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National Crane 600H Service Manual

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National Crane 600H
Service Manual

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  • Page 1 National Crane 600H Service Manual...
  • 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 1565 Buchanan Trail East PO Box 21 Shady Grove, PA 17256-0021 T 717 597 8121 F 717 593 5999 www.manitowoc.com CHANGE OF OWNERSHIP FORM Constant improvements, engineering progress or manufacturing information may arise after this crane has been in the field for several years that will make it necessary for us to contact future owners of this machine. It is important to you that Manitowoc Crane have up-to-date records of the current owners of the crane should the need arise for us to contact you.
  • Page 4 CHANGE OF OWNERSHIP REGISTRATION Product Support strives to maintain up-to-date contact information for crane owners so that we can readily communicate information about improvements and/or engineering developments for cranes that have been in the field for several years. Product Support is pleased to announce that we have developed a QR code to allow the customer to register their crane remotely or re-register their crane if it was purchased used.
  • Page 5 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. National Crane is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 6 THIS PAGE BLANK...

  • Page 7: Table Of Contents

    600H TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 ........Introduction General .
  • Page 8 TABLE OF CONTENTS 600H SECTION 3........Electric System Electrical System Description .
  • Page 9 600H TABLE OF CONTENTS Boom Disassembly Alternative #1 ........4-12 Boom Disassembly Alternative #2 .
  • Page 10 600H-TM Outrigger Assembly ........
  • Page 11 600H TABLE OF CONTENTS SECTION 8 ........Lubrication General .
  • Page 12 TABLE OF CONTENTS 600H After Frame Modification ..........9-22 Mounting the Crane .

  • Page 13: Section 1

    This manual has been compiled to assist you in properly personnel, and the information to assist you in a timely operating and maintaining your Model 600H series National manner. We request that you first contact them for Crane (Behind the Cab and Rear Mount).

  • Page 14: New Owner

    New Owner Basic Nomenclature If you are the new owner of a National crane, please register it with National Product Support so we have the ability to The nomenclature used to describe parts of a National Crane contact you if the need arises.
  • Page 15 600H SERVICE MANUAL INTRODUCTION FIGURE 1-2 600H-RM Item Component Operator’s Console Operators Station Rated Capacity Limiter (RCL) Reel Boom Item Component Boom Nose Jack Front Outrigger (SFO), Front Outrigger Jack Boom Rest Hydraulic Tank Lift Cylinder RCL Panel Downhaul Weight, Hook Block...

  • Page 16: General Maintenance

    INTRODUCTION 600H SERVICE MANUAL GENERAL MAINTENANCE All supporting members (chains and cables) need to be parallel to each other and as near perpendicular as possible The suggestions listed below are helpful in analyzing and to the top of the object being lifted.

  • Page 17: Bearings

    600H SERVICE MANUAL INTRODUCTION Bearings driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part. Antifriction Bearings Gaskets When an antifriction bearing is removed, cover it to keep out dirt and abrasives.

  • Page 18: Electrical

    INTRODUCTION 600H SERVICE MANUAL Keep the System Clean Remove the batteries If the machine is not used for an extended period of time. Store the batteries in a warm, dry When removing components of a hydraulic system, cover all place, preferably on wooden shelves. Never store on openings on both the component and the crane.

  • Page 19: Fatigue Of Welded Structures

    Loctite® are specified throughout the Service and nuts being used. Manual. The following types of Loctite® brand adhesives are The torque tables are provided by National Crane for available from the Parts Department of the local National reference when performing maintenance.
  • Page 20 INTRODUCTION 600H 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 21 600H 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...
  • Page 22 INTRODUCTION 600H 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...
  • Page 23 600H 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...
  • Page 24 INTRODUCTION 600H 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...
  • Page 25 600H 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...
  • Page 26 INTRODUCTION 600H 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.
  • Page 27 600H 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...
  • Page 28 INTRODUCTION 600H SERVICE MANUAL Inch Series with Fine Threads (UNF) – Untreated (black finish) Table 1-10 (Continued) Torque (ft/lb) Size Grade Maximum Nominal Minimum 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...
  • Page 29 600H SERVICE MANUAL INTRODUCTION Table 1-11 Metric Series with Coarse Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum 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 M14x2 10.9...
  • Page 30 INTRODUCTION 600H SERVICE MANUAL Table 1-11 Metric Series with Coarse Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum 2681 2578.5 2476 M36x4 10.9 3964 3812 3660 12.9 4639 4461 4283 Table 1-12Metric Series with Fine Threads – Untreated (black finish)

  • Page 31: Weld Studs

    600H SERVICE MANUAL INTRODUCTION Table 1-12Metric Series with Fine Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum 464.5 M20x1.5 10.9 12.9 M22x1.5 10.9 888.5 12.9 1111 1068 1025 803.5 M24x2 10.9 1176 1130.5 1085 12.9...

  • Page 32: Wire Rope

    ANSI/ASME B30.5, federal regulations, and National Crane specifications. The inspection interval shall be determined by Keeping Records a qualified person and shall be based on expected rope life as determined by experience, severity of environment, A signed and dated report of the wire rope’s condition at...

  • Page 33: Environmental Conditions

    600H SERVICE MANUAL INTRODUCTION relationship between visual inspection and the rope’s actual lubricant applied shall be of the type which does not hinder internal condition at the time of removal from service. visual inspection. Those sections of rope which are located...

  • Page 34: Inspection

    • Abuse Points: The point where the wire rope is Standard as referenced by Federal Government Agencies subjected to abnormal scuffing and scraping. and as recommended by National Crane. All wire rope will eventually deteriorate to a point where it is no longer usable. 1-22...

  • Page 35: Care Of Wire Rope

    600H SERVICE MANUAL INTRODUCTION 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 36: Wire Rope Replacement (All Wire Rope)

    INTRODUCTION 600H SERVICE MANUAL Wire Rope Replacement (All Wire Rope) • National recommends that boom extension cables be replaced every seven (7) years. No precise rules can be applied to wire rope replacement • Do not use a swivel on rotation resistant rope. A swivel because of the variables involved.
  • Page 37 600H SERVICE MANUAL INTRODUCTION twisting. Cut off both ends of the wire and pound the twist flat NOTE: Non-preformed wire rope should have two seizings against the rope (Figure 1-9). located on each side of the cut (Figure 1-10). PREFORMED...
  • Page 38 INTRODUCTION 600H SERVICE MANUAL THIS PAGE BLANK 1-26 08-19-2022 Control # 092-13...

  • Page 39: Section 2

    600H SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Hydraulic System Description....2-4 Oil Cooler Service & Maintenance (Optional) ..2-8 Servicing the Control Valves .
  • Page 40 HYDRAULIC SYSTEM SERVICE MANUAL 600H Description Symbol Description Symbol Hydraulic Reservoir - Stores, cools, and Filter - Removes contamination from cleans machines hydraulic fluid supply. hydraulic fluid. Hydraulic Return Lines - Terminated at (1) Filter with Bypass Valve - Bypass valve below fluid level (2) above fluid level.
  • Page 41 600H SERVICE MANUAL HYDRAULIC SYSTEM Description Symbol Description Symbol Single Acting Cylinder - Extended Manually Operated - Valve shifted hydraulically and retracted with a spring. manually with check to allow flow back to tank. Double Acting Cylinder - Extended and retracted hydraulically.

  • Page 42: Hydraulic System Description

    Adjustments and repairs shall be done only by designated pump is not bidirectional and can only be used when the personnel who are properly trained. Use only National Crane shaft rotates only in the proper direction. If you need to verify supplied parts to repair the crane.

  • Page 43: Draining And Flushing

    600H SERVICE MANUAL HYDRAULIC SYSTEM Due to manufacturing methods, there is a natural curvature 11. Connect the return lines and raise the outrigger jack to a hydraulic hose. The hose should be installed so any cylinders to the stowed position. Replenish the reservoir hydraulic oil level as necessary.

  • Page 44: Removing Air From The Hydraulic System

    HYDRAULIC SYSTEM SERVICE MANUAL 600H When hydraulic oils are changed, recheck the reservoir practicable, and allow the boom to remain in this position hydraulic oil level after brief system operation and add overnight. This should allow entrapped air to find its way hydraulic oil as required.

  • Page 45: Hydraulic Filter Replacement

    The filter must be serviced with National Crane replacement elements at recommended intervals to assure the warranty A sight gauge is located on the side of the reservoir and has remains in effect.

  • Page 46: Oil Cooler Service & Maintenance (Optional)

    HYDRAULIC SYSTEM SERVICE MANUAL 600H Item Component Hydraulic Reservoir Temperature Gauge Hydraulic Oil Level Gauge Access Cover Fill Cap/Breather Bowl Filter Element Gauge Filter Filter Cap Capscrews (6) FIGURE 2-1 Element Installation Oil Cooler Service & Maintenance (Optional) Install the new element into the filter bowl (housing).

  • Page 47: Servicing The Control Valves

    600H SERVICE MANUAL HYDRAULIC SYSTEM SERVICING THE CONTROL VALVES When all valve sections are positioned on assembly studs, replace stud nuts and tighten evenly to 32 ft-lb Disassembly and Reassembly of Control (43 N.m) torque for crane valve and 25 ft-lb (34 N.m) torque for hoist valve.

  • Page 48: Control Valve Relief Adjustment

    HYDRAULIC SYSTEM SERVICE MANUAL 600H Backup Washers Spool Seal Bonnets Assembly Crane Valve Cover Retainer Plate 10 ft-lb (13.5 N.M) Hoist Valve Cover 5 ft-lb (6.7 N.M) Work Ports Outlet Cover Crane Valve Cover 10 ft-lb (13.5 N.M) Spool Action...

  • Page 49: Hydraulic System Troubleshooting Chart

    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 National Product Support for O-Ring boss seal kits. HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution Check & replace damaged fittings or "O" Rings.
  • Page 50 HYDRAULIC SYSTEM SERVICE MANUAL 600H HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution Check proper drive rotation. Make sure pump shaft is turning (i.e. drive coupling is engaged). Check for Pump not installed correctly. sources of suction leaks, inlet flange tight? Pinched...
  • Page 51 600H SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution Loose turntable bearing. Torque bearing mounting bolts. Loose swing gearbox mounting bolts. Tighten bolts. Worn gears or bearing. Replace worn parts or adjust gearbox spacing. Operator control of lever too erratic.

  • Page 52: Jib Jack Troubleshooting

    HYDRAULIC SYSTEM SERVICE MANUAL 600H HYDRAULIC SYSTEM TROUBLESHOOTING CHART Condition Possible Cause Possible Solution Check load and change to applicable multipart Load too heavy. reeving. Relief valve setting too low. Check and adjust if required. Hoist will not lift or hold Motor worn excessively.

  • Page 53: Systematic Troubleshooting

    600H SERVICE MANUAL HYDRAULIC SYSTEM Systematic Troubleshooting the Hydraulic Schematic and the Illustrated Parts Catalog to identify parts and flow paths. Start at the top box and work The following step-by-step analysis will be helpful in isolating downward step-by-step. Do not try to start in the middle or and correcting almost every service problem if followed in a skip steps.
  • Page 54 HYDRAULIC SYSTEM SERVICE MANUAL 600H THIS PAGE BLANK 2-16 08-19-2022 Control # 092-13...

  • Page 55: Section 3

    600H ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS Installation ....... 3-7 Electrical System Description .

  • Page 56: Maintenance

    ELECTRIC SYSTEM 600H MAINTENANCE Applying Dielectric Grease to an Electrical Connector Use the following procedure to apply dielectric grease to an General electrical connection. Grease should be applied immediately prior to securing the connector. Ensure that grease is applied Electrical system maintenance includes troubleshooting and to all terminal sockets (Figure 3-1).

  • Page 57: Rcl System Description

    When the pins or sockets ANTI-TWO BLOCK SYSTEM DESCRIPTION show signs of arcing or burning, it may be necessary to The anti-two-block system (ATB) on your National Crane replace them. helps prevent cable damage by sensing when the end of the...

  • Page 58: Outrigger Solenoids

    ELECTRIC SYSTEM 600H OUTRIGGER SOLENOIDS The solenoids are located behind the cover on the outriggers. Remove the cover to gain access to the Outrigger component selection is controlled by four solenoids (Figure 3-3). solenoids (two on the front outrigger and two on the rear outrigger).

  • Page 59: Oil Cooler

    600H ELECTRIC SYSTEM RSOD Outriggers Solenoids FIGURE 3-4 Oil Cooler Cooler specifications is as follows: Fan RPM ..............2450 The oil cooler core must be kept clean to allow for air flow through the core. Wash the core frequently to eliminate oil CFM ................863...

  • Page 60: Hydraulic System Description

    ELECTRIC SYSTEM 600H Oil Cooler Fan Group Fan Motor Cooling Core Temperature Switch Relay 20 Amp Breaker (Resets automatically located in engine compartment firewall) FIGURE 3-5 Hydraulic System Description Solenoid Valve Sections An electrically actuated directional control valve which Solenoid Valve Assembly...

  • Page 61: Service And Maintenance

    600H ELECTRIC SYSTEM They block the open oil path through the main control valve Installation during remote operation. Install the crane on the truck by following the procedures Service and Maintenance in the Installation Section of this manual. The Electrical and Hydraulic Schematics show the Follow th e p roce dures ou tline d in t he Se rvic e a nd typical connections of the remote control system.

  • Page 62: Danger Remote Start Hazard

    ELECTRIC SYSTEM 600H The remote control system offers an excellent solution to Operation safety, speed and ease of use, less downtime, and overall Position crane at job site, set park brake, and shift maneuverability. Like and device, there are precautions and transmission to neutral.

  • Page 63: Operation

    600H ELECTRIC SYSTEM Never allow any operation until the operator has read all to the outputs. If for any reason this test fails, no output will instructions and has become completely familiar with the be allowed to function. Once this test has passed, the appropriate output will be activated.

  • Page 64: Emergency Stop Function

    ELECTRIC SYSTEM 600H b. “M” (Start) circuit energized to power start relay at When the transmitter is turned on, it will transmit a special truck engine. code for 10 seconds to instruct the receiver to initialize. This will happen only if the transmitter is Not transmitting a “N”...

  • Page 65: Service And Maintenance

    600H ELECTRIC SYSTEM Question Answer Will our current 2-way radio affect the operation No. Two-way radios are assigned to different bands in the frequency of the wireless controller? spectrum and at high frequencies. At the lower frequencies such as 49 MHz, the power density in a given area is much lower than at higher frequencies therefore much less chance of interference.

  • Page 66: Quick Test For Receiver Antenna And Cable

    ELECTRIC SYSTEM 600H radio frequency transmitting function. The current draw for connectors (Look for dead shorts in wiring and the rest of the electronics in the transmitter is in the micro- connections). amp range. For instance, when the transmitter power switch...

  • Page 67: Specifications

    600H ELECTRIC SYSTEM matching. Compare the 12 position address If crane function occurs when function switch is switches in both transmitter and receiver and activated and before trigger is pulled, readjust the low end proportional potentiometer in the receiver. See then repeat step 3B.
  • Page 68 ELECTRIC SYSTEM 600H Receiver Mounting Receiver Input and Output The receiver should be mounted on the crane console. If Each unit comes with a connector chart (Chart C) with the installed in a tool box or compartment, care should be taken appropriate input and output instruction for your unit.
  • Page 69 600H ELECTRIC SYSTEM 5 Conductor NCC Cord Wire Description Output Label Cord Wire Color Color Output 16 HCA - RCL Override Output 15 Blu/Red Turn RH Output 14 Org/Blk Turn LH Output 13 Bwn/Blk Boom Up Output 12 Red/Blk Boom Down...
  • Page 70 ELECTRIC SYSTEM 600H High End Proportional — 0 Highest Trigger Setting, F Least Trigger Setting Set The potentiometer on the transmitter to minimum, This is done by releasing trigger. Set the “Low End Proportional” hex switch in the receiver to 0.
  • Page 71 600H ELECTRIC SYSTEM The connector on the end of the cable will hook up to vertical metal. The position of a “Boom” (over or antenna connector on receiver. See Figure 3-6. around) can effect the antenna’s ability to receive a signal, creating “Dead Spots”.
  • Page 72 ELECTRIC SYSTEM 600H FIGURE 3-9 continued 3-18 08-19-2022 Control # 092-13...
  • Page 73 600H ELECTRIC SYSTEM FIGURE 3-10 NATIONAL CRANE 3-19 08-19-2022 Control # 092-13...
  • Page 74 ELECTRIC SYSTEM 600H FIGURE 3-11 3-20 08-19-2022 Control # 092-13...

  • Page 75: Section 4

    600H SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Three Section Boom Operation....4-2 5 - Section Boom w/ 2 Stage Cylinder Cable Positioning ......4-18 Special Boom Inspection .

  • Page 76: Three Section Boom Operation

    BOOM 600H 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 FIGURE 4-1 THREE SECTION BOOM OPERATION Special Boom Inspection A rod-fed, double-acting cylinder, attached to the 1...

  • Page 77: Hoist Removal

    BOOM DISASSEMBLY Remove hook block or downhaul weight. Wind up rope on hoist drum and stow wedge socket on pegs provided The 600H boom can be disassembled by using two different on 1 section. Shut down truck engine. methods. Alternative #1 disassembles the boom in the conventional manner.

  • Page 78: Boom Disassembly Alternative #1

    BOOM 600H SERVICE MANUAL section in this book. If the required service procedure is to be capscrews holding the cam plates to the section. This performed on the boom while still pinned to the turret, please will affect side clearance during re-assembly.

  • Page 79: Boom Disassembly Alternative #2

    Boom Disassembly Alternative #2 bent or bowed boom sections, gouged metal, broken welds or any abnormal conditions. Repair or replace as The 600H boom design allows for removal of the extend required. cylinder from the rear of the boom without complete disassembly of the boom sections.

  • Page 80: Three Section Boom Assembly

    BOOM 600H SERVICE MANUAL 11. Inspect all sheave pins for nicks, gouges or pitting due to 10. Place retract cables over top of retract sheaves. Install rust in the bearing surface area. Replace if any damage keeper capscrew above sheave to hold retract cables in is evident.

  • Page 81: Three Section Top/Bottom Pad Replacement (Assembled Boom)

    600H SERVICE MANUAL BOOM 21. As the extend cylinder keeper plate nears the 2 capscrews will cause loss of preload and cause section, adjust the height of the cylinder to allow the excessive side clearance between sections. cylinder to access the cylinder keeper cutouts in the 33.

  • Page 82: Front Bottom Pad Replacement

    BOOM 600H SERVICE MANUAL Note all pad locations and tag accordingly. INNER WEAR PAD CALIBRATION Inspect pads for wear using previously mentioned With a pair of inside/outside calipers, measure the inside inspection criteria. width of the outer section (Wi) at the front and back of the boom and record the smallest measurement.
  • Page 83 600H SERVICE MANUAL BOOM required [each shim is 0.03 in (0.8 mm) thick) to tighten the pads so that there is 0.03 in -.09 in (0.8 mm - 2.3 mm) clearance between the widest part of the inner Outside boom and the most narrow part of the outer boom when Inside shims and pads are installed.

  • Page 84: Four Section Boom Operation

    BOOM 600H SERVICE MANUAL Shim Calculation for Wear Pads (Example) 12.12 (308mm) at front 12.06 (306) at back near cylinder anchor bars wp =.52 (13mm) = 10.94 (278mm) at top rear pad location = 11.00 (279mm) at wp =.52 (13mm) top forward pad location = 10.94 (287mm) at...

  • Page 85: Four Section Boom Maintenance

    Contact the on 1 section. Shutdown truck engine. National Crane Care to obtain this nozzle tip (NCC Part No. Attach a lifting device to rod end of lift cylinder, remove 955047), or numerous variations of the nozzle tip can be boom lift cylinder pin keeper and pin from bottom of the purchased at local hardware or auto parts retail outlets.

  • Page 86: Boom Disassembly Alternative #1

    BOOM 600H SERVICE MANUAL Boom Disassembly Alternative #1 12. Loosen and remove six capscrews securing retract sheave pin and retract sheaves to 2 section. Remove Gaining access through rear of boom, loosen capscrews sheaves and pins. retaining the keeper plates holding the extend cable 13.

  • Page 87: Boom Disassembly Alternative #2

    600H SERVICE MANUAL BOOM Boom Disassembly Alternative #2 Assemble sheaves into 4 section sheave case. Top sheave is to be installed to the left hand side of the boom The boom design allows for removal of the extend cylinder with the spacer to the right hand side.
  • Page 88 BOOM 600H SERVICE MANUAL potential for damage. Assemble retract sheaves and holes are 0.06 in (1.5 mm) off center in the plate and retract sheave pins in rear of 3 section. Coat surfaces 0.03 in (0.8 mm) off center in the wear pad. Various...

  • Page 89: Four Section Top/Bottom Pad Replacement Assembled Boom

    600H SERVICE MANUAL BOOM 31. Visually verify that the extend cables are properly routed used. If locations are in question, refer to shim on their sheaves and continue to slide with the extend calibration section in this book. cylinder and cables into the boom sections. Keep extend 45.

  • Page 90: Top Rear Pad Replacement

    BOOM 600H SERVICE MANUAL Uneven pad wear of 3/32 in (2 mm) from side to side on the Loosen and remove the four capscrews holding the pad wear pad would be considered excessive as well. If any of doubler plate in between the 4th and 3rd sections.

  • Page 91: Cable Tension Sequence

    600H SERVICE MANUAL BOOM Extend boom so scribed lines are exposed by Measure the retraction gaps between each boom approximately 12 inches. section and scribed line and note values. Measure the extension gaps between each boom Extend and retract the boom a few times and then section and scribed line and note values.

  • Page 92: Section Boom W/ 2 Stage Cylinder Cable Positioning

    BOOM 600H SERVICE MANUAL 5 - Section Boom w/ 2 Stage Cylinder Cable Positioning 3/4/5 EXTEND 2/3/4 EXTEND 1/2/3 EXTEND 8860-1 3/2/1 RETRACT 4/3/2 RETRACT 5/4/3 RETRACT FIGURE 4-8 Cable Tightening Sequence 5 Section Boom with Two Retraction Stage Extend Cylinder Measure the retraction gaps between the first and second section and the second and third section.

  • Page 93: 4- Section Boom W/ 2 Stage Cylinder Cable Positioning

    600H SERVICE MANUAL BOOM The fourth section should have moved out. Tighten the 345 extend cable located at the back top of the third section the difference in the extension gap Tightening until the extension gap between the third and measurements.
  • Page 94 BOOM 600H SERVICE MANUAL sections are bottomed out on section stops. Ensure all At this time the second and first extendable sections should s e c t i o n s a r e f u l l y b o t t o m e d o u t a n d d o n o t s p r i n g extend and retract equally and bottom out against the stops back.(Reference Tensioning Setup Procedure pg 4-16)

  • Page 95: 4- Section Boom W/ 1 Stage Cylinder Cable Positioning

    600H SERVICE MANUAL BOOM 4- Section Boom w/ 1 Stage Cylinder Cable Positioning 2/3/4 EXTEND 1/2/3 EXTEND BASE 1ST STAGE 2ND STAGE 3RD STAGE 4th STAGE 8860-3 4/3/2 RETRACT 3/2/1 RETRACT FIGURE 4-10 Cable Tightening Sequence 4 Section Boom with (1)

  • Page 96: 3- Section Boom W/ 1 Stage Cylinder Cable Positioning

    BOOM 600H SERVICE MANUAL Retraction Extend and retract the boom a few times and then repeat measuring the retraction gaps. Measure the retraction gaps between the second and The fourth section should have moved in. third section and the third and fourth section.

  • Page 97: Cable Retention

    600H SERVICE MANUAL BOOM OPTION 1 OPTION 2 8859-1 8859-2 FIGURE 4-12 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.

  • Page 98: Lift Cylinder Repair

    BOOM 600H SERVICE MANUAL TORQUE VALUES for Second Nut: LIFT CYLINDER REPAIR Inch Series with Coarse Threads (UNC) Lift Cylinder Disassembly Minimum Disconnect shaft end of cylinder from machine. Cable end TORQUE Nut Type Retract cylinder shaft with oil from the hydraulic system...

  • Page 99: Telescope Cylinder Repair

    600H SERVICE MANUAL BOOM 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 in FIGURE 4-13 10.

  • Page 100: Telescope Cylinder Assembly

    BOOM 600H SERVICE MANUAL Remove any plug or fitting that is in the retract port in the do so will damage packing gland and or barrel assembly cylinder butt plate. Using a special drive tool, drive the when packing gland is installed.
  • Page 101 600H SERVICE MANUAL BOOM Using an overhead hoist, lift the jib assembly and align Retract the boom slowly. Observe the stow hook and and pin the jib to the boom sheave head. side stow bracket assembly alignment as the boom is retracted (View AA and BB below).

  • Page 102: Jib Jack Service And Maintenance

    BOOM 600H SERVICE MANUAL 15. Install jib stow pins and remove jib pins. Always save shims to allow future adjustment of jib stow if required Hook Assembly Stow Pin Alignment Pin in Slot FIGURE 4-22 JIB JACK SERVICE AND MAINTENANCE Be careful to prevent dirt or foreign matter from entering the system.
  • Page 103 600H SERVICE MANUAL BOOM Remove cable anchor plate (66, Figure 4-23). 27. After sliding sections apart hang retainer (64) on cylinder lug. At rear of section 1, remove hardware to free cylinder anchor plate. 28. Remove nuts and washers from cable (96) ends where they attach to section 4.

  • Page 104: Assembly

    BOOM 600H SERVICE MANUAL 57. Remove bottom wear pad assembly. Slide section 5 (1) into section 4 (2) with cables pre- installed. Be sure cables (94) are around sheave (48) 58. Remove cables (96, Figure 4-23) from grooves in front and facing rear of section.
  • Page 105 600H SERVICE MANUAL BOOM 24. Wrap, route, and stow pre-installed cables to avoid 33. Slide sections together leaving about 2 ft extended. damage at next insertion. NOTE: Cables (96, Figure 4-23) will bottom out on nuts 25. Assemble rear top wear pads (10) and screws (126) to...
  • Page 106 BOOM 600H SERVICE MANUAL Cable: Detail 2-8 Boom: Detail 9-18 Cylinder: Detail 19-20 A: Detail 2, 6, 9, 19 B: Detail 2, 7, 11, 19 C: Detail 2, 5, 6, 8, 13, 19 D: Detail 2, 5, 7, 15 E: Detail 3, 5, 8, 17...
  • Page 107 600H SERVICE MANUAL BOOM Boom Cables Extended Retract Cables 96, 97 Details 4-5 Synchronizing Cable 95 Detail 6 Extend Cable 93 Detail 7 Extend Cable 94 Detail 8 Detail 3 Retract Cable Mounts at J, K, L from Nose Detail 4...
  • Page 108 BOOM 600H SERVICE MANUAL Retract Cable Mounts at C, D, E from Base Detail 5 Synchronizing Cable 95 at A, C, K Detail 6 FIGURE 4-23 continued 4-34 08-19-2022 Control # 092-13...
  • Page 109 600H SERVICE MANUAL BOOM Extend Cable 93 at B, D, Z Detail 7 Extend Cable 94 at C, E, M, N Detail 8 FIGURE 4-23 continued NATIONAL CRANE 4-35 08-19-2022 Control # 092-13...
  • Page 110 BOOM 600H SERVICE MANUAL Section 1 at A Detail 9 Section 1 at J Detail 10 FIGURE 4-23 continued 4-36 08-19-2022 Control # 092-13...
  • Page 111 600H SERVICE MANUAL BOOM Section 2 at B Detail 11 Section 2 at K Detail 12 FIGURE 4-23 continued NATIONAL CRANE 4-37 08-19-2022 Control # 092-13...
  • Page 112 BOOM 600H SERVICE MANUAL Section 3 at C Detail 13 Section 3 at L Detail 14 FIGURE 4-23 continued 4-38 08-19-2022 Control # 092-13...
  • Page 113 600H SERVICE MANUAL BOOM Section 4 at D Detail 15 Section 4 at M Detail 16 FIGURE 4-23 continued NATIONAL CRANE 4-39 08-19-2022 Control # 092-13...
  • Page 114 BOOM 600H SERVICE MANUAL Section 5 at E Detail 17 Section 5 at N Detail 18 FIGURE 4-23 continued 4-40 08-19-2022 Control # 092-13...
  • Page 115 600H SERVICE MANUAL BOOM Section 6 at W, X, Y Detail 19 Cylinder 6 at Z Detail 20 FIGURE 4-23 continued NATIONAL CRANE 4-41 08-19-2022 Control # 092-13...
  • Page 116 BOOM 600H SERVICE MANUAL Telescope Cylinder Build-Up NOTE: Turn and adjust cylinder lugs in order to clear sections during assembly. Middle lug-horizontal. Be sure the ¼”plug on the base front nose end is in the up Outside lug with check valves-vertical (too be position.
  • Page 117 600H SERVICE MANUAL BOOM 63. Install side wear pads to section 2, top wear pads (12) 46), Shim as required. Secure with bolts (143) and and shims (52). Bottom wear pads (17), shims (45 or lockwashers (132), FIGURE 4-24 64. Install top retainer plate (7, Figure 4-24), cable retainer 69.
  • Page 118 BOOM 600H SERVICE MANUAL NOTE: Route lower cables (6) forward with nuts and 83. Install cable anchor weldment (9, Figure 4-24) to top washers on threaded ends and ensure they are in front of section 1 with bolts (16) and lockwashers (14).

  • Page 119: Six Section Boom

    600H SERVICE MANUAL BOOM SIX SECTION BOOM Extend and retract cables in the boom, extend and retract the 6 section. Synchronization (sync) cables are attached The six section boom is powered by a four-stage double/ to the 2 , and 5 boom sections.

  • Page 120: Boom Disassembly

    BOOM 600H SERVICE MANUAL BOOM DISASSEMBLY CAUTION Be careful not to damage the sync cables or extend and retract cables as the boom sections are being separated. DANGER Remove the telescope cylinder. Ensure that all stages of the telescope cylinder are fully retracted prior to removal of the telescope cylinder from •...
  • Page 121 600H SERVICE MANUAL BOOM Section Top Wear Pads FIGURE 4-27 3/8 Inch Square Hole for Cam Adjustment Section Wear Pad Cam Plate Section Cams FIGURE 4-28 NATIONAL CRANE 4-47 08-19-2022 Control # 092-13...
  • Page 122 BOOM 600H SERVICE MANUAL Top Rear Section Wear Pad Section Retract Cable Anchor Clamp Clamp Torquing Pattern. Torque to 75 lb- ft (101.6 N.m) Retract Cable Stop Wear Pad Holder Retract Cable Anchor Extend Cable Anchor Outside of 6 Section...
  • Page 123 600H SERVICE MANUAL BOOM Sheave Relief Bearing Dust Cover Retainer Relief FIGURE 4-30 Retract/Sync IMPORTANT: The relief on the bearing retainer Sheave Assembly Retainer secures the dust cover on the bearing. The relief must be toward the center of the boom when the assembly is bolted to the boom to keep the dust cover from falling off.
  • Page 124 BOOM 600H SERVICE MANUAL NOTE: If the front of the is elevated too far when sliding the 17. Tighten the wear pad and cam bolts. sections together, the back wear pads may fall off into the boom. Use a 3/8 in socket to adjust the wear pads.
  • Page 125 600H SERVICE MANUAL BOOM 20. Install the wear pads to the bottom front and side of the section (Figure 4-34). Hoist Cable Retainer Hoist Cable Section Wear Pad Retract Cable Retract Cable Side Wear Section Pads Boom FIGURE 4-33 19. Attach the top front wear pads and hoist cable retainer to...

  • Page 126: Th Th Th , And

    BOOM 600H SERVICE MANUAL Mark toward the Sync Cable center of the boom. Wear Plug Cable Guide Wear Plug Sheave Cable Cable Guide Bolts Bolts Bottom Rear Bolt holes for the bottom Wear Pad FIGURE 4-35 FIGURE 4-37 outside wear pad.
  • Page 127 600H SERVICE MANUAL BOOM FIGURE 4-39 Paint Mark Cams Wear Pad Assembly Place the sync cables attached to the 5 section inside the 4 section. Slide the 6 assembly into the 4 section until it comes in contact with the locator bar.
  • Page 128 BOOM 600H SERVICE MANUAL Slide the 6 assembly into the 4 section far 13. Install the sync cable sheaves to the top front of the enough to get the 5 section sync cables through the section boom. slots as the back of the 4 section.

  • Page 129: Telescope Cylinder Installation

    600H SERVICE MANUAL BOOM d. Install the ATB cable guide and wear pad on the bottom front of the telescope cylinder. Top Front Wear FIGURE 4-44 Pad Assembly Slide the sheave onto the bearing. OUTSIDE CAUTION The extend sheave is not secured to the shaft. The...
  • Page 130 BOOM 600H SERVICE MANUAL Extend Cables Cable Retaining Bracket Extend Cable Anchor Plates Section Extend Cables Bolts for Anchor Plates FIGURE 4-46 FIGURE 4-48 Push the cylinder into the 6 assembly until the Carefully slide the telescope cylinder into the 6 cable anchor bracket contacts the back of the 6 assembly about 1/3 the boom length.
  • Page 131 600H SERVICE MANUAL BOOM NOTE: There is not enough room to install the trunnion Bolt the trunnion retaining bracket into place and install retaining bracket after the trunnion is in place. the next trunnion bracket and trunnion. Repeat for the 4 section trunnion.

  • Page 132: Nd -1 St Section Assembly

    BOOM 600H SERVICE MANUAL NOTE: When sliding the boom sections together, keep tension on the cables to keep the cables from being jammed between the boom sections. Remove the holding valve and install a plug. Slide the 6 assembly into the 3 section boom.

  • Page 133: Sync Cable Top Anchor Brackets

    600H SERVICE MANUAL BOOM Sync Cable Top Anchor Brackets The top sync cable anchor brackets are installed on the front Section Trunnion of the 3 boom sections. Loosely bolt the sync cable anchor brackets together. Slide the bottom of the anchor bracket into the slot at the top of the boom.
  • Page 134 BOOM 600H SERVICE MANUAL Section Sync Cable Routing Section Sync Cables Section Section Inside Top Adjustment Section Section Section Clamp Section Inside Bottom Adjustment Section Sync Cable Routing Section Sync Cables Section Top Adjustment Section Inside Section Section Section Clamp...

  • Page 135: Sync Cable Adjustment

    600H SERVICE MANUAL BOOM Sync Cable Adjustment the distance between the front of the 4 section and the front of the 3 section. After all boom sections are assembled, the sync cables can be adjusted. the distance between the front of the 3 section and the front of the 2 section.
  • Page 136 BOOM 600H SERVICE MANUAL 4-62 08-19-2022 Control # 092-13...

  • Page 137: Section 5

    600H SERVICE MANUAL HOIST SECTION 5 HOIST SECTION CONTENTS Hoist Removal......5-1 Hoist Installation .
  • Page 138 HOIST 600H SERVICE MANUAL THIS PAGE BLANK 08-19-2022 Control # 092-13...

  • Page 139: Section 6

    The purpose of the swing system is to allow the crane turret The swing brake is spring applied and hydraulically released. to rotate atop the frame. The 600H Crane Swing system Hydraulic pressure for the swing brake control is supplied by provides 375 degrees rotation.
  • Page 140 SWING 600H SERVICE MANUAL NOTE: Notice the position of the motor mounting hole in relation to the brake release port for reassembly. NOTE: Use Loctite 243 on the mounting bolts when the swing drive is reinstalled. CAUTION The motor adapter is spring loaded and the capscrews should be loosened in a sequence that will allow an even load distribution on the motor adapter.
  • Page 141 600H SERVICE MANUAL SWING FIGURE 6-2 NATIONAL CRANE 08-19-2022 Control # 092-13...
  • Page 142 SWING 600H 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...

  • Page 143: Tulsa Swing Drive Assembly Procedure

    600H SERVICE MANUAL SWING 16. Remove the pinion locking bolt (46) from the output b. Torque the pinion bolt to 50 ft-lb (68 Nm), loosen planet carrier (47). Loosen the pinion bolt (49). and re-torque until the pinion locking bolt aligns with...

  • Page 144: Rotation Stop-Mechanical

    SWING 600H SERVICE MANUAL NOTE: Soak friction disk in EP-90 for 24 hrs. before installation. 16. Reinstall the retaining ring (37) into the piston. 17. Install six springs (15) into the holes in the motor adapter (3). 18. Mount the motor adapter (3) to the brake housing (2) with six cap screws (28) checking to make sure the roll pin (18) is in line with the dowel hole in piston (5).

  • Page 145: Maintenance

    600H SERVICE MANUAL SWING Now rotate the crane in the opposite direction until the plating that will cause variation from dry torque values. When rotation stop system centers the control lever. a high strength bolt is removed, or un-torqued, the bolt must be replaced with a new bolt of the same classification.
  • Page 146 SWING 600H SERVICE MANUAL the bearing is secured to the frame by 24, 1-8 UNCX4.5, Grade 8 bolts (Figure 6-9). 9867 FIGURE 6-9 Inner Race Outer Race FIGURE 6-10 08-19-2022 Control # 092-13...

  • Page 147: Torque Values

    600H SERVICE MANUAL SWING Torque Values Put a magnetic base dial indicator opposite the boom on the top of the frame (Figure 6-11). Inner Race Torquing Place the dial on the top of the swing bearing The inner race bearing bolts are located on top of the inner (Figure 6-11).

  • Page 148: Bearing Replacement

    SWING 600H SERVICE MANUAL FIGURE 6-12 BEARING REPLACEMENT NOTE: If equipped with a swivel, tag and disconnect all hydraulic lines from the swivel on the carrier side. Removal Cap or plug all lines and openings. The swivel is removed with the turret.

  • Page 149: Installation

    600H SERVICE MANUAL SWING Carefully lift the turret with bearing off the truck and set it on blocking that will not allow the turret to tilt or shift. Leave the lifting device attached. NOTE: If the current bearing is to be reinstalled, mark the position of the bearing on the turret before removal.

  • Page 150: Slew Potentiometer Orientation

    SWING 600H SERVICE MANUAL Slew Potentiometer Frame FIGURE 6-14 Rotate the slew pot gear until the reading on the RCL is 0° (±5°). This reading must be within ±5° of 0° or the RCL will not calibrate the swing position correctly.

  • Page 151: Section 7

    Removal........7-7 600H-TM Rear Jacks..... . 7-14 RSOD Beam .

  • Page 152: Removal

    OUTRIGGERS 600H SERVICE MANUAL FIGURE 7-1 Outrigger Box Bolts for Wear Pads Jack Jack Tube Lock Pin Bolt End Plate Outrigger Anchor 1 in anchors. Torque refer to Fasteners and Torque Values pg 1-7 Snap Rings CAUTION Do not bottom out the nuts on either end to prevent damage to the threads.
  • Page 153 600H SERVICE MANUAL OUTRIGGERS Unbolt and remove the pin that secures the barrel end of Pull the outrigger beam out of the outrigger box with a the extension cylinder to the outrigger box. Lower the lifting device. cylinder to the bottom of the outrigger beam.

  • Page 154: Jack Cylinder

    OUTRIGGERS 600H SERVICE MANUAL Jack Cylinder Extension Cylinder Position the outrigger so that there is enough clearance Remove the snap rings from the pin that secures the to remove the jack cylinder. extension cylinder rod end to the outrigger beam.

  • Page 155: Installation

    600H SERVICE MANUAL OUTRIGGERS INSTALLATION Outrigger Beam Apply grease (EP-MPG) to the top and bottom of the Extension Cylinder outrigger beam. Slide the extension cylinder into the outrigger beam. NOTE: To prevent nicks and gouges to the bottom of the...

  • Page 156: Removal

    OUTRIGGERS 600H SERVICE MANUAL REMOVAL Outrigger Beam Check that the jack is fully retracted and, if applicable, the float removed. Extend the outrigger beam slightly so that a lifting strap can be attached to the beam. NOTE: To prevent nicks and gouges to the bottom of the...

  • Page 157: Jack Cylinder

    600H SERVICE MANUAL OUTRIGGERS Jack Cylinder Outrigger Beam Position the outrigger so that there is enough clearance Apply grease (EP-MPG) to the top and bottom of the to remove the jack cylinder. outrigger beam. Use the access hole in the side of the outrigger beam to...

  • Page 158: Inspection

    OUTRIGGERS 600H SERVICE MANUAL NOTE: To prevent nick and gouges to the bottom of the outrigger beam, do not attach chains to the DANGER outrigger beam. Blocking material must be able to support the outrigger Tag and remove the hydraulic hoses connected to the beam and not allow the beam to tilt or slide.
  • Page 159 600H SERVICE MANUAL OUTRIGGERS Jack Cylinder Place the jack foot under the jack support tube and jack up the foot until the jack cylinder can be bolted to the top Place the jack cylinder in the jack foot and bolt the of the jack support tube.

  • Page 160: 600H-Tm Outrigger Assembly

    • outrigger box and integral T-Box assembly • outrigger beams The outrigger assembly for the 600H-TM is integral to the T-Box. The outriggers and crane frame are bolted to the • jack cylinders truck frame rail as an assembly. The outrigger assembly •...

  • Page 161: Removal

    600H SERVICE MANUAL OUTRIGGERS Removal 10. Place blocking material under the outrigger beam. 11. Pull the outrigger beam out of the outrigger box with the Check that the jack cylinder is fully retracted and the lifting device. float removed. 12. Position the outrigger beam on the blocking material.

  • Page 162: Installation

    OUTRIGGERS 600H SERVICE MANUAL Access Hole Keyhole Keeper Keeper Bolts Extension Cylinder Rod End FIGURE 7-13 Installation Slide the extension cylinder into the outrigger beam. Make sure the jack hydraulic hoses are routed as shown Reconnect the hydraulic hoses for the jack cylinder as in Figure 7-14.

  • Page 163: Jack Cylinder

    600H SERVICE MANUAL OUTRIGGERS JACK CYLINDER FIGURE 7-15 The jack cylinders extend down to provide stability for crane Top of Outrigger operation. The cylinder barrel extends down out of the jack Beam support tube. This protects the cylinder rod and reduces Access problems caused by dirt and mud.

  • Page 164: Wear Pad Adjustment

    600H-TM Rear Jacks place. The standard 600H-TM is equipped with rear jacks that only Outrigger Box Wear Pad Adjustment e x t e n d d o w n . U s e t h e d i s a s s e m b l y a n d a s s e m b l y...
  • Page 165 600H SERVICE MANUAL OUTRIGGERS configuration. The OMS utilizes one sensor in each outrigger indicating a lift can be made using the capacities from the to identify when the outriggers are extended to a predefined mid-extend outrigger load chart. MID SPAN configuration (if equipped) and FULL SPAN When power is on and the outrigger beams are extended to extended position in which they provide maximum stability.

  • Page 166: Maintenance

    Calibrate Calibrating the cylinder length sensor requires a laptop Outrigger Cylinder Length Sensor equipped with the HED Conductor software and a USB cable connector (p/n 80009992). Contact your National Crane distributor for further assistance. Jack Proximity Switch (version 1) 7958-1...
  • Page 167 600H SERVICE MANUAL OUTRIGGERS Jack Proximity Switch (version 2) Remove Disconnect electrical connector (1, Figure 11) at switch. Remove the two screws (2, Figure 11) securing the switch (4) to the jack box; remove switch. Install Fully extend jack beam (horizontally).
  • Page 168 OUTRIGGERS 600H SERVICE MANUAL THIS PAGE BLANK 7-18 08-19-2022 Control # 092-13...

  • Page 169: Section 8

    600H SERVICE MANUAL LUBRICATION SECTION 8 LUBRICATION SECTION CONTENTS General ........8-1 Internal Cable Sheave Lubrication.

  • Page 170: Arctic Lubricants And Conditions

    LUBRICATION 600H SERVICE MANUAL Arctic Lubricants and Conditions SAE Viscosity Minimum Ambient Temperature Number C (F) Temperatures Below -9°C (15°F) +5°C (+40°F) Regions with ambient temperatures below -9°C (15°F) are +10°C (+50°F) considered arctic. In general, petroleum based fluids developed especially for low temperature service may be Open Gear Lubricant used with satisfactory results in these temperatures.

  • Page 171: Arctic Hydraulic Oil

    ISO 17/14 or better cleanliness Arctic Hydraulic Oil level and must meet John Deere Standard JDM J20c. Contact your National Crane distributor or National Product Temperature Down to -9°C (15°F) to -29°C (-20°F) Support if you have any questions.
  • Page 172 LUBRICATION 600H SERVICE MANUAL keeping track of lube requirements is to maintain a job log of Over lubrication of non-sealed fittings will not harm the crane usage. fittings or components, but under lubrication shortens lifetime. Worn grease fittings that do not hold a grease gun, or those DANGER that have a stuck check ball, must be replaced.
  • Page 173 600H SERVICE MANUAL LUBRICATION 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 174: Internal Cable Sheave Lubrication

    LUBRICATION 600H SERVICE MANUAL Recommended Item Application Procedure Frequency Lubricant Remove pump and apply to 10b Pump spline shaft (direct mount) EP-MPG Semi-Annually shaft or grease gun Check and Fill: As part of daily crane Check and Fill inspection, check the gearbox for visible leaks.

  • Page 175: Boom Lubrication Inner Wear Pad

    600H SERVICE MANUAL LUBRICATION Lubricate the pins for the retract sheaves until a small amount of grease extrudes from the sheave pins. From in back of the boom, look up through the hoist mount at the pins to determine the amount of grease.

  • Page 176: Hoist Brake Oil

    LUBRICATION 600H SERVICE MANUAL Recommended lubricant is EP-3MG grease. until oil is at the bottom level of the inspection hole. Install the inspection plug and the oil vent and fill plug. The hoist brake Fully extend and set the outriggers. Refer to fill capacity is 0.23 liter (0.25 quart).

  • Page 177: Swing Gearbox And Brake Oil

    (all cylinders retracted and The filter must be serviced with National Crane replacement boom stowed) and the oil cold. elements at recommended intervals to assure the warranty If the oil level is too low, add the recommended hydraulic oil remains in effect.

  • Page 178: Carwell© Rust Inhibitor

    LUBRICATION 600H SERVICE MANUAL applied as part of a maintenance program shall be It should be of a viscosity capable of penetrating the compatible with the original lubricant, and to this end, the interstices between wires and strands. rope manufacturer should be consulted. Lubricant applied It should not be soluble in the medium surrounding it shall be of the type which does not hinder visual inspection.

  • Page 179: Cleaning Procedures

    600H SERVICE MANUAL LUBRICATION Once applied, Carwell T32-CP-90 can appear to leave a least monthly to remove all foreign matter. More frequent slightly "oily" residue on painted surfaces and until the red 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 180: Application

    LUBRICATION 600H SERVICE MANUAL NOTE: National Product Support recommends that a • Do not apply to recently primered and painted areas for qualified body repairman prepare, prime and paint at least 48 hours after paint is properly dried and cured.
  • Page 181 600H SERVICE MANUAL LUBRICATION 7650-75 Item Description Mirror Mounting Hardware Item Description Power Train Hardware Hoist Plumbing Connections O/R Hose Connections Pivot Shaft Entire underside of unit Hanger Hardware for Boom Extension Valve Bank, Hose Connections Inside All Hardware, Clips, Pi ns, Hose Connections...
  • Page 182 LUBRICATION 600H SERVICE MANUAL THIS PAGE BLANK 8-14 08-19-2022 Control # 092-13...

  • Page 183: General

    600H SERVICE CRANE INSTALLATION SECTION 9 CRANE INSTALLATION SECTION CONTENTS General ........9-1 Mount the Turret and Torsion Box to the Frame Assembly .

  • Page 184: Minimum Truck Requirements

    Requirements pg 9-8. The specifications shown in Figure 9-2 through A conventional truck cab should be used for standard Figure 9-5 are required so the basic 600H can be legally crane mounts. driven in all states and meet stability requirements. The dimensions given assume the sub-base is installed •...
  • Page 185 600H SERVICE CRANE INSTALLATION Typical Location of Serial Number Identification Tags FORWARD Turret Frame Outrigger 1st Section Boom 2nd Section 3rd Section Booms Boom Nose RSOD jack Lift Cylinder FIGURE 9-1 NATIONAL CRANE 08-19-2022 Control # 092-13...
  • Page 186 GAW Front 14,000 lb 192.00 Min 66.00 (6350.2 kg) 256.00 Min 111.00 GAW Rear 34,000 lb (15422.1 kg) 600H BC 180° Full Capacity Working Area Working Area 180° Gross Axle Weight (GAW) Rating 48,000 lb (21772.4 kg) Wheel Base 256 in (650.2 cm) Cab to Axle Trunnion (CT) 192 in (487.6 cm)
  • Page 187 GAW Front 14,000 lb 192.00 Min 66.00 (6350.2 kg) 256.00 Min 111.00 GAW Rear 34,000 lb (15422.1 kg) 600H BC 360° Full Capacity Working Area Working Area 360° Gross Axle Weight (GAW) Rating 48,000 lb (21772.4 kg) Wheel Base 256 in (650.2 cm) Cab to Axle Trunnion (CT) 192 in (487.6 cm)
  • Page 188 192.00 Min GAW Front 12,000 lb 129.00 (5443.1 kg) GAW Rear 34,000 lb (15,422.1 kg) 256.00 Min 600H RM 360° Full Capacity Working Area Working Area 360° Gross Axle Weight (GAW) Rating 46,000 lb (20865.2 kg) Wheel Base (WB) 256 in (650.2 cm) Cab to Axle Trunnion (CT) 192 in (487.6 cm)
  • Page 189 29.25 GAW Front 20,000 lb 65.38 (9071.8 kg) 168.00 Min 64.31 250.00 Min 600H TM 360° Full Capacity Working Area Working Area 360° Gross Axle Weight (GAW) Rating 54,000 lb (24,493.9 kg) Wheel Base (WB) 250 in (635 cm) Cab to Axle Trunnion (CT) 168 in (487.6 cm)

  • Page 190: Pto Horsepower Requirements

    Pump Rotation (RPM) 2500 RPM PUMP 2900 It is imperative that the three section hydraulic pump installed in a 600H application be the correct pump rotation 2800 Gasoline Engine configuration for the truck drive train/power take off rotation 2600 Optimum Speed direction.

  • Page 191: Truck Frame Strength

    1,430,000 in-lb (161,590 N-m) RBM and 13 in (213 cm3) 600H size crane, the truck frame must have a requirement S.M. through suspension to rear jacks on each truck frame for rigidity so as not to allow excessive boom movement due rail.
  • Page 192 If you have any questions concerning frame strength or to be spaced 5 in (127 mm) apart with welds at an interval of reinforcing, contact National Crane before proceeding. 4 in (102 mm). Do not weld on the flanges. TABLE A Section Modulus in Thickness 3/16 in.
  • Page 193 600H SERVICE 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)
  • Page 194 CRANE INSTALLATION 600H SERVICE TABLE D 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) 3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89)

  • Page 195: Example

    600H SERVICE CRANE INSTALLATION EXAMPLE A truck frame of 110,000 psi (758 MPa) yield strength steel has the following dimensions: 3/8 in. (9.65 mm) thick, 3 in. (76.2 mm) flanges and is 10.25 in. (260 mm) deep. To find the frame 3.00...

  • Page 196: Requirements For Optional Single Front Outrigger (Sfo)

    CRANE INSTALLATION 600H SERVICE REQUIREMENTS FOR OPTIONAL SINGLE bracket must be capable of supporting 0.50 in (12.7 mm) DIA. Grade 8 bolts to their nominal breaking strength. Torque FRONT OUTRIGGER (SFO) 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 197: Truck Frame Section Modulus Tables

    If you have any questions concerning frame strength or sure that any truck factory listed section modulus is correct. It reinforcing, contact National Crane before proceeding. is also necessary to measure the frame and check the section modulus wherever the depth and/or flange width Where thickness, depth or flange width vary, interpolation changes.
  • Page 198 CRANE INSTALLATION 600H SERVICE TABLE F 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)
  • Page 199 600H SERVICE 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. (9.65 mm) thick, 1.50 in. (38.1 mm) top flange, 3 in. (76.2 mm) bottom flange, 10.25 in.

  • Page 200: Truck Preparation

    CRANE INSTALLATION 600H SERVICE 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. PTO's are not furnished by the factory.

  • Page 201: Reinforcing/After Frame Extension

    600H SERVICE CRANE INSTALLATION For a wet mount, a gasket is required for the mounting Rotate the pump in the direction as the PTO. Rotate the flange to PTO gearbox interface. Dry mount does not pump in the mounting bracket so suction side is toward the reservoir suction port.
  • Page 202 CRANE INSTALLATION 600H SERVICE Remove bolts, clamp on reinforcing, and mark the Plan the location of the crane bolt hole location from mounting anchors so they don’t the inside of the frame interfere with the bolts, etc. (Ref) Truck frame...
  • Page 203 600H SERVICE CRANE INSTALLATION 2 (51) 1 (25.4) diameter holes for plug welds 5 (127) Planned location of mounting 2 (51) plate. Plug weld locations can be shifted to clear plate. 4 (101) 4 (101) 8 (203) Crossmember bolt holes.

  • Page 204: After Frame Modification

    CRANE INSTALLATION 600H SERVICE frame, cut out plug weld hole pattern as in Figure B. reinforcing by adding bars under these areas. The bars Slide the reinforcing angle up from the bottom, butt it to should be of the same thickness, width and yield strength as...

  • Page 205: Mounting The Crane

    600H SERVICE CRANE INSTALLATION crossmembers from back of truck frame. If AF is too short, Set the T-Box the frame will have to be lengthened. Use channels On the BC configuration the front outrigger box is welded to fabricated from 100,000 psi (758 MPa) yield material that are the T-box.

  • Page 206: Torsion Box Mounting

    Variations in tension can cause distortion, binding, or Mounting the 684TM complete separation of the turret from the frame. The 684TM crane frame is mounted with the outriggers. See 600H-TM Outrigger Assembly, page 7-10 for outrigger mounting instructions. 9-24 08-19-2022 Control # 092-13...
  • Page 207 600H SERVICE CRANE INSTALLATION BC configuration shown. On the RM configuration, both outriggers are bolted to the truck frame. Note: The reinforcing plates T-Box must extend out past the RSOD mounting brackets. Reinforcing Plates Anchor Holes for Crane Frame Mounting Bracket for...

  • Page 208: Mount The Outrigger Box

    CRANE INSTALLATION 600H SERVICE Table 9-1 Mount the Outrigger Box Item Description NOTE: See Figure 9-13 and Figure 9-14 for jack tube Torsion Box weldments. Stud Position the front outriggers on the T-Box and bolt to the truck frame with the anchor bolts and brackets.
  • Page 209 600H SERVICE CRANE INSTALLATION Rear Outrigger Box for RM Configuration. Jacks Retract Beams Retract T-Box Truck Frame REAR Driver Side Beams Out Cut to fit the inside of the truck frame. Driver Side Jack Down Beams Out Jacks Down Passenger Side...

  • Page 210: Attach The Rsod

    Beam Out Check for interference with truck frame rivets or bolt holes. 600H TM Front Outrigger Solenoid Make sure that the RSOD jack is vertical and the foot is NOTE: The solenoid is 11 in (27.9 cm) above the ground.
  • Page 211 600H SERVICE CRANE INSTALLATION Upper Brackets Weld 5/8 in Grade 8 Bolts Gusset Torque, refer to Fasteners and 3/4 in Grade 8 Bolts for the Torque Values RSOD Anchor Brackets Torque, Fasteners and refer to Torque Values , page 1-7...
  • Page 212 CRANE INSTALLATION 600H SERVICE 600H TM Rear jack Installation Jack Down Jack Up FRONT FRONT 5/8 Grade 8 Bolt 6.75” 6.00” Allow Clearance for Mud Flaps FIGURE 9-12 9-30 08-19-2022 Control # 092-13...
  • Page 213 600H SERVICE CRANE INSTALLATION Jack Tube Weldments Bar 203321 Outrigger Box 1.19 Jack Tube 18.19 16.25” on 43” Tall Truck Frame. 16.25” on 43” Tall Truck Frame. 16.25” on 43” Tall Truck Frame. GROUND 12 ref” on 43” Tall Frame.
  • Page 214 CRANE INSTALLATION 600H SERVICE Jack Tube Weldments 0.63 Jack Tube Outrigger Box 1.00 7.19 16.25” on 43” Tall Truck Frame. 16.25” on 43” Tall Truck Frame. 16.25” on 43” Tall Truck Frame. GROUND 12 ref” on 43” Tall Frame. NOTE: All welds are grade 70 or better.

  • Page 215: Install The Hydraulic System

    600H SERVICE CRANE INSTALLATION Install the Hydraulic System • P2 supplies 18 gpm (68 lpm) at 3900 psi (268.8 bar) for the boom and outrigger circuits. (Vane Section) The hydraulic system pressure is supplied by a three section • P3 supplies 10 gpm (37.8 lpm) 2350 psi (162 bar) for the pump mounted on the truck power take off (PTO).

  • Page 216: Mount The Operator Platforms And Install The Foot Throttles

    CRANE INSTALLATION 600H SERVICE Foot Throttle Throttle Cable Mounting Adjustment Bracket Return Spring Throttle Cables Operator’s Platform Throttle Cable Routing EET Mount FIGURE 9-17 Mount the Operator Platforms and Install the Foot Throttles Install the backrest and operator’s platform on both sides of the frame as shown in Figure 9-17.

  • Page 217: Can Bus System Setup

    600H SERVICE CRANE INSTALLATION NOTE: Keep the harness away from the drive line and NOTE: The number of wires required to connect to the exhaust system. EET depends on the truck EET system. Consult the truck manufacture for EET connection.

  • Page 218: Can Bus System Using Software

    CRANE INSTALLATION 600H SERVICE Table 9-2 Required Equipment (Continued) Item Example CAN bus system software, such as HED Orchestra Suite Diagnostics T-Harness Cable 9829 CAN to USB Adapter Cable 9831 FIGURE 9-20 Remove the terminating resistor from the Deutsch 9830 splitter (Figure 9-21).

  • Page 219: Can Bus System Using Programming Button

    600H SERVICE CRANE INSTALLATION CAN Bus System using Programming CAUTION Button Only trained personnel should use the programming The programming button is located on the driver’s side button to initialize the CAN bus system. Incorrect setup of console behind the sliding door above the override key the CAN bus system can cause the throttle pedals to be switch.

  • Page 220: Rcl Calibration

    Test the unit for stability on a firm level surface. If slight tipping occurs, but load can be kept from coming A Series 600H crane requires rear jacks for stability. in contact with ground by hoisting the load up, unit is With the boom stowed, set the unit up level on the stable.
  • Page 221 600H SERVICE CRANE INSTALLATION 45.34 Radius Tail Swing 680H 690H 671H 24’-0” Ret 27’-10” Ret 27’-7” Ret 80 ft Ext 90 ft Ext 71 ft Ext 21.00 143.97 94.25 118.72 72.75 Top of Truck Frame Rail ROTATION W/Oil Weight Weight 80°...
  • Page 222 CRANE INSTALLATION 600H SERVICE 45.34 Radius Tail Swing 680H 690H 671H 24’-0” Ret 27’-10” Ret 27’-7” Ret 80 ft Ext 90 ft Ext 71 ft Ext 21.00 94.25 144.09 72.75 118.72 Top of Truck Frame Rail ROTATION 80° W/Oil 94.50 0°...
  • Page 223 600H SERVICE CRANE INSTALLATION 39.84 Radius Tail Swing 18’-9.16” Ret 84 ft Ext 21.00 44.42 146.14 90.36 119.77 73.69 75.67 Top of Truck Frame Rail ROTATION 80° Dry Weight W/Oil Weight 0° 96.00 12,030 lb (5,457) 12,835 lb (5,822 kg) 9.95°...

  • Page 224: Specifications

    CRANE INSTALLATION 600H SERVICE 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)
  • Page 225 600H SERVICE CRANE INSTALLATION Retract................ 50 ±5 sec Boom Extend/Retract Four Section 16 - 49 ft Extend ............... 45 ±5 sec Retract................ 75 ±5 sec Boom Extend/Retract Four Section 27 - 90 ft Extend ............... 85 ±10 sec Retract................ 140 ±10 sec Boom Extend/Retract Four Section 24 - 80 ft Extend ...............
  • Page 226 CRANE INSTALLATION 600H SERVICE THIS PAGE BLANK 9-44 08-19-2022 Control # 092-13...

  • Page 227: Section 10

    600H 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 08-19-2022 Control # 092-13...
  • Page 228 SCHEMATICS 600H SERVICE MANUAL THIS PAGE BLANK 10-2 08-19-2022 Control # 092-13...
  • Page 229 600H-TM Outrigger Assembly ........
  • Page 230 600H Reinforcing/after Frame Extension ........9-19 Remote Control .

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