION Counterweighting Methods 2350 pounds (1066 kg) of concrete poured in the front of the bed. See “Counterweighting for 180° Stability” in this section Two methods of counterweighting may be used: Determine axle weights added by the counterweight by using a heavy front bumper and concrete in the bed or the same method as used before.
  • Page 148 CRANE INSTALLATION 500E2 SERVICE MANUAL Check the final weight of the unit with crane installed. See per man) to ensure that the axle ratings have not been “Specifications Section” for weight of 571E and center of exceeded so that DOT certifications requirements can be gravity.

  • Page 149: Concrete Poured In The Bed Measures

    500E2 SERVICE MANUAL CRANE INSTALLATION Example The method shown below can be used to shift more weight to the front of the crane than the previous methods. When using this method, check for interference with hydraulic Concrete poured in the bed measures: reservoir and truck tires.

  • Page 150: Boom Rest Requirements

    CRANE INSTALLATION 500E2 SERVICE MANUAL BOOM REST REQUIREMENTS tie down point low enough to allow room for anti-two-block weight. Do not shorten chain. Before the mounting of a crane is complete, a boom rest must be installed. A rest must be supplied for transport to The boom rest should be positioned to support the 1 reduce vibratory stress on the crane and truck and protect section boom.

  • Page 151: Can Bus System Setup

    NOTE: Only maintenance personnel who have attended the New Technology training course can purchase CAN Bus System using Software the software and cable. Contact Manitowoc Crane Care for more information. NOTE: Refer to the A-Frame Crane Software Specification Table 9-2 shows the equipment needed when setting up the and Configuration specification for detailed CAN bus system using HED software.

  • Page 152: Can Bus System Using Programming Button

    CRANE INSTALLATION 500E2 SERVICE MANUAL Engage the PTO. Turn the crane ignition switch to the RUN position. Do not start the engine. Setting Up the CAN Bus System Start the laptop and launch the CAN bus system software. Use the HED software to set EEPROMs for engine type, throttle calibration, and OMS setup.

  • Page 153: Initial Crane Run In Procedure

    500E2 SERVICE MANUAL CRANE INSTALLATION Connect cable. Module 9833 Remove terminating Install terminating resistor from splitter. resistor. Diagnostics Cable S o f t w a r e CAN to USB Adapter Cable 9835 9836 Laptop Connect USB I n s t a l l s e r i a l e n d o f 9832 to laptop.
  • Page 154 CRANE INSTALLATION 500E2 SERVICE MANUAL The stability test load will be 1.18 times the load chosen from On units not equipped with single front outriggers, tipping the load rating area of the capacity chart. from stabilizer support to front wheel support will occur as the load or boom is swung around the front.

  • Page 155: Specifications

    500E2 SERVICE MANUAL CRANE INSTALLATION SPECIFICATIONS Hydraulic Pump Pump Speed ................2500 RPM Displacements: Section P1 ..............18 GPM (68.1 LPM) at 3900 psi +100/-000 (26.89 MPa) Section P2 ..............34 GPM (128.7 LPM) 3300 psi +100/-000 (22.75 MPa) Section P3 ..............10 GPM (37.8 LPM) at 2350 psi +100/-000 (16.20 MPa) Hydraulic System Requirements: Boom and Outrigger System .........
  • Page 156 CRANE INSTALLATION 500E2 SERVICE MANUAL 9-40 Published 08/16/19 Control # 112-05...

  • Page 157: Section 10

    500E2 SERVICE MANUAL SCHEMATICS SECTION 10 SCHEMATICS For your convenience, the latest version of schematics available at the time of printing are placed in this section. National Crane 10-1 Published 08/16/19 Control # 112-05...
  • Page 158 SCHEMATICS 500E2 SERVICE MANUAL THIS PAGE BLANK 10-2 Published 08/16/19 Control # 112-05...
  • Page 159 500E2 SERVICE MANUAL Alphabetical Index After Frame Modification ..........9-22 Anti-two Block Internal Wire Repair .
  • Page 160 SERVICE MANUAL 500E2 Remote Control ............3-9 Requirements For Optional Single Front Outrigger .

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