National Crane 600H User manual

Service Manual
National Crane 600H
REFERENCE ONLY

The original language of this publication is English.
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.
• Do not idle the engine except as
necessary.
For more information, go to
www.P65warnings.ca.gov/diesel
Batteries, battery posts, terminals, and
related accessories can expose you to
chemicals, including lead and lead
compounds, which are known to the State of
California to cause cancer and birth defects or
other reproductive harm. Wash hands after
handling. For more information, go to
www.P65warnings.ca.gov
California Spark Arrestor
Operation of this 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.
REFERENCE ONLY

1565 Buchanan Trail East PO Box 21
Shady Grove, PA 17256-0021 T
717 597 8121 F 717 593 5999
www.manitowoc.com
CHANGE OF OWNERSHIP FORM
Constant improvements, engineering progress or manufacturing information may arise after this crane has
been in the field for several years that will make it necessary for us to contact future owners of this machine.
It is important to you that Manitowoc Crane have up-to-date records of the current owners of the crane
should the need arise for us to contact you. Manitowoc Crane is interested in safe efficient operation of its
cranes for their lifetime. Therefore, if you are the second, third, or subsequent owner of this crane, please fill
out the form below relating the new owner, model of crane and crane serial number information and e-mail
or send to the below address.
PREVIOUS COMPANY NAME:
CURRENT COMPANY NAME:
CONTACT NAME:
ADDRESS:
CITY/STATE: _POSTAL CODE:
TELEPHONE NUMBER:
EMAIL ADDRESS:
DATE PURCHASED CRANE MODEL _CRANE SERIAL NUMBER
Please e-mail to: [e-mail] or visit
https://www.manitowoc.com/support/change-ownership
REFERENCE ONLY

CHANGE OF OWNERSHIP REGISTRATION
Product Support strives to maintain up-to-date contact information for crane owners so that we
can readily communicate information about improvements and/or engineering developments for
cranes that have been in the field for several years.
Product Support is pleased to announce that we have developed a QR code to allow the customer
to register their crane remotely or re-register their crane if it was purchased used.
To register your crane scan the QR code below or visit https://www.manitowoc.com/warranty-
registration-form to register your crane.
REFERENCE ONLY

SERVICE MANUAL
This manual has been prepared for and is considered part of the
600H
This Manual is divided into the following sections:
SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
SECTION 3 SECTION CONTENTS
SECTION 4 BOOM
SECTION 5 HOIST
SECTION 6 SWING
SECTION 7 OUTRIGGERS
SECTION 8 LUBRICATION
SECTION 9 CRANE INSTALLATION
SECTION 10 SCHEMATICS
NOTICE
The crane serial number is the only method your distributor or the factory has of providing you with correct parts
and service information.
The crane serial number is identified on the builder’s decal attached to the right side of the turret. Always furnish
crane serial number when ordering parts or communicating service problems with your distributor or the factory.
An untrained operator subjects himself and others to death or
serious injury. Do not 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
load charts, your employer’s work rules, and applicable government
regulations.
•You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
•The Operator Manual and Load Chart are in the holder provided on
crane.
DANGER
!
© 2022 Grove U.S. L.L.C.
Revised 08-19-2022 Control # 092-13
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TOC-1
600H TABLE OF CONTENTS
T
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TABLE OF CONTENTS
SECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
New Owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fatigue Of Welded Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Loctite®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Using Torque Wrench Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Precautions and Recommendations During Inspection . . . . . . . . . . . . . . . . . . . . . 1-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Wire Rope Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Care of Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Boom Extension and Retraction Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Wire Rope Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
SECTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System
Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General Adjustment And Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Draining and Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Removing Air from the Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Label Parts when Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Welding Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Reservoir, Filter, and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Oil Cooler Service & Maintenance (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Servicing the Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Disassembly and Reassembly of Control Valves to Replace Seals. . . . . . . . . . . . . 2-9
Replacing Spool Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Control Valve Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Hydraulic System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Jib Jack Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Systematic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
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TABLE OF CONTENTS 600H
TOC-2
SECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System
Electrical System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Jump Starting Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Charging the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Dielectric Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Connector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
RCL System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Anti-two Block System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Outrigger Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Troubleshooting, Repair and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Danger Remote Start Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Radio Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Electrical Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Emergency Stop Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Quick Test for Receiver Antenna and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Boom Disassembly Alternative #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Additional Maintenance, Disassembled Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Three Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Four Section Boom Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Internal Cable Sheave Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Four Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Four Section Boom Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Four Section Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
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TOC-3
600H TABLE OF CONTENTS
T
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Boom Disassembly Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Four Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Four Section Top/bottom Pad Replacement Assembled Boom . . . . . . . . . . . . . . . . . . 4-15
Top Rear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Front Bottom Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Cable Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Tensioning Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Cable Tension Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
5 - Section Boom w/ 2 Stage Cylinder Cable Positioning. . . . . . . . . . . . . . . . . . . . 4-18
4- Section Boom w/ 2 Stage Cylinder Cable Positioning . . . . . . . . . . . . . . . . . . . . 4-19
4- Section Boom w/ 1 Stage Cylinder Cable Positioning . . . . . . . . . . . . . . . . . . . . 4-21
3- Section Boom w/ 1 Stage Cylinder Cable Positioning . . . . . . . . . . . . . . . . . . . . 4-22
Cable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Telescope Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Telescope Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Telescope Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Changing Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Five Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Six Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Sixth Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
5TH, 4TH, 3TH, and 2ND Section Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Telescope Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
3RD-2ND-1ST Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Sync Cable Top Anchor Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Sync Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist
Hoist Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
SECTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing
Swing Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Disassembly & Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tulsa Swing Drive Assembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Rotation Stop-mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Rotation Stop Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Torquing Swing Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
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TABLE OF CONTENTS 600H
TOC-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Bearing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Slew Potentiometer Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
SECTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outriggers
Bolt-On Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
integral Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Rear Outriggers (RSOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
RSOD Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
RSOD Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
RSOD Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
600H-TM Outrigger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Wear Pad Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Outrigger Beam Wear Pad Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Outrigger Box Wear Pad Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Nonadjustable Wear Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
600H-TM Rear Jacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
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TOC-5
600H TABLE OF CONTENTS
T
O
C
GROVE
SECTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Arctic Lubricants and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Chassis Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Extreme Pressure Multipurpose Gear Lubricant (EPGL) . . . . . . . . . . . . . . . . . . . . . 8-2
Open Gear Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Low Temperature Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Antifreeze/Coolant (for Cab Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Anti-wear Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Standard Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Arctic Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Hydraulic Oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Boom Lubrication Inner Wear Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Boom Lubrication Side and Bottom Wear Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Outrigger Beam Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Hoist Brake Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Hoist Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Swing Gearbox and Brake Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Wire Rope Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Carwell© Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Protecting Cranes From Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
SECTION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crane Installation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Minimum Truck Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
PTO Horsepower Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Direct Mount Pump to PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Truck Frame Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Channel (Table A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Channel Reinforcement (Table A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Angle Reinforcement (Table B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Fish Plate Reinforcement (Table C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Angle Under Reinforcement (Table D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13
Requirements For Optional Single Front Outrigger (SFO) . . . . . . . . . . . . . . . . . . . . . . 9-14
Truck Frame Section Modulus Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Welding Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Positioning Crane On Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
PTO Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Reinforcing/after Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
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TABLE OF CONTENTS 600H
TOC-6
After Frame Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Mounting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Set the T-Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Mount the Turret and Torsion Box to the Frame Assembly. . . . . . . . . . . . . . . . . . 9-23
Turret Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Torsion Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Mounting the 684TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Mount the Outrigger Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Assemble the Outriggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Attach the RSOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Install the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Mount the Operator Platforms and Install the Foot Throttles. . . . . . . . . . . . . . . . . 9-34
Install the Boom, Lift Cylinder, and Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Connect the Slew Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Connect the Electrical Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
CAN Bus System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
CAN Bus System using Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
CAN Bus System using Programming Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Initial Crane Run In Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
RCL Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Stability Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Hoist Speed and Pull. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Crane Operating Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
SECTION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematics
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NATIONAL CRANE 08-19-2022 Control # 092-13 1-1
600H SERVICE MANUAL INTRODUCTION
1
SECTION 1
INTRODUCTION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information. . . . . . . . . . . . . . . . . . . 1-1
New Owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removal and Installation . . . . . . . . . . . . . . . . . . . 1-4
Disassembly and Assembly . . . . . . . . . . . . . . . . . 1-4
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fatigue Of Welded Structures. . . . . . . . . . . . . . . . 1-7
Loctite®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fasteners and Torque Values . . . . . . . . . . . . . . . . 1-7
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Using Torque Wrench Extensions. . . . . . . . . . . . 1-19
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Keeping Records. . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Environmental Conditions . . . . . . . . . . . . . . . . . . 1-21
Dynamic Shock Loads. . . . . . . . . . . . . . . . . . . . . 1-21
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Precautions and Recommendations During
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Wire Rope Replacement . . . . . . . . . . . . . . . . . . . 1-22
Care of Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . 1-23
Boom Extension and Retraction Cables . . . . . . . 1-23
Wire Rope Replacement (All Wire Rope) . . . . . . 1-24
Seizing Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . 1-24
GENERAL
This manual has been compiled to assist you in properly
operating and maintaining your Model 600H series National
Crane (Behind the Cab and Rear Mount).
Before placing the crane in service, all operators and
persons working around the crane must thoroughly read and
understand the contents of this manual pertaining to Safety,
Operation and Maintenance. Before moving a vehicle
equipped with the crane, information relating to transporting
the vehicle must be read and observed.
This manual must be retained with the machine for use by
subsequent operating personnel.
Information in this manual does not replace federal, state or
local regulations, safety codes or insurance requirements.
The 600H has been designed for maximum performance
with minimum maintenance. With proper care, years of
trouble-free service can be expected.
Constant improvement and engineering progress makes it
necessary that we reserve the right to make specification
and equipment changes without notice.
National Crane and our Distributor Network want to ensure
your satisfaction with our products and customer support.
Your local distributor is the best equipped and most
knowledgeable to assist you for parts, service, and warranty
issues. They have the facilities, parts, factory trained
personnel, and the information to assist you in a timely
manner. We request that you first contact them for
assistance. If you feel you need factory assistance, please
ask the distributor’s service management to coordinate the
contact on your behalf.
Supplemental Information
Supplemental Information regarding Safety & Operation,
Specifications, Service & Maintenance, Installation, and
parts for options such as remote controls, augers, varying
control configurations, baskets, grapples, etc. are included in
separate manuals.
Whenever a question arises regarding your National Crane
product or this publication, please consult your National
Crane distributor for the latest information. Your National
Crane distributor is equipped with the proper tools,
necessary parts, and trained personnel to properly maintain
and service your equipment.
A Safety Compact Disc or a USB flashdrive which includes
sections on Operation, Service and a Safety Video for
National Crane operators and owners is supplied when the
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INTRODUCTION 600H SERVICE MANUAL
1-2 08-19-2022 Control # 092-13
equipment is purchased new. Additional copies are available
from your local distributor.
New Owner
If you are the new owner of a National crane, please register
it with National Product Support so we have the ability to
contact you if the need arises.
Go to https://www.manitowoccranes.com/en/
Parts_Services/ServiceAndSupport/
ChangeOfOwnershipForm and complete the form.
Basic Nomenclature
The nomenclature used to describe parts of a National Crane
are described in Figure 1-1 and Figure 1-2. This
nomenclature is used throughout this manual.
FIGURE 1-1
15
See Figure 1-2 for item number identification.
29
30
2
14
600H-BC
17
45
9
6
8
20
24
25
23
17
27
12
13
22
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NATIONAL CRANE 08-19-2022 Control # 092-13 1-3
600H SERVICE MANUAL INTRODUCTION
1
16 5
Item Component
1 Operator’s Console
2 Operators Station
3 Rated Capacity Limiter (RCL) Reel
4 Boom
5 Boom Nose
6 Boom Rest
7 Lift Cylinder
8 Downhaul Weight, Hook Block
9 Hoist
11 Outrigger Beam
12 Outrigger Jack
13 Outrigger Float
14 Outrigger Box
15 Hoist Cable, Wire Rope
16 Jib
17 Turret
18 Jack Front Outrigger (SFO), Front Outrigger Jack
20 Hydraulic Tank
21 RCL Panel
22 BoomAngle Indicator
23 Truck Frame
24 Truck Bed
25 Torsion Box, T-Box
26 Sheave
27 Crane Frame
28 Bubble Level
29 Outrigger Stop Pin
30 Rear Outrigger Out and Down (RSOD)
Item Component
1
2
27
25
7
24
14
6
11
12
13
5
26
18
8
3
23
4
59
15
17
22
20
121
28
17
11
29
14
FIGURE 1-2
600H-RM
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INTRODUCTION 600H SERVICE MANUAL
1-4 08-19-2022 Control # 092-13
GENERAL MAINTENANCE
The suggestions listed below are helpful in analyzing and
correcting problems:
•Determine the problem.
•List possible causes.
•Devise checks.
•Conduct checks in a logical order to determine the
cause.
•Consider the remaining service life of components
against the cost of parts and labor to replace them.
•Make the repair.
•Test the equipment to ensure the problem is fixed.
NOTE: Safety is the number one consideration when
working around machines. Safety is a matter of
understanding the job to be done and the application
of good common sense. It is not just a list of do’s and
don’ts. Stay clear of all moving parts.
Cleanliness
Cleanliness is important in preserving the life of the machine.
Keep dirt out of working parts and compartments. Keep
filters and seals clean. Whenever hydraulic, fuel, lubricating
oil lines, or air lines are disconnected, clean the adjacent
area as well as the point of disconnect. Cap and plug each
line or opening to prevent entry of foreign material.
Clean and inspect all parts. Be sure all passages and holes
are open. Cover all parts to keep them clean. Be sure parts
are clean when they are installed. Leave new parts in their
containers until ready for assembly. Clean the rust
preventive compound from all machined surfaces of new
parts before installing them.
Removal and Installation
Do not attempt to manually lift heavy parts that require
hoisting equipment. Do not put heavy parts in an unstable
position.
When raising a portion or a complete crane, ensure the
weight is supported by blocks rather than by lifting
equipment.
When using hoisting equipment, follow the hoist
manufacturers recommendations. Use lifting devices that
achieve the proper balance of the assemblies being lifted.
Unless otherwise specified, use an adjustable lifting
attachment for all removals requiring hoisting equipment.
Some removals require the use of lifting fixtures to obtain
proper balance.
All supporting members (chains and cables) need to be
parallel to each other and as near perpendicular as possible
to the top of the object being lifted.
If a part resists removal, check to be sure all nuts and bolts
have been removed and that an adjacent part is not
interfering.
Disassembly and Assembly
Complete each step in turn when disassembling and
assembling a component. Do not partially assemble one part
and start assembling some other part. Make all adjustments
as recommended. Always check the job after it is complete
to see that nothing has been overlooked. Recheck the
various adjustments by operating the machine before
returning it to the job.
Pressing Parts
When one part is pressed into another, use an anti-seize
compound or a molybdenum disulfide base compound to
lubricate the mating surfaces.
Assemble tapered parts dry. Before assembling parts with
tapered splines, be sure the splines are clean, dry, and free
from burrs. Position the parts together by hand to mesh the
splines before applying pressure.
Parts which are fitted together with tapered splines are
always very tight. If they are not tight, inspect the tapered
splines and discard the part if the splines are worn.
Locks
Lock washers, flat metal locks, or cotter pins are used to lock
nuts and bolts. For flat metal locks, bend one end of the lock
around the edge of the part and the other end against one
flat surface of the nut or bolt head.
Always use new locking devices on components which have
moving parts.
Use a steel flat washer between aluminum housings and
lock washers.
Shims
When shims are removed, tie them together and identify
them as to location. Keep shims clean and flat until they are
reinstalled.
CAUTION
The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
becomes less than 90°. Eyebolts and brackets should
never be bent and should only have stress in tension.
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NATIONAL CRANE 08-19-2022 Control # 092-13 1-5
600H SERVICE MANUAL INTRODUCTION
1
Bearings
Antifriction Bearings
When an antifriction 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
may be dried with compressed air BUT do not spin the
bearing. Discard the bearings if the races and balls or rollers
are pitted, scored, or burned. If the bearing is serviceable,
coat it with oil and wrap it in clean waxed paper. Do not
unwrap new bearings until time of installation. The life of an
antifriction bearing is shortened if not properly lubricated. Dirt
can cause an anitfriction bearing to lock and result in the
shaft turning in the inner race or the outer race turning within
the cage.
Double Row, Tapered Roller
Double row, tapered roller bearings are precision fit during
manufacture and components are not interchangeable. The
cups, cones, and spacers are etched with the same serial
number and letter designator. If no letter designators are
found, wire the components together to assure correct
installation. Reusable bearing components should be
installed in their original positions.
Heating Bearings
Bearings which require expansion for installation should be
heated in oil not to exceed 121 °C (250 °F). When more than
one part is heated to aid in assembly, they must be allowed
to cool and then pressed together again. Parts often
separate as they cool and contract.
Installation
Lubricate new or used bearings before installation. Bearings
that are to be preloaded must have a film of oilover the entire
assembly to obtain accurate preloading. When installing a
bearing, spacer, or washer against a shoulder on a shaft, be
sure the chamfered side is toward the shoulder.
When bearings are pressed into a retainer or bore, apply
pressure to the outer race uniformly. If the bearing is pressed
on the shaft, apply pressure on the inner race uniformly.
Preload
Preload is an initial load placed on the bearing at the time of
assembly. Consult the disassembly and assembly
instructions to determine if the bearing can be preloaded.
Be careful in applying preload to bearings requiring end
clearance. Otherwise, bearing failure may result.
Sleeve Bearings
Do not install sleeve bearings with a hammer. Use a press
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
driver or a bar with a smooth flat end. If a sleeve bearing has
an oil hole, align it with the oil hole in the mating part.
Gaskets
Be sure the holes in the gaskets correspond with the
lubricant passages in the mating parts. If it is necessary to
make gaskets, select material of the proper type and
thickness. Be sure to cut holes in the right places. Blank
gaskets can cause serious damage.
Hydraulic Systems
Visual Inspection
Do a visual inspection daily on all hydraulic components for
missing hose clamps, shields, guards, excessive dirt build
up, and leaks. Do a monthly or 250 hour inspection for the
items listed in the inspection procedure below.
Valves and Manifolds
Inspect valves and manifolds for leaking ports or sections.
Hoses and Fittings
Inspect all hoses and fittings for the following:
•Cut, kinked, crushed, flattened, or twisted hoses.
•Leaking hoses or fittings.
•Cracked, blistered, or hoses charred by heat.
•Damaged or corroded fittings.
•Fitting slippage on hoses.
If any the above conditions exist, evaluate and replace as
necessary.
The climate in which the crane operates affects the service
life of the hydraulic components. The climate zones are
defined in the table on page 1-6. Recommended
replacement of hoses is as follows:
•Climate zone C after 8,000 hours of service.
•Climate zones A and B with high ambient temperatures
and duty cycles after 4000 to 5000 hours of service.
•Climate zones D and E after 4000 to 5000 hours of
service.
Cleanliness
Contaminants in a hydraulic system affects operation and
results in serious damage to the system components.
DANGER
Pressurized hydraulic fluid can cause serious injury.
Depressurize the hydraulic system before loosening
fittings.
!
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INTRODUCTION 600H SERVICE MANUAL
1-6 08-19-2022 Control # 092-13
Keep the System Clean
When removing components of a hydraulic system, cover all
openings on both the component and the crane.
If evidence of foreign particles is found in the hydraulic
system, flush the system.
Disassemble and assemble hydraulic components on a
clean surface.
Clean all metal parts in a nonflammable cleaning fluid. Then
lubricate all components to aid in assembly.
Sealing Elements
Inspect all sealing elements (O-ring, gaskets, etc.) when
disassembling and assembling the hydraulic system
components. Installation of new elements is recommended.
Hydraulic Lines
When disconnecting hoses, tag each one to ensure proper
identification during assembly.
When installing metal tubes, tighten all bolts finger-tight.
Then, in order, tighten the bolts at the rigid end, the
adjustable end, and the mounting brackets.After tubes are
mounted, install the hoses. Connect both ends of the hose
with all bolts finger-tight. Position the hose so it does not rub
the machine or another hose and has a minimum of bending
and twisting. Tighten bolts in both couplings.
Due to manufacturing methods there is a natural curvature to
a hydraulic hose. Reinstall the hose so any bend is with this
curvature.
Electrical
Batteries
Clean the batteries with a solution of baking soda and water.
Rinse with clear water and dry. Clean the battery terminals
with fine sandpaper and coat the terminals dielectric grease.
Do not use a non-dielectric grease.
Remove the batteries If the machine is not used for an
extended period of time. Store the batteries in a warm, dry
place, preferably on wooden shelves. Never store on
concrete.Asmall charge should be introduced periodically to
keep the specific gravity rating at recommended level.
When disconnecting wires, tag each one to ensure proper
identification during reassembly.
Connectors, Harnesses, Wires, and Connectors
Visually inspect all electrical harnesses, cables, and
connectors every month or 250 hours for the following:
•Damaged, cut, blistered, or cracked insulation.
•Exposed bare wires.
•Kinked or crushed wires and cables.
•Cracked or corroded connectors, battery terminals, and
ground connections.
If any the above conditions exist, evaluate and replace as
necessary.
The climate in which the crane operates affects the service
life of the electrical components. The climate zones are
defined in the table on page 1-6. Recommended
replacement of harness and cables is as follows:
•Climate zone C after 10,000 hours of service.
•Climate zones A and B with high ambient temperatures
and duty cycles after 8000 hours of service.
•Climate zones D and E after 10,000 hours of service.
•Salt water conditions after 8,000 hours of service.
.
CAUTION
Disconnect batteries prior to working on the electrical
system.
Climate Zone Classification
Zone Classification
A(Tropical Moist) Latitude 15° - 25° North and South (All months average above 64° F [18° C])
B (Dry orArid) Latitude 20° - 35° North and South (Deficient of precipitation most of the year)
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)
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NATIONAL CRANE 08-19-2022 Control # 092-13 1-7
600H SERVICE MANUAL INTRODUCTION
1
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:
•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.
•Turntable bearing connection (where bearing is welded
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.
Loctite®
Always follow the directions on the Loctite® container, as not
all Loctite® types are suitable for all applications.Various
types of Loctite® are specified throughout the Service
Manual. The following types of Loctite® brand adhesives are
available from the Parts Department of the local National
Crane distributor.
Application of Medium Strength Loctite®
NOTE: The fastener may be re-used; the adhesive may be
re-applied over cured adhesive residue.
The following procedure covers the proper application and
curing method for medium strength Loctite® adhesive/
sealant (Loctite® #243).
NOTE: Ensure the threaded surface, both male and
female, is clean of contaminants and free of dirt
and oil.
1. Apply a bead perpendicular to the thread, several
threads wide, in the approximate area of threaded
engagement (see Figure 1-1).
2. In a blind hole application, a bead of several drops of
adhesive should be applied into the bottom of the hole to
be hydraulically forced up during engagement.
After application and engagement of mated threads, fixturing
will occur within five (5) minutes. Time required to achieve
full strength is 24 hours.
Fasteners and Torque Values
Use bolts of the correct length. Abolt which is too long may
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
to hold the part securely. Threads can be damaged. Inspect
them and replace fasteners, as necessary.
Torque values should correspond to the type bolts, studs,
and nuts being used.
The torque tables are provided by National Crane for
reference when performing maintenance.
Use of proper torque values is extremely important. Improper
torquing 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 torqued
accordingly.
NOTE: Some special applications require variation from
standard torque values. Reference should always
be made to component overhaul procedures for
recommendations.
CAUTION
Skin and/or Eye Hazard!
Loctite® type adhesives contain chemicals that may be
harmful if misused. Read and follow the instructions on
the container.
!
4203
FIGURE 1-3
BeadApplication
BeadApplication
8213-1
8213-2
REFERENCE ONLY

INTRODUCTION 600H SERVICE MANUAL
1-8 08-19-2022 Control # 092-13
Special attention should be given to the existence of
lubricant, plating, or other factors that might require variation
from standard torque values.
The use of lubricants on zinc-flake coated parts shall be
prohibited since this will change the required torque value.
When maximum recommended torque values have been
exceeded, the fastener should be replaced.
Previously installed bolts and nuts of Grade 8 or Class 10.9
and higher may not be reused.
When referring to the applicable torque charts, use values as
close as possible to the torque values shown to allow for
wrench calibration tolerance.
Torque Wrenches
Flexible beam type wrenches, even though they might have
a pre-set feature, must be pulled at right angle and the force
must be applied at the center of the handle. Force value
readings must be made while the tool is in motion. Rigid
handle type, with torque limiting devices that can be pre-set
to required values, eliminate dial readings and provide more
reliable, less variable readings.
NOTE: If multipliers and/or special tools are used to reach
hard to get at areas, ensure torque readings are
accurate.
Torque wrenches are precision instruments and must be
handled with care. To ensure accuracy, calibrations must be
made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
damaged, it should immediately be removed from service
until recalibrated. When using a torque wrench, any erratic or
jerking motion can result in the application of excessive or
improper torque. ALWAYS use a slow, even movement and
STOP when the predetermined value has been reached.
When using step wrenches, calculated wrench settings are
valid only when the following conditions are met:
•Torque wrenches must be those specified and forces
must be applied at the handle grip. The use of handle
extensions will change applied torque to the bolt.
•All handles must be parallel to the step wrench during
final tightening. Multiplier reaction bars may be
misaligned no more than 30 degrees without causing
serious error in torque.
•Multiplier bar handles must be propped or supported
within the outer 1/4 of the handle length, or serious
under or over tightening will occur.
To convert pounds-foot (lb-ft) of torque to newton meters
(Nm), multiply the pounds-foot quantity by 1.3558.
To convert pounds-inch (lb-in) of torque to newton meters
(Nm), multiply the pounds-inch quantity by 0.11298.
Torque Values
The following tables list the torque values for both ASME
standard and metric fasteners. The tables list the values for
grade 5 and grade 8 zinc-flake coated, untreated (black)
finish and stainless steel fasteners.
SAE Grade 1
and Grade 2
HHCS
SAE Grade 5
HHCS SAE Grade 7
HHCS SAE Grade 8
HHCS
Serrated
Flange Head
Socket Head
Shoulder
Screw
Socket Head
Capscrew
FIGURE 1-4
REFERENCE ONLY