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National Crane 600H, Service Manual

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TABLE OF CONTENTS

600H

TOC-4

General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-7
Swing Bearing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-7
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-9

Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-9
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-10

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-11
Slew Potentiometer Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-12

SECTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outriggers

Bolt-On Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-2
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4

Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5

Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5

integral Outriggers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-6
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7

Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7

Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7

Rear Outriggers (RSOD)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

RSOD Beam  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7
Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8

RSOD Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8

Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8
RSOD Beam  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-9

600H-TM Outrigger Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-10

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11
Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11

Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-12

Jack Cylinder  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-13

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-13

Wear Pad Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-14

Outrigger Beam Wear Pad Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-14
Outrigger Box Wear Pad Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-14
Nonadjustable Wear Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-14
600H-TM Rear Jacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-14
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-16

REFERENCE ONLY

Summary of Contents for 600H

Page 1: ...Service Manual National Crane 600H R E F E R E N C E O N L Y...

Page 2: ...r 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 St...

Page 3: ...e should the need arise for us to contact you Manitowoc Crane is interested in safe efficient operation of its cranes for their lifetime Therefore if you are the second third or subsequent owner of th...

Page 4: ...evelopments 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 r...

Page 5: ...crane serial number 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 opera...

Page 6: ...THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 7: ...nspection 1 22 Wire Rope Replacement 1 22 Care of Wire Rope 1 23 Boom Extension and Retraction Cables 1 23 Wire Rope Replacement All Wire Rope 1 24 Seizing Wire Rope 1 24 SECTION 2 Hydraulic System Hy...

Page 8: ...Asked Questions 3 10 Service and Maintenance 3 11 Quick Test for Receiver Antenna and Cable 3 12 Troubleshooting 3 12 Specifications 3 13 Installation 3 13 SECTION 4 Boom Three Section Boom Operation...

Page 9: ...scope Cylinder Assembly 4 26 Jib Installation and Adjustment 4 26 Jib Jack Service and Maintenance 4 28 Adding Oil 4 28 Changing Oil 4 28 Lubrication 4 28 Rust Prevention 4 28 Five Section Boom 4 28 D...

Page 10: ...7 7 Extension Cylinder 7 7 Installation 7 7 Extension Cylinder 7 7 Jack Cylinder 7 7 Outrigger Beam 7 7 Rear Outriggers RSOD 7 7 Removal 7 7 RSOD Beam 7 7 Inspection 7 8 Extension Cylinder 7 8 Jack C...

Page 11: ...raulic Oil Reservoir Level 8 9 Hydraulic Filter Replacement 8 9 Wire Rope Lubrication 8 9 Carwell Rust Inhibitor 8 10 Protecting Cranes From Corrosion 8 10 Cleaning Procedures 8 11 Inspection and Repa...

Page 12: ...erator Platforms and Install the Foot Throttles 9 34 Install the Boom Lift Cylinder and Hoist 9 34 Connect the Slew Potentiometer 9 34 Connect the Electrical Interface 9 34 CAN Bus System Setup 9 35 R...

Page 13: ...s not replace federal state or local regulations safety codes or insurance requirements The 600H has been designed for maximum performance with minimum maintenance With proper care years of trouble fr...

Page 14: ...lity to contact you if the need arises Go to https www manitowoccranes com en Parts_Services ServiceAndSupport ChangeOfOwnershipForm and complete the form Basic Nomenclature The nomenclature used to d...

Page 15: ...rigger Jack 13 Outrigger Float 14 Outrigger Box 15 Hoist Cable Wire Rope 16 Jib 17 Turret 18 Jack Front Outrigger SFO Front Outrigger Jack 20 Hydraulic Tank 21 RCL Panel 22 Boom Angle Indicator 23 Tru...

Page 16: ...hment for all removals requiring hoisting equipment Some removals require the use of lifting fixtures to obtain proper balance All supporting members chains and cables need to be parallel to each othe...

Page 17: ...nitial load placed on the bearing at the time of assembly Consult the disassembly and assembly instructions to determine if the bearing can be preloaded Be careful in applying preload to bearings requ...

Page 18: ...ne is not used for an extended period of time Store the batteries in a warm dry place preferably on wooden shelves Never store on concrete A small charge should be introduced periodically to keep the...

Page 19: ...h Loctite adhesive sealant Loctite 243 NOTE Ensure the threaded surface both male and female is clean of contaminants and free of dirt and oil 1 Apply a bead perpendicular to the thread several thread...

Page 20: ...ity that a torque wrench may have been either overstressed or damaged it should immediately be removed from service until recalibrated When using a torque wrench any erratic or jerking motion can resu...

Page 21: ...82 4 80 3 8 119 4 116 5 113 5 5 8 11 UNC 5 116 6 113 7 110 8 8 164 8 160 7 156 6 3 4 10 UNC 5 206 8 201 7 196 5 8 292 3 284 9 277 6 7 8 9 UNC 5 333 8 325 4 317 1 8 471 6 459 8 448 0 1 8 UNC 5 500 3 48...

Page 22: ...54 2 734 8 1 1 8 12 UNF 5 700 0 682 5 665 0 8 1123 5 1095 4 1067 3 1 1 4 12 UNF 5 975 0 950 6 926 2 8 1564 8 1525 7 1486 5 1 3 8 12 UNF 5 1314 4 1281 5 1248 6 8 2109 5 2056 7 2004 0 1 1 2 12 UNF 5 172...

Page 23: ...289 5 282 1 M18x2 5 8 8 246 2 240 1 233 9 10 9 350 7 341 9 333 2 12 9 410 4 400 1 389 9 M20x2 5 8 8 348 0 339 3 330 6 10 9 495 6 483 2 470 8 12 9 580 0 565 5 551 0 M22x2 5 8 8 474 4 462 6 450 7 10 9 6...

Page 24: ...l Minimum M8x1 0 8 8 21 6 21 1 20 5 10 9 31 7 30 9 30 1 12 9 37 1 36 2 35 3 M10x 75 8 8 46 8 45 6 44 4 10 9 68 7 67 0 65 3 12 9 80 4 78 4 76 4 M10x1 25 8 8 42 2 41 1 40 1 10 9 62 0 60 4 58 9 12 9 72 5...

Page 25: ...369 2 1334 9 1300 7 10 9 1950 0 1901 3 1852 5 12 9 2281 9 2224 9 2167 8 M30x2 8 8 1324 6 1291 5 1258 4 10 9 1886 6 1839 4 1792 2 12 9 2207 7 2152 5 2097 3 M33x2 8 8 1784 5 1739 9 1695 3 10 9 2541 6 24...

Page 26: ...mmended M8x1 25 13 M10x1 5 27 Table 1 6 Inch Series Screws of STAINLESS STEEL 300 18 8 with Coarse Threads Size Torque lb in lb ft 5 40 0 125 6 9 6 32 0 138 9 8 32 0 164 18 10 24 0 190 21 1 4 20 68 5...

Page 27: ...110 9 16 12 5 114 110 106 8 161 152 143 5 8 11 5 156 150 144 8 234 225 216 3 4 10 5 270 259 5 249 8 385 370 355 7 8 9 5 416 400 384 8 615 591 567 1 8 5 606 583 560 8 929 893 857 1 1 8 7 5 813 782 751...

Page 28: ...8 5 872 1 1 8 12 5 882 848 814 8 1500 1440 1380 1 1 4 12 5 1251 1203 1155 8 2092 2008 5 1925 1 3 8 12 5 1704 1638 1572 8 2833 2719 2605 1 1 2 12 5 2288 2196 5 2105 8 3640 3500 3360 Table 1 11 Metric S...

Page 29: ...10 9 322 310 298 12 9 387 372 357 M18x2 5 8 8 319 306 5 294 10 9 455 436 5 418 12 9 532 511 490 M20x2 5 8 8 447 430 413 10 9 629 605 581 12 9 756 727 698 M22x2 5 8 8 608 585 562 10 9 856 823 790 12 9...

Page 30: ...12 9 96 93 90 M12x1 8 8 101 97 5 94 10 9 150 144 138 12 9 175 168 161 M12X1 25 8 8 100 96 92 10 9 147 141 5 136 12 9 172 165 5 159 M12x1 5 8 8 100 96 92 10 9 140 135 130 12 9 168 162 156 M14x1 5 8 8...

Page 31: ...of the offset by using a square Then apply this dimension to the torque wrench setting formula See sketch below 3 If offset is positioned at right angles to the torque wrench then the offset will not...

Page 32: ...oducts as load lines hoisting cables boom extension and retraction cables pendant cables and hook block tie down cables Any deterioration observed in the wire rope should be noted in the equipment ins...

Page 33: ...ope which are located over sheaves or otherwise hidden during inspection require special attention when lubricating rope During fabrication ropes receive lubrication which provides the rope with prote...

Page 34: ...wear Monthly Inspections Inspect the eye end and length of cable normally used in daily operations Examine the rest of the cable for kinked crushed or otherwise damaged points Periodic Inspections Wir...

Page 35: ...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 flatten...

Page 36: ...nt of the complete set of extension cables National recommends that boom extension cables be replaced every seven 7 years Do not use a swivel on rotation resistant rope A swivel on this rope will caus...

Page 37: ...f the wire and pound the twist flat against the rope Figure 1 9 NOTE Non preformed wire rope should have two seizings located on each side of the cut Figure 1 10 FIGURE 1 9 FIGURE 1 10 PREFORMED NON P...

Page 38: ...INTRODUCTION 600H SERVICE MANUAL 1 26 08 19 2022 Control 092 13 THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 39: ...embly of Control Valves to Replace Seals 2 9 Replacing Spool Seals 2 9 Control Valve Relief Adjustment 2 10 Hydraulic System Troubleshooting Chart 2 11 Jib Jack Troubleshooting 2 14 Systematic Trouble...

Page 40: ...ducer Hydraulic electrical located in lift cylinder circuit for cranes RCL circuit 1 2 1 2 2 1 1 2 Filter Removes contamination from hydraulic fluid Filter with Bypass Valve Bypass valve allows hydrau...

Page 41: ...h an unloader valve cartridge Closed Center Motor Spool Pressure compensated directional control valve for motor with open port for flow back to tank Allows flow back to tank when the crane is shut do...

Page 42: ...ue to hose failure by pilot operated check valves or by pilot operated counterbalance valves if overhung loads must be controlled The standard swing gearbox is locked in place by an integrally mounted...

Page 43: ...rn lines and raise the outrigger jack cylinders to the stowed position Replenish the reservoir hydraulic oil level as necessary 12 Repeat Steps 10 and 11 for the remaining two outrigger cylinders 13 D...

Page 44: ...e boom in and out several times If the air is not readily removed lower the boom to below horizontal extend the telescope cylinders as far as practicable and allow the boom to remain in this position...

Page 45: ...s access for cleaning The cover is secured to the top of the reservoir with screws and has a gasket to prevent leaking The access hole can also be used to fill the reservoir after it has been complete...

Page 46: ...at exchanger must be kept clean to allow for efficient operation of the cooler system Frequent washing of the heat exchanger core will eliminate oil film road dirt and other foreign object buildup on...

Page 47: ...Replace the valve sections on assembly studs in the same order in which they were removed NOTE Use care in replacing valve sections to avoid dislodging o rings from counterbores 8 When all valve sect...

Page 48: ...d by plugging a port on the hoist motor with a pressure gage Some valve sections include work port reliefs The work port reliefs are shim adjustable Adjustment is made by adding or taking out shims Ad...

Page 49: ...arrier O RING FACE SEAL O RING BOSS B A O RING FACE REF O RING BOSS REF A B O RING FACE SEAL FITTING SIZE O RING BOSS THREAD SIZE B in mm A in mm TUBE O D MFGR S SIZE CODE A in mm B in mm THREAD SIZE...

Page 50: ...ic 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...

Page 51: ...s rotating boom Brake not releasing properly Check for 200 PSI brake pilot pressure Clean pilot line or adjust motor counterbalance valves Adjust or clean brake for proper release Swing speed adjustme...

Page 52: ...d inspect and replace cables Boom will not extend Proportioning cables not attached Reconnect replace and or adjust cables Anti two block system shut down Lower hook and extend load Defective anti two...

Page 53: ...atalog to identify parts and flow paths Start at the top box and work downward step by step Do not try to start in the middle or skip steps Boom creeping down Yes No Control valve in meter in position...

Page 54: ...HYDRAULIC SYSTEM SERVICE MANUAL 600H 2 16 08 19 2022 Control 092 13 THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 55: ...since 2000 have multiple computer systems crane control RCL engine transmission control that are highly susceptible to voltage amperage surges in the electrical system The batteries should be complet...

Page 56: ...pplying Dielectric Grease to an Electrical Connector Use the following procedure to apply dielectric grease to an electrical connection Grease should be applied immediately prior to securing the conne...

Page 57: ...powered by a 12V input from the truck battery through a 15 Amp fuse A toggle with in the truck cab turns the RCL system ON and a light next to the switch indicates when the RCL is active The RCL memor...

Page 58: ...two on the rear outrigger When the toggle switch on the control console activates the appropriate solenoid to divert flow to a single outrigger beam or jack The solenoids are located behind the cover...

Page 59: ...flow is diverted through the cooling core A temperature sensor in the cooling core turns on the electric fan motor when the oil temperature reaches about 140 F 60 C The hydraulic oil needs to be unde...

Page 60: ...2 An electrically actuated directional control valve which receives oil from the regulated port of the flow control valve and directs it to the various crane functions a When 12 VDC power is applied...

Page 61: ...solenoids The valve can be disassembled and cleaned when contamination is suspected If voltage drops below 10 5 V at the solenoid coil the solenoids may not operate Defective electrical equipment on t...

Page 62: ...t 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...

Page 63: ...data stream and checks for validity of the address and the start and stop bits of the received data If this is correct a proprietary software algorithm is performed to accept or reject the information...

Page 64: ...ate Should an emergency situation occur the receiver may be shut down by pressing the Emergency Stop Switch on the transmitter This must be pressed while transmitter power is in the ON position This s...

Page 65: ...y the wireless transmitter is operated at a closer range than the interfering signal and the receiver will perform properly since it will pick up the strongest signal Will two radio remote units in th...

Page 66: ...e at points B and C To do these last tests another wire may have to be used to extend the leads Troubleshooting 1 Begin the process of elimination by always checking the fuse in the receiver first and...

Page 67: ...he transmitter at this time the receiver s RF Indicator LED and the appropriate Output Status Indicator LED will be on And if the function activated such as the boom up motion does not occur check the...

Page 68: ...complete failure Receiver Input and Output Each unit comes with a connector chart Chart C with the appropriate input and output instruction for your unit There are three 3 inputs to the receiver A BNC...

Page 69: ...rn LH Output 13 Bwn Blk Boom Up Output 12 Red Blk Boom Down Output 11 Yel Blk N A Output 10 N A Output 9 Tele Retract Output 8 Blu Tele Extend Output 7 Org Hoist Up Output 6 Red Hoist Down Output 5 Br...

Page 70: ...er is at its maximum setting F If this occurs leave the low end proportional set at F 5 Now set the potentiometer on the transmitter to maximum This is done by fully pulling trigger 6 Set the High End...

Page 71: ...metal The position of a Boom over or around can effect the antenna s ability to receive a signal creating Dead Spots Cut FIGURE 3 9 Truck Solenoid Cut existing ignition wire and strip ends 0 25 inch...

Page 72: ...Connect to Existing Ignition Switch Wire in Cab Solenoid Side NOTE 1 All grounds must be referenced to the negative side of the battery 2 Start circuit wire from terminal 10 to neutral safety switch i...

Page 73: ...00H ELECTRIC SYSTEM FIGURE 3 10 Lift OPTION GROUP R4 Remote Control Hydraulic Diagram Hydraulic Lines Turn Manual Valve Pump Manual Hoist Valve LH Dn Up Tele Ext Ret Shuttle Valve Hoist Up Dn Shuttle...

Page 74: ...Tele Extend 3 Blu Tele Retract 6 Yel Blk Lift Down 5 Red Blk Lift Up 8 Brn Hoist Down 7 Red Hoist Up 9 Brn Red Flow Regulator 10 Blu Red HCA RCL Override Yel Power Ground Blu Blk Power Positive Red Bl...

Page 75: ...our Section Top bottom Pad Replacement Assembled Boom 4 15 Top Rear Pad Replacement 4 16 Front Bottom Pad Replacement 4 16 Cable Tensioning 4 16 Tensioning Setup Procedure 4 16 Cable Tension Sequence...

Page 76: ...boom operation provides that the 2nd and 3rdsection booms extend and retract equally Proper service and maintenance is required to insure smooth and proper operation Special Boom Inspection If the boo...

Page 77: ...linder lines and hoist hydraulic lines Cap all open lines and ports 6 Attach a lifting device to provide even weight distribution and raise the boom until weight is removed from the boom pivot pin Rem...

Page 78: ...move four capscrews securing the rear bottom wear pads on the 2nd section This pad serves as a bottom and side pad as well as the retract cable keeper under the retract sheaves Removal of this pad wil...

Page 79: ...ng anchor and cables out rear of boom A slight angle applied to the anchor as it is being pulled to the rear will permit easier removal 9 Continue to pull extend cylinder and cables out of rear of boo...

Page 80: ...cables over top of retract sheaves Install keeper capscrew above sheave to hold retract cables in place 11 Reeve cables over retract sheave and install keeper wear pad to bottom rear of 2nd section Th...

Page 81: ...the plate and 0 03 in 0 8 mm off center in the wear pad Various combinations of rotation of these parts allow the adjustment a Adjust pads until they are within 0 03 0 8mm off center in the wear pad V...

Page 82: ...Refer to Inner Wear Pad Calibration pg 4 8 of this section to determine Wear Pad shim thickness 1 Extend boom approximately 4 ft 120 cm out 2 Using an appropriate lifting device sling around the 3rd...

Page 83: ...section Wi Add shims as 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 boom and the most na...

Page 84: ...les attach to the tip end of the 2nd boom section are reeved around sheaves attached to the 3rd boom section and attach to the base end of the 4th boom section therefore providing retraction of the 4t...

Page 85: ...e with the boom horizontal For more information see Cable Tensioning on page 4 16 Four Section Boom Service 1 Extend and set machine outriggers Boom must be completely retracted and stowed in the boom...

Page 86: ...ell as the retract cable keeper under the retract sheaves Removal of this pad will allow the retract cables to uncoil off the retract sheaves Place retract cable ends in a location to minimize the pos...

Page 87: ...er to the right hand side 2 Attach rear wear pads on bottom of 4th section Using Loctite 243 blue Loctite all wear pad mounting capscrews 3 Install 4th section boom into 3rd section Slide together app...

Page 88: ...d the wear pad and plate or the wear pads and plate independently This is possible because the holes in these parts are offset from the center The holes are 0 06 in 1 5 mm off center in the plate and...

Page 89: ...has been disassembled and no sections have been replaced use same shim quantity and location as was previously used If locations are in question refer to shim calibration section in this book 45 Push...

Page 90: ...around the 4th section boom and lift it up until weight is removed from the bottom pads in the front of the 3rd 2nd and 1st boom sections 5 Loosen and remove the four capscrews holding the pad double...

Page 91: ...Sequence Five section boom with two stage cylinder Cable tensioning See Figure 4 8 to be in the following order 1 321 retract cables 2 123 extend synchronizing cables 3 234 extend cables 4 432 retrac...

Page 92: ...he base section may need to be loosened Retraction 1 Measure the retraction gaps between the first and second section and the second and third section If the retraction gap is greater between the firs...

Page 93: ...extend cable located at the back top of the third section the difference in the extension gap measurements 3 Extend and retract the boom a few times and then repeat measuring the extension gaps The f...

Page 94: ...have moved out 4 Tightening until the retraction gap between the first and second section and the retraction gap between the second and the third are equal At this time the second and first extendable...

Page 95: ...reater between the second and third section than the retraction gap between the first and second section 2 Tighten the 321 retract cable located at the front bottom of the base section the difference...

Page 96: ...ion gaps between the first and second section and the second and third section If the extension gap between second and third section is less than the extension gap between the first and second section...

Page 97: ...in contact with the back of the first nut Hold the first adjustment nut stationary and a torque wrench to tighten the second torqued nut against the first adjustment nut to the values indicated in TOR...

Page 98: ...f the ring out of the groove and the other to pry the ring out of the barrel assembly 6 Attach a porta power hand pump or hydraulic line from crane circuit valve to the shaft end of the cylinder De bu...

Page 99: ...retain with the external snap ring being sure that snap ring contracts completely and properly into the snap ring gland groove TELESCOPE CYLINDER REPAIR NOTE The following Telescope Cylinder Repair Di...

Page 100: ...nut to shaft 9 If necessary heat nut to 400 500 F 204 260 C to facilitate removal If heat is necessary for removal discard nut and replace with new equivalent nut as well as worn or damaged parts 10 W...

Page 101: ...the boom 8 Retract the boom slowly Observe the stow hook and side stow bracket assembly alignment as the boom is retracted View AA and BB below 9 When the boom is fully retracted the jib must be botto...

Page 102: ...mance and longest life replace the complete oil supply at least once a year 2 To drain the oil remove the filler plug 3 Lay the jack on its side and drain the oil into a suitable drain pan The oil wil...

Page 103: ...r lug 25 When sliding sections apart be sure cables 96 are inside grooves in section 4 26 Remove retainer side plates 65 from rear of section 3 27 After sliding sections apart hang retainer 64 on cyli...

Page 104: ...ion 5 with screws 18 and Loctite 243 5 Slide section 5 1 into section 4 2 with cables pre installed Be sure cables 94 are around sheave 48 and facing rear of section 6 Align sheave 48 with end plate p...

Page 105: ...plate 6 Figure 4 24 inside top 32 Install top wear pad 2 with bolts 16 and lockwashers 14 33 Slide sections together leaving about 2 ft extended NOTE Cables 96 Figure 4 23 will bottom out on nuts and...

Page 106: ...il 3 5 8 17 J Detail 2 4 10 K Detail 2 4 6 12 L Detail 3 4 8 14 M Detail 3 8 16 N Detail 3 8 17 18 W X Y Detail 2 9 19 Z Detail 3 7 20 Cable Detail 2 8 Boom Detail 9 18 Cylinder Detail 19 20 Detail 2...

Page 107: ...CE MANUAL BOOM 4 FIGURE4 23continued Detail 3 Retract Cables 96 97 Details 4 5 Synchronizing Cable 95 Detail 6 Extend Cable 93 Detail 7 Extend Cable 94 Detail 8 Boom Cables Extended Detail 4 Retract C...

Page 108: ...BOOM 600H SERVICE MANUAL 4 34 08 19 2022 Control 092 13 FIGURE4 23continued Detail 5 Retract Cable Mounts at C D E from Base Detail 6 Synchronizing Cable 95 at A C K R E F E R E N C E O N L Y...

Page 109: ...NATIONAL CRANE 08 19 2022 Control 092 13 4 35 600H SERVICE MANUAL BOOM 4 FIGURE 4 23 continued Detail 7 Extend Cable 93 at B D Z Detail 8 Extend Cable 94 at C E M N R E F E R E N C E O N L Y...

Page 110: ...BOOM 600H SERVICE MANUAL 4 36 08 19 2022 Control 092 13 FIGURE 4 23 continued Detail 9 Section 1 at A Detail 10 Section 1 at J R E F E R E N C E O N L Y...

Page 111: ...NATIONAL CRANE 08 19 2022 Control 092 13 4 37 600H SERVICE MANUAL BOOM 4 FIGURE 4 23 continued Detail 11 Section 2 at B Detail 12 Section 2 at K R E F E R E N C E O N L Y...

Page 112: ...BOOM 600H SERVICE MANUAL 4 38 08 19 2022 Control 092 13 FIGURE 4 23 continued Detail 13 Section 3 at C Detail 14 Section 3 at L R E F E R E N C E O N L Y...

Page 113: ...NATIONAL CRANE 08 19 2022 Control 092 13 4 39 600H SERVICE MANUAL BOOM 4 FIGURE 4 23 continued Detail 15 Section 4 at D Detail 16 Section 4 at M R E F E R E N C E O N L Y...

Page 114: ...BOOM 600H SERVICE MANUAL 4 40 08 19 2022 Control 092 13 FIGURE 4 23 continued Detail 17 Section 5 at E Detail 18 Section 5 at N R E F E R E N C E O N L Y...

Page 115: ...NATIONAL CRANE 08 19 2022 Control 092 13 4 41 600H SERVICE MANUAL BOOM 4 FIGURE 4 23 continued Detail 19 Section 6 at W X Y Detail 20 Cylinder 6 at Z R E F E R E N C E O N L Y...

Page 116: ...etainer nut 49 Install cylinder retainer side plates in the cylinder lugs NOTE Turn and adjust cylinder lugs in order to clear sections during assembly Middle lug horizontal Outside lug with check val...

Page 117: ...40 NOTE May have to pull cables with some effort to get to reach anchor holes NOTE Small cables 95 must be above extend cable anchor 68 and anchor bolts 72 for next step in assembly 69 Be sure lower c...

Page 118: ...16 and lockwashers 14 Install cable protector 12 84 Install cable guide rollers assembly bottom plate rollers top plate and bolts 85 Push sections together 86 Install cylinder anchor plate to rear of...

Page 119: ...is extended and retracted DANGER Ensure that all stages of the telescope cylinder are fully retracted prior to removal of the telescope cylinder from the boom assembly or prior to installation of the...

Page 120: ...BOOM ASSEMBLY Assemble the boom in the following order 6TH section 6TH 5TH 4TH section assembly telescope cylinder installation 3RD 2ND 1ST section assembly sync cable adjustment and torquing Sixth S...

Page 121: ...Control 092 13 4 47 600H SERVICE MANUAL BOOM 4 FIGURE 4 27 6TH Section Top Wear Pads Wear Pad Cam Plate 5TH Section Cam FIGURE 4 28 3 8 Inch Square Hole for Cam Adjustment 4TH 3RD 2ND 1ST Section Cams...

Page 122: ...earing shaft are on opposite sides of the bearing Retract Cable Anchor Clamp 6TH Section 5TH Section Top Rear Wear Pad Retract Cable Stop 1 3 7 8 4 2 6 5 9 10 Clamp Torquing Pattern Torque to 75 lb ft...

Page 123: ...ar in the 5TH section The wear pads should be line access holes Relief Sheave Retainer Relief Bearing Dust Cover FIGURE 4 30 Retract Sync Sheave Assembly Mark the side that goes toward the center of t...

Page 124: ...Slide the 6TH section into the 5TH section far enough to be able to reach the retract cable Remove the retract cable from inside the 6TH section and guide the cable through the slots in the back of th...

Page 125: ...cable retainer to the front of the 5TH section 20 Install the wear pads to the bottom front and side of the 5TH section Figure 4 34 Retract Cable 5TH Section Boom FIGURE 4 33 Retract Cable FIGURE 4 34...

Page 126: ...tions for the 4TH 3TH and 2ND sections The 5TH section assembly is a follows 1 Bolt the back bottom wear pads to the 5TH Figure 4 36 section boom 2 Attach the sync cables to the side of the 5TH boom s...

Page 127: ...Slide the 6TH 5TH assembly into the 4TH section until it comes in contact with the locator bar 7 Remove the locator bar 8 With a 3 8 in socket extension adjust the cams until the rear of the 5TH sect...

Page 128: ...s installed at the top of the 3RD section after the 6TH 5TH 4TH assembly is inserted into the 3RD section See page 4 60 for the installation procedure 16 Attach the top front wear pads to the 4TH sect...

Page 129: ...on the retaining brackets as shown in Figure 4 46 the cables will become lodged between the cylinder and the 6TH section boom and damage the cables DANGER Ensure that all stages of the telescope cyli...

Page 130: ...or to the back of the 6TH section and tighten all bolts 6 Install the trunnion on the telescope cylinder into the 5TH boom section Leave a 2 in space between the back of the boom section and the trunn...

Page 131: ...trunnion 8 Repeat for the 4TH section trunnion CAUTION Do not extend or retract the telescope cylinder when not attached to the boom sections The trunnions close together when not attached to the boom...

Page 132: ...ly into the 3RD section boom 2 Use the locator bar as shown Figure 4 52 to aid in positioning the 6TH 5TH 4TH assembly in the 3RD section so that the wear pad lines up with the wear pad access holes K...

Page 133: ...r 2 Slide the bottom of the anchor bracket into the slot at the top of the boom 3 Pull the threaded cable stop through the brackets secure with the nuts 6TH 5TH 4TH 3RD 2ND Boom Assembly FIGURE 4 53 1...

Page 134: ...t Top Adjustment Top Adjustment Bottom Adjustment 4TH Section Clamp 4TH Section 5 TH Section 3 RD Section 3 RD Section 3RD Section Sync Cables 5TH Section Clamp Top Adjustment Bottom Adjustment 4TH Se...

Page 135: ...using the torquing pattern shown in Figure 4 29 after the cables are adjusted 5 Torque the sync cables at both the top and bottom cable stops using the following sequence Tighten the threaded cable s...

Page 136: ...BOOM 600H SERVICE MANUAL 4 62 08 19 2022 Control 092 13 R E F E R E N C E O N L Y...

Page 137: ...re to a suitable holder HOIST INSTALLATION 1 Remove rope Mesh Guard from hoist 2 Lift hoist with suitable lifting device 3 Lower hoist onto the alignment ears 4 Install Mesh Guard 5 Install 6 capscrew...

Page 138: ...HOIST 600H SERVICE MANUAL 5 2 08 19 2022 Control 092 13 THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 139: ...power for the swing drive Figure 6 1 is supplied by section P3 of the hydraulic pump Oil flows from the pump to the main control valve When the hydraulic control is positioned to select right or left...

Page 140: ...d friction discs 17 from the brake piston 5 Inspect stator plates for excessive grooving or burn spots Also inspect friction discs for wear Replace as required 9 Remove the piston 5 from the brake hou...

Page 141: ...092 13 6 3 600H SERVICE MANUAL SWING 6 I 29 28 39 3 24 8 18 15 5 22 21 20 19 37 17 16 27 2 9 36 23 50 54 55 54 56 57 50 51 52 50 53 4 34 41 43 44 48 49 45 43 46 47 48 11 42 1 12 7 10 6 26 24 32 35 FIG...

Page 142: ...ce as required Item Component 1 Gear Housing 2 Brake Housing 3 Motor Adapter 4 Gear Set 5 Brake Piston 6 Pinion Shaft 7 Outboard Bearing 8 Brake Driver 9 Thrust Plate 10 Seal 11 Inboard Bearing 12 Bea...

Page 143: ...bolt aligns with the slot on the nut portion of the pinion bolt at 25 ft lb 34 Nm If the pinion bolt is between slots always tighten to the next slot NOTE Install a 1 2 13 bolt into the end of the pi...

Page 144: ...inside of the frame rotate the flag rod until it is centered between the two stop pins on either side of the flag 2 Make certain that the turn lever is vertically aligned If not adjust the lever at th...

Page 145: ...Force value readings must be made while the tool is in motion Rigid handle type with torque limiting devices that can be pre set to required values eliminate dial readings and provide more reliable le...

Page 146: ...secured to the frame by 24 1 8 UNCX4 5 Grade 8 bolts Figure 6 9 17 16 15 14 13 12 11 10 18 20 21 22 23 24 25 26 19 7 6 5 4 3 1 2 8 9 10 11 12 14 15 13 23 22 21 20 19 17 16 18 24 FIGURE 6 9 2 3 4 5 6 7...

Page 147: ...symptoms it may have reached the end of its useful life metal particles in the grease increased drive power required noise rough operation acceleration in the increase in bearing clearance Measure the...

Page 148: ...battery cables 5 Remove the boom and lift cylinder following the procedures outlined in Boom Removal pg 4 3 NOTE If equipped with a swivel tag and disconnect all hydraulic lines from the swivel on th...

Page 149: ...propriate lifting device align the turret over the frame at the same position that it was before removal 4 Carefully lower the turret into position on the bearing plate NOTE If equipped be careful not...

Page 150: ...r is meshed with the swing bearing teeth 8 Back off the slew pot gear slightly so that there is a 0 125 0 188 in 3 1 4 7 mm gap between the slew pot gear teeth the swing bearing gear teeth 9 Tighten t...

Page 151: ...sembly 7 10 Removal 7 11 Inspection 7 11 Installation 7 11 Extension Cylinder 7 11 Removal 7 11 Installation 7 12 Jack Cylinder 7 13 Removal 7 13 Installation 7 13 Wear Pad Adjustment 7 14 Outrigger B...

Page 152: ...m the outrigger box NOTE Cap all disconnected hydraulic lines 4 Tag and remove the hydraulic lines connected to the base of the beam cylinder 5 Tag and remove the hydraulic lines connected to the chec...

Page 153: ...to the bottom of the outrigger beam 8 Pull the outrigger beam out of the outrigger box with a lifting device Top Wear Pad Bolts Retaining Bolts for Jack Cylinder Extension Cylinder FIGURE 7 2 Pin for...

Page 154: ...olts that secure the jack cylinder to the top of the jack tube 5 Slide the jack cylinder out of the jack tube Extension Cylinder 1 Remove the snap rings from the pin that secures the extension cylinde...

Page 155: ...gger Beam 1 Apply grease EP MPG to the top and bottom of the outrigger beam NOTE To prevent nicks and gouges to the bottom of the outrigger beam do not attach chains to the outrigger beam 2 With a lif...

Page 156: ...raulic lines 4 Tag and remove the hydraulic lines connected to the base of the outrigger beam 5 Remove the wear pad from the bottom of the outrigger box 6 Remove the bolts that secure the base of the...

Page 157: ...e jack cylinder 3 Slide the jack cylinder into the jack tube 4 Install the bolts that secure the jack cylinder to the top of the jack tube 5 Use the access hole in the side of the outrigger beam to ga...

Page 158: ...e is enough clearance to remove the jack cylinder and foot from the jack support tube 2 Tag and disconnect the jack cylinder hydraulic hoses Figure 7 10 3 Remove the check valve from the jack cylinder...

Page 159: ...under the jack support tube and jack up the foot until the jack cylinder can be bolted to the top of the jack support tube 4 Bolt the jack cylinder to the jack support tube 5 Reinstall the check valve...

Page 160: ...integral T Box assembly outrigger beams jack cylinders required hoses and mounting hardware FIGURE 7 11 Outrigger and Integral T Box Assembly Crane Frame Outrigger Beam Adjustable Wear Pads Jack Cylin...

Page 161: ...er loose connection or damaged hydraulic line Installation 1 Apply grease EP MPG to the bottom of the outrigger beam 2 Screw the bottom wear pads on the outrigger box in until about 0 25 in 6 4 mm is...

Page 162: ...er beam Make sure the jack hydraulic hoses are routed as shown in Figure 7 14 4 Insert the extension cylinder rod into the keyhole and reinstall the keeper 5 Bolt the barrel end to the of the extensio...

Page 163: ...e 3 Tag and disconnect the hydraulic hoses to the jack cylinder 4 Remove the check valve from top of the jack cylinder NOTE The weight of the jack cylinder is about 119 lbs 54 kg dry 5 Remove the two...

Page 164: ...e top of the outrigger box 2 Screw the bottom wear pads on the outrigger box in and back off about 1 2 turn 3 Screw the side wear pads on the outrigger box in and back off about 1 4 turn Nonadjustable...

Page 165: ...the remaining outrigger beams are fully extended point the Outrigger Status Indicator flashes green indicating a lift can be made using the capacities from the mid extend outrigger load chart When po...

Page 166: ...software and a USB cable connector p n 80009992 Contact your National Crane distributor for further assistance Jack Proximity Switch version 1 Remove 1 Disconnect electrical connector 1 Figure 10 at...

Page 167: ...uring the switch 4 to the jack box remove switch Install 1 Fully extend jack beam horizontally 2 Using two screws 2 Figure 11 secure the switch 4 to jack box 3 Connect electrical connector 1 Figure 11...

Page 168: ...OUTRIGGERS 600H SERVICE MANUAL 7 18 08 19 2022 Control 092 13 THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 169: ...brication requirements for the truck chassis Refer to truck service manual for this information The service intervals specified are for normal operation where moderate temperature humidity and atmosph...

Page 170: ...LGI Class 1 2 specifications Low Temperature Grease This special grease for low temperature remains plastic at 51 C 60 F with melting point of 138 C 280 F The grease is a heavy duty extreme pressure t...

Page 171: ...f the reservoir To inspect the hydraulic oil fill a small glass container with a sample of the reservoir oil and another glass container with fresh oil Let the samples stand undisturbed for one or two...

Page 172: ...stances work at an elevated height without using proper fall protection as required by local state or federal regulations CAUTION Lubrication intervals are to be used only as a guide Actual intervals...

Page 173: ...oil filter service interval 4 Breather hydraulic oil reservoir Clean Monthly 5 Sheave pins boom 2 plcs jib 1 plc EP MPG Grease gun Weekly 6 Wire rope loadline EP OGL Brush or spray Semi Annually 7 Boo...

Page 174: ...Oil Can As Required Quarterly 13 Swing Drive Gearbox GL 5 Check Fill Change Check and Fill As part of daily crane inspection check the gearbox for visible leaks Change After first 50 Operating Hours e...

Page 175: ...on wear pads with a grease gun 6 Extend the boom to line up the access holes 2 on the 3rd section with the wear pads on the 4th section Apply grease to the 4th section wear pads with a grease gun 7 Ra...

Page 176: ...Gearbox Oil Hoist Gearbox Oil Change Gearbox oil is drained by first removing the drain plug 33 Figure 8 4 by rotating the drum so that the plug is visible through the lower hole in the side plate See...

Page 177: ...e of the reservoir This sight gauge has a decal beside it that indicates a full level and an low oil level The oil required to bring it from the low line to the full line is 5 gallons Do not fill the...

Page 178: ...tiff wire brush and solvent compressed air or live steam Immediately after the wire rope is cleaned it should be lubricated Many techniques may be used bath dripping pouring swabbing painting pressure...

Page 179: ...ed even though other parts remain dry or in high humidity or when temperatures are just above the freezing point Cleaning Procedures To help protect against corrosion of National Cranes National Produ...

Page 180: ...t treatment in 6 9 months Do not apply to recently primered and painted areas for at least 48 hours after paint is properly dried and cured For minor touch up areas a 24 hour period is needed for cure...

Page 181: ...are for Boom Extension 4 All Hardware Clips Pi ns Hose Connections not painted O R Pins Clips 5 Wire Rope 6 Boom Nose Pins Clips 7 Hook Block Downhaul Weight 8 Mirror Mounting Hardware 9 Power Train H...

Page 182: ...LUBRICATION 600H SERVICE MANUAL 8 14 08 19 2022 Control 092 13 THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 183: ...System using Software 9 36 CAN Bus System using Programming Button 9 37 Initial Crane Run In Procedure 9 37 RCL Calibration 9 38 Stability Test 9 38 Specifications 9 42 Hydraulic Pump 9 42 Hydraulic...

Page 184: ...e installation to the cab the WB and CT dimensions must be increased Refer to Mounting Configuration on for additional information Truck Frame Select a truck frame that minimizes or eliminates frame r...

Page 185: ...9 3 600H SERVICE CRANE INSTALLATION 9 Frame FIGURE 9 1 2nd Section 3rd Section Booms Typical Location of Serial Number Identification Tags Boom Nose Lift Cylinder Turret 1st Section Boom FORWARD RSOD...

Page 186: ...180 2 cm3 Frame Section Modulus FSO Attach Point 110 000 psi 2 in3 32 7cm3 Minimum Truck Weight Front 8 700 lb 3946 2 kg Minimum Truck Weight Rear 8 600 lb 3900 8 kg Estimated Final Weight truck and...

Page 187: ...10 000 psi 20 in3 260 5 cm3 Frame Section Modulus Over Rear jacks 110 000 psi 13 in3 213 cm3 Frame Section Modulus Rear of Front Spring Hanger 110 000 psi 11 in3 180 2 cm3 Frame Section Modulus FSO At...

Page 188: ...i 15 9 in3 260 5 cm3 Frame Section Modulus Rear of Front Spring Hanger 110 000 psi 11 in3 180 2 cm3 Frame Section Modulus FSO Attach Point 110 000 psi 2 in3 32 7cm3 Minimum Truck Weight Front 6 500 lb...

Page 189: ...le Front Outrigger SFO 110 000 psi 30 in3 491 6 cm3 Frame Section Modulus at SFO Attach Point 110 000 psi 2 in3 32 7 cm3 Frame Section Modulus at Front Spring Hanger 110 000 psi 11 in3 180 2 cm3 Minim...

Page 190: ...take off rotation direction Make certain which direction the power take off output shaft rotates before selecting a clockwise cw or counter clockwise ccw rotation hydraulic pump Either cw or ccw rotat...

Page 191: ...6 in 7 94 mm and 3 8 in 9 52 mm with each grouping a flange width and web depth column When the depth of frame channel and flange width is known the point at which these two lines intersect is the sec...

Page 192: ...s 1 4 in 6 35 mm D in mm W in mm 2 5 64 3 76 3 5 89 4 102 8 203 6 9 113 7 8 128 8 8 144 9 7 159 in 3 cm 3 9 229 8 2 134 9 2 151 10 3 169 11 4 187 10 254 9 5 156 10 7 175 11 9 195 13 1 215 11 279 11 0...

Page 193: ...41 5 6 92 5 8 95 6 0 98 6 2 102 10 5 267 6 8 111 7 1 116 7 3 120 7 5 123 11 5 292 8 1 133 8 4 138 8 6 141 8 9 146 12 5 318 9 5 156 9 8 161 10 1 166 10 4 170 13 5 343 11 0 180 11 4 187 11 7 192 12 0 19...

Page 194: ...2 249 16 5 270 17 8 292 19 2 315 14 5 368 16 9 277 18 3 300 19 7 323 21 2 347 15 5 394 18 7 306 20 2 331 21 7 356 23 3 382 Thickness 5 16 in 7 94 mm D in mm W in mm 3 76 3 5 89 4 102 4 5 114 8 5 216...

Page 195: ...tween a 10 in 254 mm deep channel and a 10 5 in 267 mm deep channel to get the section modulus of a 10 25 in 260 mm deep channel 10 in 254 mm deep channel 15 4 in 3 252 cm3 10 5 in 267 mm deep channel...

Page 196: ...wn is required The bracket must be capable of supporting 0 50 in 12 7 mm DIA Grade 8 bolts to their nominal breaking strength Torque the mounting bolts supplied with the SFO to 110 ft lb 149 N m Do no...

Page 197: ...erning frame strength or reinforcing contact National crane before proceeding Thickness 3 16 in 4 76 mm D in mm W in mm 1 25 1 53 38 2 51 8 203 3 2 52 3 9 64 4 6 75 in 3 cm 3 9 229 3 8 62 4 7 77 5 5 9...

Page 198: ...343 8 8 144 9 1 149 9 4 154 9 6 157 14 5 368 10 1 166 10 5 172 10 7 175 11 0 180 Thickness 5 16 in 7 94 mm D in mm W in mm 2 75 70 3 25 83 3 75 95 4 25 108 3 5 89 0 9 15 1 0 16 1 0 16 1 0 16 in 3 cm 3...

Page 199: ...n 38 1 mm D 11 0 in 279 mm Section Modulus I I 9 in 3 195 cm3 4 Interpolate between the two values 10 in 254mm deep channel 10 2 in 3 167cm3 11 in 279mm deep channel 11 9 in 3 195cm3 10 5 in 267 mm de...

Page 200: ...east 258 in 655 cm with a minimum length of 24 in 60 96 cm from the center of tandems to the center of the rear axle PTO INSTALLATION Select the PTO according to the PTO Selection pages shown earlier...

Page 201: ...vers from the pump inlet and outlet and make sure that the suction and pressure sides of the pump are correct NOTE An arrow is cast into the rear of the pump housing to identify rotation Make sure the...

Page 202: ...ane mounting anchors and bolt reinforcing in place See Figure C for recommended drilling and bolting procedure Use 5 8 Grade 8 bolts drill holes to 39 64 diameter drive fit bolts and torque according...

Page 203: ...the spring hangers and against the existing truck frame and forward reinforcing Torch out the marked areas in the long leg of the angle deep enough so that the lip of the angle can be slid up from the...

Page 204: ...ion reinforcing is required as may be the case with a truck frame that tapers down to approximately 6 in 15 24 cm deep through the suspension a channel may be fabricated through the suspension for add...

Page 205: ...osition the truck so that the truck frame is level 2 Place the T box on the truck frame as determined by the configuration drawing and minimum truck requirements NOTE The top and bottom T box reinforc...

Page 206: ...mponent and the bolt must be installed according to specifications Special attention should be given to the existence of lubricant and plating that will cause variation from dry tightening values When...

Page 207: ...end out past the RSOD mounting brackets Truck Frame BC configuration shown On the RM configuration both outriggers are bolted to the truck frame Truck Frame Saw the Anchor Retaining Bracket to fit ins...

Page 208: ...nt outrigger boxes are integral to the T box on cranes where the operators station is mounted behind the truck cab Assemble the Outriggers Assemble the outriggers as shown in the parts manual and conn...

Page 209: ...out the nuts on either end of the anchor studs to prevent damage to the threads Cut to fit the inside of the truck frame REAR Jacks Retract Beams Retract Passenger Side Beams Out Driver Side Beams Ou...

Page 210: ...s to the RSOD mounting bracket 8 Clamp the upper brackets to the anchor bars 9 Position the upper brackets on the T box and tack weld in place 10 Drill three holes in the anchor bar using the upper br...

Page 211: ...3 4 in Grade 8 Bolts for the RSOD Anchor Brackets Torque refer to Fasteners and Torque Values page 1 7 Weld 5 8 in Grade 8 Bolts Torque refer to Fasteners and Torque Values Gusset Note All welds must...

Page 212: ...TALLATION 600H SERVICE 9 30 08 19 2022 Control 092 13 600H TM Rear jack Installation FIGURE 9 12 6 75 6 00 Allow Clearance for Mud Flaps Jack Up Jack Down 5 8 Grade 8 Bolt FRONT FRONT R E F E R E N C...

Page 213: ...be Outrigger Box 16 25 on 43 Tall Truck Frame NOTE All welds are grade 70 or better With complete crane installed on the truck position the vertical to 1 19 dimension as shown If more ground penetrati...

Page 214: ...ete crane installed on the truck position the vertical to 1 19 dimension as shown If more ground penetration is needed rotate bar 203321 16 25 on 43 Tall Truck Frame 12 ref on 43 Tall Frame 16 25 on 4...

Page 215: ...Section P3 supplies 10 gpm 37 8 lpm 2350 psi 162 bar for the swing circuit Gear Section Install the hydraulic tank Figure 9 16 behind the cab Connect the hydraulic hoses to the pump sections as marke...

Page 216: ...described in Section 4 Install the hoist a described in Section 5 For hoist cable and wedge socket installation see Section 4 of the Operators Manual Connect the Slew Potentiometer Connect the slew p...

Page 217: ...e of the following methods to initialize the CAN bus system CAN bus system software See CAN Bus System using Software page 9 36 Programming button method CAN Bus System using Programming Button page 9...

Page 218: ...e splitter 5 Connect the serial port to the CAN to USB adapter cable 6 Connect the USB adapter cable to the laptop 7 Engage the PTO 8 Turn the crane ignition switch to the RUN position Do not start th...

Page 219: ...ction indicated on the control levers Refer to the appropriate sections in this manual to correct any problems NOTE Add oil to reservoir as required to keep air out of the system 6 Adjust the throttle...

Page 220: ...to keep it about 6 in off the ground Do not exceed loaded radius Slowly rotate the boom throughout the work area As the boom is rotated the boom will have to be raised and or lowered to maintain the l...

Page 221: ...80H 64 93 in 55 95 cm 55 95 in 142 cm 16 236 7 365 kg 17 090 lb 7 752 kg 690H 77 45 in 197 cm 60 08 in 153 cm 17 653 lb 8 007 kg 18 515 lb 8 398 kg 88 50 Ret 120 00 Mid 208 00 Ext Top of Truck Frame R...

Page 222: ...0 9 95 0 25 75 144 09 94 25 72 75 Top of Truck Frame Rail G H C L ROTATION 118 72 21 00 Above weights do not include RSOD PTO pump bed and SFO G H Dry Weight W Oil Weight 671H 95 90 in 244 cm 51 25 in...

Page 223: ...k Frame Rail 53 06 96 00 39 84 Radius Tail Swing 18 9 16 Ret 84 ft Ext 80 9 95 0 26 38 146 14 90 36 119 77 Top of Truck Frame Rail C L ROTATION 73 69 44 42 CG 75 67 21 00 Above weights do not include...

Page 224: ...al 378 5 L at full mark System capacity 125 gal 473 L Filtration 5 Micron Return Flow rates listed are at free flow condition approx 100 psi 1 MPa Crane Operating Speeds Rotation 375 35 5 sec 1 8 0 2...

Page 225: ...c 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 75 10 sec Retract 125 10 sec Boom Extend Retract Five...

Page 226: ...CRANE INSTALLATION 600H SERVICE 9 44 08 19 2022 Control 092 13 THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 227: ...19 2022 Control 092 13 10 1 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 R E...

Page 228: ...SCHEMATICS 600H SERVICE MANUAL 10 2 08 19 2022 Control 092 13 THIS PAGE BLANK R E F E R E N C E O N L Y...

Page 229: ...t Assembled Boom 4 15 General Adjustment And Repair Procedures 2 4 General Maintenance 1 4 Hoist Installation 5 1 Hoist Removal 4 3 Hoist Removal 5 1 Hydraulic Oil Reservoir Level 8 9 Hydraulic System...

Page 230: ...Specifications 9 42 Stability Test 9 38 Swing Description 6 1 Swing Gearbox And Brake 6 1 Telescope Cylinder Repair 4 25 Theory of Operation 6 1 Three Section Boom Assembly 4 6 Three Section Boom Mai...

Page 231: ...R E F E R E N C E O N L Y...

Page 232: ...R E F E R E N C E O N L Y...

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