NC600E2 SM CTRL114 09 Prop65 2019

National Crane 600E-2
Service Manual
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THIS PAGE BLANK
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SERVICE MANUAL
This Manual has been prepared for and is considered part of -
600E2
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This Manual is Divided into the following Sections:
SECTION 1
SECTION 2
INTRODUCTION
HYDRAULIC SYSTEM 3
SECTION 3 ELECTRIC SYSTEM
SECTION 4 BOOM
SECTION 5 HOIST
SECTION 6 SWING
SECTION 7 LUBRICATION
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SECTION 8 TROUBLESHOOTING
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SECTION 9 CRANE INSTALLATION
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NOTICE
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The crane serial number is the only method your distributor or the factory has of providing you with correct parts and service
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information.
The crane serial number is identified on the builder’s decal attached to the crane frame. Always furnish crane serial number
when ordering parts or communicating service problems with your distributor or the factory.
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! DANGER
An untrained operator subjects himself and others to death or
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serious injury. Do not operate this crane unless:
• You are trained in the safe operation of this crane. National Crane is
not responsible for qualifying personnel.
• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
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load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are
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in place and in proper condition.
The Operator Manual and Load Chart are in the holder provided on
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crane.
© 2019 Grove U.S. L.L.C.

Published 05-14-2019 Control # 114-09
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WARNING
California Proposition 65
Breathing diesel engine exhaust exposes you
to chemicals known to the State of California
to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an enclosed area, vent the exhaust to
the outside.
• Do not modify or tamper with the exhaust
system.
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• Do not idle the engine except as
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For
necessary.
more information, go to
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www.P65warnings.ca.gov/diesel
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Batteries, battery posts, terminals, and

related accessories can expose you to
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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. F or more i n f o r ma t i o n , g o t o
www.P65warnings.ca.gov
California Spark Arrestor
Operation of this equipment may create
sparks that can start fires around dry
vegetation. A spark arrestor may be required.
The owner/operator should contact local fire
agencies for laws or regulations relating to fire
prevention requirements.
The original language of this publication is English.

SERVICE MANUAL 600E2 TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Jump Starting Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Connectors, Harnesses, Wires, and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
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Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
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Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
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Fasteners and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
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Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
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Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Precautions and Recommendations During Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Wire Rope Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Care of Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Boom Extension and Retraction Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Wire Rope Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Adjustment and Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hydraulic System Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Label Parts when Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Removing Air From the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Oil Cooler Service and Maintenance (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Servicing the Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Disassembly and Reassembly of Control Valves to Replace Seals . . . . . . . . . . . . . . . . 2-5
Replacing Spool Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Unloader Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Control Valve Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
National Crane TOC-1

TABLE OF CONTENTS SERVICE MANUAL 600E2
SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System

Anti-two Block System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Anti-two Block Internal Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Three Section Boom ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4 Section Boom ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
2/3/4 Stage anti-two block Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Anti-two block Internal Wire System: Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
1/2 Stage Anti-two Block Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Disassembly Of 1/2 Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
2/3/4 Stage Anti-two Block Wire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Replacement Of Proportioning Cable For 1/2 Stage Of Anti-two Block Wire. . . . . . . . . . . . 3-12
1/2 Stage Anti-Two Block Wire Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
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1/2 Stage Anti-Two Block Wire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
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Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
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Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
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HCA Maintenance & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HCA System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
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JIB Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Single Character Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Jib Load Limiting Device Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
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Outrigger Monitoring System (OMS) (Optional—Standard in North America) . . . . . . . . . . . 3-17
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Danger Remote Start Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Troubleshooting, Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Radio Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Quick Test for Receiver Antenna and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Special Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Three Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Three Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hoist Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Disassembly Alternative #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
TOC-2
Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Additional Maintenance, Disassembled Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Three Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Three Section Top/Bottom Pad Replacement (Assembled Boom). . . . . . . . . . . . . . . . . 4-7
Top Rear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Front Bottom Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Inner Wear Pad Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Four Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Four Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Four Section Cable Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Four Section Boom Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Four Section Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Boom Disassembly Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Four Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Four Section Top/bottom Pad Replacement Assembled Boom . . . . . . . . . . . . . . . . . . . . . 4-14
Top Rear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Front Bottom Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Cable Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
y e
Cable Tensioning Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
ef or
Cable Tension Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
nl c 4- Section Boom w/ 2 Stage Cylinder Cable Positioning . . . . . . . . . . . . . . . . . . . . . . . 4-17

4- Section Boom w/ 1 Stage Cylinder Cable Positioning . . . . . . . . . . . . . . . . . . . . . . . 4-18
O en
3- Section Boom w/ 1 Stage Cylinder Cable Positioning . . . . . . . . . . . . . . . . . . . . . . . 4-19
R F
Cable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
er
Extend Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Extend Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Extend Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist
Hoist Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Disassembly and Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tulsa Swing Drive Assembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Rotation Stop-mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Rotation Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Torquing Swing Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Slew Potentiometer Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Arctic Conditions Below 0°F (-18°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Chassis Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Extreme Pressure Multipurpose Gear Lubricant (EPGL) . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Open Gear Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Chassis Grease Low Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Anti-wear Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Standard Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Intermediate Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
y e
Wide Range Intermediate Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ef or
Arctic Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
nl c
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
O en
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
R F
Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Side and Bottom Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hoist Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
er
Maintenance Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Oil Level Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Hoist Brake Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Hoist Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Carwell© Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Protecting Cranes from Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
SECTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting
Hydraulic System Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Systematic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HCA Troubleshooting Flow Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Installation

Crane to Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Minimum truck Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Mounting Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Configuration 1 - 600E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Configuration 2 - 600E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Configuration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TOC-4
TM Rear Stow - 647E2, 638E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Configuration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
TM Front Stow - 647E2, 638E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Configuration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Rear Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Tractor Trailer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
PTO Horsepower Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Direct Mount Pump to PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Truck Frame Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Channel (Table A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Channel Reinforcement (Table A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Angle Reinforcement (Table B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Fish Plate Reinforcement (Table C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Angle Under Reinforcement (Table D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Requirements For Optional Single Front Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Truck Frame Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
y e
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
ef or
Positioning Crane On Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
nl c
PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
O en
Reinforcing/after Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
R F
After Frame Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

Crane Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Crane Component Installation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
er
Torsion Box and ASH Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Install Torsion Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Mount the Turret and Torsion Box to the Frame Assembly . . . . . . . . . . . . . . . . . . . . . 9-23
Turret Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Torsion Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Mount the Outrigger Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
ASH to Torsion Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Assemble the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Hydraulic Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Wire Rope Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Hoist to Truck Cab Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Pin Bearing Inspection And Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Pin Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Trunnion Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Counterweighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Counterweighting Determination Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Counterweighting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Counterweighting Methods for Stability Around the Rear 180°. . . . . . . . . . . . . . . . . . . 9-34
Boom Rest Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
CAN BUS System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
CAN Bus System using Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
CAN Bus System using Programming Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

Initial Crane Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39

Stability Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
HCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Hoist Speed and Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Crane Operating Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
SECTION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Schematics
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TOC-6
600E2 SERVICE MANUAL INTRODUCTION
SECTION 1
1
INTRODUCTION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Fatigue of Welded Structures. . . . . . . . . . . . . . . . . 1-6
Supplemental Information . . . . . . . . . . . . . . . . . . . 1-1 Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fasteners and Torque Values . . . . . . . . . . . . . . . . 1-7
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-2
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Removal and Installation . . . . . . . . . . . . . . . . . . . 1-3 Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Disassembly and Assembly . . . . . . . . . . . . . . . . . 1-3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Environmental Conditions . . . . . . . . . . . . . . . . . . 1-20
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . 1-20
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Precautions and Recommendations
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Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
During Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 1-21
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Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
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Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
1-5
Wire Rope Replacement . . . . . . . . . . . . . . . . . . . 1-22
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Care of Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Jump Starting Hazard . . . . . . . . . . . . . . . . . . . . . . 1-5
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Boom Extension and Retraction Cables . . . . . . . 1-23

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . 1-5
Wire Rope Replacement (All Wire Rope) . . . . . . 1-23
Connectors, Harnesses, Wires, and
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-23
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Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
GENERAL Constant improvement and engineering progress makes it

necessary that we reserve the right to make specification
This manual has been compiled to assist you in properly and equipment changes without notice.
operating and maintaining your Model 600E2 Series National Crane and our distributor network want to ensure
National Crane. your satisfaction with our products and customer support.
Before placing the crane in to service, all operators and Yo u r l o c a l d i s t r i b u t o r i s b e s t e q u i p p e d a n d m o s t
persons working around the crane must thoroughly read and knowledgeable to assist you for parts, service and warranty
understand the contents of the Operators Handbook issues. They have the facilities, parts, factory trained
pertaining to Safety, Operation and Maintenance. Before personnel, and the information to assist you in a timely
moving a vehicle equipped with the crane, information manner. We request that you first contact them for
relating to transporting the vehicle must be read and assistance. If you feel you need factory assistance, please
observed. ask the distributor’s service management to coordinate the
contact on your behalf.
This manual must be retained with the machine for use by
subsequent operating personnel. Supplemental Information
Information in this manual does not replace federal, state or Supplemental Information regarding Safety & Operation,
local regulations, safety codes or insurance requirements Specifications, Service & Maintenance, Installation, and
This National Crane has been designed for maximum parts for options such as remote controls, augers, varying
performance with minimum maintenance. With proper care, control configurations, baskets, grapples, etc. is included in
years of trouble-free service can be expected. separate sections of this manual, if applicable.
National Crane Published 05-14-2019 Control # 114-09 1-1

INTRODUCTION 600E2 SERVICE MANUAL
Whenever a question arises regarding your National Crane New Owner

product or this publication, please consult your National
Crane distributor for the latest information. Your National If you are the new owner of a National crane, please register
Crane distributor is equipped with the proper tools, it with Manitowoc Crane Care so we have the ability to
necessary parts, and trained personnel to properly maintain contact you if the need arises.
and service your equipment. G o t o h t t p s : / / w w w. m a n i t o w o c c r a n e s . c o m / e n /
A Safety Compact Disc or a USB flash drive which includes Parts_Services/ServiceAndSupport/
sections on Operation, Service and a Safety Video for ChangeOfOwnershipForm and complete the form.
National Crane operators and owners is supplied when the
equipment is purchased new. Additional copies are available
from your local distributor.
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600E2 Series Major Components
Item Component Item Component

1 Hoist 5 Stabilizers
2 Boom 6 Hydraulic Reservoir
3 Sheaves 7 Control Console
4 Boom Rest 8 Outriggers
GENERAL MAINTENANCE • Conduct checks in a logical order to determine the

cause.
The suggestions listed below are helpful in analyzing and
• Consider the remaining service life of components
correcting problems:
against the cost of parts and labor to replace them.
• Determine the problem.
• Make the repair.
• List possible causes.
• Test the equipment to ensure the problem is fixed.
• Devise checks.
NOTE: Safety is the number one consideration when
working around machines. Safety is a matter of
1-2 Published 05-14-2019 Control # 114-09

understanding the job to be done and the application various adjustments by operating the machine before
of good common sense. It is not just a list of do’s and returning it to the job. 1
don’ts. Stay clear of all moving parts.
Pressing Parts
Cleanliness
When one part is pressed into another, use an anti-seize
Cleanliness is important in preserving the life of the machine. compound or a molybdenum disulfide base compound to
Keep dirt out of working parts and compartments. Keep lubricate the mating surfaces.
filters and seals clean. Whenever hydraulic, fuel, lubricating
oil lines, or air lines are disconnected, clean the adjacent Assemble tapered parts dry. Before assembling parts with
area as well as the point of disconnect. Cap and plug each tapered splines, be sure the splines are clean, dry, and free
line or opening to prevent entry of foreign material. from burrs. Position the parts together by hand to mesh the
splines before applying pressure.
Clean and inspect all parts. Be sure all passages and holes
are open. Cover all parts to keep them clean. Be sure parts Parts which are fitted together with tapered splines are
are clean when they are installed. Leave new parts in their always very tight. If they are not tight, inspect the tapered
containers until ready for assembly. Clean the rust splines and discard the part if the splines are worn.
preventive compound from all machined surfaces of new
parts before installing them.
Locks
Lock washers, flat metal locks, or cotter pins are used to lock
Removal and Installation nuts and bolts. For flat metal locks, bend one end of the lock
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around the edge of the part and the other end against one
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Do not attempt to manually lift heavy parts that require flat surface of the nut or bolt head.
position.
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hoisting equipment. Do not put heavy parts in an unstable
Always use new locking devices on components which have
moving parts.
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When raising a portion or a complete crane, ensure the
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weight is supported by blocks rather than by lifting Use a steel flat washer between aluminum housings and
equipment. lock washers.
When using hoisting equipment, follow the hoist Shims
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manufacturers recommendations. Use lifting devices that
achieve the proper balance of the assemblies being lifted. When shims are removed, tie them together and identify
Unless otherwise specified, use an adjustable lifting them as to location. Keep shims clean and flat until they are
attachment for all removals requiring hoisting equipment. reinstalled.
Some removals require the use of lifting fixtures to obtain
proper balance. Bearings
All supporting members (chains and cables) need to be Anti-friction Bearings
parallel to each other and as near perpendicular as possible
to the top of the object being lifted. When an anti-friction bearing is removed, cover it to keep out
dirt and abrasives. Wash bearings in non-flammable
cleaning solution and allow them to drain dry. The bearing
CAUTION may be dried with compressed air BUT do not spin the
The capacity of an eyebolt diminishes as the angle bearing. Discard the bearings if the races and balls or rollers
between the supporting members and the object are pitted, scored, or burned. If the bearing is serviceable,
becomes less than 90°. Eyebolts and brackets should coat it with oil and wrap it in clean waxed paper. Do not
never be bent and should only have stress in tension. unwrap new bearings until time of installation. The life of an
anti-friction bearing is shortened if not properly lubricated.
If a part resists removal, check to be sure all nuts and bolts Dirt can cause an anti-friction bearing to lock and result in the
have been removed and that an adjacent part is not shaft turning in the inner race or the outer race turning within
interfering. the cage.
Disassembly and Assembly Double Row, Tapered Roller
Complete each step in turn when disassembling and Double row, tapered roller bearings are precision fit during
assembling a component. Do not partially assemble one part manufacture and components are not interchangeable. The
and start assembling some other part. Make all adjustments cups, cones, and spacers are etched with the same serial
as recommended. Always check the job after it is complete number and letter designator. If no letter designators are
to see that nothing has been overlooked. Recheck the found, wire the components together to assure correct

installation. Reusable bearing components should be up, and leaks. Do a monthly or 250 hour inspection for the
installed in their original positions. items listed in the inspection procedure below.
Heating Bearings Valves and Manifolds

Bearings which require expansion for installation should be Inspect valves and manifolds for leaking ports or sections.
heated in oil not to exceed 250 °F (121 °C). When more than Hoses and Fittings
one part is heated to aid in assembly, they must be allowed
to cool and then pressed together again. Parts often Inspect all hoses and fittings for the following:
separate as they cool and contract.
• Cut, kinked, crushed, flattened, or twisted hoses.
Installation • Leaking hoses or fittings.
Lubricate new or used bearings before installation. Bearings • Cracked, blistered, or hoses charred by heat.
that are to be preloaded must have a film of oil over the entire
assembly to obtain accurate preloading. When installing a • Damaged or corroded fittings.
bearing, spacer, or washer against a shoulder on a shaft, be • Fitting slippage on hoses.
sure the chamfered side is toward the shoulder.
If any the above conditions exist, evaluate and replace as
When bearings are pressed into a retainer or bore, apply
necessary.
pressure to the outer race uniformly. If the bearing is pressed
on the shaft, apply pressure on the inner race uniformly. The climate in which the crane operates affects the service
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life of the hydraulic components. The climate zones are
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Preload d e f i n e d i n t h e t a b l e o n p a g e 1 -5 . R e c o m m e n d e d
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Preload is an initial load placed on the bearing at the time of
a s s e m b l y. C o n s u l t t h e d i s a s s e m b l y a n d a s s e m b l y
replacement of hoses is as follows:
• Climate zone C after 8,000 hours of service.
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instructions to determine if the bearing can be preloaded.
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• Climate zones A and C with high ambient temperatures

Be careful in applying preload to bearings requiring end and duty cycles after 4000 to 5000 hours of service.
clearance. Otherwise, bearing failure may result.
• Climate zones D and E after 4000 to 5000 hours of
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Sleeve Bearings service.
Do not install sleeve bearings with a hammer. Use a press Cleanliness
and be sure to apply the pressure directly in line with the
bore. If it is necessary to drive on a bearing, use a bearing Contaminants in a hydraulic system affects operation and
driver or a bar with a smooth flat end. If a sleeve bearing has results in serious damage to the system components.
an oil hole, align it with the oil hole in the mating part.
Keep the System Clean
Gaskets When removing components of a hydraulic system, cover all
openings on both the component and the crane.
Be sure the holes in the gaskets correspond with the
lubricant passages in the mating parts. If it is necessary to If evidence of foreign particles is found in the hydraulic
make gaskets, select material of the proper type and system, flush the system.
thickness. Be sure to cut holes in the right places. Blank
gaskets can cause serious damage. Disassemble and assemble hydraulic components on a
clean surface.
Hydraulic Systems Clean all metal parts in a nonflammable cleaning fluid. Then
lubricate all components to aid in assembly.
! DANGER Sealing Elements

Pressurized hydraulic fluid can cause serious injury. Inspect all sealing elements (O-ring, gaskets, etc.) when
Depressurize the hydraulic system before loosening disassembling and assembling the hydraulic system
fittings. components. Installation of new elements is recommended.
Visual Inspection Hydraulic Lines

Do a visual inspection daily on all hydraulic components for When disconnecting hoses, tag each one to ensure proper
missing hose clamps, shields, guards, excessive dirt build identification during assembly.

When installing metal tubes, tighten all bolts finger-tight. and transmission control) that are highly susceptible to
Then, in order, tighten the bolts at the rigid end, the voltage/amperage surges in the electrical system. 1
adjustable end, and the mounting brackets. After tubes are
The batteries should be completely disconnected from the
mounted, install the hoses. Connect both ends of the hose
crane electrical system and charged using a battery charger
with all bolts finger-tight. Position the hose so it does not rub
of appropriate voltage level or replace the batteries with fully
the machine or another hose and has a minimum of bending
charged batteries. Refer to Charging the Battery, page 1-5.
and twisting. Tighten bolts in both couplings.
Due to manufacturing methods there is a natural curvature to Charging the Battery
a hydraulic hose. Reinstall the hose so any bend is with this
When charging the batteries, do not turn on the battery
curvature.
charger until the charging leads have been connected to the
battery(s). Also, if the battery(s) are found to be frozen, do
ELECTRICAL not attempt to charge them. Remove the battery(s) from the
crane, allow them to thaw, and then charge the battery(s) to
Batteries full capacity.
Clean the batteries with a solution of baking soda and water. “Slow charging” is preferred to “fast charging”. Fast charging
Rinse with clear water and dry. Clean the battery terminals saves time but risks overheating the battery(s). Slow
with fine sandpaper and coat the terminals with dielectric charging at six (6) amps or less develops less heat inside the
grease. Do not use a non-dielectric grease. battery and breaks up the sulfate on the battery plates more
efficiently to bring the battery up to full charge. The use of a
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Remove the batteries if the machine is not used for an
“smart charger” that automatically adjusts the charging
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extended period of time. Store the batteries in a warm, dry
amperage rate should be used.
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place, preferably on wooden shelves. Never store on
concrete. A small charge should be introduced periodically to
Connectors, Harnesses, Wires, and
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keep the specific gravity rating at recommended level.
Connectors
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CAUTION Visually inspect all electrical harnesses, cables, and

Disconnect batteries prior to working on the electrical connectors every month or 250 hours for the following:
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system.
• Damaged, cut, blistered, or cracked insulation.
When disconnecting wires, tag each one to ensure proper • Exposed bare wires.
identification during reassembly.
• Kinked or crushed wires and cables.
Jump Starting Hazard • Cracked or corroded connectors, battery terminals, and
ground connections.
Do not attempt to jump start the crane.
If any the above conditions exist, evaluate and replace as
necessary.
CAUTION The climate in which the crane operates affects the service
It is strongly recommended that the batteries not be life of the electrical components. The climate zones are
“jumped” with a different vehicle, portable power pack, d e f i n e d i n t h e t a b l e o n p a g e 1 -5 . R e c o m m e n d e d
etc. The surge of power from these sources can replacement of harness and cables is as follows:
irreparably damage the various electronic controls and
computer systems. Jump starting the crane batteries • Climate zone C after 10,000 hours of service.
with a different vehicle while the engine is running can • Climate zones A and C with high ambient temperatures
damage the donor vehicle electronics as well if done and duty cycles after 8000 hours of service.
improperly.
• Climate zones D and E after 10,000 hours of service.
All crane models, particularly those produced since 2000, • Salt water conditions after 8,000 hours of service.
have multiple computer systems (crane control, RCL, engine
.
Climate Zone Classification
Zone Classification
A (Tropical Moist) Latitude 15° - 25° North and South (All months average above 64° F [18° C])
B (Dry or Arid) Latitude 20° - 35° North and South (Deficient of precipitation most of the year)

Climate Zone Classification

Zone Classification
C (Moist Mid-Latitude) Latitude 30° - 50° North and South (Temperate with mild winters)
D (Moist Mid-Latitude) Latitude 50° - 70° North and South (Cold winters)
E (Polar) Latitude 60° - 75° North and South (Extremely cold winters and summers)
Dielectric Grease
Dielectric grease was applied to the following connections at
the factory when the crane was assembled. When servicing
electrical connections, dielectric grease must be re-applied
to these connections.
Rubber
• All Deutsch Connectors Seal
• All Valve Solenoid connections on Hydraulic valves and
Transmissions
• All Harness Connections
• RCL Module Connections (except M12 and M8
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connectors)
Excluded Connections
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Do not apply dielectric grease to the following connections:
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Terminal
• All Connections Inside the Cab Sockets
• M12 and M8 Connectors 9746
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• Pin-type Contacts Example. For illustration purposes FIGURE 1-1
only. Your connector may differ.
Applying Dielectric Grease to an Electrical Connector
4. Use a clean towel to remove excess grease from the
Use the following procedure to apply dielectric grease to an surface of the connector, and wipe grease into the
electrical connection. Grease should be applied immediately terminal sockets (Figure 1-1).
prior to securing the connector. Ensure that grease is applied
to all terminal sockets (Figure 1-1). 5. Ensure grease is applied to each terminal socket. The
towel with excess grease can be used to fill empty
1. Check the connection for moisture before application of terminal sockets (Figure 1-1).
the grease. If moisture is found, clean or replace the
connector as necessary. 6. Ensure grease is applied to the entire surface of the
connector’s rubber seal (Figure 1-1).
2. Screw a tip or trigger assembly on to the can of dielectric
grease if necessary. NOTE: Do not allow grease to come in contact with any
painted surface, or any other components.
3. Apply the grease onto socket (female) contacts.
7. If clean up is necessary, contact cleaner or petroleum
distillates can be used.
8. Secure the connector when complete.
FATIGUE OF WELDED STRUCTURES

Highly stressed welded structures are subject to cracking
(fatigue) when repeatedly subjected to varying stresses
caused by twisting, shock, bending, and overloads. Inspect
equipment periodically for weld fatigue. The frequency of
inspections depends on the age of the equipment, the
severity of the application, and the experience of the
operators and the maintenance personnel. The following are

known high stress areas and should be inspected as part of

a preventive maintenance program: Bead Application 1
• Hydraulic cylinder and boom pivot attaching points.
• Outrigger pads, beams, boxes and attachment
structures.
• On the frame in the area of doubler plates and
crossmembers. 4203
• Turntable bearing connection (where bearing is welded Bead Application
to the crane turret).
• Counterweight support structures (were applicable).
• Hydraulic cylinder end connections.
The above is provided only as a guide and your inspection
plan should not be limited to the areas listed. A visual
inspection of all weldments is good practice.
8213-2 8213-1
LOCTITE FIGURE 1-2
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1. Apply a bead perpendicular to the thread, several
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! threads wide, in the approximate area of threaded
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Loctite type adhesives contain chemicals that may be
engagement (see Figure 1-1).
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harmful if misused. Read and follow the instructions on 2. In a blind hole application, a bead of several drops of
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the container. adhesive should be applied into the bottom of the hole to
be hydraulically forced up during engagement.
Follow the directions on the Loctite container. There are 3. After application and engagement of mated threads,
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different Loctite types for different applications. The following fixturing will occur within five (5) minutes. Time required
types of Loctite brand adhesives are available from the parts to achieve full strength is 24 hours.
department of the local National Crane distributor.
Application of Medium Strength Loctite® FASTENERS AND TORQUE VALUES

NOTE: The fastener may be re-used; the adhesive may be Use bolts of the correct length. A bolt which is too long may
re-applied over cured adhesive residue. bottom before the head is tight against the part it is to hold. If
a bolt is too short, there may not be enough threads engaged
The following procedure covers the proper application and to hold the part securely. Threads can be damaged. Inspect
curing method for medium strength Loctite® adhesive/ them and replace fasteners, as necessary.
sealant (Loctite® #243).
Torque values should correspond to the type bolts, studs,
NOTE: Ensure the threaded surface, both male and and nuts being used.
female, is clean of contaminants and free of dirt
and oil. Adhesive/Sealant Application The torque tables are provided by National Crane for
reference when performing maintenance.
Use of proper torque values is extremely important. Improper
tightening can seriously affect performance and reliability.
Identification of fastener grade is always necessary. When
marked as a high strength bolt (grade 5, 8, etc.), the
mechanic must be aware that he/she is working with a highly
stressed component and the fastener should be tightened
accordingly.
NOTE: Some special applications require variation from
standard torque values. Reference should always
be made to component overhaul procedures for
recommendations.

Special attention should be given to the existence of improper tighteninq. ALWAYS use a slow, even movement
lubricant, plating, or other factors that might require variation and STOP when the predetermined value has been reached.
from standard torque values.
When using step wrenches, calculated wrench settings are
The use of lubricants on zinc-flake coated parts shall be valid only when the following conditions are met:
prohibited since this will change the required torque value.
• Torque wrenches must be those specified and forces
When maximum recommended torque values have been must be applied at the handle grip. The use of handle
exceeded, the fastener should be replaced. extensions will change applied torque to the bolt.
Previously installed bolts and nuts of Grade 8 or Class 10.9 • All handles must be parallel to the step wrench during
and higher may not be reused. final tightening. Multiplier reaction bars may be
misaligned no more than 30 degrees without causing
When referring to the applicable torque charts, use values as
serious error in torque.
close as possible to the torque values shown to allow for
wrench calibration tolerance. • Multiplier bar handles must be propped or supported
within the outer 1/4 of the handle length, or serious
Torque Wrenches under or over tightening will occur.
Flexible beam type wrenches, even though they might have To convert pounds-foot (lb-ft) of torque to Newton meters
a pre-set feature, must be pulled at right angle and the force (Nm), multiply the pounds-foot quantity by 1.3558.
must be applied at the center of the handle. Force value
readings must be made while the tool is in motion. Rigid To convert pounds-inch (lb-in) of torque to Newton meters
y e
handle type, with torque limiting devices that can be pre-set (Nm), multiply the pounds-inch quantity by 0.11298.
ef or
to required values, eliminate dial readings and provide more
nl c
reliable, less variable readings.
Torque Values
The following tables list the torque values for both ASME
O en
NOTE: If multipliers and/or special tools are used to reach
standard and metric fasteners. The tables list the values for
R F
hard to get at areas, ensure torque readings are

grade 5 and grade 8 zinc-flake coated, untreated (black)
accurate.
finish and stainless steel fasteners.
Torque wrenches are precision instruments and must be
NOTE:
er
handled with care. To ensure accuracy, calibrations must be
made on a scheduled basis. Whenever there is a possibility Torque Values
that a torque wrench may have been either overstressed or
The following tables list the torque values for both ASME
damaged, it should immediately be removed from service
standard and metric fasteners. The tables list the values for
until recalibrated. When using a torque wrench, any erratic or
grade 5 and grade 8 zinc-flake coated, untreated (black)
jerking motion can result in the application of excessive or
finish and stainless steel fasteners.
SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8

and Grade 2 HHCS HHCS HHCS
HHCS
Socket Head Socket Head Serrated

Capscrew Shoulder Flange Head
Screw
FIGURE 1-3

Table 1-1 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated 1
Nominal Size, Threads per Torque (ft/lb)
Inch, and Series Grade
Designation Maximum Nominal Minimum
5 6.6 6.4 6.2

1/4-20 UNC
8 9.3 9.0 8.8
5 13.5 13.2 12.8
5/16-18 UNC
8 19.1 18.6 18.1
5 24.0 23.4 22.8
3/8-16 UNC
8 33.9 33.1 32.2
5 38.4 37.4 36.5
7/16-14 UNC
8 54.3 52.9 51.5
5 58.6 57.1 55.7
1/2-13 UNC
8 82.8 80.7 78.6
y e
5 84.5 82.4 80.3
ef or
9/16-12 UNC
nl c 8
5
119.4
116.6
116.5
113.7
113.5
110.8
O en
5/8-11 UNC
R F
8 164.8 160.7 156.6

5 206.8 201.7 196.5
3/4-10 UNC
8 292.3 284.9 277.6
er
5 333.8 325.4 317.1
7/8-9 UNC
8 471.6 459.8 448.0
5 500.3 487.8 475.3
1-8 UNC
8 707.0 689.3 671.6
5 624.0 608.4 592.8
1 1/8-7 UNC
8 1001.4 976.4 951.4
5 880.5 858.5 836.5
1 1/4-7 UNC
8 1413.1 1377.8 1342.5
5 1154.5 1125.6 1096.7
1 3/8-6 UNC
8 1852.8 1806.5 1760.2
5 1532.0 1493.7 1455.4
1 1/2-6 UNC
8 2458.8 2397.3 2335.8
Table 1-2 Inch Series with Fine Threads (UNF) – Zinc Flake Coated
5 7.5 7.3 7.1

1/4-28 UNF
8 10.6 10.4 10.1

Table 1-2 Inch Series with Fine Threads (UNF) – Zinc Flake Coated (Continued)
5 15.0 14.6 14.2

5/16-24 UNF
8 21.1 20.6 20.1
5 27.2 26.5 25.8
3/8-24 UNF
8 38.4 37.5 36.5
5 42.9 41.8 40.7
7/16-20 UNF
8 60.6 59.1 57.6
5 66.0 64.4 62.7
1/2-20 UNF
8 93.3 90.9 88.6
5 94.3 91.9 89.6
9/16-18 UNF
8 133.2 129.9 126.6
5 132.1 128.8 125.5
y e
5/8-18 UNF
ef or
8 186.7 182.0 177.3
nl c
3/4-16 UNF
5
8
231.0
326.4
225.2
318.2
219.4
310.1
O en
R F
5 367.7 358.5 349.3

7/8-14 UNF
8 519.6 506.6 493.6
5 547.4 533.7 520.0
er
1-12 UNF
8 773.5 754.2 734.8
5 700.0 682.5 665.0
1 1/8-12 UNF
8 1123.5 1095.4 1067.3
5 975.0 950.6 926.2
1 1/4-12 UNF
8 1564.8 1525.7 1486.5
5 1314.4 1281.5 1248.6
1 3/8-12 UNF
8 2109.5 2056.7 2004.0
5 1723.9 1680.8 1637.7
1 1/2-12 UNF
8 2766.8 2697.6 2628.4
Table 1-3 Metric Series with Coarse Threads – Zinc Flake Coated
Nominal Size, Threads per Torque (Nm)
Property
millimeter, and Series
Class Maximum Nominal Minimum
Designation
10.9 3.6 3.5 3.4
M4x0.7
12.9 4.2 4.1 4.0
10.9 7.2 7.0 6.8
M5x0.8
12.9 8.4 8.2 8.0

Table 1-3 Metric Series with Coarse Threads – Zinc Flake Coated (Continued)
1
Property
Designation
8.8 8.3 8.1 7.9
M6x1.0 10.9 12.2 11.9 11.6
12.9 14.3 13.9 13.6
8.8 20.2 19.7 19.2
M8x1.25 10.9 29.6 28.9 28.2
12.9 34.7 33.8 33.0
8.8 40.0 39.0 38.0
M10x1.5 10.9 58.7 57.2 55.8
12.9 68.7 67.0 65.3
8.8 69.7 68.0 66.2
M12x1.75 10.9 102.4 99.8 97.2
y e
ef or
12.9 119.8 116.8 113.8
nl c
M14x2
8.8
10.9
111.4
163.6
108.6
159.5
105.8
155.4
O en
R F
12.9 191.5 186.7 181.9

8.8 172.8 168.5 164.1
M16x2 10.9 253.8 247.4 241.1
er
12.9 296.9 289.5 282.1
8.8 246.2 240.1 233.9
M18x2.5 10.9 350.7 341.9 333.2
12.9 410.4 400.1 389.9
8.8 348.0 339.3 330.6
M20x2.5 10.9 495.6 483.2 470.8
12.9 580.0 565.5 551.0
8.8 474.4 462.6 450.7
M22x2.5 10.9 675.7 658.8 641.9
12.9 790.7 770.9 751.2
8.8 601.3 586.3 571.3
M24x3 10.9 856.4 835.0 813.6
12.9 1002.2 977.1 952.1
8.8 881.6 859.6 837.5
M27x3 10.9 1255.7 1224.3 1192.9
12.9 1469.4 1432.7 1395.9
8.8 1195.3 1165.5 1135.6
M30x3.5 10.9 1702.5 1659.9 1617.3
12.9 1992.3 1942.4 1892.6

Table 1-3 Metric Series with Coarse Threads – Zinc Flake Coated (Continued)
Property
Designation
8.8 2089.8 2037.6 1985.3
M36x4 10.9 2976.4 2902.0 2827.6
12.9 3483.0 3395.9 3308.9
Table 1-4 Metric Series with Fine Threads – Zinc Flake Coated
Property
Designation
8.8 21.6 21.1 20.5
M8x1.0 10.9 31.7 30.9 30.1
12.9 37.1 36.2 35.3
y e
8.8 46.8 45.6 44.4
ef or
M10x.75 10.9 68.7 67.0 65.3
nl c 12.9 80.4 78.4 76.4

O en
8.8 42.2 41.1 40.1
R F
M10x1.25 10.9 62.0 60.4 58.9

12.9 72.5 70.7 68.9
er
8.8 79.5 77.5 75.5
M12x1.0 10.9 116.7 113.8 110.9
12.9 136.6 133.2 129.8
8.8 76.2 74.2 72.3
M12x1.25 10.9 111.8 109.0 106.3
12.9 130.9 127.6 124.3
8.8 72.9 71.1 69.2
M12x1.5 10.9 107.1 104.4 101.7
12.9 125.3 122.1 119.0
8.8 120.2 117.2 114.2
M14x1.5 10.9 176.5 172.1 167.7
12.9 206.6 201.4 196.2
8.8 184.4 179.8 175.2
M16x1.5 10.9 270.9 264.1 257.3
12.9 317.0 309.1 301.2
8.8 276.6 269.7 262.8
M18x1.5 10.9 394.0 384.2 374.3
12.9 461.1 449.6 438.0

Table 1-4 Metric Series with Fine Threads – Zinc Flake Coated (Continued)
1
Property
Designation
8.8 405.7 395.5 385.4
M20x1 10.9 577.8 563.3 548.9
12.9 676.1 659.2 642.3
8.8 386.0 376.3 366.7
M20x1.5 10.9 549.7 535.9 522.2
12.9 643.3 627.2 611.1
8.8 520.8 507.8 494.8
M22x1.5 10.9 741.7 723.2 704.7
12.9 868.0 846.3 824.6
8.8 655.8 639.4 623.0
M24x2 10.9 934.0 910.6 887.3
y e
ef or
12.9 1092.9 1065.6 1038.3
nl c
M27x2
8.8
10.9
951.4
1355.0
927.6
1321.1
903.8
1287.2
O en
R F
12.9 1585.6 1546.0 1506.3

8.8 1369.2 1334.9 1300.7
M30x1.5 10.9 1950.0 1901.3 1852.5
er
12.9 2281.9 2224.9 2167.8
8.8 1324.6 1291.5 1258.4
M30x2 10.9 1886.6 1839.4 1792.2
12.9 2207.7 2152.5 2097.3
8.8 1784.5 1739.9 1695.3
M33x2 10.9 2541.6 2478.0 2414.5
12.9 2974.2 2899.8 2825.4
8.8 2340.1 2281.6 2223.1
M36x2 10.9 3332.8 3249.5 3166.2
12.9 3900.2 3802.6 3705.1
Table 1-5 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads
Size Torque (Nm)
M2.5x0.45 0.4
M3x0.5 0.9
M4x0.7 1.5
M5x0.8 3.1
M6x1 5.3

Table 1-5 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads (Continued)
Size Torque (Nm)
M8x1.25 13
M10x1.5 27
Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength.
Stainless steel fasteners tend to gall while being tightened. To reduce this risk, lubricate the threads and torque at low speeds
without interruptions. Do not use excessive pressure. Impact wrenches are not recommended.
Table 1-6 Inch Series Screws of STAINLESS STEEL 300 (18-8) with Coarse Threads
Torque
Size
lb-in lb-ft
#5-40 (0.125) 6.9 -
#6-32 (0.138) 9 -
#8-32 (0.164) 18 -
y e
#10-24 (0.190) 21 -
ef or
1/4-20 68 -
5/16-18
nl c 120 10
O en
3/8-16 210 17.5
R F
Torque Values for fasteners with lubrication these torque and preload values result in an 80% utilization of the yield strength.
Stainless steel fasteners tend to gall while being tightened. To reduce this risk, lubricate the threads and torque at low speeds
er
without interruptions. Do not use excessive pressure. Impact wrenches are not recommended.
Table 1-7 Inch Series Bearing Bolts – Untreated (black finish)

5/8-11 UNC 8 234 225 216

5/8-18 UNF 8 250 240 230
3/4-10 UNC 8 385 370 355
7/8-9 UNC 8 615 591 567
1-8 UNC 8 929 893 857
1 1/4-7 UNC 8 2043 1964 1885
Table 1-8 Metric Series Bearing Bolts– Untreated (black finish)

millimeter, and Series Class
M20X2.5 12.9 756 727 698

M24X3 10.9 1089 1047 1005
M24X3 12.9 1306 1256 1206
M27X3 10.9 1591 1530 1469

Table 1-9 Inch Series with Coarse Threads (UNC) – Untreated (black finish) 1
Torque (ft/lb)
Size Grade
Maximum Nominal Minimum
5 9.0 8.4 7.7
1/4-20
8 12.5 12 11.5
5 19 18 17
5/16-18
8 26 25 24
5 32 31 30
3/8-16
8 48 46 44
5 52 50 48
7/16-14
8 73 70 67
5 78 75 72
1/2-13
8 120 115 110
y e
5 114 110 106
ef or
9/16-12
8 161 152 143
nl c
5/8-11
5 156 150 144
O en
8 234 225 216
R F
5 270 259.5 249

3/4-10
8 385 370 355
er
5 416 400 384
7/8-9
8 615 591 567
5 606 583 560
1-8
8 929 893 857
5 813 782 751
1 1/8-7
8 1342 1288 1234
5 1141 1097 1053
1 1/4-7
8 2043 1964 1885
5 1519 1461 1403
1 3/8-6
8 2496 2396 2296
5 2028 1946.5 1865
1 1/2-6
8 3276 3150 3024
Table 1-10 Inch Series with Fine Threads (UNF) – Untreated (black finish)
Torque (ft/lb)
Size Grade
5 10 9.5 9
1/4-28
8 14.5 14 13.5

Table 1-10 Inch Series with Fine Threads (UNF) – Untreated (black finish) (Continued)
Torque (ft/lb)
Size Grade
5 21 20 19
5/16-24
8 26 25 24
5 36 35 34
3/8-24
8 53 51 49
5 57 55 53
7/16-20
8 85 82 79
5 88 84.5 81
1/2-20
8 125 120 115
5 126 121 116
9/16-18
8 177 170 163
5 182 174.5 167
5/8-18
y e
8 250 240 230
ef or
5 312 299.5 287
nl c
3/4-16
8 425 409 393
O en
5 458 439.5 421
R F
7/8-14
8 672 646 620
5 658 632 606
1-12
er
8 1009 970 931
5 670 644.5 619
1-14
8 945 908.5 872
5 882 848 814
1 1/8-12
8 1500 1440 1380
5 1251 1203 1155
1 1/4-12
8 2092 2008.5 1925
5 1704 1638 1572
1 3/8-12
8 2833 2719 2605
5 2288 2196.5 2105
1 1/2-12
8 3640 3500 3360
Table 1-11 Metric Series with Coarse Threads – Untreated (black finish)
Property Torque (Nm)

Size
8.8 3.1 2.9 2.8
M4x0.7 10.9 4.5 4.3 4.1
12.9 5.4 5.2 4.9

Table 1-11 Metric Series with Coarse Threads – Untreated (black finish) (Continued)

1
Size
8.8 6.5 6.2 5.9
M5x0.8 10.9 9.2 8.9 8.5
12.9 11 10.5 10
8.8 11 10.5 10
M6x1 10.9 16 15 14
12.9 19 18 17
8.8 27 26 25
M8x1.25 10.9 38 36.5 35
12.9 45 43.5 42
8.8 53 51 49
M10x1.5 10.9 75 72 69
y e
12.9 89 86 83
ef or
8.8 93 89 85
nl c
M12x1.75 10.9 130 125 120
O en
12.9 156 150 144
R F
8.8 148 142 136

M14x2 10.9 212 203.5 195
er
12.9 248 238 228
8.8 230 221 212
M16x2 10.9 322 310 298
12.9 387 372 357
8.8 319 306.5 294
M18x2.5 10.9 455 436.5 418
12.9 532 511 490
8.8 447 430 413
M20x2.5 10.9 629 605 581
12.9 756 727 698
8.8 608 585 562
M22x2.5 10.9 856 823 790
12.9 1029 989 949
8.8 774 744 714
M24x3 10.9 1089 1047 1005
12.9 1306 1256 1206
8.8 1134 1090 1046
M27x3 10.9 1591 1530 1469
12.9 1910 1836.5 1763

Table 1-11 Metric Series with Coarse Threads – Untreated (black finish) (Continued)

Size
8.8 1538 1479 1420
M30x3.5 10.9 2163 2080 1997
12.9 2595 2495 2395
8.8 2681 2578.5 2476
M36x4 10.9 3964 3812 3660
12.9 4639 4461 4283
Table 1-12Metric Series with Fine Threads – Untreated (black finish)

Size
8.8 29 28 27
y e
M8x1 10.9 41 39.5 38
ef or
nl c 12.9
8.8
49
57
47
55
45
53
O en
M10x0.75 10.9 81 78 75
R F
12.9 96 93 90
8.8 57 55 53
er
M10x1.25 10.9 81 78 75
12.9 96 93 90
8.8 101 97.5 94
M12x1 10.9 150 144 138
12.9 175 168 161
8.8 100 96 92
M12X1.25 10.9 147 141.5 136
12.9 172 165.5 159
8.8 100 96 92
M12x1.5* 10.9 140 135 130
12.9 168 162 156
8.8 160 153.5 147
M14x1.5 10.9 229 220 211
12.9 268 257 246
8.8 248 238.5 229
M16x1.5 10.9 348 335 322
12.9 418 402 386

Table 1-12Metric Series with Fine Threads – Untreated (black finish) (Continued)

1
Size
8.8 345 331.5 318
M18x1.5 10.9 491 471 451
12.9 575 552 529
8.8 471 453 435
M20X1 10.9 694 667.5 641
12.9 812 781 750
8.8 483 464.5 446
M20x1.5 10.9 679 653 627
12.9 816 785 754
8.8 657 632 607
M22x1.5 10.9 924 888.5 853
y e
12.9 1111 1068 1025
ef or
8.8 836 803.5 771
nl c
M24x2 10.9 1176 1130.5 1085
O en
12.9 1410 1356 1302
R F
8.8 1225 1171.5 1130

M27x2 10.9 1718 1652.5 1587
er
12.9 2063 1983.5 1904
8.8 1530 1471.5 1413
M30x1.5 10.9 2253 2166.5 2080
12.9 2637 2536 2435
8.8 1661 1597.5 1534
M30x2 10.9 2336 2246.5 2157
12.9 2800 2695 2590
8.8 2141 2059 1977
M33x2 10.9 3155 3034 2913
12.9 3692 3550.5 3409
8.8 2795 2688 2581
M36x2 10.9 4118 3960 3802
12.9 4818 4634 4450
Table 1-13: Weld Stud Torque Values
WELD STUDS
Unless otherwise specified the following grade 2 torque
values (+/- 10%) apply.
T-2-4

WIRE ROPE Dynamic Shock Loads

General Subjecting wire rope to abnormal loads shortens the ropes
life expectancy. Examples of this type of loading are as
The following information includes inspection, replacement, follows:
and maintenance guidelines for wire rope as established by • High velocity movement followed by abrupt stops
ANSI/ASME B30.5, federal regulations, and National (hoisting or swinging of a load).
Manitowoc specifications. The inspection interval shall be
determined by a qualified person and shall be based on • Suspending loads while traveling over irregular surfaces
expected rope life as determined by experience, severity of such as railroad tracks, potholes, and rough terrain.
environment, percentage of capacity lifts, frequency of • Moving a load that is beyond the cranes rated capacity.
operation, and exposure to shock loads. Periodic inspections
need not be at equal calendar intervals and should be Lubrication
performed at shorter time intervals as the wire rope
approaches the end of its useful life. A periodic inspection The object of rope lubrication is to reduce internal friction and
shall be performed at least once a year. The following to prevent corrosion. New lubricant needs be added
i n f o r m a t i o n c o n ta i n s i n s p e c t i o n a n d m a i n t e n a n c e throughout the life of the rope. It is important that lubricant
procedures for wire ropes used on National products as load applied needs to be compatible with the original lubricant.
lines, hoisting cables, boom extension and retraction cables, Consult the rope manufacturer for proper lubricant. The
pendant cables, and hook block tie down cables. lubricant applied shall be of the type which does not hinder
y e
visual inspection. Those sections of rope which are located
Any deterioration observed in the wire rope should be noted
ef or
over sheaves or otherwise hidden during inspection require
in the equipment inspection log and an assessment
nl c
concerning wire rope replacement should be made by a
qualified person.
special attention when lubricating rope.
During fabrication, ropes receive lubrication which provides
O en
the rope with protection for a reasonable time if stored under
R F
Keeping Records proper conditions. After the rope is put into service, periodic
applications of a suitable rope lubricant are required. The
A signed and dated report of the wire rope’s condition at wire rope lubricant should have the following characteristics:
each periodic inspection must be kept on file at all times. The
er
report must cover all inspection points listed in this section. • Be free from acids and alkalis and should have sufficient
The information in the records can then be used to establish adhesive strength to remain on the ropes.
data which can be used to determine when a wire rope • Be of a viscosity capable of penetrating the interstices
should be replaced. between wires and strands.
It is recommended that the wire rope inspection program • Not be soluble in the medium surrounding it under the
include reports on the examination of wire rope removed actual operating conditions (i.e. water).
from service. This information can be used to establish a
relationship between visual inspection and the rope’s actual • Have a high film strength.
internal condition at the time of removal from service. • Resist oxidation.
Environmental Conditions Remove dirt from the rope before applying lubrication. Use a
stiff wire brush and solvent, compressed air, or live steam to
The life expectancy of wire rope may vary due to the degree clean the rope. Lubricate the rope immediately after
of environmental hostility. Variation in temperature, cleaning. Methods of lubrication are bath, dripping, pouring,
continuous excessive moisture levels, exposure to corrosive swabbing, painting, or pressure spray (Figure 1-4). Apply the
chemicals or vapors, or subjecting the wire rope to abrasive lubricant at the top bend in the rope because at that point the
material can shorten wire rope life. Frequent inspections and strands are spread and more easily penetrated. Do not
maintenance of the wire rope is recommended for preventing lubricate a loaded rope. The service life of wire rope is
premature wear and to insure long-term performance. directly proportional to the amount of lubricant reaching the
working parts of the rope.

FIGURE 1-4
Precautions and Recommendations During • Significant corrosion.

Inspection • Broken or cut strands.
• Always use safety glasses for eye protection. • Number, distribution and type of visible broken wires.
y e
• Wear protective clothing, gloves, and safety shoes as • Core failure in rotation resistant ropes.
ef or
appropriate.
nl c
• Measure the rope’s diameter across crowns of the
• Prior electrical contact with a power line or other electric
arc damage.
O en
strands when determining if rope has become damaged,
refer to Figure 1-5. • Significantly corroded, cracked, bent, or worn end
R F
connections.
Only inspect the outer surface of a cable. Never attempt to
open the cable.
er
Pay particular attention to areas of the rope where wear and

other damage is likely to occur:
• Pick-up Points: Sections of wire rope that are repeatedly
stressed during each lift, such as those sections in
contact with sheaves.
1 • End Attachments: The point where a fitting is attached to

the wire rope or the point where the wire rope is attached
to the hoist drum.
A925
• Abuse Points: The point where the wire rope is
FIGURE 1-5 subjected to abnormal scuffing and scraping.
Inspection Daily Inspections

All cable in continuous service must be inspected at the
All hoist cable in service needs to be inspected on a daily,
beginning of each work day. Inspect the eye end and length
monthly, and quarterly basis. Cable which has been idle for a
of cable that is used in daily operation. The end should be
period of a month or more must be given a thorough
inspected for abrasion, corrosion, broken wires, and loose or
inspection before it is placed in service. These inspections
broken servings. Inspect the remainder of the cable length
should cover all types of deterioration including:
used for daily operations for points showing kinks, sharp
• Distortion such as kinking, crushing, un-stranding, bird bends, or any other evidences of damage or excessive wear.
caging, main strand displacement or core protrusion.
Monthly Inspections
• Loss of cable diameter in a short cable length or
unevenness of outer strands indicates the cable needs Inspect the eye end and length of cable normally used in
to be replaced. daily operations. Examine the rest of the cable for kinked,
crushed or otherwise damaged points.

Periodic Inspections
Wire rope should be inspected periodically/annually, or at a
shorter time interval, if necessitated by environmental or
other adverse conditions, and shall cover the entire length of
the wire rope. Periodic inspection should include all previous
items listed under Inspection, plus the following:
• Inspect for severely corroded or broken wires at end 1 2 3 4 5 6
connections. • In rotation resistant ropes: two randomly distributed
• Inspect wire rope in areas subjected to rapid broken wires in six rope diameters or four randomly
deterioration such as: distributed broken wires in 30 rope diameters
- Sections in contact with saddles, equalizer sheaves, • Wear of one-third the original diameter of outside
or other sheaves where wire rope travel is limited. individual wires. Worn rope, usually indicated by flat
spots on the outer wires is unsafe for further use when
- Sections of wire rope at or near terminal ends where less than two-thirds the thickness of the outer wire
corroded or broken wires may protrude. remains.
• Inspect boom nose sheaves, hook block sheaves, boom • Necking down of the rope indicates core failure.
extension/extension sheaves, auxiliary boom nose
sheaves, and hoist drums for wear. Damaged sheaves
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or hoist drums can accelerate wear and cause rapid
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deterioration of the wire rope.
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Inspect the eye end of the cable for greater wear than the
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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
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total length of the cable. • Kinking, crushing, bird caging, or any other damage
resulting in distortion of the rope structure.
Wire Rope Replacement
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• Evidence of heat damage.
No precise rules can be given for determination of the exact
time for replacement of wire rope since many variable factors • Reductions from nominal diameter of more than 5%.
are involved. Determination regarding continued use or
• One outer wire broken at its point of contact with the core
replacement of wire rope depends largely upon the good
of the rope which has worked its way out of, and
judgment of an appointed and qualified person who
protrudes or loops out from the rope structure.
evaluates the remaining strength in a used rope after
allowance for any deterioration disclosed by inspection. Care of Wire Rope
Wire rope replacement should be determined by the
Handle wire rope with care to prevent damage to the
following information excerpted from a National Consensus
individual wires which affect the overall strength and
Standard as referenced by Federal Government Agencies
performance of the rope. Do not allow the formation of kinks,
and as recommended by Manitowoc. All wire rope will
because this displaces the strands of wire from their original
eventually deteriorate to a point where it is no longer usable.
position and relation to each other causing severe bending
Wire rope shall be taken out of service when any of the
and unequal tensions in the strands. This distortion and wire
following conditions exist:
displacement cannot be corrected even under high tension
• Six randomly distributed broken wires in one rope lay or and a permanent weak point remains in the rope. Displaced
three broken wires in one strand in one lay. The rope is or raised wires indicate a previous kink, but does not show
unsafe for further use if there are either three broken the damaged condition of the inner rope wires.
wires in one strand (Breaks 2, 3, 4) or a total of six
Never pull wire rope over a non-rotating support such as a
broken wires in all strands in any one lay.
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 Agencies and Manitowoc Crane Care recommendations to
broken flanges can cut or otherwise damage the rope. help determine when wire rope needs to be replaced. Wire 1
rope shall be taken out of service when any of the following
An even distribution of rope coils over the hoist drum is
conditions exist:
essential to smooth operation. This prevents the rope from
cutting down through or crushing other coils on the drum • In running ropes, six randomly distributed broken wires
resulting in damage to and difficulty in unwinding the rope. in one lay or three broken wires in one strand in one lay
(Figure 1-6).
Boom Extension and Retraction Cables
Periodic Inspection
One Lay
It is recommended that a weekly inspection of all boom
extension and retraction cables be performed using the 6 1 2 3 4 5 6
following guidelines. The inspection shall cover all visible
areas of the extension and retraction cables of an assembled
boom. Note that extending and/or retracting the boom may
be required to access visual inspection holes.
The inspection shall cover the entire length of the extension
One lay is parallel to the rope center-line and is the
and retraction cables of a disassembled boom prior to distance for one strand to make a complete spiral
reassembly.This inspection should be used to monitor around the rope.
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progressive degradation and to discover severe damages
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FIGURE 1-6
necessitating wire rope replacement or equipment repair.
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Inspection criteria are as follows:
• In standing ropes, more than two broken wires in one lay
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• reduction of rope diameter below nominal diameter. in sections beyond end connections or more than one
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broken wire at an end connection.

• severely corroded or broken wires at end connections.
• Wear of one-third the original diameter of outside
• severely corroded, cracked, bent, worn, or improperly
individual wires.
applied end connections.
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• Kinking, crushing, bird caging, or any other damage
• deterioration in areas such as:
resulting in distortion of the rope structure.
- sections in contact with saddles, equalizer sheaves,
• Evidence of heat damage from any cause.
or other sheaves where rope travel is limited.
• Reductions from nominal diameter of more than 5%.
- sections of wire rope at or near terminal ends where
corroded or broken wires may protrude. • Severe corrosion evidenced by pitting.
- sections of wire rope in contact with stationary • In rotation resistant rope, two randomly distributed
surfaces where abrasion or chafing may take place broken wires in six rope diameters or four randomly
as a result of equipment vibration. distributed broken wires in 30 rope diameters.
• damaged or wobbly boom extension and retraction • National Crane recommends that for cable extended
sheaves which can cause rapid deterioration of wire booms, a single damaged wire rope assembly shall
rope. require replacement of the complete set of extension
cables.
• unusual cable sag/stretch. Be sure cables used in sets
all have an equal tension applied. Repeated need for • National Crane recommends that boom extension
adjustment of an individual cable is evidence of cable cables be replaced every seven (7) years.
stretch and indicates the need for a more thorough
• Do not use a swivel on rotation resistant rope. A swivel
inspection to determine and correct the cause.
on this rope will cause premature rope core failure.
Wire Rope Replacement (All Wire Rope)
Seizing Wire Rope
No precise rules can be applied to wire rope replacement
It is important to seize the ends of rotation resistant wire
because of the variables involved. Determining the condition
ropes to prevent the displacement and unraveling of the
of the wire rope depends largely upon the judgment of a
individual wires and strands at the ends. All preformed and
qualified person.
non-preformed styles of wire rope need to be seized prior to
The information below is excerpted from a National cutting. Seizings must be placed on both sides of the point
Consensus Standard as referenced by Federal Government

where the wire rope is to be cut. The two methods for seizing
wire ropes are described below.
Method 1
Using a length of soft annealed wire, place one end in the
groove between two strands of the wire rope. Turn the long
end of the annealed wire at right angles to the wire and wrap
it tightly over the portion in the groove.
The two ends of the annealed wire should be twisted
together tightly. Cut off the excess wire and pound the twist
flat against the wire rope (Figure 1-7).
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FIGURE 1-8
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NOTE: Non-preformed wire rope should have two seizings

located on each side of the cut (Figure 1-9).
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FIGURE 1-7
PREFORMED
Before Cutting
Method 2
Wind a length of soft annealed wire around the wire rope at
least seven times. Twist the two ends together in the center After Cutting
of the seizing. Tighten the seizing by alternately prying and
twisting. Cut off both ends of the wire and pound the twist flat
against the rope (Figure 1-8).
NON-PREFORMED
Before Cutting
6 Rope
After Cutting Diameters
FIGURE 1-9

600E2 SERVICE MANUAL HYDRAULIC SYSTEM
SECTION 2
HYDRAULIC SYSTEM
SECTION CONTENTS
Hydraulic System Description. . . . . . . . . . . . . . . . 2-1 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2
General Adjustment and Repair Procedures . . . . 2-1
Hydraulic System Maintenance Precautions . . . . 2-3 Oil Cooler Service and Maintenance (Optional) . . 2-5
Label Parts when Disassembling . . . . . . . . . . . . . 2-3 Servicing the Control Valves . . . . . . . . . . . . . . . . . 2-5
Hydraulic Oil Recommendations. . . . . . . . . . . . . . 2-3 Disassembly and Reassembly of Control
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . 2-3 Valves to Replace Seals . . . . . . . . . . . . . . . . . . . . 2-5
Removing Air From the Hydraulic System . . . . . . 2-4 Replacing Spool Seals. . . . . . . . . . . . . . . . . . . . . . 2-6
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Unloader Valve Service . . . . . . . . . . . . . . . . . . . . . 2-6
Maintenance Records . . . . . . . . . . . . . . . . . . . . . . 2-5 Control Valve Relief Adjustment . . . . . . . . . . . . . . 2-7
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HYDRAULIC SYSTEM DESCRIPTION
The hydraulic system of this machine is an open center type
pump rotation, contact your National Crane distributor or
Manitowoc Crane Care.
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consisting of a fixed displacement three section high The crane hydraulic system includes a hydraulic capacity
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pressure pump which supplies oil to a main control valve and alert system. This system is a hydraulically operated,
a hoist control valve. The main control valve is equipped with maximum capacity sensing device that monitors lift cylinder
a main inlet and a mid inlet. The main inlet supplies oil to the pressure. As pressure in the lift cylinder approaches its
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turn function, the mid inlet supplies the remainder of the maximum predetermined level, which can be monitored on
crane function requirements. The main control valves the console mounted range gauges, a hydraulic pressure
contain inlet section reliefs or port reliefs which limit pressure switch activates an integral hydraulic dump circuit in the
in the hydraulic system to acceptable levels and control main control valve, disabling the crane functions that
crane movements. increase the over capacity condition.
The large single section control valve supplies oil to hoist up All load bearing cylinders on this machine are protected from
and down. The inlet section contains a screw adjustable inadvertent movement or collapse due to hose failure by pilot
main relief. The first work section of the multi-section main operated check valves or by pilot operated counterbalance
control valve controls turn right and left.This work section is valves if overhung loads must be controlled.
supplied oil by the main inlet section which contains a screw The standard swing gearbox is locked in place by an integrally
adjustable relief valve. The remaining work sections are mounted spring applied brake and a dual counterbalance motor
boom telescope, boom lift, and outrigger functions in that holding valve. The swing brake and counterbalances are piloted
order. The oil to these sections is supplied by the mid inlet open and closed by operating swing left or right and are
section which also contains a main relief valve. The hoist and automatically reapplied by ceasing the swing function.
the main circuits are all connected through shuttles to a Maximum swing speed can be limited using the swing speed
pressure gauge located on the control console. adjustment valve.
The hydraulic oil is supplied by a truck frame mounted oil
reservoir, which is equipped with a replaceable canister type GENERAL ADJUSTMENT AND REPAIR
return oil filter. The truck power take off driven hydraulic PROCEDURES
pump is sized to supply 34 gpm (129 lpm) to the hoist circuit,
18 gpm (68 lpm) to the boom lift and telescope circuits and
10 gpm (38 lpm) to the turn function at 2500 rpm pump shaft Before maintenance, adjustments and repairs are started on
speed. Higher pump speeds may result in excessive heat a crane, the following precautions shall be taken as
generation in the hydraulic system. The pump is not applicable:
bidirectional and can only be used when the shaft rotates
• Place a warning tag in a conspicuous location at the
only in the proper direction. If you need to verify or change
controls stating that the machine requires adjustment or
repair before it can be operated.

HYDRAULIC SYSTEM SERVICE MANUAL 600E2
• Park the crane where it will cause the least interference Label Parts when Disassembling
with other equipment or operations in the area.
When removing or disconnecting a group of wires or cables,
• Place all controls at the off position and set the brakes to tag each one to ensure proper identification during re-
prevent inadvertent motion. assembly.
• Disable all methods used to start the crane's engine. When shims are removed, tie them together and identify
• Lower the boom to the ground or otherwise secured them as to location. Keep shims clean and flat until they are
against dropping. reinstalled.
• Lower the hook block to ground or otherwise secured Hydraulic Oil Recommendations
against dropping.
For the hydraulic oil specifications, Reference Lubrication
• Relieve the hydraulic pressure from all hydraulic circuits Chart, page 7-4.
before loosening or removing hydraulic components.
After maintenance, adjustments and repairs have been
Draining and Flushing
made, do not return the crane to service until all guards have If a component has been changed because of a failure that
been reinstalled, trapped air removed from the hydraulic might allow metal or abrasive particles to enter the system,
system if required, safety devices reactivated, and all systems must be thoroughly checked, drained, and
maintenance equipment and all warning tags removed. flushed.
Maintenance, adjustments, and repairs shall be done only by
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1. Remove the reservoir drain plug. Allow about three
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designated personnel who are properly trained. Use only minutes after hydraulic oil stops flowing from the drain
parts supplied from Manitowoc Crane Care to repair the
crane.
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port for the side walls to drain.
Clean and install the reservoir plug and fill the reservoir
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Hydraulic System Maintenance Precautions with a 50/50 mixture of fuel oil and clean hydraulic oil.
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Contaminants in a hydraulic system affect operation and 3. Cycle the crane through all functions several times.
result in serious damage to the system components. Dirty Then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the
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hydraulic systems are a major cause of component failures.
engine.
If evidence of foreign particles is found in the hydraulic
system, flush the system. 4. Remove the reservoir drain plug and drain the reservoir.
Clean and install the drain plug and fill the reservoir with
Disassemble and reassemble hydraulic components on a clean hydraulic oil.
clean surface.
NOTE: Hydraulic oil supply lines must be connected to the
Clean all metal parts in a nonflammable cleaning fluid. Then cylinders when flushing the system.
lubricate all components to aid in assembly.
Draining the various components will be aided by
Inspect all sealing elements (O-ring, gaskets, etc.) when connecting a drain line in place of the disconnected
disassembling and assembling the hydraulic system return line.
components. Installation of new sealing elements is always
recommended. 5. Disconnect the return line from the lift cylinder and raise
the boom to maximum elevation.
When installing metal hydraulic tubes, tighten all bolts finger
tight. Then, in order, tighten the bolts at the rigid end, the 6. Connect the cylinder return line and lower the boom to
adjustable end, and the mounting brackets. After tubes are its stowed position. Replenish the reservoir hydraulic oil
mounted, install the hoses. Connect both ends of the hose level as required.
with all bolts finger tight. Position the hose so it does not rub 7. Disconnect the return line from an outrigger extension
the machine or another hose and has a minimum of bending cylinder and fully extend the outrigger.
and twisting. Tighten bolts in both couplings.
8. Connect the outrigger return line and retract the
Due to manufacturing methods, there is a natural curvature outrigger. Replenish the reservoir hydraulic oil level as
to a hydraulic hose. The hose should be installed so any necessary.
bend is with this curvature.
9. Repeat Steps 7 and 8 for the remaining outriggers.
In case of replacement hoses with angled stem reusable
fittings, the hose curvature must be taken into consideration
when assembling and positioning the angled stem.

After the reservoir is filled, operate all circuits and recheck

the reservoir sight gauge. Add hydraulic oil as required.
CAUTION
When draining the outrigger cylinders, always operate Removing Air From the Hydraulic System
either both front or both rear cylinders together to prevent Air entering the hydraulic oil will normally be removed
twisting the crane. automatically by passage of the hydraulic oil over the baffles
10. Disconnect the return lines from a pair of outrigger jack

cylinders and activate the cylinders to their maximum
in the hydraulic reservoir. If a component has been replaced,
the reservoir level is too low, or a leak develops in the suction
lines to the pumps, air can enter the system. If air becomes
2
down positions. entrapped in the hydraulic oil, it may be detectable in pumps
11. Connect the return lines and raise the outrigger jack and motor operated components such as the swing
cylinders to the stowed position. Replenish the reservoir mechanism and hoist(s), because it can cause these units to
hydraulic oil level as necessary. become noisy during operation. If noisy operation occurs,
first check the level of the hydraulic reservoir and replenish
12. Repeat Steps 10 and 11 for the remaining two outrigger as necessary. Then inspect for leaks in the suction lines
cylinders. leading to the pumps.
13. Disconnect the return line from the telescope cylinder Minute leaks may be hard to locate. If a leak is not readily
and fully extend the boom. detectable, use the following way to check for it:
14. Connect the return line and retract the boom. Replenish • Seal all normal openings in the hydraulic system and the
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the reservoir hydraulic oil level as necessary. reservoir. Using a positive means to control the pressure
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(like a regulator), pressurize the hydraulic system to
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15. Disconnect the return lines from steer cylinders and turn
the wheels to the extreme right. 0.138 to 0.276 bar (2 to 4 psi) and inspect all joints and
fittings for evidence of leaks. A soap solution applied to
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16. Connect the return lines and turn the wheels to the the fittings and joints may also prove helpful in detecting
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extreme left and then back to center. Replenish the minute leaks while the system is pressurized. Remove
reservoir hydraulic oil level as necessary. the pressure, repair any leaks found, and reopen any
17. Raise the crane on outriggers. openings (such as a vent) closed for inspection. Refill
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the reservoir after completing any repairs or service.
18. Disconnect the return line from the main hoist motor and Operate all hydraulic circuits several times in both
fully hoist up the hoist. directions.
19. Connect the return line to the main hoist motor and fully • This action should return any entrapped air to the
hoist down the hoist, then hoist up again. Replenish the reservoir where it can be removed from the hydraulic oil
reservoir hydraulic oil level as necessary. by the baffles.
20. Disconnect one of the lines from the swing motor and
drive the motor in the direction it will go.
21. Connect the line to the swing motor, then drive the swing CAUTION
motor in the opposite direction until the boom is centered
Always locate the machine on a firm supporting surface,
and forward. Replenish the reservoir hydraulic oil level
extend the outriggers and level the machine and position
as necessary.
the boom over the front to extend the boom at low angles.
Injury or damage to the machine may result if this caution
is not followed.
CAUTION
When hydraulic oils are changed or added, ensure that
• To remove entrapped air from telescope cylinders, lower
hydraulic oils of different manufacturers are of the same
the boom to below horizontal and fully telescope the
specifications, however, discoloration (milkiness) may
boom in and out several times.
occur. Mixing incompatible hydraulic oils may result in
improper operation or damage to the machine. • If the air is not readily removed, lower the boom to below
horizontal, extend the telescope cylinders as far as
When hydraulic oils are changed, recheck the reservoir practicable, and allow the boom to remain in this position
hydraulic oil level after brief system operation and add overnight. This should allow entrapped air to find its way
hydraulic oil as required. Ensure the crane is level and in the to the holding valve so that telescoping the boom IN the
travel mode of operation when the hydraulic system is being next morning should force the air back to the reservoir.
filled. The system must be filled with all cylinders retracted. Ensure the boom is first telescoped IN (not OUT) in the
Fill the reservoir to the full mark on the reservoir sight gauge.

morning. Telescoping OUT may cause air to be forced

back into the cylinder.
CAUTION
Do not attempt to loosen fittings in pressurized lines or
while the hydraulic pumps are in operation.
Extreme care must be used when removing any plugs or
restrictions from a hydraulic system suspected to have
entrapped air that may be pressurized. Moderate to minor
injury may result from pressurized air in a hydraulic
system.
• Entrapped air may be removed from cylinders having

wet rods by cycling. On certain cylinders, a plugged port
is provided on the rod end to bleed off entrapped air.
• In the event that air entrapment should persist, bleeding
of air by loosening various clamp and screw type fittings Hydraulic Filter
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may become necessary.
Return oil filtration has been designed to handle the
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maximum system flow and to protect the hydraulic system
•
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If the above procedures fail to eliminate air entrapment,
contact your authorized National Crane distributor. components.
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The filter is mounted on the oil reservoir, and is a replaceable
Parts Replacement
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canister type return oil filter. The filter must be serviced with
Parts found damaged or out of tolerance when maintenance National Crane replacement elements at recommended
is being performed should be replaced. Refer to the intervals to assure the warranty remains in force.
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Manitowoc Crane Care Parts Catalog for proper replacement
parts. Oil Cooler Service and Maintenance
(Optional)
Maintenance Records
The heat exchanger must be kept clean to allow for efficient
Dated records must be kept for inspection of critical operation of the cooler system. Frequent washing of the heat
components, such as brakes, crane hooks, wire ropes, exchanger core will eliminate oil film, road dirt and other
hydraulic cylinders, and relief valve pressure settings. These foreign object buildup on the heat exchanger fins which
records must be kept where they can be easily obtained and reduces cooling efficiency.
reviewed.
Frequent inspection and tightening of hose clamp line
Hydraulic Oil Reservoir connections will eliminate the possibility of end connection
failure due to back pressure from cold startup.
The hydraulic oil reservoir has a sight gauge located on the
side of the reservoir. This sight gauge has a decal beside it If cooler system fails to provide adequate performance,
that indicates a “full” level and an “add oil” level. The oil reduced air or oil flow through the heat exchanger is the
required to bring it from the “add” line to the “full” line is 5 probable cause. The cooling fan should be inspected for
gallons. Do not fill the reservoir above the “full” line. The oil proper operation. Any obstructions to air flow should be
level should be checked with the crane parked on a level corrected (cooler too close to other truck components,
surface, in the transport condition (all cylinders retracted and foreign matter in heat exchanger fins, etc.) All hydraulic lines
boom stowed) and the oil cold. should be periodically checked for obstructions, hose kinks
or other flow restrictions.

SERVICING THE CONTROL VALVES 8. When all valve sections are positioned on assembly
studs, replace stud nuts and tighten evenly to 32 ft-lb
Disassembly and Reassembly of Control (43 Nm) torque for crane valve and 25 ft-lb (34 Nm)
Valves to Replace Seals torque for hoist valve.
NOTE: If stud nuts are not tightened to the proper torque,
NOTE: For clarification, the inlet cover containing the main
valve spools may bind or stick, or cause section
relief is called the left side of the valve assembly.
1. Before disassembly, numerically mark each valve for
correct reassembly.
seals to extrude.
Replacing Spool Seals

2
2. Remove three stud nuts from the end section. Valve sections and covers are identified by numbers cast into
the body.
3. Remove valve sections by sliding from assembly studs.
1. Remove bonnet assembly parts from back of valves and
4. If valve sections are to be added or removed, use the
keep in order of disassembly.
proper length stud.
2. Remove all parts connected to the spool on the front of
NOTE: Use assembly nuts, three required, with all
the valve.
assembly studs. No lock washers! All studs are
stress-proof material and should be replaced only NOTE: Do not remove the spool because the seals can be
with original equipment replacement parts. replaced externally. To prevent the spool from
turning, insert a screw driver through clevis slot. Do
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5. Thoroughly clean O-ring counterbores and ground
not hold the spool with a wrench. This will destroy
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surfaces of each section.
the finish.
6.
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Replace the four O-rings for crane valve, the three O-
rings for the hoist valve, and seals. There are two seals
3. Remove retainer plate, retainer plate washers, back-up
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washers, and spool seals.
per section. Buna-N seals are standard.
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4. Thoroughly clean counterbore.

7. Replace the valve sections on assembly studs in the
same order in which they were removed. 5. Lightly oil new seals. Slide over valve spool and insert in
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seal counterbore.
NOTE: Use care in replacing valve sections to avoid
dislodging O-rings from counterbores.
Backup Washers
Spool Seal
Bonnets
Assembly
Crane Valve Cover Retainer Plate
10 ft-lb (13.5 Nm) Hoist
Valve Cover 5 ft-lb (6.7
Nm)
Work
Ports
Outlet
Cover
Crane Valve Cover
10 ft-lb (13.5 Nm) Hoist Spool Action
Valve Cover Bonnets
5 ft-lb (6.7.8 Nm)
Inlet Cover
Outlet
Inlet
NOTE: Remove cap

to adjust main relief. Linkage End
Main Relief of Spool

Unloader Valve Service In the event that one of these three functions do not operate
or operates with a delay and the crane is not overloaded or
See “Anti-two Block System Description” on page 3-1 if an two-blocked, the following air purging procedure should be
electrical problem has occurred. followed. If no improvement is seen after completing the
This crane has three work sections equipped with unloader following procedure twice, follow the troubleshooting steps
(dump) valves. The functions connected to the unloader outlined for checking and inspecting the solenoid valve and
valves are hoist up, boom down and boom extend. The unloaders in this hydraulic circuit outlined below.
purpose of these unloaders is to stop control oil from 1. Purposely trip the ATB switch to open the solenoid
reaching the functions in the event of a two-block occurrence (dump) valve.
or overload condition. Hydraulic lines extend between the
unloader valve on each of these sections to a single solenoid 2. Operate hoist up, boom down and boom extend
(dump) valve. The hydraulic oil in these lines can drain out separately for about a minute, longer if the oil is cold.
over a period of time, when the pump is not engaged, or may 3. Operate all three functions simultaneously.
be lost during servicing the unit. Air may enter these lines at
such a time. If the unloader hydraulic lines have air in them, 4. Release the ATB switch.
these three functions may not operate or may exhibit a delay 5. Check the operation of each function.
in their operation.
6. Repeat procedure if necessary.
NOTE: Internal parts of the unloader valves are not
serviceable. In the event that one of these three functions will not operate
and the crane is not overloaded or two- blocked, the
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following procedure is used to diagnose the problem.
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Disconnect drain line from the

outlet end of the unloader valve.
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Install cap fitting to the plug outlet

end of the unloader valve.
Operate the function.
Function operates correctly.
NO YES
Oil is passing through the check The poppet in the unloader is not
valve in another unloader. seated correctly. remove unloader and
flush to dislodge contamination.
Cap each of the other unloaders in

turn to identify the unloader with Reinstall, retest and replace unloader
the faulty check valve. if problem persists.
Flush to remove contamination

otherwise replace unloader valve.

CONTROL VALVE RELIEF ADJUSTMENT Some valve sections include work port reliefs. The work port
reliefs are shim adjustable. Adjustment is made by adding or
The control valves supplied on this crane are equipped with taking out shims. Adding a 0.010 shim will increase pressure
adjustable relief valves. After some time of use, it may be 100 psi (0.68 MPa). See “Specifications” section for correct
necessary to make some adjustment in pressure because of pressure settings.
spring weakening, etc. The relief valves are adjustable only
through a specific pressure range. Never set pressure above recommendations.
Both the inlet and mid-inlet of the main control valve and inlet
of the hoist valve have screw adjustable main relief valves.
2
Turning the relief in increases pressure relief setting; turning WARNING
the relief out decreases pressure relief setting. If the machine does not perform properly at these
pressures, the problem is not the relief valve and no
The turn circuit pressure can be checked by plugging a port
attempt should be made to readjust the setting. If the relief
on the turn motor with a pressure gauge. The pressure on
valves are set to higher pressures than those listed
the main control valve stack should be checked by booming
above, the warranty on the machine is void. Also the
the lift cylinder down against the end of the cylinder stroke.
machine could operate in a manner such as to endanger
The hoist circuit pressure can be checked by plugging a port
personnel safety.
on the hoist motor with a pressure gauge.
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O-RING FACE SEAL
O-RING BOSS
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O-RING O-RING B
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A
B
FACE (REF) BOSS (REF)
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A
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O-RING FACE SEAL FITTING SIZE O-RING BOSS

MFGR
THREAD B inches A inches TUBE ’S A inches B inches THREAD
SIZE (mm) (mm) O. D. SIZE (mm) (mm) SIZE
CODE
9/16-18 0.07 (1.78) 0.301 (7.64) 0.250 4 0.351 (8.92) 0.072 (1.83) 7/16-20
11/16-16 0.07 (1.78) 0.364 (9.24) 0.375 6 0.458 (11.63) 0.078 (1.98) 9/16-18
13/16-16 0.07 (1.78) 0.489(12.42) 0.500 8 0.644 (16.36) 0.087 (2.21) 3/4-16
1-14 0.07 (1.78) 0.614 (15.60) 0.625 10 0.755 (19.18) 0.097 (2.46) 7/8-14
1 3/16-12 0.07 (1.78) 0.739 (18.77) 0.750 12 0.924 (23.47) 0.116 (2.95) 1 1/16-12
1 7/16-12 0.07 (1.78) 0.926 (23.52) 1.000 16 1.171 (29.74) 0.116 (2.95) 1 5/16-12
1 11/16-12 0.07 (1.78) 1.176 (29.87) 1.250 20 1.475 (37.46) 0.118 (3.00) 1 5/8-12
2-12 0.07 (1.78) 1.489 (37.82) 1.500 24 1.720 (43.69) 0.118 (3.00) 1 7/8-12
NOTE: Contact your National Crane distributor or Manitowoc Crane Care for O-ring boss seal kits.

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600E2 SERVICE MANUAL ELECTRIC SYSTEM
SECTION 3
ELECTRIC SYSTEM
SECTION CONTENTS
Anti-two Block System Description . . . . . . . . . . . 3-1 Hydraulic Capacity Alert System . . . . . . . . . . . . . 3-15
Anti-two Block Operation . . . . . . . . . . . . . . . . . . . 3-2 HCA Maintenance & Repair. . . . . . . . . . . . . . . . . 3-15
Anti-two Block Internal Wire Repair . . . . . . . . . . . 3-2 HCA System Adjustment . . . . . . . . . . . . . . . . . . . 3-15
Three Section Boom ATB Wire Repair . . . . . . . . . 3-2 JIB Load Limiting Device . . . . . . . . . . . . . . . . . . . 3-16
4 Section Boom ATB Wire Repair. . . . . . . . . . . . . 3-4 Single Character Display . . . . . . . . . . . . . . . . . . . 3-17
2/3/4 Stage anti-two block Wire Replacement . . . 3-5 Jib Load Limiting Device Troubleshooting . . . . . . 3-17 3
Anti-two block Internal Wire System: Four Outrigger Monitoring System (OMS) (Optional—
Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Standard in North America) . . . . . . . . . . . . . . . . . 3-17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
1/2 Stage Anti-two Block Wire Replacement . . . . 3-8 Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
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Disassembly Of 1/2 Stage . . . . . . . . . . . . . . . . . . . 3-8 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
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Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Danger Remote Start Hazard . . . . . . . . . . . . . . . 3-21
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Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Service and Maintenance . . . . . . . . . . . . . . . . . . 3-21
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2/3/4 Stage Anti-two Block Wire
Troubleshooting, Repair and Replacement . . . . . 3-21
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Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Radio Remote Controls. . . . . . . . . . . . . . . . . . . . . 3-22
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
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Replacement Of Proportioning Cable
For 1/2 Stage Of Anti-two Block Wire . . . . . . . . . 3-12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
1/2 Stage Anti-Two Block Wire Operation . . . . . 3-12 Service and Maintenance . . . . . . . . . . . . . . . . . . 3-23
1/2 Stage Anti-Two Block Wire Maintenance . . . 3-12 Quick Test for Receiver Antenna and Cable . . . . 3-23
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
ANTI-TWO BLOCK SYSTEM DESCRIPTION the tension on the switch. At this point the contacts in the
switch open, breaking electrical continuity through the circuit
The anti-two block system on your National Crane helps provided by the internal anti-two block cord routed through
prevent cable damage by sensing when the end of the hoist the boom. When this continuity is broken, the unloader
cable is near the boom tip and disables the functions that cartridges de-energize and divert the function oil to tank. An
cause a two block condition. indicator light is provided on the control console to alert the
The anti-two block system consists of normally open, work operator when a two-block condition is detected.
port unloader valves in the main and hoist control valves. On machines equipped with an optional Rated Capacity
When the cartridge solenoid is energized, the crane Limiter (RCL) System, the anti-two block system is integral
functions normally, when de-energized, the oil to the boom with the RCL wiring and display. An audible, visual warning
extend, boom down, and hoist up crane functions are of the two block condition is provided in the display console.
diverted to tank. These solenoids are controlled by a limit See RCL Operators Handbook for additional information.
switch, which is attached to the boom or jib sheave case.
This switch is held in the closed position by a chain Normal functioning is restored by hoisting down (or retracting
suspended weight. The weight, which is looped around the boom) until the weight is once again suspended freely.
hoist cable, causes the contacts to remain closed until the Occasionally if the hoist up and boom extend functions are
hoist cable end attachments contact the weight and release operated at maximum speed in the dump mode, the back

ELECTRIC SYSTEM 600E2 SERVICE MANUAL
pressure induced in the circuit will cause the hoist up or • Shrink tube or electrical tape
boom extend functions to creep slightly (with no load on the
Proceed as Follows:
hook). Such a condition is not cause for alarm, as the back
pressure is not of sufficient magnitude to damage the cable 1. Retract boom completely.
or end connections.
2. Loosen and remove capscrew and cable clamp
Anti-two Block Operation arrangement from sheave case attachment point of anti-
two block wire. Remove quick connect plug on anti-two
The internal anti-two block wire is routed from the control block wire by unscrewing base of plug and
console to the hoist mount end of the boom, following the disconnecting individual wires from connections. Note
path of the extend cables to the rear of the 3rd section boom. pigtail length at this time and wire/terminal number
This is the length of the wire that proportions in and out with location for proper reassembly.
the boom length, similar to the route of the extend cables. At
3. Pull end of anti-two block wire through side plates of 3rd
this point at the rear of the 3rd section, the wire loops around
section boom to gain in-line wire path.
and anchors at the anti-two block cable clamp on the extend
cable anchor. The anti-two block wire, now attached at the 4. Attach replacement anti-two block wire to damaged wire
rear of the 3 rd section, runs the length of the section and with a temporary splice, securing the conductors with
attaches to the 3rd section sheave case. The wire then loops end to end butt connectors and shrink tube or electrical
around the clamp arrangement on the sheave case and tape. This connection must be secured well enough to
routes through access holes in the side plate of the boom. pull the new wire through the boom.
The wire terminates at a quick connect three conductor plug
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designed for anti-two block switch or jib interface. 5. At the hoist mount end, reach into the rear of the boom
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and loosen the capscrew on the anti-two block cable
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ANTI-TWO BLOCK INTERNAL WIRE REPAIR
clamp enough to let the cable run around it with minimal
effort. This clamp is located on the extend cable anchor.
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In the event of a break in continuity of the anti-two block wire 6. Disassemble spade bolt anchor attaching anti-two block
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routed internally in the boom, the anti-two block hydraulic wire to the extend cable plate on the hoist mount end of
system will sense a problem and make certain crane the boom.
functions inoperative. Before repair or replacement of
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internal wire, check for continuity loss at the anti-two block 7. Pull wire from hoist mount end. Replacement wire
switch, damaged, missing, or corroded connectors and temporary splice may need assistance reeving around
overall system condition. Due to the environmental exposure anti-two block cable clamp in rear of 3rd section. If
of the system, a thorough check of the circuit should be excessive force is needed to pull wire through, inspect
performed. the wire routing and make adjustments as needed to
avoid breaking the temporary splice. If splice fails at this
The two methods for removal and reinstallation of the anti- point, wire routing Alternative #2 should be used.
two block wire are: Alternative #1 is used if the wire has
experienced a continuity failure in one or both of the 8. Pull wire through boom, leaving enough wire on sheave
conductors, but the rubber jacket of the wire is still intact. case end to properly attach and terminate wire.
Alternative #2 is used if the wire has been completely cut or 9. Tighten anti-two block wire clamp located in rear of 3rd
either end of the wire is inaccessible. section.
Three Section Boom ATB Wire Repair 10. Route sheave case end of anti-two block wire around
clamp in sheave case, and through holes in side plates.
Pulling on this end will tension the static length of
anti-two block wire clamped in the 3rd. Approximately
WARNING 15-25 lb (6-11 kg) will be sufficient to provide proper
Do not, under any circumstances, work at an elevated operation. Tighten sheave case anti-two block wire
height without using proper fall protection as required by clamp.
local, state or federal regulations
11. Reassemble quick disconnect plug to anti-two block
Alternative #1 wire. Proper wire attachment is critical for proper anti-
two block system operation.Consult electrical schematic
This procedure pulls the replacement wire through the boom, in this book for proper connector wiring.
following the path of the defective wire.
12. Temporary splice should now be approximately 10 feet
Special tools or equipment: (3 m) past the hoist mount end of the boom. Break
splices and slide strain relief/cord grip onto wire, into
• Two end-to-end electrical butt connectors
approximate position inside the boom.

13. Assemble spring and spade bolt to cord grip and Visually guide the wire and installation tool over the
reassemble anchor components to extend cable anchor center sheave on the extend cylinder sheave case.
plate on the hoist mount. Slide cord grip up anti-two
7. Push installation tool and wire through boom until it
block wire into boom to increase spring tension on
appears at the hoist mount end, detach wire from
moving length of anti-two block wire. Approximately
installation tool, route wire through open top of hoist
2 inches (50 mm) of spring extension tension should be
mount and temporarily tie off to a convenient anchor
adequate for proper operation.
point. Pull installation tool out sheave case end of boom.
14. Visually inspect interior routing of anti-two block wire for
excess slack in wire, inaccurate routing of wire, etc.
correct any problems before boom operation. 8. From sheave case end of boom, attach other end of
replacement wire to installation tool with electrical tape.
Alternative #2 Insert installation tool and wire into the boom sheave
case, in the open area between the sheave case side
This procedure is to be used for anti-two block wire
plates. Visually guide this end under the center sheave 3
replacement in the event of a complete separation of the
on the extend cylinder sheave case.
wire, or the inability to access one or both of the ends outside
the boom assembly. This procedure routes a new anti-two 9. Push installation tool and wire through boom until it
block wire through the boom without having an existing wire appears at the hoist mount end. Do not detach wire from
to pull it through (Alternative #1). installation tool.
Special tools or equipment: 10. From hoist mount end of boom, locate installation tool
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and attached wire, and pull the wire out of the boom
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• Electrical tape
section, removing the slack loop from the sheave case
•
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Installation tool end of the boom. This will place the wire close to, if not
on the center sheave of the extend cylinder.
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To route the wire the entire length of the boom, a long tube,
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to be used as a installation tool, must be utilized to transport 11. Move to the sheave case end of the boom. Visually
the end of the anti-two block wire from one end of the boom determine if the wire has properly located itself onto the
assembly to the other. A telescopic grease applicator for the sheave. If not, manipulate the wire placement through
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boom, hydraulic tubing or electrical conduit are all the end of the boom and place the wire on the sheave. A
possibilities for an installation tool. The installation tool 5 ft (1.50 m) long access tool (hook end) will simplify this
should be at a minimum 2 ft (61cm) longer than the retracted procedure greatly.
boom assembly.
12. From the hoist mount end of the boom, assemble the
1. Retract boom completely. anti-two block wire clamp on the extend cable anchor in
the rear of the 3rd section. Loop anti-two block wire
2. Loosen and remove anti-two block cable clamp
around clamp and lightly tighten capscrew holding
arrangements from sheave case and 3rd section extend
clamp together. Keeping a slight amount of tension on
anchor. Remove spade bolt anchor from extend cable
the wire at this point will keep the wire properly located
anchor plate in the hoist mount end of boom.
on the sheave.
3. Remove quick disconnect plug on anti-two block wire by
13. From the sheave case end, pull the installation tool and
unscrewing base of plug and disconnecting individual
wire end out of the boom. The route of the anti-two block
wires from connections. Note pigtail length at this time,
wire in the boom is now complete.
and wire/terminal number location for proper
reassembly. 14. Pull wire at either end of boom to adjust length of wire on
sheave case end to properly attach and terminate wire.
4. Pull anti-two block wire out of boom assembly. Visually
inspect boom interior from both ends to verify all the 15. Tighten anti-two block wire clamp located in rear of 3rd
cable has been removed from the boom. Visually section.
inspect center sheave on extend cylinder for damage.
16. Route sheave case end of anti-two block wire around
5. Start installation of replacement wire on the sheave case clamp in sheave case and through holes in side plates.
end of the boom assembly. Using electrical tape, attach Pulling on this end will tension the static length of anti-
one end of replacement wire to the end of the installation two block wire clamped in the 3rd. About 15-25 lb
tool. (7-11 kg) is sufficient to provide proper operation.
Tighten sheave case anti-two block wire clamp.
6. Insert installation tool and wire into sheave case in the
center open area between the sheave case side plates. 17. Reassemble quick disconnect plug to anti-two block
wire. Proper wire attachment is critical for proper anti-

two block system operation. Consult electrical system will sense a problem and make certain crane
schematic in this book for proper connector wiring functions inoperative. Before repair or replacement of
internal wire, check for continuity loss at the anti-two block
18. From hoist mount end of boom, slide strain relief/cord
switch, damaged, missing, or corroded connectors and
grip onto wire, into approximately position inside the
overall system condition. Due to the environmental exposure
boom.
of the system, a thorough check of the circuit should be
19. Assemble spring and spade bolt to cord grip and performed.
reassemble anchor components to extend cable anchor
If the internal wire has lost continuity it will probably be
plate on the hoist mount. Slide cord grip up anti-two
necessary to replace only one of the two stages in the circuit,
block wire into boom to increase spring tension on
the 1/2 stage or the 2/3/4 stage. A simple continuity test of
moving length of anti-two block wire. About 2 inches
both stages should identify which one contains the failure.
(50 mm) of spring extension tension should be adequate
for proper operation. 1. Unplug Weather-Pack connector linking the two stages
together, located at the end of the 2nd section.
excess slack in wire, inaccurate routing of wire, etc. 2. With the anti-two block switch in its closed position
Correct any problems before boom operation. (weight suspended from switch or overridden), check
continuity across the Weather-Pack terminals on the 2/
4 Section Boom ATB Wire Repair 3/4 stage. If continuity exists, the 1/2 stage contains the
break. If there is no continuity in the 2/3/4 stage, recheck
anti-two block switch function and recheck continuity to
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positively determine a wire fault.
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WARNING
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Do not, under any circumstances, work at an elevated
3. If the fault is suspected in the 1/2 stage, unplug
Weather-Pack connector at the turret end. At the end of
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height without using proper fall protection as required by the 2nd section boom, install a jumper wire across the
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terminals at either end of the 1/2 stage. Check continuity

at the opposite end of the 1/2 stage.
Operation: Internal Anti-Two Block Wire
After determining which wire stage the fault is located in,
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The internal anti-two block wire is routed from the control refer to the following procedures for anti-two- block wire
console to the hoist mount end of the boom, through the replacement.
access cutout in the bottom of the 1st section, then reeves
around a path on the inside bottom plate of the 1st section. 1/2 Stage Anti-Two Block Wire Replacement
This path incorporates a traveling block arrangement that
clamps the anti-two block wire to the bottom of the 2 nd The 1/2 stage anti-two block wire system is located between
section and allows wire movement relative to that section. the 1st and 2nd boom sections, riding on the top of the bottom
This wire terminates with a Weather-Pack connector at the plate of the 1st section. The maintenance on this system can
hoist mount end of the 2nd section. This system is the 1/2 be accomplished with the boom assembled but would be
stage. From this connector inside the boom, the anti-two greatly simplified by removing the 2/3/4 boom assembly from
block wire follows the path of the extend cables to the rear of the 1st.
the 4th section boom. This length of wire proportions in and
out with the boom length, similar to the route of the extend Disassembly of 1/2 Stage
cables. At this point at the rear of the 4th section, the wire 1. Remove capscrews and clamp bar from 2nd section by
loops around and anchors at the anti-two- block cable clamp gaining access through rear of 1st, under extend cylinder
on the extend cable anchor. The anti- two-block wire, now butt plate.
attached at the rear of the 4th, runs the length of the section
and attaches to the 4th section sheave case. The wire then 2. Unplug Weather-Pack connector between the 1/2 stage
loops around the clamp arrangement on the sheave case and the 2/3/4 stage, located on the rear of the 2nd
and routes through access holes in the side plate of the section.
boom, this is the 2/3/4 stage. The wire terminates at a quick 3. Unplug Weather-Pack connector under the 1st section
connect two conductor plug designed for anti-two block boom, and remove the nut and washer from the cord
switch or jib interface. clamp on the bottom of the 1st section. Route the
appropriate end through the access cutout on the
Maintenance bottom plate.
In the event of a break in continuity of the anti-two- block wire
routed internally in the boom, the anti-two- block hydraulic

4. Loosen and remove the capscrews anchoring the pulley To route the wire the entire length of the boom, a long tube,
block and cord clamp plate from the hoist mount end of to be used as an installation tool, must be utilized to transport
the 1st section. the end of the anti-two block wire from one end of the boom
assembly to the other. A telescopic grease applicator for the
5. Loosen and remove the capscrews anchoring the pulley
boom, hydraulic tubing or electrical conduit are all
block and cord clamp plate from the sheave case end of
possibilities for an installation tool. The installation tool
the 1st section.
should be at a minimum 2 ft (0.5 m) longer than the retracted
6. Pull on loose end of the cord and pulley block on sheave boom assembly.
case end of 1st section. Two pulley blocks, 75 ft (23 m) of
1. Place parts on long work surface (top plate of boom).
cord, and the traveling block (2 pulley blocks linked
Refer to illustration for proper component placement,
together) should pull free of the 1st section.
reeve cable through pulleys and traveling block.
7. Visually inspect parts and boom sections for possible
2. Place system into boom using anti-two block installation
cause of wire fault. Verify all parts are disassembled out
of boom sections.
tool. 3
3. Confirm proper placement of components. Installation of
Assembly of 1/2 Stage components in correct location is critical for proper
operation.
Special tool - Installation tool
Weather Pack
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Shrink Tube Approx 40 in
Connector
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Approx 50 in Clamp Point
Pulley
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Cord Clamp
Plate 2nd Section Cord Clamp
1st Section Traveling Plate
Boom Boom Block
Weather Pack
Connector
4. Location of the traveling block is critical to correct 8. Assemble capscrews and clamp bar to 2nd section,
operation. The traveling block moves in the opposite clamping section of wire assembly at point that shrink
direction of the 2nd section boom. Extra wire is included tube is installed over wires.
in the wire assembly to place the traveling block in the
9. Reconnect Weather-Pack connectors.
correct position. Access to the clamp bar on the 2nd
section can only be achieved through the rear of the 1st 10. Verify proper operation of the complete anti-two- block
section, therefore the boom is near full retraction when system.
the clamp bar attaches the wire assembly to the 2nd
section. The traveling block needs to be over the 2/3/4 Stage anti-two block Wire Replacement
halfway point of the length (closer to the sheave case
The procedure for removal and reinstallation of the 2/3/4
end) of the 1st section before the wire assembly is
stage anti-two block wire can be accomplished using two
clamped to the 2nd section.
different methods depending on the severity of the damage.
5. Install capscrews in the front and rear of the 1st section Alternative #1 should be used if the wire has experienced a
anchoring pulleys to the 1st section. continuity failure in one or both of the conductors, but the
rubber jacket of the wire is still intact. Alternative #2 is to be
6. Install capscrews in the front or rear cord clamp plate.
used if the wire has been completely cut or either end of the
Tighten the capscrews to secure the cord.
wire is inaccessible.
7. At the opposite end loosely install capscrews in the cord
Do not, under any circumstances, work at an elevated height
clamp plate. Pull on cord to remove any slack and
without using proper fall protection as required by local, state
tighten the capscrews to secure the cord.
or federal regulations.

Alternative #1 proper anti-two block system operation. Consult

electrical schematic in this book for proper connector
This procedure pulls the replacement wire through the boom wiring.
12. “Temporary splice” should now be approximately 10 feet
Special tools or equipment: (3 m) past the hoist mount end of the boom. Break
• Two end-to-end electrical butt connectors “splice” and slide strain relief cord grip onto wire, into
approximate position inside the boom.
• Shrink tube or electrical tape
13. Assemble spring to cord grip and reassemble anchor
1. Retract boom completely. components to extend cable anchor plate in the 2nd
2. Loosen and remove capscrew and cable clamp section. Slide cord grip up anti-two- block wire into boom
arrangement from sheave case attachment point of anti- to increase spring tension on moving length of anti-two
two block wire. Remove quick connect plug on switch block wire. Approximately 2 inches (50 mm) of spring
end of anti-two block wire by unscrewing base of plug extension tension should be adequate for proper
and disconnecting individual wires from connections. operation.
Note pigtail length at this time and wire/terminal number 14. Assemble Weather-Pack connector in appropriate
location for proper reassembly. position.
3. Pull end of anti-two block wire through side plates of 4th 15. Visually inspect interior routing of anti-two block wire for
section boom to gain in-line wire path. excess slack in wire, inaccurate routing of wire, etc.
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4. Attach replacement anti-two block wire to damaged wire Correct any problems before boom operation.
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with a “temporary splice”, securing the conductors with
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end to end butt connectors and shrink tube or electrical
tape. This connection must be secured well enough to
Alternative #2
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This procedure is to be used for anti-two block wire
pull the new wire through the boom.
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5. At the hoist mount end, reach into the rear of the boom wire, or the inability to access one or both of the ends outside
and loosen the capscrew on the anti-two block cable the boom assembly. This procedure routes a new anti-two
clamp enough to let the cable run around it with minimal block wire through the boom without having an existing wire
er
effort. This clamp is located on the extend cable anchor to pull it through (Alternative #1).
in the 4th section.
Special tools or equipment:
6. Disassemble capscrew attaching cord grip spring anti- • Electrical tape
two block wire to the extend cable anchor on the 2nd
section at the hoist mount end of the boom. • Installation tool
7. Pull wire from hoist mount end. Replacement wire To route the wire the entire length of the boom, a long tube,
“temporary splice” may need assistance reeving around to be used as an installation tool, must be utilized to transport
anti-two block cable clamp in rear of 4th section. If the end of the anti-two block wire from one end of the boom
excessive force is needed to pull wire through, observe assembly to the other. A telescopic grease applicator for the
wire routing and make adjustments as needed to avoid boom, hydraulic tubing or electrical conduit are all
breaking “temporary splice.” If splice fails at this point, possibilities for an installation tool. The installation tool
wire routing Alternative #2 should be used. should be at a minimum 2 feet (0.5 m) longer than the
retracted boom assembly.
8. Pull wire through boom, leaving enough wire on sheave
case end to properly attach and terminate wire. 1. Retract boom completely.
9. Tighten anti-two block wire clamp located in rear of 4th 2. Loosen and remove anti-two block cable clamp
section. arrangements from sheave case and 4th section extend
anchor. Remove capscrew from extend cable anchor in
10. Route sheave case end of anti-two block wire around the 2nd section boom.
clamp in sheave case, and through holes in side plates.
Pulling on this end will tension the static length of anti- 3. Remove quick disconnect plug on the switch end of the
two block wire clamped in the 4th section. Approximately anti-two block wire by unscrewing base of plug and
15-25 lb (6-11 kg) is sufficient to provide proper disconnecting individual wires from connections. Note
operation. Tighten sheave case anti-two block wire pigtail length at this time, and wire terminal number
clamp. location for proper reassembly.
11. Reassemble switch end quick disconnect plug to anti- 4. Pull anti-two block wire out of boom assembly. Visually
two block wire. Proper wire attachment is critical for inspect boom interior from both ends to verify all the

cable has been removed from the boom. Visually 16. Route sheave case end of anti-two block wire around
inspect center sheave on extend cylinder for damage. clamp in sheave case and through holes in side plates.
Pulling on this end will tension the static length of anti-
5. Start installation of replacement wire on the sheave case
two block wire clamped in the 4th. about 15-25 lb (7-
end of the boom assembly. Using electrical tape, attach
11 kg) is sufficient to provide proper operation. Tighten
one end of replacement wire to the end of the installation
sheave case anti-two block wire clamp.
tool.
17. Reassemble quick disconnect plug to anti-two block
6. Insert installation tool and wire into sheave case in the
wire. Proper wire attachment is critical for proper anti-
center open area between the sheave case side plates.
two block system operation. Consult electrical
Visually guide the wire and installation tool over the
schematic in this book for proper connector wiring
center sheave on the extend cylinder sheave case.
18. From hoist mount end of boom, slide strain relief/cord
7. Push installation tool and wire through boom until it
grip onto wire, into the approximate position inside the
appears at the hoist mount end. Detach wire from
installation tool. Route wire through open top of hoist
boom. 3
mount and temporarily tie off to a convenient anchor 19. Assemble spring to cord grip and reassemble anchor
point. Pull installation tool out sheave case end of boom. components to extend cable anchor in the 2nd section.
Slide cord grip up anti-two block wire into boom to
8. From sheave case end of boom, attach other end of
increase spring tension on moving length of anti-two
replacement wire to installation tool with electrical tape.
block wire. About 2 inches (50 mm) of spring extension
Insert installation tool and wire into the boom sheave
tension should be adequate for proper operation.
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case in the open area between the sheave case side
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plates. Visually guide this end under the center sheave 20. Visually inspect interior routing of anti-two block wire for
9. nl c
on the extend cylinder sheave case.
Push installation tool and wire through boom until it
excess slack in wire, inaccurate routing of wire, etc.
Correct any problems before boom operation.
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appears at the hoist mount end. Do not detach wire from
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installation tool. ANTI-TWO BLOCK INTERNAL WIRE

SYSTEM: FOUR SECTION BOOM
10. From hoist mount end of boom, locate installation tool
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and attached wire, and pull the wire out of the boom Operation
section, removing the slack loop from the sheave case
end of the boom. This will place the wire close to, if not The internal anti-two block wire system is routed through the
on the center sheave of the extend cylinder. boom in two stages. The first stage, 1/2, runs between the
top plates of the first and second sections on a traveling
11. Move to he sheave case end of the boom. Visually
block. The 1/2 and 2/3/4 sections are joined with a Weather-
determine if the wire has properly located itself onto the
Pack connector. The second stage, 2/3/4, is anchored at the
sheave. If not, manipulate the wire placement through
back of the second section, passes over the sheave at the
the end of the boom and place the wire on the sheave. A
end of the telescoping cylinder and is then anchored at the
5 ft (1.50 m) long access tool (hook end) will simplify this
hoist end of the fourth section. After running the length of the
procedure greatly.
boom inside of the fourth section, it is connected to the anti-
12. From the hoist mount end of the boom, assemble the two block switch mounted on the side of the sheave case.
anti-two block wire clamp on the extend cable anchor in
the rear of the 4th section. Loop anti-two block wire Maintenance
around clamp and lightly tighten capscrew holding
In the event of a break in continuity of the anti-two block wire,
clamp together. Keeping a slight amount of tension on
the hydraulic portion of the system will be disabled and make
the wire at this point will keep the wire properly located
certain crane functions inoperative. Before repair or
on the sheave.
replacement of either of the two stages, check for continuity
13. From the sheave case end, pull the installation tool and loss at the anti-two block switch, connector damage or
wire end out of the boom. The route of the anti-two block corrosion, and overall system condition. Due to the
wire in the boom is now complete. environmental exposure of the system, a thorough check of
the circuit should be performed.
14. Pull wire at either end of boom to adjust length of wire on
sheave case end to properly attach and terminate wire. If the internal wire has lost continuity it will probably be
necessary to replace only one of the two stages in the circuit,
15. Tighten anti-two block wire clamp located in rear of 4th the 1/2 or the 2/3/4 stage. A simple continuity test of both
section. stages should identify which one contains the failure.

1. Unplug the Weather-Pack connector linking the two 5. Remove capscrews and retaining plates from the top
stages together at the hoist end of the second boom backs of the first and second sections.
section.
6. Attach replacement anti-two block wire to damaged wire
2. With the anti-two block switch in its closed position with a “temporary splice”, securing the conductors with
(weight suspended from switch or overridden with the end-to-end butt connectors and shrink tube or electrical
red flag), check continuity across the Weather-Pack tape. This connection must be secured well enough to
terminals on the 2/3/4 stage. If there is no continuity in pull the new wire through the boom.
the 2/3/4 stage, re-check continuity of the anti-two block
7. Slowly pull the new wire into the boom by pulling on the
switch on its own and re-check continuity of the 2/3/4
opposite end of the damaged wire. If this method fails,
wire to ensure the wire is the problem. If continuity
Alternative #2 should be used.
exists, the problem is in the 1/2 stage.
8. Once enough new wire has been pulled past the
3. If the fault is suspected in the 1/2 stage, unplug the
retaining plate location, remove temporary splice,
connector at the turret. Install a jumper wire across the
reattach the retaining plate and install the connector on
terminals of one of the connectors and check for
that end of the wire. The connectors on this cable are
continuity at the opposite connector.
two separate styles. Make sure the Weather-Pack
After determining which wire stage contains the fault, refer to connector is on the end that will attach to the 2/3/4 wire.
the following procedures for replacement.
9. Loosely attach the retaining plate on the other end of the
new wire.
1/2 STAGE ANTI-TWO BLOCK WIRE
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10. While pulling on the new wire with a tension of about
ef or
REPLACEMENT
15-25 lb (7-11 kg), tighten the capscrews on the
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The 1/2 stage anti-two block wire is located between the top
plates of the 1st and 2nd boom sections, riding on a traveling
retaining plate.
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11. Using the length recorded earlier, measure the cord and
block. The maintenance of this wire can be accomplished
R F
attach the connector. The connectors on this cable are

with the boom fully assembled but would be simplified if the
2/3/4 boom assembly was re moved from the first section.
connector is on the end that will attach to the 2/3/4 wire.
er
12. Install a jumper across the terminals of one of the
connectors and check for continuity at the opposite
WARNING connector. If the new wire does not have continuity,
Do not, under any circumstances, work at an elevated check the terminals to ensure they have been attached
height without using proper fall protection as required by correctly.
13. Do not proceed until this wire shows continuity.
DISASSEMBLY OF 1/2 STAGE excess slack in wire, inaccurate routing of wire, etc.
Correct any problems before boom operation.
Alternative #1
15. Make all wire connections, reattach the wire to the
This procedure pulls the replacement wire through the boom
cushion clamp on the bottom of the boom and check
system for correct operation.
16. Slowly cycle the boom while checking for proper wire
• Two end-to-end electrical butt connectors operation.
• Shrink tube or electrical tape
Alternative #2
1. Retract boom completely.
This procedure is used for anti-two block wire re placement
2. Unplug Weather-Pack connector between 1/2 and 2/3/4 in the event of a complete separation of the wire or the
stage, located at rear of second boom section. inability to access one or both ends of the damaged wire
outside of the boom assembly.
3. Unplug connector in turret and disconnect wire from
cushion clamp on bottom of first boom section. Specials tools or equipment
4. Measure the amount of wire from the retaining plates to • Electrical tape
the connectors on both ends of the 1/2 wire. Record • Installation tools
these numbers for later use.

1. Retract boom completely. Do not allow the retention button on the steel cable to go
inside of the boom.
2. Measure the lengths of the two ends of the anti- two-
block wires that are outside of the clamps on the first and 14. At the hoist end of the boom, reach inside of the boom
second boom sections. Record these dimensions. and draw out the two tools hooked over the top plate of
the second section.
3. Remove capscrews and retaining plates from the top
plates of the first and second sections. Remove both 15. At the sheave case end of the boom, reinstall the spacer
ends of the damaged anti-two block cord from the boom. plate between the top front of the first and second
sections. Make sure that the steel cable is still running
4. Extend the boom until the reinforcing plate on the top of
through the slot in the spacer bar.
the second section is outside of the first section by about
24 inches (61cm). 16. At the hoist end of the boom, draw the two ends of the
new wire out of the boom until the retention button on the
5. At the sheave case end of the boom, remove the two
steel cable is drawn against the spacer bar.
capscrews and washer from the spacer bar under the
bottom of the first section top plate. 17. Run the new wire back and forth through the traveling
3
block sheave to make sure it runs freely. Do this by
6. Using the anchor button on the steel cable, which drives
alternately pulling on one end or the other of the new
the anti-two block wire, remove the spacer bar and pull
wire while maintaining slight tension on the other end of
the traveling blocks out of the boom.
the wire.
7. Inspect the steel cable for damage or defects.
18. Loosely replace the retention clamps on the wire after
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measuring out one end to ensure the correct wire length
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8. Extend the boom to maximum extension. This provides
the least amount of overlap between the two sections for the connector.
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and makes it easier to hook an installation tool at the
19. Tighten the clamp on the measured end of the wire and
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back of the second section.
replace the connector. The connectors on this cable are
R F
9. Using #9 wire or another stiff yet bendable material, two separate styles. Make sure the Weather-Pack
make two tools which are about 72 inches (183 cm) in connector is on the end that will attach to the 2/3/4 wire.
length with a hook at one end which has an opening of
20. While pulling on the new wire with a tension of about
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0.5 inch (1.3 cm).
15-25 lb (7-11 kg), tighten the capscrews on the second
10. Insert the hooked end of the two “tools” into the space retaining plate.
between the tops of the first and second sections and
21. Using the length recorded earlier, measure the cord and
run them back until the tools hook over the top plate of
attach the connector. The connectors on this cable are
the second section.
11. Run the replacement wire through the open sheave (one connector is on the end that will attach to the 2/3/4 wire.
sheave will have the steel cable routed through it
22. Install a jumper across the terminals of one of the
already) of the traveling block and temporarily attach
connectors and check for continuity at the opposite
each end of the new wire to the two tools. You have now
connector. If the new wire does not have continuity,
made a big loop with the two tools and the new wire
check the terminals to ensure they have been attached
routed through the sheave.
correctly.
12. Slowly retract the boom maintaining tension on the new
23. Do not proceed until this wire shows continuity.
wire, both sides of the loop, and the steel proportioning
cable. At the time when the reinforcing plate is about 24. Visually inspect interior routing of anti-two block wire for
24 inches (61 cm) outside of the first section, you need excess slack in wire, inaccurate routing of wire, etc.
to allow the traveling block to pass back into the first Correct any problems before boom operation.
section.
25. Make all wire connections, reattach the wire to the
13. While still maintaining tension on both sides of the loop cushion clamp on the bottom of the boom and check
of the new wire and a little tension on the steel system for correct operation.
proportioning cable, retract the boom to full retraction.
26. Slowly cycle the boom while checking for proper wire
operation.

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1/2 Wire Routing
R F
2/3/4 STAGE ANTI-TWO BLOCK WIRE 1. Retract boom completely.

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REPLACEMENT 2. Loosen and remove capscrew and cable clamp from
sheave case attachment point. Remove connector from
The procedure for removal and reinstallation of the 2/3/4
wire, measure and record pigtail length from attachment
stage anti-two block wire can be accomplished using two
point, and pull end of wire through the side plates of the
different methods depending on the severity of the damage.
boom to align the end with the wire routing over the
Alternative #1 should be used if the wire has experienced a
telescope cylinder.
continuity failure in the conductors but the rubber jacket of
the wire is still intact. Alternative #2 is to be used if the wire 3. Attach replacement anti-two block wire to the damaged
has been completely cut or either end of the wire is not wire using the end-to-end butt connectors and tape or
accessible. shrink tube. This connection must be secured well
enough to pull the new wire through the boom.
4. At the hoist mount end of the boom, reach into the rear
WARNING of the boom and loosen the capscrew on the anti-two
block cable clamp enough to let the cable run around it
with minimal effort. This clamp is located on the extend
height without using proper fall protection as required by
cable anchor at the back bottom of the fourth section.
5. Disassemble capscrew attaching cord grip/ spring/anti-
Alternative #1 two block wire to the extend cable anchor on the 2nd
boom section at the hoist mount end of the boom.
This procedure pulls the replacement wire through the boom
following the path of the defective wire. 6. Slowly pull the damaged wire from the hoist mount end
of the boom. The splice on the end of the replacement
Special tools or equipment: wire may need help moving around the cable clamp at
• Two end-to-end butt connectors the bottom back end of the fourth section. If excessive
force is needed to pull the wire through, observe the
• Shrink tube or electrical tape routing for obstructions and make adjustments to avoid
breaking the splice. If the splice fails Alternative #2 may
need to be used.

7. Pull the wire through the boom until enough wire is left 1. Retract the boom completely.
on the sheave case end of the boom to attach the
2. Loosen and remove the anti-two block clamp from the
connector and route and anchor the wire. Refer to
sheave case and fourth section extend cable anchor.
measurement taken earlier.
3. Remove the capscrew from extend cable anchor at the
8. Tighten the clamp at the back bottom of the fourth
back of the second boom section.
section.
4. Remove the connector from the wire at the sheave case
9. Apply about 15-25 lb (7-11 kg) of tension to the wire at
end of the boom. Measure and record the length of the
the sheave case end of the boom. Tighten the clamp on
pigtail from the cable clamp to the connector.
the wire in the sheave case.
5. Remove all damaged wire from the boom. Visually
10. Reattach the connector to the wire and make the
inspect the interior of the boom to make sure all of the
connection between the new wire and the anti-two block
damaged wire is removed. Inspect sheave at the end of
switch. The connectors on this cable are two separate
styles. Make sure the Weather-Pack connector is on the
the telescope cylinder to make sure it is not damaged. 3
end that will attach to the 1/2 wire. 6. Start installation of the replacement at the sheave case
end of the boom. Tape one end of the new wire to one
11. Cut the splice from the new wire and slide the cord grip
end of the installation tool.
to its approximate final position.
7. Insert installation tool and wire into the sheave case in
12. Reattach spring to cord grip and reassemble the parts at
the center open area between the sheave case side
the cable anchor on the back of the second boom
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plates. Visually guide the wire and installation tool over
section. Slide cord grip up anti-two block wire into boom
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the center sheave on the telescope cylinder sheave
to increase spring tension on moving length of anti-two
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block wire. Approximately 2 inches (51 mm) of spring
extension tension should be adequate for proper
case.
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8. Push installation tool and wire until it can be pulled
operation. through the hoist end of the boom. Detach wire from tool
R F
and pull tool back out the sheave case end of the boom.
13. Reattach the connector to the wire and make the
connection between the new wire and the anti-two block 9. Attach the other end of the wire to the tool and again
er
switch. The connectors on this cable are two separate insert the tool into the boom between the sheave case
styles. Make sure the Weather-Pack connector is on the side plates. This time guide the tool into the boom and
end that will attach to the 1/2 wire. under the center sheave of the telescope cylinder.
14. Visually inspect interior routing of anti-two block wire for 10. Push tool and attached wire through the boom until it
excess slack in wire, wrong routing of wire, etc. Correct can be grasped from hoist end. Do not detach wire at
any problems before boom operation. this time.
Alternative #2 11. Apply tension to both ends of the new wire. This will
draw the new wire into the groove of the center sheave
This procedure is to be used for anti-two block wire of the telescope cylinder sheave case.
12. From the sheave case end of the boom, verify that the
wire, or the inability to access one or both ends of the
wire is in the groove of the center sheave. If the wire is
damaged wire. This procedure routes a new anti- two-block
not properly aligned, a 5-foot (1.5 m) piece of stiff wire
wire through the boom without having an existing wire to pull
may have to be used to guide the wire into the groove.
it through (Alternative #1).
13. At the hoist mount end of the boom, assemble the clamp
attached to the extend anchor at the bottom back of the
• Electrical tape fourth boom section.
• Installation tool 14. Loop the wire that is still taped to the tool around the
To route the wire the entire length of the boom, a long tube, clamp and slowly draw the tool back out of the sheave
to be used as an installation tool, must be utilized to transport case end of the boom.
the end of the new anti-two block wire from one end of the 15. The routing of the new wire is now complete and the tool
boom assembly to the other. A telescopic grease applicator can be detached from the wire. Visually inspect the wire
for the boom, hydraulic tubing or electrical conduit are all routing to make sure that it is correctly routed.
possibilities for use as an installation tool. The installation
tool should be at a minimum 2 feet (0.5 m) longer than the 16. Pull the wire from either the sheave case or hoist end of
retracted boom length. the boom to get the end lengths closer to what is
required.

17. Tighten the clamp at the bottom back of the fourth position inside of the boom. Install the capscrew into the
section. spring and cable anchor. While applying tension to the
wire, slide the cord grip out the wire until there is
18. Reassemble the clamp at the sheave case and while
approximately 2 inch (50 MM) of spring extension for
applying 15-25 lb (7-11 kg) of tension to the new wire,
proper operation.
tighten the clamp. Measure the length of pigtail required
and reassemble the connector onto the wire. Route the 20. Attach connector to wire. The connectors on this cable
connector through the sheave case and make the are two separate styles. Make sure the Weather-Pack
connection with the anti-two block switch. The connector is on the end that will attach to the 1/2 wire.
connectors on this cable are two separate styles. Make
21. Visually inspect routing and anchors for correct
sure the Weather-Pack connector is on the end that will
assembly, excessive slack and/or capscrew torque, etc.
attach to the 1/2 wire.
Verify continuity of new anti-two- block wire.
19. At the hoist end of the boom, install the cord grip and
spring onto the new wire at the approximate final
Center Sheave on
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Telescoping Cylinder Anchor at Top Back
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of Second Section Weather Pack
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R F
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Clamp at Sheave Case

Anchor at Top Back
of Fourth Section
anti-two block Switch
2/3/4 Wire Routing
REPLACEMENT OF PROPORTIONING the reinforcing plate on the second section during boom
CABLE FOR 1/2 STAGE OF ANTI-TWO retraction.
BLOCK WIRE 1/2 Stage Anti-Two Block Wire Maintenance
1/2 Stage Anti-Two Block Wire Operation The wire can be replaced with the boom assembled. If the
wire has separated and become lodged in the boom extend
The 1/2 stage of the anti-two block wire is driven by a small and/or retract sheaves, boom disassembly will probably be
diameter steel proportioning cable. This cable drives the required. There are two alternatives to the steel cables'
traveling block, which carries the live wire of the system. The replacement. Alternative #1 will deal with an intact cable and
location of the traveling block at full extension and retraction alternative #2 will deal with a cable that has been cut into two
is critical to the proper operation of this system. If the pieces. The replacement cable supplied through Manitowoc
traveling block is not located correctly, it could either fall off of Crane Care works for several different lengths of booms. It
the back of the second section during boom extension or be will have to be installed and cut to the correct length during
pinched between the first and second section top plates by assembly.

8. At the sheave case end of the boom, install the spacer

MODEL LENGTH (X) and capscrews in the top front of the first section. Make
680E2 525.00 sure that the new anti-two block wire is routed through
the slot in the spacer bar.
649E2 339.50
9. Visually inspect the routing of the proportioning cable to
Alternative #1 make sure that it is properly seated in the sheave
grooves.
Special Tools:
10. Cut off the excess wire from the new wire that is sticking
• Electrical tape out of the first section leaving a length of about 24 inches
(61 cm). This will allow a short amount of wire to use to
• Short Cord or Wire
apply tension and for the installation of the cable stop
1. Retract the boom completely. and shrink tube without dealing with a lot of extra wire.
2. At the hoist mount end of the boom, remove the 5/16-1 11. Slide the cable stop onto the end of the wire sticking out 3
8NC grade 5 capscrew through the slot on the top plate of the end of the first section and run it up against the
of the first boom section. spacer bar. While pulling on the steel cable with a
tension of about 15-25 lb (7-11 kg), tighten the screw in
3. Pull the end of the cable out of the back of the boom and
the cable stop.
connect a short piece of wire or cord through the loop.
Anchor the cord in order to keep control of the end of the 12. Slide a new piece of shrink tube onto the end of the wire,
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cable. run it up against the cable stop, and apply heat to shrink
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the tube. This will prevent the end of the wire from
4. At the sheave case end of the boom. Remove the two
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capscrews and spacer bar from the top front end of the
first boom section. As the spacer bar is removed, pull the
fraying.
13. Cut off the excess wire leaving about 1 inch (25 mm) of
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steel cable along with the bar. The cord on the opposite wire with shrink tube sticking out of the cable stop.
R F
end of the steel cable will allow some length of cable to

14. Slowly operate the boom to make sure the sheaves turn
be pulled from the boom. Do not pull hard enough to
and the cable runs correctly.
break the hoist end of the cable loose.
er
5. Remove the cable stop from the end of the old Alternative #2
proportioning cable and fasten the eyelet end of the new
This is the method to be used in the event the proportioning
wire to the old cable with electrical tape.
cable has been cut during use. In this method a long
6. While maintaining some amount of tension on the new installation tool is used to run the new wire from one end of
wire pull the old wire out of the boom at the hoist end of the boom to the other.
the boom assembly. When the eyelet of the new wire
Special tools:
becomes visible at the hoist end of the boom, stop
pulling on the wire. • Electrical tape
• Installation tool
665.00 1. Retract the boom completely.
1.00
2. At the hoist end of the boom, remove the 5/16 -1 8NC
capscrew from the top plate of the second section. This
capscrew is accessible through a slot in the top plate of
the first section.
Cut cable here 3. Remove the old wire from the boom.
X ± 1.00
after tightening
4. Extend the boom until the reinforcing plate on the
second section is extended about 24 inches (61 cm) out
7. Detach the old and new wires. Insert the eyelet of the of the first section.
new wire into the space between the top plates of the
5. At the sheave case end of the boom, remove the two
first and second sections. Reattach the wire to the top
capscrews and the spacer plate from the front top of the
plate of the second section with the 5/16-18NC grade 5
first section. As the spacer plate is pulled from the boom,
capscrew that was removed earlier.
bring the old wire out of the boom.
6. Extend the boom completely.

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1/2 Wire Routing
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7. Use a piece of #9 wire as an installation tool. Make a 13. Again using the #9 wire, reach into the space between
hook with an opening of about ½ inch (13 mm) on one the first and second sections and hook and pull the
R F
end. With the other end of the #9 wire, run the wire traveling block out of the boom assembly. Inspect the
through the eyelet on the new wire and bend the wire traveling block for damage.
over to make a hook. Tape the #9 wire and new
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14. Route the proportioning cable around the sheave
proportioning cable to make sure these parts stay
mounted to the top plate of the first section. Then run the
together as the cable is installed. The new wire is now
new steel cable through the open sheave of the traveling
attached to the installation tool.
block.
8. Insert the tool into the space between the top plates of
15. At the hoist end of the boom, slowly pull the circuit wire
the first and second sections and hook it over the back of
back out of the back of the boom until it reaches its
the top plate on the second section.
original location. A crimped area on the jacket of the wire
9. Slowly retract the boom while maintaining tension on the should be visible and line up with the clamp plate.
new steel cable. Loosely tighten the retaining plate capscrews.
10. When the boom is fully retracted, reach into the boom 16. If the parts are properly aligned, the center pin of the
and pull the tool on out of the back of the boom. Detach sheave on the sheave case end of the traveling block
the tool from the new proportioning cable. Route the end should be about 1-1/2 inches (29 cm) behind the center
of the new wire around the sheave at the back of the first of the sheave bolted to the top plate of the first section. If
section and align the eyelet of the cable with the hole in the traveling block is not located correctly, it will be
the top plate of the second section. Loosely install the 5/ damaged during boom extension or retraction.
16-18 NC capscrew.
17. Tighten the 5/16-1 8NC capscrew at the top hoist end of
11. On the power circuit side of the anti-two block system, the second section. Tighten the capscrews in the
disconnect the connectors in the turret and remove the retaining plate at the hoist end of the first section.
cushion clamp at the bottom of the boom. Loosen the
18. At the sheave case end of the boom, install the spacer
cable clamp on the top hoist end of the first section.
and capscrews in the top front of the first section. Make
Loosening this wire will allow the traveling block to be
sure that the new anti-two block proportioning cable is
drawn out of the front end of the boom assembly.
routed through the slot in the spacer bar.
12. While the new steel proportioning cable is being held
19. Visually inspect the routing of the proportioning cable to
and guided to prevent damage, extend the boom until it
make sure that it is properly seated in the sheave
is fully extended.
grooves.

20. Cut off the excess wire from the new wire that is sticking 1. Refer to Hydraulic Schematic and System Description to
out of the first section leaving a length of about 24 inches gain a thorough understanding of the capacity alert
(61 cm). This will allow a short amount of wire to use to system before proceeding with any maintenance.
apply tension and for the installation of the cable stop
2. System adjustment must be checked every three
and shrink tube without dealing with a lot of extra wire.
months for accuracy. Refer to the preceding section on
21. Slide the cable stop onto the end of the wire sticking out System Adjustment.
of the end of the first section and run it up against the
3. Always be sure the boom is adequately supported and
spacer bar. While pulling on the steel cable with a
no hydraulic pressure remains in the lines before the
tension of about 15-25 lb (7-11 kg), tighten the screw in
pilot pressure line fittings are loosened.
the cable stop.
22. Slide a new piece of shrink tube onto the end of the wire, HCA System Adjustment
run it up against the cable stop, and apply heat to shrink
the tube. This will prevent the end of the wire from
fraying.
The hydraulic capacity alert system should be checked for
proper adjustment during initial crane start-up and quarterly
3
thereafter. The procedure for proper adjustment should be
23. Cut off the excess wire leaving about 1 inch (25 mm) of performed as follows:
wire with shrink tube sticking out of the cable stop.
NOTE: Trapped air must be bled from the system before
24. Slowly operate the boom to make sure the sheaves turn adjustments are made.
and the cable runs correctly.
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1. Remove the console cover on the operators console.
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.
HYDRAULIC CAPACITY ALERT SYSTEM
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This hydraulic capacity alert (HCA) system uses the work WARNING
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port unloader solenoids in the anti-two block system as the
Before loosening any fittings, support the boom.
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hydraulic system dump circuit.

The hydraulic capacity alert system has an override switch 2. Start the truck and set the crane up for operation as
a n d b ut t o n l o c a t e d o n t h e o p e r a t o r ’s c o n s o l e t h a t prescribed in the Operators Manual.
er
momentarily overrides the hydraulic capacity alert and anti- 3. Select a test weight that is equal to crane capacity at an
two block systems and restores power to crane functions. intermediate boom length and radius.
When trip pressure is reached, the pressure sensing switch 4. Work with loads which have loaded boom angles near
breaks electrical continuity to the work port unloader 30°. Starting with the boom at the chosen reference
solenoid in the main control valve.When power is removed angle and a radius less than the chosen radius, pick the
from this solenoid, the unloader valves allow the oil flowing to weight up with the hoist and begin extending the boom.
hoist up, telescope out and boom down to flow to tank. This
path to tank will prevent further operation of these functions. 5. As the boom is extending, lower the load with the hoist to
When the overload condition is corrected by hoisting down, keep the load near the ground.
retracting the boom, or raising the boom, the pressure
6. Monitor the load range gauge located in the console as
sensing switch allows the work port unloader solenoids to be
the boom is extending. The gauge is plumbed directly
powered, thereby allowing the crane to function normally.
into the lift cylinder pilot line and the pressure reading
should increase to what is defined as capacity load
HCA Maintenance & Repair pressure as the selected intermediate boom length and
The following step-by-step analysis will be helpful in isolating radius is reached.
and correcting almost every service problem if followed in a
7. The intermediate boom length is determined by a line
step-by-step systematic manner. Use this information with
and corresponding dimension decal on the side of the
the Hydraulic Schematic and the Illustrated Parts Catalog to
second section boom. The chosen radius is measured
identify parts and follow flow paths. Start at top box and work
from the centerline of rotation to the loadline.
downward step by step. Do not try to start in the middle or
skip steps.

14. Once proper adjustment is verified, return the boom to a

firmly supported position, stop the truck engine and
replace covers.
Cover Operators
Console
8. If the gauge reading does not increase while extending, HCA pressure
lower the load to the ground and check the system switch
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Adjustment
plumbing according to the hydraulic schematic.
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Knob
Re-plumb the system according to the schematic and
. nl c
illustrated parts page or replace faulty pressure gauge.
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WARNING
Before loosening any fittings, support the boom.
JIB LOAD LIMITING DEVICE
er
9. When the pressure reaches capacity load pressure, the The jib load limiting device is an electromechanical
overload system should activate and boom extension maximum capacity sensing system that stops normal crane
will stop. This is defined as trip pressure. This point functions which cause an overload condition when the
should be at or very close to the red/yellow color change maximum capacity of the jib is exceeded. In the event that an
on the load range gauge. over capacity condition occurs, the jib load limiting device is
10. Trip pressure should be reached as the boom extension actuated by a load cell which causes the boom down, extend
reaches the chosen radius. If the overload system trips out, and hoist up functions to become inoperative. On jibs
before the chosen radius is reached or allows extension with a manually extendable section, a configuration switch
beyond the chosen radius, adjustment is required. If the operated by the extension retaining pin distinguishes
system is activated before trip pressure is reached, between an extended jib and a retracted jib. This system
lower the load and turn the knurled collar on the HCA allows for continued operation of the hoist down, boom up,
pressure switch clockwise to increase trip pressure. and boom retract. This allows the operator to bring the load
to a shorter operating radius or set the load down in order to
11. When the gauge reaches trip pressure, turn the eliminate an overload condition. Once the overload has been
setscrew counterclockwise until the system solenoid is reduced, normal operation can be resumed. This system
deactivated and tighten the locking nut. uses the work port unloader solenoid in the anti-two block
12. Retract the boom until the pilot pressure is reduced system as the hydraulic system dump circuit.
enough to reactivate the system solenoid. The hydraulic When trip force is reached, the jib load limiting device breaks
capacity alert indicator light will go out when the solenoid electrical continuity to the work port unloader solenoid in the
is reactivated. main control valve. When power is removed from this
13. Check the trip pressure setting by extending the load solenoid, the unloader valves allow the oil flowing to hoist up,
until the chosen radius is reached. As the chosen radius telescope out and boom down to flow to tank. This path to
is reached, the system solenoid should be deactivated tank will prevent further operation of these functions. When
and the indicator light should come on. Readjust switch the overload condition is corrected by hoisting down,
head if trip pressure is not correct. retracting the boom, or raising the boom, the jib load limiting
device allows the work port unloader solenoid to be powered
thereby allowing the crane to function normally.

During operation at near capacity loads, care must be taken After the table number is displayed, the display starts to
to operate the controls smoothly or the system may be sequence through the following information. After reaching
shocked into the dump mode prematurely. the end of the sequence, the display starts again at the
current load reading.
Single Character Display
• Current load reading (lbs.):
The electronics box of the jib load limiting devices equipped
- 4 digits, decimal point on
with a single character display that provides the following
information: • Current limit value (lbs.):
• startup codes - 4 digits, decimal point flashing
• table number selected • Error codes (only if an error exists):
• current load reading - 4 digits, first and last digits are blanks.
• current limit value - 0-invalid table number, 3
• error codes
- 1-load readings higher than the limit.
• current angle reading.
• Current angle reading:
On power-up, the unit first displays the startup codes. The
- 4 digits, decimal point off, displays in tenths of
startup codes can be a sequence of up to four single digits,
degrees.
but is usually only one digit which is a “2”. Each number is
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displayed for 1/2 second.
Jib Load Limiting Device Troubleshooting
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Startup codes are:
See chart in Section 8 of this manual.
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• Code (1) Indicates the unit is being initialized. This only
happens the first time the unit is powered up after it is OUTRIGGER MONITORING SYSTEM (OMS)
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programmed.
(OPTIONAL—STANDARD IN NORTH
• Code (2) Indicates that the previously stored table is AMERICA)
er
being erased. This is displayed when the unit is powered
on and the switches are not set for the new table Operation
numbers.
The Outrigger Monitoring System (OMS) aids the operator in
• Code (3) Is displayed only before a new table number is ensuring that the crane is properly setup on outriggers and
stored. The “2” is displayed first. stabilizers. The OMS utilizes one sensor in each outrigger
• Code (8) The switches are set up with the new table and one proximity switch in each horizontally extending
number and the old number is erased. On the next stabilizer to identify when the outriggers and stabilizer beams
power on, the new table number is read in and stored. are extended to a point in which they provide maximum
stability.
After the startup codes, the table number is displayed in the
form of three sequential single digits. The first digit is always The OMS utilizes an LED indicator to communicate to the
zero. The digits are displayed for about 1 second each. operator the position of the outriggers and stabilizers. The
Outrigger Status Indicator is a bi-color LED located at each
control station.

Maintenance 4. Connect electrical connector (1, Figure 3-1) to sensor.

5. Calibrate sensor. Refer to Calibrate, page 3-18.
Outrigger Cylinder Length Sensor (Version
1) Calibrate
Calibrating the cylinder length sensor requires a laptop
equipped with the HED Conductor software and a USB cable
connector (p/n 80009992). Contact your National Crane
distributor for further assistance.
Outrigger Proximity Switch (Version 2)

3
1 On newer versions of the crane, the OMS and RCL use
proximity switches to determine if the outriggers are fully
2 extended. The switches are located between the operator’s
cab and A-frame outriggers. The proximity switch (1,
Figure 3-2) uses a tab (2) on the outrigger arm to determine
when the outrigger is fully extended.
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7939-3
er
FIGURE 3-1
Remove
1. Fully retract outriggers.
2. Disconnect electrical connector (1, Figure 3-1) at
sensor.
3. Remove setscrews (2, Figure 3-1) securing sensor
holding plate.
4. Slide sensor (3, Figure 3-1) out of sensor holding
bracket.
1
Install
1. Fully retract outriggers. 2
2. Slide sensor (3, Figure 3-1) into holding bracket. 9365 FIGURE 3-2
For illustration purposes only.
3. Using the two setscrews (2, Figure 3-1) and sensor Your crane may differ.
holding bracket, secure sensor to the hydraulic cylinder.

indicator on the operator’s console turns from

constant red to constant green when the outrigger is
1 fully extended.
2 or
3
4 - If equipped with an RCL and OMS systems,
outrigger status is shown on the QScale monitor.
Make sure all outrigger status symbols turn from red
to green when the outriggers are fully extended.
5
Angled Stabilizer Hydraulic (ASH) Proximity
Switch (version 1)
3
6 7
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1
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9366
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Remove
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1. Fully retract the outriggers.

4
2. Disconnect the proximity switch (1, Figure 3-2) and 3
er
5
sensor plug (3).
3. Remove capscrews (1, Figure 3-3), lockwashers (2),
and nuts (3) to remove plate (4) and proximity switch (5) 2
from chassis. 7939-4
4. Loosen jam nuts (6) and remove proximity switch (5)
from plate (4). 6
FIGURE 3-4
Install
Remove
1. Fully retract the outriggers.
1. Disconnect electrical connector (1, Figure 3-4) at switch.
2. Install proximity switch (5) on plate (4) using two jam
nuts (6). 2. Remove the two screws (2, Figure 3-4) securing the
mounting bracket/switch assembly to the stabilizer box.
3. Install switch (5) and plate (4) on chassis using
capscrews (1), lockwashers (2), and nuts (3). 3. Loosen jam nut (3, Figure 3-4) securing switch (4) to
mounting bracket. Remove switch.
4. Connect proximity switch (Figure 3-2) to sensor plug.
Install
NOTE: The proximity switch should be a maximum of 6.4
mm (0.25 in.) from the outrigger tab. 1. Fully extend stabilizer beam.
5. With power on, fully extend the outriggers. When active, 2. Thread switch (4, Figure 3-4) into mounting bracket (5)
the LED light (7) on the proximity switch illuminates so that face of switch protrudes 10 mm through bracket.
constant yellow. Depending on how the vehicle is 3. Using two screws (2, Figure 3-4), secure mounting
equipped, verify that the proximity switch output is bracket/switch assembly to stabilizer box.
working as follows:
4. Tighten jam nut (3, Figure 3-4) on switch.
- If equipped with Outrigger Monitoring (OMS) and
HCA systems, make sure the outrigger status 5. Connect electrical connector (1, Figure 3-4) to switch.

6. With power on and stabilizer beam fully extended, illuminates; retract stabilizer beam and ensure LED is
ensure LED (6, Figure 3-4) on proximity switch not illuminated.
illuminates; retract stabilizer beam and ensure LED is
not illuminated. Rear Stabilizer Out and Down (RSOD)
Proximity Switch
Angled Stabilizer Hydraulic (ASH) Proximity
Switch (version 2)
3
2
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4
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3
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7939-4
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4
FIGURE 3-6
er
FIGURE 3-5
Remove
Remove
2. Loosen jam nut (2, Figure 3-6) securing switch (3) to
stabilizer box; remove switch.
2. Remove the two screws (2, Figure 3-5) securing the
Install
switch (4) to the stabilizer box; remove switch.
1. Fully retract stabilizer beam.
Install
2. Thread switch (3, Figure 3-6) into stabilizer box so that
1. Fully extend stabilizer beam (horizontally).
face of switch is recessed 1 to 2 mm in the wear pad.
2. Using two screws (2, Figure 3-5), secure the switch (4)
3. Tighten jam nut (2, Figure 3-6) on switch.
to stabilizer box.
4. Connect electrical connector (1, Figure 3-6) to switch.
3. Connect electrical connector (1, Figure 3-5) to switch.
5. With power on and stabilizer beam fully extended,
4. With power on and stabilizer beam fully extended,
ensure LED (4, Figure 3-6) on proximity switch
ensure LED (3, Figure 3-5) on proximity switch
illuminates; retract stabilizer beam and ensure LED is
not illuminated.

REMOTE CONTROL
Safety DANGER
Starting truck engine with drive train engaged will cause
death or serious injury.
DANGER Do not start truck engine unless drive train is in neutral.
This crane is not insulated. The remote control provides
no protection against the electrocution hazard. Do not Before attempting to start truck with remote control make
operate near live electrical power lines. All warnings in the sure the drive train is in neutral.
Safety and Operation Section of this manual and on the When not using the remote control, disconnect power to the
crane relative to operating and safety procedures and remote control system with the selector switch installed in the
power line clearances must be observed when using the truck cab. This will prevent inadvertent operation of the crane
crane remote control. if the hand control is operated. Protect and monitor the hand
control unit to prevent damage and unplanned operation.
3
The remote control system offers an excellent solution to
safety, speed and ease of use, less downtime, and overall Operation
maneuverability. Like and device, there are precautions and
common sense that work hand in hand to assure safe and For operation instructions, see the Operator Manual.
reliable operations.
Service and Maintenance
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Never allow any operation until the operator has read all
ef or
instructions and has become completely familiar with the Follow t he p roce dure s o utline d in t he Se rvice and
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total system. Should anything happen unexplained,
unpredicted, or incorrect operation, immediately shut down
Maintenance Section of the Owner’s Manual to maintain
proper crane operation. The following procedure and
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the complete system and investigate! This includes shutting intervals represent additional required maintenance for a
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down all electronics, hydraulics, power take-offs, and crane equipped with a remote control option.
engines. Never resume operation until the problem has been
corrected! Initial Start Up
er
The return line oil filter cartridge should be changed after four
Danger Remote Start Hazard hours of operation and then again at 12 hours of operation.
After this initial break in period, normal maintenance
procedures found in the crane Service and Maintenance
DANGER Section of this book can be followed.
Starting truck engine with drive train engaged will cause
unexpected movement of the truck resulting in death or Troubleshooting, Repair and Replacement
serious injury. A few of the remote control components can be repaired, all
Do not install remote start relay on any chassis that can can be replaced. The following is a list of these items and
be started while transmission is in gear. recommended method of repair or replacement.
Before a remote start relay can be installed, the chassis
Circuit Breaker
must be equipped with a switch that prevents the engine
from starting while the transmission is in gear. There are two automatic resetting breakers in the system,
one 15 amp under the hood that protects the entire system
The remote start relay has been intentionally supplied and a 10 amp on the frame that protects the hand control. If a
separately from the rest of the remote engine compartment breaker is opening, it is an indication that there is a short
wiring. Before installing the remote start relay on any circuit somewhere in the system. It will generally stay open
chassis, the installer must verify that the chassis can not be from 30-60 seconds.
started while the transmission is in gear. The remote start
relay is only to be installed on a chassis that is equipped with Relays
a switch (neutral safety switch) that prevents the engine from Three 12 VDC, normally open, automotive type relays are
starting while the transmission is in gear. A chassis not installed under the truck hood on the ignition start and throttle
equipped with or that can not be equipped with a neutral advance circuits. One automotive type relay is installed in the
safety switch will not have the start relay installed and control console on the HCA-RCL override circuit. They are
therefore can not be started with the radio transmitter only. used so that current through the hand control does not
become excessive. These relays will occasionally fail from
physical damage, corrosion or excessive current through the

relay. Failure is evident when the relay will not close as

power is applied to the pilot terminal or will not open when
power is removed from the pilot terminal. These relays DANGER
cannot be repaired and must be replaced. Starting truck engine with drive train engaged will cause
unexpected movement of the truck resulting in death or
Solenoid Valve
serious injury.
If the solenoid valve is inoperative, it is generally because of: Do not install remote start relay on any chassis that can
• Contamination in the valve. be started while transmission is in gear.
Before a remote start relay can be installed, the chassis
• Not enough electrical power to operate solenoids.
must be equipped with a switch that prevents the engine
The valve can be disassembled and cleaned when from starting while the transmission is in gear.
contamination is suspected. If voltage drops below 10.5 V at
the solenoid coil, the solenoids may not operate. Defective RADIO REMOTE CONTROLS
electrical equipment on the truck will generally cause this low
voltage condition. Check the truck battery, voltage regulator Safety
and generator (alternator) in this case.
The radio remote control system offers an excellent solution
Installation to safety, speed and ease of use, less downtime, and overall
maneuverability. Like any device, there are precautions and
1. Install the crane on the truck by following the procedures common sense that work hand in hand to assure safe and
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in the Installation Section of this manual.
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reliable operations.
2.
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The Electrical and Hydraulic Schematics show the
typical connections of the remote control system.
Never allow any operation until the operator has read all
instructions and has become completely familiar with the
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a. The Pump pressure line is connected to the total system. Should anything happen unexplained,
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pressure port of the solenoid valve. unpredicted, or incorrect operation, immediately shut down
the complete system and investigate! This includes shutting
b. Install all electrical components and wires using the down all electronics, hydraulics, power take-offs, and
parts pages and electric schematic as reference for
er
engines. Never resume operation until the problem has been
this installation. This machine is wired at the factory corrected!
for a 12 VDC, negative ground electrical system.
When used on other than 12 VDC systems, a
suitable 12 VDC source must be provided to power
DANGER
the remote control. This remote control is not
intended for use with positive ground systems. Starting truck engine with drive train engaged will cause
death or serious injury.
c. Mount relay assembly in engine compartment in a
Do not start truck engine unless drive train is in neutral.
convenient location and connect the appropriate
wires to the terminal block as shown in wiring Before attempting to start truck with remote control make
schematic. Only install remote start relay on a sure the drive train is in neutral.
chassis equipped with a switch that prevents the
engine from starting while the transmission is in When not using the remote control, disconnect power to the
gear. remote control system with the selector switch installed in the
truck cab. This will prevent inadvertent operation of the crane
d. Adjust throttle actuator so it advances engine speed if the hand control is operated. Protect and monitor the hand
to approximately 80% maximum manual operating control unit to prevent damage and unplanned operation.
speed.
Always turn the truck ignition off and start the unit using the
remote hand control. This will allow the truck engine to be
turned off with the remote hand control. If the truck ignition is
on, the stop and emergency stop functions will not function.
Operation
For operation instructions, see the Operator Manual.

Service and Maintenance Troubleshooting

A premium quality 9 volt alkaline non-rechargeable battery is 1. Begin the process of elimination by always checking the
recommended. These batteries have a current rating of 600 fuse in the receiver first and then checking all wiring and
milliamps. When transmitting, current draw is 25 milliamps. connectors (Look for dead shorts in wiring and
Most of the current draw when transmitting is used by the connections).
radio frequency transmitting function. The current draw for
2. If the transmitting range drops or intermittent movement
the rest of the electronics in the transmitter is in the micro-
occurs when activating a function, read the following:
amp range. For instance, when the transmitter power switch
is on and the unit is not being used, the current draw is less a. Make sure the 9 volt battery is good in the
than one milliamp. This means that leaving the power switch transmitter.
in the ON position over night will not necessarily mean that
b. Be sure the antenna is free of vertical metal
the 9 volt battery will be dead. The system requires a battery
obstruction (minimum 2 feet).
that has a minimum voltage of 7.2 volts for satisfactory
operation. Rechargeable batteries are not recommended c. Any excess antenna cable should not be coiled
3
because of their poor charge memory. Their ability to take a together.
charge tends to degrade over time.
d. Check antenna cable connector at the receiver. Be
To install the 9 volt battery, remove the battery cover on the certain the antenna is properly installed and that
rear of the transmitter. Removal of the battery cover is easily there is nothing touching the bare portion of wires at
achieved by releasing the latch clip. Care should be taken the antenna connection. (Be sure antenna is
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not to use excessive force to prevent damage to the cover. installed properly.)
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Insert the battery making sure the polarity of the terminals
are correct.
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not working, check the following:
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Transmitter a. Remove cover on the receiver and refer to the
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As with any electronic device, care should be taken not to “Receiver Printed Circuit Board” drawing,
subject the transmitter to excessive abuse. The radio Figure 3-7, in the installation instructions.
transmitter is a very rugged instrument and will withstand b. With power to the receiver, the Power Indicator LED
er
normal use. The transmitter housing is made of a durable will be on. Turn transmitter power on. At this time the
material and will serve many years of use. The toggle receiver ’s RF Indicator LED will be on for 10
switches are industrial grade, self-cleaning, environmental seconds and you will hear the power relay engage.
sealed switches. To remove dirt, grease, oil, etc., wipe with a (Anytime after transmitter power is on, a function
cloth soaked with soap and water. may be activated.) To verify that the power relay is
For those hard stains, a light alcohol based cleaner should engaged and that the transmitter is transmitting,
be used. Should moisture build up inside the housing, activate the emergency stop on the transmitter. This
remove the cover and allow to air dry. This process may be will disable the power relay and the transmitter will
sped up using a blow dryer set on a low heat range. transmit for 10 seconds.The RF and Power
Indicator LED’s will be on. During this time any
Quick Test for Receiver Antenna and Cable toggle switch activated will only send the
emergency stop signal. To reset the receiver and
Test the antenna harness with points A, B, C, D. transmitter, turn the transmitter power off and back
Test Point A — Inner Conductor of Connector on. At this time the receiver’s RF Indicator LED will
Test Point B — Outer Connector Housing be on for 10 seconds (without activating a toggle on
Test Point C — Larger Ring Terminal the transmitter) and you will hear the power relay
Test Point D — Small Ring Terminal engage.
Using an ohmmeter set at the minimum resistance scale, 1. When a function is activated on the transmitter,
make the following measurements with the antenna cable two or three LED’s are turned on in the receiver:
disconnected from the receiver. With one meter test lead on (1) RF Indicator LED, (2) Output Status
“A” and the other on “B”, there should be no continuity Indicator LED, (3) Master Control LED (may or
(Maximum resistance reading). Next, attach one meter lead may not be utilized on the equipment).
to “A” and the other to “D”. There should be minimum 2. With power relay engaged, check each function
resistance (near 0 ohms). The same will be true at points “B” by activating each toggle. Make sure that each
and “C”. To do these last tests, another wire may have to be of the receivers Output Status Indicator LED’s
used to extend the leads. turn on. Suppose the appropriate Output Status

Indicator LED doesn’t come on, read ahead b. If the appropriate Output Status Indicator LED is
through 4. turned on and there is no power to the orange
3. If the power relay doesn’t engage, there is a connector pin, this indicates that a circuit failure has
possibility that the address codes are not occurred and the radio controller must be repaired
matching. Compare the 12 position address at the factory.
switches in both transmitter and receiver and 5. If crane function occurs when function switch is
then repeat step 3B. If they both match and still activated and before trigger is pulled, readjust the low
the power relay doesn’t engage, set all 12 of the end proportional potentiometer in the receiver. See
dip switches to the OFF position in both the Installation Section for correct procedure.
receiver and transmitter and then repeat step
3B. At this point if the radio controller works or Specifications
not, call the factory to either be assigned a new
address code or to have the controller shipped
back to the factory for repair. Transmitter Description
4. With a function activated and all three indicator
Composite plastic (high impact
LED’s ON and there is no voltage registering on Material
plastic material)
the voltmeter, check the output fuse. There is a
7.5 amp fast blow fuse on each output. There is Seal Water resistant enclosure
an extra fuse and clip on the PC board. Remove Color Light gray
and replace blown fuse. If fuse repeatedly fails,
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Industrial environmentally sealed
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you may have a dead short in your wiring Switch Type
toggle
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harness or the electric coil or relay is failing. Do
not use anything other than the recommended
Dimension
9” L x 5-3/4” W x 4-3/4” D (including
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fuse furnished on the receiver PC board. handle)
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c. If the transmitter face plate has been removed and Approximate Weight 2.5 lb
replaced, then three problems could have been
9 volt battery (disposable, not
introduced. Troubleshoot as follows: Power Source
rechargeable)
er
1. Remove faceplate from transmitter. Make sure
that leads to each lead screw on toggles are Antenna External 6: (Rubber Ducky)
secure and will not be at an angle where it Operating Temperature -20°C to +50°C (-4°F to +122°F)
would be touching anything when replacing the
Frequency 49 MHz Band
faceplate.
2. Disconnect wiring harness from PC board and >20,000 combinations including RF
Address Codes
then reconnect the same way. Be sure that no bands
wires are loose at connector and that connector
is secure on connector pins. The wiring harness
should be positioned between toggle housings Receiver Description
or where it is not hanging down creating a bind
Material 18 gauge aluminum housing
when replacing the faceplate.
3. Refer to 3B. Color Light gray
Dimension 9” L x 7” W x 2” D
Example to follow on existing equipment
Approximate Weight 3 lb
4. Activate a function (boom up) on the transmitter, at this
time the receiver’s RF Indicator LED and the appropriate Number Outputs 1 to 17
Output Status Indicator LED will be on. And if the Control Voltage Range 10 - 24 VDC
function activated, such as the boom up motion does not
occur, check the following: Power Supply Operation 10 - 24 VDC
a. Be sure that the appropriate orange connector pin Connector Cage-Clamp style connection
matches the Output Status Indicator LED. There Temperature Range -20°C to +50°C (-4°F to +122°F)
shou ld be 12 o r 24 vo lts DC t o tha t outp ut,
Fused Outputs 7.5 Amp fast blow fuse
depending on the power supplied from the vehicle. If
it is determined there is power to the output, then
the wiring and hydraulic system should be checked.

Installation When connecting the individual wires, be sure that the

connector clamps onto the bare stripped wire only! If any
Transmitter wire insulation gets into the connector, this may cause a poor
connection and cause intermittent or complete failure.
Each unit’s address code has been preset by the factory.
(We advise not to change codes without first consulting the Receiver Input and Output
factory.)
Each unit comes with a connector chart (Chart C) with the
Receiver Mounting appropriate input and output instruction for your unit. There
are three (3) inputs to the receiver: (A) BNC connector, (B)
The receiver should be mounted on the crane console. If
Positive DC current, (C) Negative ground. The unit derives
installed in a tool box or compartment, care should be taken
power from a 10 to 24 volt DC power system that is negative
in routing cable and wires so when tools and supplies are
ground. It is required to install a power switch for the receiver
inserted or removed they do not snag or pull on the cabling.
in series (in-line) with the DC power system (battery). Refer
If mounting on a vertical plane, ideal mounting would be to to the Receiver Printed Circuit Board drawing, Figure 3-7. 3
place the connectors pointing down. Adequate planning is
1. When power is supplied to the receiver the Power
required so wire routing can be accomplished. You must
Indicator LED will come on. If not, verify correct polarity
keep in mind that the unit comes standard with 20 feet of
of power and condition of fuse.
antenna cable. Use the mounting holes on the receiver for
securing the system. Once mounted, remove the cover to 2. Turn on the power to the transmitter. At this time the
inspect the Status Indicators. (Refer to the Receiver Printed transmitter will send out a 10 second signal to the
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Circuit Board drawing, Figure 3-7, in the following steps.) receiver to initialize the system.
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Connector Instructions
Strip all wires to be inserted into the 20 pin connector, to a
a. At this time, the RF Indicator LED and the on-board
relay will be energized. Once the initial 10 seconds
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have lapsed, the RF Indicator LED will illuminate
length of 3/8 to 1/2 inch (10 mm to 13 mm). Solder the loose
R F
each time the transmitter is activated.

wire strands into one solid wire. Insert a small straight blade If only the RF Indicator LED illuminates when the
screwdriver into the square hole of the desired pin. Prying transmitter is activated but does not energize the
towards the face (lid) of the receiver, insert the appropriate relay, verify that the 12 position address switches on
er
stripped wire into the round hole directly below the the receiver match those inside the transmitter.
screwdriver. Release the screwdriver and the connection is
complete. This connector will accept wire sizes from 14 3. Activate each function with the transmitter and notice
gauge to 22 gauge wire. that the appropriate output Status Indicator LED
illuminates inside the receiver. (The LED’s parallel to the
orange connector.)

Output Status
RF Indicator Indicators Antenna
Connector
Bank B (1) Spare Fuse

7.5 Amp Fuses
Bank A
High End
Proportional
Low End
Proportional Wago Connector
12 Position
Address Switch
Power Indicator
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Master Control LED Power Relay 15 Amp Blade Fuse
nl c Receiver Printed Circuit Board FIGURE 3-7

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R F
5 Conductor
NCC Cord Wire
Description Output Label Cord Wire
Color
er
Color
N/A Output 16
HCA - RCL Override Output 15 Blu/Red
Turn RH Output 14 Org/Blk
Turn LH Output 13 Bwn/Blk
Boom Up Output 12 Red/Blk
Boom Down 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 Brn
N/A Output 4
Throttle Output 3 Red/Blu Blk
Start Output 2 Blk/Blu Org
Ignition Output 1 Blu/Blk Yel
Proportional Master Control Bwn/Red
N/A Option

5 Conductor
NCC Cord Wire
Description Output Label Cord Wire
Color
Color
Battery V+ Battery (+) Blk Red
Ground Ground (-) Yel Blu
proportional output to the proportional valve. Please refer to
the Receiver Printed Circuit Board drawing, Figure 3-7.
Low End Proportional — 0 Least Trigger Setting, F Highest
Trigger Setting
This pot is used to set starting movement on the trigger.
High End Proportional — 0 Highest Trigger Setting, F Least 3
Trigger Setting
1. Set The potentiometer on the transmitter to
minimum, This is done by releasing trigger.
2. Set the “Low End Proportional” hex switch in
the receiver to 0.
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3. With the receiver powered, activate the
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transmitter and depress the desired function to
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etc.)
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4. While maintaining Transmission, slowly
R F
Insert a small straight blade

increment the Low End Proportional hex switch
screwdriver into the square hole of the until movement of the activated function begins.
desired pin. Prying towards the face No movement is desired when activating a
er
(lid) of the receiver, insert the
appropriate stripped wire into the function at minimum potentiometer setting;
round hole directly below the therefore, back up one step on the hex switch.
screwdriver. Release the screwdriver
and the connection is complete. Activate each function switch to assure that no
FIGURE 3-8
function moves when the switch is on.
Occasionally, a machine will not move even
These (*) switches when the low end potentiometer is at its
These switches to match
those inside transmitter to be in ON position 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.
12 Position Bank A Bank B
Address Switch
6. Set the High End Proportional to 0.
Low End High End
Proportional Proportional 7. Again activate the desired function. Be careful
Set Switches as Shown FIGURE 3-9 since now the function activated will be at full
speed!
Setup Procedure for the Proportional Channel 8. While maintaining transmission, slowly
increment the High End Proportional hex switch
Not all proportional valves are ideal. That is, they do not all
until a noticeable decrease in function speed is
begin to operate at exactly the same voltage nor do they all
noticed. Now back up the High End
reach their full travel at exactly the same voltage. Many
Proportional hex switch 1 to 2 settings.
proportional valves work in a narrow “window” of voltage
span. Therefore, a method has been designed to allow the 9. Failure to properly set the high end pot will
installer to configure the proportional output to conform to the result in a decrease in the motion range of the
proportional valves’ characteristics. This allows the trigger when proportioning a function.
transmitter proportional potentiometer to control the The procedure is now complete and proportional control will
proportional valve through its entire range of travel. function through the complete range of the transmitter
After the receiver is installed properly, the following steps potentiometer.
should allow the installer to quickly match the receiver’s

Antenna Mounting that you do not wrap any excess antenna cable in loops.)
The connector on the end of the cable will hook up to
Care should be taken in installing the antenna. When
antenna connector on receiver. See Figure 3-7.
mounting antenna, keep in mind that the unit comes
standard with 20 feet (6.1 m) of antenna cable. If driving an NOTE: Regarding Antenna Placement; Place antenna in
electric over hydraulic pump or any type of electric motor, an open area, at least 18 inches (45.7 cm) from any
mount the antenna away from the motor since that may emit vertical metal. The position of a “Boom” (over or
spurious interference. This will reduce the possibility of around) can effect the antenna’s ability to receive a
electrical interference. For best operation, mount antenna on signal, creating “Dead Spots”.
underside of boom. Otherwise pick a location that has the
best visibility and a ground plane with a diameter that is at
least twice the height of the antenna. (Note: it is important
Truck Solenoid
Start Ignition
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Neutral Safety Switch

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Compartment wiring Diagram)
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(Remote Control Engine
R F
OPTION GROUP
(Before Remote Installation)

sheet 1
-Cut existing ignition wire and strip ends 0.25 inch

-Connect these two wires as shown on schematic
Solenoid Side
er
Truck Cab
Cut
Switch Side
Switch
Clutch
Truck Ignition
Switch
FIGURE 3-10

OPTION GROUP
(Remote Control Engine
Compartment wiring Diagram)
sheet 2
12VDC Grnd
Remote Relay Mounting Board in Engine Compartment
National Crane
Remote
Start Throttle Ignition Ignition 12VDC Grnd
Aux Battery
C. Breaker
(Not required on
all units)
600E2 SERVICE MANUAL
R F
Remote
Indicator Truck Cab
Light (After Remote
Installation)
On Off
Remote
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Power
Existing*
Ignition Switch
Switch
Wire
er
(Switch
# 86 Throttle
Side)
Clutch
Switch
# 30 Remote Ignition
# 86 Ignition & Remote Ignition
# 87 Throttle
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# 87 Start Truck
Grnd Ignition
Terminal Switch
# 85 Ignition
# 30 Start
# 85 Throttle
# 30 Throttle
# 30 Ignition
# 85 Start
# 85 Remote Ignition

# 86 Start
# 87 Ignition & Remote Ignition

Existing Start
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Light Grnd Wire from
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Bat Grnd Ignition Switch
(See Note 2) To Truck

To Solenoid
Throttle Neutral Safety Switch
Switch +12VDC
(Start)
5 Conductor Cord * Connect to Existing Ignition

from Remotes (Radio Switch Wire in Cab (Solenoid Side)
NOTE: 1. All grounds must be referenced to the negative side of the battery. Receiver or Relay
2. Start circuit wire from terminal 10 to neutral safety switch is only to be Chassis)
installed if start relay is installed on chassis.
3. Items denoted with (*) is the existing ignition wire cut for remote
installation.
FIGURE 3-10 continued
3-29
ELECTRIC SYSTEM
3
OPTION GROUP
3-30
(R4 Remote Control Hydraulic Diagram)
Hydraulic Lines
Hoist
Up Dn
ELECTRIC SYSTEM
Shuttle
Valve Manual Valve
Pump
Manual
R F
Hoist
Valve
Dn Turn
Shuttle
Valve Lift LH
Up
Ext
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Tele
Ret
er
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Selector

Gauge
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Pump
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FIGURE 3-11
OPTION GROUP
(R4 Radio Remote Electrical Schematic)
Receiver Box Assembly

Solenoid 20 Cond. NCC 5 Cond. Cord
Function
Rotation Limit Terminal Cord Wire Color Wire Color
Switches
2 Brn/Blk Turn LH
National Crane
Normally Closed
1 Org/Blk Turn RH
4 Org Tele Extend

SW2 SW1
Blk Org/Blk 3 Blu Tele Retract
Wht
Blk 6 Yel/Blk Lift Down
Brn/Blk
5 Red/Blk Lift Up
8 Brn Hoist Down

R F
Wht
Brn/Red 7 Red Hoist Up
9 Brn/Red Flow Regulator
10 Blu/Red HCA - RCL Override
Yel Power - Ground Blu

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Blk Power - Positive Red
20/18 Cord from
Radio Receiver Blu/Blk Remote Ignition Yel
er
Blk/Blu Start Org
Red/Blu Throttle Blk
Red
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Blk

Blk
Wht Red
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Grn Blu/Red
Wht
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Grn
Blk/Blu Org 5 Conductor
Blu/Blk Yel Cord to Engine
Red
Blk Red/Blu Blk
Relay
Yel Blu
Red Red
Wht
Yel
Blk
FIGURE 3-12
3-31
ELECTRIC SYSTEM
3
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er

600E2 SERVICE MANUAL BOOM
SECTION 4
BOOM
SECTION CONTENTS
Three Section Boom Operation. . . . . . . . . . . . . . . 4-2 Four Section Top/bottom Pad Replacement
Special Boom Inspection . . . . . . . . . . . . . . . . . . . 4-2 Assembled Boom . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Three Section Boom Maintenance . . . . . . . . . . . . 4-2 Top Rear Pad Replacement . . . . . . . . . . . . . . . . 4-15
Three Section Cable Tensioning. . . . . . . . . . . . . . 4-2 Front Bottom Pad Replacement . . . . . . . . . . . . . 4-15
Hoist Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Cable Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Cable Tensioning Setup Procedure. . . . . . . . . . . 4-15
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Cable Tension Sequence . . . . . . . . . . . . . . . . . . 4-16
Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4- Section Boom w/ 2 Stage Cylinder
Boom Disassembly Alternative #1 . . . . . . . . . . . . 4-4 Cable Positioning. . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Boom Disassembly Alternative #2 . . . . . . . . . . . . 4-5 4- Section Boom w/ 1 Stage Cylinder
Additional Maintenance, Disassembled Boom . . . 4-5 Cable Positioning. . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Three Section Boom Assembly. . . . . . . . . . . . . . . 4-5 3- Section Boom w/ 1 Stage Cylinder
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Three Section Top/Bottom Pad Replacement Cable Positioning. . . . . . . . . . . . . . . . . . . . . . . . . 4-19
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(Assembled Boom) . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Cable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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Top Rear Pad Replacement . . . . . . . . . . . . . . . . . 4-7 Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . 4-21
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Front Bottom Pad Replacement . . . . . . . . . . . . . . 4-8 Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . 4-21
4
R F
Inner Wear Pad Calibration . . . . . . . . . . . . . . . . . . 4-8 Extend Cylinder Repair . . . . . . . . . . . . . . . . . . . . . 4-22

Four Section Boom Operation. . . . . . . . . . . . . . . . 4-9 Extend Cylinder Disassembly . . . . . . . . . . . . . . . 4-22
Extend Cylinder Assembly. . . . . . . . . . . . . . . . . . 4-23
Four Section Boom Maintenance . . . . . . . . . . . . 4-10
er
Internal Cable Sheave Lubrication . . . . . . . . . . . 4-10 Jib Installation and Adjustment . . . . . . . . . . . . . . 4-23
Four Section Cable Tensioning. . . . . . . . . . . . . . 4-10 Jib Jack Service and Maintenance . . . . . . . . . . . 4-25
Four Section Boom Service . . . . . . . . . . . . . . . . 4-10 Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Four Section Boom Disassembly . . . . . . . . . . . . 4-10 Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Disassembly Alternative #1 . . . . . . . . . . . 4-11 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Disassembly Alternative #2 . . . . . . . . . . . 4-12 Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Four Section Boom Assembly. . . . . . . . . . . . . . . 4-12

BOOM 600E2 SERVICE MANUAL
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R F
er
Item Component
Item Component
5 Extend Cable Anchor
1 Extend Cable Adjustment
6 Retract Anchor
2 Section 1
7 Section 2
3 Retract Cable
8 Section 3
4 Retract Cable Adjustment
9 Tip
THREE SECTION BOOM OPERATION Special Boom Inspection

A rod-fed, double-acting cylinder, attached to the 1st and 2nd If the boom has not been disassembled and inspected in the
boom sections, supports and propels the 2nd boom section. last five years or 3,000 hours of use, the boom is to be
The extend cables attach to the base end of the 1st boom completely torn down to allow a thorough inspection of the
section, are reeved around sheaves attached to the cylinder, extend and retract cables, sheaves, and pins.
and attach to the base end of the 3rd boom section, providing
support and extension the 3rd boom section. THREE SECTION BOOM MAINTENANCE
st
The retract cables attach to the tip end of the 1 boom
section, are reeved around sheaves attached to the 2 nd Three Section Cable Tensioning
boom section, and attach to the base end of the 3rd boom 1. For instructions about 3-section boom cable tensioning,
section, therefore providing retraction of the 3 rd boom see 3- Section Boom w/ 1 Stage Cylinder Cable
section. This type of boom operation provides that the 2nd Positioning on page 4-19.
and 3rd section booms extend and retract equally. Proper
service and maintenance is required to insure smooth and
proper operation.

HOIST REMOVAL 6. Remove Rope Guard mesh and attach suitable lifting
device to hoist and take up the slack.
7. Remove capscrews and washers (3 each side).
DANGER 8. Lift hoist clear of boom and secure to a suitable holder.
height without using proper fall protection as required by BOOM REMOVAL
local, state or federal regulations.
Cg From Pivot
1. Extend and set the outriggers. Boom Length Boom Weight
Point
2. Fully retract the boom and place in a horizontal position. 71 ft (21.6 m) 5583 lb (2832 kg) 140 in (3.56 m)
47 ft (14.3 m) 4294 lb (1948 kg) 96 in (3.02 m)
38 ft (11.5 m) 3782 lb (1716) 79 in (2.01m)
1. Extend and set machine outriggers. Boom must be
completely retracted and stowed in the boom rest.
2. If equipped, remove swing around jib. See Operator
Manual, Section 4.
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3. Remove hook block or downhaul weight. Wind up rope
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on hoist drum and stow wedge socket on pegs provided
nl c on 1st section. Shut down truck engine.

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4. Attach a lifting device to rod end of lift cylinder, remove
4
R F
boom lift cylinder pin keeper and pin from bottom of the
1st section boom. Lower lift cylinder to a suitable
support.
er
Item Component 5. Tag and disconnect extend cylinder lines and hoist
hydraulic lines. Cap all open lines and ports.
1 hoist
6. Attach a lifting device to provide even weight distribution
2 Boom and raise the boom until weight is removed from the
3 Capscrew (6 places) boom pivot pin. Remove boom pivot pin keeper and
boom pivot pin. Lift boom free of turret.
4 Hydraulic Hose
5 Hoist Down Hose 2 BOOM DISASSEMBLY
6 Hoist Up Hose 3 The 600E2 boom can be disassembled by using two different
7 Hoist Alignment Ears methods. Alternative #1 disassembles the boom in the
conventional manner. Alternative #2 removes the extend
cylinder from the rear of the boom, after removal of the hoist.
3. Remove hookblock or downhaul weight. Wind up rope This feature facilitates cylinder service without complete
on hoist drum and stow wedge socket on pegs provided boom teardown.
on 1st section. Shut down truck engine.
For reference, the front of the boom refers to the sheave
4. Tag and remove the hydraulic hoses (the inside hose case end, the rear of the boom is the hoist mount end. Left
“up” and the outside “down”). Cap all hoses. and right are viewed from front to rear.
5. Pull hydraulic hoses through the access hole towards If the boom is to be unpinned from the turret of the crane
turret. structure, please refer to the Boom Removal Procedure
section in this book. If the required service procedure is to be
performed on the boom while still pinned to the turret, please
follow these directions.
CAUTION
The combined weight of the hoist and 325 ft. of wire rope
is 660 lbs (300 kg).

11. Loosen and remove four capscrews securing the rear

bottom wear pads on the 2nd section. This pad serves as
DANGER a bottom and side pad as well as the retract cable
keeper under the retract sheaves. Removal of this pad
Do not, under any circumstances, work at an elevated will allow the retract cables to uncoil off the retract
height without using proper fall protection as required by sheaves. Place retract cable ends in a location to
local, state or federal regulations. minimize the possibility of damage.
Boom Disassembly Alternative #1 12. Loosen and remove six capscrews securing retract
sheave pin and retract sheaves to 2nd section. Remove
1. Gaining access through rear of boom, loosen capscrews sheaves and pins.
retaining the extend cable anchor in the rear of the 3rd
13. Loosen and remove two capscrews functioning as upper
section as well as the capscrew on the anti-two block
retract cable keepers.
wire clamp on the anchor assembly.
14. Loosen and remove two capscrews securing lock bar to
2. Extend boom 24 inches (60 cm). Loosen and remove
the extend cylinder collar. This bar constrains the
the nuts which secure the extend cables to the cable
vertical movement of the extend cylinder. Remove bar.
anchor plate. Remove nut from anti-two block spade
bolt. Tag and disconnect hydraulic lines to the extend 15. Loosen capscrews retaining extend cable anchor to
cylinder. back of the 3rd section. Total removal of the capscrews
will allow the cable anchor to be completely
3. Drape extend cables and anti-two block cable inside
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disassembled, backing capscrews out approximately
boom, and slide cable anchor plate out of the side of the
ef or
0.50 inch (12 mm) will allow the anchor assembly to
hoist mount if hoist has been removed from boom.
4.
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Loosen and remove two capscrews, lockwashers and
slide rearward out of the section as the extend cylinder is
removed.
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spacers which anchor the extend cylinder rod butt plate
16. Support extend cylinder with an appropriate lifting
R F
to the rear of the 1st section.

device and pull the extend cylinder out of the boom while
5. Loosen and remove two capscrews and lockwashers keeping the extend cables and anti-two block wire
securing spacer bar to the inside top of the front of the tensioned slightly by hand to minimize the possibility of
er
1st section. Remove spacer bar. damage to the cables. Pull cylinder to within 3 feet (91
cm) of complete removal from the boom sections.
6. Loosen and remove four capscrews securing wear pads
to the bottom of the 1st section. Removal of side wear 17. Reach into the rear of the 3rd section and loosen and
pads is optional. Adequate clearance exists between remove the anti-two block cable clamp on the extend
adjoining section side pads for boom disassembly. If cable anchor. Pull the extend cable anchor out from its
side pad removal is required, tag all pads, shims, and retaining pocket on the bottom of the 3rd section. A slight
corresponding locations for proper reassembly. angle applied to the anchor as it is being pulled to the
rear will permit easier removal through the 2nd section.
7. Support 2nd 3rd assembly at the front with an appropriate
lifting method. Raise the 2nd 3rd assembly inside the 1st 18. Remove the extend cylinder from the boom.
section to allow for front bottom pad removal. Remove
a. Do not allow sheaves to fall off the pin on the end of
bottom wear pads.
the extend cylinder.
8. With the 2nd & 3rd assembly supported, slide assembly
b. Remove extend cables. Place cylinder and cables in
out of the 1st. Relocation of the sling point on the 2nd &
suitable area to prevent possible damage.
3rd assembly will be necessary for proper balancing of
the assembly as it slides out of the 1st section. Keep 19. Remove retract cables from the back of the 3rd section
tension on retract cables as the assembly is pulled out of by manipulating cable end through the slot in the anchor.
the 1st, to minimize the chance of retract cable damage. Place cables in location to prevent possible damage.
9. Place 2nd & 3rd assembly on a suitable horizontal 20. anti-two block wire can be removed if necessary by
surface. Take care not to pinch or crush retract cables disassembly of the clamp arrangement at the sheave
while lifting or supporting assembly. case and pulling wire through boom.
10. Remove top rear wear pads on the 2nd section. They will 21. Loosen and remove two capscrews, cable guide, wear
lift off the cam plates easily. Do not remove or loosen the pad and spacer bar from the front top of the second
capscrews holding the cam plates to the section. This section.
will affect side clearance during re-assembly.

22. Loosen and remove four capscrews attaching the 8. Lift extend cylinder up until it contacts inside of boom
bottom pad plate to the second section. Slightly lift third section. Remove anti-two block wire clamp from extend
section, and remove pad plate. cable anchor. Remove anchor by pulling anchor and
cables out rear of boom. A slight angle applied to the
23. Slide 3rd section out of 2nd section. Removal of side
anchor as it is being pulled to the rear will permit easier
pads is optional, as the side pads have adequate
removal.
clearance for boom disassembly. If removal of side pads
is required, tag all shims, pads and corresponding 9. Continue to pull extend cylinder and cables out of rear of
locations for proper re-assembly. boom. Remove extend cables and store in an area to
minimize the possibility of damage.
24. Loosen and remove all remaining capscrews and wear
pads from boom sections. Additional Maintenance, Disassembled
Boom Disassembly Alternative #2 Boom
The 600E2 boom design allows for removal of the extend 1. Clean all boom sections and inspect for wear, dents,
cylinder from the rear of the boom without complete bent or bowed boom sections, gouged metal, broken
disassembly of the boom sections. This procedure allows welds or any abnormal conditions. Repair or replace as
quick access to the cylinder, retract cables, and various required.
internal boom components for service or replacement. 2. Inspect all sheaves for excessive groove wear or
abnormal rim wear. Replace as required.
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3. Inspect all sheave bearings for excessive wear or cut
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DANGER liner material. If installed bearing diameter is 0.015 inch
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(.38 mm) larger than the pin diameter, bearing must be
replaced. Any cut or gouge which causes the bearing
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local, state or federal regulations. liner to be distorted is cause for bearing replacement.
4
R F
4. Clean and inspect all cable assemblies according to the

1. Remove hoist. Please refer to the hoist removal section wire rope inspection procedures in this section. Pay
in this book. particular attention to any wire breakage within 6 feet
er
2. Gaining access through rear of boom, loosen capscrews (180 cm) of the end connections. Replace cable
retaining the extend cable anchor in the rear of the 3rd assemblies as required. Lubricate all cable assemblies
section as well as the anti-two block wire clamp on the before reinstalling them in the boom.
anchor assembly. Loosen and remove two capscrews 5. Inspect all sheave pins for nicks, gouges or pitting due to
retaining lock bar to extend cylinder. Remove lock bar rust in the bearing surface area. Replace if any damage
3. Extend boom 24 inches (61 cm). Loosen and remove is evident.
the nuts which secure the extend cables to the cable 6. Inspect anti-two block wire full length for damage, check
anchor plate. Remove nut from anti-two block spade for electrical continuity.
bolt.
4. Drape extend cables and anti-two block wire inside THREE SECTION BOOM ASSEMBLY
boom, and slide cable anchor plate out of the side of the
hoist mount. NOTE: Do not use Loctite on any cable threaded ends.
Always use the locknut and nut provided.
5. Loosen and remove two capscrews, lockwashers and
spacers which anchor the extend cylinder rod butt plate When initially assembling threaded ends of cables,
to the rear of the 1st section. thread the first nut on past the flat in the cables so
adjustment can be made later.
6. Using appropriate lifting device, lift extend cylinder up
and out of retaining slot on rear of 2nd section. Refer to Inner Wear Pad Calibration on page 4-8 of
Retracting cylinder with an external hydraulic power this section to determine Wear Pad shim thickness.
source during this step may be necessary. 1. Assemble sheaves into 3rd section sheave case. Top
7. Pull cylinder out through rear of boom assembly sheave is to be installed to the left hand side of the boom
approximately one-half the length of the cylinder. with the spacer to the right hand side.
Turning of the butt plate and rod 90 degrees may aid in 2. Attach rear wear pads on bottom of 3rd section. Using
sliding cylinder through hoist mount area. Keep extend Loctite 243 blue, Loctite all wear pad mounting
cables tight to minimize the possibility of damage. capscrews.

3. Install 3rd section boom into 2nd section. Slide together bottom rear of 3rd section. Route anti-two block cable
approximately 5 feet (150 cm). over extend cable anchor as anchor slides into 3rd
section. Be aware of extend and anti-two block cable
4. Assemble bottom front wear pads for 2nd section and
location when inserting cylinder into boom sections,
Teflon plugs. Attach pads to pad plate.
inadvertent crushing or other damage to cables will
5. Using appropriate lifting device, lift 3rd section to allow warrant replacement.
for wear pad/pad plate installation in front of 2nd. Install
16. Tighten capscrews clamping extend anchor together.
wear pad/pad plate assembly. Slide sections together
These capscrews will protrude through the 3rd section
within 12 inches (30 cm) of full retraction.
bottom plate, locking the anchor in position.
6. Install front side wear pads with appropriate shims,
17. Loop anti-two block cable at the extend cable anchor in
between 3rd and 2nd sections. If boom has been
the 3rd and install anti-two block cable clamp. Do not
disassembled, and no sections have been replaced, use
completely tighten clamp capscrew.
same shim quantity and location as was previously
used. 18. Assemble anti-two block clamp in the sheave case.
Reeve anti-two block cable around anchor and through
7. Route anti-two block wire through 3rd section, keeping
holes in side plate of sheave case. Pull approximately 2
bulk of wire at the rear of the boom sections. Routing
feet (60 cm) of cable out the end of the boom for proper
can be accomplished using an installation tool, such as
routing and termination.
a telescopic boom grease applicator, electrical conduit,
or hydraulic tubing. Route anti-two block wire between 19. Tighten anti-two block clamp on the extend cable anchor
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sheave case side plates. If locations are in question, in the rear of the boom. Tension anti-two block cable
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refer to Shim Calibration Section in this manual. from the sheave case end of the boom, and tighten anti-
8.
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Uncoil retract cable assemblies, and insert button end
into anchors in back of the 3rd section. Place uncoiled
two block clamp located in sheave case.
20. Visually verify that the extend and anti-two block cables
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cable in area that will minimize the potential for damage. are properly routed on their sheaves and continue to
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slide the extend cylinder and cables into the boom

9. Assemble retract sheaves and retract sheave pins in
sections. Keep extend and anti-two block cables
rear of 2nd section. Coat surfaces of bearings with
supported and slightly tensioned during insertion of
er
grease before assembly.
cylinder, to maintain proper cable placement.
10. Place retract cables over top of retract sheaves. Install
21. As the extend cylinder keeper plate nears the 2nd
keeper capscrew above sheave to hold retract cables in
section, adjust the height of the cylinder to allow the
place.
cylinder to access the cylinder keeper cutouts in the
11. Reeve cables over retract sheave and install keeper/ doubler plates on the sides of the 2nd section.
wear pad to bottom rear of 2nd section. This pad acts as
22. Drop the cylinder down into the vertical cutouts in the
a side pad, bottom pad, and a cable retainer.
doubler plates on the sides of the 2nd section.
12. Assemble exterior extend cylinder components. Install
23. Install lock bar and capscrews to the extend cylinder.
and center sheave pin into butt plate of extend cylinder.
Install bearings into extend cable sheaves. Coat surface 24. Position 2nd/3rd/ cylinder assembly in position to be
of bearings with grease and assemble extend sheaves inserted into 1st section. Lay retract cables out under
on sheave pin. 2nd/3rd/ cylinder to allow easy installation as the booms
are assembled.
13. Wrap approximately 10 feet (300 cm) of each 5/8 inch
(15.88 mm) diameter extend cable around extend 25. Slide 2nd/3rd/ cylinder assembly into 1st section boom
sheaves and install extend cable anchor. Do not tighten approximately 2 feet (60 cm). Use caution during this
capscrews clamping anchor together completely. These step to keep retract cables straight and on the correct
capscrews if tightened completely will not allow cable side of the boom assembly as the sections are
anchor to install into 3rd section. Route anti-two block assembled.
cable over center sheave on extend cylinder.
26. Continue to slide 2nd/3rd/ cylinder assembly into 1st until
14. Install wear pad over extend cylinder sheave side plates. it is approximately halfway into 1st.
This serves as a wear pad to keep the end of the extend
27. Assemble bottom front wear pads in 1st section, trapping
cylinder centered in the boom, as well as an extend
ends of retract cables in slots on bottom of 1st section.
cable retainer.
Lift 2nd/3rd/cylinder assembly up to ease installation.
15. Slide extend cylinder /extend cables into 2nd/3rd boom
28. Slide boom together to within 12 inches (30 cm) of
assembly enough to assemble extend cable anchor into
complete retraction. Install upper front spacer bar in 1st

section and upper front wear bar and cable guide Three Section Top/Bottom Pad Replacement
assembly to 2nd. (Assembled Boom)
29. Retract boom completely, using proper hardware and
NOTE: Refer to Inner Wear Pad Calibration on page 4-8 of
spacers, connect extend cylinder butt plate to the hoist
this section to determine Wear Pad shim thickness.
mount. Hydraulic power source can be utilized at this
time if slight cylinder length adjustment is necessary. Inspect top and bottom wear pads periodically for signs of
abrasion or excessive wear. Excessive is defined as:
30. Slide extend cable anchor into position in hoist mount.
Push threaded ends of 5/8 inch (15.88 mm) extend - 3/16 of an inch (4.76 mm) from the original pad
cables through holes in anchor and assemble hex nuts thickness.
onto threaded ends.
- Top rear pad thickness 0.75 inch (19.05 mm).
31. Assemble top/rear wear pads to the top of the 2nd and
3rd boom sections with the cam plates. Wear pads can - Bottom front 1st section 1 inch (25.4 mm).
be inserted from the hoist mount end of the boom. Install
- Bottom front 2nd section 0.50 inch (12.7 mm).
capscrews through holes in outer boom sections.
- Uneven pad wear of 3/32 inch (2.38 mm) from side
32. The wear pad on each side at the top/rear of the boom
to side on the wear pad.
can be adjusted over a range of 3/16 in (4.8 mm) by
rotating, end for end, the wear pad and plate or the wear If any of these conditions exist, the top and bottom pads can
pads and plate independently. This is possible because be replaced without complete disassembly of the boom.
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the holes in these parts are offset from the center. The
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holes are 0.06" (1.5 mm) off center in the plate and 0.03” Top Rear Pad Replacement
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(0.8 mm) off center in the wear pad. Various
combinations of rotation of these parts allow the
this section to determine Wear Pad shim thickness.
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adjustment.
4
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a. Adjust pads until they are within 0.03” (0.8mm) off
center in the were pad. Various combinations of 2. Remove capscrews through access holes on top rear of
rotation of these parts allows the adjustment. sections.
er
b. Torque retainer capscrews to 110 ft-lb (149 N-m). 3. Remove wear pads and cam plates from the rear of the
Failure to properly torque capscrews will cause loss boom through open hoist mount end.
of preload and cause excessive side clearance
4. Note all pad locations and tag accordingly.
between sections.
5. Inspect pads for wear using previously mentioned
33. Approximately 10 feet (300 cm) of anti-two block cable
inspection criteria.
will be available on the hoist mount end of the boom to
route and hookup to the control console wiring. Find the 6. Assemble top/rear wear pads to the top of the 2nd and
end of this cable and slide the cord grip/strain relief 3rd boom sections with the cam plates. Wear pads can
hookup onto it and slide it up the cable into approximate be inserted from the hoist mount end of the boom. Install
position inside the boom. capscrews through holes in outer boom sections.
34. Assemble the extension spring and spade bolt to the 7. The wear pad on each side at the top/rear of the boom
cord grip. Assemble the spade bolt through the extend can be adjusted over a range of 3/16” (4.8 mm) by
cylinder anchor with a hex nut. Adjust tension on anti- rotating, end for end, the wear pad and plate or the wear
two block cable by sliding cord grip down cable into the pads and plate independently. This is possible because
boom. Approximately 2 inches (5 cm) of spring the holes in these parts are offset from the center. The
extension should be adequate for proper boom holes are 0.06" (1.5 mm) off center in the plate and 0.03"
operation. (0.8 mm) off center in the wear pad. Various
35. Visually check each end of boom for proper extend,
adjustment.
retract and anti-two block cable routing and placement.
Make certain anti-two block cable is correctly on sheave. a. Adjust pads until they are within 0.03” (0.8mm) off
Inspect from sheave case end. center in the wear pad. Various combinations of
rotation of these parts allows the adjustment.
36. Adjust slack out of extend and retract cables at hex nut
adjustment points. Slowly cycle boom in and out several b. Torque retainer capscrews to 110 ft-lb (149 N-m).
times. Torque cables per procedure located elsewhere Failure to properly torque capscrews will cause loss
in this book.

of preload and cause excessive side clearance 2. With the inside/outside calipers, measure the outside
between sections. width of the inner section (W0) at each side pad location.
Record the largest measurement.
Front Bottom Pad Replacement
this section to determine Wear Pad shim thickness. Wo 2 PLCS
1. Extend boom approximately 4 feet (120 cm) out. TOP
2. Using an appropriate lifting device, sling around the 3rd

section boom and lift it up until weight is removed from Wo 1 PLC
the bottom pads in the front of the 2nd and 1st boom BOTTOM
sections.
3. Loosen and remove the four capscrews holding the pad
INNER SECTION
doubler plate in between the 3rd and 2nd sections,
remove plate, remove pads from this plate. Note all pad
locations and tag accordingly.
4. Loosen and remove the four capscrews holding the
bottom front wear pads to the 1st section, remove pads. twp twp
Retract cable adjustment ends may have to be loosened
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during this step. Note all pad locations and tag
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accordingly.
5. nl c
If disassembly of cables was required:
3. Measure the thickness of the wear pads and record
(twp).
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- Replace all wear pads.
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- Wear pad plate.

- Re-torque retract cables.
er
INNER WEAR PAD CALIBRATION

1. With a pair of inside/outside calipers, measure the inside
width of the outer section (Wi) at the front and back of
the boom and record the smallest measurement. If the
section has cylinder anchor bars, take a measurement
directly in front of these bars
4. Subtract the largest outside width (W0) of the inner
section and the thickness of the two pads (twp) from the
inside width of the outer section (Wi). Add shims as
required [each shim is 0.03 inches (.8 mm) thick) to
Wi tighten the pads so that there is 0.03 inch -0.09 inch (.8
CYLINDER mm - 2.3 mm) clearance between the widest part of the
ANCHOR BARS
inner boom and the most narrow part of the outer boom
OUTER when shims and pads are installed. In some cases it will
SECTION be necessary to have an unequal number of shims
behind the pads at the top and bottom side pad
locations. See example.

Shim Calculation for Wear Pads (Example)
Wi = 12.12 (308mm) at front

12.06 (306) at back near
cylinder anchor bars
twp =.52 (13mm)
Wo = 10.94 (278mm) at
top rear pad location
Wo = 11.00 (279mm) at twp =.52 (13mm)

top forward pad location
Wo = 10.94 (287mm) at
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bottom rear pad location
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4
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Top Rear Bottom Rear

Wi = 12.06 (306 mm) 12.06 (306) mm
er
-Wo = -10.94 (-278 mm) -10.94 (-278 mm)
-twp = -0.52 (-13 mm) -0.52 (-13 mm)
-twp = -0.52 (-13 mm) -0.52 (-13 mm)
Clearance Before Shims = 0.008 (2 mm) 0.08 (2 mm)
Left Side Shim = -0.03 (-0.8 mm) -0.03 (-0.8mm)
Final Clearance = 0.05 (1.2 mm) 0.05 (1.2 mm)
FOUR SECTION BOOM OPERATION sheaves attached to the 2nd boom section, and attach to the
base end of the 3 rd boom section, therefore providing
The boom service and maintenance section of this manual retraction of the 3rd boom section. The 4th section retract
includes both the three and four section boom information. cables attach to the tip end of the 2 nd boom section, are
Use appropriate information for your particular boom length. reeved around sheaves attached to the 3rd boom section,
A rod-fed, two-stage double-acting cylinder, attached to the and attach to the base end of the 4th boom section, therefore
1st, 2nd, and 3rd boom sections, supports and propels the 2nd providing retraction of the 4th boom section. A proportioning
and 3rd boom sections. The extend cables attach to the base cable attached to the rear of the 1st section, reeved around a
end of the 2nd boom section, are reeved around sheaves sheave at the tip of the 2nd section, and anchored to the rear
attached to the cylinder, and attach to the base end of the 4th of the 3 rd section maintain proper cylinder extension
boom section, therefore providing support and extension of proportion, therefore maintaining equal boom section
the 4th boom section. The 3rd section retract cables attach to proportion. Detailed service and maintenance is required to
the tip end of the 1 st boom section, are reeved around insure smooth and proper operation.

FOUR SECTION BOOM MAINTENANCE Four Section Boom Service
Boom Length Boom Weight CG from pivot point

WARNING 90’ 7210 lb (3270 kg) 145” (3.68 m)
height without using proper fall protection as required by 80’ 6395 lb (2901 kg) 124” (3.14 m)
local, state or federal regulations 1. Extend and set machine outriggers. Boom must be
completely retracted and stowed in the boom rest.
Internal Cable Sheave Lubrication
2. If equipped, remove swing around jib according to
Special Tools: Nozzle or needle grease gun fitting. procedures outlined in the Operators Handbook.
The lubrication points on the sheaves are not equipped with 3. Remove hookblock or downhaul weight, wind up rope on
grease fittings (zerks), therefore a 0.25 inch (6.35 mm) hoist drum and stow wedge socket on pegs provided on
diameter nozzle grease gun tip will be required. Contact 1st section. Shutdown truck engine.
Manitowoc Crane Care to obtain this nozzle tip (NCC Part
No. 955047), or numerous variations of the nozzle tip can be 4. Attach a lifting device to rod end of lift cylinder, remove
purchased at local hardware or auto parts retail outlets. boom lift cylinder pin keeper and pin from bottom of the
1st section boom. Lower lift cylinder to a suitable
NOTE: Observation through the sheave case for the support.
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extend sheaves and the hoist mount for retract
5. Tag and disconnect extend cylinder lines and hoist
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sheaves will visually determine the amount of
hydraulic lines. Cap all open lines and ports.
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grease necessary for proper lubrication. A slight
amount of grease extrusion around the pin joint is 6. Attach a lifting device to provide even weight distribution
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adequate for proper lubrication. and raise the boom until weight is removed from the
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Lubrication of the extend cable sheaves located on the boom boom pivot pin. Remove boom pivot pin keeper and
tip end of the extend cylinder, and the retract cable sheaves boom pivot pin. Lift boom free of turret.
located on the inside rear of the 2nd and 3rd section and the
FOUR SECTION BOOM DISASSEMBLY
er
extend cable sheave attached to the bottom of the top plate
of the second section at the sheave case end of the boom,
The 600E boom can be disassembled by using two different
are accomplished as follows:
methods. Alternative #1 disassembles the boom in the
1. Extend boom until grease access hole becomes visible conventional manner. Alternative #2 removes the extend
in side plate of 2 nd section as it extends out of 1 st cylinder from the rear of the boom, after removal of the hoist.
section. This feature facilitates cylinder service with out complete
boom teardown.
2. Visually check alignment between the 2nd section
access hole and the access holes in 3rd and 4th section. For reference, the front of the boom refers to the sheave
When these holes become aligned, the end of the case end, the rear of the boom is the hoist mount end. Left
extend cable sheave pin will be visible and accessible and right are viewed from front to rear.
for lubrication.
If the boom is to be unpinned from the turret of the crane
3. This boom extended position will coincide with proper structure, please refer to the Boom Removal Procedure
alignment of the access holes in the rear of the 1st section in this book. If the required service procedure is to be
section for lubrication of the retract sheaves attached to performed on the boom while still pinned to the turret, please
the rear of the 2nd and 3rd section. follow these directions.
.
4. The extend cable sheave located on the bottom of the
top plate of the 2nd section at the sheave case end of the
boom can be accessed at any boom length for WARNING
lubrication. Do not, under any circumstances, work at an elevated
Four Section Cable Tensioning local, state or federal regulations
5. For more information about 4-section boom cable
1. Extend and set the outriggers.
tensioning, see Cable Tensioning on page 4-15.
2. Fully retract the boom and place in a horizontal position.

Boom Disassembly Alternative #1 sheaves. Place retract cable ends in a location to

minimize the possibility of damage.
1. Gaining access through rear of boom, loosen capscrews
retaining the keeper plates holding the extend cable 12. Loosen and remove six capscrews securing retract
anchor and retract cables in the rear of the 3rd section, sheave pin and retract sheaves to 2nd section. Remove
remove keeper plates. Loosen capscrew on the anti-two sheaves and pins.
block wire clamp on the anchor assembly. 13. Loosen and remove two capscrews functioning as upper
2. Extend boom 24 inches (60 cm). Loosen and remove retract cable keepers. Remove retract cables.
the nuts which secure the extend cables to the cable 14. Loosen and remove two capscrews securing lock bar to
anchor plate. Remove nut from anti- two-block spade the extend cylinder collar. This bar constrains the
bolt. Tag and disconnect hydraulic lines to the extend vertical movement of the extend cylinder. Remove bar.
cylinder.
15. Loosen capscrews retaining extend cable anchor to
3. Drape extend cables and anti-two block cable in side back of the 4th section. Total removal of the capscrews
boom, and slide cable anchor plate out of the side of the will allow the cable anchor to be completely
hoist mount if hoist has been removed from boom. disassembled, backing capscrews out approximately.50
4. Loosen and remove two capscrews, lock washers and inch (12 mm) will allow the anchor assembly to slide
spacers which anchor the extend cylinder rod butt plate rearward out of the section as the extend cylinder is
to the rear of the 1st section. removed.
16. Support extend cylinder with an appropriate lifting
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5. Loosen and remove two capscrews and lock washers
device and pull the extend cylinder out of the boom while
ef or
securing spacer bar to the inside top of the front of the
1st section. Remove spacer bar. keeping the extend cables and anti- two-block wire
6. nl c
Loosen and remove four capscrews securing wear pads
tensioned slightly by hand to minimize the possibility of
damage to the cables. Pull cylinder to within 3 feet (91
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to the bottom of the 1st section. Removal of side wear cm) of complete removal from the boom sections. 4
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pads is optional. Adequate clearance exists between

adjoining section side pads for boom disassembly. If 17. Reach into the rear of the 4th section and loosen and
side pad removal is required, tag all pads, shims, and remove the anti-two block cable clamp on the extend
er
corresponding locations for proper reassembly. cable anchor. Pull the extend cable anchor out from its
retaining pocket on the bottom of the 4th section. A slight
7. Support 2nd-3rd-4th assembly at the front with an angle applied to the anchor as it’s being pulled to the
appropriate lifting method. Raise the 2nd- 3rd-4th rear will permit easier removal through the 2nd and 3rd
assembly inside the 1st section to allow for front bottom sections.
pad removal. Remove bottom wear pads.
18. Remove the extend cylinder from the boom. Do not
8. With the 2nd-3rd-4th 4th assembly supported, slide allow the sheaves to fall off the pin on the end of the
assembly out of the 1st. Relocation of the sling point on extend cylinder. Remove extend cables. Place cylinder
the 2nd-3rd-4th assembly will be necessary for proper and cables in suitable area to prevent possible damage.
balancing of the assembly as it slides out of the 1st
section. Keep tension on retract cables as the assembly 19. anti-two block wire can be removed if necessary by
is pulled out of the 1st to minimize the chance of retract disassembly of the clamp arrangement at the sheave
cable damage. case and pulling wire through boom.
9. Place 2nd-3rd-4th assembly on a suitable horizontal 20. Loosen and remove two capscrews, cable guide, wear
surface. Take care not to pinch or crush retract cables pad and spacer bar from the front top of the second
while lifting or supporting assembly. section.
10. Remove top rear wear pads on the 2nd section. They will 21. Loosen and remove four capscrews attaching the
lift off the cam plates easily. Do not remove or loosen the bottom pad plate to the second section. Slightly lift third
capscrews holding the cam plates to the section. This section, and remove pad plate.
will affect side clearance during re-assembly. 22. Slide 3rd section out of 2nd section. Removal of side
11. Loosen and remove four capscrews securing the rear pads is optional, as the side pads have ad equate
bottom wear pads on the 2nd section. This pad serves as clearance for boom disassembly. If removal of side pads
a bottom and side pad as well as the retract cable is required, tag all shims, pads and corresponding
keeper under the retract sheaves. Removal of this pad locations for proper re-assembly.
will allow the retract cables to uncoil off the retract 23. Loosen and remove all remaining capscrews and wear
pads from boom sections.

Boom Disassembly Alternative #2 1. Assemble sheaves into 4th section sheave case. Top
sheave is to be installed to the left hand side of the boom
The boom design allows for removal of the extend cylinder with the spacer to the right hand side.
from the rear of the boom without complete disassembly of
the boom sections. This procedure allows quick access to 2. Attach rear wear pads on bottom of 4th section. Using
the cylinder, retract cables, and various internal boom Loctite 243 blue, Loctite all wear pad mounting
components for service or replacement. If this procedure is capscrews.
used for disassembly, reverse procedure for reassembly, or 3. Install 4th section boom into 3rd section. Slide together
locate the appropriate step in the assembly procedure in this approximately 5 feet (150 cm).
manual to start reassembly from.
. 4. Assemble bottom front wear pads for 3rd section and
Teflon plugs. Attach pads to pad plate.
WARNING 5. Using appropriate lifting device, lift 4th section to allow

Do not, under any circumstances, work at an elevated for wear pad/pad plate installation in front of 3rd. Install
height without using proper fall protection as required by wear pad/pad plate assembly. Slide sections together
local, state or federal regulations within 12 inches (30 cm) of full retraction.
6. Install cable guide and upper spacer to front of 3rd
1. Remove hoist. section
2. Gaining access through rear of boom, loosen and 7. Install front side wear pads with appropriate shims,
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remove capscrews retaining the extend cable anchor in between 4th and 3rd sections. If boom has been
ef or
the rear of the 4th section as well as the anti-two block disassembled, and no sections have been replaced, use
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wire clamp on the anchor assembly. Loosen and remove
two capscrews retaining lock bar to extend cylinder.
used. If locations are in question, refer to shim
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Remove lock bar calibration section in this book. Slide boom sections
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3. Loosen and remove the nuts which secure the extend completely together.
cables to the extend cable anchor in the back of the 8. Assemble top rear wear pads to the top of the 4th boom
second section, remove capscrews from keeper plates section. Wear pads can be inserted from the hoist mount
er
holding extend anchor in place, remove keepers. end of the boom, and the cam plates dropped through
Remove anchor. Remove nut from anti-two block spade the holes in the aligned boom top plates.
bolt.
The wear pad on each side at the top/rear of the boom
4. Drape extend cables and anti-two block wire in side can be adjusted over a range of 3/16” (4.8 mm) by
boom, and slide cable anchor plate out of the side of the rotating, end for end, the wear pad and plate or the wear
hoist mount. pads and plate independently. This is possible because
5. Loosen and remove two capscrews, lock washers and the holes in these parts are offset from the center. The
spacers which anchor the extend cylinder rod butt plate holes are 0.06" (1.5 mm) off center in the plate and 0.03"
to the rear of the 1st section. (.8 mm) off center in the wear pad. Various combinations
of rotation of these parts allow the adjustment.
6. Using appropriate lifting device, lift extend cylinder up
and out of retaining slots on rear of 2nd and 3rd sections. a. Adjust pads until they are within 0.03” (.8mm) off
Retracting cylinder with an external hydraulic power center in the were pad. Various combinations of
source during this step may be necessary. rotation of these parts allows the adjustment.
7. Pull cylinder out through rear of boom assembly b. Torque retainer capscrews to 110 ft-lb (149 N-m).
approximately one-half the length of the cylinder. Failure to properly torque capscrews will cause loss
Turning of the butt plate and rod 90 degrees may aid in of preload and cause excessive side clearance
sliding cylinder through hoist mount area. Keep extend between sections.
cables tight to minimize the possibility of damage. 9. Uncoil 4/3/2 retract cable assemblies, and insert button
end into anchors in back of the 4th section. Place
FOUR SECTION BOOM ASSEMBLY uncoiled cable in area that will minimize the potential for
damage.
NOTE: Do not use Loctite on any cable threaded ends.
Always use the locknut and nut provided. 10. Uncoil 1/2/3 retract cable assemblies, and insert button
end into cable anchor pockets in back of the 3rd section.
When initially assembling threaded ends of cables, thread Place uncoiled cable in area that will minimize the
the first on past the flat in the cables so adjustment can be potential for damage. Assemble retract sheaves and
made later.

retract sheave pins in rear of 3rd section. Coat surfaces holes are 0.06" (1.5 mm) off center in the plate and 0.03"
of bearings and keeper plates with grease before ( 0 . 8 m m ) o f f c e n t e r i n t h e w e a r p a d . Va r i o u s
assembly. combinations of rotation of these parts allow the
adjustment.
11. Place retract cables anchored to 4th over the top of the
retract sheaves on the 3rd. Install keeper capscrew a. Adjust pads until they are within 0.03” (0.8mm) off
above sheave to hold retract cables in place. center in the were pad. Various combinations of
12. Reeve cables over retract sheave and install keeper/
wear pad to bottom rear of 3rd section. This pad acts as b. Torque retainer capscrews to 110 ft-lb (149 N-m).
a side pad, bottom pad, and a cable retainer. Loctite rear Failure to properly torque capscrews will cause loss
wear pad hardware on bottom of 3rd section with Loctite of preload and cause excessive side clearance
243 blue. Loctite all wear pad mounting capscrews. between sections.
13. Loop the 1/2/3 extend cable in half and place it on the 22. Position sheave and sheave pin located in cable loop on
top of the 3rd section, with the loop end towards the top of 3rd to allow capscrew installation, through top
sheave case end and the threaded and button end plate of 2nd. Install capscrews and torque to
towards the rear of the section. specification, clamping sheave pin and sheave to the
bottom of the 2nd section top plate.
14. Install clamp plate and capscrews with the button end of
the cable installed in the anchor slot on the rear top of 23. Assemble retract sheaves, retract sheave pins and
the 3rd section. cable keeper plates in rear of 2nd section. Coat surfaces
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of bearings with grease before assembly.
15. Place sheave pin and sheave for the 1/2/3 extend cable
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in position on the sheave case end of the boom, inside 24. Place retract cables anchored to 3rd over top of retract
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the loop of cable sheaves attached to rear of 2nd. Install keeper capscrew
above sheave to hold retract cables in place.
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16. Install 3rd and 4th section boom assembly into 2nd
4
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section. Slide together approximately 5 feet (150 cm). 25. Reeve cables over retract sheave and install keeper/
Use caution as retract cables and upper extend cable wear pad to bottom rear of 2nd section. This pad acts as
attached to the 4th-3rd section assembly slide into the a side pad, bottom pad, and a cable retainer.
2nd section to prevent damage or crossing of cables.
er
26. Assemble exterior extend cylinder components. Install
17. Assemble bottom front wear pads for 2nd section and and center sheave pin and anti-two block sheave into
Teflon plugs. Attach pads to pad plate. sheave case end of extend cylinder. Install bearings into
extend cable sheaves. Coat surface of bearings with
18. Using appropriate lifting device, lift 3rd and 4th section
grease and assemble extend sheaves on sheave pin.
assembly to allow for wear pad/pad plate installation in
front of 2nd. Install wear pad/pad plate assembly. Slide 27. Wrap approximately 10 feet (300 cm) of each 5/8 inch
sections together within 12 inches (30 cm) of full (15.88 mm) diameter 2/3/4 extend cable around extend
retraction. sheaves and install 4th section extend cable anchor
around cables at button end. Do not tighten capscrews
19. Install cable guide and spacer to top of 2nd section
clamping anchor together completely. These capscrews
20. Install front side wear pads with appropriate shims if tightened completely will not allow cable anchor to
between 3rd and 2nd sections. If boom has been install into 4th section.
disassembled, and no sections have been replaced, use
28. Install wear pad over extend cylinder sheave side plates.
This serves as a wear pad to keep the end of the extend
used. If locations are in question, refer to shim
cylinder centered in the boom, as well as an extend
calibration section in this book. Slide sections fully
cable retainer.
together
29. Slide extend cylinder/extend cables into 2nd/3rd/4th
21. Assemble top rear wear pads to the top of the 3rd boom
boom assembly enough to assemble extend cable
section. Wear pads can be inserted from the hoist mount
anchor into bottom rear of 4th section. Be aware of
end of the boom, and the cam plates dropped through
extend cable location when inserting cylinder into boom
the holes in the aligned boom top plates.
sections, inadvertent crushing or other damage to
The wear pad on each side at the top/rear of the boom cables will warrant replacement.
can be adjusted over a range of 3/16” (4.8 mm) by
30. Tighten capscrews clamping extend cable anchor
rotating, end for end, the wear pad and plate or the wear
together. This will also lock anchor in place in the anchor
pads and plate independently. This is possible because
cutouts in the 4th section.

31. Visually verify that the extend cables are properly routed used. If locations are in question, refer to shim
on their sheaves and continue to slide with the extend calibration section in this book.
cylinder and cables into the boom sections. Keep extend
45. Push boom together until extend cylinder butt plate
cables supported and slightly tensioned during insertion
makes contact with the rear cylinder anchor plates in the
of cylinder to maintain proper cable placement.
rear of the 1st section. Install spacers, washers and
32. As the extend cylinder nears complete insertion into the capscrews, attaching cylinder to 1st section boom. If
2nd/3rd/4th section assembly, adjust the height of the cylinder is misaligned with anchor points, cylinder butt
cylinder to allow the cylinder anchor collars to access plate can be rotated to achieve proper alignment
the cylinder keeper cut outs in the doubler plates on the (holding valve up, parallel with boom top plate).
sides of the 2nd and 3rd sections.
46. Assemble top rear wear pads to the top of the 2nd boom
33. Drop the cylinder down into the vertical cutouts in the section. Wear pads can be inserted from the hoist mount
doubler plates on the sides of the 2nd and 3rd sections. end of the boom, and the cam plates dropped through
Cylinder length or boom section placement may have to the holes in the aligned boom top plates.
be adjusted to allow cylinder collars to drop into their
The wear pad on each side at the top/rear of the boom
proper position.
can be adjusted over a range of 3/16 inch (4.8 mm) by
34. Install lock bar and capscrews to the extend cylinder rotating, end for end, the wear pad and plate or the wear
collar in the 3rd section. pads and plate independently. This is possible because
35. Route 2/3/4 anti-two block cable segment through boom
holes are 0.06 inch (1.5 mm) off center in the plate and
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sections (see Anti-Two- Block Installation section) and
0.03 inch (0.8 mm) off center in the wear pad. Various
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attach accordingly.
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36. Install large extend cable anchor into anchor cut outs in
the doubler plates in the rear of the 2nd by routing the 5/
adjustment.
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a. Adjust pads until they are within 0.03 inch (0.8mm)
8 inch (15.88 mm) extend cables through the anchor
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off center in the were pad. Various combinations of

and the small 3/8 inch (9.53 mm) cable over the anchor.
Slide anchor fully into cutout.
b. Torque retainer capscrews to 110 ft-lb (149 N-m).
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37. Install keeper plates and hardware. This keeper plate
Failure to properly torque capscrews will cause loss
retains both the horizontal movement of the extend
anchor and the vertical movement of the extend cylinder.
between sections.
38. Anchor 2/3/4 anti-two block cord in the extend anchor
47. Install thick hoist attachment bar through hoist mount.
(see anti-two block Installation section) using
This bar anchors the 3/8 inch (9.53 mm) extend cable
appropriate hardware.
and serves as the upper hoist attach ment point. Hold
39. Route 1/2 anti-two block segment on the bottom of the this bar up in its slot with a spacer on each side. This will
1st section boom (see anti-two block Internal Wire facilitate easier assembly.
System section).
48. Install the threaded end of the 3/8 inch (9.53 mm) extend
40. Install 2/3/4 section boom assembly into lst section cable through hole in center of the hoist attachment bar.
boom, use caution when sliding sections together, 3rd
49. Slightly tighten all cables. Cycle boom slowly to assure
retract cables must maintain their position to prevent
proper operation before torquing cables. Refer to the
damage, do not let boom rest on cables. Damage will
Four Section Cable Tensioning section to properly
result.
torque the cables in the extend system. Cables must be
41. Assemble bottom front wear pads for 1st section and torqued to proper specifications for proper boom
Teflon plugs. operation.
42. Using appropriate lifting device, lift 2/3/4 section 50. Install hoist.
assembly to allow for wear pad installation in front of 1st.
Install wear pads. Slide sections together within 12 FOUR SECTION TOP/BOTTOM PAD
inches (30 cm) of full retraction. REPLACEMENT ASSEMBLED BOOM
43. Install upper spacer to front of 1st section.
Inspect top and bottom wear pads periodically for signs of
44. Install front side wear pads with appropriate shims abrasion or excessive wear. Excessive is defined as 3/16 of
between 2nd and 1st sections. If boom has been an inch (4.76 mm) from the original pad thickness, top rear
disassembled, and no sections have been replaced, use pad thickness 0.75 inch (19 mm), bottom front 1st section 1
same shim quantity and location as was previously inch (25 mm), bottom front 2nd and 3rd section 0.44 inch (13

mm). Uneven pad wear of 3/32 inch (2 mm) from side to side 5. Loosen and remove the four capscrews holding the pad
on the wear pad would be considered excessive as well. If doubler plate in between the 4th and 3rd sections.
any of these conditions exist, the top and bottom pads can Remove plate. Remove pads from this plate. Note all
be re placed without complete disassembly of the boom. pad locations and tag accordingly.
Top Rear Pad Replacement 6. Loosen and remove the four capscrews holding the pad
doubler plate in between the 3rd and 2nd sections.
Pad maintenance on the four section can be made easier by Remove plate. Remove pads from this plate. Note all
removal of the hoist and or removal of the hoist mounting bar pad locations and tag accordingly.
spanning the end of the 1st section. Additional clearance can
7. Loosen and remove the four capscrews holding the pads
be achieved by loosening the large extend cables and
in between the 2nd and 1st sections. Remove pads.
removing the extend cable anchor located in the 2nd section.
Note all pad locations and tag accordingly.
2. Remove capscrews through access holes on top rear of inspection criteria.
sections.
9. Install new pads with Teflon inserts on plates or boom
3. Remove wear pads, shims, and cam plates from the rear sections. Reassemble plates in boom in proper
of the boom through open hoist mount end. locations.
4. Note all pad locations and tag accordingly.
CABLE TENSIONING
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inspection criteria. A boom assembly is considered properly timed when
6.
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Assemble new wear pads with the cam plates and install
telescoping sections extend equally relative to each other
and bottom out simultaneously at full retraction and do not
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through the hoist mount end of the boom. Install
4
spring back out after retract pressure is returned to neutral.
capscrews through holes in outer boom sections. The
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wear pad on each side at the top/rear of the boom can Hydraulic extend cylinder construction will dictate which
be adjusted over a range of 3/16-inch (4.8 mm) by extendable section will be the driver that the other extend
rotating, end for end, the wear pad and plate or the wear sections will need to be ad justed to utilizing cable
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pads and plate independently. This is possible because adjustment.
the holes in these parts are offset from the center. The A single stage cylinder will control first extendable section.
holes are 0.06 inch (1.5 mm) off center in the plate and
0.03 inch (0.8 mm) off center in the wear pad. Various A dual stage cylinder will control second extendable section.
combinations of rotation of these parts allow the Timing sequence of cables will depend on number of
adjustment. sections and the extend cylinder construction.
a. Adjust pads until they are within 0.03 inch (0.8mm) Design intent of the cable tensioning is to balance the
off center in the wear pad. Various combinations of preload of extend and retract cables for each extendable
rotation of these parts allows the adjustment. section. In addition, sequencing of the sections during
b. Torque retainer capscrews to 110 ft-lb (149 N-m). retraction requires retract cables of every section to be
Failure to properly torque capscrews will cause loss indexed relative to each other.
between sections. Cable Tensioning Setup Procedure
Tensioning must be done with the boom in the horizontal
Front Bottom Pad Replacement position.
1. Extend boom approximately 4 feet (120 cm) out. When tightening/loosening the first (adjustment) nuts on
2. Remove cable guides and upper spacer bars from front cables, secure cable using the wrench flats at the front of the
of boom sections cable ends to prevent cable twist. Excess twisting of cables
can cause premature failure.
3. Loosen and remove hex nuts on retract cables on the
front of the 1st and 2nd sections Ensure boom is completely assembled and fully retracted.
4. Using an appropriate lifting device, sling around the 4th 1. Mark the front of each section with a chalk line as
section boom and lift it up until weight is removed from indicated in Figure 5.
the bottom pads in the front of the 3rd, 2nd, and 1st 2. Extend and retract boom several times to establish
boom sections. working state of cables.

3. Extend boom so scribed lines are exposed by 6. Measure the retraction gaps between each boom
approximately 12 inches. section and scribed line and note values.
4. Measure the extension gaps between each boom 7. Extend and retract the boom a few times and then
section and scribed line and note values. repeat measuring the extension gaps.
5. Retract boom so that the scribed lines are exposed by 8. Adjust all corresponding cables according to Cable
approximately 6 inches. Tightening Sequence instructions.
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8860-5
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FIGURE 5
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Cable Tension Sequence 1. 123 extend cables.

2. 321 retract cables.
Four section boom with two stage cylinder.
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3. 234 extend cables.
Cable tensioning to be in the following order:
1. 321 retract cables
2. 123 extend (synchronizing) cables. Three section boom with one stage cylinder.
3. 234 extend cables Cable tensioning to be in the following order:
4. 432 retract cables. 1. 123 extend cables.

Four section boom with one stage cylinder.
Cable tensioning to be in the following order:

4- Section Boom w/ 2 Stage Cylinder Cable Positioning
1/2/3 EXTEND
TIP
2/3/4 EXTEND
BASE 1ST STAGE

2ND STAGE
3RD STAGE 4th STAGE
8860-2
4/3/2 RETRACT
3/2/1 RETRACT
FIGURE 6
Cable Tightening Sequence 4 Section Boom with Two Retraction
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Stage Extend Cylinder
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1. Measure the retraction gaps between the first and
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Boom must be in horizontal position when adjusting cable
tension (See Figure 6.) Retract boom fully ensuring sections
second section and the second and third section.
If the retraction gap is greater between the first and second
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4
are bottomed out on section stops. Ensure all sections are
section than the retraction gap between the second and third
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fully bottomed out and do not spring back.(Reference Cable

section;
Tensioning)
2. Tighten the 123 synchronizing cable located at the back
321 and 123 cable balancing of the base section the difference in the retraction gap
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Extension measurements.
1. Measure the extension gaps between the first and 3. Extend and retract the boom a few times and then
second section and the second and third section. repeat measuring the retraction gaps.
If the extension gap between first and second section is less The third section should have moved out.
than the extension gap between the second and third 4. Tightening until the retraction gap between the first and
section; second section and the retraction gap between the
2. Tighten 321 retract cable located at the front bottom of second and the third are equal.
the base section the difference in the extension gap At this time the second and first extendable sections should
measurements. extend and retract equally and bottom out against the stops
3. Extend and retract the boom a few times and then simultaneously.
repeat measuring the extension gaps.
234 and 432 cable balancing
The second section should have moved out.
Extension
4. Tightening until the extension gap between the first and
1. Measure the extension gaps between the third and
second section and the extension gap between the
fourth section and the second and third section.
second and the third are equal.
If the extension gap between third and fourth section is less
If when tightening the 321 retract cable the third section
than the extension gap between the second and third
starts to go out with the second section the 123
section;
synchronizing cable located at the top back of the base
section may need to be loosened. 2. Tighten the 234 extend cable located at the back top of
the second section the difference in the extension gap
measurements.
3. Extend and retract the boom a few times and then

The fourth section should have moved out. 2. Tighten the 432 retract cable located at the front bottom
of the second section the difference in the retraction gap
4. Tightening until the extension gap between the third and
measurements.
fourth section is equal to the extension gap between the
second and third section. 3. Extend and retract the boom a few times and then
repeat measuring the retraction gaps.
Retraction
The fourth section should have moved in.
1. Measure the retraction gaps between the second and
third section and the third and fourth section. 4. Tightening until the retraction gap between the third and
fourth section is equal to the retraction gap between the
If the retraction gap is greater between the third and fourth
second and third section.
section than the retraction gap between the second and third
section; At this time the all extendable sections should extend and
retract equally and bottom out against the stops
simultaneously.
1/2/3 EXTEND 2/3/4 EXTEND

TIP
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BASE 1ST STAGE
2ND STAGE
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4th STAGE
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8860-3
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3/2/1 RETRACT 4/3/2 RETRACT

FIGURE 7
Cable Tightening Sequence 4 Section Boom with (1) The third section should have moved out.
Boom must be in horizontal position when adjusting cable second section and the extension gap between the
tension (See Figure 7.) Retract boom fully ensuring sections second and the third are equal.
Retraction
fully bottomed out and do not spring back.(Reference Cable
Tensioning Setup Procedure) 1. Measure the retraction gaps between the first and
321 and 123 cable balancing
If the retraction gap is greater between the second and third
Extension section than the retraction gap between the first and second
1. Measure the extension gaps between the first and section;
second section and the second and third section. 2. Tighten the 321 retract cable located at the front bottom
If the extension gap between second and third section is less of the base section the difference in the retraction gap
than the extension gap between the first and second section; measurements.
2. Tighten 123 extend cable located at the back top of the 3. Extend and retract the boom a few times and then
base section the difference in the extension gap repeat measuring the retraction gaps.
measurements. The third section should have moved in.

4. Tightening until the retraction gap between the first and 4. Tightening until the extension gap between the third and
second section and the retraction gap between the fourth section is equal to the extension gap between the
second and the third are equal. second and third section.
At this time the second and first extendable sections should Retraction
extend and retract equally and bottom out against the stops
1. Measure the retraction gaps between the second and
simultaneously.
third section and the third and fourth section.
234 and 432 cable balancing If the retraction gap is greater between the third and fourth
Extension section than the retraction gap between the second and third
section;
1. Measure the extension gaps between the third and
fourth section and the second and third section. 2. Tighten the 432 retract cable located at the front bottom
of the second section the difference in the retraction gap
If the extension gap between third and fourth section is less measurements.
than the extension gap between the second and third
section; 3. Extend and retract the boom a few times and then
2. Tighten the 234 extend cable located at the back top of
the second section the difference in the extension gap The fourth section should have moved in.
measurements. 4. Tightening until the retraction gap between the third and
fourth section is equal to the retraction gap between the
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repeat measuring the extension gaps. second and third section.
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The fourth section should have moved out. At this time the all extendable sections should extend and
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simultaneously.
4
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TIP
EXTEND CABLE
BASE
8860-4 1ST SECTION 2ND SECTION 3RD SECTION
RETRACT CABLE
FIGURE 8
Cable Tightening Sequence 3 Section Boom with (1) 321 and 123 cable balancing
Extension
Boom must be in horizontal position when adjusting cable
1. Measure the extension gaps between the first and
tension (See Figure 8.) Retract boom fully ensuring sections
fully bottomed out and do not spring back.(Reference Cable If the extension gap between second and third section is less
Tensioning on page 4-15). than the extension gap between the first and second section;
2. Tighten 123 extend cable located at the back top of the
base section the difference in the extension gap
measurements.

3. Extend and retract the boom a few times and then 2. Tighten the 321 retract cable located at the front bottom
repeat measuring the extension gaps. of the base section the difference in the retraction gap
measurements.
The third section should have moved out.
second section and the extension gap between the
second and the third are equal. The third section should have moved in.
Retraction 4. Tightening until the retraction gap between the first and
second section and the retraction gap between the
1. Measure the retraction gaps between the first and
second and the third are equal.
At this time the all extendable sections should extend and
If the retraction gap is greater between the second and third
section than the retraction gap between the first and second
simultaneously.
section;
OPTION 1
5 5 OPTION 2
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3
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4
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8859-1 8859-2
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2 2
1 1
FIGURE 9
Cable Retention NOTE: (OPTION 2) method used ONLY when space

constraints prevent OPTION 1 usage.
Cable Retention Hardware
When tightening/loosening the first (adjustment) nuts on
Item Description cables, secure cable using the wrench flats at the front of the
cable ends to prevent cable twist.
1 Threaded Cable End
After the cable adjustment procedure is completed for the
2 Nut (Adjustment)
entire boom assembly. The second (torqued) nut must be
3 Nut (Positive Lock) installed on all retract and extend cables.
4 Setscrew The second nut should be hand tightened until it comes in
5 Washer contact with the back of the first nut.
6 Nut (Torqued) Hold the first (adjustment) nut stationary and a torque
wrench to tighten the second (torqued) nut against the first
Nut configuration (see Figure 9) will be First Nut (adjustment) nut to the values indicated in TORQUE
(ADJUSTMENT) and Second Nut (TORQUED). VALUES for Second Nut:

Third (positive lock) nut installation is to be placed on each of LIFT CYLINDER REPAIR
the extend cables. The retract cables do not require the third
(positive lock) nut. Lift Cylinder Disassembly
The third nut should be hand tightened until the tapped hole 1. Disconnect shaft end of cylinder from machine.
for the set screw is tangent to the end face of the wrench flat.
2. Retract cylinder shaft with oil from the hydraulic system
Install set screw into Third nut and tighten. until about 12 inches (30 cm) of shaft is extended. The
(OPTION 2) method used ONLY when space constraints barrel must be filled with oil to prevent a compressed air
prevent OPTION 1 usage (see Figure 9). chamber being formed which could result in injury at
disassembly.
TORQUE VALUES for Second Nut:
3. Remove the cylinder from the machine and place on
Inch Series with Coarse Threads (UNC) supports with an oil pan directly beneath the cylinder
head area.
Minimum
Cable end Nut TORQUE 4. Using the proper size of external snap ring pliers,
Nut Type expand the snap ring completely and remove from
Thread Size Strength ft lb
GRADE groove. Slide large washer forward to gain access to the
packing gland.
Hex Jam
1/2-13 SAE 2 12 5. Using a special drive tool, drive the packing gland into
(HALF)
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the barrel assembly to expose the round cross section
Hex Jam
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5/8-11 SAE 2 31 retaining ring. Then use a small needle nose locking
(HALF)
3/4-10 nl c
SAE 2
Hex Jam
47
plier to clamp the round cross section retaining ring to
prevent it from rotating in the groove. Use two straight
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4
(HALF) blade screw drivers: one to pry the end of the ring out of
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the groove and the other to pry the ring out of the barrel
Hex Jam assembly.
7/8-9 SAE 2 63
(HALF)
6. Attach a porta-power hand pump or hydraulic line from
Hex Jam
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1-8 SAE 2 199 crane circuit valve to the shaft end of the cylinder. De-
(HALF)
burr groove edge. Failure to do so will damage barrel or
Hex Jam packing gland.
1 ¼-7 SAE 2 203
(HALF)
7. Operate hand pump or crane circuit valve, preferably the
Hex Jam boom telescope circuit, to force packing gland out of
1 ½-6 SAE 5 250
(FULL) barrel.
Hex Jam 8. Remove holding valve from cylinder to allow removal of
1 ¾-5 ASTM B 250
(FULL) shaft and piston assembly. Remove the shaft and piston
assembly by hand.
Metric Series with Coarse Threads
Minimum
Cable end Nut TORQUE
Nut Type
Thread Size Property Nm
Class
Hex Jam
M16x2 5 26
(THIN)
Hex Jam
M20x2.5 5 66
(THIN)

Pressure line from a porta-power

or hydraulic line from the crane
circuit valve. Read step 5 and 6
before performing this step.
Cylinder Barrel
Retaining Ring
Washer
Snap Ring
Shaft extended
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about 12 inches
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9.
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Disassemble the piston set by removing nut, replace EXTEND CYLINDER REPAIR
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worn or damaged parts. Note: Loctite 680 is used during
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original assembly to secure nut to shaft. If necessary,

heat nut to 400-500° F (204-260°C) to facilitate removal.
If heat is necessary for removal, discard nut and replace
Boom Extend
with new equivalent nut as well as worn or damaged
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parts.
10. Wipe and inspect all cylinder internal and external
surfaces for damage.
11. Remove seals and bearings from packing gland and
piston. Replace all seals and bearings.
12. Reassemble shaft and piston set in the proper order with
external snap ring, large washer, internal round section Boom Retract
ring, packing gland, stop tube, piston to shaft O-ring,
piston, and locknut. Loctite locknut onto shaft using type
680 according to Loctite recommendations. Torque
locknut to 600 ft-lbs (813 Nm).
13. Grease piston assembly and install the shaft assembly Extend Cylinder Disassembly
with piston, O-ring, stop tube, packing gland, internal
1. After cylinder has been removed from boom, place on
round ring, large washer, and external snap ring into
supports and place drain pan under holding valve and
barrel assembly.
cylinder head area.
14. Using special drive tool, drive the packing gland into the
2. Retract cylinder shaft with oil from the hydraulic system
barrel assembly.
until about 12 inches (30 cm) of shaft is extended. The
15. Insert one end of round ring into groove in barrel barrel must be filled with oil to prevent a compressed air
assembly and spiral the ring into groove with straight chamber being formed which could result in injury at
blade screw driver. disassembly. Relieve any trapped hydraulic pressure
which might remain in the cylinder.
16. Slide large washer into position on end of packing gland
and retain with the external snap ring being sure that 3. Remove any plug or fitting that is in the retract port in the
snap ring contracts completely and properly into the cylinder butt plate. Using a special drive tool, drive the
snap ring gland groove. packing gland into the barrel assembly to expose the

round cross section retaining ring. Then use a small 3. Grease piston assembly and install the shaft assembly
needle nose locking plier to clamp the round cross with piston, O-ring, stop tube, packing gland, internal
section retaining ring to prevent it from rotating in the round ring into barrel assembly.
groove. Use two straight blade screw drivers: one to pry
4. Using special drive tool, drive the packing gland into the
the end of the ring out of the groove and the other to pry
barrel assembly.
the ring out of the barrel assembly.
5. Insert one end of round ring into groove in barrel
4. De-burr ring groove edge after removing round ring.
assembly and spiral the ring into groove with straight
Failure to do so will damage packing gland and or barrel
blade screw driver.
assembly when packing gland is removed.
6. Cycle test cylinder to ensure no leaks exist. Support end
5. Plug retract port in the cylinder butt plate with SAE #8 O-
of cylinder as it extends and retracts.
ring boss plug and pull on the rod assembly to force
packing gland out of the barrel assembly.
JIB INSTALLATION AND ADJUSTMENT
6. If step 5 fails to break packing gland loose from the
barrel assembly, remove the plug from the retract port 1. Loosely bolt the two ear assemblies with shims and bars
and plug the extend port in the cylinder butt plate (SAE as shown to the side of the first boom section.
#8 O-ring boss). Apply retract pressure to cylinder to
break packing gland loose. Remove holding valve and NOTE: Note: All measurements are in inches (mm).
extend and retract plugs from butt plate and pull packing
gland out by hand.
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3/4” Grade 5
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7. As soon as the packing gland is sufficiently loosened, (Typ 4 Plcs) 0.38 (10) Bar
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properly support the rod assembly and carefully remove
it by hand. Place rod assembly on supports. Exercise 0.06 (1.6)
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Shims
4
caution in the support and removal of the rod assembly 0.38 (10)
Bar
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as damage to the chrome surface requires rod assembly

replacement.
8. Disassemble the piston set by removing nut, replace
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worn or damaged parts.
0.06 (1.6)
NOTE: Loctite 680 is used during original assembly to Shims
secure nut to shaft.
0.38 (10)
9. If necessary, heat nut to 400-500° F (204-260°C) to Bar
facilitate removal. If heat is necessary for removal,
discard nut and replace with new equivalent nut as well
as worn or damaged parts.
2. Loosely bolt the hook assembly to the side of the first
10. Wipe and inspect all cylinder internal and external boom section.
surfaces for damage.
11. Remove seals and bearings from packing gland and
piston. Replace all seals and bearings.
12. Inspect wear pad on barrel assembly and replace as Typ 4 Plcs
required.
Extend Cylinder Assembly

1. Reassemble shaft and piston set in the proper order with
internal round section ring, packing gland, stop tube,
piston to shaft O-rings, piston, and locknut. Loctite
locknut onto shaft using type 680 according to Loctite
recommendations. Torque locknut to 300 ft-lbs (407Nm).
2. De-burr ring groove edge in barrel assembly and inspect
all internal and external surfaces for damage. Failure to 3. Extend the boom approximately one foot (300 mm).
do so will damage packing gland and or barrel assembly 4. Using an overhead hoist, lift the jib assembly and align
when packing gland is installed. and pin the jib to the boom sheave head.

Ramp Side Stow

Bracket on Jib
Stow Hook
on Boom
Alignment
Pin
Stow Pin
5. With jib pinned to the sheave head, swing the jib parallel
to the boom and install the pin which keeps the jib from Front Bar Not
swinging (the pin is attached by cable to the end of the (Top & Bottom Acceptable
jib).
.
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Shims
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Upper Support
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Jib Ears Acceptable
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Lower Support
CAUTION
6. Slowly retract the boom until the jib ears are within 0.50 Make sure ramp slides up to the stow hook and does not
inch (13 mm) of the ear assemblies on the first section. hit the end of the ramp.
Observe the vertical alignment of the jib ears and ear
assemblies and add or remove shims until the jib is 9. When the boom is fully retracted, the jib must be
supported by the jib ears. The jib will typically rest only bottomed out securely in the ear assemblies. If the
on the upper support. alignment pins are not aligned properly, the hook
assembly and front bars will have to be positioned as
Alignment Pin shown so the jib cannot slide forward or backward as the
boom is elevated.
10. Try to remove the jib pins. If the pins are too tight, the
stow hook assembly or front bars will have to be
adjusted.
11. Torque all capscrews to their specified torque value (see
7. Observe the horizontal alignment of the slot in the ear “Fasteners and Torque Values Table in Section 2. Install
assemblies and the alignment pin in the jib. Horizontal stow pin in lock assembly and remove the jib pins.
adjustment of the stow ears is provided by oversize bolt
12. Extend and retract boom to insure proper alignment of
holes in the stow ear. Move the ears in or out to achieve
jib pins.
proper alignment. Position the top ear so it holds the top
of the jib in toward the boom and the bottom ear so that it 13. Install jib pins and remove the stow pins.
holds the bottom of the jib away from the bottom of the
14. Extend and retract the boom and jib to ensure proper
boom.
alignment of jib stow brackets.
8. Retract the boom slowly. Observe the stow hook and
15. Install jib stow pins and remove jib pins. Always save
side stow bracket assembly alignment as the boom is
shims to allow future adjustment of jib stow if required
retracted (View AA and BB below).

Hook Assembly
Stow Pin
Alignment
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Pin in Slot
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4
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JIB JACK SERVICE AND MAINTENANCE 3. Lay the jack on its side and drain the oil into a suitable
drain pin. The oil will run slowly because air must enter
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Important: Use only a good grade hydraulic jack oil, as oil drains out.
transmission oil, or turbine oil. Avoid mixing types of oil. Do
not use brake fluid, alcohol, glycerin, detergent motor oil, or 4. Be careful to prevent dirt or foreign matter from entering
dirty oil. Improper fluid can cause serious Internal damage to the system.
the jack rendering it inoperative. 5. Replace with proper oil as described above.
Adding Oil Lubrication
1. With saddle fully lowered and piston depressed, set jack Add proper lubrication oil to all pivoting sections every three
in upright level position and remove oil filler plug. months.
2. Fill until oil is level with filler plug hole.
Rust Prevention
Changing Oil Check ram every three months for any sign of rust or
1. For best performance and longest life, replace the corrosion. Clean as needed and wipe with an oil saturated
complete oil supply at least once a year. cloth.
2. To drain the oil, remove the filler plug. NOTE: When the jack is not in use, always leave the
saddle and ram all the way down.

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600E2 SERVICE MANUAL HOIST
SECTION 5
HOIST
SECTION CONTENTS
Hoist Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
HOIST REMOVAL NOTE: Tag hydraulic hoses to avoid confusion during

reassembly (the inside hose “up” and the outside is
“down”).
CAUTION
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The combined weight of the hoist and 325 ft. of wire rope
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is 660 lbs (300 kg).
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6. Attach suitable lifting device to hoist and take up the
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slack. 5
7. Remove 6 mounting capscrews and washers (3 on each
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side).
8. Lift which clear of boom and secure to a suitable holder
Item Component HOIST INSTALLATION

1 Hoist 1. Remove rope Mesh Guard from hoist.
2 Boom 2. Lift hoist with suitable lifting device.
3 Capscrew (6 plcs) 3. Lower hoist onto the alignment ears.
4 Case Drain
4. Install Mesh Guard.
5 Hoist Down Hose
5. Install 6 capscrews and washers. Torque capscrews to
6 Hoist Up Hose 220 ± 20ft lb (300 ± 30 N.m.
7 Hoist Alignment Ears 6. Inspect hydraulic hoses and anti chafing sleeve for wear
or damage. Replace as required.
7. Route hoses with anti chafing sleeve installed through
1. Extend and set the outriggers. access hole in turret assembly.
2. Fully retract the boom and place in a horizontal position. 8. Install hoist up hydraulic hose to lower inside fitting on
3. Remove hook block or downhaul weight.Shut down which motor.
truck engine. 9. Install hoist down hydraulic hose to outside fitting on
4. Remove and cap hydraulic hoses. hoist motor.

HOIST 600E2 SERVICE MANUAL
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THIS PAGE BLANK
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600E2 SERVICE MANUAL SWING
SECTION 6
SWING
SECTION CONTENTS
Swing Gearbox And Brake. . . . . . . . . . . . . . . . . . . 6-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Disassembly and Assembly Instructions. . . . . . . . 6-1 Swing Bearing Bolts. . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Drive Disassembly . . . . . . . . . . . . . . . . . . . 6-1 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Tulsa Swing Drive Assembly Procedure. . . . . . . . 6-4 Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Rotation Stop-mechanical . . . . . . . . . . . . . . . . . . . 6-5 Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . 6-11
Rotation Stop Adjustment . . . . . . . . . . . . . . . . . . . 6-5 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Slew Potentiometer Orientation . . . . . . . . . . . . . . 6-12
Torquing Swing Bearing Bolts . . . . . . . . . . . . . . . 6-6 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
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SWING GEARBOX AND BRAKE
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CAUTION
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Disassembly and Assembly Instructions The motor adapter is spring loaded and the capscrews
This section describes the disassembly and assembly should be loosened in a sequence that will allow an even
procedures for the swing gearbox. Item numbers shown in load distribution on the motor adapter.
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parentheses throughout this procedure, refer to the exploded
parts breakdown drawing. 5. Inspect the motor adapter O-ring (24) for wear. Replace
if necessary.
Swing Drive Disassembly 6. Remove the six springs (15) and the brake driver (8)
from the brake housing (2).
6
1. Remove drive from vehicle and drain gearbox lubricant
by removing the drain plug (26). 7. Remove retaining ring (37) from the brake piston (5).
2. Remove the motor from the motor adapter (3). 8. Remove the stator plates (16) and friction discs (17)
3. Remove the brake assembly from the gear housing from the brake piston (5). Inspect stator plates for
assembly (1) by removing six socket head excessive grooving or burn spots. Also, inspect friction
capscrews (27). discs for wear. Replace as required.
NOTE: The position of the brake port in conjunction with 9. Remove the piston (5) from the brake housing (2).
the drain and fill holes in the housing for NOTE: Notice the position of the dowel pin hole in piston
reassembly. with the brake release port for reassembly.
4. Separate the motor adapter assembly (3) from the brake A port-a-power can be used to assist in removal of piston by
housing (2) by removing six capscrews (28). slowly pressurizing the brake release port until piston clears
NOTE: Notice the position of the motor mounting hole in the top of the housing.
relation to the brake release port for reassembly.

SWING 600E2 SERVICE MANUAL
0.080
( 2.03
in mm
(
0.085 2.16 O-Rings
Back-up Ring
Replace if the Back-up Ring
thickness is below Piston
0.070 in (1.78 mm)
Friction Disc
No Wear
11. Inspect the thrust plate (9) for excessive grooving and
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replace if necessary by removing snap ring (36).
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12. Remove the brass thrust washer (34) and sun gear (41).
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10. Inspect the piston O-rings (20 &21) and the back-up 13. Remove input planet set (3, part of gear set 4) from gear
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rings (19 & 22) for damage, replace if necessary. housing (1) by pulling straight up and out of the housing.
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29
28
39
3
34
41
24
43
8
11 44 50 15
18
42 51
1 5
52
45 50 22
48
53 21
43 20
4
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46 19
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49
26
12
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50
54
37
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17
7
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35 32 55
10 48 54
56
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6
16
57 27
2 6
36
23
Grease Fitting
Breather/Oil Fill
Oil Drain Plug
Brake Release Port

Item Component Item Component Item Component

1 Gear Housing 16 Stator Plates 36 Snap Ring
2 Brake Housing 17 Friction Plates 37 Retaining Ring
3 Motor Adapter 19 Back-up Ring 41 Sun Gear
4 Gear Set 20 O-ring 43 Retaining Ring
5 Brake Piston 21 O-ring 44 Input Carrier
6 Pinion Shaft 22 Back-up Ring 45 Sun Gear
7 Outboard Bearing 23 O-ring 46 Locking Bolt
8 Brake Driver 24 Fill Plug 47 Output Planet Carrier
9 Thrust Plate 26 Drain Plug 48 Retaining Rings
10 Seal 27 Socket Head Capscrew 49 Pinion Bolt
11 Inboard Bearing 28 Socket Head Capscrew 51 Planet Gear
12 Bearing Cup 32 Breather 52 Needle Bearings
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15 Spring 34 Thrust Washer 53 Planet Pin
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35 Grease Fitting
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14. Remove the retaining ring (43) from the input carrier 18. Remove the inboard bearing (11) and inspect for wear.
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(44), remove the output sun gear (45), and inspect for
19. Remove the pinion shaft (6) from the housing (1) and
wear and replace as necessary.
inspect the pinion shaft, seal, and bearing for wear.
15. Remove retaining rings (48), press out the planet pin
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20. Remove outboard bearing (7) and seal (10). Inspect for
(53), remove the planet gear (51), and needle bearings
wear and replace if necessary.
(52), inspect for unusual wear. Replace as required.
16. Remove the pinion locking bolt (46) from the output Tulsa Swing Drive Assembly Procedure
planet carrier (47). Loosen the pinion bolt (49).
1. Press the inboard and outboard bearing cup (12) into the
gear housing (1) if replaced.
2. Grease pack the bearing cones, items (7), with EP 2
Pinion Locking Bolt
before installation.
3. Install the outboard cone (7) into the outboard cup (12).
Press the seal (10) into the gear housing(1) from the
outboard side.
4. Slide the output pinion (6) into the housing (1) from the
outside.
5. Install the inboard bearing cone (11).
6. Separate the gear set (4) into sections.
7. Apply Loctite to the threads of the pinion bolt (49). Install
Pinion Bolt the output carrier (47) into the gear housing (1).
a. Tighten the pinion bolt halfway, check the alignment
of the output carrier (47) with the spline on the
pinion shaft (6), and then tighten the pinion bolt the
17. Remove the retaining rings (48). Lift output planet set rest of the way.
out of the housing (1). Press out the planet pin (57);
b. Torque the pinion bolt to 50 ft-lb (68 Nm), loosen
remove the planet gear (55) and needle bearings (54).
and re-torque until the pinion locking bolt aligns with
Inspect for unusual wear. Replace as required.

the slot on the nut portion of the pinion bolt at 25 ft-lb NOTE: Soak friction disk in EP-90 for 24 hrs. before
(34 Nm) If the pinion bolt is between slots always installation.
tighten to the next slot.
16. Reinstall the retaining ring (37) into the piston.
NOTE: Install a 1/2-13 bolt into the end of the pinion shaft
17. Install six springs (15) into the holes in the motor adapter
on the outboard side and check the rolling torque.
(3).
Preload of the bearing rolling torque should be 35-
50 ft-lb (47-68 Nm). Apply Loctite to the pinion 18. Mount the motor adapter (3) to the brake housing (2)
locking bolt (46) and torque to 20 ft-lb (27 Nm). with six cap screws (28) checking to make sure the roll
pin (18) is in line with the dowel hole in piston (5).
8. Install the input carrier section (44) with Sun gear (45)
attached with retaining ring (43). NOTE: Notice the position of the motor mounting hole in
relation to the brake release port for correct
9. Install the sun gear (41) and thrust washer (34)
reassembly.
10. Assemble the brake section by first installing the 0-ring
Fill the gearbox to desired level with EP-90 gear lube.
(23) on the brake housing (2). Install six capscrews (27)
to the brake housing (2) and torque to 10 ft-lb (13 Nm).
Notice the position of the brake port in conjunction with ROTATION STOP-MECHANICAL
the drain and fill holes in the housing. The rotation stop system is designed to stop crane rotation
11. Install the O-ring (20) and back-up ring (19) on the small beyond 375 degrees in the clockwise or counterclockwise
step of the piston (5). directions. This is accomplished by mechanically returning
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the control valve to the centered position as full rotation is
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12. Install one back-up ring (22) and one O-ring (21) on the approached. The operator will feel the control lever begin to
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large step of the piston (5). Apply a slight film of oil on
the O-rings and back-up rings before installing.
pull in the opposite direction as full rotation is approached.
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The operator should not resist this counteracting force, but
13. Carefully press the assembled piston (5) into the brake
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permit the rotation stop system to return the lever to neutral.

housing (2), taking care not to damage the rings.
If a load cannot be reached or placed due to the available
NOTE: The position of the dowel pinhole in piston with the rotation, the crane must be re-positioned.
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brake release port for correct assembly.
DANGER
Pinion Locking Bolt
Attempting to over ride the rotation stop system will result 6
in damage to the crane and possible injury to the operator.
Rotation Stop Adjustment

There are two methods that can be used for adjusting the
rotation stop system.
Method 1
1. From inside of the frame, rotate the flag rod until it is
centered between the two stop pins on either side of the
flag.
Pinion Bolt
2. Make certain that the turn lever is vertically aligned. If
not, adjust the lever at the clevis connecting it to the
control valve.
14. Insert the brake driver (8) into the assembled brake 3. With the turn lever vertically adjusted, verify that the
housing (2) and piston (5). spacer is centered in the turn control rod tab.
15. Install the stator plates (16) and friction disks (17) 4. If it is not centered, loosen the two nuts, one on either
starting with one stator plate and alternating between side of the spacer. Turn the nuts in the same direction
friction disk and stator plate until six stator plates and until the spacer is centered. Tighten the nuts against the
five friction disks are used. ends of the spacer to secure it in place.
5. Verify that the flag is sill centered between the stop pins.

6. Now rotate the crane in the opposite direction until the

rotation stop system centers the control lever.
7. Make another mark on the crane frame aligned with the
center of the lift cylinder.
8. If the rotation stop system is properly adjusted, the
distance should be the same from the first mark made to
the second mark, as it is from the first mark to the third
mark.
9. If not, loosen the nut on either side of the spacer on the
flag rod actuator rod and adjust the position of the
spacer. Tighten the two nuts and repeat steps 3 through
7 above until proper adjustment is achieved.
MAINTENANCE
General
FIGURE 6-1 The swing bearing is the most critical maintenance point of
the crane. It is here, at the centerline of rotation, that
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stresses of loads are concentrated. In addition, the bearing
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provides the only attachment between the turret and frame.
Method 2
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maintenance of the turret-to-bearing attach bolts IS A MUST
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1. Follow the crane set-up procedures in this manual to set
to ensure safe and efficient operation.
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outriggers and jacks and level the machine.

2. With the crane properly set-up, raise the boom to near TORQUING SWING BEARING BOLTS
full boom angle (75-80 degrees). This must be done with
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the boom fully retracted and with no load attached to the General
loadline.
3. Slowly rotate the boom until it is directly over the front of
the truck (behind cab mounting). With the boom directly ! DANGER
over the front, place a mark at the top of the frame It is mandatory that swing bearing and T-box attaching
aligned with the center of the lift cylinder. bolts be inspected and re-torqued after the first 300 hours
of crane operation and every 500 hours thereafter. The
bolts may loosen and cause the crane to separate from
the carrier which will result in damage to the crane and
possible injury or death to personnel.
Maintaining proper torque value for bolts is extremely

important for structural strength, performance, and reliability
of the crane. Variations in torque can cause distortion,
binding, or complete separation of the turret from the frame.
CAUTION
Repeated re-torquing may cause bolts to stretch. If bolts
keep working loose, they must be replaced with new bolts
of the proper grade and size.
FIGURE 6-2
Proper identification of bolt grade is important. When marked
as a high strength bolt (grade 8), the serviceman must be
4. Rotate the crane clockwise, or counterclockwise until aware of bolt classifications and that he is installing a high
the rotation stop system centers the control lever. strength heat-treated tempered component and the bolt
5. Again make a mark at the crane frame aligned with the must be installed according to specifications. Special
center of the lift cylinder. attention should be given to the existence of lubricant and

plating that will cause variation from dry torque values. When If it is reported by the crane operator or suspected that the
a high strength bolt is removed, or un-torqued, the bolt must crane has been overloaded beyond the capacities specified
be replaced with a new bolt of the same classification. above the bold line on the cranes’ capacity chart, then all
Torque the capscrews to recommended values, refer to swing bearing bolts must be inspected for looseness and
Fasteners and Torque Values, page 1-7. re-torqued to specifications.
NOTE: Zinc flake coated bearing bolt heads are stamped Torque the swing bearing bolts according to the procedures
with the suffix “ZF” as a visual identifier. outlined in this section.
KNOW YOUR TORQUE WRENCH! Flexible beam type When using step wrenches, calculated wrench settings are
wrenches, even though they might have a pre-set feature, valid only when the following conditions are met.
must be pulled at right angle and the force must be applied at
1. Torque wrenches must be those specified and forces
the center of the handle. Force value readings must be made
must be applied at the handle grip. The use of handle
while the tool is in motion. Rigid handle type, with torque
extensions will change applied torque to the bolt.
limiting devices that can be pre-set to required values,
eliminate dial readings and provide more reliable, less 2. All handles must be parallel to the step wrench during
variable readings. final tightening. Multiplier reaction bars may be
misaligned no more than 30 degrees without causing
NOTE: If multipliers and/or special tools are used to reach
serious error in torque.
hard to get at areas, ensure torque readings are
accurate. 3. Multiplier bar handles must be propped or supported
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within the outer 1/4 of the handle length, or serious
Torque wrenches are precision instruments and must be
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under or over tightening will occur.
handled with care. To ensure accuracy, calibrations must be
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made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
Swing Bearing Bolts
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damaged, it should immediately be removed from service The inner race of the bearing is secured to the turret by 26
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until re-calibrated. When using a torque wrench, any erratic capscrews (Figure 6-3). The outer race of the bearing is
or jerking motion can result in the application of excessive or secured to the frame by 24 capscrews (Figure 6-3).
improper torque. ALWAYS use a slow, even movement and
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STOP when the predetermined value has been reached.

1
24 9
16 17
8 5
20 13
21 3 11 19
13 25
5 7
12 21
17 15
9 23
FRONT 4 1 2 3 REAR
24 10
22 16 18 11
6
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26 14
20 12 4 22
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6 7
18 15
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9828
10 23
2 FIGURE 6-3
Inner Race
Outer Race
FIGURE 6-4

Torque Values • increased drive power required
Torque all swing bearing bolts to a final torque. Refer to • noise

“Fasteners and Torque Values” on page 1-7. • rough operation
Inner Race Torquing • acceleration in the increase in bearing clearance
The inner race bearing bolts are located on top of the inner Measure the internal clearance of the swing bearing to
race (Figure 6-4). determine if it needs to be replaced. (Reference National
Crane Technical Support Information TSI #10)
1. Extend and set the outriggers.
1. Place the boom in the boom rest and set the outriggers.
2. Fully elevate the boom.
2. Put a magnetic base dial indicator opposite the boom on
3. Torque all bolts to 80% of the specified torque value the top of the frame (Figure 6-5).
following a star pattern sequence as shown in Figure 6-3
starting with bolt number 1. Refer to “Fasteners and 3. Place the dial on the top of the swing bearing
Torque Values” on page 1-7. (Figure 6-5).
Tools used are the socket, multiplier, backlash adapter, 4. Power the boom down onto the boom rest.
necessary extensions, and torque wrench. 5. Set the dial indicator at zero.
4. Return to bolt 1 and torque all bolts using the same star 6. Raise the boom about 3 in above the boom rest.
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pattern sequence to the final torque value specified. The
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same tools are used as in step 3. 7. Record the deflection indicated on the dial.
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Outer Race Torquing
8. Repeat steps 4 through 7 three times and average the
readings.
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The outer race bearing bolts are located on top of the outer 9. If the average is greater than 0.090 in, replace the
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race (Figure 6-4). bearing.

1. Extend and set the outriggers. 10. If the average is less than 0.090 in, repeat the
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2. Fully elevate the boom. measurement at every 45° around the total working area
of the crane (Figure 6-6).
3. Torque all bolts to 80% of the specified torque value
a. Measure the deflection at positions 2,3,7, and 8 for
following star pattern sequence as shown in Figure 6-3
starting with bolt number 1. Refer to “Fasteners and 180° rotation and positions 2 and 8 for 360° rotation. 6
Torque Values” on page 1-7. b. Use another crane to support the end of the boom
Tools used are the socket, multiplier, backlash adapter, when the boom is powered down.
necessary extensions, and torque wrench. c. Locate the dial indicator opposite the boom.
4. Return to bolt 1 and torque all bolts using the same star d. Set the dial indicator to zero.
pattern sequence to the final torque value specified. The
same tools are used as in step 3. e. Raise the boom about 3 in.
f. Record the reading on the dial indicator.
g. Repeat steps d through f three times.
BEARING CLEARANCE
h. Average the readings.
If a swing bearing exhibits the following symptoms, it may
i. If the averages is greater than 0.090 in at any
have reached the end of its useful life.
position, replace the bearing.
• metal particles in the grease

Top of Swing
Bearing
Magnetic Base
Dial Indicator
Top of Frame
FIGURE 6-5
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2
4
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1 5
8
6
7 FIGURE 6-6

BEARING REPLACEMENT Installation

Removal
1. Fully extend and set the outriggers enough to take up ! DANGER
the slack in the pads. Do not reuse the swing bearing bolts. The swing bearing
NOTE: Do not raise the machine on the outriggers. is torqued to the applied torque of the grade 8 bolts. New
bolts ensure proper torque and bolt strength for securing
2. Rotate the boom to about 10° off the rear position so that the swing bearing and turret to the frame.
the boom is clear of the boom rest.
NOTE: The lift cylinder pins need to be accessible from the NOTE: If the current bearing is reinstalled, align the
marked teeth on the swing drive pinion shaft with
truck deck.
the marked teeth on the bearing.
3. Elevate the boom slightly and shut down the engine.
1. Using an appropriate lifting device, set the turret on the
4. Tag and disconnect the battery cables. swing bearing. If the same bearing is being used,
position it as marked prior to removal.
5. Remove the boom and lift cylinder following the
procedures outlined in “Boom Removal” on page 4-3. 2. Install new bolts and washers securing the bearing to the
turret. Refer to “Inner Race Torquing” on page 6-9.
NOTE: If equipped with a swivel, tag and disconnect all
hydraulic lines from the swivel on the carrier side. 3. Using an appropriate lifting device, align the turret over
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Cap or plug all lines and openings. The swivel is the frame at the same position that it was before
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removed with the turret. removal.
6.
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Attach a suitable lifting device to the turret. Remove any 4. Carefully lower the turret into position on the bearing
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slack in the sling. Do not pull up on the turret. plate.
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NOTE: If equipped, be careful not to damage the swivel

assembly.
! DANGER
5. Install all bolts and washers to secure the outer race of
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Ensure the lifting device is capable of supporting the
the swing bearing to the T-box frame. Refer to “Outer
boom assembly.
Race Torquing” on page 6-9.
7. Remove all bolts and washers from the outer race of the
swing bearing. 6
! DANGER
Ensure blocking material can support the turret.
Maximum
8. Carefully lift the turret with bearing off the truck and set it Eccentricity
on blocking that will not allow the turret to tilt or shift. Tooth
Leave the lifting device attached.
NOTE: If the current bearing is to be reinstalled, mark the
position of the bearing on the turret before removal.
9. Remove all bolts from the inner race of the swing
bearing.
0.008 Shim
10. Lift the turret off the swing bearing and set on blocking. Pinion
NOTE: The bearing weighs about 415 lb (188.2 kg).

Check the bearing teeth for chipping or cracking. If any
evidence of these is found, replace the bearing. Ensure the
bolt holes are free of dirt, oil, or foreign material.
FIGURE 6-7

NOTE: If a new bearing is installed, a new pinion gear NOTE: If equipped with a swivel, reconnect the hydraulic
must also be used. lines as per removal tags.
6. Install the swing drive pinion so that the high point 7. Install the boom and lift cylinder following the procedures
(maximum eccentricity) is aligned with the turret bearing outlined in Section 4- BOOM.
high point. Check the backlash with a (0.008 in)
8. Reconnect the batteries.
0.203 mm thick shim (Figure 6-7). If the pinion must be
moved to achieve proper backlash, contact your local 9. Check the slew potentiometer for proper orientation as
National Crane distributor. described below.
Slew
Potentiometer
Frame
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FIGURE 6-8
potentiometer needs to be oriented to 0° (± 5°) before the

RCL can be calibrated for the swing parameters.
The following procedure is to mechanically adjust the slew
pot to zero when the slew pot is out of the ±5° specified by
the RCL. This procedure can also be used for installing a
Zero Adjustment new slew pot.
Angle
1. Place the boom at 0° over the truck centerline.
2. Remove the slew pot from the turret.
10°
3. Make sure the slew pot is plugged into the RCL
connector and turn the RCL on.
0° is when the boom is over the 4. Go to the RCL slew angle calibrate screen as described
rear of the truck centerline,
regardless of mounting
in the RCL service manual.
configuration. 5. Rotate the slew pot gear until the reading on the RCL is
0° (±5°). This reading must be within ±5° of 0° or the
FIGURE 6-9
RCL will not calibrate the swing position correctly.
6. Reinstall the slew potentiometer in the turret.
Slew Potentiometer Orientation 7. Slide the slew pot forward to make sure the slew pot
gear is meshed with the swing bearing teeth.
The slew potentiometer is located inside the turret and limits
the swing to 410° (205° left and 205° right). The

8. Back off the slew pot gear slightly so that there is a 0.125 11. Verify the slew angle calibration by swinging the boom
- 0.188 in (3.1 - 4.7 mm) gap between the slew pot gear 180° to the right and left according to instructions on the
teeth the swing bearing gear teeth. slew angle calibrate screen.
12. If the readings are not correct, recalibrate the slew angle
with the RCL.
CAUTION
NOTE: Refer to the RCL manual for calibration of the slew
There must be 0.125 - 0.188 in (3.1 - 4.7 mm) gap
angle and 0° orientation.
between the slew pot gear teeth the swing bearing gear
teeth to keep from damaging the slew pot gear shaft.
Testing
9. Tighten the bolts on the slew pot bracket. Activate the crane and check for proper function.
10. Calibrate the slew angle with the RCL. NOTE: If the turret does not turn freely after bearing and
pinion replacement, contact your local distributor.
NOTE: When verifying the slew angle calibration in step
11, refer to your slew angle calibrate screen.
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600E2 SERVICE MANUAL LUBRICATION
SECTION 7
LUBRICATION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Internal Cable Sheave Lubrication. . . . . . . . . . . . . 7-5
Surface Protection for Cylinder Rods . . . . . . . . . . 7-1 Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . 7-6
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Side and Bottom Boom Wear Pad Lubrication . . . 7-6
Arctic Conditions Below 0°F (-18°C). . . . . . . . . . . 7-2 Hoist Maintenance and Service . . . . . . . . . . . . . . . 7-6
Chassis Grease . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Maintenance Scheduling . . . . . . . . . . . . . . . . . . . . 7-7
Extreme Pressure Multipurpose Gear Oil Level Maintenance . . . . . . . . . . . . . . . . . . . . . . 7-7
Lubricant (EPGL) . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Open Gear Lubricant . . . . . . . . . . . . . . . . . . . . . . 7-2 Hoist Brake Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Chassis Grease Low Temp. . . . . . . . . . . . . . . . . . 7-2 Hoist Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Anti-wear Additives . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Hydraulic Oil Reservoir Level. . . . . . . . . . . . . . . . . 7-8
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Standard Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . 7-2 Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 7-8
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Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . 7-2 Carwell© Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . . 7-9
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Protecting Cranes from Corrosion . . . . . . . . . . . . . 7-9
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Wide Range Intermediate Hydraulic Oil . . . . . . . .
Arctic Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7-3 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . 7-10
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Environmental Protection . . . . . . . . . . . . . . . . . . . 7-3 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 7-10
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Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Areas of Application. . . . . . . . . . . . . . . . . . . . . . . 7-11
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
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GENERAL can allow moisture to corrode the underlying steel. At typical

ambient temperatures, hydraulic oil is too thick to penetrate
Following a designated lubrication procedure is important to these cracks. Normal machine operating temperatures will
ensure a maximum crane life. The procedures and allow hydraulic oil to warm sufficiently to penetrate these
lubrication charts in this section include information on the cracks and if machines are operated daily, protect the rods.
types of lubricants used, the location of the lubrication points, Machines that are stored, transported, or used in a corrosive
the frequency of lubrication, and other information. This environment (high moisture, rain, snow, or coastline 7
section does not include lubrication requirements for the conditions) need to have the exposed rods protected more
truck chassis. Refer to truck service manual for this frequently by applying a protectant. Unless the machine is
information. operated daily, exposed rod surfaces will corrode. Some
cylinders will have rods exposed even when completely
The service intervals specified are for normal operation
retracted. Assume all cylinders have exposed rods, as
where moderate temperature, humidity, and atmospheric
corrosion on the end of the rod can ruin the cylinder.
conditions prevail. In areas of extreme conditions, the
service periods and lubrication specifications should be It is recommended that all exposed cylinder rods be
altered to meet existing conditions. For information on protected using Boeshield® T-9 Premium Metal Protectant.
extreme condition lubrication, contact your local National Manitowoc Crane Care has Boeshield T-9 Premium Metal
Crane distributor or Manitowoc Crane Care. Protectant available in 12 oz. cans that can be ordered
through the Parts Department.
Surface Protection for Cylinder Rods
NOTE: Cylinder operation and inclement weather will
Steel cylinder rods include a thin layer of chrome plating on r e m o v e t h e B o e s h i e l d p r o t e c ta n t . I n s p e c t
their surfaces to protect them from corroding. However, machines once a week and reapply Boeshield to
chrome plating inherently has cracks in its structure which unprotected rods.

LUBRICATION 600E2 SERVICE MANUAL
Lubricants Open Gear Lubricant

Specific recommendations of brand and grade of lubricants This is a special high-graphite adhesive lubricant that helps
are not made here due to regional availability, operating to eliminate fretting corrosion, is water resistant, and forms a
conditions, and the continual development of improved dry lubrication film which does not attract dust. Lubricant
products. Where questions arise, contact your National meets NLGI Class 1-2 specifications.
Crane distributor or Manitowoc Crane Care.
Chassis Grease Low Temp
Arctic Conditions Below 0°F (-18°C)
This special grease for low temperature remains plastic at
In general, petroleum based fluids developed especially for -60°F (-51°C) with melting point of 280°F (138°C). The
low temperature service may be used with satisfactory grease is a heavy duty extreme pressure type lubricant
results. However, certain fluids, such as halogenated (Lubricate Low Temp or equal).
hydrocarbons, nitro hydrocarbons, and phosphate ester
hydraulic fluids, might not be compatible with hydraulic Anti-wear Additives
system seals and wear bands. If you are in doubt about the
Excessive wear in the system may cause a loss in volumetric
suitability of a specific fluid, check with your authorized
efficiency, and may cause shutdowns for maintenance. An
National Crane distributor or Manitowoc Crane Care.
efficient anti-wear oil protects the components against
NOTE: All fluids and lubricants may be purchased by rusting, resists oxidation and helps prevent wear.
contacting the Manitowoc Crane Care Parts
Hydraulic Oil
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Department.
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Regardless of temperature and oil viscosity, always use Oil in a hydraulic system serves as the power transmission
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suitable start-up procedures to ensure adequate lubrication
during system warm-up.
medium, system lubricant and coolant. Selection of the
proper oil is essential to ensure satisfactory system
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performance and life. The most important factors in selecting
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Chassis Grease an oil for hydraulic service are viscosity and anti-wear
additives.
Lubricating grease of proper consistency is to be applied
periodically at relatively frequent intervals with grease guns
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through grease fittings. Minimum apparent viscosity of 300 CAUTION
SUS (Saybolt Universal Seconds) at 100° F (38° C) is Operation of the crane with incorrect hydraulic oil in sub
recommended. freezing temperature (below 32°F, 0°C) can cause
damage to the extend cylinder.
Extreme Pressure Multipurpose Gear
Lubricant (EPGL) Standard Hydraulic Oil
This gear lubricant is compounded to achieve high load
carrying capacity and meet the requirements of either API- Above 10°F (-12°C)
GL-5 or MIL-L-2105C. Unless otherwise specified, The factory fill standard hydraulic oil is ISO grade 46/68. This
SAE 80W-90 viscosity may be used for year round service. fluid is acceptable for operating temperatures above 10°F (-
Low temperature usage is restricted as follows: 12°C).
SAE Viscosity Minimum Ambient Temperature Intermediate Hydraulic Oil

Number F (C)
75W -40 (-40) (-10°F to 80°F) (-23°C to 27°C)
80W -15 (-26) For colder operating environments, the standard fluid may be
replaced with a Low Service Temperature Multi Viscosity
85 +10 (-12)
Hydraulic Oil with High Viscosity index 175+.
90 +20 (-7)
140 +40 (+5)
Wide Range Intermediate Hydraulic Oil
250 +50 (+10) (-30°F to 80°F) (-34°C to 27°C)
For even colder operating conditions, the standard fluid may
be replaced with a petroleum based fluid developed
especially for colder environments.

Arctic Hydraulic Oil • Always fill or add fluids with a funnel or a filling pump.
• Immediately clean up any spills.
(-10°F and below) (-23°C and below)
In general, petroleum based fluids developed especially for LUBRICATION POINTS
low temperature service may be used with satisfactory
A regular frequency of lubrication must be established based
results. However, certain fluids, such as halogenated
on component operating time. The most efficient method of
hydrocarbons, nitro hydrocabons and phosphate ester
keeping track of lube requirements is to maintain a job log of
hydraulic fluids might not be compatible with hydraulic
crane usage.
system seals and wear bands. Arctic hydraulic oil is not
recommended for service in ambient temperatures above All oil levels are to be checked with the crane parked on a
32°F (0°C). level surface in transport position, and while the oil is cold,
unless otherwise specified. On plug type check points, the oil
If you are in doubt about the suitability of a specific fluid,
levels are to be at the bottom edge of the fill port.
check with your authorized National Crane distributor or
Manitowoc Crane Care. Over lubrication of non-sealed fittings will not harm the
fittings or components, but under lubrication shortens
NOTE: All fluids and lubricants may be purchased by
lifetime.
contacting the Manitowoc Crane Care Parts
Department. Worn grease fittings that do not hold a grease gun, or those
that have a stuck check ball, must be replaced.
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ENVIRONMENTAL PROTECTION When wear pads or rotation bearings are lubricated, cycle
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Dispose of waste properly! Improperly disposing of waste the components and lubricate again to ensure complete
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can threaten the environment. lubrication of the entire wear area.
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Potentially harmful waste used in National Cranes includes
CAUTION
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— but is not limited to — oil, fuel, grease, coolant, air

conditioning refrigerant, filters, batteries, and cloths which Lubrication intervals (page 7-3) are to be used only as a
have come into contact with these environmentally harmful guide. Actual intervals should be formulated by the
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substances. operator to correspond accordingly to conditions such as
continuous duty cycles and/or hazardous environments.
Handle and dispose of waste according to local, state, and
federal environmental regulations.
The following describe the lubrication points and gives the
When filling and draining crane components, observe the lube type, lube interval, lube amount, and application of
following: each. Each lubrication point is numbered, and this number
corresponds to the index number shown on the Lubrication
• Do not pour waste fluids onto the ground, down any Chart. Lube description and symbols are found in tables
drain, or into any source of water. below.
• Always drain waste fluids into leak proof containers that
are clearly marked with what they contain. 7
Symbol Description National Crane Lube Specification
EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. 6829003477
EP-3MG Extreme Pressure Moly Grease 6829015304
GL-5 Extended Service Interval Gear Lubricant - SAE Grade 80W-90 6829012964
AFC - 50/50 50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941, ASTM D6210 6829101130
HYDO Hydraulic Oil - Must meet ISO 4406 cleanliness level 17/14 6829006444
EO-15W/40 Engine Oil - SAE 15W-40, API Service Classification CI-4 or better 6829003483
EP-OGL Open Gear Lubricant, CEPLATTYN 300 Spray, NLGI Grade 1-2 6829102971
AGMA EP-4 Extreme Pressure Gear Lubricant. 6829100213
WRL Wire Rope Lubricant 6829015236
LTG Low Temperature Grease, NLGI Grade 1 6829225828

LUBRICATION CHART
13
18
Oil Fill/Breather
Oil Drain
14 12
5
18 16 19 4
10a 20
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7
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23
19
20
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11
2 3
15
9a
9b 22
1
NOTE: Torque diffuser to
51 lb-ft (69 Nm). Openings
must face bottom of tank.
21
Recommended
Item Application Procedure Frequency
Lubricant
1 Hydraulic oil reservoir HYDO Check fill change Weekly, semi-annually, as required
After first 40 hrs. as indicated by
2 Oil filter, magnetic plug, hydraulic oil reservoir Change or clean
gauge thereafter.
3 Breather, hydraulic oil reservoir Clean Monthly
4 Sheave pins: boom (3 plcs), jib (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
Remove pump and apply to
9b Pump spline shaft (direct mount) EP-MPG Semi-Annually
shaft or grease gun

Recommended
Item Application Procedure Frequency
Lubricant
Check and Fill Check and Fill: As part of daily crane
inspection, check the gearbox for
visible leaks.
10a Hoist gearbox SAE 90 EP
Change
Change: Every 1000 hours or
6 months
visible leaks.
10b Hoist brake HYDO
Change
Change: Every 1000 hours or
6 months
11 Control linkage EO-15W/40 Oil Can As Required
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visible leaks.
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12
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Swing drive gearbox GL-5
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Change: After first 50 hours of
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Change operation and every 500 hours

thereafter.
13 Swing gear teeth EP-OGL Spray Can Monthly
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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
Any time boom is disassembled or
16 Extension cables (not shown) WRL Spray or brush
5 years
17 Boom Wear Pads (not shown) EP-MPG Brush or roller Monthly or as required
18 Swing Motor Pinion Bearing EP-MPG Grease gun Sparingly every 50 hours
19 Extend Sheaves EP-3MG Grease gun Weekly
Retract Sheaves: Extend the boom until the
20 retract sheave grease holes are visible through EP-3MG Grease gun Weekly
21
the access holes along side of boom.
Diffuser strainer, Hydraulic oil reservoir Clean Semi-Annually with oil change
7
22 Magnetic plug, hydraulic oil reservoir Clean At oil filter service interval
23 Continuous rotation swivel (optional) EP-MPG Grease gun Monthly
Internal Cable Sheave Lubrication The lubrication points on the internal sheaves require a
grease gun adapter because there are no grease fittings on
the sheaves.
Special Tools:
DANGER
Do not, under any circumstances, work at an elevated Nozzle or needle grease gun fitting:
height without using proper fall protection as required by - 0.25 inch (6.35 mm) diameter nozzle grease gun tip
local, state or federal regulations (National P/N 955047).
- Contact Manitowoc Crane Care to obtain this nozzle
tip.

NOTE 1: To determine the amount of grease required, 3. Extend boom to position the wear pad access holes
visually inspect the sheaves. From the front of directly above the wear pads on the fourth boom section,
the boom, look back through the sheave case at apply grease to the pads using the brush or gun.
the extend sheaves. From the back of the boom,
4. After grease is applied to all wear pads raise the boom to
look up through the hoist mount at the retract
the maximum angle and slowly extend the boom to full
sheaves. A small amount of grease extrusion
extension and slowly retract completely.
around the pin is adequate.
5. Repeat steps 1 - 4 three times to ensure the boom is
The extend sheaves are located on the boom tip end of the
fully lubricated.
extend cylinder, and the retract sheaves are located on the
inside rear of the 2nd section. Lubrication is as follows: Side and Bottom Boom Wear Pad
1. Extend boom until grease access hole (Item 19 on the Lubrication
Lubrication Points diagram) becomes visible on side of
1. Fully extend and set the outriggers.
2nd section.
2. Lower the boom to horizontal.
2. Check alignment between the 2nd section access hole
3. Fully extend the boom and apply grease to the side and
and the 3rd section access holes. When these holes
become aligned, the end of the extend cable sheave pin bottom of the 2nd and 3rd sections with a brush.
is visible and accessible for lubrication. 4. Raise the boom to about 75° and retract the boom
3. This boom position also aligns the access holes at the 5. Extend and retract the boom several times until the
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rear of the 1st section for lubrication of the retract grease is evenly spread.
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sheaves.
6. Repeat steps 1-3 as necessary to ensure the boom is
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Inner Boom Pad Lubrication fully lubricated.
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1. With the boom fully retracted, apply grease to the wear
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pads on the top of second boom section with a small

paint brush or a grease gun.
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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.
7635
HOIST MAINTENANCE AND SERVICE recommended. Regular oil changes with the correct oil for
the ambient temperature conditions and an annual
For safe and consistent operation of this hoist a regular inspection of the wear components will help ensure a long
program of preventive maintenance is strongly life for your planetary geared products.

Maintenance Scheduling Drain /Add New Hoist Brake Oil

The owner is to ensure proper inspection intervals, in To drain and add new oil, remove the drain plug (Figure 7-1),
compliance with the API RP 2D Section 4 requirements or inspection plug and vent plug and drain the brake oil.
the ANSI B30.5, 5-2.3, and will review hoist usage Reinstall drain plug and add fluid at the brake oil vent hole
categories on a periodic basis. A Qualified Inspector should until oil is at the bottom level of the inspection hole. Install the
perform all maintenance and inspections. inspection plug and the oil vent and fill plug. The hoist brake
fill capacity is 0.23 liter (0.25 quart).
• For hoists in occasional use, less than 10 hours per
month, API RP 2D recommends a pre-use inspection NOTE: Brake lubricants are satisfactory for operation in
and an annual 12-month inspection based on average temperatures from -23° C to 66° C
use over a quarter. (-10° F to +150° F). For operation outside this
r a n g e , c o n ta c t M a n i t o w o c C r a n e C a r e f o r
• For hoists in moderate use, more than 10 but less than
recommendations.
50 hours per month, API RP 2D recommends a pre-use
.
inspection, quarterly inspection, and an annual 12-
month inspection based on average use over a quarter.
! DANGER
• For hoists in heavy use, more than 50 hours per month,
Do not use EP type gear lubes in the brake section. This
API RP 2D recommends a pre-use inspection, monthly
may prevent proper operation and cause the load to fall
inspection, quarterly inspection, and an annual 12-
month inspection. resulting in serious injury or death.
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Oil Level Maintenance
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The oil level in the gearbox and brake housing should be Brake Oil Vent
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checked and adjusted as part of the pre-use inspection. If the and Fill Plug
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oil level drops frequently or oil leakage is detected during an

inspection, maintenance should be performed to correct any
problems.
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Oil Change Interval
The oil in the gearbox and brake sections is recommended to
be changed after every 1000 hours or 6 months of usage.
Hoist Brake Oil

Brake Oil Drain
Plug
! DANGER
7
Do not, under any circumstances, work at an elevated 9468 FIGURE 7-1
local, state or federal regulations.
Check Hoist Brake Oil Hoist Gearbox Oil

.
Hoist Gearbox Oil Change
CAUTION
The maximum fill capacity for the hoist brake is 0.23 liter Gearbox oil is drained by first removing the drain plug
(0.25 quart). Over-filling the hoist brake can cause (Figure 7-2) by rotating the drum so that the plug is visible
damage to the hoist. through the lower hole in the side plate. Screw in a piece of
1 inch pipe to allow the oil to drain, and then with a hex
To check the hoist brake oil, remove the vent and fill plug wrench remove the drain plug located inside of the 1 inch
(Figure 7-1) and visually inspect the oil level. The maximum pipe. Examine the used oil for signs of significant metal
fill capacity for the hoist brake is 0.23 liter (0.25 quart). deposits and then dispose of it in a proper manner. Remove
the 1 inch pipe.
Rotate the drum so that the port is visible through the upper
hole in the side plate. Install a 1 inch pipe with elbow into the

upper hole in the side plate. Fill the gearbox with 1.42 liters
(1.50 quarts) of EP-90 oil. Remove the pipe and elbow, then
replace the plug. Hydraulic Oil Level
For information about changing hoist brake oil, see Drain /

Add New Hoist Brake Oil, page 7-7. See Lubrication Points,
page 7-3 for recommended oil type and grade for your
application.
.
Sight Gauge
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1” Fill Pipe
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Breather
WIRE ROPE LUBRICATION
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Gearbox
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Drain Hole A wire rope cannot be lubricated sufficiently during

manufacture to last it’s entire life. Therefore, new lubricant
must be added throughout the life of a rope to replace factory
lubricant which is used or lost. It is important that lubricant
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Gearbox
Level/Fill Hole applied as part of a maintenance program shall be
compatible with the original lubricant, and to this end, the
rope manufacturer should be consulted. Lubricant applied
1” Pipe
Nipple Fill/Drain shall be of the type which does not hinder visual inspection.
Plug Those sections of rope which are located over sheaves or
otherwise hidden during inspection and maintenance
FIGURE 7-2 procedures require special attention when lubricating rope.
The object of rope lubrication is to reduce internal friction and
to prevent corrosion.
HYDRAULIC OIL RESERVOIR LEVEL
During fabrication, ropes receive lubrication; the kind and
The hydraulic oil reservoir has a sight gauge located on the amount depends on the rope’s size, type, and anticipated
side of the reservoir. This sight gauge has a decal beside it use. This in-process treatment will provide the finished rope
that indicates a “full” level and an “low oil” level. The oil with ample protection for a reasonable time if it is stored
required to bring it from the “low” line to the “full” line is 5 under proper conditions. But, when the rope is put into
gallons. Do not fill the reservoir above the “full” line. The oil service, the initial lubrication may be less than needed for the
level should be checked with the crane parked on a level full useful life of the rope. Because of this possibility, periodic
surface in the transport condition (all cylinders retracted and applications of a suitable rope lubricant are necessary.
boom stowed) and the oil cold.
The following are important characteristics of a good wire
rope lubricant:
1. It should be free from acids and alkalis.
2. It should have sufficient adhesive strength to remain on
the ropes.
3. It should be of a viscosity capable of penetrating the
interstices between wires and strands.

4. It should not be soluble in the medium surrounding it techniques may be used; bath, dripping, pouring, swabbing,
under the actual operating conditions (i.e. Water). painting, pressure spray.
5. It should have a high film strength. Whenever possible, the lubricant should be applied at the
top of a bend in the rope, because at that point the strands
6. It should resist oxidation.
are spread by bending and are more easily penetrated.
Before applying lubrication, accumulations of dirt or other There should be no load on the rope while it is being
abrasive material should be removed from the rope. lubricated. It should be noted, the service life of wire rope will
Cleaning can be accomplished by using a stiff wire brush and be directly proportional to the effectiveness of the method
solvent, compressed air, or live steam. Immediately after the used and amount of lubricant reaching the working parts of
wire rope is cleaned, it should be lubricated. Many the rope.
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CARWELL© RUST INHIBITOR glass, plastic or rubber, it must be removed using standard
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steam-cleaning techniques.
Protecting Cranes from Corrosion Carwell works in various ways: (1) it eliminates the moisture
containing salt, dirt and other pollutants by lifting and
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National Crane Group's cranes are manufactured to high
removing them from the metal surface; (2) the film creates a
quality standards, including the type of paint finish
demanded by today's industry. In partnership with our paint barrier to repel further moisture from coming in contact with
supplier, we are also doing our part to help prevent the metal; and (3) it penetrates crevices.
premature corrosion of cranes. In addition to the factory-applied Carwell coating, National
National cranes will be treated with a rust inhibitor called Crane owners must provide proper maintenance and care to
help ensure long-term protection of their crane against
Carwell® T32-CP-90. While a rust inhibitor cannot guarantee
corrosion. This procedure provides information and
that a machine will never rust, this product will help protect guidelines to help maintain the paint finish on National
against corrosion on National cranes that are treated with
this product.
Cranes. 7
The most common causes of corrosion include the following:
Carwell ® is a treatment, not a coating. It contains no
• Road salts, chemicals, dirt, and moisture trapped in the
silicones, solvents, CFCs or anything that would be classified
hard-to-reach areas;
as hazardous under OSHA Regulation 29 CFR 19 10.1200.
The product is a liquid blend of petroleum derivatives, rust • Chipping or wear of paint, cased by minor incidents or
inhibitors, water-repelling and water-displacing agents. moving components;
Special equipment is used to spray a light film onto the entire • Damage caused by personal abuse, such as using the
undercarriage and various other areas of each new crane decks to transport rigging gear, tools, or cribbing; and
prior to shipment. When applied the product has a red tint to
allow applicators to view coverage during application. This • Exposure to harsh environmental hazards such as
red tint will turn clear on its own within approximately 24 alkaline, acids, or other chemicals that can attack the
hours after application. crane's paint finish.
Once applied, Carwell T32-CP-90 can appear to leave a While the surfaces of the crane that are easily seen have the
slightly “oily” residue on painted surfaces and until the red biggest impact on the appearance of the crane, particular
tinting fades could initially be mistaken for a hydraulic oil attention should be given to the undercarriage of the crane to
leak. While the product is not harmful to painted surfaces, minimize the harmful effects of corrosion.

Exercise special care and increase the frequency of Inspection and Repair
cleanings if the crane is operated:
• Immediately following cleaning, Manitowoc Crane Care
• on roads where large quantities of salt or calcium are recommends an inspection to detect areas that may
applied to treat icy and snowy road surfaces; have become damaged by stone chips or minor
• in areas that use dust control chemicals; mishaps. A minor scratch (one that has not penetrated
to the substrate surface) can be buffed with an
• anywhere there are increased levels of wetness - automotive-type scratch remover. It is recommended
especially near salt water; that a good coat of automotive wax be applied to this
• during prolonged periods of exposure to damp area afterwards.
conditions (e.g., moisture held in mud), where certain • All identified spots and/or areas that have been
crane parts may become corroded even though other scratched through to the metal should be touched up
parts remain dry; or and repaired as soon as possible to prevent flash
• in high humidity, or when temperatures are just above rusting. To repair a major scratch (down to bare metal) or
the freezing point. minor damage, follow these procedures:
NOTE: Manitowoc Crane Care recommends that a
Cleaning Procedures qualified body repairman prepare, prime and paint
To help protect against corrosion of National Cranes, any major scratch(es) or minor damage.
Manitowoc Crane Care recommends washing the crane at
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least monthly to remove all foreign matter. More frequent
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cleaning may be needed when operating in harsh CAUTION
guidelines: nl c
environmental conditions. To clean the crane, follow these
To the extent any damage is structural in nature,
Manitowoc Crane Care must be contacted and consulted
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• High pressure water or steam is effective for cleaning as to what repairs may be required.
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the crane's undercarriage and wheel housings. Keeping

these areas clean will not only help retard the effects of • For scratches and marks in highly visible areas:
corrosion, but will also improve the ability to identify
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• Sand to remove the scratch and feather outward from
potential issues before they grow into larger problems.
the mark to blend the repair into the original surface.
Body putty may be applied as necessary to hide the
defect; then sand smooth.
CAUTION • Cover all bare metal with a primer that is compatible with
High pressure water can be forced into spaces and the original paint finish
infiltrate beyond seals. Avoid pressure washing in the
vicinity of electrical controls, panels, wiring, sensors, • and allow to dry thoroughly.
hydraulic hoses and fittings, or anything that can be • Prepare the surface prior to applying the finish coat of
damaged by high pressure cleaning/spraying. paint.
• Rinse the dirt and dust off before washing the crane. Dirt • Apply a finish coat paint using accepted blending
can scratch the crane's finish during washing/cleaning. techniques. Use of original paint colors is recommended
to insure the best color match possible.
• Hard to clean spots caused by road tar or bugs should
be treated and cleaned after rinsing and prior to For scratches and marks in areas of low visibility:
washing. Do not use solvents or gasoline. • Consider touching up the spots with a brush technique
• Wash using only soaps and detergents recommended to cover the bare metal. This will retard the effects of
for automotive paint finishes. corrosion and enable you to do the repair at a later time
during a normal maintenance interval.
• Rinse all surfaces thoroughly to prevent streaking
caused by soap residue. Spots should be touched up with quality paint. Primers tend
to be porous; using a single coat of primer only will allow air
• Allow the crane to dry thoroughly. You can accelerate and water to penetrate the repair over time.
drying by using compressed air to remove excess water.
NOTE: Polishing and waxing (using an automotive-type Application
wax) is recommended to maintain the original paint Depending upon the environment in which a crane is used
finish. and/or stored, the initial factory application of Carwell T32-

CP-90 should help inhibit corrosion for up to approximately • After application of the Carwell is complete, wash or
12 months. clean film residue from lights, windshield, grab handles,
ladders/steps and all access areas to crane, as
It is recommended that Carwell T32-CP-90 be periodically
necessary.
reapplied by the crane owner after that time to help continue
to protect against corrosion of the crane and its components. Please contact Manitowoc Crane Care should you have any
questions.
However, if a crane is used and/or stored in harsh
environments (such as islands, coastal regions, industrial Areas of Application
areas, areas where winter road salt is regularly used, etc.),
reapplication of Carwell T32-CP-90 is recommended sooner • The underside of the unit will have full coverage of the
than 12 months, e.g., repeat treatment in 6-9 months. rust inhibitor. These are the only areas that a full coat of
the rust inhibitor is acceptable on the painted surfaces.
• Do not apply to recently primered and painted areas for
Areas include; Valves, hose end and fittings, Swivel,
at least 48 hours after paint is properly dried and cured.
pumps, axles, drivelines, transmission, all interior
For minor touch up areas a 24 hour period is needed for
surfaces of the frame
cure time before applying Carwell.
• Frame application areas are; hose ends and fittings, all
NOTE: Unit must be completely dry before applying
unpainted fasteners and hardware, all bare metal
Carwell.
surfaces, outrigger pads, and back up alarms.
• Do not allow product to puddle or build-up on weather
• Superstructure applications are; hose end and fittings,
stripping, rubber gaskets, etc. Unit should not have
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wire rope on hoist roller tensioning springs on hoists, all
puddles or runs evident anywhere.
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unpainted fasteners and hardware, valves, slew ring, all
•
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To ensure proper coverage of Carwell, the product
needs to be fogged on the unit.
•
bare metal surfaces.
Boom applications areas are; pivot pins, hose end and
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• Use of pressure pots to apply the Carwell to the unit fittings, jib pins and shafts, all bare metal surfaces,
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being processed is recommended. overhaul ball / hook block pins and fasteners.
• Carwell T32-CP-90 is available in 16 ounce spray • All hardware, clips, pins, hose connections not painted
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bottles from Manitowoc Crane Care (order part number will have Carwell applied.
8898904099).

1 2 3 4 5
12
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8
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7650-41 11 10 3 9 8 7 6
5 4 13 4 15 14
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14
13
6 9 8 3 10 11
7650-42

Item Description
Item Description 8 O/R Pins, Clips
1 Boom Nose Pins, Clips 9 Power Train Hardware
2 Wire Rope Valve Bank, Hose Connections Inside
10
Turntable
All Hardware, Clips, Pi ns, Hose Connections
3 11 Entire underside of unit
not painted O/R Pins, Clips
4 Pivot Shaft 12 Hook Block/Headache Ball
5 Hoist Plumbing Connections 13 Turntable Bearing Fasteners
6 Mirror Mounting Hardware 14 Pins, Clips for Jib
7 O/R Hose Connections 15 Hanger Hardware for Jib
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600E2 SERVICE MANUAL TROUBLESHOOTING
SECTION 8
TROUBLESHOOTING
SECTION CONTENTS
Hydraulic System Troubleshooting Chart . . . . . . 8-1 Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . 8-5
Jib Load Limiting Device Troubleshooting . . . . . 8-4 Systematic Troubleshooting . . . . . . . . . . . . . . . . . 8-5
HCA Troubleshooting Flow Chart . . . . . . . . . . . . . 8-6
HYDRAULIC SYSTEM TROUBLESHOOTING CHART
Condition Possible Cause Possible Solution
Hose fittings loose, worn or damaged. Check & replace damaged fittings or “O” Rings.
Torque to manufacturers specifications. Replace oil
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Oil seal rings deteriorated by excess heat.
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seal rings by disassembling Pump unit.
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(a) Loosen then tighten single bolt to torque
specification.
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Oil Leakage by corrosion.
(b) Replace bolt.
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Remove seal carrier from pump. - Remove

damaged seal from seal carrier.
Shaft seal worn or damaged.
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If shaft is worn, install new seal in the inner position.
Reinstall seal carrier.
Check proper drive rotation. Make sure pump shaft
is turning (i.e. drive coupling is engaged). Check for
Pump not installed correctly.
sources of suction leaks, inlet flange tight? Pinched
No Flow from Pump (If
O-rings?
pump does not prime in
30 seconds STOP!) Pump not getting oil. Make sure reservoir is full of oil.
Internal leakage in cylinders, valves,
Repair component.
motors or pumps.
Insure overload system is working properly and anti-
Overload system inoperative.
two block/Overload solenoid is powered.
Load too heavy. Check Capacity Chart.
PTO not engaged. Engage PTO.
Low hydraulic fluid supply. Check and fill as required. 8
No response to control
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.

TROUBLESHOOTING 600E2 SERVICE MANUAL

Check PTO ratio, pump size and engine speed for
Pump not operating at proper speed.
proper oil flow
Low hydraulic fluid supply. Check and fill as required.
Relief valve sticking. Remove and clean.
Relief setting too low. Readjust to proper setting.
Worn pump, motor or cylinder. Replace bad part.
Plugged filter. Change filter.
Poor hydraulic system
Valve spools not fully open. Adjust linkage so valve has full throw.
performance
Boom holding valves out of adjustment. Adjust or clean as required.
Reduce engine speed, slow cycle time to cool oil or
Oil temperature too high.
add oil cooler option.
Hydraulic oil too cold or dirty. Warm oil or use less viscous oil.
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Line restricted. Check lines; clean and repair as necessary.
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Internal control valve crack. Replace valve.
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Loose turntable bearing. Torque bearing mounting bolts.
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Loose swing gearbox mounting bolts. Tighten bolts.

Worn gears or bearing. Replace worn parts or adjust gearbox spacing.
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Operator control of lever too erratic. Operate controls smoothly.
Swing moves erratic or Motor counterbalance valves dirty or not Clean or replace counterbalance valves not set at
loosely (Standard set properly. 600 psi.
system)
Replace worn brake parts or shim brake to proper
Brake not holding properly.
torque.
Bleed air from brake with bleed screw on side of
Brake releasing at wrong time or erratically.
brake.
Swing speed adjustment set too low. Adjust valve on turn motor.
Turn circuit relief valves sticking. Clean and check circuit pressure.
Turntable bearing drag. Lubricate thoroughly as rotating boom.
Swing will not turn Check for 200 + PSI brake pilot pressure. Clean pilot
(Standard System) Brake not releasing properly. line or adjust motor counterbalance valves.
Adjust or clean brake for proper release.
Swing speed adjustment set too low. Adjust valve on turn motor.


Excessive pump speed. Adjust foot throttle or check for too high PTO ratio.
Low oil temperature. Allow unit to warm up.
Low hydraulic oil supply. Check and fill.
Suction line kinked, collapsed or blocked. Clear blockage.
Excessive pump noise
Pump Cavitation Check for loose clamps.
during operation
Hydraulic oil too thick. Warm oil or use oil more applicable to environment.
Relief valve chattering. Dirt in relief valve or damaged relief.
Hydraulic tubing vibration. Check for loose tubing.
Tank breather plugged. Clean breather.
Not getting oil to cylinders. Clean and replace as required.
Worn or damaged piston seals. Replace as required.
Cylinders drift Air in hydraulic oil. Cycle operate crane cylinder to remove air.
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Loose holding valve. Tighten valve.
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Check load and change to applicable multipart
Load too heavy.
reeving.
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Relief valve setting too low. Check and adjust if required.

Hoist will not lift or hold Motor worn excessively. Replace motor.
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load
Counterbalance valve defective or leaking. Clean and replace as necessary.
anti-two block system defective. Repair anti-two block system.
Brake worn out. Repair or replace brake.
Gearbox grease low. Check and fill as required.
Hoist gearbox heats
Duty cycle too high. Reduce cycle time or speed of hoist.
Boom sections need lubrication. Grease boom.
Boom chatters during Wear pads not shimmed correctly. Re-shim as described in boom assembly section.
extension/retraction or
Worn wear pads. Replace pads.
doesn't proportion
properly Extension cables out of adjustment. Readjust cables and tension properly.
Extend or retract cables broken. Disassemble and inspect and replace cables.
Boom will not extend

Proportioning cables not attached.
anti-two block system shut down.
Reconnect, replace and/or adjust cables.
Lower hook, and extend load.
8
Defective anti-two block system Check anti-two block system; repair if defective.


JIB LOAD LIMITING DEVICE TROUBLESHOOTING
Carefully check the integrity of all circuits external to
Loose or incorrect wiring. the electronics box, from the jib tip to the console.
Compare to electrical schematic.
Check fuse at crane console. Replace if necessary.
Remove electronics box from jib, remove electronics
Blown fuse.
from housing, and check a fuse on board. Replace if
necessary.
ATB switch open. Ensure that ATB switch is closed.
No table selected. Set the unit for the proper table.
Crane Table Switch Settings: • Power down the unit, set the DIP switch to
System is in a state of • 671E2 = 11101000 10101010, and power up the unit.
constant cut-out • 690E2 = 01101000 • Power down the unit and set the DIP switch for
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• 647E2 = 01100000 the appropriate table.
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• Power up the unit.
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Load cell not calibrated To set the zero point, remove all force from the load
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cell. Power down the unit. Set switch position 8 to
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DIP Switch Positions ON. Power the system. Do not turn off power until
both the zero point and the gain have been set. To
8 7 6 5 4 3 2 1 set the zero point, press the button on the board. To
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set the gain, set switch position 8 to OFF. Set the
switch to the correct code that matches the load cell
Closed (ON) = 1 Open (OFF) = O gain. This code can be found on the tag that
accompanies the load cell. Press the button.
Wrong table selected. See no table selected above.
Ensure that the electronics box is tightly mounted to
the jib. Zero the angle sensor using the following
procedure:
• Place the level indicator on the jib over the
Angle sensor not zeroed. electronics box and level the jib.
• Power up the unit, unplug the connector to the
ATB switch, and jump pin 1 to ground.
• Remove the jumper wire, re-connect the ATB
connector, and power down the unit.
System cuts out too
early or too late Configuration switch must be closed when the jib is
Configuration switch stuck open or closed
retracted and open when the jib is extended. Adjust
(two section jibs only).
or replace switch As necessary.
Ensure that pivot pin is free, well lubricated, and
Pivot pin not free to move. allows the jib head to pivot freely. Inspect and
replace bearings in jib head assembly as required.
Foreign object stuck between jib head Remove any foreign objects which interfere with jib
assembly and jib. The only contacts head assembly operation.
between the jib head assembly and the jib
are to be the load cell and the pivot pin.


JIB JACK TROUBLESHOOTING
No oil in system Add oil to reservoir tank through oil filler hole
Does not lift load
Release valve not closed Turn handle clockwise tightly
Lifts load only part way Oil level low Add oil to reservoir tank through oil filler hole
The following valve or valves leaking
a. Suction valve
Lifts load but does not Replace jack
b. Delivery valve
hold
c. Release valve
Packings worn or damaged Replace jack
Release valve stuck, probably dirt or Transfer load then replace dirty oil, flush oil reservoir
Jack does not lower
foreign matter with kerosene
Dirty oil Change hydraulic oil
Poor lifting
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Air in hydraulic system Purge air from system
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Poor pumping action Oil seal for pump unit worn out or damaged Replace jack
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Systematic Troubleshooting the Hydraulic Schematic and the Illustrated Parts Catalog to
identify parts and flow paths. Start at the top box and work
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The following step-by-step analysis will be helpful in isolating downward step-by-step. Do not try to start in the middle or
and correcting almost every service problem if followed in a skip steps.
step by step systematic manner. Use this information with
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Boom creeping down
Control Valve Centered
Yes No
Cap sensing line between

the counterbalance valve Control valve in
and the compensating meter in position.
pressure switch.
Still creeps Stops creep

Yes No 8
Center valve Control valve in
Incorrect counterbalance Replace compensating down position
setting, bad counterbalance pressure switch normal operation
valve, leaking cylinder seals

HCA TROUBLESHOOTING FLOW CHART
Overload trips and does not reset
No
Has overload been eliminated?
Yes
Downhaul weight lifting the

Eliminate overload
anti-two block weight
No
Yes
Lower downhaul weight
Crane booms down, Yes

telescopes out, hoists up? Problem solved
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No
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fully extended?
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Yes No
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Press HCA override switch and
boom down 5° with no load.
Crane booms down, No 12 V across

telescopes out, pressure switch?
hoists up?
Yes
Yes No
Problem Solved Fuse OK 12 V to solenoid?
No No Yes
Yes
Replace fuse Troubleshoot Resistance across
12 V across wiring solenoid?
pressure switch?
Functions operate
No Sticking spool 12 ohm Replace

Replace No
clean or replace solenoid valve
Yes wiring
Yes
Problem Solved
Not all functions work
Valves sticking?
Clean or replace

600E2 SERVICE CRANE INSTALLATION
SECTION 9
CRANE INSTALLATION
SECTION CONTENTS
Crane to Truck Installation . . . . . . . . . . . . . . . . . . 9-2 Install Torsion Box . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Minimum truck Requirements . . . . . . . . . . . . . . . . 9-2 Mount the Turret and Torsion Box to the
Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Mounting Configurations . . . . . . . . . . . . . . . . . . . . 9-2 Turret Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Configuration 1 - 600E2 . . . . . . . . . . . . . . . . . . . . . 9-3 Torsion Box Mounting . . . . . . . . . . . . . . . . . . . . . 9-24
Configuration 2 - 600E2 . . . . . . . . . . . . . . . . . . . . . 9-3 Mount the Outrigger Box . . . . . . . . . . . . . . . . . . . 9-25
Configuration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 ASH to Torsion Box Mounting . . . . . . . . . . . . . . . 9-26
TM Rear Stow - 647E2, 638E2 . . . . . . . . . . . . . . . 9-5 Assemble the Outriggers . . . . . . . . . . . . . . . . . . . 9-27
Configuration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Hydraulic Reservoir Installation . . . . . . . . . . . . . . 9-27
TM Front Stow - 647E2, 638E2 . . . . . . . . . . . . . . 9-6 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Configuration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . 9-28
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Rear Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . 9-28
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Hoist to Truck Cab Clearance . . . . . . . . . . . . . . . 9-29
Tractor Trailer Installation . . . . . . . . . . . . . . . . . . . 9-8
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PTO Horsepower Requirements . . . . . . . . . . . . . . 9-9
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Bearing Inspection And Installation
9-30
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Direct Mount Pump to PTO. . . . . . . . . . . . . . . . . . 9-9
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
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Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Pin Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Truck Frame Strength . . . . . . . . . . . . . . . . . . . . . 9-10 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . 9-30
Section Modulus Tables. . . . . . . . . . . . . . . . . . . . 9-10 Trunnion Inspection . . . . . . . . . . . . . . . . . . . . . . . 9-30
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Channel (Table A). . . . . . . . . . . . . . . . . . . . . . . . 9-10 Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Channel Reinforcement (Table A) . . . . . . . . . . . 9-10 Counterweighting . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Angle Reinforcement (Table B). . . . . . . . . . . . . . 9-10 Counterweighting Determination Example . . . . . 9-31
Fish Plate Reinforcement (Table C) . . . . . . . . . . 9-10 Counterweighting Methods . . . . . . . . . . . . . . . . . 9-31
Angle Under Reinforcement (Table D) . . . . . . . . 9-10 Counterweighting Methods for Stability
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Around the Rear 180° . . . . . . . . . . . . . . . . . . . . . 9-34
Requirements For Optional Single Front Boom Rest Requirements. . . . . . . . . . . . . . . . . . . 9-36
Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 CAN BUS System Setup . . . . . . . . . . . . . . . . . . . . 9-37
Truck Frame Section Modulus Tables . . . . . . . . 9-16 Required Equipment . . . . . . . . . . . . . . . . . . . . . . 9-37
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 CAN Bus System using Software . . . . . . . . . . . . 9-37
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . 9-19 CAN Bus System using Programming Button . . . 9-38
Positioning Crane On Truck . . . . . . . . . . . . . . . . 9-19 Initial Crane Run In Procedure . . . . . . . . . . . . . . . 9-39
PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 Stability Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39

Hydraulic Pump Installation . . . . . . . . . . . . . . . . 9-19 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Reinforcing/after Frame Extension . . . . . . . . . . . 9-20 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . 9-40
After Frame Modification . . . . . . . . . . . . . . . . . . . 9-23
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Crane Mounting Procedure . . . . . . . . . . . . . . . . . 9-23 HCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Crane Component Installation Sequence . . . . . . 9-23
Torsion Box and ASH Stabilizer Installation . . . . 9-23
Hoist Speed and Pull . . . . . . . . . . . . . . . . . . . . . . 9-41 9
Crane Operating Speeds . . . . . . . . . . . . . . . . . . . 9-41

CRANE INSTALLATION 600E2 SERVICE
CRANE TO TRUCK INSTALLATION operated. The truck cab-to-axle dimension is then

determined by the length of the bed (the bed should be
The installation section contains information for mounting approximately centered over the rear axle) and the
and initial check out of the crane. Proper mounting is mounting space that the crane frame takes up between
required for long lasting crane performance. Improper the cab and the bed.
mounting can cause permanent damage to the truck, i.e.
frame or transmission, and the crane, i.e. pump or • Truck Frame — Try to select a truck frame that will
nonstability. Also Federal Department of Transportation minimize or eliminate frame reinforcement or extension
Laws relating to vehicle manufacture and modification such of the after frame (AF). Many frames are available that
as lights, brakes and axle loads must be met as well as State have the necessary after frame (AF) section modulus
vehicle laws relating to weights and dimensional restrictions (S.M.) and resistance to bending moment (RBM) so that
such as overall length, overhang, etc. reinforcing is not required. The front hydraulic jack is
used for a 360 degree working range around the truck.
This section is organized by first presenting detailed The frame under the cab through the front suspension
information relating to truck requirements and mounting must have the minimum S.M. and RBM because
configurations followed by a step-by-step installation reinforcing through the front suspension is often difficult
procedure including PTO selection, Pump rotation selection, because of engine, radiator mounts and steering
reinforcement, crane and stabilizer installation, mechanics. See Minimum truck Requirements, page 9-2
counterweighting, boom rests and stability testing. and Truck Frame Strength, page 9-10 for the necessary
The final manufacturer of the vehicle must certify that the section modulus and resistance to bending moment
values.
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axle ratings have not been exceeded with all permanently
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attached equipment including a full load of fuel and men [at • Additional Equipment — In addition to the axle ratings,
200 lb (90 kg) each].
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National Cranes need to meet ASME/ANSI B30.5 (latest)
wheelbase, cab-to-axle requirements and frame, it is
recommended that the truck is equipped with electronic
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when completed as cranes and ASME/ANSI B30.23 (latest) engine control, increased cooling and a transmission
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when completed as a personnel lifting system. These with a PTO opening available with an extra heavy duty
standards require welds to meet AWS D14.3 or AWS D1.1 PTO. See PTO Horsepower Requirements, page 9-9. A
respectively. Any work done in mounting must be done in conventional cab truck should be used for standard
crane mounts.
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compliance with these codes.
NOTE: Before installation, verify that the serial number on • Neutral Start Switch — If equipped with optional
the plates located on the major components match remote controls, the chassis must be equipped with a
the main serial number on the crane frame. If the switch that prevents operation of the engine starter when
serial numbers do not match, contact the factory the transmission is in gear.
before proceeding. Matching the serial numbers
insure that accurate warranty information is MOUNTING CONFIGURATIONS
recorded at the factory and aids in dispensing
The National Crane is a versatile machine and its versatility
service bulletins and other pertinent information.
can be enhanced by the manner in which it is mounted.
Following is a brief description of the mounting
MINIMUM TRUCK REQUIREMENTS configurations and the advantages of each. The minimum
Many factors must be considered in the selection of a proper weights listed below the front and rear axles for each
truck for a boom truck crane. Items which must be configuration are estimated minimum front and rear axle
considered are: weights for an 85% stability factor before the crane,
stabilizers and sub-base, if required, are installed on the
• Axle Rating — Axle ratings are determined by the chassis. The minimum weights listed below the front and rear
axles, tires, rims, springs, brakes, steering and frame axles for the New York City approved configurations are
strength of the truck. If any one of these components is estimated front and rear axle weights for 75% stability factor
below the required rating, the gross axle rating is before the crane stabilizers and sub-base are installed on the
reduced to its weakest component value. chassis.
• Wheelbase, Cab-to-Axle (CA) — The wheelbase and NOTE: These weights include the permanently attached
CA required are in part determined by the mounting equipment on the chassis, such as pumps, PTO's,
configuration but also by the boom length and the reinforcing, chassis mounted options, bed and
platform length of the particular unit. Match the platform counterweight.
length to the retracted boom length so that the boom
doesn't overhang the rear of the bed by more than that Before placing this unit in service, a final stability check as
required by legal regulations where the unit will be outlined in this section must be performed.

The maximum weights listed below the front and rear axles Requires 14,000 pound (6,350 kg) GAWRF, 34,000 pound
for each configuration are estimated maximum front and rear (15,422 kg) GAWRR, 48,000 pound (21,773 kg) GVWR, rear
axle weights for not exceeding axle capacities before the A-frame stabilizers and sub-base.
crane, stabilizers, and sub-base, if required, are installed on
Most gas powered trucks will require a heavy bumper or
the chassis.
counterweight.
CONFIGURATION 1 - 600E2 Full capacity work area is rear 180° of vehicle from outrigger
to outrigger.
This configuration allows the installation of the Series 600E2
by using the standard sub-base for 18' bed or the sub-base Truck frame must have or be capable of being reinforced to
for a 20' bed. In most cases, the chassis will not require 13 in3 (213 cm3 SM. and 1,430,000 in-lb (161,568 N.m) RBM
reinforcing and the amount of counter weight required is at front of rear springs through rear suspension to rear
minimized increasing payload capabilities. stabilizers. The truck frame under the crane must have 15.9
in3 (2613 cm SM. and 1,749,000 in-lb (197,610 N.m) RBM
minimum, spring hanger to spring hanger.
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Cwt
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R F
Ash
er
68 (172.7) Min 164 (416.6) Min

*8000 lb Min *10,500 lb
*(3926 kg) Min Note: All dimensions inch (cm)
(4763) kg
*9400 lb Max
*(4264 kg) Max
* Actual scale weights
prior to installation of
crane, sub-base, and
stabilizers Cwt
180° Full Capacity

Work Area
CONFIGURATION 2 - 600E2 This mount requires single front outrigger (SFO), proper
torsion box, and additional counterweight in the underside of

the bed for full capacity 360° around the truck. SFO gives the • 20 in3 (328 cm3) section modulus [(758 Mpa) psi steel] at
machine a solid base helping the operator control loads. the front of the T-box.
Requires 14,000 pound (6350 kg) GAWRF, 34,000 pound • 11 in3 (180 cm3) section modulus at the rear of the front
(15,422 kg) GAWRR, 48,000 pound (21,773 kg) GVVVR, spring hanger, 7.5 in 3 (122.9 cm) 3 section modulus
SFO, rear A-frame stabilizers and sub base. through the spring area.
• 2 in3 (33 cm3) minimum section modulus at the stabilizer
attachment point. The section modulus through the rear
The truck frame must have a minimum of:
suspension must be 13 in3 (213 cm3).
SFO
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2 in3 11 in3
33 cm3 180 cm3
7.5 in3 20 in3

er
123 cm3 328 cm3
68 (172.7) Min 164 (416.6) Min Note: All dimensions inch (cm)
*7700 lb Min
*(3493 kg)
*9000 lb Max
*(4082 kg
*Actual scale weights prior
to installation of crane,
Counter sub-base, and stabilizers
Weight
360° Full Capacity

Work Area

CONFIGURATION 3 Requires 16,000 pound (7257 kg) GAWRF, 34,000 pound

(15,422 kg) GAWRR and 50,000 pound (22,680 kg) GVWR,
TM Rear Stow - 647E2, 638E2 ASH-TM rear stabilizers and tractor mount sub-base. Full
capacity work area is rear 180° of vehicle from outrigger to
This configuration allows the installation of the Series 600E2 outrigger. Addition of a single front outrigger (SFO) makes
on a chassis without using the standard sub-base. However, the unit 360° stable. Full 360° stability cannot be attained
it will require a heavy tandem truck and in many cases will without a SFO. Truck frame must have or be capable of
require counterweight. Swing clearance, overall length and being reinforced to 30 in.3 S.M. (492 cm3) and 3,300,000 in-
boom stow position should be checked before mounting the lb (372,850 N . m) RBM under the crane, spring hanger to
crane. spring hanger.
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ASH
R F
122 in (309.9 cm) Min
222 in (563.9 cm) Min

er
*11,800 lb Min Light Subframe Spacer *10,000 lb Min
(5,352 kg) (4,563 kg)
*10,500 lb Min Heavy Subframe Spacer *9,000 lb Min
(4,763 kg) (4,082 kg)
*Actual scale weights prior to

installation of crane, sub-base
and stabilizers. Includes fifth
wheel and boom rest.
9
Full Capacity Work Area 180° Full Capacity
With SFO Work Area


(15,422 kg) GAWRR and 54,000 pound (24 494 kg) GVWR,
TM Front Stow - 647E2, 638E2 ASH-TM rear stabilizers and tractor mount sub-base. Full
capacity work area is rear 180° of vehicle from outrigger to
This configuration allows the installation of the Series 600E2 outrigger. Addition of a single front outrigger (SFO) will make
on a chassis without using the standard sub-base. However, the unit 360° stable. Full 360° stability cannot be attained
it will require a heavy tandem truck and in many cases will without a SFO. Truck frame must have or be reinforced to 30
require counterweight. Swing clearance, overall length and in.3 S.M. (492 cm3) and 3,300,000 in-lb (372850 N.m) RBM
boom stow position should be checked before mounting the under the crane, spring hanger to spring hanger.
crane.
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ef or
nl c 122 in (309.9 cm) Min
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R F
**222 in (563.9 cm) Min

*11,000 lb Min Light Subframe Spacer *10,500 lb Min
(4,990 kg) (4,763 kg)
er
*Actual scale weights prior to
*10,500 lb Min Heavy Subframe Spacer *9,000 lb Min
installation of crane, sub-base
(4,763 kg) (4,082 kg)
and stabilizers. Includes fifth
wheel and boom rest.
** Longer wheelbase or extended

bumper will be required for all
booms except the 38 ft (1158.2 cm)
boom to keep the front overhang
under 48 in (121.9 cm).
180° Full Capacity

Full Capacity Work Area Work Area
With Front Stabilizer


(15,422 kg) GAWRR and 46,000 pound (20 866 kg) GVWR,
Rear Mount front overframe outriggers, rear stabilizer and heavy duty
rear mount sub-base. Counterweight may have to be added
This type of mount enables the operator to position the crane to ensure unit stability if the truck does not meet minimum
closer to the load in tight working areas. 360° stability at full weight requirements. Truck frame must have 15.9 in 3
rated load can be attained with front out and down (261 cm3) S.M. and 1,749,000 in-lb (197637 N.m) RBM from
outriggers, heavy duty, rear mount subbase and a single rear rear of crane through front outriggers.
stabilizer. Weights shown for front and rear axles are weights
of the truck chassis and bed prior to installation of crane, Truck frame must have or be capable of being lengthened to
subbase, front outriggers and rear stabilizer. an AF of 112 inches (2844 mm) minimum.
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CWT
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R F
er
66 in 156 in 77 in
(167.8 cm) (396.2 cm) (195.6 cm)
Overframe
Outrigger
CWT
Rear
360° Full Capacity

Stabilizer
9
Working Area

TRACTOR TRAILER INSTALLATION The Boom/Front Overhang (distance from the front bumper
to boom tip) must also be calculated to assure State and
Swing clearance, overall length and boom stow position are Federal Regulation compliance is met.
all factors which must be considered for a tractor-trailer
installation. If the boom will be stowed to the front, care must
be taken to ensure that cab height is not excessive.
SR
Crane Frame
and Console
Fifth Wheel Position
Fifth Wheel
Height Above
Truck Frame
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Torsion Box
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Truck Frame
The diagram above shows dimensions which are important when planning a tractor trailer installation for
a 600E2. Swing Radius (SR) can be found by using the table below.
Corner Front of Trailer to Center of Kingpin

Trailer Nose Radius in (cm)
in (cm) 24 (60.9) 30 (76.2) 36 (91.4) 42 (106.6) 48 (121.9)
Flat Square 54 (137.1) 57 (144.7) 60 (152.4) 64 (162.5) 69 (175.2)
Flat 5 (12.7) 52 (132) 55 (139.7) 58 (147.3) 62 (157.4) 66 (167.6)
Flat 10 (25.4) 51 129.5) 53 (134.6) 56 (142.2) 60 (152.4) 64 (162.5)
Flat 18 (45.7) 49 (124.4) 51 (129.5) 53 (134.6) 56 (142,2) 61 (154.9)
Oval Oval 48 (121.9) 48 (121.9) 49 (124.4) 51 (129.5) 54 (137.1)

PTO HORSEPOWER REQUIREMENTS

The unit is equipped with a three section pump that supplies
34 GPM (129 LPM) to the hoist, 18 GPM (68 LPM) to the
CAUTION
boom and outriggers, and 10 GPM (38 LPM) to the swing Do not turn the pump in the opposite direction of the
(turn) circuit. To provide these flows, the pump shaft must indicating arrow on the pump housing. Pump failure will
turn at 2500 RPM. The PTO requirement is a torque rating of result.
at least 200 ft-lb (271 Nm) or 40 HP (30 KW) per 1000 RPM
of PTO shaft speed. Do not confuse engine crankshaft rotation with power take
off rotation. If the power take off shaft rotates opposite the
The PTO requirement is a torque rating of at least 200 ft-lb
engine crankshaft, it is turning in a clockwise (cw) direction
(271 N-m) or 40 HP (30 Kw) per 1000 RPM of PTO shaft
when viewed from the rear of the truck. If the power take off
speed.
shaft rotates the same as the engine crankshaft, it is turning
in a counter-clockwise (ccw) direction when viewed from the
Direct Mount Pump to PTO
rear of the truck. See illustration below.
Most pumps can be direct mounted to the PTO using adapter
Operating speeds and performance of the crane are based
assemblies available from the PTO supplier. If the pump is
on proper pump outputs to the hoist, lift, telescope and swing
direct mounted, its weight should be supported by a strap
circuits.The speeds shown below are optimum operating
between the pump and the transmission. The splined shaft
speeds. The engine must be operated at a speed such that
coupling in a direct mount pump installation requires
the horsepower developed is adequate to pull the pumps
y e
lubrication. #200S Silver Streak Special Multi-Lube (Medium)
under pressure. See pump rotation section to determine
ef or
should be applied to the shaft during original installation and
correct pump for your application.
nl c
reapplied to the shaft or zerk provided on PTO housing shaft
semi-annually thereafter.
ENGINE SPEED PTO RATIO
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Pump Rotation (RPM) 2500 RPM PUMP
R F
2900 86%
It is imperative that the three section hydraulic pump
installed in a 600E2 application be the correct pump rotation Gasoline Engine 2800 89%
er
configuration for the truck drive train/power take off rotation Optimum Speed 2600 96%
direction. Make certain which direction the power take off Range 2500 100%
output shaft rotates before selecting a clockwise (cw) or
counter-clockwise (ccw) rotation hydraulic pump. Either cw 2400 104%
or ccw rotation pumps are available, and are marked clearly Diesel Engine 2200 114%
with a directional arrow on the pump housing. Optimum Speed 2000 125%
Range
1800 139%
1600 156%
1500 167%
View from Rear of Truck
Engine CCW
Engine CCW
PTO CCW PTO CW

TRUCK FRAME STRENGTH (1197,610 N-m) RBM and 15.9 in3 (261 cm3) S.M. under the
crane frame between the front and rear springs with
In order for a truck frame to be suitable for accepting a Series 1,430,000 in-lb (161,590 N-m) RBM and 13 in3 (213 cm3)
600E2 size crane, the truck frame must have a requirement S.M. through suspension to rear stabilizers on each truck
for rigidity so as not to allow excessive boom movement due frame rail. For 360° stability, the truck frame must have a
to truck frame deflection, and it must be strong enough to 15.9 in 3 (261 cm 3 ) section modulus [1,749,000 in-lb
resist the loading induced by the crane so as not to (197,610 N-m) RBM] minimum at the crane frame between
permanently bend or deform. Section Modulus (S.M.) is a the front and rear springs with 1,430,000 in-lb (161,590 N-m)
measurement of the area of the truck frame and determines RBM and 13 in.3 (213 cm3) S.M. through suspension to rear
the rigidity of the frame. Resistance to bending moment stabilizers on each truck frame rail. Listed below is a table
(RBM) is a measurement of strength and is determined by showing the commonly used truck frame and reinforcing
multiplying the section modulus of each frame rail by the materials and the section modulus required for each material
yield strength of the rail material. to ensure adequate strength and rigidity. In all cases, the
For a standard, behind-the-cab mount, 180° stability, the minimum requirements for section modulus and RBM must
Series 600E2 crane requires a minimum of 1,749,000 in-lb be met.
REQUIRED FRAME STRENGTH

Minimum Section
Truck Frame or Minimum
Modulus RBM Under Rmb Through
Reinforcing Section Modulus
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Through Rear Crane Suspension
Material Under Crane
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Suspension
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360° Stability
110,000 PSI
20 in3 328 cm3) 13 in3 (213 cm3)
2,200,000 in-lb 1,430,000 in-lb
O en
(758 MPa) (248,624 Nm) (161,570 Nm)
R F
110,000 PSI 1,749,000 in-lb 1,430,000 in-lb

(758 MPa) 15.9 in3 (261 cm3) 13 in3 (213cm3) (197,637 Nm) (161,570 Nm)
180° Stability
er
50,000 PSI 1,650,000 in-lb 850,000 in-lb
(345 MPa) 33.0 in3 (541 cm3) 17.0 in3 (279 cm3) (186,425 Nm) (96,050 N-m)
SECTION MODULUS TABLES channel is obtained from Table A and should be added to the
section modulus obtained from the truck frame.
The following tables will determine the section modulus of
the truck frame. Always measure the truck frame and check Angle Reinforcement (Table B)
the tables to be sure that any truck factory listed section
modulus is correct. If the truck is reinforced with an angle, refer to Table B for the
data on the added strength provided by the angle.
Channel (Table A) Add this to the section modulus of the channel obtained from
Table A provides the section modulus of channel frames in Table A.
thicknesses of 3/16 inch (4.76 mm), 1/4 inch (6.35 mm), 5/16
inch (7.94 mm), and 3/8 inch (9.52 mm) with each grouping a Fish Plate Reinforcement (Table C)
flange width and web depth column. When the depth of The frame can be strengthened by adding a fish plate of
frame channel and flange width is known, the point at which suitable thickness and depth equal to the frame. The section
these two lines intersect is the section modulus from that modulus of the fish plate can be obtained from Table C and
particular channel. this must be added to the section modulus of the frame to
If the section modulus of the channel does not meet the obtain the total section modulus.
requirements, the channel should be reinforced in the most
applicable method following. Angle Under Reinforcement (Table D)
This table lists the section modulus of an angle with the
Channel Reinforcement (Table A) flange under the truck frame that is added to a frame with an
In order to provide more strength, a channel of suitable angle reinforcement already added. Add the section
thickness can be added to the existing frame. The depth and modulus from Table D to the section modulus obtained from
flange width of this channel should be chosen so it fits over tables A and B to determine total section modulus.
the existing frame. The section modulus of the needed

The edges of the reinforcing angles or channels are to be Where thickness, depth or flange width vary, interpolation
flush with the edges of the frame. between tables or variables within a given table will provide
the strength for the section.
Welding. Two rows of 1 inch (25.4 mm) diameter plug welds
are to be placed in a staggered pattern of the web; the rows If you have any questions concerning frame strength or
to be spaced 5 inches (127 mm) apart with welds at an reinforcing, contact National Crane before proceeding.
interval of 4 inches (102 mm). Do not weld on the flanges.
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TABLE A
Section Modulus in3 (cm3)
D
Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm)
W in. (mm) W in. (mm)
D in. (mm) D in. (mm)
2.5 (64) 3 (76) 3.5 (89) 4 (102) 2.5 (64) 3 (76) 3.5 (89) 4 (102)
8 (203) 5.3 (87) 6.0 (98) 6.7 (110) 7.5 (123) 8 (203) 6.9 (113) 7.8 (128) 8.8 (144) 9.7 (159)
9 (229) 6.3 (103) 7.1 (116) 7.9 (130) 8.7 (143) 9 (229) 8.2 (134) 9.2 (151) 10.3 (169) 11.4 (187)
y e
10 (254) 7.3 (120) 8.2 (134) 9.1 (149) 10.0 (164) 10 (254) 9.5 (156) 10.7 (175) 11.9 (195) 13.1 (215)
ef or
in3 (cm3)
in3 (cm3)
11 (279)
12 (305)
nl c
8.4 (138)
9.5 (156)
9.4 (154) 10.4 (170) 11.4 (187)
10.6 (174) 11.7 (192) 12.8 (210)
11 (279)
12 (305)
11.0 (180) 12.3 (202) 13.6 (223) 14.9 (244)
12.5 (205) 13.9 (228) 15.3 (251) 16.8 (275)
O en
13 (330) 10.8 (177) 11.9 (195) 13.1 (215) 14.3 (234) 13 (330) 14.1 (231) 15.6 (256) 17.2 (282) 18.8 (308)
R F
14 (356) 12.0 (197) 13.3 (218) 14.6 (239) 15.9 (261) 14 (356) 15.8 (259) 17.5 (287) 19.1 (313) 20.8 (341)
15 (381) 13.4 (220) 14.7 (241) 16.1 (264) 17.5 (287) 15 (381) 17.5 (287) 19.3 (316) 21.2 (348) 23.0 (377)
er
2.5 (64) 3 (76) 3.5 (89) 4 (102) 2.5 (64) 3 (76) 3.5 (89) 4 (102)
8 (203) 8.4 (138) 9.5 (156) 10.7 (175) 11.9 (195) 8 (203) 9.8 (161) 11.2 (184) 12.5 (205) 13.9 (228)
9 (229) 10.0 (164) 11.3 (185) 12.6 (206) 13.9 (228) 9 (229) 11.7 (192) 13.2 (216) 14.8 (243) 16.3 (267)
10 (254) 11.6 (190) 13.1 (215) 14.6 (239) 16.0 (262) 10 (254) 13.6 (223) 15.4 (252) 17.1 (280) 18.8 (308)
in3 (cm3)
in3 (cm3)
11 (279) 13.4 (220) 15.0 (246) 16.6 (272) 18.3 (300) 11 (279) 15.7 (257) 17.7 (290) 19.6 (321) 21.5 (352)
12 (305) 15.3 (251) 17.1 (280) 18.8 (308) 20.6 (338) 12 (305) 18.0 (295) 20.1 (329) 22.2 (364) 24.3 (398)
13 (330) 17.3 (284) 19.2 (315) 21.1 (346) 23.1 (379) 13 (330) 20.3 (333) 22.6 (370) 24.9 (408) 27.2 (446)
14 (356) 19.4 (318) 21.4 (351) 23.5 (385) 25.6 (420) 14 (356) 22.8 (374) 25.3 (415) 27.8 (456) 30.3 (497)
15 (381) 21.6 (354) 23.8 (390) 26.0 (426) 28.3 (464) 15(381) 25.4 (416) 28.1 (461) 30.8 (505) 35.5 (582)

W
TABLE B
D
2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108)
7.5 (191) 2.2 (36) 2.3 (38) 2.3 (38) 2.4 (39) 7.5 (191) 2.9 (48) 3.0 (49) 3.1 (51) 3.2 (52)
8.5 (216) 2.8 (46) 2.9 (48) 3.0 (49) 3.0 (49) 8.5 (216) 3.7 (61) 3.8 (62) 3.9 (64) 4.0 (66)
9.5 (241) 3.4 (56) 3.5 (57) 3.6 (59) 3.7 (61) 9.5 (241) 4.5 (74) 4.7 (77) 4.8 (79) 5.0 (82)
in3 (cm3)
in3 (cm3)
10.5 (267) 4.1 (67) 4.3 (70) 4.4 (72) 4.5 (74) 10.5 (267) 5.5 (90) 5.7 (93) 5.8 (95) 6.0 (98)
11.5 (292) 4.9 (80) 5.1 (84) 5.2 (85) 5.4 (88) 11.5 (292) 6.5 (106) 6.7 (110) 6.9 (113) 7.1 (116)
12.5 (318) 5.8 (95) 6.0 (98) 6.1 (100) 6.3 (103) 12.5 (318) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136)
13.5 (343) 6.7 (110) 6.9 (113) 7.1 (116) 7.3 (120) 13.5 (343) 8.8 (144) 9.1 (149) 9.4 (154) 9.6 (157)
y e
14.5 (368) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136) 14.5 (368) 10.1 (166) 10.5 (172) 10.7 (175) 11.0 (180)
ef or
nl c
O en
R F

2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108)
7.5 (191) 3.6 (59) 3.7 (61) 3.9 (64) 4.0 (66) 7.5 (191) 4.3 (70) 4.5 (74) 4.6 (75) 4.8 (79)
er
8.5 (216) 4.6 (75) 4.7 (77) 4.9 (80) 5.0 (82) 8.5 (216) 5.5 (90) 5.7 (93) 5.9 (97) 6.0 (98)
9.5 (241) 5.6 (92) 5.8 (95) 6.0 (98) 6.2 (102) 9.5 (241) 6.7 (110) 7.0 (115) 7.2 (118) 7.4 (121)
in3 (cm3)
in3 (cm3)
10.5 (267) 6.8 (111) 7.1 (116) 7.3 (120) 7.5 (123) 10.5 (267) 8.1 (133) 8.4 (138) 8.7 (143) 8.9 (146)
11.5 (292) 8.1 (133) 8.4 (138) 8.6 (141) 8.9 (146) 11.5 (292) 9.7 (159) 10.0 (164) 10.3 (169) 10.6 (174)
12.5 (318) 9.5 (156) 9.8 (161) 10.1 (166) 10.4 (170) 12.5 (318) 11.3 (185) 11.7 (192) 12.1 (198) 12.4 (203)
13.5 (343) 11.0 (180) 11.4 (187) 11.7 (192) 12.0 (197) 13.5 (343) 13.1 (215) 13.6 (223) 14.0 (229) 14.3 (234)
14.5 (368) 12.6 (206) 13.0 (213) 13.4 (220) 13.7 (224) 14.5 (368) 15.1 (247) 15.5 (254) 16.0 (262) 16.4 (269)
TABLE C
D Section Modulus in3 (cm3)
TH
D in. (mm)
TH in. (mm)
8 (203) 9 (229) 10 (254) 11 (279) 12 (305) 13 (330) 14 (356) 15 (381) 16 (406)
3/16 (4.76) 2.0 (33) 2.51 (41) 3.10 (51) 3.75 (61) 4.46 (73) 5.24 (86) 6.08 (100) 6.98 (114) 7.94 (130)
1/4 (6.35) 2.66 (44) 3.37 (55) 4.16 (68) 5.03 (82) 5.99 (98) 7.03 (115) 8.15 (134) 9.36 (153) 10.5 (172)
in3 (cm3)
5/16 (7.94) 3.33 (55) 4.21 (69) 5.20 (85) 6.29 (103) 7.49 (123) 8.79 (144) 10.19 (167) 11.7 (192) 13.31 (218)
3/8 (9.52) 4.0 (66) 5.06 (83) 6.25 (102) 7.56 (124) 9.00 (148) 10.56 (173) 12.25 (201) 14.06 (230) 16.0 (262)
7/16 (11.11) 4.67 (76) 5.9 (97) 7.29 (119) 8.82 (144) 10.5 (172) 12.32 (202) 14.29 (234) 16.4 (269) 18.66 (306)

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TABLE D
D
3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89) 4 (102) 4.5 (114)
8.5 (216) 5.7 (93) 6.4 (105) 7.0 (115) 7.7 (126) 8.5 (216) 7.7 (126) 8.6 (141) 9.4 (154) 10.3 (169)
9.5 (241) 6.7 (110) 7.4 (121) 8.1 (133) 8.9 (146) 9.5 (241) 9.1 (149) 10.0 (164) 10.9 (179) 11.9 (195)
10.5 (267) 7.7 (126) 8.5 (139) 9.3 (152) 10.1 (166) 10.5 (267) 10.5 (172) 11.5 (188) 12.5 (205) 13.6 (223)
in3 (cm3)
in3 (cm3)
11.5 (292) 8.8 (144) 9.7 (159) 10.6 (174) 11.4 (187) 11.5 (292) 11.9 (195) 13.1 (215) 14.2 (233) 15.4 (252)
12.5 (318) 10.0 (164) 10.9 (179) 11.9 (195) 12.8 (210) 12.5 (318) 13.5 (221) 14.7 (241) 16.0 (262) 17.2 (282)
13.5 (343) 11.2 (184) 12.2 (200) 13.2 (216) 14.3 (234) 13.5 (343) 15.2 (249) 16.5 (270) 17.8 (292) 19.2 (315)
14.5 (368) 12.5 (205) 13.6 (223) 14.6 (239) 15.7 (257) 14.5 (368) 16.9 (277) 18.3 (300) 19.7 (323) 21.2 (347)
y e
15.5 (394) 13.8 (226) 15.0 (246) 16.1 (264) 17.3 (284) 15.5 (394) 18.7 (306) 20.2 (331) 21.7 (356) 23.3 (382)
ef or
nl cThickness 5/16 in. (7.94 mm) Thickness 3/8 in. (9.52 mm)
O en
R F

3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89) 4 (102) 4.5 (114)
8.5 (216) 9.8 (161) 10.8 (177) 11.9 (195) 12.9 (211) 8.5 (216) 11.9 (195) 13.2 (216) 14.4 (236) 15.6 (256)
er
9.5 (241) 11.5 (188) 12.6 (206) 13.8 (226) 15.0 (246) 9.5 (241) 14.0 (229) 15.3 (251) 16.7 (274) 18.1 (297)
10.5 (267) 13.3 (218) 14.5 (238) 15.8 (259) 17.1 (280) 10.5 (267) 16.2 (266) 17.7 (290) 19.2 (315) 20.7 (339)
in3 (cm3)
in3 (cm3)
11.5 (292) 15.1 (247) 16.5 (271) 18.0 (295) 19.4 (318) 11.5 (292) 18.4 (302) 20.1 (329) 21.8 (357) 23.5 (385)
12.5 (318) 17.1 (280) 18.6 (305) 20.2 (331) 21.7 (356) 12.5 (318) 20.9 (342) 22.6 (370) 24.5 (402) 26.3 (431)
13.5 (343) 19.2 (315) 20.8 (341) 22.5 (369) 24.2 (397) 13.5 (343) 23.4 (384) 25.3 (415) 27.3 (447) 29.3 (480)
14.5 (368) 21.4 (351) 23.1 (379) 24.9 (408) 26.7 (438) 14.5 (368) 26.0 (426) 28.1 (461) 30.2 (495) 32.4 (531)
15.5 (394) 23.7 (388) 25.5 (418) 27.4 (449) 29.4 (482) 15.5 (394) 28.8 (472) 31.0 (508) 33.3 (546) 35.6 (583)

EXAMPLE
A truck frame of 110,000 psi (758 MPa) yield strength steel has the following dimensions: 3/8 in.
(9.65 mm) thick, 3 in. (76.2 mm) flanges and is 10.25 in. (260 mm) deep. To find the frame 3.00
section modulus: (76.2)
1. From Table A, 3/8 in. (9.65 mm) thickness,
10.25
• W (width) = 3 in. (76.2 mm), (260)
• D (depth) = 10 in. (254 mm)

• section modulus = 15.4 in.3 (252 cm3.
Inch 0.375
2. From Table A, 3/8 in. (9.65 mm) thickness, (mm) (9.65)
• W = 3 in. (76.2 mm),
• D = 11 in. (279 mm),
• Section Modulus = 17.7 in.3 (290 cm3).
3. Interpolating between the two values:
• 10 in. (254 mm) deep channel = 15.4 in.3 (252 cm3)
y e
ef or
•
nl c
10.5 in. (267 mm) deep channel
15.4 in.3 ÷ 17.7 in.3
O en
= = 16.55 in.3
R F
2
252 cm3 ÷ 290 cm3
=
2 = 271 cm3
er
4. Now interpolate between 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.
• 10.5 in. (267 mm) deep channel = 16.55 in.3 (271 cm3)
• 10.25 in. (260 mm) deep channel
15.4 in.3 ÷ 16.55 in.3
= = 15.98 in.3
2
252 cm3 ÷ 271 cm3
=
2 = 262 cm3
5. A 3/8 in. (9.65 mm) x 3 in. (76.2 mm) x 10.25 in. (260 mm) truck frame has a 15.98 in.3 (262 cm3)
Section Modulus and RBM of 110,000 psi x 15.98 in.3 = 1,757,800 in. lbs. (758 MPa x 262 cm3 =
198,596 N.m)
• 10.5 in. (267 mm) deep channel = 16.55 in.3 (271 cm3)
• 10.25 in. (260 mm) deep channel l
15.4 in.3 ÷ 16.55 in.3
= = 15.98 in.3
2
252 cm3 ÷ 271 cm3
=
2 = 262 cm3
6. 15.98 in.3 (262 cm3) Section Modulus, 110,000 psi (758 MPa) steel is adequate for a standard
mount with a torsion box.

REQUIREMENTS FOR OPTIONAL SINGLE bracket must be capable of supporting 0.50 inch (12.7 mm)
FRONT OUTRIGGER DIA. Grade 8 bolts to their nominal breaking strength. Torque
the mounting bolts supplied with the SFO to 110 ft-lb (149
The truck frame must have adequate strength from under the N·m).
crane frame through the front suspension to the bumper
Do not use spacers between the bumper bracket and the
assembly for single front outrigger (SFO) installation. A truck
SFO bumper assembly.
frame yield strength of 110,000 psi (758 MPa) is required.
If the bumper bracket and front of the truck frame do not
The following diagram shows the required section modulus
meet these specifications, an extended frame truck must be
at various stations along the front end of the truck frame for a
used. Contact factory for details. Details for mounting a SFO
standard behind-the-cab mount with torsion box.
on an extended frame truck are included in that installation
In order to safely mount a SFO in place of the normal front instruction. However, the Section Modulus requirements
bumper, a minimum bolt pattern as shown is required. The outlined below do apply.
Front
Axle
Front of
CL
T-Box
y e
ef or
nl c
O en
R F
er
2.0 in3 11.0 in3 15.9 in3

(33 cm3) 7.5 in3 (180 cm3) (261 cm3)
(123 cm3)
Section Modulus per Truck
Frame Rail (Frame Rail Yield
Stress = 110,000 psi (785 MPa)
Bumper
4.50 in (11.4 cm) Min

TRUCK FRAME SECTION MODULUS Angle (Table F). Use Table F for an angle section such as
TABLES when a flange and part of the web of a truck frame channel is
removed.
Use Table E and Table F below along with Tables A through
Where thickness, depth or flange width vary, interpolation
D in the preceding section of this manual for determining the
between tables or variables within a given table will provide
section modulus of the truck frame.
Always measure the truck frame and check the tables to be
If you have any questions concerning frame strength or
sure that any truck factory listed section modulus is correct. It
reinforcing, contact National Crane before proceeding.
is also necessary to measure the frame and check the
section modulus wherever the depth and/or flange width Where thickness, depth or flange width vary, interpolation
changes. between tables or variables within a given table will provide
Channel (Table E). Table E supplements Table A for
narrower truck frame flanges. Use the width of the narrow If you have any questions concerning frame strength or
flanges for “W” to find the section modulus from Table E. reinforcing, contact National crane before proceeding.
TABLE E
y e
D Section Modulus in3 (cm3)
ef or
nl c
O en
R F

1 (25) 1.53 (38) 2 (51) 1 (25) 1.53 (38) 2 (51)
8 (203) 3.2 (52) 3.9 (64) 4.6 (75) 8 (203) 4.1 (67) 5.0 (82) 5.9 (97)
er
9 (229) 3.8 (62) 4.7 (77) 5.5 (90) 9 (229) 5.0 (82) 6.0 (98) 7.1 (116)
10 (254) 4.6 (75) 5.5 (90) 6.4 (105) 10 (254) 5.9 (97) 7.1 (116) 8.3 (136)
in3 (cm3)
in3 (cm3)
11 (279) 5.4 (88) 6.4 (105) 7.4 (121) 11 (279) 7.0 (115) 8.3 (136) 9.6 (157)
12 (305) 6.3 (103) 7.4 (121) 8.5 (139) 12 (305) 8.2 (134) 9.6 (157) 11.0 (180)
13 (330) 7.2 (118) 8.4 (138) 9.6 (157) 13 (330) 9.4 (154) 10.9 (179) 12.5 (205)
14 (356) 8.2 (134) 9.5 (156) 10.8 (177) 14 (356) 10.7 (175) 12.4 (203) 14.1 (231)
15 (381) 9.3 (152) 10.6 (174) 12.0 (197) 15 (381) 12.1 (198) 13.9 (228) 15.7 (257)
Thickness 5/16 in. (7.94 mm)

Thickness 3/8 in. (9.52 mm)
W in. (mm)
D in. (mm) W in. (mm)
1 (25) 1.53 (38) 2 (51) D in. (mm)
1 (25) 1.53 (38) 2 (51)
8 (203) 4.9 (80) 6.1 (100) 7.2 (118)
8 (203) 5.7 (93) 7.1 (116) 8.4 (138)
9 (229) 6.0 (98) 7.3 (120) 8.6 (141)
9 (229) 7.0 (115) 8.6 (141) 10.1 (166)
10 (254) 7.2 (118) 8.7 (142) 10.1 (166)
10 (254) 8.4 (138) 10.2 (167) 12.0 (197)
in3 (cm3)
11 (279) 8.5 (139) 10.1 (166) 11.8 (193)

in3 (cm3)
11 (279) 10.0 (164) 11.9 (195) 13.8 (226)

12 (305) 9.9 (162) 11.7 (192) 13.5 (221)
12 (305) 11.6 (190) 13.8 (226) 15.9 (261)
13 (330) 11.5 (188) 13.4 (220) 15.3 (251)
13 (330) 13.4 (220) 15.7 (257) 18.0 (295)
14 (356) 13.1 (215) 15.2 (249) 17.3 (284)
14 (356) 15.4 (252) 17.8 (292) 20.3 (333)
15 (381) 14.8 (242) 17.1 (280) 19.3 (316)
15 (381) 17.4 (285) 20.1 (329) 22.8 (374)

TABLE F
D
2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108)
3.5 (89) 0.6 (10) 0.6 (10) 0.6 (10) 0.6 (10) 3.5 (89) 0.8 (13) 0.8 (13) 0.8 (13) 0.8 (13)
4.5 (114) 0.9 (15) 1.0 (16) 1.0 (16) 1.0 (16) 4.5 (114) 1.2 (20) 1.3 (21) 1.3 (21) 1.3 (21)
5.5 (140) 1.4 (23) 1.4 (23) 1.4 (23) 1.5 (25) 5.5 (140) 1.8 (30) 1.8 (30) 1.9 (31) 1.9 (31)
6.5 (165) 1.8 (30) 1.9 (31) 2.0 (33) 2.0 (33) 6.5 (165) 2.4 (39) 2.5 (41) 2.6 (43) 2.6 (43)
y e
7.5 (191) 2.9 (48) 3.0 (49) 3.1 (51) 3.2 (52)
ef or
7.5 (191) 2.2 (36) 2.3 (38) 2.3 (38) 2.4 (39)
in3 (cm3)
in3 (cm3)
8.5 (216)
9.5 (241)
nl c
2.8 (46)
3.4 (56)
2.9 (48)
3.5 (57)
3.0 (49)
3.6 (59)
3.0 (49)
3.7 (61)
8.5 (216)
9.5 (241)
3.7 (61)
4.5 (74)
3.8 (62)
4.7 (77)
3.9 (64)
4.8 (79)
4.0 (66)
5.0 (82)
O en
10.5 (267) 4.1 (67) 4.3 (70) 4.4 (72) 4.5 (74) 10.5 (267) 5.5 (90) 5.7 (93) 5.8 (95) 6.0 (98)
R F
11.5 (292) 4.9 (80) 5.1 (84) 5.2 (85) 5.4 (88) 11.5 (292) 6.5 (106) 6.7 (110) 6.9 (113) 7.1 (116)
12.5 (318) 5.8 (95) 6.0 (98) 6.1 (100) 6.3 (103) 12.5 (318) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136)
13.5 (343) 6.7 (110) 6.9 (113) 7.1 (116) 7.3 (120) 13.5 (343) 8.8 (144) 9.1 (149) 9.4 (154) 9.6 (157)
er
14.5 (368) 7.6 (124) 7.9 (129) 8.1 (133) 8.3 (136) 14.5 (368) 10.1 (166) 10.5 (172) 10.7 (175) 11.0 (180)
2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 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) 3.5 (89) 1.1 (18) 1.1 (18) 1.1 (18) 1.2 (20)
4.5 (114) 1.5 (25) 1.5 (25) 1.6 (26) 1.6 (26) 4.5 (114) 1.8 (30) 1.8 (30) 1.9 (31) 1.9 (31)
5.5 (140) 2.2 (36) 2.3 (38) 2.3 (38) 2.4 (39) 5.5 (140) 2.6 (43) 2.7 (44) 2.7 (44) 2.8 (46)
6.5 (165) 3.0 (49) 3.1 (51) 3.2 (52) 3.2 (52) 6.5 (165) 3.5 (57) 3.7 (61) 3.8 (62) 3.8 (62)
7.5 (191) 3.6 (59) 3.7 (61) 3.9 (64) 4.0 (66) 7.5 (191) 4.3 (70) 4.5 (74) 4.6 (75) 4.8 (79)
in3 (cm3)
in3 (cm3)
8.5 (216) 4.6 (75) 4.7 (77) 4.9 (80) 5.0 (82) 8.5 (216) 5.5 (90) 5.7 (93) 5.9 (97) 6.0 (98)
9.5 (241) 5.6 (92) 5.8 (95) 6.0 (98) 6.2 (102) 9.5 (241) 6.7 (110) 7.0 (115) 7.2 (118) 7.4 (121)
10.5 (267) 6.8 (111) 7.1 (116) 7.3 (120) 7.5 (123) 10.5 (267) 8.1 (133) 8.4 (138) 8.7 (143) 8.9 (146)
11.5 (292) 8.1 (133) 8.4 (138) 8.6 (141) 8.9(146) 11.5 (292) 9.7 (159) 10.0 (164) 10.3 (169) 10.6 (174)
12.5 (318) 9.5 (156) 9.8 (161) 10.1 (166) 10.4 (170) 12.5 (318) 11.3 (185) 11.7 (192) 12.1 (198) 12.4 (203)
13.5 (343) 11.0 (180) 11.4 (187) 11.7 (192) 12.0 (197) 13.5 (343) 13.1 (215) 13.6 (223) 14.0 (229) 14.3 (234)
14.5 (368) 12.6 (206) 13.0 (213) 13.4 (220) 13.7 (224) 14.5 (368) 15.1 (247) 15.5 (254) 16.0 (262) 16.4 (269) 9

EXAMPLE:
Refer to the sample truck frame cross sections in Table E. Truck frame yield strength is I I 0,000 psi (758 MPa) with
the following dimensions at the front axle location: 3/8 in. (9.65 mm) thick, 1.50 in. (38.1 mm) top flange, 3 in. (76.2
mm) bottom flange, 10.25 in. (260 mm) deep. To find the frame section modulus:
1. Use a channel with 1.50 (38.1 mm) flanges since I.50 in. (38.1 mm) is the smaller flange width.
2. From Table E, 3/8 in. (9.65 mm) thickness:
• W (width) = 1.50 in. (38.1 mm)
• D (depth) = 10.0 in. (254 mm)
• Section Modulus = 10.2 in3 (167 cm3)
3. From Table E, 3/8 in. (9.65 mm) thickness
• W = 1.50 in. (38.1 mm),
• D = 11.0 in. (279 mm)
• Section Modulus = I I.9 in.3 (195 cm3)
4. Interpolate between the two values:
y e
10 in.(254mm) deep channel = 10.2 in.3 (167cm3)
ef or
•
•
• nl c
11 in.(279mm) deep channel = 11.9 in.3 (195cm3)
10.5 in.(267 mm) deep channel
O en
R F
10.2 in.3 + 11.9 in.3

= = 11.0 in.3
2
er
167 cm3 + 195 cm3
= = 181 cm3
2
5. Now interpolate between a 10.0 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.
• 10.0 in. (254 mm) deep channel = 10.2 in.3 (167cm3)
• 10.5 in. (267 mm) deep channel = 11.0 in.3 (181cm3)
• 10.25 in. (260 mm) deep channel
10.2 in.3 + 11.0 in.3

= = 10.6 in.3
2
167 cm3 + 181 cm3

= = 174 cm3
2
1.50
(38.1)
Frame Section Modulus at the front axle location is 10.6 in.3 (174 cm3). This is greater
10.25
than the 7.5 in.3 (123 in.3) required so the truck frame is strong enough at this location. (260)
3.0 0.375
(76.2) (9.65)
Inch
(mm)

TRUCK PREPARATION PTO INSTALLATION

Plan installation completely before any work is done. Plan Select the PTO according to the PTO Selection pages shown
the location of the crane for the final front and rear axle earlier in this section. PTO's are not furnished by the factory.
weights and boom overhang. Check final weight. see
1. Install the PTO and PTO shifting mechanism according
Counterweighting Section to verify that final truck weight with
to the PTO manufacturer's instructions. If PTO has a
crane, reinforcement, counterweight and options such as jib,
reverse gear, it must be blocked out. Pump must not run
etc. complies with the appropriate laws.
backwards.
Welding Precautions Hydraulic Pump Installation
- Sensitive truck computer system and crane's RCL
or ji b load limiting device computer system
components may be damaged by welding on the CAUTION
truck or crane. The following precautions should be To avoid pump failure, do not turn the pump in the
taken: opposite direction of the indicating arrow on the pump
housing.
- Disconnect truck battery cables (positive and
negative). 2. If PTO integral mount flanges are to be used, the pump
- Attach welding ground lead as close as possible to can be mounted directly to the PTO. Be sure adequate
area to be welded. clearance exists for this type of pump mount.
y e
Sometimes the pump is powered through a drive line
ef or
- Remove the jib from the crane before welding on the with the pump located no more than 42 inches (107 cm)
nl c
crane or remove the jib sheave case assembly from
the jib before welding on the jib.
from the PTO. The drive line should not exceed a 7°
angle. The drive line U-joint yokes on both ends of the
O en
drive shaft must be parallel with each other. Drive lines
POSITIONING CRANE ON TRUCK
R F
should be sized so they can safely carry the maximum

pump horsepower requirements. See “PTO Selection”
The final user of the crane must be aware of all state axle pages. Drive lines are not furnished by the factory.
and length laws in force at the time of crane mounting and
er
position the crane on the truck accordingly. Following are 3. Plan the location of the pump mounting bracket and
items which must be considered. drive line, if used, so that ample clearance is maintained
between pump and truck drive shaft or exhaust system.
1. Overall Length: Most states have a maximum straight Pump should be situated so that hydraulic lines can be
truck length limit of 40 feet (12.19 m). Using too long a connected without sharp bends especially the large
WB truck could cause the unit to exceed this limit. suction line from the reservoir. Pump mounting brackets
2. Axle Weights: All states allow 20,000 lb (9072 kg) single may be attached to existing frame crossmembers or a 6
axle weight and 34,000 lb (15,422 kg) tandem axle inch (15 cm) channel crossmember can be made and
weights on primary roads, however, some states restrict installed.
axle weight to less on secondary roads or at certain 4. Install pump mounting bracket (driveline driven pumps
times throughout the year. Be aware of your state's axle only) securely to the truck frame. Attach pump to pump
laws and the roads the machine will operate on for mounting plate or directly to the PTO using capscrews
weight restrictions due to secondary roads, bridges, provided.
winter driving conditions, etc.
a. Install the pump support bar at the rear of the pump
3. Overhang: The most restrictive overhang laws call for a and bolt or weld the upper end to a crossmember if
maximum of 3 feet (.91 m) in front of the truck. Many the pump is driven by a driveline.
states have a maximum of 4 feet (122 cm) overhang in
back of the truck. Check on your state requirements. b. For a direct mounted PTO bolt to transmission.
4. Federal Bridge Law: The Federal Bridge Law in effect c. The rear of the pump must be supported regardless
currently states that in order to carry 54,000 pounds of the mounting method.
(24,494 kg) on a three axle truck, the extremes of any
group of axles must be at least 23.5 feet (7.16 m) apart.
5. The splines of the pump shaft and the drive coupling 9
need Lubrication. If the gearbox is a wet drive then no
This equates to a truck with a wheelbase of at least 258
grease is required because the gearbox oil will lubricate
inches (655 cm) with a minimum length of 24 inches
the splines. If the gearbox coupling is sealed then the
(60.96 cm) from the center of tandems to the center of
splines needs to be greased with Heavy Lithium Grease
the rear axle.
covering all the splines

6. For a wet mount, a gasket is required for the mounting Rotate the pump in the direction as the PTO. Rotate the
flange to PTO gearbox interface. Dry mount does not pump in the mounting bracket so suction side is toward
require a gasket. the reservoir suction port.
7. Torque the mounting flange nuts to 50 ft. lbs (222 Nm).
REINFORCING/AFTER FRAME EXTENSION
NOTE: Some of the pipe fittings used are sealed by means
of two threaded tapered sections, one male and .
one female. When these two tapers meet, you will
note a sudden increase in the force required to
CAUTION
screw the fittings together. This is true of all tapered The hydraulic piston pump case must be pre-filled with oil
pipe threads. Further tightening will not only fail to prior to startup. Failure to do so will result in pump failure.
increase the pressure tightness of the joint, but
may ruin the connections and make correct 1. Refer to “Truck Frame Strength” and “Section Modulus”
assembly impossible. tables. Determine section modulus by actual
measurement of the truck frame. If reinforcing is
Other fittings are of the o-ring boss type. These are required, always use at least 100,000 psi (758 MPa)
installed by first screwing the lock nut flush to the steel to minimize the amount of reinforcing required. Use
upper thread land and installing fitting into port until Grade 90 weld material for any welding to be done.
the nut contacts the surface of the port. Adjust
fitting to desired direction. Tighten locknut. 2. Strip the frame of obstructions in the area to be
reinforced or extended, one side at a time. If the truck
y e
Most pressure fittings are the O-ring face seal frame cross members are bolted in, remove the bolts.
ef or
types. A small O-ring is compressed between the Do not attempt to remove any rivets.
nl c
male and the female fittings of the joint. Be sure the
O-ring is present on the fitting and seated properly 3. Place the reinforcing on the truck frame and clamp in
O en
in its groove before the fittings are tightened. place. Mark the location of any rivets by striking the
R F
outside of the reinforcing over the rivet area so that the

8. Remove the dust covers from the pump inlet and outlet rivets make an impression on the inside of the
and make sure that the suction and pressure sides of the reinforcing. Mark the approximate location of the crane
pump are correct. mounting anchors so that no obstructions exist. Remove
er
NOTE: An arrow is cast into the rear of the pump housing the reinforcing and drill or torch cut clearance holes for
to identify rotation. Make sure the rotation is bolts or rivets. See Figure A.
correct.
Remove bolts, clamp on

reinforcing, and mark the Plan the location of the crane
bolt hole location from mounting anchors so they don’t
the inside of the frame interfere with the bolts, etc.
(Ref) Truck frame
The bolt hole clearance is

1/16 to 1/8 in diameter
larger than the bolt shank
(Ref) Reinforcing
Do not remove the rivets.
Clamp on reinforcing and strike
NOTE: All dimensions The rivet hole clearance the reinforcing in this area to
are inches (millimeters) is 1/2 in diameter larger mark the location of rivets
than the rivet head
Figure A

4. If reinforcing is to be welded on, torch cut hole pattern in place, install any crossmember bolts that were previously
reinforcing being careful to clear crane mounting removed, then drill through reinforcing and truck frame being
anchors. Install reinforcing, clamp in place, install any careful to clear crane mounting anchors and bolt reinforcing
crossmember bolts that were previously removed and in place. See Figure C for recommended drilling and bolting
weld to truck frame as shown in Figure B. procedure. Use 5/8, Grade 8 bolts, drill holes to 39/64
diameter, drive fit bolts and torque according to “Torque
In some cases, because of customer stipulation or truck
Values For Grade 5 and 8 Bolts” table in Section 2.
manufacturer voiding their warranty, bolt-on reinforcing is
required. In these cases, install the reinforcing, clamp in
2 (51)
1 (25.4) diameter
5 (127) holes for plug welds
Planned location of mounting

2 (51)
plate. Plug weld locations can
y e
4 (101) be shifted to clear plate.
ef or
4 (101)
nl c 8 (203)
O en
R F
Crossmember bolt holes

plug weld. Holes can be
shifted slightly to clear.
er
Clearance holes for rivets on weld or

on reinforcement. Can be filet welded
around to eliminate plug weld holes.
Figure B
8 (203) Typ
2 (51) Min
2 (51) Min
4 (101) 8 (203) Typ

9
NOTE: All dimensions are inches (millimeters)
Figure C

If the frame through the rear suspension does not meet frame, cut out plug weld hole pattern as in Figure B.
minimum specifications for RBM and section modulus as Slide the reinforcing angle up from the bottom, butt it to
shown on “Truck Frame Strength” table, the frame can be existing forward reinforcing and weld rear suspension
reinforced by adding an angle type of reinforcing (Figure D). reinforcing to forward reinforcing. Replace as much of
See “Section Modulus tables, Table B for the required size of the spring hanger cut out areas as possible and butt
reinforcing. weld these pieces in.
5. Strip all easily removable equipment from the frame If reinforcing angle is to be bolted on, drill hole pattern and
through the suspension such as spring stops, etc. Butt install bolts according to Figure C. Reinforce spring hanger
the reinforcing angle up against the reinforcing forward cut outs and the weld area, suspension reinforcing to forward
of the suspension and mark the areas that will require reinforcing by adding bars under these areas. The bars
cutting so that the angle will slide up around the spring should be of the same thickness, width and yield strength as
hangers and against the existing truck frame and the reinforcing angle lip, and should be long enough to
forward reinforcing. Torch out the marked areas in the extend at least 6 inches (152 mm) beyond either side of the
long leg of the angle deep enough so that the lip of the weld or cut out areas. Weld these reinforcing bars to the
angle can be slid up from the underneath the frame to underside of the reinforcing with length-wise welds. Do Not
contact either existing truck frame or spring hanger Weld Across The Flanges. Replace any equipment that had
brackets (if they extend down below the existing truck been removed.
frame). If reinforcing angle is to be welded to truck
y e
Reinforcing under crane
ef or
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material as possible. Butt weld
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Butt weld
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Overload spring stop.
S k h a bo
Remove and replace.
wi ong
ip lte th
t
we rn ed
al
l d at e g e
al
Weld 6 (152)
l b we
er
ar l d
Skip 6 (152)
s
Weld 6 (152)
s
Skip 6 (152)
Weld 12 (304)
Truck frame (REF)
6 (152)
6 (152)
6 (152)
NOTE: All dimensions are
inches (millimeters)
6 (152)
Reinforcing (REF)
Figure D

AFTER FRAME MODIFICATION 13. Install Boom
If additional suspension reinforcing is required, as may be 14. Install hoist cable

the case with a truck frame that tapers down to 15. Fill hydraulic reservoir
approximately 6 inches (15.24 cm) deep through the
suspension, a channel may be fabricated through the Torsion Box and ASH Stabilizer Installation
suspension for additional strength. To do this, install the
angle as described in the previous step, making sure that the 1. Determine installation position for the crane considering
long leg of the angle extends to the top of the truck frame. A the operating area of the crane, space for saddle tanks,
bar of the same material strength, thickness, length and truck frame crossmembers, or anything that might affect
flange width as the reinforcing angle is then added to the top installation and be sure the frame is clear of any
of the truck frame. The bar is butt welded to the top of the obstructions that might interfere with proper installation.
forward reinforcing, then skip-welded with 6 inches (15.24 2. Center the sub-base on chassis at the proper location.
cm) of weld, 6 inches (15.24 cm) no weld, etc., along both
edges of the bar, front to back. Length of after frame (AF) 3. If sub-base does not fit tightly on truck frame at all
may have to be modified for crane installation. If AF is too locations, do not force them together to remove gaps
long, cut off excess and remove any crossmembers from since they will not affect the units stiffness or strength.
back of truck frame. If AF is too short, the frame will have to Add spacers as required to level truck bed before
be lengthened. Use channels fabricated from 100,000 psi attaching it to the torsion box.
(758 MPa) yield material that are the same size as the truck
Install Torsion Box
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frame. Weld these channels to the ends of the existing truck
ef or
frame channels. Bevel the ends of the channels to get 100% Install outriggers on crane frame. Attach the appropriate
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weld joints with Grade 90 weld material. Fabricate an inner
channel of the same thickness as the truck frame channels
hoses to the outrigger cylinders. Cycle the outriggers to fill
with oil completely and install the latch plate to hold
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to span the weld joint for at least 12 inches (30 cm) on each outriggers in place during travel.
side of joint. Plug weld this channel to the inside of the truck
R F
frame, then skip weld the inside edge of the top and bottom Mount the Turret and Torsion Box to the
flanges to the truck frame flanges
Frame Assembly
er
CRANE MOUNTING PROCEDURE Position the turret assembly and the torsion box on the frame
assembly so that the mounting bolts can be attached through
The following is a suggested sequence of steps required to the plates attaching the assemblies to the frame
successfully mount the crane on the truck. This is only one of (Figure 9-1).
several possible ways to mount the crane and is offered as
an aid to planning the mounting of the crane. Turret Mounting
Crane Component Installation Sequence 1. Position the turret assembly (Reference Table 9-1).
1. Position Torsion Box and mark frame locations for 2. Install the standard SAE washer (4) against the head of
Hydraulic Reservoir and ASH the 1-1/4 inch bolt (3).
2. Remove Torsion Box 3. Install the DTI crush washer (7) with the bumps facing
away from the SAE washer (4), facing towards the
3. Install hydraulic pump hardened washer (14).
4. Locate and drill holes for Hydraulic Reservoir NOTE: Do not allow the DTI crush washer to turn during
5. Install Hydraulic Reservoir tightening of fastener or damage may occur to the
bumps on DTI crush washer causing improper
6. Install pump lines to Reservoir torque.
7. Position Torsion Box NOTE: The DTI crush washer cannot be re-used and must
8. Install ASH be replaced if the studs become loose or are
9. Install Truck Bed

removed.
9
4. Install the DTI hardened washers (14).
10. Install Frame Assembly
5. Assemble and install the bolt and washer assembly
11. Install Outriggers through the holes in plate (5) and install plate on outer
12. Route and connect hydraulic hoses to Reservoir and surface of the truck chassis.
Main Control Valve

6. Locate and install plate, crush (6) to the inside of chassis

frame channel. Ensure plate, crush is machined to
properly fit to the inside the frame channel of the truck ! WARNING
chassis conforming to the frame rail. Crushing Hazard!
NOTE: Cut the plate and neatly machine as necessary to The T-box attaching bolts should be inspected after the
fit inside the truck frame. first 300 hours of crane operation and every 500 hours
thereafter. The bolts may loosen and cause the crane to
7. Align and install bolt (3) passing through mounting holes
separate from the carrier which will result in damage to
in plate, crush (6) and aligning through inner mounting
the crane and possible injury or death to personnel.
holes in the turret.
8. Install the standard SAE washer (4) and nuts (8) on top Proper identification of bolt grade is important. When marked
side of the turret and snug tight. as a high strength bolt (grade 8), the service technician must
be aware of bolt classifications and that he is installing a high
9. Install the outer bolt and washer assembly in the outer strength heat-treated tempered component and the bolt
turret assembly mounting holes. 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.
WARNING When a high strength bolt is removed, or un-tightened, the
bolt must be rep laced with a new bo lt of t he same
When tightening nuts keep the plate parallel to truck classification.
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frame. Failure to do so causes uneven edge loading and
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stud failure. NOTE: The DTI crush washer cannot be re-used and must
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10. Snug all bolts in a star pattern.
be replaced if the bolts are replaced.
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Torsion Box Mounting
11. Tighten evenly in a star pattern until the direct tension
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indicator (DTI) crush washer (7) compresses and the 1. Position the torsion box assembly onto the chassis
silicon indicator is visible between the washers. frame (Figure 9-1).
2. Attach the torsion box to frame using the bolt and plate
er
NOTE: The DTI crush washer cannot be re-used and must
be replaced if the studs are removed. assembly procedure as referenced in (Turret Mounting).
NOTE: Tighten only until the DTI crush washer (7) is

compressed and the silicon indicator is visible
regardless of the torque value. WARNING
Proper tightening should be verified by inserting When tightening bottom nuts keep the plate parallel to
0.127mm (.005 in) feeler gauge between the truck frame. Failure to do so causes uneven edge loading
hardened washer and the DTI washer at each and stud failure.
bump. An example of the acceptable tightening
would be the refusal of at least half way around the 3. Install plate, rear light (10) to rear of the torsion box
DTI washer with 4 or more out of 7 insertions of a using attaching hardware capscrew (11), washer (12),
feeler gauge entering into the gap between and locknut (13).
washers but not touching the bolt.

2 8
Machine plate as
necessary to anchor and
fit inside the truck frame
6
4
1
9 Truck Frame
5 5
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Plate must be parallel to truck
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frame or bolt failure will result
9136
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7
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4
er
3
8552-3
FIGURE 9-1
Table 9-1 Item Description

Item Description
12 Washer - 3/8
1 Torsion Box
13 Locknut - 3/8
2 Protector
14 Washer - 1 1/4
3 Bolt - 1 1/4 X 30
4 Washer, Hardened Mount the Outrigger Box
5 Plate, clamp Position the front outriggers on the T-Box and bolt to the
truck frame with the anchor bolts and brackets, Reference
6 Plate, crush
(Figure 9-3).
7 1-1/4 DTI A325 Crush Washer
Position the rear outriggers on the T-Box and bolt to the truck
8 Locknut - 1 1/4 frame with the anchor bolts brackets.
9 Bar NOTE: The front outrigger boxes are integral to the T-box
on cranes where the operators station is mounted
10 Plate - Rear Light
behind the truck cab. 9
11 Bolt - 3/8

ASH TO TORSION BOX MOUNTING
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Torsion Box
(Ref)
Stabilizer Assy
(Ref)
Truck Frame
(Ref)
Tube Assy
(Ref)
Typical Both Sides

Typical Both Sides
Custom BOM for
Appropriate ASH
Spacer Kit (Ref)
FIGURE 9-2

Assemble the Outriggers Before placing reservoir in service, remove cleanout

cover and inspect to ensure proper installation of
4. Assemble the outriggers as shown in the parts manual diffuser.
and connect the hydraulics as per hydraulic schematics.
Connect the solenoids to the outrigger selector switch 2. Connect hoist drain, pump drain, and pump suction to
on the control panel. couplings on reservoir before filling with oil.
Alternate between studs at each corner during the tightening 3. Install the return line from the crane frame to the filter on
process to insure studs are straight and bottom clamp plate the side of the reservoir.
is kept parallel with truck frame. Failure to keep clamp plate NOTE: The weight of suction and return hose and
parallel with truck frame will cause uneven edge loading and plumbing must be supported to prevent damage to
cause premature stud failure. the reservoir. Install support brackets and clamp or
tie hoses up to eliminate strain on reservoir
Hydraulic Reservoir Installation connections.
1. Find a location for and install hydraulic oil reservoir.
Mounting brackets may be bolted to the truck frame.
Torsion Box (Ref)
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(6 Plcs)
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To hoist
Drain
To Return
Manifold
9
To Pump FIGURE 9-3

BOOM INSTALLATION 4. Support outer end of boom securely and use the
overhead hoist to position the lift cylinder with the control
Lift Cylinder Installation valve to pin the cylinder to the boom ears. Torque pin
keeper capscrews to proper torque.
NOTE: Before attempting to assemble the boom and lift
cylinder to the frame, see Pin Bearing Inspection 5. Grease the three pin joints with gun grease and operate
And Installation Procedure, page 9-30. Before the boom and lift cylinder through several complete
connecting hoses, boom must be opposite (180°) cycles before placing machine in operation.
the rotation stop to minimize hose twist. 6. Route the 1/2 inch R12 telescope hoses over the turret
1. Pin lift cylinder barrel in position in the turret. back plate and to the back side of the boom. Connect
the telescope cylinder connections at the back of the
2. Pin boom pivot to turret. (It is necessary to use a lifting boom.
device hoist for lifting boom and lift cylinder.)
7. Route the 3/4 inch R12 hoist hoses and the 1/4 inch R1
3. Connect the 1/2 inch R12 hoses to the lift cylinder. hoist drain hose through the turret then through the
holes in the side of the hoist side plates and connect to
the hoist fittings.
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Boom
Pivot Pin
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Lift Cylinder
Pivot Pin
Lift Cylinder
Pivot Pin FIGURE 9-4
Wire Rope Installation using the wedge socket provided.
1. Unspool approximately 15 feet (8 m) of cable and route 3. Remove the cable keeper T-handle pin from the sheave
the cable through the boom cable guides from the front case and lay the cable over the top sheave. Replace the
of the boom to the hoist. top cable keeper pin.
2. Install one end of the loadline cable into the hoist drum

4. Unspool the remainder of the cable out from the back of 6. Continue winding the cable on the second, third and
the truck being sure the cable is straight and without fourth layer of the drum. Keep the cable paying in
kinks. Attach downhaul weight, wedge socket, hook and straight to the boom to avoid side loading the boom. The
cable clamp to the end of cable as shown in Loadline preceding layers will wrap smoothly guided by the first
Section. Torque cable clamp (clip) to 95 ft-lb (128 N·m). layer wrapping.
This torque must be rechecked after initial operation of
7. After cable is completely wrapped on drum, replace
the crane. Be sure cable clamp is attached to the free
remaining cable keeper bolts on the sheave case. Attach
end of the cable only. If equipped with optional 2/3 part
wedge socket and cable clip to end of cable per
block, omit downhaul weight and assemble as shown in
illustration in Loadline Section of parts manual and
Loadline Section. Special care should be taken to reeve
torque cable clip bolts to 95 ft-lb (128 N·m) for 9/16 inch
the cable through the wedge socket as shown below.
cable.
5. Spool the loadline onto the hoist drum while maintaining
approximately 500 pounds (250 kg) of tension on the Wedge Socket
cable (attaching a small vehicle to the end of the loadline Live
End Dead
with another person lightly riding the vehicle brakes End Dead Live End is
while the cable is spooling on the drum will accomplish End Entering
Wrong Side
this). While the first half of the hoist bare drum is filling, it
will be necessary to force the cable to wrap tightly
against the preceding wrap by pounding the cable
against the preceding wrap with a rubber mallet until at
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least half of the drum is full. The remaining half of the
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drum should wrap tightly because the fleet angle of the 20 x Cable Dia
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cable will tend to pull the cable to the center of the drum
thus wrapping tightly.
Minimum
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RIGHT WRONG
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Terminator Wedge Socket
Torque Value Table

Cable Size (inches) 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4
Torque ft/lbs 45 65 65 95 95 130 225 225 225 360
Torque values shown are based upon clean dry threads free of lubrication.
9
Hoist to Truck Cab Clearance stacks or air horns may interfere with the hoist mount when
the boom is elevated and rotated. Shorten exhaust stacks or
Check for hoist mount tail swing clearance at top of cab. Any move air horns, etc. to ensure clearance.
equipment that extends above the truck cab such as exhaust

Painting counterbored depth by tapping lightly with a rubber

mallet. The head diameter of the mallet should exceed
If crane is to be repainted, mask all decals prior to final paint the outside diameter of the bearing to ensure that the
or install all new decals in accordance with location drawings bearing is not damaged during assembly into the bore.
and illustrated parts catalog over final paint.
3. If the bearing appears to be loose in the bore (if it can be
PIN BEARING INSPECTION AND pushed in with hand pressure alone), it is permissible to
tighten the bearing by center punching the bore
INSTALLATION PROCEDURE diameter in approximately 50 places around and
throughout the 2 inch (51mm) deep bored area. Center
Pin Inspection punching will raise the metal around the edge of the
1. Remove the protective covering from pins and inspect punch mark and this raised metal will hold the bearing
each pin for nicks, gouges or deep wide scratches. A firmly in place during machine operation.
small nick or gouge up to 1/8 inch (3 mm) diameter can 4. After all bearings have been installed and before
be repaired by dressing the edges of the imperfection attempting to assemble the machine, insert the pins
with a file so that no metal protrudes above the circular through both bearings in each end of the lift cylinder and
surface of the pin. through the boom pivot bearings to insure alignment and
2. A circular scratch of up to 1/16 inch (1.5 mm) wide or fit are correct. Also check the two sets of pin holes in the
deep can be repaired as in 1 above. turret and the pin holes in the boom ears to ensure that
the pins will slide freely through the leading hole and
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3. A lengthwise scratch on the pin of up to 1/32 inch start in the opposite hole. If a pin starts to bind through
ef or
(0.8 mm) wide or deep can be repaired as in 1 above. the leading hole, do not force the pin any further to avoid
4.
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Pins with defects larger than those listed in 1, 2 or 3
should be replaced.
damaging the pin surface finish. Remove the pin and
clean any corrosion of burrs out of the holes with a round
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file or emery cloth.
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Bearing Installation 5. When pinning the boom to the turret, and the lift cylinder
1. The bearings furnished with this machine are made up to the turret and boom, use a round smooth bar of
of a tough epoxy impregnated wound glass backing approximately 1-1/2 inch (38 mm) diameter as a pry bar
er
shell with a thin inner layer of filament wound bearing to align the pin holes. A pry bar with a sharp edge, such
material. The outer bearing material should be visually as a crowbar, can gouge or cut bearing and this may
checked for imperfections. Bearings with cracks or lead to premature bearing failure.
gouges larger than 1/4 inch (6 mm) diameter on the
outside diameter should be replaced. COUNTERWEIGHTING
2. Inspect the inner diameter surface of the bearing. Any Refer to Mounting Configuration pages in this section. The
scratches, cut or gouges which have penetrated through amount of counterweight and its location is dependent upon
the inner liner may cause premature failure of the the stability working area (180° x behind the truck or 360° x
bearing. The bearing should be replaced. around the truck), the weight of the truck and all permanently
attached equipment. Permanently attached equipment which
Trunnion Inspection can be considered as counterweight includes the bed,
reinforcing, PTO and pumps, tool boxes, etc. The torsion
The trunnion bore should either have a machined step or resisting subbase and rear stabilizers are considered part of
have a spring spacer installed to prevent inward movement this crane and not part of the counterweight. Additional
of the bearing. If equipped with a spring spacer, check to counterweight is usually added to the underside of the bed
make sure the opening is positioned over the grease hole. and/or to the torsion resisting subbase. On some trucks, a
heavy front bumper may also be required for stability around
Bearing Inspection the rear.
1. Two bearings are to be installed in the boom pivot The 85% tipping factor as outlined in OSHA and ANSI
trunnion located directly below the hoist and the specifications means that when lifting the full capacity loads
remaining four bearings are to be installed in the lift most likely to cause the truck (with outriggers and stabilizer
cylinder, two at each side of the rod end of the cylinder set) to overturn, the unit is at 85% of tipping over. Increasing
and two at each side of the butt end of the cylinder. this full capacity load by 117.6% (overloading) will cause the
2. The bearings should be started in their respective bores unit to tip over.
by rotating the bearing while applying inward pressure In order to determine the amount of counterweight required,
with the hand. Once the bearing has been started it is necessary to add up the weight that each permanently
squarely into its bore, it can be driven to its full

attached piece of equipment will place on the front and rear the weights listed on the “Mounting Configuration”
axles of the truck along with the initial truck chassis weight (Installation Section) pages to determine the amount and
and then compare the total front and rear axle weights with location of counterweight required.
Counterweighting Determination Example

A typical truck is shown below with all the permanently attached equipment also shown. A series 690E crane will be
mounted on this truck and a 180° stability working area around the rear of the truck is desired as in “Configuration 1” See
“Mounting Configuration” in Installation Section.
68 in 52 in
(172 cm) (132 cm)
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0 in 232 in
248 in
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7500 lb (3402 kg)
Initial Chassis
60 in
(152 cm)
(589 cm)
8800 lb (3992 kg)

(630 cm)
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Weight Initial Chassis 1200 lb (544 kg)
150 lb (68 kg)
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Weight Bed Weight

Pump and PTO Weight
(Wt) x (Dist from Front Axle)

= Rear Axle Wt Wt - Rear Axle Wt = Front Axle Wt
er
Wheel Base
Rear Front
Rear Axle Weight Front Axle Weight
Initial Front Axle Weight
(7500) x 0 (3402) x 0
= 0 lb = 0 kg 7500 - 0 = 7500 lb 3402 - 0 = 3402 kg
232 589
(150) x 60 (68) x 152
Pump and PTO Weight = 39 lb = 18 kg
232 589 150 - 39 = 111 lb 68 - 18 = 50 kg
(8800) x 232 (3922) x 589

Initial Rear Axle Weight = 8800 lb = 3922 kg 8800 - 8800 = 0 lb 3922 - 3922 = 0 kg
232 589
(1200) x 248
Bed Weight = 1283 lb (544) x 630 = 582 kg 1200 - 1283 = -83 lb 544 - 582 = -38 kg
232 589
Add the front and rear axle 10122 lb 4592 kg 7528 lb 3414 kg
weights
Compare with weight required
for this type of mount from
Mounting Configuration 1 10500 lb 4763 kg 8000 lb 3629 kg
Difference 378 lb 171 kg 472 lb 215 kg 9
Counterweighting Methods b. concrete in the bed only.
Two methods of counterweighting may be used: The easiest and most economical method is usually
concrete in bed only. The amount of counterweight required
a. a heavy front bumper and concrete in the bed or

will be 1132 + 918 = 2050 pounds (513 + 417 = 930 kg). Use counterweight to determine where the weight acts. If the
2350 pounds (1066 kg) of concrete poured in the front of the counterweight is oddly shaped, figure the center and weight
bed. See “Counterweighting for 180° Stability” in this section of each regular shape. Weights ahead of the front axle
require using a negative (-) distance in calculations.
Determine axle weights added by the counterweight by using
the same method as used before. Figure the center of the
68 in 52 in
(172 cm) (132 cm)
35 in
(88.9 cm)
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155 in (393.7 cm) 232 in (589.2 cm)
1500 lb (680 kg)
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0 in Concrete
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(1500) x 155 (1500) - 1002 = 498 lb

= 1002 lb
232
1150 lb (520 kg) Bed Concrete
(680) x 394 (680) - 455 = 255 kg
= 455 kg
589
378 lb 472 lb
Required Counterweight
171 kg 215 kg
Difference 624 lb 26 lb
283 kg 12 kg
The rear axle weight is 624 lbs (283 kg) heavier than required and the front axle weight is 26 lbs (12 kg) heavier than required.
Check the final weight of the unit with crane installed. See ASH stabilizers [830 pounds (377 kg)]. Use 4” set back (Cab
“Specifications Section” for weight of 571E2 and center of to Torsion Box).
gravity. Note that this weight does not include weight of rear

Check the final unit weight with a full load of diesel (7.3 lbs After the unit is completely assembled, the stability test must
per gal) (0.87 kg per liter) and men (200 lbs per man) (90 kg be run in accordance with the Stability Test Procedure at the
per man) to ensure that the axle ratings have not been end of this section to verify crane stability.
exceeded so that DOT certifications requirements can be
met.
83 in
(210.8 cm)
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68 in
232 in
(173 cm)
R F
(589 cm)
25 in
289 in (734 cm)
0 in (63.5 cm)
176 in (447 cm) 800 lb (363 kg)
er
17300 lb (7847 kg) Rear Stabilizer Wt
690E Crane Wt
10122 lb 7528 lb
Base Unit
4592 kg 3414 kg
1002 lb 498 lb
Counterweight
498 kg 225 kg
(17300) x 176
= 13124 lb (17300) - 13124 = 4176 lb
232
Add Crane Weight
(7847) x 371
= 5953 kg (7847) - 5953 = 1894 kg
589
(800) x 289 (800) - 997 = -197 lb

= 997 lb
232
Rear Stabilizer Weight
(363) x 734 (363) - 452 = -89 kg
= 452 kg
589
25245 lb
9
Total 12005 lb
11451 kg 5445 kg

Counterweighting Methods for Stability Around the Rear 180°
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NOTE: Note: Shaded areas indicate concrete

The method shown below can be used to shift more weight Example
to the front of the crane than the previous methods. When
using this method, check for interference with hydraulic Concrete poured in the bed measures:
reservoir and truck tires. Bed attachment to truck should be • 4 inches (10.16 cm) deep
planned in advance. If the bed is attached to the torsion box
by bolting through the slots in torsion box, leave an open • 86 inches (218.44 cm) wide
area in concrete counterweight for hardware access. The • 70 inches (177.80 cm) long.
weight of the concrete can be determined by multiplying the
volume in cubic inches by 0.083 lb per cubic inch. The weight of the concrete is 4 x 86 x 70 x0.083 = 2000 lb.
(907 kg). The center of this weight is in the center of the
concrete slab.
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8 in (20.3 cm)
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44 in
111.8 cm)

BOOM REST REQUIREMENTS tie down point low enough to allow room for anti-two block
weight. Do not shorten chain.
Before the mounting of a crane is complete, a boom rest
must be installed. A rest must be supplied for transport to The boom rest should be positioned to support the 1 st
reduce vibratory stress on the crane and truck and protect section boom. Be careful to avoid contacting the boom at or
rotation system from transient damage. near the end where the retract cables are located. Contact
with these cables will result in costly repairs.
Below are shown typical configuration designed to meet
boom support requirements. These Boom Rests are The boom rest saddle provided is designed to support the 1st
available at your National Crane distributor. section boom. It will be necessary to modify the saddle to
make it narrower and reposition the support cushions under
The loadline shall be hooked to some point on the bed, truck the boom side plates if the boom is extended to reach the
frame, etc. to secure the hook weight during transport. Install boom rest.
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Horizontal or Removable Mount
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for Greater Load Space.

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Bed Box

CAN BUS SYSTEM SETUP Table 9-2 Required Equipment (Continued)
Before the engine is started from the crane for the first time, Item Example
the CAN bus system must be set up. The following
information must be entered to initialize the CAN bus
system:
• Select the make of the truck engine.
CAN to USB Adapter
• Calibrate the throttle pedals. Cable
The throttle pedals also must be calibrated if a pedal is

replaced.
Use one of the following methods to initialize the CAN bus 9830
system:
• CAN bus system software. See CAN Bus System using
Software, page 9-37.
• Programming button method. CAN Bus System using Software Key
Programming Button, page 9-38.
Required Equipment
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9835
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NOTE: Only maintenance personnel who have attended
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the New Technology training course can purchase
the software and cable. Contact Manitowoc Crane CAN Bus System using Software
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Care for more information.
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NOTE: Refer to the A-Frame Crane Software Specification

Table 9-2 shows the equipment needed when setting up the and Configuration specification for detailed
CAN bus system using HED software. instructions to calibrate or troubleshoot using the
OMS software.
er
Table 9-2 Required Equipment
Use the following procedures to calibrate the CAN bus
Item Example system using HED software.
Connecting Cables and Adapters

Laptop PC
1. Locate the terminating resistor (1, Figure 9-5) and
Deutsch splitter (2) near the OMS throttle module (3) on
CAN bus system software,
the driver’s side of the crane frame.
such as HED Orchestra
Suite
Diagnostics T-Harness
Cable
9829

8. Turn the crane ignition switch to the RUN position. Do

not start the engine.
Setting Up the CAN Bus System

1. Start the laptop and launch the CAN bus system
software.
3 2. Use the HED software to set EEPROMs for engine type,
throttle calibration, and OMS setup.
1
2 3. Use the software debug feature to verify that the setup is
complete.
4. Disconnect and close the CAN bus system software
application.
5. Disconnect the diagnostic cable from the laptop and
crane. Install the terminating resistor in the splitter.
6. Disengage the PTO.
CAN Bus System using Programming
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Button
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The programming button is located on the driver’s side
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switch.
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9831
FIGURE 9-5
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2. Remove the terminating resistor from the Deutsch CAUTION

splitter (Figure 9-6). Only trained personnel should use the programming
er
button to initialize the CAN bus system. Incorrect setup of
3. Install the terminating resistor in to the diagnostics
the CAN bus system can cause the throttle pedals to be
cable.
inoperable.
4. Connect the diagnostic cable to the splitter.
Refer to the A-Frame Crane Software Specification and
5. Connect the serial port to the CAN to USB adapter
Configuration specification for detailed instructions about
cable.
using the push button method of initializing the CAN bus
6. Connect the USB adapter cable to the laptop. system.
7. Engage the PTO.

3 Connect cable.
OMS
Module
9833
2 Install terminating Remove terminating

1
resistor. resistor from splitter.
Diagnostics Cable CAN to USB Software

Adapter Cable Key
9835
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9836
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Laptop
9832
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5 Connect USB
to laptop.
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diagnostics cable to CAN
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to USB adapter cable. FIGURE 9-6
INITIAL CRANE RUN IN PROCEDURE 6. Upon completion, overall height of crane vehicle
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combination must be measured and posted inside of cab
1. Engage the PTO and run the truck engine at idle to informing driver of overall height.
activate the pump (approximately 600 rpm). Turn the
crane power switch on and operate the crane and
STABILITY CHECK
outriggers though all of their functions at least six (6)
times to purge cylinders of air. Operate the control The chassis weight, before the crane is mounted, is intended
valves slowly with the truck engine at idle and cycle each for use only as a guideline in determining the total weight
cylinder through its complete stroke each time. Check to required for the unit to be stable with an 85% tipping factor
see that movement of outriggers and boom correspond (i.e. when lifting capacity load, the unit is at 85% of tipping or
with direction indicated on switches and levers. Refer to less).
hydraulic or electrical schematic and parts pages to
In order to ensure the stability of the unit with an 85% tipping
correct any problems.
factor, a live load stability test must be performed on each
NOTE: Add oil to reservoir as required to keep air from completed unit. Proceed as follows:
reentering the system.
1. Test the unit for stability on a firm level surface.
2. Set throttle according to engine RPM and PTO ratio to
2. A Series 600E2 crane requires rear stabilizers for
get 2500 RPM pump shaft speed.
stability. With the boom stowed, set the unit up level on
3. When all cylinders have operated through complete the outriggers and stabilizers.
cycles, stow crane and place the outriggers in the up
3. For stability testing this unit use the boom length, radius
position. The oil level should be visible near the top of
and angle from the following table. Then follow the
the sight gauge.
4. Lift and stability test must now be performed on the unit.
instructions to calculate the correct test weight. 9
Hoist and crane tests should be conducted to insure Boom Loaded Loaded
Model
proper performance. Length Angle Radius
5. After testing is completed, the mounting bolts and all 690E2 78' (23.77 m) 39.5° 60' (18.29 m)
cable clamp bolts should be re-torqued to specifications.

The stability test load will be 1.18 times the load chosen from On units not equipped with single front outriggers (SFO),
the load rating area of the capacity chart. tipping from stabilizer support to front wheel support will
occur as the load or boom is swung around the front. Do not
Example: 690E2
attempt to lift rated loads around the front of the truck unless
• Boom Length: 78' (23.77 m) the unit is equipped with a SFO.
• Loaded Radius: 60' (18.29 m) Note: This does not apply to cranes with a rear mount
configuration.
• Load Rating: 2250 lb (1021 kg)
NOTE: Weights of accessories installed on the boom or
• Stability Test Load: 1.18 x 2250 lb (1021 kg) = 2655 lb
loadline (including downhaul weight) must be
(1204 kg) (Includes weights of slings and downhaul
deducted from the calculated load when checking
blocks.)
stability.
Be sure the stability test weight is accurate. A 1% increase in
1. If slight tipping occurs, but load can be kept from coming
stability test weight will mean up to a 10% increase in
in contact with ground by hoisting the load up, unit is
counterweight. Extend the boom to the maximum boom
stable. If not, counterweighting will have to be added to
length and hoist the stability load off the ground. Slowly
get unit in a stable condition or decal must be added to
boom the load down so the load will swing out, until the
define areas of full stability and areas of reduced
loaded radius is reached. As the boom is lowered keep
capacity because of stability. If the unit is equipped with
hoisting the load up to keep it about 6 inches off the ground.
a jib, the stability test should be repeated. Use the fully
extended jib capacity multiplied times 1.18 at the lowest
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Do not exceed loaded radius angle that the jib is rated fully extended.
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Slowly rotate the boom throughout the work area. As the
boom is rotated, the boom will have to be raised and/or
2. When adding counterweight to the vehicle, it is usually
most effective when added as close to the crane as
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lowered to maintain the loaded radius because of subbase possible. After adding counterweight, the above
flexure.
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procedure must be repeated to insure the added

counterweight is adequate.
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SPECIFICATIONS
Hydraulic Pump
Pump Speed.......................................................................... 2500 RPM
Displacements:
Section P1..................................................................... 18 GPM (68.1 LPM) at 3900 psi +100/-000 (26.89 MPa)
Section P2 .................................................................... 34 GPM (128.7 LPM) at 3300 psi +100/-000 (22.75
MPa)
Section P3..................................................................... 10 GPM (37.8 LPM) at 2350 psi +100/-000 (16.20 MPa)
Hydraulic System
Requirements:
Boom and Outrigger System ......................................... 18 GPM (68 LPM), 3900 psi +100/-000 (26.89 MPa)
Boom Extend ................................................................ 18 GPM (68 LPM), 2800 psi +50/50 (19.31 MPa)
Boom Retract ................................................................ 18 GPM (68 LPM), 2900 psi +100/-000 (20.00 MPa)
Hoist System ................................................................. 34 GPM (129 LPM), 3300 psi +100/-000 (22.75 MPa)
Turn............................................................................... 10 GPM (37.8 LPM), 2350 psi +100/-000 (16.20 MPa)
Reservoir
Capacity ........................................................................ 66 Gallons (250 L)
Filtration ........................................................................ 10 Micron Return
Flow rates listed are at free flow condition (approx. 100 psi/ 1 MPa)
HCA
Load charts are based on 2650 psi (18.27 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 Breaking Strength ............. 38,500 lb (17,463 kg)
Hoist Speed and Pull

Hoist Pull Hoist Speed BOS Hoist Speed Rope Capacity
Layer
lbs (kg) fpm (mpm) fpm (mpm) ft (m)
1 10,200 (4527) 111 (34) 157 (48) 64 19
2 9,200 (4173) 123 (38) 173 (53) 136 41
3 8,400 (3810) 135 (41) 190 (58) 215 65
4 7,700 (3493) 147 (45) 207 (63) 301 91
5 7,100 (3221) 159 (49) 224 (68) 394 120
NOTE: All ratings based on 34 GPM at 3300 psi (128.7 LPM at 22.75 MPa)
Burst of Speed maximum pull = 3000 lb (1361 kg)
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Crane Operating Speeds
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Rotation 375°......................................................................... 35 ± 5 sec (1.8 ± 0.2 rpm) Swing speed based on and
adjustment knob in closed position.
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Boom up -10° to 80° .............................................................. 25 ± 5 sec
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Boom Down 80° to -10° ......................................................... 20 sec ± 5 sec

Boom Extend/Retract Three Section 16 - 38 ft
Extend (60° elevation) ................................................... 25 ± 5 sec
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Retract (60° elevation)................................................... 25 ± 5 sec, 53 fpm (16.1 mpm)
Extend (60° elevation) .................................................. 45 ± 5 sec
Retract (60° elevation)................................................... 75 ± 5 sec
Boom Extend/Retract Four Section 24 - 80 ft
Extend (60° elevation) ................................................... 75 ± 10 sec
Boom Extend/Retract Four Section 27 - 90 ft

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600E2 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.
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10
SCHEMATICS 600E2 SERVICE MANUAL
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600E2 SERVICE MANUAL ALPHABETICAL INDEX
Alphabetical Index
1/2 Stage Anti-two Block Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

2/3/4 Stage Anti-two Block Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
After Frame Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Anti-two Block Internal Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Anti-two block Internal Wire System: Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Anti-two Block System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ASH to Torsion Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Rest Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Cable Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
CAN BUS System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Carwell© Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Configuration 1 - 600E2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
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Configuration 2 - 600E2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
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Configuration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
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Configuration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Configuration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
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Control Valve Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
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Counterweighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Crane Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Crane to Truck Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
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Disassembly Of 1/2 Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Extend Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Fasteners and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Four Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Four Section Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Four Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Four Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Four Section Top/bottom Pad Replacement Assembled Boom . . . . . . . . . . . . . . . . . . 4-14
General Adjustment and Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
HCA Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hoist Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hoist Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Hoist Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hydraulic System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Initial Crane Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Inner Wear Pad Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
National Crane APL-1

ALPHABETICAL INDEX SERVICE MANUAL 600E2
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

JIB Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Minimum truck Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Mounting Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Outrigger Monitoring System (OMS) (Optional—Standard in North America) . . . . . . . 3-17
Pin Bearing Inspection And Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Positioning Crane On Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
PTO Horsepower Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Radio Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Reinforcing/after Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Replacement Of Proportioning Cable For 1/2 Stage Of Anti-two Block Wire . . . . . . . . 3-12
Requirements For Optional Single Front Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Rotation Stop-mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
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Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
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Servicing the Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
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Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Stability Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
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Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
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Three Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Three Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Torquing Swing Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
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Tractor Trailer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Truck Frame Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Truck Frame Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
APL-2
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National Crane 600E-2

© 2019 Grove U.S. L.L.C.

Batteries, battery posts, terminals, and

The original language of this publication is English.

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

National Crane TOC-1

SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System

JIB Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

nl c 4- Section Boom w/ 2 Stage Cylinder Cable Positioning . . . . . . . . . . . . . . . . . . . . . . . 4-17

Cable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

National Crane TOC-3

Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Installation

TM Rear Stow - 647E2, 638E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

After Frame Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

National Crane TOC-5

Initial Crane Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39

Boom Extension and Retraction Cables . . . . . . . 1-23

GENERAL Constant improvement and engineering progress makes it

National Crane Published 05-14-2019 Control # 114-09 1-1

Whenever a question arises regarding your National Crane New Owner

600E2 Series Major Components

Item Component Item Component

GENERAL MAINTENANCE • Conduct checks in a logical order to determine the

1-2 Published 05-14-2019 Control # 114-09

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Heating Bearings Valves and Manifolds

• Climate zones A and C with high ambient temperatures

! DANGER Sealing Elements

Visual Inspection Hydraulic Lines

1-4 Published 05-14-2019 Control # 114-09

CAUTION Visually inspect all electrical harnesses, cables, and

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Climate Zone Classification

FATIGUE OF WELDED STRUCTURES

1-6 Published 05-14-2019 Control # 114-09

known high stress areas and should be inspected as part of

Application of Medium Strength Loctite® FASTENERS AND TORQUE VALUES

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hard to get at areas, ensure torque readings are

SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8

Socket Head Socket Head Serrated

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5 6.6 6.4 6.2

8 164.8 160.7 156.6

5 7.5 7.3 7.1

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5 15.0 14.6 14.2

5 367.7 358.5 349.3

1-10 Published 05-14-2019 Control # 114-09

12.9 191.5 186.7 181.9

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nl c 12.9 80.4 78.4 76.4

M10x1.25 10.9 62.0 60.4 58.9

1-12 Published 05-14-2019 Control # 114-09

12.9 1585.6 1546.0 1506.3

National Crane Published 05-14-2019 Control # 114-09 1-13