Manitowoc National Crane 600E-2 Operator's Manual
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Manitowoc National Crane 600E-2 Operator's Manual

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National Crane 600E-2
Operator Manual

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Summary of Contents for Manitowoc National Crane 600E-2

  • Page 1 National Crane 600E-2 Operator Manual...
  • Page 3 OPERATOR MANUAL This manual has been prepared for and is considered part of the 600E2 This Manual is divided into the following sections: SECTION 1 INTRODUCTION SECTION 2 SAFETY PRECAUTIONS SECTION 3 OPERATING CONTROLS AND PROCEDURES SECTION 4 SET-UP SECTION 5 LUBRICATION PROCEDURE AND CHARTS SECTION 6 MAINTENANCE CHECKLIST...
  • Page 4 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 5: Table Of Contents

    600E2 OPERATOR MANUAL TABLE OF CONTENTS SECTION 1 ..........Introduction Supplemental Information .
  • Page 6 TABLE OF CONTENTS OPERATOR MANUAL 600E2 Hand Signals ........... . . 2-33 Jib .
  • Page 7 600E2 OPERATOR MANUAL TABLE OF CONTENTS HCA Load Range Gauge ..........3-8 HCA System Operation .
  • Page 8 TABLE OF CONTENTS OPERATOR MANUAL 600E2 Chassis Grease Low Temp ......... . . 5-1 Anti-wear Additives .
  • Page 9 600E2 OPERATOR MANUAL TABLE OF CONTENTS Tire Load And Inflation Table ......... 6-11 Specifications.
  • Page 10 TABLE OF CONTENTS OPERATOR MANUAL 600E2 THIS PAGE BLANK TOC-6...

  • Page 11: Supplemental Information

    If you are the new owner of a National crane, please register knowledgeable to assist you for parts, service and warranty it with Manitowoc Crane Care so we have the ability to issues. They have the facilities, parts, factory trained contact you if the need arises.
  • Page 12 Should the distributor not be immediately available, contact should be made directly with Manitowoc Crane Care. The crane must not be returned to service until it is thoroughly inspected for any evidence of damage. All damaged parts must be repaired or replaced as authorized by your local National Crane distributor or Manitowoc Crane Care.

  • Page 13: Safety Messages

    Should the distributor not be immediately available, Identifies hazards that could result in minor or moderate contact should be made directly with Manitowoc Product injury if the message is ignored. Safety at the address below. The equipment must not be returned to service until it is thoroughly inspected for any evidence of damage.

  • Page 14: Operator Information

    Product Safety at: maintained equipment. You risk lives when operating faulty machinery - including your own. The Manitowoc Company, Inc. 1565 East Buchanan Trail If adjustments or repairs are necessary, the operator shall Shady Grove, PA 17256-0021 notify the next operator.

  • Page 15: Operational Aids

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS • You read, understand, and follow the safety and inoperative or malfunctioning, the following requirements o p e r a t i n g r e c o m m e n d a t i o n s c o n t a i n e d i n t h e shall apply for continued use or shutdown of the equipment: manufacturer’s manuals, your employer’s work rules, •...

  • Page 16: Anti-Two-Blocking Device

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Know the weight of all loads and always check the capacity Two-blocking is more likely to occur when both the main and of the equipment as shown on the Load Chart before making auxiliary hoist lines are reeved over the main boom nose and any lifts.

  • Page 17: Load Charts

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Load Charts Read and follow the following safety decal for equipment with a single front outrigger. Load Charts represent the absolute maximum allowable loads, which are based on either tipping or structural limitations of the equipment under specific conditions. Knowing the precise load radius, boom length, and boom angle should be a part of your routine planning and operation.

  • Page 18: Wind Speeds

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 NOTE: The wind speed corresponding to the Beaufort scale in the table is mean wind speed at 10 m (33 ft) elevation over a period of 10 minutes. Table 2-1 Beaufort Wind Scale Maximum Wind Speed Beaufort Visible Indicator Description...
  • Page 19 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Simplified Method to Determine Maximum Permissible Wind Speed Determine 3-Second Gust 0.14 V(z) = [(z/10) + 0.4]v [m/s] Wind Speed at boom tip, 0.14 V(z) = [(z/33) + 0.4]v [mph] V(z) 13.4 m/s < V(z) < 20.1 m/s V(z) >...
  • Page 20 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Determination of 3-second wind gust speed at boom Size and Shape of the load: tip height: These rated capacities are also based on the assumption that the Wind Resistance Area of load, Awr is not more The following example illustrates how to calculate 3-second (load) wind gust speed at boom tip height based on mean wind...
  • Page 21 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Calculation of Projected Wind Area (Ap) Wind Wind = 8 m = 24 m 25 ft 25 ft Wind Wind 10 ft 3 ft = 75 ft = 250 ft 10 ft 3 ft 8384-1 FIGURE 2-2 Determining Wind Drag Coefficient (Cd) If the exact Wind Drag Coefficient of a shape is not known,...
  • Page 22 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Table 2-2 Wind Drag Coefficient Maximum Permissible Wind Speed If the wind resistant area of the load Awr is greater than (load) Shape the allowable wind resistant area Awr , the ratio can be (allow) used to determine a permissible wind speed V(z) for the load 1.1 to 2.0 using Table 2-3.
  • Page 23 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Rated Load Chart Example - Metric 8383-1 FIGURE 2-3 National Crane 2-11 PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 24 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Table 2-4 Example-Capacity Reduction Factors for Wind Speed V(z) Greater than 13.4 m/s - Metric (Only for lifting with main boom on fully extended outriggers, with or without stowed extension) For wind speed V(z) (3-second gust speed at boom tip height) V(z) > 13.4 m/s ≤ 20.1 m/s, the Reduced Capacity shall be calculated by multiplying the Published Rated Capacity by the following factors: Main Boom Length in Meters Wind Speed...
  • Page 25 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS At wind speeds greater than 13.4 m/s, it is not permissible to Load example 1.3a: lift a load greater than 12,040 kg, even if the wind resistance With large wind resistance area of the load Awr (load) area of the load is less than 14.45 m •...
  • Page 26 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 • Is the load to be lifted less than allowable load? Ratio = 1.37 8,000 kg ≤ 12,040 kg • Is Awr less than Awr (load) (allow) From Table 2-5, the maximum permissible wind speed at 19.83 m ≤...
  • Page 27 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Rated Load Chart Example - Non-metric 8382-1 FIGURE 2-4 National Crane 2-15 PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 28 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Refer to the above equipment configuration for the following load conditions: Example and Sample Calculations (Non-metric) Load example 2.1: The following example illustrates how to calculate allowable load while operating in wind speed (3-second wind gust With known Wind Drag Coefficient of the load Cd, speed) above 13.4 m/s (30 mph) and maximum permissible •...

  • Page 29: Lifting Operations

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS the wind resistance area of load can be estimated as: • Is Awr less than Awr (load) (allow) 216 ft ≤ 149 ft ......NO = Ap x Cd = 180 x 1.2 = 216 ft (load) Conclusion: This load is NOT permissible to lift in wind...

  • Page 30: Counterweight

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Always keep the load as near to the equipment and as close Always use enough parts-of-line to accommodate the load to to the ground as possible. be lifted. Lifting with too few parts-of-line can result in failure of the hoist rope.

  • Page 31: Tilt-Up Panel Lifting

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS • Make sure all signals are coordinated through the lift • The total gross load shall not exceed 80% of the director or person in charge of the lift. standard load chart. The operator shall be responsible to control this as the RCL does not have a feature to set •...

  • Page 32: Equipment

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 • All pile driving and extracting operations shall be showing inspections were performed on the equipment restricted to fully extended outriggers with all tires clear during the time it was used for pile driving or extraction. of the ground.

  • Page 33: Set-Up And Operation

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Example decal. For reference only. 8822 Equipment operation is dangerous when close to an The safest way to avoid electrocution is to stay away from energized electrical power source. Exercise extreme caution electrical power lines and electrical power sources. and prudent judgment.

  • Page 34: Electrocution Hazard Devices

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Boom cages and boom guards afford limited protection from electrocution hazards. They are designed to cover only the boom nose and a small portion of the boom. Performance of boom cages and boom guards is limited by their physical size, insulating characteristics, and operating environment (e.g.

  • Page 35: Special Operating Conditions And Equipment

    Thoroughly inspect the rope and all points of contact on the equipment. Should the distributor not be immediately • Near high-frequency switching stations available, contact Manitowoc Crane Care. The equipment • If a thunder storm is forecast must not be returned to service until it is thoroughly inspected for any evidence of damage and all damaged parts Use electrically conducting material for grounding.
  • Page 36 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Also see the optional equipment manual titled Personnel • The crane operator must remain at the crane controls at Basket Manual which addresses safety, inspection, testing, all times when personnel are off the ground. operation, installation, and lubrication. •...

  • Page 37: Environmental Protection

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS • ASME (formerly ANSI) B30 Series American National Follow all applicable safety precautions in this manual when Safety Standards For Cableways, Cranes, Derricks, performing equipment maintenance as well as equipment Hoists, Hooks, Jacks, and Slings; ASME B30.5, Mobile operations.

  • Page 38: Lubrication

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 for leaks. Wear gloves to protect your hands from • Consult with Manitowoc Crane Care to determine if load spraying fluid. testing is required after a structural repair is performed. • If any hydraulic fluid is injected into the skin, obtain Lubrication medical attention immediately or gangrene may result.

  • Page 39: Wire Rope

    • Never overload a rope. This means never use the rope NOTE: Rope may be purchased by contacting Manitowoc where the load applied to it is greater than the working Crane Care. load determined by the rope manufacturer.

  • Page 40: Sheaves

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Sheaves Environmental factors such as corrosive conditions and heat can damage a wire rope. Lack of lubrication can significantly shorten the useful life of a wire rope. Contact with electrical wires and resulting arcing will damage a wire rope.

  • Page 41: Engine

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS • If equipped, disconnect battery with the battery Do not use the dead end lug on the boom nose for tying disconnect switch before disconnecting the ground down the boom during transport. Damage to the lug and battery cable.

  • Page 42: Work Practices

    Do not make modifications or additions to the equipment’s access system that have not been evaluated and approved Stay alert at the wheel. by Manitowoc Crane Care. If equipped, ensure that the hoist access platform hand rail Do not step on surfaces on the equipment that are not and step are in the travel configuration.

  • Page 43: Job Preparation

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Job Preparation equipment in an area with flammable dust or vapors, unless good ventilation has removed the hazard. Before equipment use: Carbon monoxide fumes from the engine exhaust can cause • Barricade the entire area where the equipment is suffocation in an enclosed area.

  • Page 44: Lifting

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Check the hoist brake by raising the load a few inches, stopping the hoist and holding the load. Be sure the hoist brake is working correctly before continuing the lift. When lowering a load always slow down the load’s descent before stopping the hoist.

  • Page 45: Hand Signals

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS Be sure everyone is clear of the equipment and work area before making any lifts. Never swing over personnel, regardless of whether load is suspended from or attached to the boom. Hand Signals A single qualified signal person shall be used at all times when: •...
  • Page 46 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Reprinted from ASME B30.5-2014, by permission of The American Society of Mechanical Engineers. All Rights Reserved. 9580 FIGURE 2-6 2-34 PUBLISHED 04-26-2019 CONTROL # 113-09...

  • Page 47: Parking And Securing

    600E2 OPERATOR MANUAL SAFETY PRECAUTIONS PARKING AND SECURING • Lock the operator’s cab (if applicable) and install vandal guards, if used. COLD WEATHER OPERATION WARNING Cold weather operation requires additional caution on the Tipping Hazard! part of the operator. When parking the equipment and leaving it unattended Check operating procedures in this manual for cold weather follow the instructions for the Controls and Operating starting.
  • Page 48 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 would retract approximately 196 mm (7 3/4 in) [see Table 2- cool. The load will lower as the telescope cylinder(s) retracts 8]. A cylinder extended 1.5 m (5 ft) in which the oil cools allowing the boom to come in. Also, the boom angle will 15.5°C (60°F) would only retract approximately 38 mm (1 1/ decrease as the lift cylinder(s) retracts causing an increase 2 in).

  • Page 49: Overload Inspection

    • Stop operating the crane and contact Manitowoc Crane Care immediately for overloads of 50% and T h e f o l l o w i n g i l l u s t r a t i o n s m a y n o t b e a n e x a c t higher.

  • Page 50: Boom Inspection

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Boom Inspection 9, 10 2, 3 9, 10 Illustration for reference only. Your crane may be different. 2-38 PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 51 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS NOTE: The following checklist includes all features that can be found on National Cranes. Your crane may not have some features. Overload less than 25% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect for damage.

  • Page 52: Superstructure Inspection

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Superstructure Inspection 10,11 Illustration for reference only. Your crane may be different. 2-40 PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 53 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS NOTE: The following checklist includes all features that can be found on National Cranes. Your crane may not have some features. Overload less than 25% Lift Cylinder Inspect for leaks. See topic in Introduction section Wire Rope Inspect all for damage.

  • Page 54: Carrier Inspection

    SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 Carrier Inspection 5, 6 Illustration for reference only. Your crane may be different. 2-42 PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 55 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS NOTE: The following checklist includes all features that can be found on National Cranes. Your crane may not have some features. Overload less than 25% Stabilizer Inspect for leaks. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% Stabilizer...
  • Page 56 SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 THIS PAGE BLANK 2-44 PUBLISHED 04-26-2019 CONTROL # 113-09...

  • Page 57: Section 3

    If the vehicles equipped with automatic transmission, the contacting your local National Crane distributor, or by power take-off must be engaged with the engine at idle. contacting Manitowoc Crane Care directly). Refer to transmission manufacturers instructions for special procedures. CAUTION...

  • Page 58: Transmission

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 Warm-up Procedures for All Temperature Ranges: Warm-up Procedures for Temperatures Below -7°C (20°F): Upon startup, allow the engine to idle for 3 to 5 minutes before operating with a load. Ensure the boom is fully retracted and near maximum lift angle with no load applied.

  • Page 59: Charging The Battery

    600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Swing Speed Adjustment All crane models, particularly those produced since 2000, have multiple computer systems (crane control, RCL, engine Located on turn motor inside frame. Turn knob in to increase & transmission control) that are highly susceptible to voltage/ maximum swing speed.

  • Page 60: Hydraulic Capacity Alert System (Hca) Load Range Gauge

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 Hydraulic Capacity Alert System (HCA) Load Load Chart Range Gauge This chart shows capacities of crane at various operating areas and hoist capacities with appropriate reeving. Boom Angle Indicator DANGER Located on either side of the base boom section and used to Do not use the Load Range Gauge with a extension.
  • Page 61 600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: Item 20 is located behind the access door on the operators console as shown. Item Component A2B/Extension Overload Light Boom Angle Indicator Load Chart FIGURE 3-1 Swing Speed Adjustment Level Indicator Item Component Front Throttle Item...

  • Page 62: Hoist System Operation

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 HOIST SYSTEM OPERATION Using Multiple Part Lines The hoist is mounted at the rear of the boom and has The hoist load rating chart on each machine provides the capacities independent from the rest of the crane The hoist information for pull limitations on the hoist with various can normally pull more than the crane itself can withstand.

  • Page 63: Optional Hoist Burst Of Speed (Bos)

    600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES OPTIONAL HOIST BURST OF SPEED (BOS) ANTI-TWO BLOCK (A2B) SYSTEM The “Burst of Speed” increases hoist line speed 50% over With untrained or inexperienced or distracted operators, two normal operation by diverting oil from the multi-bank control blocking the hoist cable is a very real possibility.

  • Page 64: Hydraulic Capacity Alert System

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 are extended to a point in which they provide maximum the HCA and the Anti-Two-Block or extension load limiting stability. systems as the cause of power loss. The OMS utilizes an LED indicator to communicate to the CAUTION operator the position of the outriggers and stabilizers.

  • Page 65: Hca System Operation

    600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES The load range gauge is provided to aid the operator when operating near the rated capacity of the crane. The gauge only provides accurate indication when the lift control lever is in neutral. The gauge movement is not proportional to the load on the hook.

  • Page 66: Three Section Boom Operation

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 When trip force is reached, the extension load limiting device These systems do not prevent structural or stability breaks electrical continuity to the work port unloader overloads to the crane or hoist caused by: solenoid in the main control valve.

  • Page 67: Anti-Two-Block (A2B) Weight Installation

    600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THREE SECTION BOOM Item Component Item Component Base Section Extend Cable Retract Cable Section Section FIGURE 3-4 The retract cables attach to the tip end of the 1 boom section and are reeved around sheaves attached to the 2 boom section.

  • Page 68: Wedge Socket Installation

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 Wedge Socket Installation Install cable on the hoist drum in accordance with the following procedure. Inspect the wedge and socket. Remove any rough Position the cable over the boom nose sheave and route edges and burrs.
  • Page 69 600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES the socket. The dead-end treatment is used to restrain to cableways, cranes, derricks, hoists, hooks, jacks, and the wedge from becoming dislodged from the socket s ling s. I t stat es , in s ec tio n 5 -1 .7 .3, “ (c) Swag ge d, should the rope suddenly become unloaded due to the compressed, or wedge socket fittings shall be applied as overhaul ball or hook block striking the ground, etc.

  • Page 70: Remote Control

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 REMOTE CONTROL safety switch will not have the start relay installed and therefore cannot be started with the radio transmitter only. The following sections describe the remote control function. For detailed installation, maintenance, and troubleshooting information, see the Service Manual.

  • Page 71: Hydraulic System Description

    600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES 15. Turn Hydraulic Capacity Alert/RCL and Remotes/SLP They block the open oil path through the main control valve power switches OFF - in truck cab. during remote operation. 16. Disconnect hand control and store in truck, (If equipped with hard wire remotes).

  • Page 72: Electrical Circuit Description

    OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 Transmitter seconds to “initialize” the receiver. This switch should be placed in the OFF position when not using the The transmitter generates an RF signal which is FM remote controls. Failure to do so will greatly reduce the modulated.

  • Page 73: Frequently Asked Questions

    600E2 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES turned on, the receiver will not be initialized. Once the operation, the transmitter must again send the special code receiver has been initialized, the unit will be allowed to to re-activate the receiver. To achieve this, turn transmitter operate.
  • Page 74 OPERATING CONTROLS AND PROCEDURES OPERATOR MANUAL 600E2 Question Answer Will two radio remote units in the same vicinity No. Each receiver and transmitter have address codes which are set operate each other? by the factory and are shipped as a set. Therefore, serial numbers should be recorded for future reference should assistance from the factory be necessary.

  • Page 75: Section 4

    600E2 OPERATOR MANUAL SET-UP SECTION 4 SET-UP Pre-Operation Inspection and Calibration EQUIPMENT FAMILIARIZATION Verification All members of the crew should become familiar with the Check the electrical wiring connecting the various parts location and operation of controls, the correct operating of the system for physical damage.

  • Page 76: Work Site Selection

    SET-UP OPERATOR MANUAL 600E2 outrigger and stabilizer pads with bearing pads. Some concrete and asphalt surfaces are relatively thin and cannot CAUTION support outrigger or stabilizer loading. Concrete can break If the light and audible alarm (extension-equipped cranes) through and cause instability. do not function as described and the crane movements Variation in chassis, outrigger, and mounting configurations are not stopped, the system is not working properly.

  • Page 77: Site Selection

    600E2 OPERATOR MANUAL SET-UP Position the crane on a firm, level surface. making a lift. If it is suspected that the bubble level indicator is out of adjustment, verify and adjust the Extend and set the outriggers. Level the crane, as bubble level using the procedures under Bubble Level indicated by the bubble level indicator, using the Adjustment, page 4-2.

  • Page 78: Lifting Over The Front With A Sfo

    SET-UP OPERATOR MANUAL 600E2 Lifting Over the Front with a SFO Before Making the Lift Check all controls for proper operation by operating each system through one complete cycle. This is particularly important after the unit has been serviced or repaired.

  • Page 79: Set-Up

    600E2 OPERATOR MANUAL SET-UP All outriggers and stabilizers are extended with positive NOTE: Rated loads shown on the load chart pertain to this contact on firm, level surface, the tires are free of the machine as originally manufactured and equipped. ground and the machines level within 1°.

  • Page 80: Definitions

    SET-UP OPERATOR MANUAL 600E2 Rated loads are based on Loaded Boom Angle freely suspended loads. Block Loaded boom angle is the angle between the first section Always position the boom boom and the horizontal, after lifting the rated load at the tip directly over the load Sling rated radius.

  • Page 81: Load Determination Examples

    600E2 OPERATOR MANUAL SET-UP Determine the weight of the load and load handling Ending Point: The load rating at the ending point is 3950 lbs equipment. (1792 kg). The boom will be at 62 ft (18.90m) extension and the loaded radius is 40 ft (12.19 m). Determine the radius from center line of crane rotation to position of load.

  • Page 82: Boom Extension Operation Safety

    SET-UP OPERATOR MANUAL 600E2 NOTE: Crane must be reeved for 2 part to lift the 9,000 lbs extended and operate with extension by boom (4082 kg) load. angle when main boom is not fully extended. Do not exceed rated extension capacities at any Two part hoist capacity is 15,400 lbs (6985 kg) reduced boom lengths.
  • Page 83 600E2 OPERATOR MANUAL SET-UP Operate boom and turn functions very slowly and carefully when using a boom extension since extensions can increase boom length by 50%. CAUTION Area where extension swings around must be clear of • Boom tip attachment can contact extension in stowed obstructions and power lines when stowing and position when boom is fully retracted.

  • Page 84: Side Folding-Swing Around Boom Extension Operation

    SET-UP OPERATOR MANUAL 600E2 Extension in Operating Position Stow Extension Deployment Extension Swing Stow Loop Swing Around Extension Retaining Extension Load Line Attachment Deployment Point SIDE FOLDING-SWING AROUND BOOM Using lift function, raise boom to a horizontal position. EXTENSION OPERATION Using telescope function,...

  • Page 85: Stowing Procedure

    600E2 OPERATOR MANUAL SET-UP 14. Using hoist function, unspool enough loadline to reeve control in neutral, the boom can creep out when loadline over extension sheave case. Keep slight below horizontal. tension on loadline to avoid bird caging of loadline on For manually extendable extensions, pull extension hoist drum.

  • Page 86: Boom Extension Maintenance

    SET-UP OPERATOR MANUAL 600E2 the 1 section boom, first lifting the extension and then engaging the extension side stow bracket and the boom hook completely upon full retraction of the boom. CAUTION 14. Install stow pin A with spring clip into the ramp/side stow Extension Weights bracket assembly...

  • Page 87: Adjustable Swing Speed Valve

    600E2 OPERATOR MANUAL SET-UP CAUTION Avoid “shock loads” created by quickly opening and closing the release while jack is under load. This may result in overloading of the hydraulic circuit and possible damage to the jack. When extension is stowed on side of crane, always leave ram and handle sleeve pushed all the way down to reduce exposure to rusting.
  • Page 88 SET-UP OPERATOR MANUAL 600E2 THIS PAGE BLANK 4-14 PUBLISHED 04-26-2019 CONTROL # 113-09...

  • Page 89: Environmental Protection

    This suitability of a specific fluid, check with your authorized section does not include lubrication requirements for the National Crane distributor or Manitowoc Crane Care. truck chassis. Refer to the truck service manual for this NOTE: All fluids and lubricants may be purchased by information.

  • Page 90: Anti-Wear Additives

    Arctic hydraulic oil is not ® protected using Boeshield T-9 Premium Metal Protectant. recommended for service in ambient temperatures above Manitowoc Crane Care has Boeshield T-9 Premium Metal 32°F (0°C). PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 91 600E2 OPERATOR MANUAL LUBRICATION PROCEDURE AND CHARTS Protectant available in 12 oz. cans that can be ordered The following describe the lubrication points and gives the through the Parts Department. lube type, lube interval, lube amount, and application of each. Each lubrication point is numbered, and this number NOTE: Cylinder operation and inclement weather will corresponds to the index number shown on the Lubrication...

  • Page 92: Lubrication Chart

    LUBRICATION PROCEDURE AND CHARTS OPERATOR MANUAL 600E2 Lubrication Chart Oil Fill/Breather Oil Drain NOTE: Torque diffuser to 51 lb-ft (69 Nm). Openings must face bottom of tank. Recommended Item Application Procedure Frequency Lubricant Hydraulic oil reservoir HYDO Check fill change Weekly, semi-annually, as required After first 40 hrs.

  • Page 93: Internal Cable Sheave Lubrication

    0.25 inch (6.35 mm) diameter nozzle grease gun tip local, state or federal regulations (National P/N 955047). • Contact the Manitowoc Crane Care to obtain this tip. • Observation through the sheave case for the extend sheaves and the hoist mount for retract...

  • Page 94: Inner Boom Pad Lubrication

    LUBRICATION PROCEDURE AND CHARTS OPERATOR MANUAL 600E2 NOTE: To determine the amount of grease required, Extend boom to position the wear pad access holes visually inspect the sheaves. From the front of the directly above the wear pads on the fourth boom section, boom, look back through the sheave case at the apply grease to the pads using the brush or gun.

  • Page 95: Maintenance Scheduling

    600E2 OPERATOR MANUAL LUBRICATION PROCEDURE AND CHARTS Maintenance Scheduling Drain /Add New Hoist Brake Oil The owner is to ensure proper inspection intervals, in To drain and add new oil, remove the drain plug (Figure 5-1), compliance with the API RP 2D Section 4 requirements or inspection plug and vent plug and drain the brake oil.

  • Page 96: Hydraulic Oil Reservoir Level

    LUBRICATION PROCEDURE AND CHARTS OPERATOR MANUAL 600E2 with 1.42 liters (1.50 quarts) of EP-90 oil. Remove the pipe page 5-4 for recommended oil type and grade for your and elbow, then replace the plug (33). application. For information about changing hoist brake oil, see Drain / Add New Hoist Brake Oil, page 5-7.

  • Page 97: Carwell© Rust Inhibitor

    600E2 OPERATOR MANUAL LUBRICATION PROCEDURE AND CHARTS • bath Whenever possible, the lubricant should be applied at the top of a bend in the rope, because at that point the strands • dripping are spread by bending and are more easily penetrated. •...

  • Page 98: Cleaning Procedures

    Manitowoc Crane Care recommends that a To help protect against corrosion of National Cranes, qualified body repairman prepare, prime and paint Manitowoc Crane Care recommends washing the crane at any major scratch(es) or minor damage. least monthly to remove all foreign matter. More frequent c l e a n i n g m a y b e n e e d e d w h e n o p e r a t i n g i n h a r s h environmental conditions.

  • Page 99: Application

    It is recommended that Carwell T32-CP-90 be periodically necessary. reapplied by the crane owner after that time to help continue Please contact Manitowoc Crane Care should you have any to protect against corrosion of the crane and its components. questions.
  • Page 100 LUBRICATION PROCEDURE AND CHARTS OPERATOR MANUAL 600E2 7650-41 7650-42 5-12 PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 101 600E2 OPERATOR MANUAL LUBRICATION PROCEDURE AND CHARTS 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, Pins, Hose Connections Entire underside of unit not painted O/R Pins, Clips Hook Block/Overhaul Ball Pivot Shaft Turntable Bearing Fasteners...
  • Page 102 LUBRICATION PROCEDURE AND CHARTS OPERATOR MANUAL 600E2 THIS PAGE BLANK 5-14 PUBLISHED 04-26-2019 CONTROL # 113-09...

  • Page 103: Crane Inspection And Maintenance

    600E2 OPERATOR MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST CRANE INSPECTION AND MAINTENANCE Daily Inspections A regular schedule of inspection and maintenance is Check the following items: essential to keep your unit in peak operating efficiency. Engine oil level. Operators or service personnel responsible for the care of the unit must be completely familiar with the type and Hydraulic oil level.

  • Page 104: Weekly Inspections

    MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 23. Control and drive mechanisms for excessive wear and/ All items listed under daily, weekly and monthly or contamination from lubricants, water or other foreign inspections. matter. Loose bolts and fasteners in all areas. Torque pin retainer bolts.

  • Page 105: Hoist Cable Inspection And Maintenance

    • Wear protective clothing, gloves, and safety shoes as and local regulatory agencies. appropriate. NOTE: Wire rope may be purchased through Manitowoc • Measure the rope’s diameter across crowns of the Crane Care. strands when determining if rope has become damaged, refer to Figure 6-1.

  • Page 106: Wire Rope Replacement

    MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 • Core failure in rotation resistant ropes. sheaves, and hoist drums for wear. Damaged sheaves or hoist drums can accelerate wear and cause rapid • Prior electrical contact with a power line or other electric deterioration of the wire rope.

  • Page 107: Rope Construction

    9/16 in. (14.3mm) Dia. Wire Rope: trained. Use only parts supplied by your National Crane 6X25 General Purpose Distributor or Manitowoc Crane Care to repair the crane. 6X25 Nominal Breaking Strength: EXTENSION JACK SERVICE AND 16.8 tons (15,241 kg)

  • Page 108: Lubrication

    MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 Single Character Display Lay the jack on its side and drain the oil into a suitable drain pan. The oil will run slowly because air must enter The electronics box of the extension load limiting device is as oil drains out.

  • Page 109: Hydraulic System Trouble Diagnosis

    600E2 OPERATOR MANUAL MAINTENANCE CHECKLIST HYDRAULIC SYSTEM TROUBLE possible cause and possible solution. These are not all inclusive but are designed to help isolate the problem and DIAGNOSIS should be checked before calling the factory Service The following chart lists malfunctions which may occur Department during equipment operation, followed immediately by Condition...
  • Page 110 MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 Condition Possible Cause Possible Solution Loose turntable bearing. Torque bearing mounting bolts. Loose swing gearbox mounting bolts. Tighten bolts. Replace worn parts or adjust gearbox Worn gears or bearing. spacing. Operator control of lever too erratic. Operate controls smoothly.
  • Page 111 600E2 OPERATOR MANUAL MAINTENANCE CHECKLIST Condition Possible Cause Possible Solution Check load and change to applicable Load too heavy. multipart reeving. Relief valve setting too low. Check and adjust if required. Motor worn excessively. Replace motor. Hoist will not lift or hold load Counterbalance valve defective or Clean and replace as necessary.

  • Page 112: Extension Jack Troubleshooting

    MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 Condition Possible Cause Possible Solution Check to see which table is selected using the single character display. If the wrong Wrong table selected. table is selected, select the proper table using the procedure in the system installation section.

  • Page 113: Tire Load And Inflation Table

    600E2 OPERATOR MANUAL MAINTENANCE CHECKLIST Tire Load And Inflation Table NOTE: The values in the tables below are as published by the Tire and Rim Association 2005. Your vehicle Definite tire inflation pressures are established for each tire may be equipped with other tire sized or the same size depending upon the load imposed on the tires.
  • Page 114 MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 Radial Ply Metric Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15° Drop Center Rims Tire and Rim Association Standard Radial Ply Metric Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15°...
  • Page 115 600E2 OPERATOR MANUAL MAINTENANCE CHECKLIST Metric Wide Base Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Tires Used as Singles Mounted on 15° Drop Center Rims Tire and Rim Association Standard Radial Ply Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15°...

  • Page 116: Specifications

    MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 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) at 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 117: Crane Operating Speeds

    600E2 OPERATOR MANUAL MAINTENANCE CHECKLIST Crane Operating Speeds Rotation 375°................. 35 ± 5 sec (1.8 ± 0.2 rpm) Swing speed based on and adjustment knob in closed position. Boom up -10° to 80° .............. 25 ± 5 sec Boom Down 80° to -10° ............20 sec ± 5 sec Boom Extend/Retract Three Section 16 - 38 ft Extend (60°...
  • Page 118 MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 THIS PAGE BLANK 6-16 PUBLISHED 04-26-2019 CONTROL # 113-09...
  • Page 119 600E2 OPERATOR MANUAL Alphabetical Index Accidents ............. 2-1 Adjustable Swing Speed Valve .
  • Page 120 OPERATOR MANUAL 600E2 Temperature Effects on Hydraulic Cylinders ....... . 2-35 Three Section Boom Operation .

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