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Manitowoc National Crane 600E-2, Operator'S Manual

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Manitowoc National Crane 600E-2 Operator'S Manual Download Page 107

National Crane

PUBLISHED 04-26-2019 CONTROL # 113-09

6-5

600E2 OPERATOR MANUAL

MAINTENANCE CHECKLIST

6

and unequal tensions in the strands. This distortion and wire
displacement cannot be corrected even under high tension
and a permanent weak point remains in the rope. Displaced
or raised wires indicate a previous kink, but does not show
the damaged condition of the inner rope wires.

Never pull wire rope over a non-rotating support such as a
spindle bar, a pin, or an inoperative sheave. This practice
causes severe abrasion to the outer strand wires. A properly
operating sheave or snatch block is essential to safety and
long service life of the rope.

Do not use worn sheaves or sheaves with flat grooves
because they do not provide sufficient support to prevent the
distortion and flattening of the rope. Sheaves with nicked or
broken flanges can cut or otherwise damage the rope.

An even distribution of rope coils over the hoist drum is
essential to smooth operation. This prevents the rope from
cutting down through or crushing other coils on the drum
resulting in damage to and difficulty in unwinding the rope.

Rope Construction

  

If wire rope replacement is required for crane extension
system, replacement ropes must be obtained through the
Manitowoc Crane Care. Extension ropes are pre-stretched
and have special connections for proper operation

If wire rope replacement is required for crane loadline, care
should be taken in selecting a wire rope suitable for crane
use. Wire rope strength requirements are shown on the
crane load chart to match the hoist option selected when the
crane was purchased. Rope construction required is optional
with 6 x 25 and Dyform being the most common lifting ropes.
High strength, rotation resistant is preferred and furnished
standard by National Crane. This rope eliminates single part
line load spin. It also eliminates load block spin up when
multi-part reeving is used which results in prolonged rope
life. 

CRANE ADJUSTMENTS AND REPAIRS

Before adjustments and repairs are started on a crane, the
following precautions shall be taken as applicable:

1.

A warning tag should be placed in a conspicuous place
at the controls stating that the machine requires
adjustment or repair before it can be operated.

2.

The crane should be placed where it will cause the least
interference with other equipment or operations in the
area.

3.

All controls at the off position and all operating features
secured from inadvertent motion by brakes or other
means.

4.

All methods used to start the truck's engine rendered
inoperative.

5.

Power plant stopped or disconnected at take-off.

6.

Boom lowered to the ground or otherwise secured
against dropping.

7.

Load block lowered to ground or otherwise secured
against dropping.

8.

Relieve hydraulic oil pressure from all hydraulic circuits
before loosening or removing hydraulic components.

After adjustments and repairs have been made, the crane
shall not be returned to service until all guards have been
reinstalled, trapped air removed from hydraulic system if
required, safety devices reactivated, and maintenance
equipment and all warning tags removed.

Any hazardous conditions disclosed by the inspection
requirements listed above shall be corrected before
operation of the crane is resumed. Adjustments and repairs
shall be done only by designated personnel who are properly
trained. Use only parts supplied by your National Crane
Distributor or Manitowoc Crane Care to repair the crane.

EXTENSION JACK SERVICE AND 
MAINTENANCE

Important: Use only a good grade hydraulic jack oil,
transmission oil, or turbine oil.  Avoid mixing types of oil.  Do
not use brake fluid, alcohol, glycerin, detergent motor oil, or
dirty oil. Improper fluid can cause serious internal damage to
the jack rendering it inoperative.

Adding Oil

1.

With saddle fully lowered and piston depressed, set jack
in upright level position and remove oil filler plug.

2.

Fill until oil is level with filler plug hole.

Changing Oil

1.

For best performance and longest life, replace the
complete oil supply at least once a year.

2.

To drain the oil, remove the filler plug.

Standard

9/16 in. (14.3mm) Dia. Wire Rope:

Rotation Resistant

18X25 Nominal Breaking Strength:

19.25 Tons (17,463 kg)

Optional

9/16 in. (14.3mm) Dia. Wire Rope:

6X25 General Purpose

6X25 Nominal Breaking Strength:

16.8 tons (15,241 kg)

Fo

r

 

Reference

 

Only

Summary of Contents for National Crane 600E-2

Page 1: ...Operator Manual National Crane 600E 2 F o r R e f e r e n c e O n l y ...

Page 2: ...F o r R e f e r e n c e O n l y ...

Page 3: ... when ordering parts or communicating service problems with your distributor or the factory 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 th...

Page 4: ...more information go to www P65warnings ca gov diesel Batteries battery posts terminals and related accessories can expose you to chemicals including lead and lead compounds which are known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling For more information go to www P65warnings ca gov California Spark Arrestor Operation of this equ...

Page 5: ...nterweight 2 18 Outrigger Lift Off 2 18 Multiple Equipment Lifts 2 18 Tilt Up Panel Lifting 2 19 Pile Driving and Extracting 2 19 Equipment 2 20 Equipment Inspection 2 20 Electrocution Hazard 2 20 Set Up and Operation 2 21 Electrocution Hazard Devices 2 22 Electrical Contact 2 22 Special Operating Conditions and Equipment 2 23 Grounding the Equipment 2 23 Personnel Handling 2 23 Environmental Prot...

Page 6: ... 3 Turn 3 3 Swing Speed Adjustment 3 3 Boom 3 3 Boom Telescope 3 3 Hoist 3 3 Stabilizers Up Down 3 3 Stabilizers Extend Retract 3 3 Outriggers 3 3 Foot Throttle 3 3 Emergency Stop Switch 3 3 Horn 3 3 Hydraulic Capacity Alert System HCA Load Range Gauge 3 4 HCA Overload Light 3 4 Anti Two Block Extension Overload Light 3 4 Key Override Switch 3 4 Override Button 3 4 Load Chart 3 4 Boom Angle Indica...

Page 7: ...cation 4 1 Work Site Selection 4 2 Before Leaving the Cab 4 2 Proper Leveling of the Crane 4 2 Bubble Level Adjustment 4 2 Site Selection 4 3 Setting the Outriggers and Stabilizers 4 3 Lifting Over the Rear 4 3 Lifting Over the Front with a SFO 4 4 Before Making the Lift 4 4 Reading and Understanding the load Charts 4 4 Set Up 4 5 Operation 4 5 Definitions 4 6 Determining Load Capability 4 6 Load ...

Page 8: ...g Procedures 5 10 Inspection and Repair 5 10 Application 5 11 Areas of Application 5 11 SECTION 6 Maintenance Checklist Crane Inspection And Maintenance 6 1 Inspection 6 1 Daily Inspections 6 1 Weekly Inspections 6 2 Monthly Inspections 6 2 Periodic Annual Inspection 6 2 Special Boom Inspection 6 2 Stability 6 2 Hoist Cable Inspection and Maintenance 6 3 Keeping Records 6 3 Environmental Condition...

Page 9: ...R MANUAL TABLE OF CONTENTS 1 Tire Load And Inflation Table 6 11 Specifications 6 14 Hydraulic Pump 6 14 Hydraulic System 6 14 Reservoir 6 14 HCA 6 14 Hoist Speed and Pull 6 14 Crane Operating Speeds 6 15 F o r R e f e r e n c e O n l y ...

Page 10: ...TOC 6 TABLE OF CONTENTS OPERATOR MANUAL 600E2 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 11: ...the information to assist you in a timely manner We request that you first contact them for assistance If you feel you need factory assistance please ask the distributor s service management to coordinate the contact on your behalf Supplemental Information Supplemental Information regarding Safety Operation Specifications Service Maintenance Installation and parts for options such as remote contro...

Page 12: ...dent or damage to equipment the local National Crane distributor must be immediately advised of the incident and consulted on necessary inspections and repairs 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 re...

Page 13: ...ring a false sense of security when using them They are there to assist not direct the operation Operational aids or warning devices can be mechanical electrical electronic or a combination thereof They are subject to failure or misuse and should not be relied upon in place of good operating practices You are the only one who can be relied upon to assure the safety of yourself and those around you...

Page 14: ...day before the start of each shift Ensure that routine maintenance and lubrication are being dutifully performed Don t operate a damaged or poorly maintained equipment You risk lives when operating faulty machinery including your own If adjustments or repairs are necessary the operator shall notify the next operator OPERATOR QUALIFICATIONS Qualified person is defined as one who by reason of knowle...

Page 15: ...ed as soon as is reasonably possible If immediate repair or recalibration of an operational aid is not possible and there are exceptional circumstances which justify continued short term use of the equipment when operational aids are inoperative or malfunctioning the following requirements shall apply for continued use or shutdown of the equipment Steps shall be taken to schedule repairs and recal...

Page 16: ... boom or hoisting up Let out load line s simultaneously to prevent two blocking the boom tip s and the hook block etc The closer the load is carried to the boom nose the more important it becomes to simultaneously let out hoist rope as the boom is lowered Keep load handling devices a minimum of 107 cm 42 in below the boom nose at all times Two blocking can be prevented Operator awareness of the ha...

Page 17: ... boom angle should be a part of your routine planning and operation Actual loads including necessary allowances should be kept below the capacity shown on the applicable Load Chart Load Chart capacities are based on freely suspended loads You must use the appropriate Load Chart when determining the capability of the equipment in the configuration required to perform the lift Maximum lifting capaci...

Page 18: ...ve the lift may also be limited by the projected wind area of the load Ap and by the wind drag coefficient Cd This limit can be determined by comparing the Actual wind resistance area with the Allowable wind resistance area Refer to Figure 2 1 for a simplified calculation method to determine permissible wind speed Maximum Wind Speed Beaufort Number Description m s km h mph Visible Indicator Effect...

Page 19: ...oad Calculate Awr load Ap X Cd Determine Cd of Load Ap maximum height X maximum length See Figure 2 2 Lifting is not permitted Cease Lifting Operations V z 20 1 m s 45 mph 13 4 m s V z 20 1 m s 30 mph V z 45 mph Use Main Boom on Fully Extended Outriggers ONLY V z 13 4 m s 30 mph Main Boom Allowable load Published Rated Capacity Allowable Load Published Rated Capacity X Capacity Reduction Factor fr...

Page 20: ...tion Size and Shape of the load These rated capacities are also based on the assumption that the Wind Resistance Area of load Awr load is not more than 0 0012 square meters per kilogram 0 0059 sq ft per pound of load See below Formulas 2 4 and 2 5 The load capacities shall be reduced to account for the larger wind resistance area of load and 3 second wind gust speed at boom tip height Use tag line...

Page 21: ...nding Wind Drag Coefficient Cd values If the exact Wind Drag Coefficient of a shape is not known use the maximum value of the shape s range Table 2 2 If the wind drag coefficient of the load cannot be estimated or determined it shall be assumed that Cd 2 4 Ap 24 m2 Ap 8 m2 Wind Wind 8 m 1 m 3 m 8 m 1 m 3 m Ap 250 ft2 Ap 75 ft2 Wind Wind 25 ft 3 ft 10 ft 25 ft 3 ft 10 ft 8384 1 FIGURE 2 2 F o r R e...

Page 22: ... load using Table 2 3 Table 2 3 Awr Ratio and Permissible Wind Speed V z Non metric 8384 2 Shape Cd 1 1 to 2 0 0 3 to 0 4 0 6 to 1 0 0 8 to 1 2 0 2 to 0 3 0 05 to 0 1 Approximately 1 6 Turbine Blade or Complete Rotor Note Permissible and rated wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph For Rated Capacity...

Page 23: ...National Crane PUBLISHED 04 26 2019 CONTROL 113 09 2 11 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS 2 Rated Load Chart Example Metric FIGURE 2 3 8383 1 F o r R e f e r e n c e O n l y ...

Page 24: ...are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed m s For Rated Capacity at 13 4 m s 12 2 11 4 10 6 10 0 9 5 For Allowable Capacity at 20 1 m s 18 3 17 0 15 9 15 0 14 2 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 sto...

Page 25: ...14 45 m2 YES Conclusion This load is permissible to lift in wind speed up to 20 1 m s Load example 1 3a With large wind resistance area of the load Awr load Load to be lifted of 14 000 kg Projected Wind Area Ap 21 85 m2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap X Cd 21 85 x 1 2 26 22 m2 Refer to the above Lifting Limits at wind speed V z 13 4 m s...

Page 26: ... for lifting with main boom on fully extended outriggers with or without stowed extension For wind speed Vz 3 second gust speed at boom tip height is greater 30 mph 45 mph the Reduced Capacity shall be calculated by multiplying the Published Rated Capacity by the following factors Main Boom Length in Feet Wind Speed Vz 30 mph 45 mph 36 40 50 60 70 80 90 100 110 Factor 0 9 0 9 0 8 0 8 0 8 0 8 0 8 0...

Page 27: ...National Crane PUBLISHED 04 26 2019 CONTROL 113 09 2 15 600E2 OPERATOR MANUAL SAFETY PRECAUTIONS 2 Rated Load Chart Example Non metric FIGURE 2 4 8382 1 F o r R e f e r e n c e O n l y ...

Page 28: ... Coefficient of the load Cd load to be lifted of 19 500 lb Projected Wind Area Ap 70 ft2 Wind Drag Coefficient Cd 1 5 then the wind resistance area of load can be estimated as Awr load Ap x Cd 70 x 1 5 105 ft2 Refer to the above Lifting Limits at wind speed V z 30 mph and 45 mph Comparing the load and wind resistant area to the allowable Is the load to be lifted less than allowable load 19 500 lb ...

Page 29: ...ph but permitted to lift at a reduced wind speed calculated as follows Ratio 1 37 From Table 2 7 the maximum permissible wind speed at ratio of 1 37 rounded to next higher table value of 1 4 is 38 0 mph Lifting Operations Before lifting position the equipment on a firm surface properly extend and set the outriggers and level the equipment Depending on the nature of the supporting surface adequate ...

Page 30: ...tructions Always use enough parts of line to accommodate the load to be lifted Lifting with too few parts of line can result in failure of the hoist rope Counterweight On equipment equipped with removable counterweights ensure the appropriate counterweight sections are properly installed for the lift being considered Do not add material to the counterweight to increase capacity United States Feder...

Page 31: ...of the standard load chart The operator shall be responsible to control this as the RCL does not have a feature to set reduced lifting limits The auxiliary hoist line shall be considered part of the deducts to determine net allowable load The panel shall be lifted so that the hoist lines are in line with the equipment The load shall be controlled to prevent rotation of the load and to ensure the l...

Page 32: ...ction begins All hoist hooks shall be equipped with a positive locking latch Equipment Inspection In addition to the equipment s frequent and periodic inspections dated daily records shall be maintained showing inspections were performed on the equipment during the time it was used for pile driving or extraction All anti two block warning devices and RCL systems shall be inspected daily and verifi...

Page 33: ...contrary from the utility company or owner The rules in this Operator Manual must be followed at all times even if the electrical power lines or equipment have been de energized The safest way to avoid electrocution is to stay away from electrical power lines and electrical power sources It is not always necessary to contact a power line or power source to become electrocuted Electricity depending...

Page 34: ...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 dust dirt moisture etc The insulating characteristics of these devices can be compromised if not kept clean free of contamination and undamaged Proximity sensing and warning devices are available in different types Some use boom nose local...

Page 35: ...l precautions Permit no one to touch the magnet or load Alert personnel by sounding a warning signal when moving a load Do not allow the cover of the electromagnet power supply to be open during operation or at any time the electrical system is activated Shut down the crane completely and open the magnet controls switch prior to connecting or disconnecting magnet leads Use only a non conductive de...

Page 36: ...truction Use of a National Crane crane to handle personnel is acceptable provided The requirements of the applicable national state and local regulations and safety codes are met A determination has been made that use of crane to handle personnel is the least hazardous means to perform the work The crane operator shall be qualified to operate the specific type of hoisting equipment used in the per...

Page 37: ...ts should be performed when structural or lifting members are involved Follow all applicable safety precautions in this manual when performing equipment maintenance as well as equipment operations Keep the equipment free of mud dirt and grease at all times Dirty equipment introduces hazards wears out faster and makes proper maintenance difficult Cleaning solutions used should be non flammable non ...

Page 38: ...gs have been removed by the person s who installed them After maintenance or repairs Replace all guards and covers that have been removed Remove all tags connect the battery and perform a function check of all operating controls Consult with Manitowoc Crane Care to determine if load testing is required after a structural repair is performed Lubrication The equipment must be lubricated according to...

Page 39: ...l of the rope The following is a brief outline of the basic information required to safely use wire rope Wire ropes wear out The strength of a rope begins to decrease when the rope is put to use and continues to decrease with each use Rope will fail if worn out overloaded misused damaged or improperly maintained The nominal strength sometimes called catalog strength of a rope applies only to a new...

Page 40: ... wedge socket with live end of rope aligned with the centerline of pin and assure proper length of tail dead end protrudes beyond the socket Sheaves Inspect the boom nose and hook block sheaves for proper operation excessive wear and damage every 50 hours or weekly Inoperable damaged and or worn sheaves cause rapid deterioration of rope Ensure sheaves carrying ropes that can be momentarily unloade...

Page 41: ...pment is adequately secured to the transporting vehicle Do not use the dead end lug on the boom nose for tying down the boom during transport Damage to the lug and boom can result from usage as a tie down point Before transporting the equipment on a road or highway first check state and local restrictions and regulations Either the hook block may be reeved over the main boom nose or the headache b...

Page 42: ...es ear protectors reflective clothing safety goggles and heavy gloves may be required Equipment Access You must take every precaution to ensure you do not slip and or fall off the equipment Falling from any elevation could result in serious injury or death Never exit or enter the equipment operator cab or deck by any other means than the access system s provided i e steps and grab handles Use the ...

Page 43: ...n and function of all machine controls Make sure all persons are away from the equipment and the Travel Select Lever is in the N Neutral position with the parking brake engaged before starting the engine Sparks from the equipment s electrical system and or engine exhaust can cause an explosion Do not operate this equipment in an area with flammable dust or vapors unless good ventilation has remove...

Page 44: ...d personnel equipment or other objects Lift one load at a time Do not lift two or more separately rigged loads at one time even if the loads are within the equipment s rated capacity Never leave the equipment with a load suspended Should it become necessary to leave the equipment lower the load to the ground and stop the engine before leaving the operator s station Remember all rigging equipment m...

Page 45: ...il communications are restored Keep your attention focused on the equipment s operation If for some reason you must look in another direction stop all equipment movement first Obey a signal to stop from anyone JIB To avoid death or serious injury follow the procedures in this manual during erection stowage and use of the jib Install and secure all pins properly Control movement of jib at all times...

Page 46: ...PERATOR MANUAL 600E2 2 34 PUBLISHED 04 26 2019 CONTROL 113 09 9580 FIGURE 2 6 Reprinted from ASME B30 5 2014 by permission of The American Society of Mechanical Engineers All Rights Reserved F o r R e f e r e n c e O n l y ...

Page 47: ...l for cold weather starting Don t touch metal surfaces that could freeze you to them Clean the equipment of all ice and snow Allow ample time for hydraulic oil to warm up In freezing weather park the equipment in an area where it cannot become frozen to the ground The drive line can be damaged when attempting to free frozen equipment If applicable to your equipment frequently check all air tanks f...

Page 48: ...n will also occur in reverse If equipment is set up in the morning with cool oil and the daytime ambient temperature heats the oil the cylinders will extend in similar proportions Table 2 8 and Table 2 9 have been prepared to assist you in determining the approximate amount of retraction extension that may be expected from a hydraulic cylinder as a result of change in the temperature of the hydrau...

Page 49: ...l time events Warnings could be sent 24 hours or more after the actual event Coeff 0 000774 1 C STROKE Temperature Change C m 5 10 15 20 25 30 35 40 45 50 55 1 5 6 12 17 23 29 35 41 46 52 58 64 3 12 23 35 46 58 70 81 93 104 116 128 4 5 17 35 52 70 87 104 122 139 157 174 192 6 23 46 70 93 116 139 163 186 209 232 255 7 5 29 58 87 116 145 174 203 232 261 290 319 9 35 70 104 139 174 209 244 279 313 34...

Page 50: ...RECAUTIONS OPERATOR MANUAL 600E2 2 38 PUBLISHED 04 26 2019 CONTROL 113 09 Boom Inspection 4 8 1 7 5 6 1 2 3 9 10 9 10 Illustration for reference only Your crane may be different F o r R e f e r e n c e O n l y ...

Page 51: ...des Inspect all for damage 2 Collar Wear Pads Pad Retainers Inspect all for damage 3 Collar welds Inspect all for damage 4 Pinning Areas Inspect all for cracks 5 Telescopic Sections Inspect for bent or twisted sections Check the boom for straightness 6 Lift Cylinder Head Area Inspect for bends or cracked welds 7 Turret Base Section Inspect for cracked welds 8 Jib Section Inspect for bent or twiste...

Page 52: ...AUTIONS OPERATOR MANUAL 600E2 2 40 PUBLISHED 04 26 2019 CONTROL 113 09 Superstructure Inspection 2 7 1 3 8 10 11 6 5 4 9 Illustration for reference only Your crane may be different F o r R e f e r e n c e O n l y ...

Page 53: ... to 49 1 Lift Cylinder Inspect for leaks 2 Wire Rope Inspect all for damage See topic in Introduction section of Service Manual 3 Turntable Bearing Check bolts for proper torque See topic in Swing section of Service Manual 4 Hoist Drums Inspect each for damage 5 Hoist Brakes Brakes must hold rated line pull 6 Bearing Main Boom Pivot Pin Inspect for deformation cracked welds 7 Lift Cylinder Lower M...

Page 54: ...RECAUTIONS OPERATOR MANUAL 600E2 2 42 PUBLISHED 04 26 2019 CONTROL 113 09 Carrier Inspection 3 1 1 1 2 2 2 3 3 4 4 5 6 Illustration for reference only Your crane may be different F o r R e f e r e n c e O n l y ...

Page 55: ...nspect for leaks 2 Outrigger Pads Inspect for deformation and cracked welds Overload from 25 to 49 1 Stabilizer Cylinders Inspect for leaks 2 Outrigger Pads Inspect for deformation and cracked welds 3 Outrigger Beams Inspect for deformation and cracked welds 4 Outrigger Boxes Inspect for deformation and cracked welds 5 Welds Inspect for cracks 6 Paint Inspect for cracked paint which could indicate...

Page 56: ...SAFETY PRECAUTIONS OPERATOR MANUAL 600E2 2 44 PUBLISHED 04 26 2019 CONTROL 113 09 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 57: ...cold temperatures Operate individual crane functions to ensure they are sufficiently warmed prior to performing a lift Operation of cranes at full rated capacities in temperatures between 9 C 15 F and 40 C 40 F or lower should be accomplished only by competent operators who possess the skill experience and dexterity to ensure smooth operation Shock loading shall be avoided Operation Below 40 C For...

Page 58: ...superstructure at a speed of less than one RPM for at least one complete revolution in the opposite direction Warm up Procedures for Temperatures Below 7 C 20 F 1 Ensure the boom is fully retracted and near maximum lift angle with no load applied 2 Rotate the superstructure at a speed of less than one half RPM for at least two complete revolutions in one direction then rotate the superstructure at...

Page 59: ...lever to RIGHT to rotate the boom in a clockwise direction as viewed from the top of the crane Operate the turn control lever to LEFT to rotate the boom in a counterclockwise direction as viewed from the top on the crane For cranes NOT equipped with continuous rotation a mechanical rotation stop pulls the turn control lever back to the center position when engaged Boom rotation is stopped over the...

Page 60: ...de of the base boom section and used to determine main boom angle with respect to horizontal For reference only Boom Length Indicator Located on either side of the second boom section The letters on the intermediate boom lengths correspond to the letters on the load chart The length indicators are used to define boom length and with the load chart and load radius are used to determine the maximum ...

Page 61: ...r 13 HCAS Overload Light Item Component 14 A2B Extension Overload Light 15 Boom Angle Indicator 16 Load Chart 17 Swing Speed Adjustment 18 Level Indicator 19 Front Throttle 20 HCA ATB Override Key Switch 21 Boom Length Indicator 22 HCA ATB Override Button 23 Torsion Box 24 Fuse 10 amp 25 Outrigger Status Indicator Item Component 21 15 23 19 18 17 16 1 7 6 12 5 4 3 2 11 8 9 14 22 13 20 2 3 4 5 6 8 ...

Page 62: ... the lift 5 When lifting a load approaching the rated hoist load raise the load a few inches and return the control to neutral to determine if the brake is working properly 6 Do not drag loads in any direction with the hoist 7 Never attempt to lift loads which are not loose and free such as frozen down material or poles out of ground 8 Maintain tension on the loadline at all times to prevent the c...

Page 63: ...This switch is held in the closed position by a chain suspended weight The weight which is looped around the hoist cable causes the contacts to remain closed until the hoist cable end attachments contact the weight and release the tension on the switch At this point the contacts in the switch open breaking electrical continuity through the circuit provided by the internal A2B cord routed through t...

Page 64: ...own in order to eliminate an over capacity condition Once the excessive cylinder pressure has been reduced by bringing the load to a shorter radius or setting the load down normal operation can be resumed This hydraulic capacity alert system uses the work port unloader solenoids in the anti two block system as the hydraulic system dump circuit The hydraulic capacity alert system has an override sw...

Page 65: ...ess than rated load condition when operating the lift control especially during boom down operation EXTENSION LOAD LIMITING DEVICE System Description The extension load limiting device is an electro mechanically operated maximum capacity sensing device that stops all normal crane functions that cause overload when maximum capacity of the extension is exceeded In the event that an over capacity con...

Page 66: ... Limiting Device to detect all possible overload conditions These systems do not prevent structural or stability overloads to the crane or hoist caused by 1 Freely swinging loads or operating in an out of level condition which will result in excessive side loading 2 Side loading due to pulling sideways on the boom with boom rotation or load hoist Load must always be directly under boom tip 3 Sudde...

Page 67: ...ght Installation To prevent the hoist cable from slipping out of the ant two block weight rig the weight as shown below INSTALLING CABLE ON THE HOIST NOTE The cable should preferably be straightened before installation on the hoist drum Item Component 1 Base 2 Extend Cable 3 Tip 4 3rd Section THREE SECTION BOOM 5 2nd Section 6 Retract Cable 7 1st Section Item Component 1 6 5 7 4 2 3 FIGURE 3 4 CAU...

Page 68: ...DUCTION in the Service Manual for wire rope procedures 3 Make sure the live end Figure 3 7 of the rope is directly in line with the ears of the socket and the direction of pull to which the rope will be subjected If the rope is loaded into the socket incorrectly under a load the rope will bend as it leaves the socket and the edge of the socket will wear into the rope causing damage to the rope and...

Page 69: ...e of rope to the rope dead end DO NOT CLAMP THE LIVE END The U bolt should bear against the dead end The saddle of the clip should bear against the short extra piece Torque the U bolts according to the table titled Wire Rope Clip Torque Values Table 3 1 Other sources for information with which crane users should be familiar and follow is provided by the American Society of Mechanical Engineers Ame...

Page 70: ...operated Protect and monitor the hand control unit to prevent damage and unplanned operation Operation 1 Position crane at job site set park brake and shift transmission to neutral 2 Start truck from inside truck cab 3 Engage P T O 4 Set outriggers 5 Stop truck engine 6 Connect hand control cord to receptacle on crane If equipped with hard wire remotes 7 Turn Hydraulic Capacity Alert RCL and Remot...

Page 71: ...ote hoist operation They block the open oil path through the main control valve during remote operation RADIO REMOTE CONTROLS The following sections describe the radio remote controls For detailed maintenance installation and troubleshooting information about the radio remote controls see the Service Manual Safety The radio remote control system offers an excellent solution to safety speed and eas...

Page 72: ...C power becomes available to the receiver Hand Control Circuitry 1 The hand control transmitter is activated by turning the power switch to the ON position The radio transmits ten seconds to initialize the receiver This switch should be placed in the OFF position when not using the remote controls Failure to do so will greatly reduce the life of the 9 volt battery in the hand control transmitter 2...

Page 73: ...you use amplitude modulation AM or fre quency modulation FM FM is utilized FM is a must in electrically noisy environments These environments include areas with welders power lines industrial machinery etc A good analogy is a standard automobile radio In the above mentioned areas the radio will have static on AM stations Your FM stations assure definite clarity and a common extended range Will our...

Page 74: ... for any prolonged period of time Should water get inside remove top cover of transmitter and allow components to air dry Replace battery reassemble and continue use What type of battery is used A standard alkaline 9 volt battery is recommended The Duracell Cop per Top is a representative battery that fits the battery enclosure cor rectly and provides an acceptable service life How long will the b...

Page 75: ...tion Inspection and Calibration Verification 1 Check the electrical wiring connecting the various parts of the system for physical damage 2 Check the anti two block switches and weights for free movement If the operator cannot see the load handling device approaching the boom nose he shall have an assistant signal person watch the load handling device The operator shall be prepared to stop the mac...

Page 76: ...t full span 131 psi 0 9 MPa on standard outrigger pads Support surface bearing capacities vary by a large amount from 833 psi 5 7 MPa on bed rock down to 14 psi 0 1 MPa on soft clay Loose sand or soft asphalt will support even less load It is imperative that the operator take proper precautions to insure the outrigger foot has adequate cribbing for existing soil conditions If specific outrigger fo...

Page 77: ... inches off the ground 3 Adjust the outriggers until the bubble in the level indicator is in the center of the bulls eye and the Outrigger Status Indicator if equipped illuminates constant green Do not allow the tires to touch the ground 4 Using the level indicator adjust the stabilizers until the bubble is in the center of the bulls eye Do not allow the tires to touch the ground Ensure Outrigger ...

Page 78: ...ed in excess of the maximum rated loads specified on the load chart Overloading can create serious potential safety hazards and can also shorten the service life of your unit It is important that you know the weight and radius of any load that you are attempting to handle This should be done by use of a dynamometer and tape measure or by contacting your supervisor Overloading a crane can cause man...

Page 79: ...m is shortened NOTE Rated loads shown on the load chart pertain to this machine as originally manufactured and equipped Modifications to the machine or use of equipment that is not factory specified or approved can be hazardous Refer to capacity deduction chart for weights which must be deducted from rated loads when accessories are attached to boom or loadline Set Up 1 Inspect vehicle and crane i...

Page 80: ... 16 Operate controls slowly and smoothly to avoid damage to crane or personnel 17 Boom must be in carrying rack and outriggers fully retracted for travel 18 Do not operate crane within 10 feet 3 05m of live power lines Definitions Load Radius Horizontal distance from the centerline of rotation before loading to the center of the vertical load line or block with load applied Loaded Boom Angle Loade...

Page 81: ... building roof Ending Point The load rating at the ending point is 3950 lbs 1792 kg The boom will be at 62 ft 18 90m extension and the loaded radius is 40 ft 12 19 m The crane has enough capacity at each end of the lift to allow the lift to be made Refer to hoist load chart Crane is reeved for single part line Allowable load for single part lines 7700 lbs 3492 kg well above the 2480 lbs 1124 kg to...

Page 82: ...th a extension deployed The HCA will not prevent the crane from being operated in an overload condition The extension is equipped with a extension load limiting device which will prevent the extension from being operated in an overload condition The operator should proceed to lift the load as smoothly as possible BOOM EXTENSION OPERATION SAFETY 1 The anti two block switch weight and cord must be a...

Page 83: ...d if a boom tip attachment option is installed Manually Extendable Boom Extension 1 Extension retaining pin E must always be installed when operating 2 All swing around stow and unstowing operations shall be done with extension retracted and pinned 3 The extendable section may slide out of 1st section extension to the mechanical stop when pin E is removed Keep personnel clear of area CAUTION Boom ...

Page 84: ...g lift function raise boom to a horizontal position 9 Using telescope function slowly extend boom approximately one foot This procedure will pull the extension out of the stow bracket 10 Using tag line swing extension into deployed position 11 Remove cable keeper pins from boom sheave case and extension Remove hook block Pivot extension slightly to allow for loadline to be removed from boom sheave...

Page 85: ... the 2nd sections fully retracted 3 Reinstall extension retention pin through the 1st and 2nd section extension assembly and install spring clip 4 Remove loadline from extension sheave case Place loadline in area to avoid possible damage from stow procedure 5 Disconnect twist lock anti two block wire connector at rear of 1st section extension Connect twist lock connector to anti two block switch c...

Page 86: ...extension Prior to using the Extension Jack complete Steps 1 to 12 in the Side Folding Swing Around Deployment Procedure 1 Remove jack handle and using the flattened end close jack release valve by turning the handle clockwise until it is firmly closed 2 Insert the round end of the handle into the handle sleeve and pump jack until ram contacts boom sheave case 3 Continue to pump slowly until exten...

Page 87: ...reference or varying applications An adjustment dials located on the swing holding valve mounted on the swing motor inside the crane frame The valve has an adjustment screw with a lock collar Loosen the lock collar when adjusting the speed then tighten the lock collar to maintain swing speed limit setting The adjustment dial allows the maximum swing speed to be reduced as required CAUTION Avoid sh...

Page 88: ...SET UP OPERATOR MANUAL 600E2 4 14 PUBLISHED 04 26 2019 CONTROL 113 09 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 89: ...are not made here due to regional availability operating conditions and the continual development of improved products Where questions arise contact your National Crane distributor or Manitowoc Crane Care Arctic Conditions Below 18 C 0 F In general petroleum based fluids developed especially for low temperature service may be used with satisfactory results However certain fluids such as halogenate...

Page 90: ...tablished based on component operating time The most efficient method of keeping track of lube requirements is to maintain a job log of crane usage All oil levels are to be checked with the crane parked on a level surface in transport position and while the oil is cold unless otherwise specified On plug type check points the oil levels are to be at the bottom edge of the fill port Over lubrication...

Page 91: ...ls are found in tables below Symbol Description National Crane Lube Specification EP MPG Extreme Pressure Multipurpose Grease Lithium Soap Base NLGI Grade 2 A6 829 003477 EP 3MG Extreme Pressure Moly Grease A6 829 015304 GL 5 Extended Service Interval Gear Lubricant SAE Grade 80W 90 A6 829 012964 AFC 50 50 50 50 Blended Fully Formulated Antifreeze Coolant SAE J1941 ASTM D6210 A6 829 101130 HYDO Hy...

Page 92: ...ve pins boom 3 plcs extension 1 pl EP MPG Grease gun Weekly 5 Wire rope loadline EP OGL Brush or spray Semi Annually 6 Boom pivot pin EP MPG Grease gun Monthly 7 Lift cylinder pins 2 ea EP MPG Grease gun Monthly 8 Swing bearing turret not shown EP MPG Grease gun Weekly 9a Pump drive U Joint 2 ea EP MPG Grease gun Monthly 9b Pump spline shaft direct mount EP MPG Remove pump and apply to shaft or gr...

Page 93: ... crane inspection check the gearbox for visible leaks Change After first 50 hours of operation and every 500 hours thereafter 13 Swing gear teeth EP OGL Spray Can Monthly 14 Boom extension LTG Brush roller or grease gun Monthly or as required 15 Outrigger beams bottom sides LTG Brush or roller Monthly or as required 16 Extension cables not shown WRL Spray or brush Any time boom is disassembled or ...

Page 94: ...aint brush or a grease gun 2 Extend boom to position the wear pad access holes directly above the wear pads on the third boom section apply grease to the pads using the brush or gun 3 Extend boom to position the wear pad access holes directly above the wear pads on the fourth boom section apply grease to the pads using the brush or gun 4 After grease is applied to all wear pads raise the boom to t...

Page 95: ...New Hoist Brake Oil To drain and add new oil remove the drain plug Figure 5 1 inspection plug and vent plug and drain the brake oil Reinstall drain plug and add fluid at the brake oil vent hole 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 fill capacity is 0 23 liter 0 25 quart NOTE Brake lubricants are satisfacto...

Page 96: ... which are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope The object of rope lubrication is to reduce internal friction and to prevent corrosion During fabrication ropes receive lubrication the kind and amount depends on the rope s size type and anticipated use This in process treatment will provide the finished...

Page 97: ...used to spray a light film onto the entire undercarriage and various other areas of each new crane prior to shipment When applied the product has a red tint to allow applicators to view coverage during application This red tint will turn clear on its own within approximately 24 hours after application Once applied Carwell T32 CP 90 can appear to leave a slightly oily residue on painted surfaces an...

Page 98: ...mended to maintain the original paint finish Inspection and Repair Immediately following cleaning Manitowoc Crane Care recommends an inspection to detect areas that may have become damaged by stone chips or minor mishaps A minor scratch one that has not penetrated to the substrate surface can be buffed with an automotive type scratch remover It is recommended that a good coat of automotive wax be ...

Page 99: ...f Carwell the product needs to be fogged on the unit Use of pressure pots to apply the Carwell to the unit being processed is recommended Carwell T32 CP 90 is available in 16 ounce spray bottles from Manitowoc Crane Care order part number 8898904099 After application of the Carwell is complete wash or clean film residue from lights windshield grab handles ladders steps and all access areas to cran...

Page 100: ...ATION PROCEDURE AND CHARTS OPERATOR MANUAL 600E2 5 12 PUBLISHED 04 26 2019 CONTROL 113 09 6 11 1 4 14 3 1 2 3 4 5 7 8 3 5 13 9 8 10 13 8 6 9 7650 42 7650 41 12 10 11 15 4 14 8 F o r R e f e r e n c e O n l y ...

Page 101: ...nections not painted O R Pins Clips 4 Pivot Shaft 5 Hoist Plumbing Connections 6 Mirror Mounting Hardware 7 O R Hose Connections 8 O R Pins Clips 9 Power Train Hardware 10 Valve Bank Hose Connections Inside Turntable 11 Entire underside of unit 12 Hook Block Overhaul Ball 13 Turntable Bearing Fasteners 14 Pins Clips for Jib 15 Hanger Hardware for Jib Item Description F o r R e f e r e n c e O n l ...

Page 102: ...LUBRICATION PROCEDURE AND CHARTS OPERATOR MANUAL 600E2 5 14 PUBLISHED 04 26 2019 CONTROL 113 09 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 103: ...tems listed under periodic inspection Federal Laws through OSHA and ANSI B30 5 require that dated and signed records of these periodic inspections be kept A crane inspection log book is available from National Crane to assist you in keeping records Daily Inspections Check the following items 1 Engine oil level 2 Hydraulic oil level 3 Radiator coolant level 4 Loose parts or damage to structures or ...

Page 104: ...line and check according to rope maintenance procedure Periodic Annual Inspection Check the following items 1 All items listed under daily weekly and monthly inspections 2 Loose bolts and fasteners in all areas Torque pin retainer bolts 3 All pins bearings shafts and gears for wear cracks or distortion to include all pivot outriggers and sheave pins and bearings 4 Boom angle and boom length indica...

Page 105: ...rrosive chemicals or vapors or subjecting the wire rope to abrasive material may shorten normal wire rope life Frequent periodic inspections and maintenance of wire rope is recommended for preventing premature wear and to insure long term satisfactory performance NOTE Refer to Wire Rope Lubrication page 5 8 for wire rope lubrication requirements Dynamic Shock Loads Subjecting wire rope to abnormal...

Page 106: ...oist drums for wear Damaged sheaves or hoist drums can accelerate wear and cause rapid deterioration of the wire rope Inspect the eye end of the cable for greater wear than the rest of the cable If the cable is in good condition reverse the cable on the drum so that the wear is equalized along the total length of the cable Wire Rope Replacement No precise rules can be given for determination of th...

Page 107: ... be taken as applicable 1 A warning tag should be placed in a conspicuous place at the controls stating that the machine requires adjustment or repair before it can be operated 2 The crane should be placed where it will cause the least interference with other equipment or operations in the area 3 All controls at the off position and all operating features secured from inadvertent motion by brakes ...

Page 108: ...on The system will compare the measured force to the table and will provide lockout when the table value is exceeded The system should be checked for proper operation during initial crane start up and quarterly thereafter Single Character Display The electronics box of the extension load limiting device is equipped with a single character display that provides the following information startup cod...

Page 109: ... and fill as required Suction line blocked Drain tank and hose and remove blockage Broken hydraulic pressure line Replace as required Defective hydraulic pump See Pump Service Manual Incorrect relief valve setting Adjust relief Relief valve sticking Clean relief Poor hydraulic system performance Pump not operating at proper speed Check PTO ratio pump size and engine speed for proper oil flow Low h...

Page 110: ...uit pressure Turntable bearing drag Lubricate thoroughly as rotating boom Brake not releasing properly Check for 200 PSI brake pilot pressure Clean pilot line or adjust motor counterbalance valves Swing speed adjustment set too low Adjust or clean brake for proper release Adjust valve on turn motor Excessive pump noise during operation Excessive pump speed Adjust foot throttle or check for too hig...

Page 111: ...own Lower hook and extend load Defective anti two block system Check anti two block system repair if defective System is in a state of constant cut out Loose or incorrect wiring Carefully check the integrity of all circuits external to the electronics box from the extension tip to the console Compare to electrical schematic Blown fuse Check fuse at crane console Replace if necessary Remove electro...

Page 112: ...s required Foreign object stuck between extension head assembly and extension The only contacts between the extension head assembly and the extension are to be the load cell and the pivot pin Remove any foreign objects which interfere with extension head assembly operation Extension Jack Troubleshooting Will not lift load No oil in system Release valve not closed Add oil to reservoir tank through ...

Page 113: ...with other tire sized or the same size tires rated differently Always check the tire sidewalls to verify the maximum capacity and inflation Inflation pressure and loading must not exceed the values shown on the wheel or rim Tire and Load Inflation Tables Letters in parenthesis denote the load range for which the bold face loads are a maximum International load index numbers are shown after the loa...

Page 114: ...s 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 Drop Center Rims Tire and Rim Association Standard F o r R e f e r e n c e O n l y ...

Page 115: ...cks 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 Drop Center Rims Tire and Rim Association Standard F o r R e f e r e n c e O n l y ...

Page 116: ...L Filtration 10 Micron Return Flow rates listed are at free flow condition approx 100 psi 1 MPa HCA Load charts are based on 3150 psi 21 72 MPa Constant Pressure 2800 psi 19 31 MPa Trip Pressure on HCA Hoist System Wire Rope Standard 325 ft 99 m of 9 16 14 3 mm diameter Rotation Resistant Nominal Breaking Strength 38 500 lb 17 463 kg 325 ft 99 m of 9 16 14 3 mm diameter Rotation Resistant Nominal ...

Page 117: ...25 5 sec 53 fpm 16 1 mpm Boom Extend Retract Three Section 16 49 ft Extend 60 elevation 45 5 sec Retract 60 elevation 75 5 sec Boom Extend Retract Three Section 24 60 ft Extend 60 elevation 45 5 sec Retract 60 elevation 40 5 sec Boom Extend Retract Three Section 27 71 ft Extend 60 elevation 55 5 sec Retract 60 elevation 50 5 sec Boom Extend Retract Four Section 24 80 ft Extend 60 elevation 75 10 s...

Page 118: ...MAINTENANCE CHECKLIST OPERATOR MANUAL 600E2 6 16 PUBLISHED 04 26 2019 CONTROL 113 09 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 119: ...Maintenance 6 3 Hoist Maintenance and Service 5 6 Hoist Rope 2 26 Hoist System Operation 3 6 Hydraulic Capacity Alert System 3 8 Hydraulic Oil Reservoir Level 5 8 Hydraulic System Trouble Diagnosis 6 7 Installing Cable On The Hoist 3 11 Jib 2 33 Jump Starting Hazard 3 2 Lubrication Points 5 2 Maintenance 2 25 Oil Cooler Service Maintenance Optional 6 6 Operational Aids 2 3 Operator Information 2 2...

Page 120: ... Effects on Hydraulic Cylinders 2 35 Three Section Boom Operation 3 10 Transporting the equipment 2 29 Travel Operation 2 29 Truck Cab Controls 3 1 Wind Forces 2 5 Wire Rope Lubrication 5 8 Work Practices 2 30 F o r R e f e r e n c e O n l y ...

Page 121: ...F o r R e f e r e n c e O n l y ...

Page 122: ...F o r R e f e r e n c e O n l y ...

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