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SERVICE MANUAL
This Manual has been prepared for and is considered part of -

600E Telescoping Crane 2

Crane Model Number

This Manual is Divided into the following Sections:

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SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
SECTION 3 ELECTRIC SYSTEM
SECTION 4 BOOM
SECTION 5 WINCH 4
SECTION 6 SWING
SECTION 7 LUBRICATION
SECTION 8 TROUBLESHOOTING
SECTION 9 CRANE INSTALLATION
SECTION 10 OPTIONAL EQUIPMENT
SECTION 11 600E SYSTEM SCHEMATICS 5
NOTICE

The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
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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.

To prevent death or serious injury:

• Avoid unsafe operation and maintenance.
• This crane must be operated and maintained by trained and
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experienced personnel. National Crane is not responsible for
qualifying these personnel.
• Do not operate or work on this crane without first reading and
understanding Operator’s Manual and Rating Plate supplied with
crane.
• If Operator’s Manual or Capacity Charts are missing from crane,
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contact your distributor for new ones.

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© 2006 Manitowoc Crane Group

Revised 02/13/2006 Control # 029-04

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Manitowoc Cranes, Inc.
2401 South 30th Street
Manitowoc, WI 54220
(920) 684-6621
(920) 683-6277 (fax)
http://www.manitowoccranegroup.com/MCG_MC/Home/EN/BrandHome.aspp

Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)
http://www.groveworldwide.com/na/eng/default.htm

National Crane Corporation

1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)
http://www.manitowoccranegroup.com/MCG_NAT/Home/EN/BrandHome.asp

Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)
http://www.manitowoccranegroup.com/mcg_pot_am/home/en/brandhome.asp

Technical Field Parts Factory Training

Publications Service Service
600E TABLE OF CONTENTS

TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Adjustment And Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hydraulic System Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Label Parts When Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pressure Compensator Control ("PA") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pump Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Service Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
New Hydraulic Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Servicing The Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Replacing Spool Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Auxiliary Control Valve (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Oil Cooler Service & Maintenance (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fasteners And Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Torque Values For Grade 5 And 8 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Using Torgue Wrench Extenxions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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

Anti-Two Block Internal Wire System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block Internal Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3 Section Boom ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Special tools or equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Special tools or equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4 Section Boom ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operation: Internal Anti-Two Block Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Disassembly Of 1/2 Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Assembly Of 1/2 Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
2/3/4 Stage Anti-Two-Block Wire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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TABLE OF CONTENTS 600E

Anti-two-block Internal Wire System I 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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
1/2 Stage Anti-Two Block Wire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HCA Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HCA Maintenance & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HCA System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Jib Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Single Character Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Three Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Three Section Cable Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3 Section Boom Disassembly Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3 Section Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Inner Wear Pad Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Four Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Four Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
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 . . . . . . . . . . . . . . . . . . 4-15
Top Rear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Front Bottom Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

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600E TABLE OF CONTENTS

Shim Calculation For Wear Pads (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Single Section Extend Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
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Extend Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Extend Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Multi-Stage Extend Cylinder Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Cylinder disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Replacing Holding Valve on Multi-Stage Extend Cylinder . . . . . . . . . . . . . . . . . . . 4-20
Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winch
Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing
Tulsa Rotation Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Disassembly & Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tulsa Swing Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tulsa Swing Drive Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Comer Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Comer Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Rotation Stop-mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Rotation Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chassis Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Extreme Pressure Multipurpose Gear Lubricant (EPGL). . . . . . . . . . . . . . . . . . . . . . 7-1
Open Gear Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chassis Grease Low Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Coupling Lube Spline Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Anti-wear Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Hydraulic OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Standard Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Wide Range Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Arctic Hydraulic Oil.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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TABLE OF CONTENTS 600E

Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Winch Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Brake Oil Level (for Tulsa Winch only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

SECTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting
Hydraulic System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HCA Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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

Crane to Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
minimum truck requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Mounting Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Jib protection Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Configuration 1 - 600E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Configuration 2 - 600E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Pto Horsepower Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Direct Mount Pump to PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
PTO Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Truck Frame Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Channel (Table A).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Channel Reinforcement (Table A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Angle Reinforcement (Table B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Fish Plate Reinforcement (Table C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Angle Under Reinforcement (Table D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Requirements For Optional Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Truck Frame Section Modulus TableS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Positioning Crane On Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Reinforcing/after Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
After Frame Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Crane to Truck Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Crane Component Installation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Torsion Box and ASH Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Install Torsion Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Hydraulic Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Winch to Truck Cab Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27

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600E TABLE OF CONTENTS

Pin Bearing Inspection And Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27

Pin Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Trunnion Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
1
Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Counterweighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Counterweighting Determination Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Counterweighting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Initial Crane Run in Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Boom Rest Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Stability Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
System Flow and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
HCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Winch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Winch Speed and Pull. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Crane Operating Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

Sections 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Equipment

Radio Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
R 4 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Remote Solenoid Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Flow Control valve in Inlet Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Solenoid Valve Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Pressure Relief Valve (part of solenoid valve) in inlet section. . . . . . . . . . 10- 1
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Receiver Input & Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
R4 Remote System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Connector Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Antenna Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Setup Procedure for the Proportional Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Trouble Shooting , Repair And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Partial or Complete Unit Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Troubleshooting Functional Test of R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

SECTION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Schematics

600E Jib protection Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
600E Hydraulic System Schematic (without R4 remote control) . . . . . . . . . . . . . . . . . . 11-2
600E Electrical Schematic (Without R4 Remote Control) . . . . . . . . . . . . . . . . . . . . . . . 11-3
Electrical Schematic R4 Radio Remote (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Electrical Schematic R4 Radio Remote (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Electrical Schematic R4 Radio Remote (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Electrical Schematic R4 Radio Remote (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Hydraulic System Schematic With R4 Radio Remote . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

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TABLE OF CONTENTS 600E

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1-6
600E INTRODUCTION

SECTION 1
1
INTRODUCTION
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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1-ii
600E INTRODUCTION

SECTION 1
1
INTRODUCTION
GENERAL fa cto ry ass ista nce , ple ase as k t he de ale r’s se rvi ce
management to coordinate the contact on your behalf.
This manual has been compiled to assist you in properly
operating and maintaining your Model 600E Series National Supplemental Information
Crane. Supplemental Information regarding Safety & Operation,
Before placing the crane in to service, all operators and Specifications, Service & Maintenance, Installation, and
persons working around the crane must thoroughly read and parts for options such as remote controls, augers, varying
understand the contents of the Operators Handbook control configurations, baskets, grapples, etc. is included in
pertaining to Safety, Operation and Maintenance. Before separate sections of this manual, if applicable.
moving a vehicle equipped with the crane, information Whenever a question arises regarding your National product
relating to transporting the vehicle must be read and or this publication, please consult your National Dealer for
observed. the latest information. Your National Dealer is equipped with
This manual must be retained with the machine for use by the proper tools, necessary National parts and trained
subsequent operating personnel. service personnel to properly maintain and service your
crane.
Information this manual does not replace federal, state or
local regulations, safety codes or insurance requirements
The National Crane has been designed for maximum
performance with minimum maintenance. With proper care,
years of trouble-free service can be expected. DANGER
Constant improvement and engineering progress makes it Failure to observe all the instructions contained in this
necessary that we reserve the right to make specification manual could result in death or serious injury to the
and equipment changes without notice. operator or bystanders or damage to the equipment.

National Crane and our Dealer Network want to ensure your Safety Information
satisfaction with our products and customer support. Your
local dealer is the best equipped and most knowledgeable to A Safety Compact Disc (CD) which includes sections on
assist you for parts, service and warranty issues. They have Operation, Safety and Maintenance for National Crane
the facilities, parts, factory trained personnel, and the operators and owners is supplied when the crane is
information to assist you in a timely manner. We request that purchased new. Additional copies are available from your
you first contact them for assistance. If you feel you need local distributor.

1-1
INTRODUCTION 600E

1-2
600E HYDRAULIC SYSTEM

SECTION 2
HYDRAULIC SYSTEM
TABLE OF CONTENTS
Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Adjustment And Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hydraulic System Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2
Label Parts When Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pressure Compensator Control ("PA") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Servicing The Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Replacing Spool Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
HCA/LMI Switch Troubleshooting (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
HCA/LMI Switch Troubleshooting (Sheet 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
HCA/LMI Switch Troubleshooting (Sheet 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
HCA/LMI Positioner Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Winch, Lift, and Tele Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ASH Audible Alarm Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Crane Test After Positioner Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Auxiliary Control Valve (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Oil Cooler Service & Maintenance (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Fasteners And Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Torque Values For Grade 5 And 8 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Using Torque Wrench Extinctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

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2-ii
600E SERVICE MANUAL HYDRAULIC SYSTEM

SECTION 2
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DESCRIPTION 1. A warning tag should be placed in a conspicuous place
at the controls stating that the machine requires adjustment
The hydraulic system features a variable displacement or repair before it can be operated.
piston pump providing up to 44 gpm oil flow at a maximum
2. The crane should be placed where it will cause the least
2
pressure of 3800 psi. One eight section Main Valve controls
all standard crane functions. A smaller, optional three section interference with other equipment or operations in the area.
valve is available to control up to three auxiliary functions 3. All controls at the off position and all operating features
such as an auger, etc.. secured from inadvertent motion by brakes or other means.
When the engine is running the Pump Enable Valve is 4. All methods used to start the truck’s engine rendered
activated allowing the pump go to its maximum inoperative.
compensated setting. The maximum pressure for Tele, Turn,
Winch, and Lift Up functions is limited by work port reliefs in 5. Power plant stopped or disconnected at take-off.
the Main Valve. Lift down and Tele retract metering control is 6. Boom lowered to the ground or otherwise secured
accomplished by High ratio (low pressure required to fully against dropping.
open) counterbalance valves and the spool design of the
main valve. 7. Load block lowered to ground or otherwise secured
against dropping.
An adjustable relief valve is built into the inlet section of the
Main Valve. Constant pump pressure results in excellent 8. Relieve hydraulic oil pressure from all hydraulic circuits
multi- function operation regardless of load. before loosening or removing hydraulic components.

Pump output flow is controlled by the demand requirement of After adjustments and repairs have been made, the crane
the selected function(s) up to a maximum of 44 gpm. Main shall not be returned to service until all guards have been
valve spools are designed to both meter the flow and limit the reinstalled, trapped air removed from hydraulic system if
maximum flow to each function. Available oil flow is required, safety devices reactivated, and maintenance
optimized by using "gravity" for Lift down -- no pump flow is equipment and all warning tags removed.
necessary (For auger applications a field kit can be installed Adjustments and repairs shall be done only by designated
to force lift down conventionally.). personnel who are properly trained. Use only National Crane
Anti-two block and crane overload conditions (Lift cylinder supplied parts to repair the crane.
base end pressure indicated on the Load Range Gage)
deactivate the Pump Enable Valve so that the pump is taken Hydraulic System Maintenance Precautions
off stroke and goes to its minimum displacement. If either of Contaminants in a hydraulic system affect operation and will
these conditions occurs: result in serious damage to the system components. Dirty
1. A 100 psi check valve between the pump outlet and the hydraulic systems are a major cause of component failures.
main valve inlet assures that: If evidence of foreign particles is found in the hydraulic
- No oil reaches the main valve system, flush the system.

- And helps to drive the pump to its lowest Disassemble and assemble hydraulic components on a
displacement. clean surface.

2. A 5 psi check valve between the Pump Enable Valve and Clean all metal parts in a nonflammable cleaning fluid. Then
the base end of the Lift cylinder assures that no pressure lubricate all components to aid in assembly.
can back-feed to open the Lift down counterbalance Inspect all sealing elements (O-ring, gaskets, etc.) when
valve. disassembling and assembling the hydraulic system
components. Installation of new sealing elements is always
GENERAL ADJUSTMENT AND REPAIR recommended.
PROCEDURES When installing metal hydraulic tubes, tighten all bolts finger
Before adjustments and repairs are started on a crane, the tight. Then, in order, tighten the bolts at the rigid end, the
following precautions shall be taken as applicable: 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

2-1
HYDRAULIC SYSTEM 600E SERVICE MANUAL

the machine or another hose and has a minimum of bending Hydraulic Filter
and twisting. Tighten bolts in both couplings.
Return oil filtration has been designed to handle the
Due to manufacturing methods, there is a natural curvature maximum system flow and to protect the hydraulic system
to a hydraulic hose. The hose should be installed so any components.
bend is with this curvature.
The filter is mounted on the oil reservoir, and is a replaceable
In case of replacement hoses with angled stem reusable canister type return oil filter. The filter must be serviced with
fittings, the hose curvature must be taken into consideration National Crane replacement elements at recommended
when assembling and positioning the angled stem. intervals to assure the warranty remains in force.

Label Parts When Disassembling

When removing or disconnecting a group of wires or cables, HYDRAULIC PUMP
tag each one to ensure proper identification during re-
assembly.
When shims are removed, tie them together and identify
them as to location. Keep shims clean and flat until they are
reinstalled.

Welding Precautions
Sensitive truck computer system and crane’s jib load limiting
device computer system components may be damaged by
welding on the truck or crane. The following precautions
should be taken:
- Disconnect truck battery cables (positive and
negative)
- Attach welding ground lead as close as possible to
area to be welded.
- Remove the jib from the crane before welding on the
crane or remove the jib sheave case assembly from
Description
the jib before welding on the jib. The P2060 Pump is a variable displacement pump with the
capability of varying the output flow from zero to maximum
HYDRAULIC OIL RESERVOIR displacement. The amount of flow produced is dependent
upon the length of stroke of the pumping pistons and the
speed the pump is driven at. The stroke is determined by the
position of the swash plate. Maximum stroke is achieved at
an angle of l6 degrees. The rotating barrel, driven by the
prime mover, moves the pistons in a circular path and the
piston slippers move against the face of the swash plate.
When the swash plate is in a vertical position, there is no
piston stroke and consequentially, no output flow. When the
swash plate is positioned at an angle, the pistons are forced
in and out of the barrel and fluid displacement takes place.
The greater the angle of the swash plate, the greater the
piston stroke.
The hydraulic oil reservoir has a sight gauge located on the The pump requires a PTO with a torque rating of at least 200
side of the reservoir. This sight gauge has a decal beside it ft-lb (271N . m) or 40 HP (30Kw) per 1000 rpm of PTO shaft
that indicates a “full” level and an “add oil” level. The oil speed. With the PTO driving the pump at 2800 RPM the
required to bring it from the “add” line to the “full” line is 5 hydraulic system is provided with a flow of 44 gpm (200
gallons. Do not fill the reservoir above the “full” line. The oil LPM) and a pressure of 3800 psi.
level should be checked with the crane parked on a level
surface, in the transport condition (all cylinders retracted and All control is achieved by the proper positioning of the swash
boom stowed) and the oil cold. plate. The swash plate position is controlled by a dual acting

2-2
600E SERVICE MANUAL HYDRAULIC SYSTEM

servo piston on one end of the swash plate working against .Hydraulic Pump Installation
the bias spring on the opposite end.
The dual acting piston has a 4:1 ratio, with the small CAUTION
diameter connected to pump outlet pressure and the large An arrow is cast into the rear pump housing to identify
diameter connected to the metered port of the control. rotation. Rotation is viewed form the shaft end of the
pump. Make sure pump is the correct rotation for the PTO
When pressures on both ends of the servo piston are the
being used.
same, the swash plate will move towards zero displacement 2
due to the 4:1 ratio on the dual acting piston. An increase of
pressure, high enough to overcome the 4:1 differential, will 3. If PTO integral mount flanges are to be used, the pump
result in the pump coming on stroke. The metering spools of can be mounted directly to the PTO. Be sure adequate
the pump control vary the pressure on the large area of the clearance exists for this type of pump mount.
servo piston, which results in a certain swashplate position. Sometimes the pump is powered through a drive line
with the pump located no more than 42 inches (107 cm)
Pressure Compensator Control ("PA") from the PTO. The drive line should not exceed a 7°
angle. The drive line U-joint yokes on both ends of the
Pressure compensator control is used to limit the maximum drive shaft must be parallel with each other. Drive lines
system pressure. The control acts such that full pump should be sized so they can safely carry the maximum
displacement is achieved unless the system valve restricts pump horsepower requirements. See "PTO Selection"
the output flow or the load pressure reaches the maximum pages. Drive lines are not normally furnished by the
setting of the control spring. If the pump flow is restricted by factory.
the system valve, the pump will provide only the flow
demanded, but at the maximum pressure setting of the 4. Plan the location of the pump mounting bracket and
compensator control. If the outlet flow is completely blocked, drive line, if used, so that ample clearance is maintained
the pump will destroke to zero displacement and maintain between pump and truck drive shaft or exhaust system.
the pressure at the setting of the compensator spring. Pump should be situated so that hydraulic lines can be
connected without sharp bends especially the large
In the two-spool "PA" control, the bottom spool is the suction line from the reservoir. Pump mounting brackets
pressure compensator control. The top spool is non may be attached to existing frame crossmembers or a 6
functional in the "PA" control, but allows for easy conversion inch (15 cm) channel crossmember can be made and
to a load sense or remote pressure control if desired. installed.
The pressure compensator control spool is biased in one 5. Install pump mounting bracket (driveline driven pumps
direction by an adjustable spring. The pump outlet pressure only) securely to the truck frame. Attach pump to pump
is sensed on the other end and works against the spring to mounting plate or directly to the PTO using capscrews
position the spool. provided.
When the pressure is below the setting of the adjustable a. Install the pump support bar at the rear of the pump
spring, the spool is held in a position that opens the control and bolt or weld the upper end to a crossmember if
port to tank (through the pump case) and the outlet pressure the pump is driven by a driveline.
pushes the swashplate to maximum displacement.
b. For a direct mounted PTO attach to a transmission
The pump will maintain maximum flow up to near the bolt.
pressure setting of the compensator spring. At about 5 bar
(75 PSI) below the setting of the spring, the compensator c. The rear of the pump must be supported regardless
spool starts to compress the spring and the spool moves of the mounting method.
allowing the pump outlet oil to be metered into the servo 6. The splines of the pump shaft and the drive coupling
piston moving the swash plate toward the zero flow angle. need Lubrication. If the gearbox is a wet drive then no
The adjustment range of the "PA" control is from 100 to 320 grease is required because the gearbox oil will lubricate
bar (1450 -4640 PSI). The pressure compensator control is the splines. If the gearbox coupling is sealed then the
factory set per the model code. The setting is coded in tens splines needs to be greased with Heavy Lithium Grease
of bar, so for example a 320 bar setting is specified code 32. covering all the Splines
The standard maximum pressure setting option is 10, which 7. For a wet mount, a gasket is required for the mounting
is 100 bar. flange to PTO gearbox interface. Dry mount does not
require a gasket.

8. Torque the mounting flange nuts to 50 ft. lbs (222N. m).

2-3
HYDRAULIC SYSTEM 600E SERVICE MANUAL

NOTE: Some of the pipe fittings used are sealed by 13. Start engine.
means of two threaded tapered sections, one
a. Idle engine for two to three minutes with no
male and one female. When these two tapers
functions actuated. Check for leaks and repair if
meet, you will note a sudden increase in the
required. Lay your hand on the pump to check for
force required to screw the fittings together.
excessive heat build-up. If the pump section is too
This is true of all tapered pipe threads. Further
hot to keep your hand on, stop the engine
tightening will not only fail to increase the
immediately. If the pump makes excessive noise, it
pressure tightness of the joint, but may ruin the
is probably sucking air, keeping the pump from
co nn ec ti on s a nd m ak e c orrec t as sem bl y
priming. If this occurs, stop engine, and inspect all
impossible.
connections of the suction hose/tube for a lose
Other fittings are of the o-ring boss type. These are connection, or for a missing or damaged o ring. Re-
installed by first screwing the lock nut flush to the start engine and run until pump takes prime or a
upper thread land and installing fitting into port until maximum of 30 seconds. If pump does not prime in
the nut contacts the surface of the port. Adjust 30 seconds, stop motor and repeat until pump
fitting to desired direction. Tighten locknut. primes.
Most pressure fittings are the O-ring face seal b. Increase RPM to 1500-1800 for 1-2 minutes with no
types. A small O-ring is compressed between the functions actuated and again, make checks outlined
male and the female fittings of the joint. Be sure the in step A. Incrementally increase throttle to full RPM
O-ring is present on the fitting and seated properly and then cycle the functions that the pump supplies,
in its groove before the fittings are tightened. to verify proper speed (verify pump flow).
9. Remove the dust covers from the pump inlet and outlet
and determine that the suction and pressure sides of the
pump are correct while rotating the pump in the same
direction as the PTO. Mount the pump with the drain port
in the upper position. Mounting the pump with this
orientation will allow the pump to remain in the primed
condition through succeeding startups.

CAUTION
The hydraulic piston pump case must be pre-filled with oil
prior to startup. Failure to do so will result in pump failure.

10. Fill the reservoir with the proper hydraulic fluid to the
high-level mark on the reservoir sight gage.
11. The biggest concern is to make sure we are not sucking
air into the pump inlet or allowing the pump suction or
inlet fluid to "bleed-back" to the reservoir when the
engine is stopped. Therefore, assure that all suction or Pump shown is a counter clockwise
inlet lines are airtight. rotation. Clockwise rotation pump will
12. Remove plug as shown in figure #1 below and add a cup
have inlet and outlet ports reversed.
of hydraulic fluid to the pump case to help lubricate parts
during start-up priming.

2-4
 600E SERVICE MANUAL HYDRAULIC SYSTEM

MAIN CONTROL VALVE 7. Replace valve sections on assembly studs in the same
order in which they were removed.
The Main Control Valve is a pressure compensated,
sectional valve that provides precise pressure and flow NOTE: Use care in replacing valve sections to avoid
control for simultaneous operation of multiple functions. It dislodging o-rings from counterbores.
also gives you the ability to consistently meter flow to specific 8. When all valve sections are positioned on assembly studs,
requirements regardless of load changes or system pressure replace stud nuts and tighten evenly to 30 ± 2 ft. lb (40.6 ±
fluctuations.
2.7 N . m) torque for crane valve and 25 ft-lb (34N . m) torque
Servicing The Control Valves for winch valve.
NOTE: If stud nuts are not tightened to the proper
Seal Replacement torque, valve spools may bind or stick, or
cause section seals to extrude.
NOTE: For clarification, we shall call the inlet cover
containing the main relief the left side of the Replacing Spool Seals
valve assembly.
Valve sections and covers are identified by numbers cast
1. Before disassembly, it is suggested that each valve into the body.
section be marked nu merically to avo id i ncorre ct
reassembly. 1. Remove bonnet assembly parts from back of valves and
keep in order of disassembly.
2. Remove three assembly stud nuts from the end section
using a 9/16" thin wall socket. 2. Remove all parts connected to the spool on the front of the
valve.
3. Remove valve sections by sliding from assembly studs.
NOTE: Do not remove the spool as the seals can be
4. If valve sections are to be added or removed, use the replaced externally. Prevent spool from turning
proper length assembly stud. or moving by inserting a screw driver through
NOTE: Use assembly nuts, three required, with all clevis slot, or running a rod through the pin
assembly studs. No lockwashers! All studs are hole and using a handle. Do not hold the spool
stress-proof material and should be replaced with a wrench. This will destroy the finish.
only with original equipment replacement Always replace all spool seal parts with parts
parts. included in spool seal replacement kit.

5. Thoroughly clean O-ring counterbores and ground 3. Remove boot retainer plate, seal retainer plate washers,
surfaces of each section. Do not lubricate O-rings or back-up washers and spool seals.
ground surfaces during re-assembly. Lubricants can 4. Thoroughly clean counterbore.
cause warping of sections and cause spools to jam.
5. Lightly oil new seals. Slide over valve spool and insert in
6. Replace the four O-rings for crane valve and three O-rings seal counterbore.
for winch valve, two seals per section. Buna-N seals are
standard.
2-5
HYDRAULIC SYSTEM 600E SERVICE MANUAL

ATB/LMI Switch Troubleshooting when ALL functions are "Locked Out"

(Sheet 1 of 3)

Shut down Crane

Disconnect electrical harness from all three HCA/LMI Switches

Ensure that all control rods are in the Neutral position

Test individual switches for continuity

Do any of the Switches indicate an "open"?

No Yes

If the crane is still not functioning properly

after test and or repair, call Manitowoc Adjust or replace switch found to be "open".
Crane Care.

After switch repair, re-test crane.

If re-test is successful, reconfigure crane for normal operation.
If the crane is still not functioning properly after test and or repair,
call Manitowoc Crane Care.

HCA/LMI Switch Troubleshooting (Sheet 1)

2-6
600E SERVICE MANUAL HYDRAULIC SYSTEM

Intermittent or Partial Operation of ATB/LMI Switches Troubleshooting (Sheet 2)

Start Crane, engage PTO and bring

Activate the Anti-Two Block Switch
Hydraulic System on line.

INTERMITTENT OR PARTIAL Move Boom lever from "Neutral" to the

OPERATION OF ATB SYSTEM "Boom Down" and "Boom Up" direction
If your crane has any of the following several times. Boom Up should work,
problems proceed with this Troubleshooting Boom down should not work.
Test

1. Partial Lockout of ATB. Does the Boom move

Does Boom move up?
2. Winch, Tele, or Boom still operate when down or "pulse"
they should be locked out.
3. Pulsating functions Yes No Yes
Go to ATB Testing
Switch is operating and
properly Troubleshooting No
Sheet 3

Move Winch lever from "Neutral" to the

"Winch Up" direction and to "Winch Down"
several times. Winch Up should not work ,
Winch down should work

Does the Winch

Does the Winch
move up or No
move down?
"pulse"

Yes No Yes
Go to ATB Testing
Switch is operating and
properly Troubleshooting
Sheet 3

Move Tele lever from "Neutral" to the

"Tele Out" direction and to "Tele
Retract" several times. Tele out should
not work , Tele in should work
If the crane is
s t i l l n o t
functioning
Does the Tele Does the Tele
properl y after
In move? Out move or No
test and or
"pulse"
r ep ai r, c al l
Manitowoc
Yes No Yes Crane Care.
Go to ATB
Switch is operating
Testing and
properly
Troubleshooting
Sheet 3

HCA/LMI Switch Troubleshooting (Sheet 2)

2-7
HYDRAULIC SYSTEM 600E SERVICE MANUAL

Individual ATB/LMI Switch Electrical Test (Sheet 3)

Shut down Crane

Disconnect electrical harness from HCA/LMI Switch

Test individual switch for continuity

While observing Multi-meter, operate Function in "Lock Out" direction.

Is Continuity Lost?

Yes No

Adjust or replace
Switch is operating properly
Switch

After switch repair, re-test

crane.
If re-t es t is su cc es sf ul ,
reconfigure crane for normal
operation.
If t he c rane is st ill not
functioning properly after
t e s t an d or r ep ai r , c al l
Manitowoc Crane Care.

HCA/LMI Switch Troubleshooting (Sheet 3)

2-8
600E SERVICE MANUAL HYDRAULIC SYSTEM

8 2 3 4 5
1

1. Winch 6. ASH Audible

Alarm Switches (2)
2. Lift
7. HCA Switches (3)
3. Tele 6
8. Jam Nut
4. Driver Side ASH

5. Passenger Side
9. Positioner Switch 7
(typical)
ASH

HCA/LMI Positioner Switch Adjustment 8. Turn switch in an additional 1/8 turn.

The Main Control Valve has five Positioner Switches (Refer 9. Tighten locknut to 5-10 Ft-lb.
to the drawing on page 2-3) and the drawing below: 10. Apply Loctite 290 between locknut and switch.
- Winch HCA Switch 11. Complete “Crane Test After Positioner Switch
- Lift HCA Switch Adjustment.” procedure on page 2-10.

- Tele HCA Switch ASH Audible Alarm Switch Adjustment

- 2 ASH Audible Alarm Switches 1. Start the crane and bring the hydraulic system up to
normal operating temperature.
The Winch, Lift, and Tele HCA Switches have identical
adjustment procedures. The ASH Audible Alarm Switches 2. Shut down crane.
have a slightly different adjustment procedure.
3. Ensure Valve Spool is in Neutral.
Winch, Lift, and Tele Switch Adjustment 4. Disconnect electrical leads.
1. Start the crane and bring the hydraulic system up to NOTE: Two wrenches are required to adjust switch,
normal operating temperature. one to hold the switch housing and the other to
2. Shut down crane. loosen/tighten the locknut.

3. Ensure Valve Spool is in Neutral. 5. Loosen locknut.

4. Disconnect electrical leads. 6. Attach continuity tester to switch terminals.

NOTE: Two wrenches are required to adjust switch, 7. Screw switch into bonnet until continuity tester indicates
one to hold the switch housing and the other to switch contacts have closed.
loosen/tighten the locknut. 8. Back switch out until switch contacts open, then back
5. Loosen locknut. switch out and additional 2/3 turn.

6. Attach continuity tester to switch terminals. 9. Tighten locknut to 5-10 Ft-lb.

7. Screw switch into bonnet until continuity tester indicates 10. Apply Loctite 290 between locknut and switch.
switch contacts have closed. 11. Complete “Crane Test After Positioner Switch
Adjustment.” procedure on page 2-10.

2-9
HYDRAULIC SYSTEM 600E SERVICE MANUAL

Crane Test After Positioner Switch Adjustment. AUXILIARY CONTROL VALVE (OPTIONAL)
1. Start crane and Two Block system by: The Auxiliary Control Valve hydraulically control optional
a. Have assistant hold ATB Weight up to relieve accessories such the Single Front Outrigger (SFO) and other
weight on the ATB Switch. hydraulic components installed on the crane.

OR OIL COOLER SERVICE & MAINTENANCE

b. Physically remove ATB Weight. (OPTIONAL)
2. Actuate the function (s) adjusted and verify the following: The heat exchanger must be kept clean to allow for efficient
a. Winch UP disabled, Winch DOWN operates operation of the cooler system. Frequent washing of the
properly. heat exchanger core will eliminate oil film, road dirt and other
foreign object buildup on the heat exchanger fins which
b. Lift DOWN disabled, Lift UP operates properly. reduces cooling efficiency.
c. Tele OUT disabled, Tele IN operates properly. Frequent inspection and tightening of hose clamp line
d. ASH Alarms sound during ASH movement. connections will eliminate the possibility of end connection
failure due to back pressure from cold startup.
3. If test is unsatisfactory, re-adjust switch (s) and re-test.
If cooler system fails to provide adequate performance,
4. If test is satisfactory, install ATB Weight (if removed) and reduced air or oil flow through the heat exchanger is the
shut down crane. probable cause. The cooling fan should be inspected for
proper operation. Any obstructions to air flow should be
corrected (cooler too close to other truck components,
foreign matter in heat exchanger fins, etc.). All hydraulic lines
should be periodically checked for obstructions, hose kinks
or other flow restrictions.

2-10
600E SERVICE MANUAL HYDRAULIC SYSTEM

FASTENERS AND TORQUE VALUES If a fastener must be replaced and a similar grade is not
available, always use a higher grade torqued to the same
Use bolts of the correct length. A bolt which is too long may value as the original grade. As soon as available, the correct
bottom before the head is tight against the part it is to hold. If grade fastener should be installed to avoid a future state of
a bolt is too short, there may not be enough threads engaged confusion by the improper installation.
to hold the part securely. Threads can be damaged. Inspect
them and replace fasteners as necessary. Special attention should be given to the existence of
lubricant, plating, or other factors that might require variation
Torque values must correspond to the type bolts, studs, and from standard torque values. 2
nuts being used.
When maximum recommended torque values have been
Use of proper torque values is extremely important. Improper exceeded, the fastener should be replaced.
torquing can seriously affect performance and reliability.
NOTE: Temperature variation, vibration, and elasticity
Identification of fastener grade is always necessary. When of metals can result in the gradual reduction of
marked as a high strength bolt (grade 8, 5, etc.), the bolt torque. Bolts should be re-torqued as
mechanic must be aware that he is working with a highly outlined in the inspection and maintenance
stressed component and the fastener should be torqued procedure.
accordingly.

NATIONAL CRANE FITTING O-RING PART NUMBERS

O -R IN G F A C E S E A L F IT T IN G S IZ E O - R IN G B O S S
B A A B
PAR T TR EAD T U BE S IZ E TR EAD PAR T
In c h e s In c h e s In c h e s In c h e s
N U M BER S IZ E O .D . CO DE S IZ E N U M BER
(m m ) (m m ) (m m ) (m m )
.0 7 .3 0 1 .3 5 1 .0 7 2
** 8 9 7 0 6 3 9 /1 6 - 1 8 .2 5 0 4 7 /1 6 - 2 0 888412*
( 1 .7 8 ) ( 7 .6 4 ) (8 .9 2 ) ( 1 .8 3 )
1 1 /1 6 - .0 7 .3 6 4 .4 5 8 .0 7 8
** 8 9 7 0 6 4 .3 7 5 6 9 /1 6 - 1 8 888414*
16 ( 1 .7 8 ) ( 9 .2 4 ) (1 1 .6 3 ) ( 1 .9 8 )
1 3 /1 6 - .0 7 .4 8 9 .6 4 4 .0 8 7
** 8 9 7 0 6 5 .5 0 0 8 3 /4 - 1 6 888415*
16 ( 1 .7 8 ) (1 2 .4 2 ) (1 6 .3 6 ) ( 2 .2 1 )
.0 7 .6 1 4 .7 5 5 .0 9 7
** 8 9 7 0 6 6 1 -1 4 .6 2 5 10 7 /8 - 1 4 888416*
( 1 .7 8 ) (1 5 .6 0 ) (1 9 .1 8 ) ( 2 .4 6 )
1 3 /1 6 - .0 7 .7 3 9 .9 2 4 .1 1 6 1 1 /1 6 -
** 8 9 7 0 6 7 .7 5 0 12 888417*
12 ( 1 .7 8 ) (1 8 .7 7 ) (2 3 .4 7 ) ( 2 .9 5 ) 12
1 7 /1 6 - .0 7 .9 2 6 1 .1 7 1 .1 1 6 1 5 /1 6 -
** 8 9 7 0 6 8 1 .0 0 0 16 888419*
12 ( 1 .7 8 ) (2 3 .5 2 ) (2 9 .7 4 ) ( 2 .9 5 ) 12
1 1 1 /1 6 - .0 7 1 .1 7 6 1 .4 7 5 .1 1 8
** 8 9 7 0 6 9 1 .2 5 0 20 1 5 /8 - 1 2 888420*
12 ( 1 .7 8 ) ( 2 9 .8 7 (3 7 .4 6 ) ( 3 .0 0 )
.0 7 1 .4 8 9 1 .7 2 0 .1 1 8
** 8 9 7 0 7 0 2 -1 2 1 .5 0 0 24 1 7 /8 - 1 2 888421*
( 1 .7 8 ) ( 3 7 .8 2 (4 3 .6 9 ) ( 3 .0 0 )
* * 8 9 7 2 3 4 O - R in g F a c e S e a l K it ( 1 2 e a ) * 8 8 8 4 2 2 O - R in g B o s s S e a l K it

2-11
HYDRAULIC SYSTEM 600E SERVICE MANUAL

TORQUE VALUES FOR GRADE 5 AND 8 BOLTS

G R AD E 8
UNC G R AD E 5 T IG H T EN IN G TO R Q U E
T IG H T EN IN G TO R Q U E
SIZE ft-lb (N .m )
ft-lb (N .m )
1/4 — 20 8 ± 2 (11 ± 3) 12 ± 2 (16 ± 3)
5/16 — 18 17 ± 3 (23 ± 4) 25 ± 4 (34 ± 5)
3/8 — 16 30 ± 5 (41 ± 7) 45 ± 7 (61 ± 10)
7/16 — 14 50 ± 8 (68 ± 11) 70 ± 11 (95 ± 15)
1/2 — 13 75 ± 11 (100 ± 15) 110 ± 11 (150 ± 15)
9/16 — 12 110 ± 11 (150 ± 15) 150 ± 15 (200 ± 20)
5/8 — 11 150 ± 15 (200 ± 20) 220 ± 22 (300 ± 30)
3/4 — 10 260 ± 26 (350 ± 35) 380 ± 38 (520 ± 52)
7/8 — 9 400 ± 40 (540 ± 54) 600 ± 60 (810 ± 81)
1 — 8 580 ± 58 (790 ± 79) 900 ± 90 (1220 ± 122)
1- 1/8 — 7 800 ± 80 (1080 ± 108) 1280 ± 128 (1740 ± 174)
1- 1/4 — 7 1120 ± 112 (1520 ± 152) 1820 ± 182 (2470 ± 247)
1- 3/8 — 6 1460 ± 146 (1980 ± 198) 2380 ± 238 (3230 ± 323)
1- 1/2 — 6 1940 ± 194 (2630 ± 263) 3160 ± 316 (4280 ± 428)

G R AD E 8
UNF G R AD E 5 T IG H T EN IN G TO R Q U E
T IG H T EN IN G TO R Q U E
SIZE ft-lb (N .m )
ft-lb (N .m )
1/4 — 28 10 ± 2 (14 ± 3) 14 ± 2 (19 ± 3)
5/16 — 24 19 ± 3 (26 ± 4) 25 ± 4 (34 ± 5)
3/8 — 24 35 ± 5 (47 ± 7) 50 ± 8 (68 ± 11)
7/16 — 20 55 ± 8 (75 ± 11) 80 ± 12 (110 ± 16)
1/2 — 20 90 ± 14 (120 ± 16) 120 ± 12 (160 ± 16)
9/16 — 18 120 ± 12 (160 ± 16) 170 ± 17 (230 ± 23)
5/8 — 18 180 ± 18 (240 ± 24) 240 ± 24 (320 ± 32)
3/4 — 16 300 ± 30 (410 ± 41) 420 ± 42 (570 ± 57)
7/8 — 11 440 ± 44 (600 ± 60) 660 ± 66 (890 ± 89)
1 — 12 640 ± 64 (870 ± 87) 1000 ± 100 (1360 ± 136)
1- 1/8 — 12 880 ± 88 (1190 ± 119) 1440 ± 144 (1950 ± 195)
1- 1/4 — 12 1240 ± 124 (1680 ± 168) 2000 ± 200 (2710 ± 271)
1- 3/8 — 12 1680 ± 168 (2280 ± 228) 2720 ± 272 (3690 ± 369)
1- 1/2 — 12 2200 ± 220 (2980 ± 298) 3560 ± 356 (4830 ± 483)

NOTE:
Torque values are in foot pounds (N.m). Torque values apply to plain finish and zinc plated fasteners. Torque
values specified are dry with as received residual oils. Special lubricants are not recommended.
Torque values for bolts listed above are not affected with the use of Loctite. Loctite should not be used on rotation
bearing fasteners. Hardend washers should be used with Grade 8 fasteners.

Grade of stud bolts is identified by radial lines stamped in

Grade 5 Grade 8 the end with the shortest thread length.

2-12
600E SERVICE MANUAL HYDRAULIC SYSTEM

Torque Wrenches Using Torque Wrench Extinctions

Torque wrenches are precision instruments and are to be 1. Torque wrench extensions are designed to extend the
handled with care to ensure calibrated accuracy. Calibration range or versatility of torque wrenches. Torque wrench
checks should be made on a scheduled basis. Whenever scale readings or limit settings shall be computed with
the wrench might be either overstressed or damaged, it the following formulas when an extension handle is
should immediately be removed from service until re- employed. The sketch below shows which formula is to
calibrated. An erratic or jerking motion of the wrench can be used, adding “A” or subtracting “A” when calculating
easily result in excessive torque. ALWAYS use a slow the torque wrench setting.
2
wrench movement and STOP when the predetermined value
has been reached. TW = Ta x L or TW = Ta x L
L+A L-A
NOTE:
Torque values are in foot pounds (Nm). Torque Ta = Torque required (specified)
values apply to plain finish and zinc plated fasteners.
Torque values specified are dry with as received residual TW = Wrench scale reading or limit setting of
oils. Special lubricants are not recommended. torque wrench
Torque values for bolts listed above are not affected
with the use of Loctite. L = Length of torque wrench in inches (center of
Loctite should not be used on rotation bearing drive tang to handle pivot pin or center of
fasteners. Hardend washers should be used with Grade hand grip - extension handles are
8 fasteners considered part of wrench length, when
used)

A = Length of adapter extensions in inches

2. If the offset C/L is not in line with the torque wrench C/L, 3. If offset is positioned at right angles
then you must measure the distance from the C/L of the to the torque wrench, then the offset will not change the
torque wrench to the C/L of the offset by using a square. effective length. Therefore, TW-wrench setting and Ta-
Then apply this dimension to the torque wrench setting applied torque, will be the same value as if no offset were
formula. See sketch below. used..

2-13
HYDRAULIC SYSTEM 600E SERVICE MANUAL

2-14
600E ELECTRIC SYSTEM

SECTION 3
ELECTRIC SYSTEM
TABLE OF CONTENTS
Anti-Two Block Internal Wire System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Anti-two Block Internal Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3 Section Boom ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Special tools or equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Special tools or equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3
4 Section Boom ATB Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operation: Internal Anti-Two Block Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Disassembly Of 1/2 Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Assembly Of 1/2 Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
2/3/4 Stage Anti-Two-Block Wire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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
1/2 Stage Anti-Two Block Wire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HCA Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HCA Maintenance & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
HCA System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Jib Load Limiting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Single Character Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-i
ELECTRIC SYSTEM 600E

PAGE INTENTIONALLY LEFT BLANK

3-ii
600E SERVICE MANUAL ELECTRIC SYSTEM

SECTION 3
ELECTRIC SYSTEM
winch up, boom down and telescope out functions. In the
ANTI-TWO BLOCK INTERNAL WIRE spool positions of neutral, winch down, telescope in, or boom
up the function flow is not interrupted.
SYSTEM
When the crane is two-blocked, the bonnet switch circuit will
Anti-two Block System Description only allow the operator to winch down, telescope retract, or
boom down. Activation of winch down or telescope retract
The Anti-Two Block System (ATB) consists of a normally function will once again allow the two-block weight to hang
open Pump Enable Valve, a bonnet switch circuit and an freely on the winch rope which re-energizes the anti-two
anti-two block circuit. When the Pump Enable Valve is block circuit which in turn re-energizes the Pump Enable
energized, the crane functions normally, when de-energized, Valve and reactivates the pump flow in all functions.
the pump de-strokes and oil flow ceases. This solenoid is 3
controlled by two parallel circuits, one is an anti-two block
circuit composed of a limit switch and weight, which is
attached to the boom or jib sheave case. The other circuit is Anti-two Block Operation
composed of the bonnet switches located on the main The internal anti-two-block wire is routed from the control
control valve spools, winch, telescope, and lift. Both circuits console to the winch mount end of the boom, following the
must be broken to de-energize the Pump Enable Valve and
thus stop pump output flow and crane functions. path of the extend cables to the rear of the 3 rd section boom.
This is the length of the wire that proportions in and out with
On the anti-two block circuit, the sheave case switch is held the boom length, similar to the route of the extend cables. At
in the closed position by a chain suspended weight. The this point at the rear of the 3 rd section, the wire loops around
weight, which is looped around the winch cable, causes the and anchors at the anti-two-block cable clamp on the extend
contacts t o rema in closed unt il the winch cable end cable anchor. The anti-two-block wire, now attached at the
attachments contact the weight and release the tension on
rear of the 3 rd, runs the length of the section and attaches to
the switch. At this point the contacts in the switch open,
breaking electrical continuity through the circuit provided by the 3rd section sheave case. The wire then loops around the
the internal anti-two block cord routed through the boom. clamp arrangement on the sheave case and routes through
When the anti-two block limit switch continuity is broken, the access holes in the side plate of the boom. The wire
anti-two block circuit is de-energized. An indicator light is terminates at a quick connect / 2 conductor plug designed for
provided on the control console to alert the operator when a anti-two-block switch or jib interface.
two-block condition is detected.
ANTI-TWO BLOCK INTERNAL WIRE REPAIR
The bonnet switch circuit on the main control valves spools,
winch, telescope, and lift always stays energized when the In the event of a break in continuity of the anti-two-block wire
spools are in neutral or boom up, telescope retract, or the routed internally in the boom, the anti-two-block hydraulic
winch down function is used. The winch down or telescope system will sense a problem and make certain crane
retract functions relieve the two-block situation. Attempting functions inoperative. Before repair or replacement of
to use winch up, telescope extend, or boom down will cause internal wire, check for continuity loss at the anti-two-block
the bonnet switch circuit to be broken and thereby de- switch, damaged, missing, or corroded connectors and
energized. This de-energizing of the bonnet circuit occurs overall system condition. Due to t he envir onmental
every time winch up, boom down, or telescope extend is exposure of the system, a thorough check of the circuit
used regardless of what the anti-two block is seeing. should be performed.
Remember, that both circuits must be broken to remove
The procedure for removal and reinstallation of the anti-two-
current to the Pump Enable Valve and thereby stop pump
block wire can be accomplished using two different methods
flow and crane function movement.
depending on the severity of the damage. Alternative #1
As stated previously, if both of the circuits become de- should be used if the wire has experienced a continuity
energized, the Pump Enable Valve will also become de- failure in one or both of the conductors, but the rubber jacket
energized and the pump swash plate will de-stroke and of the wire is still intact. Alternative #2 is to be used if the
pump output flow will cease thus stopping all crane function wire has been completely cut or either end of the wire is
movement. Note that the pump flow will only cease for the inaccessible.

3-1
ELECTRIC SYSTEM 600E SERVICE MANUAL

3 SECTION BOOM ATB WIRE REPAIR 8. Pull wire through boom, leaving enough wire on sheave
case end to properly attach and terminate wire.

9. Tighten anti-two-block wire clamp located in rear of 3rd

section.
WARNING 10. Route sheave case end of anti-two-block wire around
Do not, under any circumstances, work at an elevated clamp in sheave case, and through holes in side plates.
height without using proper fall protection as required by Pulling on this end will tension the static length of anti-
local, state or federal regulations two-block wire clamped in the 3 rd. Approximately 15-25
lb (6-11 kg) will be sufficient to provide proper operation.
Alternative #1 Tighten sheave case anti-two-block wire clamp.

This procedure pulls the replacement wire through the boom, 11. Reassemble quick disconnect plug to anti-two-block
following the path of the defective wire. wire. Proper wire attachment is critical for proper anti-
two-block system operation.Consult electrical schematic
Special tools or equipment: in this book for proper connector wiring.

1. Two end-to-end electrical butt connectors 12. Temporary splice should now be approximately 10 feet
(3 m) past the winch mount end of the boom. Break
2. Shrink tube or electrical tape splices and slide strain relief/cord grip onto wire, into
Proceed as Follows: approximate position inside the boom.

1. Retract boom completely. 13. Assemble spring and spade bolt to cord grip and
reassemble anchor components to extend cable anchor
2. Loosen and remove capscrew and cable clamp plate on the winch mount. Slide cord grip up anti-two-
arrangement from sheave case attachment point of anti- block wire into boom to increase spring tension on
two-block wire. Remove quick connect plug on anti-two- moving length of anti-two-block wire. Approximately 2"
block wire by unscrewing base of plug and (50 mm) of spring extension tension should be adequate
disconnecting individual wires from connections. Note for proper operation.
pigtail length at this time and wire / terminal number
location for proper reassembly. 14. Visually inspect interior routing of anti-two-block wire for
excess slack in wire, inaccurate routing of wire, etc.
3. Pull end of anti-two-block wire through side plates of 3rd correct any problems before boom operation.
section boom to gain in-line wire path.
4. Attach replacement anti-two-block wire to damaged wire
with a temporary splice, securing the conductors with Alternative #2
end to end butt connectors and shrink tube or electrical
tape. This connection must be secured well enough to This procedure is to be used for anti- two- blo ck wire
pull the new wire through the boom. replacement in the event of a complete separation of the
wire, or the inability to access one or both of the ends outside
5. At the winch mount end, reach into the rear of the boom the boom assembly. This procedure routes a new anti-two-
and loosen the capscrew on the anti-two-block cable block wire through the boom without having an existing wire
clamp enough to let the cable run around it with minimal to pull it through (Alternative #1).
effort. This clamp is located on the extend cable anchor.
Special tools or equipment:
6. Disassemble spade bolt anchor attaching anti-two-block
wire to the extend cable plate on the winch mount end of 1. Electrical tape
the boom. 2. Installation tool
7. Pull wire from winch 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 a installation tool, must be utilized to transport
anti-two-block cable clamp in rear of 3rd 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 bo om , h yd ra ul ic t ub in g or ele ct r ica l co nd ui t ar e a ll
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’ (61cm) longer than the retracted
boom assembly.

3-2
600E SERVICE MANUAL ELECTRIC SYSTEM

1. Retract boom completely. clamp together. Keeping a slight amount of tension on

the wire at this point will keep the wire properly located
2. Loosen and remove anti-two-block cable clamp
on the sheave.
arrangements from sheave case and 3rd section extend
anchor. Remove spade bolt anchor from extend cable 13. From the sheave case end, pull the installation tool and
anchor plate in the winch mount end of boom. wire end out of the boom. The route of the anti-two-
block wire in the boom is now complete.
3. Remove quick disconnect plug on anti-two-block wire by
unscrewing base of plug and disconnecting individual 14. Pull wire at either end of boom to adjust length of wire on
wires from connections. Note pigtail length at this time, sheave case end to properly attach and terminate wire.
and wire/terminal number location for proper
15. Tighten anti-two-block wire clamp located in rear of 3rd
reassembly.
section.
4. Pull anti-two-block wire out of boom assembly. Visually
16. Route sheave case end of anti-two-block wire around
inspect boom interior from both ends to verify all the
cable has been removed from the boom. Visually
clamp in sheave case and through holes in side plates. 3
Pulling on this end will tension the static length of anti-
inspect center sheave on extend cylinder for damage.
two-block wire clamped in the 3rd. Approximately 15-25
5. Start installation of replacement wire on the sheave case lb (7-11 kg) will be sufficient to provide proper operation.
end of the boom assembly. Using electrical tape, attach Tighten sheave case anti-two-block wire clamp.
one end of replacement wire to the end of the installation
tool. 17. Reassemble quick disconnect plug to anti-two-block
wire. Proper wire attachment is critical for proper anti-
6. Insert installation tool and wire into sheave case in the two-block system operation. Consult electrical
center open area between the sheave case side plates. schematic in this book for proper connector wiring
Visually guide the wire and installation tool over the
center sheave on the extend cylinder sheave case. 18. From winch mount end of boom, slide strain relief/cord
grip onto wire, into approximately position inside the
7. Push installation tool and wire through boom until it boom.
appears at the winch mount end, detach wire from
installation tool, route wire through open top of winch 19. Assemble spring and spade bolt to cord grip and
mount and temporarily tie off to a convenient anchor reassemble anchor components to extend cable anchor
point. Pull installation tool out sheave case end of boom. plate on the winch mount. Slide cord grip up anti-two-
block wire into boom to increase spring tension on
8. From sheave case end of boom, attach other end of moving length of anti-two-block wire. Approximately 2"
replacement wire to installation tool with electrical tape. (50 mm) of spring extension tension should be adequate
Insert installation tool and wire into the boom sheave for proper operation.
case, in the open area between the sheave case side
plates. Visually guide this end under the center sheave 20. Visually inspect interior routing of anti-two-block wire for
on the extend cylinder sheave case. excess slack in wire, inaccurate routing of wire, etc.
Correct any problems before boom operation.
9. Push installation tool and wire through boom until it
appears at the winch mount end. Do not detach wire
4 SECTION BOOM ATB WIRE REPAIR
from installation tool.
10. From winch mount end of boom, locate installation tool
and attached wire, and pull the wire out of the boom
section, removing the slack loop from the sheave case
end of the boom. This will place the wire close to, if not WARNING
on the center sheave of the extend cylinder. Do not, under any circumstances, work at an elevated
11. Move to the sheave case end of the boom. Visually height without using proper fall protection as required by
determine if the wire has properly located itself onto the local, state or federal regulations
sheave. If not, manipulate the wire placement through
the end of the boom and place the wire on the sheave. A
5’ (1.50 m) long access tool (hook end) will simplify this
procedure greatly. Operation: Internal Anti-Two Block Wire
12. From the winch mount end of the boom, assemble the The internal anti-two-block wire is routed from the control
anti-two-block wire clamp on the extend cable anchor in console to the winch mount end of the boom, through the
the rear of the 3 rd section. Loop anti-two-block wire access cutout in the bottom of the 1st section, then reeves
around clamp and lightly tighten capscrew holding around a path on the inside bottom plate of the 1st section.

3-3
ELECTRIC SYSTEM 600E SERVICE MANUAL

This path incorporates a traveling block arrangement that 3. If the fault is suspected in the 1/2 stage, unplug Weather-
clamps the anti-two-block wire to the bottom of the 2nd Pack connector at the turret end. At the end of the 2nd
section and allows wire movement relative to that section. section boom, install a jumper wire across the terminals at
This wire terminates with a Weather-Pack connector at the either end of the 1/2 stage. Check continuity at the opposite
winch mount end of the 2nd section. This system is the ½ end of the ½ stage.
stage. From this connector inside the boom, the anti-two-
After determining which wire stage the fault is located in,
block wire follows the path of the extend cables to the rear of
refer to the following procedures for anti-two- block wire
the 4th section boom. This length of wire proportions in and
replacement.
out with the boom length, similar to the route of the extend
cables. At this point at the rear of the 4th section, the wire
1/2 Stage Anti-Two-Block Wire Replacement
loops around and anchors at the anti-two- block cable clamp
on the extend cable anchor. The anti- two-block wire, now The 1/2 stage anti-two-block wire system is located between
attached at the rear of the 4th, runs the length of the section the 1st and 2nd boom sections, riding on the top of the
and attaches to the 4th section sheave case. The wire then bottom plate of the 1st section. The maintenance on this
loops around the clamp arrangement on the sheave case system can be accomplished with the boom assembled but
and routes through access holes in the side plate of the would be greatly simplified by re moving the 2/3/4 boom
boom, this is the 2/ 3/4 stage. The wire terminates at a quick assembly from the 1st.
connect two conductor plug designed for anti-two-block
switch or jib interface. Disassembly Of 1/2 Stage
Maintenance 1. Remove capscrews and clamp bar from 2nd section by
gaining access through rear of 1st, under extend cylinder
In the event of a break in continuity of the anti-two- block wire butt plate.
routed internally in the boom, the anti-two- block hydraulic
2. Unplug Weather-Pack connector between the 1/2 stage
system will sense a problem and make certain crane
and the 2/3/4 stage, located on the rear of the 2nd section.
functions inoperative. Before repair or re placement of
internal wire, check for continuity loss at the anti-two-block 3. Unplug Weather-Pack connector under the 1st section
switch, damaged, missing, or corroded connectors and boom, and remove the nut and washer from the cord clamp
overall system condition. Due to the environmental exposure on the bottom of the 1st section. Route the appropriate end
of the system, a thorough check of the circuit should be through the access cutout on the bottom plate.
performed.
4. Loosen and remove the capscrews anchoring the pulley
If the internal wire has lost continuity it will probably be block and cord clamp plate from the winch mount end of the
necessary to replace only one of the two stages in the circuit, 1st section.
the 1/2 stage or the 2/3/4 stage. A simple continuity test of
both stages should identify which one contains the failure. 5. Loosen and remove the capscrews anchoring the pulley
block and cord clamp plate from the sheave case end of the
1. Unplug Weather-Pack connector linking the two stages 1st section.
together, located at the end of the 2nd section.
6. Pull on loose end of the cord and pulley block on sheave
2. With the anti-two-block switch in its closed position (weight case end of 1st section. Two pulley blocks, 75 feet (23 m) of
suspended from switch or overridden), check continuity cord, and the traveling block (2 pulley blocks linked together)
across the Weather-Pack terminals on the 2/3/4 stage. If should pull free of the 1st section.
continuity exists, the 1/2 stage contains the break. If there is
no continuity in the 2/3/4 stage, recheck anti-two- block 7. Visually inspect parts and boom sections for possible
switch fun ction an d r eche ck con tinu ity to p ositi vely cause of wire fault. Verify all parts are disassembled out of
determine a wire fault. boom sections.

3-4
600E SERVICE MANUAL ELECTRIC SYSTEM

3
7. At the opposite end loosely install capscrews in the cord
clamp plate. Pull on cord to remove any slack [ lb (11-14 kg)]
Assembly Of 1/2 Stage and tighten the capscrews to secure the cord.
Special tools or equipment: 8. Assemble capscrews and clamp bar to 2nd section,
clamping section of wire assembly at point that shrink tube is
• Installation tool
installed over wires.
To route the wire the entire length of the boom, a long tube,
9. Reconnect Weather-Pack connectors.
to be used as an installation tool, must be utilized to transport
the end of the anti-two-block wire from one end of the boom 10. Verify proper operation of the complete anti-two- block
assembly to the other. A telescopic grease applicator for the system.
boo m, h ydra ulic t ub ing o r e lectr ical condu it a re all
possibilities for an installation tool. The installation tool 2/3/4 STAGE ANTI-TWO-BLOCK WIRE
should be at a minimum 2 feet (.5 m) longer than the
retracted boom assembly.
REPLACEMENT
The procedure for removal and reinstallation of the 2/3/4
1. Place parts on long work surface (top plate of boom).
stage anti-two-block wire can be accomplished using two
Refer to illustration for proper component placement, reeve
different methods depending on the severity of the damage.
cable through pulleys and traveling block.
Alternative #1 should be used if the wire has experienced a
2. Place system into boom using anti-two-block installation continuity failure in one or both of the conductors, but the
tool. rubber jacket of the wire is still intact. Alternative #2 is to be
used if the wire has been completely cut or either end of the
3. Confirm proper placement of components. Installation of
wire is inaccessible.
compo nent s in co rre ct loca tion is crit ical fo r p rope r
operation. Do not, under any circumstances, work at an elevated height
without using proper fall protection as required by local, state
4. Location of the traveling block is critical to correct
or federal regulations.
operation. The traveling block moves in the opposite
direction of the 2nd section boom. Extra wire is included in
Alternative #1
the wire assembly to place the traveling block in the correct
position. Access to the clamp bar on the 2nd section can only This procedure pulls the replacement wire through the boom
be achieved through the rear of the 1st section, therefore the following the path of the defective wire.
boom is near full retraction when the clamp bar attaches the
Special tools or equipment:
wire assembly to the 2nd section. The traveling block needs
to be over the halfway point of the length (closer to the • Two end-to-end electrical butt connectors
sheave case end) of the 1 st se ct io n before the wire
• Shrink tube or electrical tape
assembly is clamped to the 2nd section.
1. Retract boom completely.
5. Install capscrews in the front and rear of the 1st section
anchoring pulleys to the 1st section. 2. Loosen and remove capscrew and cable clamp
arrangement from sheave case attachment point of anti-two-
6. Install capscrews in the front or rear cord clamp plate.
block wire. Remove quick connect plug on switch end of anti-
Tighten the capscrews to secure the cord.

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ELECTRIC SYSTEM 600E SERVICE MANUAL

two-block w ire by unscrewing base of plug and 14. Assemble Weather-Pack connector in appropriate
disconnecting individual wires from connections. Note pigtail position.
length at this time and wire/terminal number location for
15. Visually inspect interior routing of anti-two-block wire for
proper reassembly.
excess slack in wire, inaccurate routing of wire, etc. Correct
3. Pull end of anti-two-block wire through side plates of 4th any problems before boom operation.
section boom to gain in-line wire path.
Alternative #2
4. Attach replacement anti-two-block wire to damaged wire
with a "temporary splice", securing the conductors with end This procedure is to be used for anti- two- blo ck wire
to end butt connectors and shrink tube or electrical tape. This replacement in the event of a complete separation of the
connection must be secured well enough to pull the new wire wire, or the inability to access one or both of the ends outside
through the boom. the boom assembly. This procedure routes a new anti-two-
block wire through the boom without having an existing wire
5. At the winch mount end, reach into the rear of the boom
to pull it through (Alternative #1).
and loosen the capscrew on the anti- two-block cable clamp
enough to let the cable run around it with minimal effort. This Special tools or equipment:
clamp is located on the extend cable anchor in the 4th
• Electrical tape
section.
• Installation tool
6. Disassemble capscrew attaching cord grip spring anti-two-
block wire to the extend cable anchor on the 2nd section at To route the wire the entire length of the boom, a long tube,
the winch mount end of the boom. to be used as an installation tool, must be utilized to transport
the end of the anti-two-block wire from one end of the boom
7. Pull wire from winch mount end. Replacement wire assembly to the other. A telescopic grease applicator for the
"temporary splice" may need assistance reeving around anti- bo om , h yd ra ul ic t ub in g or ele ct r ica l co nd ui t ar e a ll
two-block cable clamp in rear of 4th section. If excessive possibilities for an installation tool. The installation tool
force is needed to pull wire through, observe wire routing and should be at a minimum 2 feet (.5 m) longer than the
make adjustments as needed to avoid breaking "temporary retracted boom assembly.
splice". If splice fails at this point, wire routing Alternative #2
should be used. 1. Retract boom completely.

8. Pull wire through boom, leaving enough wire on sheave 2 . L o o s e n an d r e m o v e a n t i - t wo - b l o ck ca b l e cl a m p

case end to properly attach and terminate wire. arrangements from sheave case and 4th section extend
anchor. Remove capscrew from extend cable anchor in the
9. Tighten anti-two-block wire clamp located in rear of 4th 2nd section boom.
section.
3. Remove quick disconnect plug on the switch end of the
10. Route sheave case end of anti-two-block wire around anti- two -block wire by unscr ewin g base o f plug and
clamp in sheave case, and through holes in side plates. disconnecting individual wires from connections. Note pigtail
Pulling on this end will tension the static length of anti-two- length at this time, and wire terminal number location for
block wire clamped in the 4th section . Approximately 15-25 proper reassembly.
lb (6-11 kg) will be sufficient to provide proper operation.
Tighten sheave case anti-two-block wire clamp. 4. Pull anti-two-block wire out of boom assembly. Visually
inspect boom interior from both ends to verify all the cable
11. Reassemble switch end quick disconnect plug to anti- has been removed from the boom. Visually inspect center
two-block wire. Proper wire attachment is critical for proper sheave on extend cylinder for damage.
an ti- two -b lock sys tem o per at ion . Cons ult el ect ric al
schematic in this book for proper connector wiring. 5. Start installation of replacement wire on the sheave case
end of the boom assembly. Using electrical tape, attach one
12. "Temporary splice" should now be approximately 10 feet end of replacement wire to the end of the installation tool.
(3 m) past the winch mount end of the boom. Break "splice"
and slide strain relief cord grip onto wire, into approximate 6. Insert installation tool and wire into sheave case in the
position inside the boom. center open area between the sheave case side plates.
Visually guide the wire and installation tool over the center
13. Assemble spring to cord grip and reassemble anchor sheave on the extend cylinder sheave case.
components to extend cable anchor plate in the 2nd section.
Slide cord grip up anti-two- block wire into boom to increase 7. Push installation tool and wire through boom until it
spring tension on moving length of anti-two-block wire. ap pe ar s a t th e win ch m ou nt e nd . Det a ch wir e f ro m
Approximately 2 inches (50 mm) of spring extension tension installation tool. Route wire through open top of winch mount
should be adequate for proper operation. and temporarily tie off to a convenient anchor point. Pull
installation tool out sheave case end of boom.

3-6
600E SERVICE MANUAL ELECTRIC SYSTEM

8. From sheave case end of boom, attach other end of inches (50 mm) of spring extension tension should be
replacement wire to installation tool with electrical tape. adequate for proper operation.
Insert installation tool and wire into the boom sheave case in
20. Visually inspect interior routing of antitwo-block wire for
the open area between the sheave case side plates. Visually
excess slack in wire, inaccurate routing of wire, etc. Correct
guide this end under the center sheave on the extend
any problems before boom operation.
cylinder sheave case.
9. Push installation tool and wire through boom until it ANTI-TWO-BLOCK INTERNAL WIRE
appears at the winch mount end. Do not detach wire from SYSTEM: FOUR SECTION BOOM
installation tool.
10. From winch mount end of boom, locate installation tool Operation
and attached wire, and pull the wire out of the boom section,
The internal anti-two-block wire system is routed through the
removing the slack loop from the sheave case end of the
boom in two stages. The first stage, 1/2, runs between the
boom. This will place the wire close to, if not on the center
sheave of the extend cylinder.
top plates of the first and second sections on a traveling 3
block. The 1/2 and 2/3/4 sections are joined with a Weather-
11. Move to he sheave case end of the boom. Visually Pack connector. The second stage, 2/3/4, is anchored at the
determine if the wire has properly located itself onto the back of the second section, passes over the sheave at the
sheave. If not, manipulate the wire placement through the end of the telescoping cylinder and is then anchored at the
end of the boom and place the wire on the sheave. A 5 feet winch end of the fourth section. After running the length of
(1.50 m) long access tool (hook end) will simplify this the boom inside of the fourth section, it is connected to the
procedure greatly. anti-two-block switch mounted on the side of the sheave
case.
12. From the winch mount end of the boom, assemble the
anti-two-block wire clamp on the extend cable anchor in the Maintenance
rear of the 4th section. Loop anti-two-block wire around
clamp and lightly tighten capscrew holding clamp together. In the event of a break in continuity of the anti-two- block
Keeping a slight amount of tension on the wire at this point wire, the hydraulic portion of the system will be disabled and
will keep the wire properly located on the sheave. make certain crane functions inoperative. Before repair or
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
corr osion , an d over all syst em co nditio n. Due to t he
wire in the boom is now complete.
environmental exposure of the system, a thorough check of
14. Pull wire at either end of boom to adjust length of wire on the circuit should be performed.
sheave case end to properly attach and terminate wire.
If the internal wire has lost continuity it will probably be
15. Tighten anti-two-block wire clamp located in rear of 4th necessary to replace only one of the two stages in the circuit,
section. the 1/2 or the 2/3/4 stage. A simple continuity test of both
stages should identify which one contains the failure.
16. Route sheave case end of anti-two-block wire around
clamp in sheave case and through holes in side plates. 1. Unplug the Weather-Pack connector linking the two
Pulling on this end will tension the static length of anti-two- stages together at the winch end of the second boom
block wire clamped in the 4th. Approximately 15-25 lb (7-11 section.
kg) will be sufficient to provide proper operation. Tighten
2. With the anti-two-block switch in its closed position (weight
sheave case anti-two-block wire clamp.
suspended from switch or overridden with the red flag),
17. Reassemble quick disconnect plug to anti-two- block check continuity across the Weather-Pack terminals on the
wire. Proper wire attachment is critical for proper anti-two- 2/3/4 stage. If there is no continuity in the 2/3/4 stage, re
block system operation. Consult electrical schematic in this check continuity of the anti-two-block switch on its own and
book for proper connector wiring recheck continuity of the 2/3/4 wire to ensure the wire is the
problem. If continuity exists, the problem is in the 1/2 stage.
18. From winch mount end of boom, slide strain relief/cord
grip onto wire, into the approximate position inside the boom. 3. If the fault is suspected in the 1/2 stage, unplug the
connector at the turret. Install a jumper wire across the
19. Assemble spring to cord grip and reassemble anchor terminals of one of the connectors and check for continuity at
components to extend cable anchor in the 2nd section. Slide the opposite connector.
cord grip up anti-two-block wire into boom to increase spring
tension on moving length of anti-two-block wire. Approx. 2 After determining which wire stage contains the fault, refer to
the following procedures for replacement.

3-7
ELECTRIC SYSTEM 600E SERVICE MANUAL

1/2 STAGE ANTI-TWO BLOCK WIRE 11. Using the length recorded earlier, measure the cord and
REPLACEMENT attach the connector. The connectors on this cable are two
separate styles. Make sure the Weather-Pack connector is
The 1/2 stage anti-two-block wire is located between the top on the end that will attach to the 2/3/4 wire.
plates of the 1st and 2nd boom sections, riding on a traveling
12. Install a jumper across the terminals of one of the
block. The maintenance of this wire can be accomplished
conne ct ors a nd check for co ntinuit y at th e opp osite
with the boom fully assembled but would be simplified if the
connector. If the new wire does not have continuity, check
2/3/4 boom assembly was re moved from the first section.
the terminals to ensure they have been attached correctly.
Do not, under any circumstances, work at an elevated height
13. Do not proceed until this wire shows continuity.
without using proper fall protection as required by local, state
or federal regulations. 14. Visually inspect interior routing of anti-two-block wire for
excess slack in wire, inaccurate routing of wire, etc. Correct
DISASSEMBLY OF 1/2 STAGE any problems before boom operation.
15. Make all wire connections, reattach the wire to the
Alternative #1 cushion clamp on the bottom of the boom and check system
This procedure pulls the replacement wire through the boom for correct operation.
following the path of the defective wire. 16. Slowly cycle the boom while checking for proper wire
Special tools or equipment: operation.
• Two end-to-end electrical butt connectors Alternative #2
• Shrink tube or electrical tape
This procedure is used for anti-two-block wire re placement
1. Retract boom completely. in the event of a complete separation of the wire or the
inability to access one or both ends of the damaged wire
2. Unplug Weather-Pack connector between 1/2 and 2/3/4
outside of the boom assembly.
stage, located at rear of second boom section.
Specials tools or equipment
3. Unplug connector in turret and disconnect wire from
cushion clamp on bottom of first boom section. • Electrical tape

4. Measure the amount of wire from the retaining plates to • Installation tools
the connectors on both ends of the 1/2 wire. Record these 1. Retract boom completely.
numbers for later use.
2. Measure the lengths of the two ends of the anti- two-block
5. Remove capscrews and retaining plates from the top wires that are outside of the clamps on the first and second
backs of the first and second sections. boom sections. Record these dimensions.
6. Attach replacement anti-two-block wire to damaged wire 3. Remove capscrews and retaining plates from the top
with a "temporary splice", securing the conductors with end- plates of the first and second sections. Re move both ends of
to-end butt connectors and shrink tube or electrical tape. the damaged anti-two-block cord from the boom.
This connection must be secured well enough to pull the new
wire through the boom. 4. Extend the boom until the reinforcing plate on the top of
the second section is outside of the first section by about 24
7. Slowly pull the new wire into the boom by pulling on the inches (61cm).
opposite end of the damaged wire. If this method fails,
Alternative #2 should be used. 5. At the sheave case end of the boom, remove the two
capscrews and washer from the spacer bar under the bottom
8. Once enough new wire has been pulled past the retaining of the first section top plate.
plate location, remove temporary splice, reattach the
retaining plate and install the connector on that end of the 6. Using the anchor button on the steel cable, which drives
wire. The connectors on this cable are two separate styles. the anti-two-block wire, remove the spacer bar and pull the
Make sure the Weather-Pack connector is on the end that traveling blocks out of the boom.
will attach to the 2/3/4 wire. 7. Inspect the steel cable for damage or defects.
9. Loosely attach the retaining plate on the other end of the 8. Extend the boom to maximum extension. This provides
new wire. the least amount of overlap between the two sections and
10. While pulling on the new wire with a tension of about 15- makes it easier to hook an installation tool at the back of the
25 lb (7-11 kg), tighten the capscrews on the retaining plate. second section.

3-8
600E SERVICE MANUAL ELECTRIC SYSTEM

9. Using #9 wire or another stiff yet bendable material, make 22. Install a jumper across the terminals of one of the
two tools which are about 72 inches (183 cm) in length with a conne ct ors a nd check for co ntinuit y at th e opp osite
hook at one end which has an opening of 0.5 inch (1.3 cm). connector. If the new wire does not have continuity, check
the terminals to ensure they have been attached correctly.
10. Insert the hooked end of the two "tools" into the space
between the tops of the first and second sections and run 23. Do not proceed until this wire shows continuity.
them back until the tools hook over the top plate of the
24. Visually inspect interior routing of anti-two-block wire for
second section.
excess slack in wire, inaccurate routing of wire, etc. Correct
11. Run the replacement wire through the open sheave (one any problems before boom operation.
sheave will have the steel cable routed through it already) of
25. Make all wire connections, reattach the wire to the
the traveling block and temporarily attach each end of the
cushion clamp on the bottom of the boom and check system
new wire to the two tools. You have now made a big loop with
for correct operation.
the two tools and the new wire routed through the sheave.
12. Slowly retract the boom maintaining tension on the new
26. Slowly cycle the boom while checking for proper wire
operation.
3
wire, both sides of the loop, and the steel proportioning
cable. At the time when the rein forcing plate is about 24
inches (61 cm) outside of the first section, you need to allow 2/3/4 STAGE ANTI-TWO BLOCK WIRE
the traveling block to pass back into the first section. REPLACEMENT
13. While still maintaining tension on both sides of the loop of The procedure for removal and reinstallation of the 2/3/4
the new wire and a little tension on the steel proportioning stage anti-two-block wire can be accomplished using two
cable, retract the boom to full retraction. Do not allow the different methods depending on the severity of the damage.
retention button on the steel cable to go inside of the boom. Alternative #1 should be used if the wire has experienced a
continuity failure in the conductors but the rubber jacket of
14. At the winch end of the boom, reach inside of the boom
the wire is still intact. Alternative #2 is to be used if the wire
and draw out the two tools hooked over the top plate of the
has been completely cut or either end of the wire is not
second section.
accessible.
15. At the sheave case end of the boom, reinstall the spacer
Do not, under any circumstances, work at an elevated height
plate between the top front of the first and second sections.
without using proper fall protection as required by local, state
Make sure that the steel cable is still running through the slot
or federal regulations.
in the spacer bar.
16. At the winch end of the boom, draw the two ends of the Alternative #1
new wire out of the boom until the retention button on the
This procedure pulls the replacement wire through the boom
steel cable is drawn against the spacer bar.
following the path of the defective wire.
17. Run the new wire back and forth through the traveling
Special tools or equipment:
block sheave to make sure it r uns f reely. Do this by
alternately pulling on one end or the other of the new wire • Two end-to-end butt connectors
while maintaining slight tension on the other end of the wire. • Shrink tube or electrical tape
18. Loosely replace the retention clamps on the wire after 1. Retract boom completely.
measuring out one end to ensure the correct wire length for
the connector. 2. Loosen and remove capscrew and cable clamp from
sheave case attachment point. Remove connector from wire,
19. Tighten the clamp on the measured end of the wire and measure and record pigtail length from attachment point, and
replace the connector. The connectors on this cable are two pull end of wire through the side plates of the boom to align
separate styles. Make sure the Weather-Pack connector is the end with the wire routing over the telescope cylinder.
on the end that will attach to the 2/3/4 wire.
3. Attach replacement anti-two-block wire to the damaged
20. While pulling on the new wire with a tension of about 15- wire using the end-to-end butt connectors and tape or shrink
25 lb (7-11 kg), tighten the capscrews on the second tube. This connection must be secured well enough to pull
retaining plate. the new wire through the boom.
21. Using the length recorded earlier, measure the cord and 4. At the winch mount end of the boom, reach into the rear of
attach the connector. The connectors on this cable are two the boom and loosen the capscrew on the anti-two-block
separate styles. Make sure the Weather-Pack connector is cable clamp enough to let the cable run around it with
on the end that will attach to the 2/3/4 wire. minimal effort. This clamp is located on the extend cable
anchor at the back bottom of the fourth section.

3-9
ELECTRIC SYSTEM 600E SERVICE MANUAL

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

3-10
600E SERVICE MANUAL ELECTRIC SYSTEM

15. The routing of the new wire is now complete and the tool REPLACEMENT OF PROPORTIONING
can be detached from the wire. Visually inspect the wire CABLE FOR 1/2 STAGE OF ANTI-TWO
routing to make sure that it is correctly routed.
BLOCK WIRE
16. Pull the wire from either the sheave case or winch end of
the boom to get the end lengths closer to what is required. 1/2 Stage Anti-Two Block Wire Operation
17. Tighten the clamp at the bottom back of the fourth The 1/2 stage of the anti-two-block wire is driven by a small
section. diameter steel proportioning cable. This cable drives the
18. Reassemble the clamp at the sheave case and while traveling block, which carries the live wire of the system. The
applying 15-25 lb (7-11 kg) of tension to the new wire, tighten location of the traveling block at full extension and retraction
the clamp. Measure the length of pigtail required and is critical to the proper operation of this system. If the
re ass emb le th e c onn ect or o nto t he wir e. Rou te th e traveling block is not located correctly, it could either fall off
c o n n e ct o r t h r o u g h t h e s h e a v e c a s e a n d m a k e t h e of the back of the second section during boom extension or
connection with the anti-two-block switch. The connectors on be pinched between the first and second section top plates 3
this cable are two separate styles. Make sure the Weather- by the reinforcing plate on the second section during boom
Pack connector is on the end that will attach to the ½ wire. retraction.

19. At the winch end of the boom, install the cord grip and 1/2 Stage Anti-Two Block Wire Maintenance
spring onto the new wire at the approximate final position
inside of the boom. Install the capscrew into the spring and The wire can be replaced with the boom assembled. If the
cable anchor. While applying tension to the wire, slide the wire has separated and become lodged in the boom extend
cord grip out the wire until there is approximately 2 inch (50 and/or retract sheaves, boom disassembly will probably be
MM) of spring extension for proper operation. required. There are two alternatives to the steel cables'
replacement. Alternative #1 will deal with an intact cable and
20. Attach connector to wire. The connectors on this cable alternative #2 will deal with a cable that has been cut into two
are two separate styles. Make sure the Weather-Pack pieces. The replacement cable supplied through National
connector is on the end that will attach to the 1/2 wire. Crane Crane Care works for several different lengths of
booms. It will have to be installed and cut to the correct
21. V isually insp ect rou ting an d ancho rs for corr ect
length during assembly.
assembly, excessive slack and/or capscrew torque, etc.
Verify continuity of new anti-two- block wire.

MODEL LENGTH (X)

685E 555.50
680E 525.00
649E 339.50

3-11
ELECTRIC SYSTEM 600E SERVICE MANUAL

Alternative #1 boom assembly. When the eyelet of the new wire becomes
visible at the winch end of the boom, stop pulling on the wire.
Special Tools:
7. Detach the old and new wires. Insert the eyelet of the new
o Electrical tape wire into the space between the top plates of the first and
o Short Cord or Wire second sections. Reattach the wire to the top plate of the
second section with the 5/16-18NC grade 5 capscrew that
1. Retract the boom completely. was removed earlier.
2. At the winch mount end of the boom, remove the 5/16-1 8. At the sheave case end of the boom, install the spacer and
8NC grade 5 capscrew through the slot capscrews in the top front of the first section. Make sure that
on the top plate of the first boom section. the new anti-two-block wire is routed through the slot in the
spacer bar.
3. Pull the end of the cable out of the back of the boom and
connect a short piece of wire or cord through the loop. 9. Visually inspect the routing of the proportioning cable to
Anchor the cord in order to keep control of the end of the make sure that it is properly seated in the sheave grooves.
cable. 10. Cut off the excess wire from the new wire that is sticking
4. At the sheave case end of the boom. Remove the two out of the first section leaving a length of about 24 inches (61
capscrews and spacer bar from the top front end of the first cm). This will allow a short amount of wire to use to apply
boom section. As the spacer bar is removed, pull the steel tension and for the installation of the cable stop and shrink
cable along with the bar. The cord on the opposite end of the tube without dealing with a lot of extra wire.
steel cable will allow some length of cable to be pulled from 11. Slide the cable stop onto the end of the wire sticking out
the boom. Do not pull hard enough to break the winch end of of the end of the first section and run it up against the spacer
the cable loose. bar. While pulling on the steel cable with a tension of about
5. Remove the cable sto p from the end of the old 15-25 lb (7-11 kg), tighten the screw in the cable stop.
proportioning cable and fasten the eyelet end of the new wire 12. Slide a new piece of shrink tube onto the end of the wire,
to the old cable with electrical tape. run it up against the cable stop, and apply heat to shrink the
6. While maintaining some amount of tension on the new tube. This will prevent the end of the wire from fraying.
wire pull the old wire out of the boom at the winch end of the 13. Cut off the excess wire leaving about 1 inch (25 mm) of
wire with shrink tube sticking out of the cable stop.
14. Slowly operate the boom to make sure the sheaves turn
and the cable runs correctly.

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600E SERVICE MANUAL ELECTRIC SYSTEM

Alternative #2 on the new wire and bend the wire over to make a hook.
Tape the #9 wire and new proportioning cable to make sure
This is the method to be used in the event the pro portioning these parts stay together as the cable is installed. The new
cable has been cut during use. In this method a long wire is now attached to the installation tool.
installation tool is used to run the new wire from one end of
the boom to the other. 8. Insert the tool into the space between the top plates of the
first and second sections and hook it over the back of the top
Special tools: plate on the second section.
• Electrical tape 9. Slowly retract the boom while maintaining tension on the
• Installation tool new steel cable.
1. Retract the boom completely. 10. When the boom is fully retracted, reach into the boom
and pull the tool on out of the back of the boom. Detach the
2. At the winch end of the boom, remove the 5/16 -1 8NC tool from the new proportioning cable. Route the end of the
capscrew from the top plate of the second section. This new wire around the sheave at the back of the first section 3
capscrew is accessible through a slot in the top plate of the and align the eyelet of the cable with the hole in the top plate
first section. of the second section. Loosely install the 5/16-18 NC
3. Remove the old wire from the boom. capscrew.

4. Extend the boom until the reinforcing plate on the second 11. On the power circuit side of the anti-two-block system,
section is extended about 24 inches (61 cm) out of the first disconnect the connectors in the turret and remove the
section. cushion clamp at the bottom of the boom. Loosen the cable
clamp on the top winch end of the first section. Loosening
5. At the sheave case end of the boom, remove the two
this wire will allow the traveling block to be drawn out of the
capscrews and the spacer plate from the front top of the first
front end of the boom assembly.
section. As the spacer plate is pulled from the boom, bring
the old wire out of the boom. 12. While the new steel proportioning cable is being held and
guided to prevent damage, extend the boom until it is fully
6. Extend the boom completely.
extended.
7. Use a piece of #9 wire as an installation tool. Make a hook
13. Again using the #9 wire, reach into the space between
with an opening of about ½ inch (13 mm) on one end. With
the first and second sections and hook and pull the traveling
the other end of the #9 wire, run the wire through the eyelet

3-13
ELECTRIC SYSTEM 600E SERVICE MANUAL

block out of the boom assembly. Inspect the traveling block that the new anti-two-block proportioning cable is routed
for damage. through the slot in the spacer bar.
14. Route the proportioning cable around the sheave 19. Visually inspect the routing of the proportioning cable to
mounted to the top plate of the first section. Then run the make sure that it is properly seated in the sheave grooves.
new steel cable through the open sheave of the traveling
20. Cut off the excess wire from the new wire that is sticking
block. Visually inspect to ensure the wire is routed correctly.
out of the first section leaving a length of about 24 inches (61
15. At the winch end of the boom, slowly pull the circuit wire cm). This will allow a short amount of wire to use to apply
back out of the back of the boom until it reaches its original tension and for the installation of the cable stop and shrink
location. A crimped area on the jacket of the wire should be tube without dealing with a lot of extra wire.
visible and line up with the clamp plate. Loosely tighten the
21. Slide the cable stop onto the end of the wire sticking out
retaining plate capscrews.
of the end of the first section and run it up against the spacer
16. If the parts are properly aligned, the center pin of the bar. While pulling on the steel cable with a tension of about
sheave on the sheave case end of the traveling block should 15-25 lb (7-11 kg), tighten the screw in the cable stop.
be about ll-1/2 inches (29 cm) behind the center of the
22. Slide a new piece of shrink tube onto the end of the wire,
sheave bolted to the top plate of the first section. If the
run it up against the cable stop, and apply heat to shrink the
traveling block is not located correctly, it will be damaged
tube. This will prevent the end of the wire from fraying.
during boom extension or retraction.
23. Cut off the excess wire leaving about 1 inch (25 mm) of
17. Tighten the 5/16-1 8NC capscrew at the top winch end of
wire with shrink tube sticking out of the cable stop.
the second section. Tighten the capscrews in the retaining
plate at the winch end of the first section. 24. Slowly operate the boom to make sure the sheaves turn
and the cable runs correctly.
18. At the sheave case end of the boom, install the spacer
and capscrews in the top front of the first section. Make sure

3-14
600E SERVICE MANUAL ELECTRIC SYSTEM

3. Always be sure the boom is adequately supported

and no hydraulic pressure remains in the lines before
HYDRAULIC CAPACITY ALERT SYSTEM the pilot pressure line fittings are loosened.
The Hydraulic Capacity Alert System (HCA) consists of a
normally open Pump Enable Valve, a bonnet switch circuit
and a capacity alert circuit. Both circuits must be broken to HCA System Adjustment
deactivate the pump flow.
The hydraulic capacity alert system should be checked for
When trip pressure is reached, the pressure sensing switch proper adjustment during initial crane start-up and quarterly
breaks electrical continuity in the HCA circuit to the Pump thereafter. The procedure for proper adjustment should be
Enable Valve. The Pump Enable Valve gets power from 2 performed as follows: Trapped air must be bled from the
circuits, the HCA circuit and the main valve bonnet circuit. system before adjustments are made.
The bonnet circuit will keep the Pump Enable Valve live
unless the actions that incre ase the load ra diu s a re 1. Remove the console cover depending on crane model. 3
activated. These are telescope extend, boom down, and
winch up. When both circuits are broken, the normally open
dump pump solenoid will open which will destroke the pump WARNING
and stop all crane function. When the overload condition is
corrected by winching down, retracting the boom, or raising Before loosening any fittings, support the boom.
the boom, the pressure sensing switch allows the Pump
Enable Valve to reactivate and thereby reactivates all crane 2. Start the truck and set the crane up for operation as
functions. prescribed in the Operators Handbook.
3. Select a test weight that is equal to crane capacity at an
HCA Override intermediate boom length and radius.
The override system consists of a momentary push button 4. Work with loads which have loaded boom angles near
switch located on the operators console. To momentarily 30°. Starting with the boom at the chosen reference
override, depress push button on console. This will activate angle and a radius less than the chosen radius, pick the
the pump dump solenoid and return power to winch , weight up with the winch and begin extending the boom.
telescope out, and boom down functions.
5. As the boom is extending, lower the load with the winch
to keep the load near the ground.
6. Monitor the load range gage located in the console as
the boom is extending. The gage is plumbed directly into
WARNING the lift cylinder pilot line and the pressure reading should
The override switch is not to be used during normal use of increase to what is defined as capacity load pressure as
the crane or as and aid in using crane in an over load or the selected intermediate boom length and radius is
anti-two blocked condition
reached.

HCA Maintenance & Repair

The following step-by-step analysis will be helpful in isolating
and correcting almost every service problem if followed in a
step-by-step systematic manner. Use this information with
the Hydraulic Schematic and the Illustrated Parts Catalog to
identify parts and follow flow paths. Start at top box and work
downward step by step. Do not try to start in the middle or
skip steps.

1. Refer to Hydraulic Schematic and System Description to

gain a thorough understanding of the capacity alert
system before proceeding with any maintenance.
2. System adjustment must be checked every three
months for accuracy. Refer to the preceding section on
System Adjustment.

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ELECTRIC SYSTEM 600E SERVICE MANUAL

7. The intermediate boom length is determined by a line 13. Check the trip pressure setting by extending the load
and corresponding dimension decal on the side of the until the chosen radius is reached. As the chosen radius
second section boom. The chosen radius is measured is reached, the system solenoid should be deactivated
from the centerline of rotation to the loadline. and the indicator light should come on. Readjust switch
head if trip pressure is not correct.
8. If the gage reading does not increase while extending,
lower the load to the ground and check the system 14. Once proper adjustment is verified, return the boom to a
plumbing according to the hydraulic schematic. Re- firmly supported position, stop the truck engine and
plumb the system according to the schematic and replace covers.
illustrated parts page or replace faulty pressure gage..
JIB LOAD LIMITING DEVICE
The jib load limiting device is an electromechanical operated,
WARNING maximum capacity sensing device that will stop all of the
Before loosening any fittings, support the boom. normal crane functions that cause overload when maximum
capacity of the jib is exceeded. In the event that an over
9. When the pressure reaches capacity load pressure, the capacity condition occurs, the jib load limiting device is
overload system should activate and boom extension actuated by sensing excessive force on a load cell which
will stop. This is defined as trip pressure. This point causes the boom down, extend out, and winch up functions
should be at or very close to the red/yellow color change to become inoperative. These are the functions that
on the load range gage. increase the over capacity condition. On jibs with a manually
extendable section, a configuration switch operated by the
10. Trip pressure should be reached as the boom extension extension retaining pin distinguishes between an extended
reaches the chosen radius. If the overload system trips jib and a retracted jib. This system allows for continued
before the chosen radius is reached or allows extension operation of the winch down, boom up, and boom retract
beyond the chosen radius, adjustment is required. If the functions, the functions that normally allow the operator to
system is activated before trip pressure is reached, bring the load to a shorter operating radius or set the load
lower the load, remove and turn the knurled collar on the down in order to eliminate an over capacity condition. Once
HCA pressure switch clockwise to increase trip the excessive force on the load cell has been reduced by
pressure. bringing the load to a shorter radius or setting the load down,
normal operation can be resumed.
The Jib Load Limiting Device consists of a normally open
Pu mp Enable Valve, a bonnet switch circuit and a
capacity alert/ATB/Jib Load Limit Device circuit. Both
circuits must be broken to deactivate the pump flow. Two
indicator lights located on the operator’s console alert the
operator of function power loss and discriminate between the
hydraulic capacity alert and the anti-two-block or jib load
limiting systems as the cause of power loss. In the event of a
two-block or jib overload condition, an audible alarm will
sound in addition to the lighting of the indicator light.
When trip force is reached, the jib load limiting device breaks
electrical continuity to the hydraulic capacity alert/ATB/jib
load limit device circuit to the Pump Enable Valve. When the
overload situation breaks electrical continuity in this circuit,
Pressure Relief Switch the ATB/JIB warning light on the console should come on
and the audible alert alarm should sound off. The Pump
11. When the gage reaches trip pressure, turn the setscrew Enable Valve gets power from 2 circuits, the HCA/ATB/jib
counterclockwise until the system solenoid is load limit device circuit and the main valve bonnet circuit.
deactivated and tighten the locking nut. The bonnet circuit will keep the Pump Enable Valve live
unless the actions that increase the jib overload are
12. Retract the boom until the pilot pressure is reduced activated. These are telescope extend, boom down, and
enough to reactivate the system solenoid. The hydraulic winch up. When both circuits are broken, the normally open
capacity alert indicator light will go out when the solenoid dump pump solenoid will open which will de-stroke the pump
is reactivated. and stop all crane function. When the overload condition is
corrected by winching down, retracting the boom, or raising

3-16
600E SERVICE MANUAL ELECTRIC SYSTEM

the boom, the jib load limiting related circuit resets and 3. This is displayed only before a new table number is
allows the Pump Enable Valve to reactivate and thereby stored in EEPROM. The 2 will be displayed first.
reactivates all crane functions and shuts off the warning light
4. The switches are set up with the combination of
and the audible alert alarm
numbers to erase the table number. On the next power
During operation at near capacity loads, care must be on, the table number will be read in and stored to
taken to operate the controls smoothly or the system may EEPROM.
be shocked into the dump mode prematurely. After the startup codes, the table number will be displayed in
Single Character Display the form of 3 digits. The first digit will always be a zero. The
digits will each be displayed for about 1 second.
The electronics box of the jib load limiting devices equipped
with a single character display that provides the following After the table number is displayed, the display will begin to
information: sequence through the following information. After reaching
the end of the sequence, the display will start again at the
• startup codes current load reading. 3
• table number selected Current load reading (lbs.):
• current load reading - 4 digits, decimal point on
• current limit value • Current limit value (lbs.):
• error codes - 4 digits, decimal point flashing
• current angle reading. • Error codes (only if an error exists):
On power-up, the unit first displays startup codes. The - 4 digits, first and last digits are blanks.
startup code can consist of up to four digits, but will usually
be only the single digit "2". Each number will be displayed for - 0-invalid table number,
only ½ second. The codes are: - 1-load readings higher than the limit.
1. The EPROM is being initialized. This should only • Current angle reading:
happen the first time the units powered on after it is
programmed. - 4 digits, decimal point off, displays in tenths of
degrees.
2. The unit is checking for the combination of numbers that
erase the previously stored table number in the Jib Load Limiting Device Troubleshooting
EEPROM. This will be displayed when the unit is
powered on and the switches are not set with this See chart in Section 8 of this manual.
combination of numbers.

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ELECTRIC SYSTEM 600E SERVICE MANUAL

PAGE INTENTIONALLY LEFT BLANK.

3-18
600E BOOM

SECTION 4
BOOM
TABLE OF CONTENTS
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Three Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Three Section Cable Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3 Section Boom Disassembly Alternative #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3 Section Boom Disassembly Alternative #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Inner Wear Pad Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4
Four Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Four Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
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 . . . . . . . . . . . . . . . . . . 4-15
Top Rear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Front Bottom Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Shim Calculation For Wear Pads (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Single Section Extend Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Extend Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Extend Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Multi-Stage Extend Cylinder Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Cylinder disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Replacing Holding Valve on Multi-Stage Extend Cylinder . . . . . . . . . . . . . . . . . . . 4-20
Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-i
BOOM 600E

PAGE INTENTIONALLY LEFT BLANK

4-ii
600E SERVICE MANUAL BOOM

SECTION 4
BOOM

1. Extend Cable Adjustment 4. Retract Cable Adjustment 7. Section 2

2. Section 1 5. Extend Cable Adjustment 8. Section 3
3. Retract Cable 6. Extend Cable Anchor 9. Tip

THREE SECTION BOOM OPERATION section, therefore providing retraction of the 3 rd boom
section. This type of boom operation provides that the 2 nd
A rod-fed, double-acting cylinder, attached to the 1 st and 2nd
and 3 rd section booms extend and retract equally. Proper
boom sections, supports and propels the 2 nd boom section.
service and maintenance is required to insure smooth and
The extend cables attach to the base end of the 1 st boom proper operation.
section, are reeved around sheaves attached to the cylinder,
and attach to the base end of the 3 rd boom section, providing Special Boom Inspection
support and extension the 3 rd boom section. If the boom has not been disassembled and inspected in the
st last five years or 3,000 hours of use, the boom is to be
The retract cables attach to the tip end of the 1 boom
completely torn down to allow a thorough inspection of the
section, are reeved around sheaves attached to the 2 nd extend and retract cables, sheaves, and pins.
boom section, and attach to the base end of the 3 rd boom

4-1
BOOM 600E SERVICE MANUAL

THREE SECTION BOOM MAINTENANCE 3. Remove hook block or downhaul weight. Wind up rope
on winch drum and stow wedge socket on pegs provided
Three Section Cable Tensioning on 1st section. Shut down truck engine.
After boom reassembly or from time to time if interior
proportioning cables appear loose, cable tensioning may be
required. Tensioning must be done with the boom horizontal.
1. Slightly tighten all cables. Then cycle the boom approxi-
mately 4 feet (120 cm) out and in a few times to equalize
the extend and retract cable/ boom section sequence
positioning.
2. Fully retract boom. Do not induce and hold hydraulic
pressure. At full retraction, observing through the winch
mount end of the boom, the second section should be
bottomed on the extend cylinder butt plate, and the third
section should be bottomed on the thick vertical side
plates welded to the inside of the second section.

NOTE: It is important to achieve these boom postitions

before torquing.
3. If the boom sections do not bottom out as specified
(boom is out of sequence), adjust cables to achieve
proper section positioning.
4. Torque retract cables to 6 ft-lb (8.13 Nm). Cable
adjustment point is located at the sheave case end of 1. Winch 5. Winch Down Hose 2
the boom, on the bottom of the 1 st section. Use the flats
2. Boom 6. Winch Up Hose 3
at the front of the cable ends to keep the cables from
turning while torquing retainer nuts. 3. Capscrew (6 plcs) 7. Winch Alignment Ears
5. Torque extend cables to 20 ft-lb (27.11 Nm). Cable 4.Hyd Hose 1
adjustment point is located at the rear of the boom on
the cable anchor bar going through the winch mount. 4. Remove and cap hydraulic hoses.

6. Repeat Steps 4 and 5. a. Tag hydraulic hoses to avoid confusion during re-
assembly (the inside hose “up” and the outside is
7. Torque the retract cables to 12 ft-lb (16.26 Nm). “down”).
8. Torque the extend cables to 30 ft-lb (40.67 Nm). 5. Pull hydraulic hoses thru access hole towards turret.
9. Cycle the boom fully, check that all cables are torqued
properly and that all sections are retracted completely,
then add jam nuts to all cables. All threaded cable ends
must be equipped with retainer nuts and jam nuts.
CAUTION
WINCH REMOVAL The combined weight of the winch and 325 ft. of wire rope
is 660 lbs (300 kg).
1. Extend and set the outriggers.
6. Remove Rope Guard mesh and attach suitable lifting
device to winch and take up the slack.
DANGER
7. Remove 6 mounting capscrews and washers (3 on each
Do not, under any circumstances, work at an elevated side).
height without using proper fall protection as required by
local, state or federal regulations. 8. Lift winch clear of boom and secure to a suitable holder.

2. Fully retract the boom and place in a horizontal position.

4-2
600E SERVICE MANUAL BOOM

3 Section Boom Disassembly Alternative #1

1. Gaining access through rear of boom, loosen capscrews
BOOM REMOVAL
retaining the extend cable anchor in the rear of the 3rd
Boom Length Boom Weight CG from pivot point section as well as the capscrew on the anti-two-block
71’ 5583 lb (2532 kg) 140" (3.56 m) wire clamp on the anchor assembly.
47' 4294 lb (1948kg) 96" (2.44m)
38’ 3782 lb (1716 kg) 79” (2.01m) 2. Extend boom 24 inches (60 cm). Loosen and remove
the nuts which secure the extend cables to the cable
1. Extend and set machine outriggers. Boom must be com- anchor plate. Remove nut from anti-two-block spade
pletely retracted and stowed in the boom rest. bolt. Tag and disconnect hydraulic lines to the extend
cylinder.
2. If equipped, remove swing around jib according to
procedures outlined in the Operators Handbook, Section 3. Drape extend cables and anti-two-block cable inside
4. boom, and slide cable anchor plate out of the side of the
winch mount if winch has been removed from boom.
3. Remove hook block or downhaul weight. Wind up rope
on winch drum and stow wedge socket on pegs provided 4. Loosen and remove two capscrews, lockwashers and
st
on 1 section. Shut down truck engine. spacers which anchor the extend cylinder rod butt plate
to the rear of the 1st section.
4. Attach a lifting device to rod end of lift cylinder, remove
boom lift cylinder pin keeper and pin from bottom of the 5. Loosen and remove two capscrews and lockwashers 4
1st section boom. Lower lift cylinder to a suitable securing spacer bar to the inside top of the front of the
support. 1st section. Remove spacer bar.

5. Tag and disconnect extend cylinder lines and winch 6. Loosen and remove four capscrews securing wear pads
hydraulic lines. Cap all open lines and ports. to the bottom of the 1st section. Removal of side wear
pads is optional. Adequate clearance exists between
6. Attach a lifting device to provide even weight distribution
adjoining section side pads for boom disassembly. If
and raise the boom until weight is removed from the
side pad removal is required, tag all pads, shims, and
boom pivot pin. Remove boom pivot pin keeper and
corresponding locations for proper reassembly.
boom pivot pin. Lift boom free of turret.
7. Support 2nd-3 rd assembly at the front with an
Boom Disassembly
appropriate lifting method. Raise the 2nd-3rd assembly
The 600E boom can be disassembled by using two different inside the 1st section to allow for front bottom pad
methods. Alternative #1 disassembles the boom in the removal. Remove bottom wear pads.
conventional manner. Alternative #2 removes the extend
cylinder from the rear of the boom, after removal of the 8. With the 2nd & 3rd assembly supported, slide assembly
winch. This feature facilitates cylinder service without out of the 1st. Relocation of the sling point on the 2nd &
complete boom teardown.
3rd assembly will be necessary for proper balancing of
For reference, the front of the boom refers to the sheave the assembly as it slides out of the 1st section. Keep
case end, the rear of the boom is the winch mount end. Left tension on retract cables as the assembly is pulled out of
and right are viewed from front to rear. the 1st , to minimize the chance of retract cable damage.
If the boom is to be unpinned from the turret of the crane
9. Place 2nd & 3rd assembly on a suitable horizontal
structure, please refer to the Boom Removal Procedure
surface. Take care not to pinch or crush retract cables
section in this book. If the required service procedure is to be
while lifting or supporting assembly.
performed on the boom while still pinned to the turret, please
follow these directions. 10. Remove top rear wear pads on the 2nd section. They will
lift off the cam plates easily. Do not remove or loosen the
capscrews holding the cam plates to the section. This
will affect side clearance during re-assembly.
11. Loosen and remove four capscrews securing the rear
DANGER
bottom wear pads on the 2nd section. This pad serves as
Do not, under any circumstances, work at an elevated a bottom and side pad as well as the retract cable
height without using proper fall protection as required by keeper under the retract sheaves. Removal of this pad
local, state or federal regulations. will allow the retract cables to uncoil off the retract

4-3
BOOM 600E SERVICE MANUAL

sheaves. Place retract cable ends in a location to clearance for boom disassembly. If removal of side pads
minimize the possibility of damage. is required, tag all shims, pads and corresponding
locations for proper re-assembly.
12. Loosen and remove six capscrews securing retract
sheave pin and retract sheaves to 2 nd section. Remove 24. Loosen and remove all remaining capscrews and wear
sheaves and pins. pads from boom sections.

13. Loosen and remove two capscrews functioning as upper 3 Section Boom Disassembly Alternative #2
retract cable keepers.
The 600E boom design allows for removal of the extend
14. Loosen and remove two capscrews securing lock bar to cylinder from the rear of the boom without complete
the extend cylinder collar. This bar constrains the disassembly of the boom sections. This procedure allows
vertical movement of the extend cylinder. Remove bar. quick access to the cylinder, retract cables, and various
15. Loosen capscrews retaining extend cable anchor to internal boom components for service or replacement.
back of the 3 rd section. Total removal of the capscrews
will allow the cable anchor to be completely
disassembled, backing capscrews out approximately
.50 inch (12 mm) will allow the anchor assembly to slide DANGER
rearward out of the section as the extend cylinder is
removed. Do not, under any circumstances, work at an elevated
height without using proper fall protection as required by
16. Support extend cylinder with an appropriate lifting local, state or federal regulations.
device and pull the extend cylinder out of the boom while
keeping the extend cables and anti-two-block wire 1. Remove winch. Please refer to the winch removal sec-
tensioned slightly by hand to minimize the possibility of tion in this book.
damage to the cables. Pull cylinder to within 3 feet (91
cm) of complete removal from the boom sections. 2. Gaining access through rear of boom, loosen capscrews
retaining the extend cable anchor in the rear of the 3rd
17. Reach into the rear of the 3 rd section and loosen and section as well as the anti-two-block wire clamp on the
remove the anti-two-block cable clamp on the extend anchor assembly. Loosen and remove two capscrews
cable anchor. Pull the extend cable anchor out from its retaining lock bar to extend cylinder. Remove lock bar
retaining pocket on the bottom of the 3rd section. A slight
3. Extend boom 24 inches (61 cm). Loosen and remove
angle applied to the anchor as it is being pulled to the
the nuts which secure the extend cables to the cable
rear will permit easier removal through the 2 nd section. anchor plate. Remove nut from anti-two-block spade
18. Remove the extend cylinder from the boom. bolt.

a. Do not allow sheaves to fall off the pin on the end of 4. Drape extend cables and anti-two-block wire inside
the extend cylinder. boom, and slide cable anchor plate out of the side of the
winch mount.
b. Remove extend cables. Place cylinder and cables in
suitable area to prevent possible damage. 5. Loosen and remove two capscrews, lockwashers and
spacers which anchor the extend cylinder rod butt plate
19. Remove retract cables from the back of the 3 rd section to the rear of the 1 st section.
by manipulating cable end through the slot in the anchor.
Place cables in location to prevent possible damage. 6. Using appropriate lifting device, lift extend cylinder up
and out of retaining slot on rear of 2nd section.
20. Anti-two-block wire can be removed if necessary by
Retracting cylinder with an external hydraulic power
disassembly of the clamp arrangement at the sheave
source during this step may be necessary.
case and pulling wire through boom.
7. Pull cylinder out through rear of boom assembly
21. Loosen and remove two capscrews, cable guide, wear
approximately one-half the length of the cylinder.
pad and spacer bar from the front top of the second
Turning of the butt plate and rod 90 degrees may aid in
section.
sliding cylinder through winch mount area. Keep extend
22. Loosen and remove four capscrews attaching the cables tight to minimize the possibility of damage.
bottom pad plate to the second section. Slightly lift third
8. Lift extend cylinder up until it contacts inside of boom
section, and remove pad plate.
section. Remove anti-two-block wire clamp from extend
23. Slide 3 rd section out of 2nd section. Removal of side cable anchor. Remove anchor by pulling anchor and
pads is optional, as the side pads have adequate cables out rear of boom. A slight angle applied to the

4-4
600E SERVICE MANUAL BOOM

anchor as it is being pulled to the rear will permit easier 3. Install 3rd section boom into 2 nd section. Slide together
removal. approximately 5 feet (150 cm).
9. Continue to pull extend cylinder and cables out of rear of
4. Assemble bottom front wear pads for 2nd section and
boom. Remove extend cables and store in an area to
Teflon plugs. Attach pads to pad plate.
minimize the possibility of damage.
5. Using appropriate lifting device, lift 3rd section to allow
Additional Maintenance, Disassembled for wear pad/pad plate installation in front of 2nd . Install
Boom wear pad/pad plate assembly. Slide sections together
1. Clean all boom sections and inspect for wear, dents, within 12 inches (30 cm) of full retraction.
bent or bowed boom sections, gouged metal, broken 6. Install front side wear pads with appropriate shims,
welds or any abnormal conditions. Repair or replace as between 3rd and 2nd sections. If boom has been
required. disassembled, and no sections have been replaced, use
2. Inspect all sheaves for excessive groove wear or same shim quantity and location as was previously
abnormal rim wear. Replace as required. used.

3. Inspect all sheave bearings for excessive wear or cut 7. Route anti-two-block wire through 3rd section, keeping
liner material. If installed bearing diameter is .015 bulk of wire at the rear of the boom sections. Routing
inch (.38 mm) larger than the pin diameter, bearing can be accomplished using an installation tool, such as
must be replaced. Any cut or gouge which causes the a telescopic boom grease applicator, electrical conduit, 4
bearing liner to be distorted is cause for bearing or hydraulic tubing. Route anti-two-block wire between
replacement. sheave case side plates. If locations are in question,
refer to Shim Calibration Section in this manual.
4. Clean and inspect all cable assemblies according to the
wire rope inspection procedures in this section. Pay 8. Uncoil retract cable assemblies, and insert button end
particular attention to any wire breakage within 6 feet into anchors in back of the 3rd section. Place uncoiled
(180 cm) of the end connections. Replace cable cable in area that will minimize the potential for damage.
assemblies as required. Lubricate all cable assemblies
9. Assemble retract sheaves and retract sheave pins in
before reinstalling them in the boom.
rear of 2nd section. Coat surfaces of bearings with
5. Inspect all sheave pins for nicks, gouges or pitting due to grease before assembly.
rust in the bearing surface area. Replace if any damage
is evident. 10. Place retract cables over top of retract sheaves. Install
keeper capscrew above sheave to hold retract cables in
6. Inspect anti-two-block wire full length for damage, check place.
for electrical continuity.
11. Reeve cables over retract sheave and install keeper/
THREE SECTION BOOM ASSEMBLY wear pad to bottom rear of 2nd section. This pad acts as
a side pad, bottom pad, and a cable retainer.
NOTE: Do not use Loctite on any cable threaded ends.
Always use the locknut and nut provided. 12. Assemble exterior extend cylinder components.
Install and center sheave pin into butt plate of extend
cylinder. Install bearings into extend cable sheaves.
NOTE: When initially assembling threaded ends of Coat surface of bearings with grease and assemble
cables, thread the first nut on past the flat in the extend sheaves on sheave pin.
cables so adjustment can be made later.
13. Wrap approximately 10 feet (300 cm) of each 5/8 inch
NOTE: Refer to Inner Wear Pad Calibration on page 4-8
(15.88 mm) diameter extend cable around extend
of this section to determine Wear Pad shim
sheaves and install extend cable anchor. Do not tighten
thickness.
capscrews clamping anchor together completely. These
1. Assemble sheaves into 3 rd section sheave case. Top capscrews if tightened completely will not allow cable
sheave is to be installed to the left hand side of the boom anchor to install into 3rd section. Route anti-two-block
with the spacer to the right hand side. cable over center sheave on extend cylinder.

2. Attach rear wear pads on bottom of 3 rd section. Using 14. Install wear pad over extend cylinder sheave side plates.
Loctite 242 blue, Loctite all wear pad mounting This serves as a wear pad to keep the end of the extend
capscrews. cylinder centered in the boom, as well as an extend
cable retainer.

4-5
BOOM 600E SERVICE MANUAL

15. Slide extend cylinder /extend cables into 2 nd/3rd boom 27. Assemble bottom front wear pads in 1st section, trapping
assembly enough to assemble extend cable anchor into ends of retract cables in slots on bottom of 1 st section.
bottom rear of 3rd section. Route anti-two-block cable Lift 2 nd/3rd/cylinder assembly up to ease installation.
rd
over extend cable anchor as anchor slides into 3
28. Slide boom together to within 12 inches (30 cm) of
section. Be aware of extend and anti-two-block cable
location when inserting cylinder into boom sections, complete retraction. Install upper front spacer bar in 1 st
inadvertent crushing or other damage to cables will section and upper front wear bar and cable guide
warrant replacement. assembly to 2nd.
16. Tighten capscrews clamping extend anchor together. 29. Retract boom completely, using proper hardware and
These capscrews will protrude through the 3 rd
section spacers, connect extend cylinder butt plate to the winch
bottom plate, locking the anchor in position. mount. Hydraulic power source can be utilized at this
time if slight cylinder length adjustment is necessary.
17. Loop anti-two-block cable at the extend cable anchor in
30. Slide extend cable anchor into position in winch mount.
the 3rd and install anti-two-block cable clamp. Do not
Push threaded ends of 5/8 inch (15.88 mm) extend
completely tighten clamp capscrew.
cables through holes in anchor and assemble hex nuts
18. Assemble anti-two-block clamp in the sheave case. onto threaded ends.
Reeve anti-two-block cable around anchor and through
holes in side plate of sheave case. Pull approximately 2 31. Assemble top/rear wear pads to the top of the 2nd and
feet (60 cm) of cable out the end of the boom for proper 3rd boom sections with the cam plates.. Wear pads can
routing and termination. be inserted from the winch mount end of the boom.
Install capscrews through holes in outer boom sections.
19. Tighten anti-two-block clamp on the extend cable
anchor in the rear of the boom. Tension anti-two-block 32. The wear pad on each side at the top/rear of the boom
cable from the sheave case end of the boom, and can be adjusted over a range of 3/16" (4.8 mm) by
tighten anti-two-block clamp located in sheave case. rotating, end for end, the wear pad and plate or the wear
pads and plate independently. This is possible because
20. Visually verify that the extend and anti-two-block cables
the holes in these parts are offset from the center. The
are properly routed on their sheaves and continue to
holes are .06" (1.5 mm) off center in the plate and .03"
slide the extend cylinder and cables into the boom
(.8 mm) off center in the wear pad. Various combinations
sections. Keep extend and anti-two-block cables
of rotation of these parts allow the adjustment.
supported and slightly tensioned during insertion of
cylinder, to maintain proper cable placement. a. Adjust pads until they are within .03” (.8mm) off
center in the were pad. Various combinations of
21. As the extend cylinder keeper plate nears the 2nd rotation of these parts allows the adjustment.
section, adjust the height of the cylinder to allow the
cylinder to access the cylinder keeper cutouts in the b. Torque retainer capscrews to 110 ft-lb (149 N-m).
Failure to properly torque capscrews will cause loss
doubler plates on the sides of the 2nd section.
of preload and cause excessive side clearance
22. Drop the cylinder down into the vertical cutouts in the between sections.
doubler plates on the sides of the 2nd section. 33. Approximately 10 feet (300 cm) of anti-two-block cable
23. Install lock bar and capscrews to the extend cylinder. will be available on the winch mount end of the boom to
route and hookup to the control console wiring. Find the
24. Position 2 nd/3rd/ cylinder assembly in position to be end of this cable and slide the cord grip/strain relief
inserted into 1st section. Lay retract cables out under hookup onto it and slide it up the cable into approximate
2nd /3rd/ cylinder to allow easy installation as the booms position inside the boom.
are assembled. 34. Assemble the extension spring and spade bolt to the
cord grip. Assemble the spade bolt through the extend
25. Slide 2nd /3rd/ cylinder assembly into 1st section boom cylinder anchor with a hex nut. Adjust tension on anti-
approximately 2 feet (60 cm). Use caution during this two-block cable by sliding cord grip down cable into the
step to keep retract cables straight and on the correct boom. Approximately 2 inches (5 cm) of spring
side of the boom assembly as the sections are extension should be adequate for proper boom
assembled. operation.
26. Continue to slide 2 nd/3rd/ cylinder assembly into 1st until 35. Visually check each end of boom for proper extend,
it is approximately halfway into 1st . retract and anti-two-block cable routing and placement.

4-6
600E SERVICE MANUAL BOOM

Make certain anti-two-block cable is correctly on be inserted from the winch mount end of the boom.
sheave. Inspect from sheave case end. Install capscrews through holes in outer boom sections.
36. Adjust slack out of extend and retract cables at hex nut 7. The wear pad on each side at the top/rear of the boom
adjustment points. Slowly cycle boom in and out several can be adjusted over a range of 3/16" (4.8 mm) by
times. Torque cables per procedure located elsewhere rotating, end for end, the wear pad and plate or the wear
in this book. pads and plate independently. This is possible because
the holes in these parts are offset from the center. The
Three Section Top/Bottom Pad Replacement holes are .06" (1.5 mm) off center in the plate and .03"
(Assembled Boom) (.8 mm) off center in the wear pad. Various combinations
of rotation of these parts allow the adjustment.
NOTE: Refer to Inner Wear Pad Calibration on page 4-8
of this section to determine Wear Pad shim a. Adjust pads until they are within .03” (.8mm) off
thickness. center in the wear pad. Various combinations of
rotation of these parts allows the adjustment.
Inspect top and bottom wear pads periodically for signs of
abrasion or excessive wear. Excessive is defined as: b. Torque retainer capscrews to 110 ft-lb (149 N-m).
Failure to properly torque capscrews will cause loss
- 3/16 of an inch (4.76 mm) from the original pad of preload and cause excessive side clearance
thickness. between sections.
- Top rear pad thickness .75 inch (19.05 mm).
Front Bottom Pad Replacement 4
- Bottom front 1 st section 1 inch (25.4 mm).
NOTE: Refer to Inner Wear Pad Calibration on page 4-8
- Bottom front 2 nd section .50 inch (12.7 mm). of this section to determine Wear Pad shim
thickness.
- Uneven pad wear of 3/32 inch (2.38 mm) from side
to side on the wear pad. 1. Extend boom approximately 4 feet (120 cm) out.

If any of these conditions exist, the top and bottom pads can 2. Using an appropriate lifting device, sling around the 3rd
be replaced without complete disassembly of the boom. section boom and lift it up until weight is removed from
the bottom pads in the front of the 2nd and 1st boom
Top Rear Pad Replacement sections.
NOTE: Refer to Inner Wear Pad Calibration on page 4-8 3. Loosen and remove the four capscrews holding the pad
of this section to determine Wear Pad shim
doubler plate in between the 3rd and 2nd sections,
thickness.
remove plate, remove pads from this plate. Note all pad
1. Retract boom completely. locations and tag accordingly.
2. Remove capscrews through access holes on top rear of 4. Loosen and remove the four capscrews holding the
sections. bottom front wear pads to the 1st section, remove pads.
3. Remove wear pads and cam plates from the rear of the Retract cable adjustment ends may have to be loosened
boom through open winch mount end. during this step. Note all pad locations and tag
accordingly.
4. Note all pad locations and tag accordingly.
5. If disassembly of cables was required:
5. Inspect pads for wear using previously mentioned
inspection criteria. - Replace all wear pads.
- Wear pad plate.
6. Assemble top/rear wear pads to the top of the 2nd and
3rd boom sections with the cam plates.. Wear pads can - Re-torque retract cables.

4-7
BOOM 600E SERVICE MANUAL

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 measure-
ment. If the section has cylinder anchor bars, take a
measurement directly in front of these bars

Wo
2 PLCS
TOP

Wo 3. Measure the thickness of the wear pads and record

1 PLC (twp).
BOTTOM

INNER SECTION

twp
2. With the inside/outside calipers, measure the outside
width of the inner section (W0) at each side pad 4. Subtract the largest outside width (W0) of the inner
location. Record the largest measurement. 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 .03 inches (.8 mm) thick) to
tighten the pads so that there is .03 inch -.09 inch (.8 mm
- 2.3 mm) clearance between the widest part of the inner
boom and the most narrow part of the outer boom when
Wi shims and pads are installed. In some cases it will be
CYLINDER necessary to have an unequal number of shims behind
the pads at the top and bottom side pad locations. See
ANCHOR
example.
BARS

OUTER SECTION

4-8
600E SERVICE MANUAL BOOM

4
FOUR SECTION BOOM MAINTENANCE
FOUR SECTION BOOM OPERATION
The boom service and maintenance section of this manual
includes both the three and four section boom information.
Use appropriate information for your particular boom length. WARNING
A rod-fed, two-stage double-acting cylinder, attached to the Do not, under any circumstances, work at an elevated
1st, 2nd and 3rd boom sections, supports and propels the 2nd height without using proper fall protection as required by
local, state or federal regulations
and 3 rd boom sections. The extend cables attach to the base
end of the 2 nd boom section, are reeved around sheaves
attached to the cylinder, and attach to the base end of the 4 th
boom section, there fore providing support and extension of Internal Cable Sheave Lubrication
the 4 th boom section. The 3 rd section retract cables attach to
Special Tools: Nozzle or needle grease gun fitting.
the tip end of the 1 st boom section, are reeved around
The lubrication points on the sheaves are not equipped with
sheaves attached to the 2 nd boom section, and attach to the
grease fittings (zerks), therefore a .25 inch (6.35 mm)
base end of the 3 rd boom section, therefore providing diameter nozzle grease gun tip will be required. Contact the
retraction of the 3 rd boom section. The 4 th section retract National CraneCrane Care to obtain this nozzle tip (NCC
cables attach to the tip end of the 2 nd boom section, are Part No. 955047), or numerous variations of the nozzle tip
reeved around sheaves attached to the 3rd boom section, can be purchased at local hardware or auto parts retail
outlets.
and attach to the base end of the 4 th boom section, therefore
providing retraction of the 4 th boom section. A proportioning NOTE: Observation through the sheave case for the
extend sheaves and the winch mount for retract
cable attached to the rear of the 1 st section, reeved around a
sheaves will visually determine the amount of
sheave at the tip of the 2 nd section, and anchored to the rear grease necessary for proper lubrication. A
of the 3 r d section maintain proper cylinder extension slight amount of grease extrusion around the
proportion, therefore maintaining equal boom section pin joint is adequate for proper lubrication.
proportion. Detailed service and maintenance is required to
insure smooth and proper operation. Lubrication of the extend cable sheaves located on the boom
tip end of the extend cylinder, and the retract cable sheaves
located on the inside rear of the 2 nd and 3rd section and the
extend cable sheave attached to the bottom of the top plate

4-9
BOOM 600E SERVICE MANUAL

of the second section at the sheave case end of the boom, boom, on the bottom of the 1 st section. Use the flats at the
are accomplished as follows: front of the cable ends to keep the cables from turning while
1. Extend boom until grease access hole becomes visible in torquing retainer nuts.
side plate of 2nd section as it extends out of 1st section. 7. Torque 1-2-3 extend cable to 6 ft-lb (8 Nm) Cable
adjustment point is located at rear of boom, on the winch
2. Visually check alignment between the 2 nd section access
crossbar spanning the 1st section
hole and the access holes in 3 rd and 4th section. When these
holes become aligned, the end of the extend cable sheave 8. Repeatsteps4, 5,6, and 7, torquing the 2-3-4 retract cables
pin will be visible and accessible for lubrication. to 12 ft-lb (16 Nm). Torque the large extend cables to 30 ft-lb
(41 Nm). The 1-2-3 retract cables to 14 ft-lb (20 Nm) and the
3. This boom extended position will coincide with proper 1-2-3 extend cable to 14 ft-lb (20 Nm)
alignment of the access holes in the rear of the 1 st section for
9. Cycle the boom fully, check that all cables are torqued
lubrication of the retract sheaves attached to the rear of the
properly and that all sections are retracted completely,
2nd and 3rd section. utilizing scribe marks or bottoming position of boom sections
4. The extend cable sheave located on the bottom of the top then add jam nuts to all cables. All threaded cable ends must
be equipped with retainer nuts and jam nuts.
plate of the 2 nd section at the sheave case end of the boom
can be accessed at any boom length for lubrication.
Four Section Boom Service
Four Section Cable Tensioning Boom CG from pivot
Boom Weight
After boom reassembly or from time to time if interior Length point
proportioning cables appear loose, cable tensioning may be 90’ 7210 lb (3270 kg) 145” (3.68 m)
required. Tensioning must be done with the boom horizontal
80’ 6395 lb (2901 kg) 124” (3.14 m)
1. S li gh t ly t ig h te n al l ca b le s. T h e n cy cl e t h e b oo m
approximately 4 feet (120 cm) out and in a few times to
equalize the exte nd and retr act cable boom se ction
1. Extend and set machine outriggers. Boom must be
sequence positioning.
completely retracted and stowed in the boom rest.
2. Fully retract boom. Do not induce and hold hydraulic
2. If equipped, remove swing around jib according to
pressure. At full retraction, observing through the winch
procedures outlined in the Operators Handbook.
mount end of the boom, the second section should be
bottomed on the extend cylinder butt plate, the third section 3. Remove hook block or downhaul weight, wind up rope on
should be bottomed on the thick vertical side plates welded winch drum and stow wedge socket on pegs provided on 1 st
to the inside of the second section, the fourth section should section. Shutdown truck engine.
be bottomed on the thick vertical side plates welded to the
inside of the third section. 4. Attach a lifting device to rod end of lift cylinder, remove
boom lift cylinder pin keeper and pin from bottom of the 1 st
3. It is important to achieve these boom section positions section boom. Lower lift cylinder to a suitable support.
before torquing. If the boom sections do not bottom out as
specified (boom is out of sequence), adjust cables to achieve 5. Tag and disconnect extend cylinder lines and winch
proper section positioning. After proper section position has hydraulic lines. Cap all open lines and ports.
been established, a scribe mark on all the sections at the
6. Attach a lifting device to provide even weight distribution
boom tip end to identify proper section position relative to
and raise the boom until weight is removed from the boom
each other may be helpful during the tensioning process.
pivot pin. Remove boom pivot pin keeper and boom pivot
4. Torque 2-3-4 retract cables to 6 ft-lb (8 Nm). Cable pin. Lift boom free of turret.
adjustment point is located at the sheave case end of the
boom, on the bottom of the 2 nd section. Use the flats at the FOUR SECTION BOOM DISASSEMBLY
front of the cable ends to keep the cables from turning while
The 600E boom can be disassembled by using two different
torquing retainer nuts.
methods. Alternative #1 disassembles the boom in the
5. Torque large extend cables to 20 ft-lb (27 Nm). Cable conventional manner. Alternative #2 removes the extend
adjustment point is located at the rear of the boom on the cylinder from the rear of the boom, after removal of the
cable anchor located in the rear of the 2 nd section winch. This feature facilitates cylinder service with out
complete boom teardown.
6. Torque 1-2-3 retract cables to 6 ft-lb (8 Nm) Cable
adjustment point is located at the sheave case end of the

4-10
600E SERVICE MANUAL BOOM

For reference, the front of the boom refers to the sheave 8. With the 2 nd -3 rd -4 t h 4 t h assembly supported, slide
case end, the rear of the boom is the winch mount end. Left
assembly out of the 1 st. Relocation of the sling point on the
and right are viewed from front to rear.
2 nd-3rd-4th assembly will be necessary for proper balancing
If the boom is to be unpinned from the turret of the crane of the assembly as it slides out of the 1 st section. Keep
structure, please refer to the Boom Removal Procedure tension on retract cables as the assembly is pulled out of the
section in this book. If the required service procedure is to be
1st to minimize the chance of retract cable damage.
performed on the boom while still pinned to the turret, please
follow these directions.. 9. Place 2 nd -3 rd -4 th assembly on a suitable horizontal
surface. Take care not to pinch or crush retract cables while
lifting or supporting assembly.
WARNING 10. Remove top rear wear pads on the 2 nd section. They will
Do not, under any circumstances, work at an elevated lift off the cam plates easily. Do not remove or loosen the
height without using proper fall protection as required by capscrews holding the cam plates to the section. This will
local, state or federal regulations affect side clearance during re-assembly.

1. Extend and set the outriggers. 11. Loosen and remove four capscrews securing the rear
bottom wear pads on the 2 nd section. This pad serves as a
2. Fully retract the boom and place in a horizontal position. bottom and side pad as well as the retract cable keeper
3. Winch removal optional. under the retract sheaves. Removal of this pad will allow the 4
retract cables to uncoil off the retract sheaves. Place retract
Boom Disassembly Alternative #1 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 anchor 12. Loosen and remove six capscrews securing retract
rd
and retract cables in the rear of the 3 section, remove sheave pin and retract sheaves to 2 nd section. Remove
keeper plates. Loosen capscrew on the anti-two-block wire sheaves and pins.
clamp on the anchor assembly. 13. Loosen and remove two capscrews functioning as upper
2. Extend boom 24 inches (60 cm). Loosen and remove the retract cable keepers. Remove retract cables.
nuts which secure the extend cables to the cable anchor 14. Loosen and remove two capscrews securing lock bar to
plate. Remove nut from anti- two-block spade bolt. Tag and the extend cylinder collar. This bar constrains the vertical
disconnect hydraulic lines to the extend cylinder. movement of the extend cylinder. Remove bar.
3. Drape extend cables and anti-two-block cable in side 15. Loosen capscrews retaining extend cable anchor to back
boom, and slide cable anchor plate out of the side of the
winch mount if winch has been removed from boom. of the 4 th section. Total removal of the capscrews will allow
the cable anchor to be completely disassembled, backing
4. Loosen and remove two capscrews, lockwashers and capscrews out approximately .50 inch (12 mm) will allow the
spacers which anchor the extend cylinder rod butt plate to anchor assembly to slide rearward out of the section as the
the rear of the 1st section. extend cylinder is removed.

5. Loosen and remove two capscrews and lockwashers 16. Support extend cylinder with an appropriate lifting device
securing spacer bar to the inside top of the front of the 1 st and pull the extend cylinder out of the boom while keeping
section. Remove spacer bar. the extend cables and anti- two-block wire tensioned slightly
by hand to minimize the possibility of damage to the cables.
6. Loosen and remove four capscrews securing wear pads to Pull cylinder to within 3 feet (91 cm) of complete removal
the bottom of the 1 st section. Removal of side wear pads is from the boom sections.
optional. Adequate clearance exists between adjoining
section side pads for boom disassembly. If side pad removal 17. Reach into the rear of the 4 th section and loosen and
is required, tag all pads, shims, and corresponding locations remove the antitwo-block cable clamp on the extend cable
for proper reassembly. anchor. Pull the extend cable anchor out from its retaining
pocket on the bottom of the 4th section. A slight angle applied
7. S uppo rt 2 n d -3 rd -4 t h asse mbly at t he fr ont with an to the anchor as it’s being pulled to the rear will permit easier
appropriate lifting method. Raise the 2nd- 3 rd-4th assembly removal through the 2 nd and 3rd sections.
inside the 1 st section to allow for front bottom pad removal.
18. Remove the extend cylinder from the boom. Do not allow
Remove bottom wear pads.
the sheaves to fall off the pin on the end of the extend

4-11
BOOM 600E SERVICE MANUAL

cylinder. Remove extend cables. Place cylinder and cables Retracting cylinder with an external hydraulic power source
in suitable area to prevent possible damage. during this step may be necessary.
19. Anti-two-block wire can be removed if necessary by 7. P ul l cy lin der o ut t hr ou gh re ar o f boo m ass emb ly
disassembly of the clamp arrangement at the sheave case approximately one-half the length of the cylinder. Turning of
and pulling wire through boom. the butt plate and rod 90 degrees may aid in sliding cylinder
through winch mount area. Keep extend cables tight to
20. Loosen and remove two capscrews, cable guide, wear
minimize the possibility of damage.
pad and spacer bar from the front top of the second section.
21. Loosen and remove four capscrews attaching the bottom FOUR SECTION BOOM ASSEMBLY
pad plate to the second section. Slightly lift third section, and
remove pad plate. Note: Do not use Loctite on any cable threaded ends. Always
use the locknut and nut provided.
22. Slide 3 rd section out of 2 nd section. Removal of side pads
When initially assembling threaded ends of cables, thread
is optional, as the side pads have ad equate clearance for
the first on past the flat in the cables so adjustment can be
boom disassembly. If removal of side pads is required, tag all
made later.
shims, pads and corresponding locations for proper re-
assembly. 1. Assemble sheaves into 4 th section sheave case. Top
23. Loosen and remove all remaining capscrews and wear sheave is to be installed to the left hand side of the boom
pads from boom sections. with the spacer to the right hand side.

2. Attach rear wear pads on bottom of 4 th section. Using

Boom Disassembly Alternative #2
Loctite 242 blue, Loctite all wear pad mounting capscrews.
The boom design allows for removal of the extend cylinder
from the rear of the boom without complete disassembly of 3. Install 4 th section boom into 3 rd section. Slide together
the boom sections. This procedure allows quick access to approximately 5 feet (150 cm).
the cylinder, retract cables, and various internal boom
4. Assemble bottom front wear pads for 3 rd section and
components for service or replacement. If this procedure is
Teflon plugs. Attach pads to pad plate.
used for disassembly, reverse procedure for reassembly, or
locate the appropriate step in the assembly procedure in this 5. Using appropriate lifting device, lift 4 th section to allow for
manual to start reassembly from. wear pad/pad plate installation in front of 3rd. Install wear
Do not, under any circumstances, work at an elevated height pad/pad plate assembly. Slide sections together within 12
without using proper fall protection as required by local, state inches (30 cm) of full retraction.
or federal regulations.
6. Install cable guide and upper spacer to front of 3 rd section
1. Remove winch.
7. Install front side wear pads with appropriate shims,
2. Gaining access through rear of boom, loosen and remove between 4th and 3 r d sections. If boom has been
capscrews retaining the extend cable anchor in the rear of disassembled, and no sections have been replaced, use
the 4 th section as well as the anti-two-block wire clamp on same shim quantity and location as was previously used. If
the anchor assembly. Loosen and remove two capscrews locations are in question, refer to shim calibration section in
retaining lock bar to extend cylinder. Remove lock bar this book. Slide boom sections completely together.
3. Loosen and remove the nuts which secure the extend 8. Assemble top rear wear pads to the top of the 4th boom
cables to the extend cable anchor in the back of the second section. Wear pads can be inserted from the winch mount
section, remove capscrews from keeper plates holding end of the boom, and the cam plates dropped through the
extend anchor in place, remove keepers. Remove anchor. holes in the aligned boom top plates.
Remove nut from anti-two-block spade bolt.
The wear pad on each side at the top/rear of the boom can
4. Drape extend cables and anti-two-block wire in side boom, be adjusted over a range of 3/16" (4.8 mm) by rotating, end
and slide cable anchor plate out of the side of the winch for end, the wear pad and plate or the wear pads and plate
mount. independently. This is possible because the holes in these
5. Loosen and remove two capscrews, lockwashers and parts are offset from the center. The holes are .06" (1.5 mm)
spacers which anchor the extend cylinder rod butt plate to off center in the plate and .03" (.8 mm) off center in the wear
pad. Various combinations of rotation of these parts allow
the rear of the 1st section.
the adjustment.
6. Using appropriate lifting device, lift extend cylinder up and
out of retaining slots on rear of 2 n d and 3 rd sections.

4-12
600E SERVICE MANUAL BOOM

a. Adjust pads until they are within .03” (.8mm) off 20. Install front side wear pads with appropriate shims
center in the were pad. Various combinations of between 3r d and 2nd s ec tions . If boom has been
rotation of these parts allows the adjustment. disassembled, and no sections have been replaced, use
b. Torque retainer capscrews to 110 ft-lb (149 N-m). same shim quantity and location as was previously used. If
Failure to properly torque capscrews will cause loss locations are in question, refer to shim calibration section in
of preload and cause excessive side clearance this book. Slide sections fully together
between sections.
21. Assemble top rear wear pads to the top of the 3 rd boom
section. Wear pads can be inserted from the winch mount
end of the boom, and the cam plates dropped through the
9. Uncoil 4/3/2 retract cable assemblies, and insert button holes in the aligned boom top plates.
end into anchors in back of the 4th section. Place uncoiled
cable in area that will minimize the potential for damage. The wear pad on each side at the top/rear of the boom can
be adjusted over a range of 3/16" (4.8 mm) by rotating, end
10. Uncoil 1/2/3 retract cable assemblies, and insert button for end, the wear pad and plate or the wear pads and plate
end into cable anchor pockets in back of the 3 rd section. independently. This is possible because the holes in these
Place uncoiled cable in area that will minimize the potential parts are offset from the center. The holes are .06" (1.5 mm)
for damage. Assemble retract sheaves and retract sheave off center in the plate and .03" (.8 mm) off center in the wear
pins in rear of 3 rd section. Coat surfaces of bearings and pad. Various combinations of rotation of these parts allow
keeper plates with grease before assembly. the adjustment.
a. Adjust pads until they are within .03” (.8mm) off
4
11. Place retract cables anchored to 4 th over the top of the
center in the were pad. Various combinations of
retract sheaves on the 3 rd . Install keeper capscrew above rotation of these parts allows the adjustment.
sheave to hold retract cables in place.
b. Torque retainer capscrews to 110 ft-lb (149 N-m).
12. Reeve cables over retract sheave and install keeper/ Failure to properly torque capscrews will cause loss
wear pad to bottom rear of 3 rd section. This pad acts as a of preload and cause excessive side clearance
side pad, bottom pad, and a cable retainer. Loctite rear wear between sections.
pad hardware on bottom of 3 rd section with Loctite 242 blue. 22. Position sheave and sheave pin located in cable loop on
Loctite all wear pad mounting capscrews.
top of 3 rd to allow capscrew installation, through top plate of
13. Loop the 1/2/3 extend cable in half and place it on the top 2 nd. Install capscrews and torque to specification, clamping
of the 3 rd section, with the loop end towards the sheave case sheave pin and sheave to the bottom of the 2 nd section top
end and the threaded and button end towards the rear of the plate.
section.
23. Assemble retract sheaves, retract sheave pins and cable
14. Install clamp plate and capscrews with the button end of
keeper plates in rear of 2 nd section. Coat surfaces of
the cable installed in the anchor slot on the rear top of the 3rd bearings with grease before assembly.
section.
24. Place retract cables anchored to 3rd over top of retract
15. Place sheave pin and sheave for the 1/2/3 extend cable
in position on the sheave case end of the boom, inside the sheaves attached to rear of 2 nd . Install keeper capscrew
loop of cable above sheave to hold retract cables in place.
25. Reeve cables over retract sheave and install keeper/
16. Install 3 rd and 4 th section boom assembly into 2 nd
section. Slide together approximately 5 feet (150 cm). Use wear pad to bottom rear of 2nd section. This pad acts as a
caution as retract cables and upper extend cable attached to side pad, bottom pad, and a cable retainer.
the 4th-3 rd section assembly slide into the 2 nd section to 26. Assemble exterior extend cylinder components. Install
prevent damage or crossing of cables. and center sheave pin and anti-two block sheave into
sheave case end of extend cylinder. Install bearings into
17. Assemble bottom front wear pads for 2nd section and extend cable sheaves. Coat surface of bearings with grease
Teflon plugs. Attach pads to pad plate. and assemble extend sheaves on sheave pin.
18. Using appropriate lifting device, lift 3 rd and 4 th section 27. Wrap approximately 10 feet (300 cm) of each 5/8 inch
assembly to allow for wear pad/pad plate installation in front (15.88 mm) diameter 2/3/4 extend cable around extend
of 2 nd. Install wear pad/pad plate assembly. Slide sections sheaves and install 4 th section extend cable anchor around
together within 12 inches (30 cm) of full retraction. cables at button end. Do not tighten capscrews clamping
anchor together completely. These capscrews if tightened
19. Install cable guide and spacer to top of 2 nd section

4-13
BOOM 600E SERVICE MANUAL

completely will not allow cable anchor to install into 4 th 39. Route 1/2 anti-two-block segment on the bottom of the
section. 1 st section boom (see Anti-Two-Block Internal Wire System
section).
28. Install wear pad over extend cylinder sheave side plates.
This serves as a wear pad to keep the end of the extend 40. Install 2/3/4 section boom assembly into l st section boom,
cylinder centered in the boom, as well as an extend cable
use caution when sliding sections together, 3rd retract cables
retainer.
must maintain their position to prevent damage, do not let
29. Slide extend cylinder/extend cables into 2 nd/3rd/4th boom boom rest on cables. Damage will result.
assembly enough to assemble extend cable anchor into
41. Assemble bottom front wear pads for 1 st section and
bottom rear of 4 th section. Be aware of extend cable location Teflon plugs.
when inserting cylinder into boom sections, inadvertent
crushing or other damage to cables will warrant 42. Using appropriate lifting device, lift 2/3/4 section
replacement. assembly to allow for wear pad installation in front of 1 st .
Install wear pads. Slide sections together within 12 inches
30. Tighten capscrews clamping extend cable anchor
(30 cm) of full retraction.
together. This will also lock anchor in place in the anchor
cutouts in the 4th section. 43. Install upper spacer to front of 1 st section.
31. Visually verify that the extend cables are properly routed 44. Install front side wear pads with appropriate shims
on their sheaves and continue to slide with the extend between 2 nd and 1st sections. If boom has been
cylinder and cables into the boom sections. Keep extend disassembled, and no sections have been replaced, use
cables supported and slightly tensioned during insertion of same shim quantity and location as was previously used. If
cylinder to maintain proper cable placement. locations are in question, refer to shim calibration section in
32. As the extend cylinder nears complete insertion into the this book.
2nd /3rd/4th section assembly, adjust the height of the cylinder 45. Push boom together until extend cylinder butt plate
to allow the cylinder anchor collars to access the cylinder makes contact with the rear cylinder anchor plates in the rear
keeper cut outs in the doubler plates on the sides of the 2 nd of the 1 st section. Install spacers, washers and capscrews,
and 3rd sections. attaching cylinder to 1 st section b oom. If cylinder is
misaligned with anchor points, cylinder butt plate can be
33. Drop the cylinder down into the vertical cutouts in the
rotated to achieve proper alignment (holding valve up,
doubler plates on the sides of the 2 nd and 3 rd sections. parallel with boom top plate).
Cylinder length or boom section placement may have to be
adjusted to allow cylinder collars to drop into their proper 46. Assemble top rear wear pads to the top of the 2 nd boom
position. section. Wear pads can be inserted from the winch mount
end of the boom, and the cam plates dropped through the
34. Install lock bar and capscrews to the extend cylinder
holes in the aligned boom top plates.
collar in the 3rd section.
The wear pad on each side at the top/rear of the boom can
35. Route 2/3/4 anti-two block cable segment through boom be adjusted over a range of 3/16" (4.8 mm) by rotating, end
sections (see Anti-Two- Block Installation section) and for end, the wear pad and plate or the wear pads and plate
attach accordingly. independently. This is possible because the holes in these
36. Install large extend cable anchor into anchor cut outs in parts are offset from the center. The holes are .06" (1.5 mm)
off center in the plate and .03" (.8 mm) off center in the wear
the doubler plates in the rear of the 2nd by routing the 5/8
pad. Various combinations of rotation of these parts allow
inch (15.88 mm) extend cables through the anchor and the
the adjustment.
small 3/8 inch (9.53 mm) cable over the anchor. Slide anchor
fully into cutout. a. Adjust pads until they are within .03” (.8mm) off
center in the were pad. Various combinations of
37. Install keeper plates and hardware. This keeper plate
rotation of these parts allows the adjustment.
retains both the horizontal movement of the extend anchor
and the vertical movement of the extend cylinder. b. Torque retainer capscrews to 110 ft-lb (149 N-m).
Failure to properly torque capscrews will cause loss
38. Anchor 2/3/4 anti-two-block cord in the extend anchor
of preload and cause excessive side clearance
(see Anti-Two-Block Installation section) using appropriate
between sections.
hardware.
47. Install thick winch attachment bar through winch mount.
This bar anchors the 3/8 inch (9.53 mm) extend cable and
serves as the upper winch attach ment point. Hold this bar up

4-14
600E SERVICE MANUAL BOOM

in its slot with a spacer on each side. This will facilitate easier side at the top/rear of the boom can be adjusted over a range
assembly. of 3/16" (4.8 mm) by rotating, end for end, the wear pad and
plate or the wear pads and plate independently. This is
48. Install the threaded end of the 3/8 inch (9.53 mm) extend
possible because the holes in these parts are offset from the
cable through hole in center of the winch attachment bar.
center. The holes are .06" (1.5 mm) off center in the plate
49. Slightly tighten all cables. Cycle boom slowly to assure and .03" (.8 mm) off center in the wear pad. Various
proper operation before torquing cables. Refer to the Four combinations of rotation of these parts allow the adjustment.
Section Cable Tensioning section to properly torque the
a. Adjust pads until they are within .03” (.8mm) off
cables in the extend system. Cables must be torqued to
center in the were pad. Various combinations of
proper specifications for proper boom operation.
rotation of these parts allows the adjustment.
50. Install winch.
b. Torque retainer capscrews to 110 ft-lb (149 N-m).
Failure to properly torque capscrews will cause loss
FOUR SECTION TOP/BOTTOM PAD of preload and cause excessive side clearance
REPLACEMENT ASSEMBLED BOOM between sections.
Inspect top and bottom wear pads periodically for signs of
Front Bottom Pad Replacement
abrasion or excessive wear. Excessive is de fined as 3/16 of
an inch (4.76 mm) from the original pad thickness, top rear 1.Extend boom approximately 4 feet (120 cm) out.
pad thickness .75 inch (19 mm), bottom front 1 st section 1 2.Remove cable guides and upper spacer bars from front of
inch (25 mm), bottom front 2 nd and 3 rd section .44 inch (13 boom sections
4
mm). Uneven pad wear of 3/32 inch (2 mm) from side to side
on the wear pad would be considered excessive as well. If 3.Loosen and remove hex nuts on retract cables on the front
any of these conditions exist, the top and bottom pads can of the 1st and 2nd sections
be re placed without complete disassembly of the boom. 4.Using an appropriate lifting device, sling around the 4th
section boom and lift it up until weight is removed from the
Top Rear Pad Replacement bottom pads in the front of the 3rd, 2nd, and 1st boom
Pad maintenance on the four section can be made easier by sections.
removal of the winch and or removal of the winch mounting 5.Loosen and remove the four capscrews holding the pad
bar spanning the end of the 1 st section. Additional clearance doubler plate in between the 4th and 3rd sections. Remove
can be achieved by loosening the large extend cables and plate. Remove pads from this plate. Note all pad locations
removing the extend cable anchor located in the 2 nd section. and tag accordingly.

1. Retract boom completely. 6.Loosen and remove the four capscrews holding the pad
doubler plate in between the 3rd and 2nd sections. Remove
2. Remove capscrews through access holes on top rear of plate. Remove pads from this plate. Note all pad locations
sections. and tag accordingly.
3. Remove wear pads, shims, and cam plates from the rear 7.Loosen and remove the four capscrews holding the pads in
of the boom through open winch mount end. between the 2nd and 1st sections. Remove pads. Note all
4.Note all pad locations and tag accordingly. pad locations and tag accordingly.

5. Inspect pads for wear using pr eviously mentioned 8. Inspect pads for wea r using p reviously mentioned
inspection criteria. inspection criteria.

6. Assemble new wear pads with the cam plates and install 9.Install new pads with Teflon inserts on plates or boom
through the winch mount end of the boom. Install capscrews sections. Reassemble plates in boom in proper locations.
through holes in outer boom sections .The wear pad on each

4-15
BOOM 600E SERVICE MANUAL

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
top forward twp = .52 (13mm)
pad location
Wo = 10.94
(287mm) at
bottom rear
pad location

TOP REAR BOTTOM REAR

Wi = 12.06 (306mm) 12.06 (306mm)
– Wo = –10.94 – (278mm) – 10.94 – (278mm)
– twp = – .52 – (13mm) – .52 – (13mm)
– twp = – .52 – (13mm) – .52 – (13mm)
Clearance before = 008 (2mm) .08 (2mm)
Shims
Left side shim = – .03 – (.8mm) – .03 – (.8mm)
Final Clearance = .05 (1.2mm) .05 (1.2mm)

4-16
600E SERVICE MANUAL BOOM

LIFT CYLINDER REPAIR 6. Attach a porta-power hand pump or hydraulic line from
crane circuit valve to the shaft end of the cylinder. De-
Lift Cylinder Disassembly burr ring groove edge. Failure to do so will damage
barrel or packing gland.
1. Disconnect shaft end of cylinder from machine.
7. Operate hand pump or crane circuit valve, preferably the
2. Retract cylinder shaft with oil from the hydraulic system boom telescope circuit, to force packing gland out of
until about 12 inches (30 cm) of shaft is extended. The barrel.
barrel must be filled with oil to prevent a compressed air
chamber being formed which could result in injury at 8. Remove holding valve from cylinder to allow removal of
disassembly. shaft and piston assembly. Remove the shaft and piston
assembly by hand.

3. Remove the cylinder from the machine and place on 9. Disassemble the piston set by removing nut, replace
supports with an oil pan directly beneath the cylinder worn or damaged parts. Note: Loctite 680 is used during
head area. original assembly to secure nut to shaft. If necessary,
heat nut to 400-500° F (204-260°C) to facilitate removal.
4. Using the proper size of external snap ring pliers,
If heat is necessary for removal, discard nut and replace
expand the snap ring completely and remove from
with new equivalent nut as well as worn or damaged
groove. Slide large washer forward to gain access to the
parts.
packing gland.
10. Wipe and inspect all cylinder internal and external
5. Using a special drive tool, drive the packing gland into
surfaces for damage.
the barrel assembly to expose the round cross section
retaining ring. Then use a small needle nose locking 11. Remove seals and bearings from packing gland and
plier to clamp the round cross section retaining ring to piston. Replace all seals and bearings.
prevent it from rotating in the groove. Use two straight
12. Reassemble shaft and piston set assembly in the proper
blade screw drivers: one to pry the end of the ring out of
order with external snap ring, large washer, internal
the groove and the other to pry the ring out of the barrel
round section ring, assembled packing gland, stop tube,
assembly.
piston to shaft O.-ring, assembled piston, and locknut.

4-17
BOOM 600E SERVICE MANUAL
Loctite locknut onto shaft using type 680 according to 5. Plug retract port in the cylinder butt plate with SAE #8
Loctite recommendations. Torque locknut to 600 ft-lbs O.-Ring boss plug and pull on the rod assembly to force
(813 Nm). packing gland out of the barrel assembly.
13. Grease piston assembly and install the shaft assembly 6. If step 5 fails to break packing gland loose from the
with piston, O.-ring, stop tube, packing gland, internal barrel assembly, remove the plug from the retract port
round ring, large washer, and external snap ring into and plug the extend port in the cylinder butt plate (SAE
barrel assembly. #8 O.-Ring boss). Apply retract pressure to cylinder to
break packing gland loose. Remove holding valve and
14. Using special drive tool, drive the packing gland into the
extend and retract plugs from butt plate and pull packing
barrel assembly.
gland out by hand.
15. Insert one end of round ring into groove in barrel
7. As soon as the packing gland is sufficiently loosened,
assembly and spiral the ring into groove with straight
properly support the rod assembly and carefully remove
blade screw driver.
it by hand. Place rod assembly on supports. Caution
16. Slide large washer into position on end of packing gland must be exercised in the support and removal of the rod
and retain with the external snap ring being sure that assembly as damage to the chrome surface will
snap ring contracts completely and properly into the necessitate rod assembly replacement.
snap ring gland groove.
8. Disassemble the piston set by removing nut, replace
worn or damaged parts.
SINGLE SECTION EXTEND CYLINDER
NOTE: Note: Loctite 680 is used during original
REPAIR
assembly to secure nut to shaft.
9. If necessary, heat nut to 400-500° F (204-260°C) to
facilitate removal. If heat is necessary for removal,
discard nut and replace with new equivalent nut as well
as worn or damaged parts.
10. Wipe and inspect all cylinder internal and external
Boom Extend 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
required.
Boom Retract
Extend Cylinder Assembly
1. Reassemble shaft and piston set assembly in the proper
Extend Cylinder Disassembly order with internal round section ring, assembled pack-
1. After cylinder has been removed from boom, place on ing gland, stop tube, piston to shaft o-rings, assembled
supports and place drain pan under holding valve and piston, and locknut. Loctite locknut onto shaft using type
cylinder head area. 680 according to Loctite recommendations. Torque lock-
nut to 300 ft-lbs (407Nm).
2. Retract cylinder shaft with oil from the hydraulic system
until about 12 inches (30 cm) of shaft is extended. The 2. De-burr ring groove edge in barrel assembly and inspect
barrel must be filled with oil to prevent a compressed air all internal and external surfaces for damage.. Failure to
chamber being formed which could result in injury at do so will damage packing gland and or barrel assembly
disassembly. Relieve any trapped hydraulic pressure when packing gland is installed.
which might remain in the cylinder. 3. Grease piston assembly and install the shaft assembly
3. Remove any plug or fitting that is in the retract port in the with piston, o-ring, stop tube, packing gland, internal
cylinder butt plate. Using a special drive tool, drive the round ring into barrel assembly.
packing gland into the barrel assembly to expose the 4. Using special drive tool, drive the packing gland into the
round cross section retaining ring. Then use a small barrel assembly.
needle nose locking plier to clamp the round cross
section retaining ring to prevent it from rotating in the 5. Insert one end of round ring into groove in barrel
groove. Use two straight blade screw drivers: one to pry assembly and spiral the ring into groove with straight
the end of the ring out of the groove and the other to pry blade screw driver.
the ring out of the barrel assembly. 6. Cycle test cylinder to ensure no leaks exist. Support end
4. De-burr ring groove edge after removing round ring. of cylinder as it extends and retracts.
Failure to do so will damage packing gland and or barrel
assembly when packing gland is removed.
4-18
600E SERVICE MANUAL BOOM

MULTI-STAGE EXTEND CYLINDER 6.Using a special drive tool, drive the packing gland into the
DISASSEMBLY AND REPAIR 2nd stage barrel assembly to expose the round cross section
retaining ring. Then use a small needle nose locking plier to
Cylinder disassembly clamp the round cross section retaining ring to prevent from
rotating in the groove. Use two straight blade screw drivers;
1.After cylinder has been disassembled from boom, place on one to pry the end of the ring out of the groove and the other
supports and place drain pan under holding valve. to pry the ring out of the barrel assembly.
2.Using hydraulic power (porta power or crane circuit) 7.Deburring groove edge. Failure to do so will damage
extend cylinder sections approximately 24 inches (60 cm). If packing gland and or barrel assembly when packing gland is
stages do not move equally, retain the moving stage to allow removed. Using a 3/16” hex key wrench, remove the locking
for equal extension of cylinder. Remove the holding valve setscrews from the 2nd stage cylinder shaft piston. Using the
from the 1st stage butt plate and drain oil. proper size spanner wrench, loosen and completely unscrew
piston from the 2nd stage cylinder shaft assembly. Remove
3.Using a special drive tool, drive the packing gland into the
nut washer and p ist on fr om 1st stag e cylinder sh aft
3rd stage barrel assembly to expose the round cross section
assembly. Remove stop tubes from the 1st and 2nd stage
4
retaining ring. Then use a small needle nose locking plier to
cylinder shaft assemblies.
clamp the round cross section retaining ring to prevent from
rotating in the groove. Use two straight blade screw drivers; 8.Wipe and inspect all cylinder internal and external surfaces
one to pry the end of the ring out of the groove and the other for damage. Wipe and inspect all threaded components for
to pry the ring out of the barrel assembly. damage to threads.
4.Deburring groove edge. Failure to do so will damage 9.Inspect wear pads on the 3rd stage barrel sheave case
packing gland and or barrel assembly when packing gland is assembly. Replace as required.
removed.
10.Ensure that the O’ring seal area of the packing gland
5.Remove the 2nd/1st stage cylinder assembly from the 3rd bores on both the 2nd stage cylinder assembly and the 3rd
stage barrel assembly and place on supports. Caution must stage barrel assembly are smooth and free of nicks and
be exercised in the support and removal of 2nd/1st stage lubricate to eliminate damage to the packing gland O’ring
cylinder assembly as damage to the chrome surface will during reassembly.
necessitate replacement.

4-19
BOOM 600E SERVICE MANUAL

Cylinder Reassembly 8.Install setscrew into piston using Loctite Type 242
according to Loctite recommendations and torque. Loctite
1.Replace cylinder packing parts as required on 1st stage and install second setscrew on top of first setscrew and
cylinder assembly. Refer to parts pages for replacement torque.
packing kit part number. Warming the U-cup seals in 140°F
(60°C) oil will allow for easier assembly. 9.Reinstall 2nd stage cylinder assembly with piston stop tube
and packing gland into 3rd stage barrel assembly to within
2.Reinstall packing gland retaining ring and stop tube onto 24 inches (60 cm) of fully assembled.
1st stage cylinder shaft assembly.
torque specifications
3.Reinstall piston and related components. Torque retaining
nut to specification. 4 section 2nd stage piston 200 ft/lb (271 N·m)
4.Insert 1st stage into 2nd stage, grease on piston seals will 1st stage nut 300 ft/lb (407 N.m)
aid installation, install packing gland and round retaining ring
Setscrew 8 ft/lb (11 N.m)
into 2nd stage.
5.Replace cylinder packing parts as required on 2nd stage Replacing Holding Valve on Multi-Stage
cylinder assembly. Refer to parts pages for replacement Extend Cylinder
packing kit part number.
The holding valve on the multi-stage extend cylinder can be
6.Reinstall packing gland, retaining ring and stop tube onto serviced without removing the cylinder from the boom.
2nd stage cylinder shaft assembly. Although the holding valve can be removed with the boom
7.Install O’ring and backup rings on inner diameter of 2nd fully retracted, the process is easier with the boom extended
stage piston and thread onto 2nd stage cylinder shaft approximately 12 inches (30 cm) per section.
assembly until snug making certain piston counterbore is When replacing the holding valve, verify the o-rings are
seated over shaft assembly properly. Take care not to seated on the holding valve prior to installing the capscrews
damage the O’ring while installing piston. Using the proper into the cylinder butt plate.
size spanner wrench, tighten piston onto 2nd stage cylinder
shaft assembly to specification.

4-20
600E SERVICE MANUAL BOOM

4. Using an overhead hoist, lift the jib assembly and align

and pin the jib to the boom sheave head.
JIB INSTALLATION AND ADJUSTMENT
1. Loosely bolt the two ear assemblies with shims and bars
as shown to the side of the first boom section.
Note: All measurements are in inches (mm).

5. With jib pinned to the sheave head, swing the jib parallel
4
to the boom and install the pin which keeps the jib from
swinging (the pin is attached by cable to the end of the
jib)..

2. Loosely bolt the hook assembly to the side of the first

boom section.

6. Slowly retract the boom until the jib ears are within 0.50
inch (13 mm) of the ear assemblies on the first section.
Observe the vertical alignment of the jib ears and ear
assemblies and add or remove shims until the jib is
3. Extend the boom approximately one foot (300 mm). supported by the jib ears. The jib will typically rest only
on the upper support.

4-21
 BOOM 600E SERVICE MANUAL

7. Observe the horizontal alignment of the slot in the ear

assemblies and the alignment pin in the jib. Horizontal
adjustment of the stow ears is provided by oversize bolt
holes in the stow ear. Move the ears in or out to achieve
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
holds the bottom of the jib away from the bottom of the
boom.
8. Retract the boom slowly. Observe the stow hook and assembly and front bars will have to be positioned as
side stow bracket assembly alignment as the boom is shown so the jib cannot slide forward or backward as the
retracted (View AA and BB below). 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
“Torque Values for Grade 5 and 8 Bolts” in Section 2).
Install stow pin in lock assembly and remove the jib pins.
12. Extend and retract boom to insure proper alignment of
jib pins.
13. Install jib pins and remove the stow pins.
14. Extend and retract the boom and jib to ensure proper
alignment of jib stow brackets.
15. Install jib stow pins and remove jib pins.

9. When the boom is fully retracted, the jib must be NOTE: Always save shims to allow future adjustment
bottomed out securely in the ear assemblies. If the of jib stow if required
alignment pins are not aligned properly, the hook

4-22
600E SERVICE MANUAL BOOM

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

4-23
BOOM 600E SERVICE MANUAL

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4-24
600E

SECTION 5

WINCH
TABLE OF CONTENTS
Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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WINCH 600E

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5-ii
600E SERVICE MANUAL WINCH

SECTION 5
WINCH
WINCH REMOVAL

CAUTION
The combined weight of the winch and 325 ft. of wire rope
is 660 lbs (300 kg).

5. Remove rope Mesh Guard.

6. Attach suitable lifting device to winch and take up the

slack.
7. Remove 6 mounting capscrews and washers (3 on each
side).
8. Lift which clear of boom and secure to a suitable holder

WINCH INSTALLATION
1. Remove rope Mesh Gaurd from winch.
2. Lift winch with suitable lifting device.
3. Lower winch onto the alignment ears.
5
1. Winch 5. Winch Down Hose
2. Boom 6. Winch Up Hose 4. Install Mesh Gaurd.

3. Capscrew (6 plcs) 7. Winch Alignment Ears 5. Install 6 capscrews and washers. Torque capscrews to
220 ± 20ft lb (300 ± 30 N.m.
4. Case Drain
6. Inspect hydraulic hoses and anti chafing sleeve for wear
1. Extend and set the outriggers. or damage. Replace as required.
2. Fully retract the boom and place in a horizontal position. 7. Route hoses with anti chafing sleeve installed through
access hole in turret assembly.
3. Remove hook block or downhaul weight.Shut down
truck engine. 8. Install winch up hydraulic hose to lower inside fitting on
which motor.
4. Remove and cap hydraulic hoses.
9. Install winch down hydraulic hose to outside fitting on
a. Tag hydraulic hoses to avoid confusion during re-
winch motor.
assembly (the inside hose “up” and the outside is
“down”).

5-1
WINCH 600E SERVICE MANUAL

THIS PAGE BLANK

5-2
600E SWING

SECTION 6
SWING
TABLE OF CONTENTS
Tulsa Rotation Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Disassembly & Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tulsa Swing Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tulsa Swing Drive Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Comer Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Comer Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Rotation Stop-mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Rotation Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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SWING 600E

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6-ii
600E SERVICE MANUAL SWING

SECTION 6
SWING
Lubrication And Maintenance
TULSA ROTATION GEARBOX AND BRAKE Manufacturer recommends changing oil after first 50 hours
of operation. Oil should be changed at 500-hour intervals
Disassembly & Assembly Instructions thereafter. All gearboxes require GL-5 grade EP 80/90 gear
This manual will primarily assist in disassembly and oil for lubrication. Some units may be equipped with a grease
assembly procedures of major components for the Swing fitting for lubrication of the output shaft bearings (pinion up
Drive. Item numbers, indicated in parentheses throughout applications). The shaft bearings should be greased
this manual, refer to the exploded parts breakdown drawing. sparingly at every 50 operating hours with a lithium or GP
bearing lube.
OIL CAPACITIES: .75 Quart (.70 L)

6-1
SWING 600E SERVICE MANUAL

Tulsa Swing Drive Disassembly NOTE: Notice the position of the dowel pin hole in
piston w ith t he brake r elease po rt for
1) Remove drive from vehicle and drain gearbox lubricant by reassembly.
removing the drain plug (26).
A port-a-power can be used to assist in removal of piston by
2) Remove the motor from the motor adapter (3). slowly pressurizing the brake release port until piston clears
3) Remove the brake assembly from the gear housing the top of the housing.
assembly (1) by removing six socket head capscrews (27). 10) Inspect the piston 0-rings (20 &21)and the back up rings
Notice the position of the brake port in conjunction with the (19 & 22) for damage, replace if necessary.
drain and fill holes in the housing for reassembly.
4) Separate the motor adapter assembly (3) from the brake
housing (2) by removing six capscrews (28).
NOTE: Notice the position of the motor mounting hole
i n re l a t i o n t o t h e b ra k e r e l e a s e p o r t f o r
reassembly.

Caution
The motor adapter is spring- loaded and the capscrews
should be loosened in a sequence that will allow an even
load distribution on the motor adapter. 11 Inspect the thrust plate (9) for excessive grooving and
replace if necessary by removing snap ring (36).
5) Inspect the motor adapter 0-ring (24) for wear. Re place if
necessary. 12)Remove the brass thrust washer (34) and sun gear (41).

6) Remove the six springs (15) and the brake driver (8) from 13) Remove input planet set (3, part of gear set 4) from gear
the brake housing (2). housing (1) by pulling straight up and out of the housing.

7) Remove retaining ring (37) from the brake piston (5). 14) Remove the retaining ring (43) from the input carrier (44),
remove the output sun gear (45), and inspect for wear and
8) Remove the stator plates (16) and friction discs (17) from replace as necessary.
the brake piston (5). Inspect stator plates for excessive
grooving or burn spots. Also, inspect friction discs for wear. 15) Remove retaining rings (48), press out the planet pin
Replace as required. (53), remove the planet gear (51), and needle bearings (52),
inspect for unusual wear. Replace as required.
16) Remove the pinion locking bolt (46) from the out put
planet carrier (47). Loosen the pinion bolt (49)

9) Remove the piston (5) from the brake housing (2).

6-2
600E SERVICE MANUAL SWING

17) Remove the retaining rings (48). Lift output planet set out 11. Install the 0-ring (20) and back-up ring (19) on the small
of the housing (1). Press out the planet pin (57); remove the step of the piston (5).
planet gear (55) and needle bearings (54). Inspect for
12. Install one back-up ring (22) and one 0-ring (21) on the
unusual wear. Replace as required.
large step of the piston (5). Apply a slight film of oil on
18) Remove the inboard bearing (11) and inspect for wear. the 0-rings and back-up rings before installing.
19) Remove the pinion shaft (6) from the housing (1) and 13. Carefully press the assembled piston (5) into the brake
inspect the pinion shaft, seal, and bearing for wear. housing (2), taking care not to damage the rings.
20) Remove outboard bearing (7) and seal (10). Inspect for NOTE: Notice the position of the dowel pinhole in
wear and replace if necessary.

Tulsa Swing Drive Assembly Procedure

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
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
the output carrier (47) into the gear housing (1).
a. Tighten the pinion bolt halfway, check the alignment piston with the brake release port for correct
of the output carrier (47) with the spline on the assembly.
pinion shaft (6), and then tighten the pinion bolt the
6
14. Insert the brake driver (8) into the assembled brake
rest of the way. housing (2) and piston (5).
b. Torque the pinion bolt to 50 ft-lb (68N . m), loosen 15. Install the stator plates (16) and friction disks (17)
and re-torque until the pinion locking bolt aligns with starting with one stator plate and alternating between
the slot on the nut portion of the pinion bolt at 25 ft-lb friction disk and stator plate until six stator plates and
(34N . m) If the pinion bolt is between slots always five friction disks are used.
tighten to the next slot. NOTE: Soak friction disk in EP-90 for 24 hrs. before
NOTE: Install a ¾-i 3 bolt into the end of the pinion installation.
shaft on the outboard side and check the rolling 16. Reinstall the retaining ring (37) into the piston.
torque. Preload of the bearing rolling torque
should be 35-50 ft-lb (47-68N. m). Apply Loctite 17. Install six springs (15) into the holes in the motor adapter
to the pinion locking bolt (46) and torque to 20 (3).
ft-lb (27N. m). 18. Mount the motor adapter (3) to the brake housing (2)
with six cap screws (28) checking to make sure the roll
8. Install the input carrier section (44) with Sun gear (45)
pin (18) is in line with the dowel hole in piston (5).
attached with retaining ring (43).
NOTE: Notice the position of the motor mounting hole
9. Install the sun gear (41) and thrust washer (34)
in relation to the brake release port for correct
10. Assemble the brake section by first installing the 0-ring reassembly.
(23) on the brake housing (2). Install six caps crews (27)
19. Fill the gearbox to desired level with EP-90 gear lube.
to the brake housing (2) and torque to 10 ft-lb (13N. m).
Notice the position of the brake port in conjunction with
the drain and fill holes in the housing.

6-3
SWING 600E SERVICE MANUAL

COMER SWING DRIVE Drain the oil while the unit is hot using the following
procedure:
Detailed information on the Comer S wing Drive was
unavailable at the time of publication of this manual. As soon a. Unscrew the drain plug and drain the oil in to a
as new information is available, the manual will be updated. suitable container. You may remove the filler and
level plugs to facilitate oil draining.
Comer Drive Lubrication b. Replace the drain plug and insert oil through the
filler plug until it begins to flow out of the level plug.
Check the gear unit for leaks daily during the first 100 hours
of operation, and weekly there after. c. Tighten the level and filler plugs.
Dr ain and r eplace the oil after the first 100 hours of
operation. Grease
Every 2000 hours of operation change the oil in the gear unit Lubricate the unit regularly, using a grease gun, in the
chamber between the oil retainer and bearing.

APPROVED LUBRICANTS FOR COMER SWING DRIVE

-20-1V 95 + 5-1V 95 +4Q -1V 95 301V 165

Iso 3448 V G 100 V G 150 V G 320 V G 150-200

M O B IL M ineral oil or M obilaearX M F 150 M obilciearX M F 320

Synthetic oil M obilciear SH C X M F 220

non leaded gear non leaded gear non leaded

CHEVRON com pound 100 com pound 150 gear com pound 320

SH E LL O m ala oil 100 Om ala oil 150 O m ala oil 320 T ivela O il SA

6-4
600E SERVICE MANUAL SWING

ROTATION STOP-MECHANICAL 4. If it is not centered, loosen the two nuts, one on either
side of the spacer. Turn the nuts in the same direction
The rotation stop system is designed to stop crane rotation until the spacer is centered. Tighten the nuts against the
beyond 375 degrees in the clockwise or counterclockwise ends of the spacer to secure it in place.
directions. This is accomplished by mechanically returning
the control valve to the centered position as full rotation is 5. Verify that the flag is sill centered between the stop pins.
approached. The operator will feel the control lever begin to
pull in the opposite direction as full rotation is approached.
The operator should not resist this counteracting force, but
permit the rotation stop system to return the lever to neutral.
If a load cannot be reached or placed due to the available
rotation, the crane must be re-positioned.

DANGER
.Attempting to over ride the rotation stop system will result
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 Method 2
rotation stop system. 1. Follow the crane set-up procedures in this manual to set
Method I outriggers and stabilizers and level the ma chine.

1. From inside of the frame, rotate the flag rod until it is 2. With the crane properly set-up, raise the boom to near
centered between the two stop pins on either side of the full boom angle (75-80 degrees). This must be done with
the boom fully retracted and with no load attached to the
loadline.
3. Slowly rotate the boom until is directly over the front of 6
the truck (behind cab mounting). With the boom directly
over the front, place a mark at the top of the frame
aligned with the center of the lift cylinder.
4. Rotate the crane clockwise, or counterclockwise until
the rotation stop system centers the control lever.
5. Again make a mark at the crane frame aligned with the
center of the lift cylinder.
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
flag. the second mark, as it is from the first mark to the third
2. Make certain that the turn lever is vertically aligned. If mark.
not, adjust the lever at the clevis connecting it to the 9. If not, loosen the nut on either side of the spacer on the
control valve. flag rod actuator rod and adjust the position of the
3. With the turn lever vertically adjusted, verify that the spacer. Tighten the two nuts and repeat steps 3 thru 7
spacer is centered in the turn control rod tab. above until proper adjustment is achieved.

6-5
SWING 600E SERVICE MANUAL

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6-6
600E LUBRICATION

SECTION 7
LUBRICATION
TABLE OF CONTENTS
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chassis Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Extreme Pressure Multipurpose Gear Lubricant (EPGL). . . . . . . . . . . . . . . . . . . . . . 7-1
Open Gear Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chassis Grease Low Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Coupling Lube Spline Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Anti-wear Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Hydraulic OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Standard Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Wide Range Intermediate Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Arctic Hydraulic Oil.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Winch Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Brake Oil Level (for Tulsa Winch only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-i
LUBRICATION 600E

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7-ii
600E SERVICE MANUAL LUBRICATION

SECTION 7
LUBRICATION
Following the designated lubrication procedure is important Open Gear Lubricant.
in ensuring maximum crane lifetime and utilization. The
procedures and lubrication charts in this section include This is a special adhesive lubricant of heavy consistency for
information on the types of lubricants used, the location of protection of wire rope and exposed gears where provisions
the lubrication points, the frequency of lubrication, and other not made for continuous lubricant replenishment. Select the
information. The information included in this section does not viscosity that gives best protection and lubrication without
include lubrication requirements for the truck chassis. Refer peeling, scaling, or excessive throw off.
to app ro pr iate tr uck ma nuf actu re r’s m anu al for t his
information. Chassis Grease Low Temp.
The service intervals specified are for normal operation This special grease for low temperature remains plastic at -
where moderate temperature, humidity and atmospheric 60°F (-51°C) with melting point of 280°F (138°C). The
conditions prevail. In areas of extreme conditions, the grease is a heavy duty extreme pressure type lubricant
service periods and lubrication specifications should be (LubriPplate Low Temp or equal).
altered to meet existing conditions. For information on
extreme condition lubrication, contact your local National Coupling Lube Spline Lubricant.
Crane Distributor or Crane Care. Coupling Lube Spline Lubricant is a synthetic-blend, heavy
du ty , an t i- wea r , ex tr em e p re ssu r e co up li ng g re a se
Lubricants recommended for the lubrication of pump shaft/PTO splines
Specific recommendations of brand and grade of lubricants when the pumps mounted directly to the PTO. This lubricant
are not made here due to regional availability, operating exhibits excellent reduced wear characteristics and has
conditions, and the continual development of improved exceptional serviceability over a wide range of temperatures.
products. Where questions arise, contact your National
Crane Distributor. Anti-wear Additives.
Excessive wear in the system may cause a loss in volumetric
Chassis Grease. efficiency, and may cause shutdowns for maintenance. An
Lubricating grease of proper consistency is to be applied efficient anti-wear oil protects the components against
periodically at relatively frequent intervals with grease guns rusting, resists oxidation and helps prevent wear.
through grease fittings. Minimum apparent viscosity of 300
SUS (Saybolt Universal Seconds) at 100° F (38° C)s Hydraulic OIL
recommended. Oil in a hydraulic system serves as the power transmission
medium, system lubricant and coolant. Selection of the
Extreme Pressure Multipurpose Gear proper oil is essential to ensure satisfactory system
Lubricant (EPGL). performance and life. The most important factors in selecting
an oil for hydraulic service are viscosity and anti-wear 7
This gear lubricants compounded to achieve high load
additives.
carrying capacity and meet the requirements of either API-
GL-5 or MIL-L-2105C. Unless otherwise specified, SAE NOTE: On units equipped with self-leveling platforms,
80W-90 viscosity may be used for year round service. Low low temperature service oils are necessary to
temperature usages restricted as follows: provide proper boom functions at temperatures
below +10°F (-12°C).

SAE M IN IM UM AM BIENT
V ISC OSITY TEM PERATUR E
NUM BER -°F (°C) CAUTION
75W - 40 (- 40) Operation of the crane with incorrect hydraulic oil in sub
80W - 15 ( -26) freezing temperature (below 32°F, 0°C) can cause
85 + 10 (-12) damage to the extend cylinder.
90 + 20 (-7)
140 + 40 ( +5)
250 + 50 (+10)

7-1
LUBRICATION 600E SERVICE MANUAL

Standard Hydraulic Oil. On plug type check points, the oil levels are to be at the
bottom edge of the fill port.
(32°F to 100°F) (0°C to 38°C) New cranes come from the
factory with ISO Viscosity Grade 32 AW Hydraulic Oil. This Over lubrication of non-sealed fittings will not harm the
fluid has a pour point of -15°F (-26°C). fittings or components, but under lubrication will definitely
lead to a shorter lifetime.
Intermediate Hydraulic Oil. Grease fittings that are worn in and will not hold the grease
(-10°F to 80°F) (-23°C to 27°C) gun, or those that have a stuck check ball, must be replaced.

For colder operating environments, the standard fluid may be When wear pads or rotation bearings are lubricated, cycle
replaced with a Low Service Temperature Multi Viscosity the components and re-lubricate to ensure complete
Hydraulic Oil with High Viscosity index 175+. lubrication of the entire wear area.

Wide Range Intermediate Hydraulic Oil. WIRE ROPE LUBRICATION

(-30°F to 80°F) (-34°C to 27°C) Wire ropes lubricated during manufacturing so the strands,
and individual wires in strands, may move and adjust as the
For even colder operating conditions, the standard fluid may
rope moves and bends. A wire rope cannot be lubricated
be replaced with a petr oleum based fluid developed
sufficiently during manufacture to last its entire life.
especially for colder environments.
Therefore, new lubricant must be added periodically
throughout the life of a rope to replace factory lubricant which
Arctic Hydraulic Oil.
is used or lost.
(-10°F and below) (-23°C and below).
The surface of some ropes may become covered with dirt,
In general, petroleum based fluids developed especially for rock dust, or other material during their operation. This
low temperature service may be used with satisfactory covering can prevent field applied lubricants from properly
results. However, certain fluids, such as hologenated penetrating into the rope. Therefore, these ropes should be
hydrocarbons, nitro hydrocabons and phosphate ester cleaned before being lubricated.
hydraulic fluids might not be compatible with hydraulic
The lubricant applied should be light bodied enough to
system seals and wear bands. This hydraulic oil is not
penetrate to the core of the rope. Lubricant may be applied
recommended for service in ambient temperatures above
effectively by various methods. It may be dripped on,
32°F (0°C).
sprayed on, or put on by brushing, but in any case it should
If you are in doubt about the suitability of a specific fluid, be applied at a place where the rope is being bent, such as at
check with your authorized National Crane distributor or a sheave. Lubrication should be applied at the top of the
Crane Care. bend, because at that point the strands are spread by
bending and are more easily penetrated. The service life of
LUBRICATION POINTS rope will be directly proportional to the effectiveness of the
method used and amount of lubricant reaching the working
A regular frequency of lubrication must be established for all parts of the rope.
lubrication points. Normally, this is based on component
operating time. The most efficient method of keeping track of A proper lubricant must reduce friction, protect against
lube requirements is to maintain a job log indicating crane corrosion, adhere to every wire and be pliable and not crack
usage. or separate when cold and yet not drip when warm.

All oil levels are to be checked with the crane parked on a

level surface in transport position, and while the oil is cold,
unless otherwise specified.

7-2
600E SERVICE MANUAL LUBRICATION

Lubrication Points

FIGURE 7-1

4. Sheave Pins (Boom -3 / Jib-1)

Lube Type - Chassis Grease
CAUTION
Lube Interval - Weekly
The following Lubrication intervals are to be used as a
guide line only. Actual lube intervals should be formulated Lube Amount - Until grease extrudes
by the operator to correspond accordingly to conditions
Application - grease fittings
such as continuous duty cycles and/or hazardous
environments. 5. Loadline - Wire Rope
Lube Type - Open Gear Lube
1. Hydraulic Oil Reservoir
Lube Interval - Semi-Annually
Lube Type - Hydraulic Oil
Lube Amount - As Required
Lube Interval - Weekly - Check and Fill
Application - Brush or Spray
Semi-Annually - Change
6. Boom Pivot Pin
Lube Amount- As Required
Lube Type - Chassis Grease
2. Oil Filter/Magnetic Plug
Lube Interval - Monthly
Lube Type - N/A
Lube Amount - As Required
Lube Interval - After First 40 hours, then quarterly
Application - Grease Gun
Lube Amount - As Required
7. Lift Cylinder Pins (2)
Application - Change and clean
Lube Type - Chassis Grease
3. Reservoir Breather
Lube Interval - Monthly
Lube Type - N/A
Lube Interval - Monthly
Lube Amount - As Required 7
Application - Grease Gun
Lube Amount - N/A
Application - Clean

7-3
LUBRICATION 600E SERVICE MANUAL

8. Turn Table Bearing 13. Swing Gear Teeth

Lube Type - Chassis Grease Lube Type - Open Gear Lube
Lube Interval - Monthly Lube Interval - Monthly
Lube Amount - Until lubricant appears at seal while Lube Amount - As Required
rotating crane.
Application - Grease Gun
Application - Grease until lubricant appears at seal while
14. Boom Extension, Sides, Bottom
rotating crane
Lube Type - See Boom Maintenance Section
9. Pump Drive U-Joint (2)
15. Outrigger Beams
Lube Type - Chassis Grease
Lube Type - Low Temperature Chassis Grease
Lube Interval - Monthly
Lube Interval - Monthly
Lube Amount - As Required
Application - Brush or Roller
Application - Grease Gun
16. Wire Rope Cables & Boom
a. Pump Spline Shaft (Direct Mount)
Lube Type - Coupling Lube Spline Lubricant Lube Type - Open Gear Lube

Lube Interval - Semi-Annually Lube Interval - Any time boom is disassembled

Lube Amount - As Required Application - Brush or Spray

Application - Remove Pump and apply to Shaft or 17. Pin Joints

Zerk provided on PTO Housing Shaft Lube Type -Penetrating Oil
10. Winch Drive Lube Interval - Monthly
Lube Type - Refer to Winch Manual for Oil Application - Spray
recommendation.
18. Boom top wear pads
Lube Interval - Weekly / Semi-Annually
Lube Type - See Boom Pad Lubrication
Lube Amount - As Required
19. Sheave Bearings
Application -
Lube Type - Chassis Grease
11. Control Linkage
Lube Interval - S emi- Annually (S ee page 7-5 for
Lube Type - SAE-10W procedure.)
Lube Interval - Quarterly 20. Diffuser
Lube Amount - As Required Lube Type - N/A
Application - Oil Can Lube Interval - Semi -Annually during Oil Change
12. Swing Drive Gearbox Application - Clean Diffuser
Lube Type - EPGL 21. Optional Continuous Rotating Swivel
Lube Interval - Lube Type - Chassis Grease
After 50 operating hours --Change
Lube Interval - Monthly
Weekly--- Check and Fill
Lube Amount - As Required
Semi-Annually -- Change
Application - Grease Gun
a. Swing Gearbox, Upper Bearing
Lube Interval - Monthly
Lube Type - Chassis Grease
Application - Grease Gun

7-4
600E SERVICE MANUAL LUBRICATION

22. Jib Sheave Case Pivot Pin lubrication of the retract sheaves attached to the rear of the
Lube Type - Chassis Grease 2nd section.

Lube Interval - Monthly Inner Boom Pad Lubrication

Lube Amount - As Required 1. With the boom fully retracted, apply grease to the wear
Application - Grease Gun pads on the top of second boom section with a small paint
brush or a grease gun.
Internal Cable Sheave Lubrication 2. Extend boom to position the wear pad access holes
directly above the wear pads on the third boom section,
apply grease to the pads using the brush or gun.
3. Extend boom to position the wear pad access holes
DANGER directly above the wear pads on the fourth boom section,
apply grease to the pads using the brush or gun.
Do not, under any circumstances, work at an elevated
height without using proper fall protection as required by 4. After grease is applied to all wear pads raise the boom to
local, state or federal regulations the maximum angle and slowly extend the boom to full
extension and slowly retract completely.
The lubrication points on the sheaves are not equipped with
5. Repeat steps 1 - 4 three times to ensure the boom is
grease fittings (zerks) and will require a grease gun adapter
fully lubricated.
to accomplish the task.
Special Tools: WINCH OIL LEVEL
Nozzle or needle grease gun fitting: To check or fill winch drum and rotation gearbox with oil,
remove fill plug and bushing. The oil should be level with this
- .25 inch (6.35 mm) diameter nozzle grease gun tip
o p e n in g . I f m o r e o il i s n e e d e d , r e f e r t o o n e o f t h e
(National P/N 955047).
manufacturer’s recommended lubricants listed in the
- Contact the Crane Care to obtain this nozzle tip. Manufacturer’s Service Manual or to the Lubrication Chart in
this manual.
NOTE: Observation through the sheave case for the
extend sheaves and the winch mount for retract
sheaves will visually determine the amount of
grease necessary for proper lubrication. A
slight amount of grease extrusion around the
pin joint is adequate for proper lubrication.
Lubrication of the extend cable sheaves located on the boom
tip end of the extend cylinder, and the retract cable sheaves
located on the inside rear of the 2 nd section is accomplished
as follows:
1. Extend boom until grease access hole (Item 19 on the
Lubrication Points diagram) becomes visible in side plate of
2nd section as it extends out of 1st section. FIGURE 7-2
2. Visually check alignment between the 2 nd section
access hole and the access hole in 3 rd section. When these
holes become aligned, the end of the extend cable sheave 1. Oil Level 2. Breather 3. Oil Level & Fill Plug
pin will be visible and accessible for lubrication.
3. This boom extended position will coincide with proper
alignment of the access hole in the rear of the 1st section for 7

7-5
LUBRICATION 600E SERVICE MANUAL

BRAKE OIL LEVEL (FOR TULSA WINCH WIRE ROPE LUBRICATION

ONLY) A wire rope cann ot be lu brica ted suffici ently dur ing
To check or fill brake fluid, elevate boom to 45° & remove manufacture to last it’s entire life. Therefore, new lubricant
brake fluid level plug, the fluid should be level with this must be added throughout the life of a rope to replace factory
opening. If more fluid is needed, refer to Manufacturer’s lubricant which is used or lost. It is important that lubricant
Service Manual for a list of lubricants . ap pl ie d as p ar t o f a ma in te na n ce p ro gr a m sh all b e
compatible with the original lubricant, and to this end, the
rope manufacturer should be consulted. Lubricant applied
shall be of the type which does not hinder visual inspection.
Those sections of rope which are located over sheaves or
otherwise hidden during inspection and maintenance
procedures require special attention when lubricating rope.
The object of rope lubrication is to reduce internal friction and
to prevent corrosion.
During fabrication, ropes receive lubrication; the kind and
amount depends on the rope’s size, type, and anticipated
use. This in-process treatment will provide the finished rope
with ample protection for a reasonable time if it is stored
under proper conditions. But, when the rope is put into
service, the initial lubrication may be less than needed for the
full useful life of the rope. Because of this possibility, periodic
applications of a suitable rope lubricant are necessary.
The following are important characteristics of a good wire
rope lubricant:
1. Fluid Level 2. Fluid Fill & Vent 3. Fluid Level Plug
1. It should be free from acids and alkalis.
2. It should have sufficient adhesive strength to remain on
HYDRAULIC OIL RESERVOIR LEVEL the ropes.
The hydraulic oil reservoir has a sight gauge located on the 3. It should be of a viscosity capable of penetrating the
side of the reservoir. This sight gauge has a decal beside it interstices between wires and strands.
that indicates a "full" level and an "low oil" level. The oil
4. It should not be soluble in the medium surrounding it
required to bring it from the "low" line to the "full" line is 5
under the actual operating conditions (i.e. Water).
gallons. Do not fill the reservoir above the "full" line. The oil
level should be checked with the crane parked on a level 5. It should have a high film strength.
surface in the transport condition (all cylinders retracted and
boom stowed) and the oil cold. 6. It should resist oxidation.
Before applying lubrication, accumulations of dirt or other
abrasive mater ial should be removed from the rope.
Cleaning can be accomplished by using a stiff wire brush and
solvent, compressed air, or live steam. Immediately after the
wir e ro pe is cle an ed , it sho ul d b e lu br ica ted . Ma ny
techniques may be used;
• bath, dripping, pouring, swabbing, painting,
pressure spray.
Whenever possible, the lubricant should be applied at the
top of a bend in the rope, because at that point the strands
are spread by bending and are more easily penetrated.
There should be no load on the rope while it is being
lubricated. It should be noted, the service life of wire rope will
be directly proportional to the effectiveness of the method
used and amount of lubricant reaching the working parts of
the rope.

7-6
600E TROUBLESHOOTING

SECTION 8
TROUBLESHOOTING
TABLE OF CONTENTS
Hydraulic System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Jib Load Limiting Device Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Jib Jack Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HCA Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8-i
TROUBLESHOOTING 600E

PAGE INTENTIONALLY LEFT BLANK

8-ii
600E SERVICE MANUAL TROUBLESHOOTING

SECTION 8
TROUBLESHOOTING
HYDRAULIC SYSTEM TROUBLESHOOTING CHART
Condition Possible Cause Possible Solution
1. Hose fittings loose, worn or Check & replace damaged fittings or
damaged. "O" Rings. Torque to manufacturers
2. Oil seal rings deteriorated by specifications. Replace oil seal rings
excess heat. by disassembling Pump unit.
(a) Loosen then tighten single bolt to
3. Bolt loose or its sealing area torque specification.
Oil Leakage deteriorated by corrosion.
(b) Replace bolt.
Remove seal carrier from pump. -
Remove damaged seal from seal
4. Shaft seal worn or damaged. carrier.
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
1. Pump not installed correctly. coupling is engaged). Check for
sources of suction leaks, inlet flange
tight? Pinched o-rings?
2. Pump not getting oil. Make sure reservoir is full of oil.
Can’t Build Any Pressure
Is it an open circuit to the reservoir.
Flow has an unrestricted path
No Flow from Pump (If pump does not
prime in 30 seconds STOP!) 1. Can only build a few hundred PSI
(20-30 bar). Is compensator setting backed out? Is
the system relief valve vented?
Pump control settings too low.
Assure control spools/springs are
assembled correctly. Assure m 6x6 set
2. Control is malfunctioning.
screw is installed in torque control feed
port.
3. Internal leakage in cylinders,
Repair component.
valves, motors or pumps.
Clean orifices in control of
contamination.
Pump won’t compensate Control is malfunctioning.
Confirm orifice and plugs are properly 8
assembled.

8-1
Troubleshooting 600E SERVICE MANUAL

Condition Possible Cause Possible Solution

Insure overload system is working
Overload system inoperative. properly and Anti-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.
No response to control
Drain tank and hose and remove
Suction line blocked.
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.
Pump compensation pressure too
Set pump
low.
Check PTO ratio, pump size and
Pump not operating at proper speed.
engine speed for 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 performance Valve spools not fully open. Adjust linkage so valve has full throw.
Boom holding valves out of
Adjust or clean as required.
adjustment.
Reduce engine speed, slow cycle time
Oil temperature too high.
to cool oil or add oil cooler option.
Hydraulic oil too cold or dirty. Warm oil or use less viscous oil.
Check lines; clean and repair as
Line restricted.
necessary.
Internal control valve crack. Replace valve.
Check Capacity Chart and reduce
Load too heavy.
load.

8-2
600E SERVICE MANUAL TROUBLESHOOTING

Condition Possible Cause Possible Solution

Loose turntable bearing. Torque bearing mounting bolts.
Loose swing gearbox mounting
Tighten bolts.
bolts.
Replace worn parts or adjust gearbox
Worn gears or bearing.
spacing.
Operator control of lever too erratic. Operate controls smoothly.
Motor counterbalance valves dirty or Clean or replace counterbalance
Swing moves erratic or loosely
not set properly. valves not set at 600 psi.
(Standard system)
Replace worn brake parts or shim
brake to proper torque.
Brake not holding properly.
Replace worn brake parts or shim
brake to proper torque
Brake releasing at wrong time or Bleed air from brake with bleed screw
erratically. on side of 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.
Check for 200 + PSI brake pilot
pressure. Clean pilot line or adjust
Swing will not turn (Standard System)
Brake not releasing properly. motor counterbalance valves.
Adjust or clean brake for proper
release.
Swing speed adjustment set too low. Adjust valve on turn motor.
Adjust foot throttle or check for too high
Excessive pump speed.
PTO ratio.
Low oil temperature. Allow unit to warm up.
Low hydraulic oil supply. Check and fill.
Suction line kinked, collapsed or
Clear blockage.
blocked.
Excessive pump noise during operation
Pump Cavitation Check for loose clamps.
Warm oil or use oil more applicable to
Hydraulic oil too thick.
environment.
Relief valve chattering. Dirt in relief valve or damaged relief.
Hydraulic tubing vibration. Check for loose tubing. 8
Tank breather plugged. Clean breather.
Not getting oil to cylinders. Clean and replace as required.
Worn or damaged piston seals. Replace as required.
Cycle operate crane cylinder to
Cylinders drift Air in hydraulic oil.
remove air.
Loose holding valve. Tighten valve.
Dirt in holding or check valve. Clean valve.

8-3
Troubleshooting 600E SERVICE MANUAL

Condition Possible Cause Possible Solution

Check load and change to applicable
Load too heavy.
multipart reeving.
Relief valve setting too low. Check and adjust if required.
Motor worn excessively. Replace motor.
Winch will not lift or hold load
Counterbalance valve defective or
Clean and replace as necessary.
leaking.
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.
Winch gearbox heats
Duty cycle too high. Reduce cycle time or speed of winch.
Boom sections need lubrication. Grease boom.
Re-shim as described in boom
Wear pads not shimmed correctly.
assembly section.
Boom chatters during extension/
Worn wear pads. Replace pads.
retraction or doesn’t proportion properly
Extension cables out of adjustment. Readjust cables and tension properly.
Disassemble and inspect and replace
Extend or retract cables broken.
cables.
Reconnect, replace and/or adjust
Proportioning cables not attached.
cables.
Boom will not extend Anti-two-block system shut down. Lower hook, and extend load.
Check anti-two-block system; repair if
Defective anti-two-block system
defective.
JIB LOAD LIMITING DEVICE TROUBLESHOOTING
Carefully check the integrity of all
circuits external to the electronics box,
System is in a state of constant cut-out Loose or incorrect wiring. from the jib tip to the console.
Compare to electrical schematic.
Check fuse at crane console. Replace
if necessary. Remove electronics box
Blown fuse. from jib, remove electronics from
housing, and check a fuse on board.
Replace if necessary.
ATB switch open. Ensure that ATB switch is closed.
Follow procedure in system installation
No table selected. section to select the correct table for
the application.

8-4
600E SERVICE MANUAL TROUBLESHOOTING

Condition Possible Cause Possible Solution

To set the zero point, remove all force
from the load cell. Remove the
electronics from the housing. Set the
Load cell not calibrated. switch position 8 to ON. Power the
system. Do not turn off power until both
the zero point and the gain have been
Load cell not calibrated set. To set the zero point, press the
button on the board. To set the gain,
set switch position 8 to OFF. Set the
switch to the correct code that matches
the load cell gain. This code can be
found on the tag that accompanies the
load cell. Press the button.
Check to see which table is selected
using the single character display. If
Wrong table selected. the wrong table is selected, select the
proper table using the procedure in the
system installation section.
Ensure that the electronics box is
tightly mounted to the jib. Zero the
Single sensor not zeroed.
angle sensor using the procedure in
the system installation section.
Configuration switch must be closed
Configuration switch stuck open or when the jib is Retracted and open
System cuts out too early or too late closed (two section jibs only). when the jib is extended. Adjust or
replace switch As necessary.
Ensure that pivot pin is free, well
lubricated, and allows the jib head to
Pivot pin not free to move. pivot freely. Inspect and replace
bearings in jib head assembly as
required.
Foreign object stuck between jib Remove any foreign objects which
head assembly and jib. The only interfere with jib head assembly
contacts between the jib head operation.
assembly and the jib are to be the
load cell and the pivot pin.
JIB JACK TROUBLESHOOTING
Add oil to reservoir tank through oil
No oil in system
Will not lift load
Release valve not closed
filler hole
8
Turn handle clockwise tightly
Add oil to reservoir tank through oil
Will lift load only part way Oil level low
filler hole
The following valve or valves leaking
a. Suction valve
Will lift load but will not hold Replace jack
b. Delivery valve
c. Release valve
Packings worn or damaged Replace jack

8-5
Troubleshooting 600E SERVICE MANUAL

Condition Possible Cause Possible Solution

Release valve stuck, probably dirt or Transfer load then replace dirty oil,
Jack will not lower
foreign matter flush oil reservoir with kerosene
Dirty oil Change hydraulic oil
Poor lifting
Air in hydraulic system Purge air from system
Oil seal for pump unit worn out or
Poor pumping action Replace jack
damaged

8-6
 600E SERVICE MANUAL TROUBLESHOOTING

HCA TROUBLE SHOOTING

Overload Trips and will not Reset

Yes Does an Overload Condition Exist

No

Has Overload Is Loadline Downhaul Weight

been Eliminated Lifting Anti-Two-Block Weight

Yes

Yes Lower Loadline Weight

Do Crane Functions Boom Down, Yes Problem Solved

Telescope Out, Winch up work

No

Is Boom Lift Cylinder

Fully Extended Is there 12v to Solenoid

Yes No Yes
Yes No
Momentarily press Manual Reset Valve to
bleed off trapped pressure with no load
Is there 12v Across Trouble Shoot C h e c k R e s is ta n c e
Pressure Switch Wiring Across Solenoid Coil.
Value should be
Yes between 9.2 and 11.2
Do Crane Functions Boom Down, No
Telescope Out, Winch up work ohms.

No
Yes
No

Problem Solved Is there an audible

Replace Solenoid
"Click" when the
No Is Fuse OK Valve
Solenoid is engerized?
Yes
No

Is there 12v to Pressure Switch Remove valve from Yes 8

cavity and check to
se e if sp ool is
sh iftin g .Cle a n Do all Functions
Replace Fuse Operate ?
Spool if necessary.
No

No
Do all Functions
Operate Replace Yes
Wiring Yes

Problem Solved Problem Solved

Check Valves Sticking.
Clean or Replace

8-7
Troubleshooting 600E SERVICE MANUAL

PAGE INTENTIONALLY LEFT BLANK

8-8
 600E CRANE INSTALLATION

SECTION 9
CRANE INSTALLATION
TABLE OF CONTENTS
Crane to Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
minimum truck requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Mounting Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Jib protection Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Configuration 1 - 600E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Configuration 2 - 600E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Configuration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
TM Rear Stow - 647E, 638E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Configuration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TM Front Stow - 647E, 638E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Configuration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Rear Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Configuration 6 - 600EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Pto Horsepower Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Direct Mount Pump to PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Pump Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
PTO Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Truck Frame Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Channel (Table A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Channel Reinforcement (Table A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Angle Reinforcement (Table B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Fish Plate Reinforcement (Table C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Angle Under Reinforcement (Table D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Requirements For Optional Front Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Truck Frame Section Modulus TableS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Positioning Crane On Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
PTO Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Reinforcing/after Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
After Frame Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Crane to Truck Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Crane Component Installation Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Torsion Box and ASH Stabilizer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Install Torsion Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Crane to Chassis Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Hydraulic Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 9
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Winch to Truck Cab Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Pin Bearing Inspection And Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

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CRANE INSTALLATION 600E

Pin Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Trunnion Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Counterweighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Counterweighting Determination Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Counterweighting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Initial Crane Run in Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Boom Rest Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Stability Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Crane Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Pump Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
System Flow and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Main Control Valve 40
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
HCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Winch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Winch Speed and Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Crane Operating Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41

9-ii
600E SERVICE MANUAL

SECTION 9

CRANE INSTALLATION
CRANE TO TRUCK INSTALLATION required rating, the gross axle rating is reduced to its
weakest component value.
This installation section provides information for mounting
and initial check out of the crane. One of the most important 2. Wheelbase, Cab-to-Axle (CA). The wheelbase and CA
elements in good long lasting crane performance is proper req u ire d a re in p a rt d ete rm in e d b y the mo un tin g
mounting. Improper mounting can cause permanent damage configuration but also by the boom length and the platform
to the truck, i.e. frame or transmission, and the crane, i.e. length of the particular unit. Match the platform length to the
p u m p o r n o n s t a b i l i t y . A l s o F e d e r a l De p a r t m e n t o f retracted boom length so that the boom doesn’t overhang the
Transportation Laws relating to vehicle manufacture and re ar o f t he be d by mor e th an th at re qu ire d by leg al
modification such as lights, brakes and axle loads must be regulations where the unit will be operated. The truck cab-to-
met as well as State vehicle laws relating to weights and axle dimension is then determined by the length of the bed
dimensional restrictions such as overall length, overhang, (the bed should be approximately centered over the rear
etc. axle) and the mounting space that the crane frame takes up
between the cab and the bed.
This section is organized by first presenting detailed
information relating to truck requirements and mounting 3. Truck Frame. Try to select a truck frame that will minimize
configurations followed by a step-by-step installation or eliminate frame reinforcement or extension of the after
procedure including PTO selection, Pump rotation selection, frame (AF). Many frames are available that have the
reinforc ement, cr ane and stabiliz er ins tallation, necessary after frame (AF) section modulus (S.M.) and
counterweighting, boom rests and stability testing. resistance to bending moment (RBM) so that reinforcing is
not required. The front hydraulic jack is used for a 360
The final manufacturer of the vehicle must certify that the degree working range around the truck. The frame under the
axle ratings have not been exceeded with all permanently cab through the front suspension must have the minimum
attached equipment including a full load of fuel and men [at S.M. and RBM because reinforcing through the front
200 lb (90 kg) each]. suspension is often difficult because of engine, radiator
National Cranes should meet ASME/ANSI B30.5 (latest) mounts and steering mechanics. See "Truck Requirements"
when completed as cranes and ASME/ANSI B30.23 (latest) and "Frame Strength" pages for the necessary section
when completed as a personnel lifting system. These modulus and resistance to bending moment values.
standards require welds to meet AWS D14.3 or AWS D1.1 4. Additional Equipment. In addition to the axle ratings,
respectively. Any work done in mounting should be done in wheelbase, cab-to-axle requirements and frame, it is
compliance with these codes. recommended that the truck is equipped with electronic
NOTE: Before proceeding with the installation, verify engine control, increased cooling and a transmission with a
that the number on the serial number plates on PTO opening available with an extra heavy duty PTO. See
the major components match the main serial "PTO Selection" pages. A conventional cab truck should be
number which is found on the crane frame. If used for standard crane mounts.
the serial numbers do not match, contact the 5. Neutral Start Switch. If equipped with optional remote
factory before proceeding. Matching the serial controls, the chassis must be equipped with a switch that
number plates insures that accurate warranty p r e ve n t s o p e r a ti o n o f t he e n g i n e s t a r t e r wh e n t h e
information will be recorded at the factory and transmission is in gear.
will aid in dispensing service bulletins and
other pertinent information.
MOUNTING CONFIGURATIONS
MINIMUM TRUCK REQUIREMENTS The National Crane is a versatile machine . The versatility
can be enhanced by the manner in which it is mounted.
Many factors must be considered in the selection of a proper
tr u ck f o r a b o om tr u ck c ra n e. It e ms wh i ch m us t b e
Follow ing is a brief description of the mounting
configurations and the advantages of each. The minimum
9
considered are: weights listed below the front and rear axles for each
1. Axle Rating. Axle ratings are determined by the axles, configuration are estimated minimum front and rear axle
tires, rims, springs, brakes, steering and frame strength of weights for an 85% stability factor before the crane,
the truck. If any one of these components is below the stabilizers and sub-base, if required, are installed on the
chassis. The minimum weights listed below the front and rear

9-1
CRANE INSTALLATION 600E SERVICE MANUAL

axles for the New York City approved configurations are for a 20’ bed. In most cases, the chassis will not require
estimated front and rear axle weights for 75% stability factor reinforcing and the amount of counter weight required is
before the crane stabilizers and sub-base are installed on minimized increasing payload capabilities.
the chassis. These weights include the permanently
Requires 14,000 pound (6350 kg) GAWRF, 34,000 pound
attached equipment on the chassis, such as pumps,
(15422 kg) GAWRR, 48,000 pound (21 773 kg) GVWR, rear
PTO’s, reinforcing, chassis mounted options, bed and
A-frame stabilizers and sub-base.
counterweight.
Most gas powered trucks will require a heavy bumper or
Before placing this unit in service, a final stability check as
counterweight.
outlined in this section must be performed.
Full capacity work area is rear 180° of vehicle from outrigger
The maximum weights listed below the front and rear axles
to outrigger.
for each configuration are estimated maximum front and rear
axle weights for not exceeding axle capacities before the Truck frame must have or be capable of being reinforced to
crane, stabilizers, and sub-base, if required, are installed on 13 in.3 (213 cm 3 SM. and 1,430,000 in-lb (161 568 N . m)
the chassis. RBM at front of rear springs through rear suspension to rear
stabilizers. The truck frame under the crane must have 15.9
CONFIGURATION 1 - 600E in.3 (2613 cm SM. and 1,749,000 in-lb (197610 N. m) RBM
This configuration allows the installation of the Series 600D minimum, spring hanger to spring hanger.
by using the standard sub-base for 18’ bed or the sub-base

* Actual scale weights prior to installation of

crane, sub-base and stabilizers.

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600E SERVICE MANUAL CRANE INSTALLATION

CONFIGURATION 2 - 600E 20 in.3 (328 cm3) section modulus [ (758

Mpa) psi steel] at the front of the T-box.
This mount requires front stabilizer, proper torsion box, and
additional counterweight in the underside of the bed for full 11 in.3 (180 cm3) section modulus at the
capacity 360° around the truck. Front stabilizer gives the
rear of the front spring hanger, 7.5 in. (12 3 cm 3 section
machine a solid base helping the operator control loads.
modulus through the spring area.
Requires 14,000 pound (6350 kg) GAWRF, 34,000 pound
(15422 kg) GAWRR, 48,000 pound (21 773 kg) GVVVR, 2 in.3 (33 cm3) minimum section modulus at
front stabilizer, rear A-frame stabilizers and sub base. the stabilizer attachment point. The section modulus through
the rear suspension must be 13 in. 3 (213 cm3 )
The truck frame must have a minimum of:

* Actual scale weights prior to installation of crane,

sub-base and stabilizers.

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CRANE INSTALLATION 600E SERVICE MANUAL

Requires 16,000 pound (7257 kg) GAWRF,

34,000 pound (15 422 kg) GAWRR and 50,000
CONFIGURATION 3 pound (22 680 kg) GVWR, ASH-TM rear stabilizers
and tractor mount sub-base. Full capacity work area
TM Rear Stow - 647E, 638E is rear 180° of vehicle from outrigger to outrigger.
Addition of a single front stabilizer will make the unit
This configuration allows the installation of the Series 360° stable. Full 360° stability cannot be attained
600E on a chassis without using the standard sub- without a front stabilizer. Truck frame must have or
base. However, it will require a heavy tandem truck and be capable of being reinforced to 30 in.3 S.M. (492
in many cases will require counterweight. Swing cm3) and 3,300,000 in-lb (372 850 N.m) RBM under
clearance, overall length and boom stow position the crane, spring hanger to spring hanger.
should be checked before mounting the crane.

* Actual scale weights prior to installation of

crane, sub-base and stabilizers. Includes
fifth wheel and boom rest.

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600E SERVICE MANUAL CRANE INSTALLATION

CONFIGURATION 4 Requires 20,000 pound (9072 kg) GAWRF, 34,000

pound (15 422 kg) GAWRR and 54,000 pound (24 494
TM Front Stow - 647E, 638E kg) GVWR, ASH-TM rear stabilizers and tractor mount
sub-base. Full capacity work area is rear 180° of
This configuration allows the installation of the Series vehicle from outrigger to outrigger. Addition of a single
600E on a chassis without using the standard sub- front stabilizer will make the unit 360° stable. Full 360°
base. However, it will require a heavy tandem truck and stability cannot be attained without a front stabilizer.
in many cases will require counterweight. Swing T r uck f ra me m us t ha ve o r be c ap ab le of b ei ng
clearance, overall length and boom stow position
reinforced to 30 in.3 S.M. (492 cm3) and 3,300,000 in-lb
should be checked before mounting the crane.
(372 850 N.m) RBM under the crane, spring hanger to
spring hanger.

9
* Actual scale weights prior to installation of
crane, sub-base and stabilizers. Includes fifth
wheel and boom rest.
** Longer wheelbase or extended bumper will
be required for all booms except the 38’ boom
to keep the front overhang under 48”
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CRANE INSTALLATION 600E SERVICE MANUAL

Requires 12,000 pound (5443 kg) GAWRF, 34,000 pound

CONFIGURATION 5 (15 422 kg) GAWRR and 46,000 pound (20 866 kg)
GVWR, front overframe outriggers, rear stabilizer and
Rear Mount heavy duty rear mount sub-base. Counterweight may
have to be added to ensure unit stability if the truck does
This type of mount enables the operator to position the crane not meet minimum weight requirements. Truck frame
closer to the load in tight working areas. 360× stability at full must have 15.9 in. 3 (261 cm3 ) S.M. and 1,749,000 in-lb
ra te d lo ad c an b e at ta in ed wi th f ro n t ou t an d do wn (197 637 N²m) RBM from rear of crane through front
outriggers, heavy duty, rear mount subbase and a single rear
outriggers.
stabilizer. Weights shown for front and rear axles are
weights of the truck chassis and bed prior to installation of Truck frame must have or be capable of being lengthened to
crane, subbase, front outriggers and rear stabilizer. an AF of 112 inches (2844 mm) minimum.

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600E SERVICE MANUAL CRANE INSTALLATION

CONFIGURATION 6 - 600EU travel height. T he 6 X 6 chassis will enhance

maneuverability in rough or adverse terrain.
This unit is equipped with a set of hydraulic "out and down"
crossframe outriggers with a 17 foot span. The crossframe An optional mid-span outrigger is available for this machine
outriggers are attached behind the cab. This truck is also to allow for setting up the crane in restricted areas. (14 ft
equipped with a set of out and down underframe stabilizers span for 690E, 10 ft span for all other boom lengths)
with a 14 foot span. The Underframe outriggers are attached Requires 16,000 pound (7257 kg) GAWRF, 34,000 pound
behind the truck chassis rear tandem axle. The behind cab (15 422 kg) GVWR, RSOD rear stabilizers and 600EU sub-
hydraulic out and down outriggers are an integral part of the base. Full capacity work area is rear 180° of vehicle from
20 foot subbase and reduce truck frame twist during crane outrigger to outrigger. Addition of a single front stabilizer will
operations. Reduced stress to the truck frame increases the make the unit 360° stable. Full 360° stability cannot be
overall chassis life. attained without a front stabilizer. Truck frame must have or
An optional short main frame is available to allow for be capable of being reinforced to 15.9 in.3 S.M. (260 cm3)
mounting on a 6 X 6 truck chassis and maintain a legal road and 1,749,000 in-lb (197 610 N.m) RBM under the crane,
spring hanger to spring hanger.

9
* Actual axle scale weights prior to installation of crane, torsion box and stabilizers
** For the 690E and 671E booms, if the distance from the front bumper (SFO) to center of rotation exceeds 165 inches (419
cm), the 40 ft (12.19 m) overall truck length restriction will be exceeded. Overall length restrictions vary from state to state.
In some states it is legal to be more than 40 ft (12.19 m) in length and some states allow over length permits.

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CRANE INSTALLATION 600E SERVICE MANUAL

care must be taken to ensure that cab height is not

TRACTOR TRAILER INSTALLATION excessive.
The Boom/Front Overhang (distance from the front
Swing clearance, overall length and boom stow position
bumper to boom tip) must also be calculated to assure
are all factors which must be considered for a tractor-
State and Federal Regulation compliance is met.
trailer installation. If the boom will be stowed to the front,

The diagram above shows dimensions which are important when planning a tractor trailer installation
for a 600E. Swing radius (SR) can be found by using the table shown below.

Trailer Corner Front of Trailer to Center of Kingpin (HP)

Nose Radius 24” 30” 36” 42” 48”
Flat Square 54” 57” 60” 64” 69”
Flat 5” 52’ 55” 58” 62” 66”
Flat 10” 51” 53” 56” 60” 64”
Flat 18” 49” 51” 53” 56” 61”
Oval Oval 48” 48” 49” 51” 54”

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600E SERVICE MANUAL CRANE INSTALLATION

PTO HORSEPOWER REQUIREMENTS Do not confuse engine crankshaft rotation with power take
off rotation. If the power take off shaft rotates opposite the
The unit is equipped with a variable displacement pump that engine crankshaft, it is turning in a clockwise (cw) direction
provides 44 gpm (200LPM) to the hydraulic system. Under when viewed from the rear of the truck. If the power take off
full hydraulic load, the unit sees 44 gpm at 3800 psi. To shaft rotates the same as the engine crankshaft, it is turning
provide this flow and pressure, the pump shaft must turn at in a counter-clockwise (ccw) direction when viewed from the
2800 RPM. rear of the truck. See illustration below.
The PTO requirement is a torque rating of at least 200 ft-lb
(271 N-m) or 40 HP (30 Kw) per 1000 RPM of PTO shaft Pump Mounting Flange
speed. The pump has A SAE B 2 bolt Mounting Flange with a SAE
B-B Splined Shaft.
Direct Mount Pump to PTO
Most pump installations can be direct mounted to the PTO PTO SELECTION
using adapter assemblies available from the PTO supplier. If
Operating speeds and performance of the crane are based
the pump is direct mounted, its weight should be supported
on proper pump outputs to the winch, lift, telescope and
by a strap between the pump and the transmission. The
swing circuits.
splined shaft coupling in a direct mount pump installation
requires lubrication. #200S Silver Streak Special Multi-Lube The speeds shown below are optimum operating speeds.
(Medium) should be applied to the shaft during original The engine must be operated at a speed such that the
installation and reapplied to the shaft or zerk provided on horsepower developed is adequate to pull the pumps under
PTO housing shaft semi-annually thereafter. pressure.

Pump Rotation See pump rotation section to determine correct pump for
your application.
It is imperative that the piston hydraulic pump installed in a
500E application be the correct pump rotation configuration
for the truck drive train/power take off rotation direction.
Make certain which direction the power take off output shaft
rotates before selecting a clockwise (cw) or counter- Engine Speed
clockwise (ccw) rotation hydraulic pump. Either cw or ccw
PTO
(RPM) for 2800
rotation pumps are available, and are marked clearly with a Ratio
RPM Pump
directional arrow on the pump housing. (%)
Shaft Speed
Optimum 2000 140
Engine
Speed 1800 156
CAUTION Range
Do not attempt to turn pump in the opposite direction of
the indicating arrow on the pump housing. Pump failure
will result.

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CRANE INSTALLATION 600E SERVICE MANUAL

TRUCK FRAME STRENGTH

9-10
600E SERVICE MANUAL CRANE INSTALLATION

SECTION MODULUS TABLES Add this to the section modulus of the channel obtained from
Table A.
The following tables will determine the section modulus of
the truck frame. Always measure the truck frame and check Fish Plate Reinforcement (Table C)
the tables to be sure that any truck factory listed section
modulus is correct. The frame can be strengthened by adding a fish plate of
suitable thickness and depth equal to the frame. The section
Channel (Table A). modulus of the fish plate can be obtained from Table C and
this must be added to the section modulus of the frame to
Table A provides the section modulus of channel frames in obtain the total section modulus.
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 Angle Under Reinforcement (Table D)
flange width and web depth column. When the depth of
frame channel and flange width is known, the point at which This table lists the section modulus of an angle with the
these two lines intersect is the section modulus from that flange under the truck frame that is added to a frame with an
particular channel. angle reinforcement already added. Add the section
modulus from Table D to the section modulus obtained from
If the section modulus of the channel does not meet the tables A and B to determine total section modulus.
requirements, the channel should be reinforced in the most
applicable method following. The edges of the reinforcing angles or channels are to be
flush with the edges of the frame.
Channel Reinforcement (Table A) Welding. Two rows of 1 inch (25.4 mm) diameter plug welds
In order to provide more strength, a channel of suitable are to be placed in a staggered pattern of the web; the rows
thickness can be added to the existing frame. The depth and to be spaced 5 inches (127 mm) apart with welds at an
flange width of this channel should be chosen so it fits over interval of 4 inches (102 mm). Do not weld on the flanges.
the existing frame. The section modulus of the needed Where thickness, depth or flange width vary, interpolation
channel is obtained from Table A and should be added to the between tables or variables within a given table will provide
section modulus obtained from the truck frame. the strength for the section.

Angle Reinforcement (Table B) If you have any questions concerning frame strength or
reinforcing , contact National Crane Crane Care before
If the truck is reinforced with an angle, refer to Table B for the proceeding.
data on the added strength provided by the angle.

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CRANE INSTALLATION 600E SERVICE MANUAL

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600E SERVICE MANUAL CRANE INSTALLATION

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CRANE INSTALLATION 600E SERVICE MANUAL

9-14
 600E SERVICE MANUAL CRANE INSTALLATION

EXAMPLE:
A truck frame of 110,000 psi (758 MPa) yield strength steel has the following dimensions: 3/8 in.
(9.65 mm) thick, 3 in. (76.2 mm) flanges and is 10.25 in. (260 mm) deep. To find the frame section
modulus:
1. From Table A, 3/8 in. (9.65 mm) thickness, W (width) = 3 in. (76.2 mm), D (depth) = 10 in. (254
mm) section modulus = 15.4 in.3 (252 cm3).
2. From Table A, 3/8 in. (9.65 mm) thickness, 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 cm 3)

11 in. (279 mm) deep channel = 17.7 in. 3 (290 cm3)

10.5 in. (267 mm) deep channel

= 15.4 in. 3 + 17.7 in. 3 = 16.55 in.3

2

= 252 cm 3 + 290 cm 3 = 271 cm 3

2
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 in. (254 mm) deep channel = 15.4 in. 3 (252 cm 3)

10.5 in. (267 mm) deep channel = 16.55 in. 3 (271 cm 3)

10.25 in. (260 mm) deep channel

= 15.4 in.3 + 16.55 in.3 = 15.98 in.3

2

= 252 cm 3 + 271 cm 3= 262 cm3

2

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

= 15.4 in.3 + 16.55 in. 3 = 15.98 in. 3

2

= 252 cm3 + 271 cm 3= 262 cm 3

2

5. 15.98 in.3 (262 cm 3) Section Modulus, 110,000 psi (758 MPa) steel is adequate for a standard mount with a torsion box.

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CRANE INSTALLATION 600E SERVICE MANUAL

REQUIREMENTS FOR OPTIONAL FRONT inch (12.7 mm) DIA. Grade 8 bolts to their nominal breaking
STABILIZER strength. Torque the mounting bolts supplied with the front
stabilizer to 110 ft-lb (149 N·m).
The truck frame must have adequate strength from under the
Do not use spacers between the bumper bracket and the
crane frame through the front suspension to the bumper
front stabilizer bumper assembly.
assembly for front stabilizer installation. A truck frame yield
strength of 110,000 psi (758 MPa) is required. If the bumper bracket and front of the truck frame do not
meet these specifications, an extended frame truck must be
The following diagram shows the required section modulus
used. Contact factory for details. Details for mounting a
at various stations along the front end of the truck frame for a
stabilizer on an extended frame truck are included in that
standard behind-the-cab mount with torsion box.
installation instruction. However, the Section Modulus
In order to safely mount a front stabilizer in place of the requirements outlined below do apply.
normal front bumper, a minimum bolt pattern as shown is
required. The bracket must be capable of supporting .50

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 600E SERVICE MANUAL CRANE INSTALLATION
TRUCK FRAME SECTION MODULUS
TABLES
Use Table E and Table F below along with Tables A through
D in the preceding section of this manual for determining the
section modulus of the truck frame. Where thickness, depth or flange width vary, interpolation
between tables or variables within a given table will provide
Always measure the truck frame and check the tables to be the strength for the section.
sure that any truck factory listed section modulus is correct. It
is also necessary to measure the frame and check the If you have any questions concerning frame strength or
section modulus wherever the depth and/or flange width reinforcing, contact National Crane before proceeding.
changes. Where thickness, depth or flange width vary, interpolation
1. Channel (Table E). Table E supplements Table A for between tables or variables within a given table will provide
narrower truck frame flanges. Use the width of the narrow the strength for the section.
flanges for "W" to find the section modulus from Table E. If you have any questions concerning frame strength or
2. Angle (Table F). Use Table F for an angle section such as reinforcing, contact National crane before proceeding.
when a flange and part of the web of a truck frame channel is
removed.

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CRANE INSTALLATION 600E SERVICE MANUAL

9-18
600E SERVICE MANUAL CRANE INSTALLATION

EXAMPLE:
Refer to the sample truck frame cross sections in Table E. Truck frame yield strength is 110,000 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 1.50 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 in.3 (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 = 11.9 in.3
(195 cm3).
4. Interpolate between the two values:

10 in.(254mm) deep channel = 10.2 in.3 (167cm3)

11 in.(279mm) deep channel = 11.9 in.3 (195cm3)

10.5 in.(267 mm) deep channel

= 10.2 in.3 + 11.9 in.3 = 11.0 in. 3

2

= 167 cm3 + 195 cm 3 = 181 cm 3

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 cm 3 = 174 cm 3

2

Frame Section Modulus at the front axle location is 10.6 in.3 (174
cm3). This is greater than the 7.5 in. 3 (123 in.3) required so the truck
frame is strong enough at this location.

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CRANE INSTALLATION 600E SERVICE MANUAL

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 LMI or
jib load limiting device computer system CAUTION
components may be damaged by welding on the An arrow is cast into the rear pump housing to identify
truck or crane. The following precautions should be rotation. Rotation is viewed form the shaft end of the
taken: pump. Make sure pump is the correct rotation for the PTO
- Disconnect truck battery cables (positive and being used.
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.
- Remove the jib from the crane before welding on the Sometimes the pump is powered through a drive line
crane or remove the jib sheave case assembly from with the pump located no more than 42 inches (107 cm)
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
POSITIONING CRANE ON TRUCK drive shaft must be parallel with each other. Drive lines
should be sized so they can safely carry the maximum
The final user of the crane must be aware of all state axle pump horsepower requirements. See "PTO Selection"
and length laws in force at the time of crane mounting and pages. Drive lines are not normally furnished by the
position the crane on the truck accordingly. Following are factory.
items which must be considered.
3. Plan the location of the pump mounting bracket and
1. Overall Length: Most states have a maximum straight drive line, if used, so that ample clearance is maintained
truck length limit of 40 feet (12.19 m). Using too long a between pump and truck drive shaft or exhaust system.
WB truck could cause the unit to exceed this limit. Pump should be situated so that hydraulic lines can be
2. Axle Weights: All states allow 20,000 lb (9072 kg) single connected without sharp bends especially the large
axle weight and 34,000 lb (15,422 kg) tandem axle suction line from the reservoir. Pump mounting brackets
weights on primary roads, however, some states restrict may be attached to existing frame crossmembers or a 6
axle weight to less on secondary roads or at certain inch (15 cm) channel crossmember can be made and
times throughout the year. Be aware of your state’s axle installed.
laws and the roads the machine will operate on for 4. Install pump mounting bracket (driveline driven pumps
weight restrictions due to secondary roads, bridges, only) securely to the truck frame. Attach pump to pump
winter driving conditions, etc. mounting plate or directly to the PTO using capscrews
3. Overhang: The most restrictive overhang laws call for a provided.
maximum of 3 feet (.91 m) in front of the truck. Many a. Install the pump support bar at the rear of the pump
states have a maximum of 4 feet (122 cm) overhang in and bolt or weld the upper end to a crossmember if
back of the truck. Check on your state requirements. the pump is driven by a driveline.
4. Federal Bridge Law. The Federal Bridge Law in effect b. For a direct mounted PTO attach to a transmission
currently states that in order to carry 54,000 pounds bolt.
(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. c. The rear of the pump must be supported regardless
This equates to a truck with a wheelbase of at least 258 of the mounting method.
inches (655 cm) with a minimum length of 24 inches 5. The splines of the pump shaft and the drive coupling
(60.96 cm) from the center of tandems to the center of need Lubrication. If the gearbox is a wet drive then no
the rear axle. grease is required because the gearbox oil will lubricate
the splines. If the gearbox coupling is sealed then the

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 600E SERVICE MANUAL CRANE INSTALLATION

splines needs to be greased with Heavy Lithium Grease engine is stopped. Therefore, assure that all suction or
covering all the Splines inlet lines are airtight.
6. For a wet mount, a gasket is required for the mounting 11. Remove plug as shown in figure #1 below and add a cup
flange to PTO gearbox interface. Dry mount does not of hydraulic fluid to the pump case to help lubricate parts
require a gasket. during start-up priming.

7. Torque the mounting flange nuts to 50 ft. lbs (222N. m). 12. Start engine.

NOTE: Some of the pipe fittings used are sealed by a. Idle engine for two to three minutes with no
means of two threaded tapered sections, one functions actuated. Check for leaks and repair if
male and one female. When these two tapers required. Lay your hand on the pump to check for
meet, you will note a sudden increase in the excessive heat build-up. If the pump section is too
force required to screw the fittings together. hot to keep your hand on, stop the engine
This is true of all tapered pipe threads. Further immediately. If the pump makes excessive noise, it
tightening will not only fail to increase the is probably sucking air, keeping the pump from
pressure tightness of the joint, but may ruin the priming. If this occurs, stop engine, and inspect all
co nn ec ti on s a nd m ak e c orrec t as sem bl y connections of the suction hose/tube for a lose
impossible. connection, or for a missing or damaged o ring. Re-
start engine and run until pump takes prime or a
Other fittings are of the o-ring boss type. These are maximum of 30 seconds. If pump does not prime in
installed by first screwing the lock nut flush to the 30 seconds, stop motor and repeat until pump
upper thread land and installing fitting into port until primes.
the nut contacts the surface of the port. Adjust
fitting to desired direction. Tighten locknut. b. Increase RPM to 1500-1800 for 1-2 minutes with no
functions actuated and again, make checks outlined
Most pressure fittings are the O-ring face seal in step A. Incrementally increase throttle to full RPM
types. A small O-ring is compressed between the and then cycle the functions that the pump supplies,
male and the female fittings of the joint. Be sure the to verify proper speed (verify pump flow).
O-ring is present on the fitting and seated properly
in its groove before the fittings are tightened.
8. Remove the dust covers from the pump inlet and outlet
and determine that the suction and pressure sides of the
pump are correct while rotating the pump in the same
direction as the PTO. Mount the pump with the drain port
in the upper position. Mounting the pump with this
orientation will allow the pump to remain in the primed
condition through succeeding startups.

CAUTION
The hydraulic piston pump case must be pre-filled with oil
prior to startup. Failure to do so will result in pump failure.

9. Fill the reservoir with the proper hydraulic fluid to the

high-level mark on the reservoir sight gage.
10. The biggest concern is to make sure we are not sucking
air into the pump inlet or allowing the pump suction or Pump shown is a counter clockwise
inlet fluid to "bleed-back" to the reservoir when the rotation. Clockwise rotation pump will
have inlet and outlet ports reversed.

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CRANE INSTALLATION 600E SERVICE MANUAL

REINFORCING/AFTER FRAME EXTENSION frame cross members are bolted in, remove the bolts.
Do not attempt to remove any rivets.
1. Refer to "Truck Frame Strength" and "Section Modulus"
tables . Determine s ec tion m odulus by ac tual 3. Place the reinforcing on the truck frame and clamp in
measurement of the truck frame. If reinforcing is place. Mark the location of any rivets by striking the
required, always use at least 100,000 psi (758 MPa) outside of the reinforcing over the rivet area so that the
steel to minimize the amount of reinforcing required. Use rivets make an impression on the inside of the
Grade 90 weld material for any welding to be done. reinforcing. Mark the approximate location of the crane
mounting anchors so that no obstructions exist. Remove
2. Strip the frame of obstructions in the area to be the reinforcing and drill or torch cut clearance holes for
reinforced or extended, one side at a time. If the truck bolts or rivets. See Figure A.

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600E SERVICE MANUAL CRANE INSTALLATION

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 toTorque
In some cases, because of customer stipulation or truck
Values for Grade 5 and 8 Bolts in Section 2.
manufacturer voiding their warranty, bolt-on reinforcing is
required. In these cases, install the reinforcing, clamp in

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CRANE INSTALLATION 600E SERVICE MANUAL

5. If the frame through the rear suspension doesn’t meet as in Figure B. Slide the reinforcing angle up from the
minimum specifications for RBM and section modulus bottom, butt it to existing forward reinforcing and weld
as shown on "Truck Frame Strength" table, it can be rear suspension reinforcing to forward reinforcing.
reinforced by adding an angle type of reinforcing as in Replace as much of the spring hanger cut out areas as
Figure D. See "Section Modulus tables, Table B for the possible and butt weld these pieces in.
required size of reinforcing. Strip all easily removable
If reinforcing angle is to be bolted on, drill hole pattern and
equipment from the frame through the suspension such
install bolts according to Figure C. Reinforce spring hanger
as spring stops, etc. Butt the reinforcing angle up
cut outs and the weld area, suspension reinforcing to forward
against the reinforcing forward of the suspension and
reinforcing by adding bars under these areas. The bars
mark the areas that will require cutting so that the angle
should be of the same thickness, width and yield strength as
will slide up around the spring hangers and against the
the reinforcing angle lip, and should be long enough to
existing truck frame and forward reinforcing. Torch out
extend at least 6 inches (152 mm) beyond either side of the
the marked areas in the long leg of the angle deep
weld or cut out areas. Weld these reinforcing bars to the
enough so that the lip of the angle can be slid up from
underside of the reinforcing with length-wise welds. Do Not
the underneath the frame to contact either existing truck
Weld Across The Flanges. Replace any equipment that
frame or spring hanger brackets (if they extend down
had been removed.
below the existing truck frame). If reinforcing angle is to
be welded to truck frame, cut out plug weld hole pattern

9-24
 600E SERVICE MANUAL CRANE INSTALLATION

AFTER FRAME MODIFICATION 13. Install Boom

If additional suspension reinforcing is required, as may be 14. Install winch cable

the c as e w ith a truc k fr am e that tapers dow n 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 subbase on the chassis at the proper
cm) of weld, 6 inches (15.24 cm) no weld, etc., along both location.
edges of the bar, front to back. Length of after frame (AF)
may have to be modified for crane installation. If AF is too 3. If subbase does not fit tightly on truck frame at all
long, cut off excess and remove any crossmembers from locations, do not force them together to remove gaps
back of truck frame. If AF is too short, the frame will have to since they will not affect the units stiffness or strength.
be lengthened. Use channels fabricated from 100,000 psi Add spacers as required to level truck bed before
(758 MPa) yield material that are the same size as the truck attaching it to the torsion box
frame. Weld these channels to the ends of the existing truck
frame channels. Bevel the ends of the channels to get 100% Install Torsion Box
weld joints with Grade 90 weld material. Fabricate an inner Install outriggers on crane frame as shown in illustrated parts
channel of the same thickness as the truck frame channels pages. Attach the appropriate hoses to the outrigger
to span the weld joint for at least 12 inches (30 cm) on each cylinders. Cycle the outriggers to fill with oil completely and
side of joint. Plug weld this channel to the inside of the truck install the latch plate to hold outriggers in place during travel.
frame, then skip weld the inside edge of the top and bottom
flanges to the truck frame flanges Crane to Chassis Mounting
CRANE TO TRUCK MOUNTING 1. Center crane frame on chassis at designated distance.
PROCEDURE 2. The standard supplied stud is 32.5" long. For most
applications, the stud will be required to be cut to a more
The following is a suggested sequence of steps required to
appropriate length per application. If studs must be
successfully mount the crane on the truck. This is only one of
shortened, cut off stud on long thread end of stud.
several possible ways to mount the crane and is offered as
Following is the recommend method to determine the
an aid to planning the mounting of the crane.
required length.
Crane Component Installation Sequence Depth of frame + 17.5" = Required stud length
1. Position Torsion Box and mark frame locations for NOTE: Do not use a cutting torch to shorten the
Hydraulic Reservoir and ASH mounting studs. If studs must be shortened,
they must be cut off with a saw.
2. Remove Torsion Box
3. Run lock nut on short 2.75" threaded end of each stud
3. Install hydraulic pump
until one thread sticks out of the lock nut. The lock nut
4. Locate and drill holes for Hydraulic Reservoir end of the stud will always be on the bottom side of the
stud when installed.
5. Install Hydraulic Reservoir
4. Insert stud to be used on internal side of truck frame into
6. Install pump lines to Reservoir hardened washer, bottom clamp plate and then the
7. Position Torsion Box restraint tabs on proper frame spacers. Insert internal
stud into crane frame and frame spacer into truck frame.
8. Install ASH Install hardened washer and nut on top end of stud.
9. Install Truck Bed
9
5. From the bottom, insert outside stud into hardened
10. Install Frame Assembly washer, bottom clamp plate, up along the outside of the
truck frame rails into the crane frame bottom plate with
11. Install Outriggers 2.75" short threaded end at bottom.
12. Route and connect hydraulic hoses to Reservoir and
Main Control Valve

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CRANE INSTALLATION 600E SERVICE MANUAL

6. Install hardened washer and first nut on top and tighten parallel with truck frame will cause uneven edge loading and
both inside and outside stud nuts on top. (Note long cause premature stud failure.
thread end of stud is to the top.)
7. Install 2nd nut on top and tighten the two nuts until they
are locked. CAUTION
8. Torque bottom lock nut to specified torque of 1120 ±112 Do not allow the nuts to bottom out on the threads on
ft-lb. either end of the studs
9. To keep the stud from turning, use a wrench to hold the
top nut.
Alternate between studs at each corner during the tightening
process to insure studs are straight and bottom clamp plate
is kept parallel with truck frame. Failure to keep clamp plate WARNING
When tightening bottom nuts keep plate parallel to
truck frame. Failure to do so will cause uneven edge
loading and cause premature stud failure.

Torsion Box Mount

Stud Torque Sequence

Tighten Second

ASSEMBLY SEQUENCE

Tighten Third

Tighten Last
Start Here

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600E SERVICE MANUAL CRANE INSTALLATION

ASH to Torson Box Mounting

CAUTION
Do not allow the nuts to bottom out on the threads on
either end of the studs

Tourque Mounting Studs to 400 ± 40 ft-lb (540 ±54 N-m)

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CRANE INSTALLATION 600E SERVICE MANUAL

Hydraulic Reservoir Installation 12. Install the return line from the crane frame to the filter on
the side of the reservoir.
10. Find a location for and install hydraulic oil reservoir.
Mounting brackets may be bolted to the truck frame. NOTE: The weight of suction and return hose and
Before placing reservoir in service, remove cleanout p l u m b in g m u s t b e su p p o r t ed t o p re v e n t
cover and inspect to ensure proper installation of d am a g e t o t h e re se rv oi r. I n st a ll su p p o rt
diffuser. brackets and clamp or tie hoses up to eliminate
strain on reservoir connections.
11. Connect winch drain, pump drain, and pump suction to
couplings on reservoir before filling with oil.

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600E SERVICE MANUAL CRANE INSTALLATION

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 5. Grease the three pin joints with gun grease and operate
the boom and lift cylinder through several complete
Inspection and Installation pages in this
cycles before placing machine in operation.
sec tion. Before connecting hoses, boom must
be opposite (180°) the rotation stop to minimize 6. Route the 1/2 inch R12 telescope hoses over the turret
hose twist. back plate and to the back side of the boom. Connect
the telescope cylinder connections at the back of the
1. Pin lift cylinder barrel in position in the turret. boom.
2. Pin boom pivot to turret. (It will be necessary to use an 7. Route the 3/4 inch R12 winch hoses and the 1/4 inch R1
overhead hoist for lifting boom and lift cylinder.) winch drain hose through the turret then through the
3. Connect the 1/2 inch R12 hoses to the lift cylinder. holes in the side of the winch side plates and connect to
the winch fittings.

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CRANE INSTALLATION 600E SERVICE MANUAL
5. Spool the loadline onto the winch drum while
maintaining approximately 500 pounds (250 kg) of
Wire Rope Installation tension on the cable (attaching a small vehicle to the end
of the loadline with another person lightly riding the
1. Unspool approximately 15 feet (8 m) of cable and route
vehicle brakes while the cable is spooling on the drum
the cable through the boom cable guides from the front
will accomplish this). While the first half of the winch
of the boom to the winch.
bare drum is filling, it will be necessary to force the cable
2. Install one end of the loadline cable into the winch drum to wrap tightly against the preceding wrap by pounding
using the wedge socket provided. the cable against the preceding wrap with a rubber
mallet until at least half of the drum is full. The remaining
3. Remove the cable keeper T-handle pin from the sheave
half of the drum should wrap tightly because the fleet
case and lay the cable over the top sheave. Replace the
angle of the cable will tend to pull the cable to the center
top cable keeper pin.
of the drum thus wrapping tightly.
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
the crane. Be sure cable clamp is attached to the free 7. After cable is completely wrapped on drum, replace
end of the cable only. If equipped with optional 2/3 part remaining cable keeper bolts on the sheave case. Attach
block, omit downhaul weight and assemble as shown in wedge socket and cable clip to end of cable per
Loadline Section. Special care should be taken to reeve illustration in Loadline Section of parts manual and
the cable through the wedge socket as shown below. torque cable clip bolts to 95 ft-lb (128 N·m) for 9/16 inch
cable.

• Properly match socket, wedge and clip to wire rope size. The wire rope must pass through the “go” hole in the wedge. It
must not pass through the “no go” hole in the wedge.
• Align live end of rope, with center line of pin.
• Secure dead end section of rope.
• Tighten nuts on clip to recommended torque. (See Table)
• Do not attach dead end to live end or install wedge backwards.
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600E SERVICE MANUAL CRANE INSTALLATION

Winch to Truck Cab Clearance Trunnion Inspection

Check for winch mount tail swing clearance at top of cab. 1.The trunnion bore should either have a machined step or
Any equipment that extends above the truck cab such as have a spring spacer installed to prevent inward movement
exhaust stacks or air horns may interfere with the winch of the bearing. If equipped with a spring spacer, check to
mount when the boom is elevated and rotated. Shorten make sure the opening is positioned over the grease hole.
exhaust stacks or move air horns, etc. to ensure clearance.
Bearing Inspection
Painting
1.Two bearings are to be installed in the boom pivot trunnion
If crane is to be repainted, mask all decals prior to final paint located directly below the winch and the remaining four
or install all new decals in accordance with location drawings bearings are to be installed in the lift cylinder, two at each
and illustrated parts catalog over final paint. side of the rod end of the cylinder and two at each side of the
butt end of the cylinder.
PIN BEARING INSPECTION AND 2.The bearings should be started in their respective bores by
INSTALLATION PROCEDURE rotating the bearing while applying inward pressure with the
hand. Once the bearing has been started squarely into its
Pin Inspection bore, it can be driven to its full counterbored depth by tapping
lightly with a rubber mallet. The head diameter of the mallet
1.Remove the protective covering from pins and inspect
should exceed the outside diameter of the bearing to ensure
each pin for nicks, gouges or deep wide scratches. A small
that the bearing is not damaged during assembly into the
nick or gouge up to 1/8 inch (3 mm) diameter can be repaired
bore.
by dressing the edges of the imperfection with a file so that
no metal protrudes above the circular surface of the pin. 3.If the bearing appears to be loose in the bore (if it can be
pushed in with hand pressure alone), it is permissible to
2.A circular scratch of up to 1/16 inch (1.5 mm) wide or deep
tighten the bearing by center punching the bore diameter in
can be repaired as in 1 above.
approximately 50 places around and throughout the 2 inch
3.A lengthwise scratch on the pin of up to 1/32 inch (.8 mm) (51mm) deep bored area. Center punching will raise the
wide or deep can be repaired as in 1 above. metal around the edge of the punch mark and this raised
metal will hold the bearing firmly in place during machine
4.Pins with defects larger than those listed in 1, 2 or 3 should
operation.
be replaced.
4. Af ter a ll b ear ing s h ave be en inst alle d a nd be for e
Bearing Installation attempting to assemble the machine, insert the pins through
both bearings in each end of the lift cylinder and through the
1.The bearings furnished with this machine are made up of a
boom pivot bearings to insure alignment and fit are correct.
tough epoxy impregnated wound glass backing shell with a
Also check the two sets of pin holes in the turret and the pin
thin inner layer of filament wound bearing material. The
holes in the boom ears to ensure that the pins will slide freely
outer bearing material should be visually checked for
through the leading hole and start in the opposite hole. If a
imperfections. Bearings with cracks or gouges larger than 1/
pin starts to bind through the leading hole, do not force the
4 inch (6 mm) diameter on the outside diameter should be
pin any further to avoid damaging the pin surface finish.
replaced.
Remove the pin and clean any corrosion of burrs out of the
2.Inspect the inner diameter surface of the bearing. any holes with a round file or emery cloth.
scratches, cut or gouges which have penetrated through the
5.When pinning the boom to the turret, and the lift cylinder to
inner liner may cause premature failure of the bearing. The
the turret and boom, use a r ound smooth bar of
bearing should be replaced.
approximately 1-1/2 inch (38 mm) diameter as a pry bar to
align the pin holes. A pry bar with a sharp edge, such as a
crowbar, can gouge or cut bearing and this may lead to
premature bearing failure.

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CRANE INSTALLATION 600E SERVICE MANUAL

COUNTERWEIGHTING 2.The 85% tipping factor as outlined in OSHA and ANSI

specifications means that when lifting the full capacity loads
1.Refer to Mounting Configuration pages in this section. The most likely to cause the truck (with outriggers and stabilizer
amount of counterweight and its location is dependent upon set) to overturn, the unit is at 85% of tipping over. Increasing
the stability working area (180× behind the truck or 360× this full capacity load by 117.6% (overloading) will cause the
around the truck), the weight of the truck and all permanently unit to tip over.
attached equipment. Permanently attached equipment which 3.In order to determine the amount of counterweight
can be considered as counterweight includes the bed, required, it is necessary to add up the weight that each
reinforcing, PTO and pumps, tool boxes, etc. The torsion permanently attached piece of equipment will place on the
resisting subbase and rear stabilizers are considered part of front and rear axles of the truck along with the initial truck
this crane and not part of the counterweight. Additional chassis weight and then compare the total front and rear axle
counterweight is usually added to the underside of the bed weights with the weights listed on the “Mounting
and/or to the torsion resisting subbase. On some trucks, a Configuration” (Installation Section) pages to determine the
heavy front bumper may also be required for stability around amount and location of counterweight required.
the rear.

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600E SERVICE MANUAL CRANE INSTALLATION

Counterweighting Determination Example

9-33
CRANE INSTALLATION 600E SERVICE MANUAL

Counterweighting Methods
Two methods of counterweighting may be used: (A) a heavy
front bumper and concrete in the bed or (B) concrete in the
bed only. The easiest and most economical method is
usually concrete in bed only. The amount of counterweight
required will be 1132 + 918 = 2050 pounds (513 + 417 = 930
kg). Use 2350 pounds (1066 kg) of concrete poured in the
front of the bed. See “Counterweighting for 180° Stability” in
this section
Determine axle weights added by the counterweight by using
the same method as used before. Figure the center of the
counterweight to determine where the weight acts. If the
counterweight is oddly shaped, figure the center and weight
of each regular shape. Weights ahead of the front axle
require using a negative (-) distance in calculations.

The rear axle weight is 624 pounds (283 kg) heavier than required and the front axle weight is 26 pounds
(12 kg) heavier than required.

9-34
600E SERVICE MANUAL CRANE INSTALLATION

.
Check the final weight of the unit with crane installed. See
“Specifications Section” for weight of 690E and center of
gravity. Note that this weight does not include weight of rear
ASH stabilizers [830 pounds (377 kg)]. Use 4” set back (Cab
to Torsion Box)

Check the final unit weight with a full load of diesel [@ 7.3 After the unit is completely assembled, the stability test must
lbs per gallon (0.87 kg per liter)] and men (@ 200 lbs (90 kg) be run in accordance with Stability Test Procedure page at
per man) to ensure that the axle ratings have not been the end of this section to verify crane stability.
exceeded so that DOT certification requirements can be
met.

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CRANE INSTALLATION 600E SERVICE MANUAL

9-36
600E SERVICE MANUAL CRANE INSTALLATION

the concrete can be determined by multiplying the volume in

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

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CRANE INSTALLATION 600E SERVICE MANUAL

INITIAL CRANE RUN IN PROCEDURE 2. Set throttle according to engine RPM and PTO ratio to
get 2400 RPM pump shaft speed.
1. With the unit in an open area for testing that will permit
full operation of all its functions, engage the PTO and run 3. When all cylinders have operated through complete
the truck engine at idle to activate the pump cycles, stow crane and place the outriggers in the up
(approximately 600 rpm). Turn the crane power switch position. The oil level should be visible near the top of
on and operate the crane and outriggers though all of the sight gage.
their functions at least six (6) times to purge cylinders of 4. Lift and stability test must now be performed on the unit.
air. Operate the control valves slowly with the truck (See Stability Test page.) Winch and crane tests should
engine at idle and cycle each cylinder through its be conducted to insure proper performance.
complete stroke each time. Check to see that
movement of outriggers and boom correspond with 5. After testing is completed, the mounting bolts and all
direction indicated on switches and levers. Refer to cable clamp bolts should be re-torqued to specifications.
hydraulic or electrical schematic and parts pages to 6. Upon completion, overall height of crane vehicle
correct any problems. combination must be measured and posted inside of cab
Note: Add oil to reservoir as required to keep air informing driver of overall height.
from reentering the system.

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600E SERVICE MANUAL CRANE INSTALLATION

The loadline shall be hooked to some point on the bed, truck

BOOM REST REQUIREMENTS frame, etc. to secure the hook weight during transport. Install
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 The boom rest should be positioned to support the 1st
must be installed. A rest must be supplied for transport to section boom. Be careful to avoid contacting the boom at or
reduce vibratory stress on the crane and truck and protect near the end where the retract cables are located. Contact
rotation system from transient damage. with these cables will result in costly repairs.
Below are shown typical configuration designed to meet The boom rest saddle provided is designed to support the
boom support require ments. These Boom Rests are 1st section boom. It will be necessary to modify the saddle to
available at your National distributor. make it narrower and reposition the support cushions under
the boom side plates if the boom is extended to reach the
boom rest.

9-39
CRANE INSTALLATION 600E SERVICE MANUAL

STABILITY CHECK counterweight. Extend the boom to the maximum boom

length and winch the stability load off the ground. Slowly
The chassis weight, before the crane is mounted, is intended boom the load down so the load will swing out, until the
for use only as a guideline in determining the total weight loaded radius is reached. As the boom is lowered keep
required for the unit to be stable with an 85% tipping factor winching the load up to keep it about 6 inches off the ground.
(i.e. when lifting capacity load, the unit is at 85% of tipping or
less). Do not exceed loaded radius.

In order to ensure the stability of the unit with an 85% tipping Slowly rotate the boom throughout the work area. As the
factor, a live load stability test must be performed on each boom is rotated, the boom will have to be raised and/or
completed unit. Proceed as follows: lowered to maintain the loaded radius because of subbase
flexure.
1. Test the unit for stability on a firm level surface.
On units not equipped with front stabilizers, tipping from
2. A Series 600E crane requires rear stabilizers for stability. stabilizer support to front wheel support will occur as the load
With the boom stowed, set the unit up level on the or boom is swung around the front. Do not attempt to lift
outriggers and stabilizers. rated loads around the front of the truck unless the unit is
3. When stability testing this unit, select the load from the equipped with a front stabilizer.
capacity chart that is listed at the longest boom NOTE: Weights of accessories installed on the boom
extension and approximately 30° of boom elevation. or loadline (including downhaul weight) must
be deducted from the calculated load when
checking stability.
Boom Loaded Loaded
Model Length Angle Radius 4. If slight tipping occurs, but load can be kept from coming
690E 78’ (23.77 m) 39.5° 60’ (18.29 m) in contact with ground by winching the load up, unit is
stable. If not, counterweighting will have to be added to
The stability test load will be 1.18 times the load chosen from get unit in a stable condition or decal must be added to
the load rating area of the capacity chart. define areas of full stability and areas of reduced
capacity because of stability. If the unit is equipped with
Example: 690E a jib, the stability test should be repeated. Use the fully
extended jib capacity multiplied times 1.18 at the lowest
Boom Length: 78’ (23.77 m)
angle that the jib is rated fully extended.
Loaded Radius: 60’ (18.29 m)
Load Rating: 2250 lb (1021 kg) 5. When adding counterweight to the vehicle, it is
Stability Test Load: usually most effective when added as close to the
1.18 x 2250 lb (1021 kg) = 2655 (1204 kg)
crane as possible. After adding counterweight, the
(Includes weights of slings and downhaul blocks.) above procedure must be repeated to insure the
added counterweight is adequate.
Be sure the stability test weight is accurate. A 1% increase in
stability test weight will mean up to a 10% increase in

9-40
600E SERVICE MANUAL CRANE INSTALLATION

CRANE SPECIFICATIONS
Pump
Variable displacement constant pressure, flow on demand piston pump provides up to 44 GPM (167 LPM) at a maximum
pressure of 3800 psi (26.20 MPa) at 2800 RPM.
Standby pressure = 90 to 100 PSI (.62 to .76 MPa)

Pump Mounting Flange

The pump has A SAE B 2 bolt Mounting Flange with a SAE B-B Splined Shaft.

System Flow and Pressure

Main Control Valve
Divides up 44 GPM to the following circuits:
Main control valve relief ............... 4300 psi ±100 (29.65 MPa)
Lift circuit ......................................Up port = 18 GPM (68 LPM),
Down port = ................................. Zero pump flow on Down = gravity down
Telescope Circuit.......................... Extend 18 GPM (68 LPM)
Port Relief ......... 2900 psi ±100(20.00 MPa)
Retract.......................................... 11.5 GPM (43.5 LPM)
Port Relief ......... 2900 psi ±100(20.00 MPa)
Turn Circuit .................................. 8 GPM (30 LPM)
Port Relief ........2350 psi ±100 (16.20 MPa)
Winch Circuit Up ..................... 25 GPM (94 LPM)
Port Relief .......... 3300 psi ±100 (22.75 MPa)
Down ................. 25 GPM (94 LPM)
Function at system relief = 800 psi (26.20 MPa)
Outrigger and Stabilizer................. 18 GPM (68 LPM)
Function at system relief = 3800 psi (26.20 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 9
Capacity Charts are based on 3150 psi (21.72 MPa) Constant Pressure (3300 psi (22.75 MPa) Trip Pressure on HCA)

Winch System
Wire Rope ............... Standard

9-41
CRANE INSTALLATION 600E SERVICE MANUAL

325 ft (99 m) of 9/16 “(14.3 mm) diameter, Rotation Resistant

Nominal Breaking Strength – 38,500 lb (17,463 kg)

Winch Speed and Pull

1 PART LINE
BOS Winch Rope
Layer Winch Pull Winch Speed
Speed Capacity
lb (kg) fpm (mpm) fpm (mpm) (feet) (m)
1 10380 4708 82 25 145 44 64 19
2 9360 4246 91 28 161 49 136 41
3 8520 3865 100 30 177 54 215 65
4 7820 3547 109 33 192 59 301 91
12
5 7230 3279 118 36 208 63 394
0

Crane Operating Speeds

Rotation, 375° .............................................40 ± 5 seconds (1.56 ±.2 RPM)
(Swing speed based on adjustment knob in closed position.)
Boom Up, (-10° to 80°) 26 ± 5 seconds
Boom Down, (80° to -10°) 25 sec. (gravity down, speed depends on load)
Boom Extend/Retract
27 – 71’ Three Section
.................................................................... Extend - 53 ± 6 seconds, 49 fpm (14.94 mpm)
.................................................................... Retract - 51 ± 6 seconds, 51 fpm (15.55 mpm)
16 - 38' Three Section
................................................................... Extend - 27 ± 6 seconds, 49 fpm (14.94 mpm)
.................................................................... Retract - 26 ± 6 seconds, 51 fpm (15.55 mpm)
19 - 47' Three Section
................................................................... Extend - 34 ± 6 seconds, 49 fpm (14.94 mpm)
................................................................... Retract - 33 ± 6 seconds, 51 fpm (15.55 mpm)
24- 80' Four Section
.................................................................... Extend - 108 ± 6 seconds, 31 fpm (9.45 mpm)
.................................................................... Retract - 116 ± 6 seconds, 29 fpm (8.84 mpm)
27 - 90’ Four Section
................................................................... Extend - 118 ± 6 seconds, 31 fpm (9.45 mpm)
................................................................... Retract - 120 ± 6 seconds, 29 fpm (8.84 mpm)

9-42
600E SERVICE MANUAL CRANE INSTALLATION

9-43
CRANE INSTALLATION 600E SERVICE MANUAL

9-44
600E OPTIONAL EQUIPMENT

SECTION 10
OPTIONAL EQUIPMENT
TABLE OF CONTENTS
Radio Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
R 4 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Remote Solenoid Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Flow Control valve in Inlet Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Solenoid Valve Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Pressure Relief Valve (part of solenoid valve) in inlet section. . . . . . . . . . 10- 1
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Receiver Input & Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
R4 Remote System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Connector Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Antenna Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Setup Procedure for the Proportional Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Trouble Shooting , Repair And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Partial or Complete Unit Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Troubleshooting Functional Test of R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10

10-i
OPTIONAL EQUIPMENT 600E

PAGE INTENSIONALLY LEFT BLANK

10-ii
600E OPTIONAL EQUIPMENT

SECTION 10
OPTIONAL EQUIPMENT
RADIO REMOTE • (B) Positive D.C. current
• (C) Negative ground
R 4 System Description
• (D) HCA/ATB "OK" Input.
Re mot e S ole noid Valve Asse mbly
The unit derives power from a 12 volt D.C. power system that
Flow Control valve in Inlet Section is negative ground. Some special applications us a 24 volt
Electrically controlled priority flow control valve which can be power system. First hook up power inputs to receiver. It is
remotely actuated to control the amount of oil flow from the required to install a power switch for the receiver in series (in-
inlet to the bypass or the regulated ports. line) with the D.C. power system (battery). Refer to the
Receiver Printed Circuit Board drawing on the next page.
Oil supply of 5 - 18 GPM is pumped to inlet port.
1. When power is supplied to the receiver the Power
With electrical voltage up to 2 volts on the valve coil, 0 GPM Indicator LED will come on. If not, verify correct polarity of
of inlet oil is directed to the solenoid valve sections and the power and condition of fuse.
remaining oil goes through the bypass port and into the
manual control valve, then back to tank. 2. Turn on the power to the transmitter. At this time the
transmitter will send out a 10 second signal to the receiver to
As voltage increases linearly from 2 to 9 volts, there is a initialize the system.
resulting linear increase of oil flow to the solenoid sections to
18 GPM maximum. Any remaining oil is directed back to tank a. At this time, the RF Indicator LED and the on-board relay
through the bypass port. will be energized. Once the initial 10 seconds have lapsed,
the RF indicator LED will illuminate each time the transmitter
S ole noid Valve S e ct ions is activated.
An electrically actuated directional control valve which If only the RF Indicator LED illuminates when the
receives oil from the regulated port of the flow control valve transmitter is activated but does not energize the relay,
and directs it to the various crane functions. verify that the 12 position address switches on the
receiver match those inside the transmitter.
When 12 VDC power is applied to any of the electro-
magnetic coils on the valve, the resulting force pushes a 3. Activate each function with the transmitter and notice that
spring centered spool from its neutral position to allow oil the appropriate output Status Indicator LED illuminates
flow out the work port opposite the energized coil. inside the receiver. (The LED’s parallel to the orange
connector.)
Oil flow through the solenoid valve is then in creased and
decreased at the flow control valve to get desired crane R4 Remote System Installation
operating speeds.
1. The Electrical and Hydraulic Schematics in this manual
Pressure Relief Valve (part of solenoid valve) in inlet section.
show the typical connections of the remote control
P ro t ec ts r e mo te c on t ro l hy dr a ul ic ci r cui t f ro m o ve r system.
pressurization. Must be set to match crane manual system
2. The pump pressure line is connected to the pressure
pressure.
port of the solenoid valve.
S hut t le Valve 3. Install all electrical components and wires using the
Biased shuttle valves are located in winch up, winch down, parts pages and electric schematic as reference for this
and turn (left and right) functions on units equipped for installation. This machine is wired at the factory for a 12
remote operation. They block the open oil path through the VDC, negative ground electrical system. When used on
main control valve during remote operation. other than 12 VDC systems, a suit able 12 VDC source
must be provided to power the remote control. This
RECEI VER I N PUT & OUTPUT remote control is not intended for use with positive
ground systems.
Each unit comes with a connector chart (chart C) with the
appropriate input and output instruction for your unit. There 4. Mount relay assembly in engine compartment in a
are four (4) inputs to the receiver: convenient location and connect the appropriate wires to
• (A) BNC connector
the terminal block as shown on wiring schematic. 10

10-1
 OPTIONAL EQUIPMENT 600E

Install remote start relay on a chassis equipped (Refer to the Receiver Printed Circuit Board drawing in the
with a switch that prevents the engine from following steps.)
starting while the transmission is in gear.
CONN ECTOR I N S TRUCTI ON S
5. Adjust throttle actuator so it advances engine speed to
approximately 80% maximum manual operating speed. 1. Strip all wires to be inserted into the 20 pin connector, to
a length of 3/8 to 1/2 inch.
2. Tin (solder) the loose wire strands into one solid wire.
DANGER 3. Insert a small straight blade screwdriver into the square
STARTING TRUCK ENGINE WITH DRIVE TRAIN hole of the desired pin. Prying towards the face (lid) of
ENGAGED WILL CAUSE UNEXPECTED MOVEMENT the receiver, insert the appropriate stripped wire into the
OF THE TRUCK RESULTING IN DEATH OR SERIOUS round hole directly below the screwdriver. Release the
INJURY screwdriver and the connection is complete.
This connector will accept wire sizes from 14 gauge to 22
RECEI VER MOUN TI N G
gauge. when connecting the individual wires, be sure that
The receiver should be mounted on the crane console as the connector clamps on the bare stripped wire only! If an
illustrated. If installed in a tool box or compartment, care wire insulation gets into the connector, this may cause a poor
should be taken in routing cable and wires to prevent connection and cause intermittent or complete failure.
damage to the receiver to the receiver and cables.
AN TEN N A MOUN TI NG
Care should be taken in installing the antenna. When
mounting the antenna, keep in mind that the unit comes
standard with 20’ of antenna cable.
If driving an electric over hydraulic pump or any type of
electric motor, mount the antenna away from the motor since
that may emit spurious interference. This will reduce the
possibility of electrical interference.
For best operation, mount antenna on underside of boom as
illustrated. 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 that you do not wrap any excess
antenna cable in loops.
The connector on the end of the cable will hook up to
antenna connector on receiver. (See Receiver Printed Circuit
R 4 Receiver Mounting Board drawing.)
Adequate planning is required so wire routing can be Place Antenna in an open area,. at least 18 inches from any
accomplished. You must keep in mind that the unit comes vertical metal. The position of a "Boom" (over or around) can
standard with 20 feet of antenna cable. Use the mounting effect the Antenna’s ability to receive a signal. Creating
holes on the receiver for securing the system. Once "Dead Spots”.
mounted, remove the cover to inspect the Status Indicators.
Follow the illustrated antenna-receiver break down page
later in this section for best results!

2 Receiver Printed Circuit Board

1

4
15 1. RF Indicator 9. Master Control LED
14 2. Output Status Indicators 10. Power Indicator
13 5 3. Antenna Connector 11. 12 Position Address Switch
12
4. (1) Spare Fuse 12. Low End Proportional
6
5. 7.5 Amp Fuses 13. High End Proportional
11 6. Wago Connector 14. Bank A.
7. 15 Amp Blade Fuse 15. Bank B.
10 8. Power Relay 16. LED (on when unit is initialized)
7
10-2 9 16 8
 600E OPTIONAL EQUIPMENT

R4 Receiver Pinouts
CONNECTOR CHART “C” (TELESCOPING)
OUTPUT NCC CORD 5 COND.. CORD
DESCRIPTION
LABEL WIRE COLOR WIRE COLOR

N/A -------------------------------------- OUTPUT 16

HCA - LMI 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 1O
N/A --------------------------------------OUTPUT 9
TELE RETRACT --------------------OUTPUT 8 ---------------------------- BLU
TELE EXTEND----------------------- OUTPUT 7 --------------------------- ORG
WINCH UP ---------------------------- OUTPUT 6 --------------------------- RED
WINCH DOWN ----------------------OUTPUT 5 ---------------------------- BRN
HCA/ATB “OK” INPUT ------------ INPUT --------------------------------- YEL/BLU
THROTTLE---------------------------- OUTPUT3 ---------------------------- RED/BLU -------------------BLK
START----------------------------------OUTPUT2 ----------------------------- BLK/BLU -------------------ORG Note: Insert a small straight blade
IGNITION -----------------------------OUTPUT 1 ---------------------------- BLU/BLK -------------------YEL screwdriver into the square hole of the
desired pin. Prying towards the face
PROPORTIONAL -------------------- MASTER CONTROL -------------- BWN/RED (lid ) of the recei ve r, in se rt th e
N/A --------------------------------------OPTION appropriate stripped wire into the
BATTERY-V+ ------------------------BATTERY(+) ------------------------ BLK RED
round hole dir ect ly below the
screwdriver. Release the screw driver
GROUND ------------------------------ GROUND(-) ------------------------- YEL BLU and the connection is complete.

R4 Receiver Switch Settings

These switches to match

those inside transmitter. These (*) switch to be in “ON” position.

*** **

12 Position Address Switch Low end High End Bank A Bank B

Proportional

NOTE: The Transmitter address is set at the factory and can not be changed in
the field.
Ensure that the Receiver address matches the Transmitter.
10

10-3
OPTIONAL EQUIPMENT 600E

12 Position Address Switch Low end High End Bank A Bank B

Proportional Proportional

Setup Procedure for the Proportional 4. While maintaining transmission, slowly increment the
Channel "Low End Proportional" hex switch until movement of the
activated function begins. No movement is desired when
Not all proportional valves are ideal. That is, they do not all activating a function at minimum potentiometer setting;
begin to operate at exactly the same voltage nor do they all therefore, back up one step on the hex switch. Activate each
reach their full travel at exactly the same voltage. Many function switch to assure that no function moves when the
proportional valves work in a narrow "window" of voltage switch is on. Occasionally, a machine will not move even
span. Therefore, a method has been designed to allow the when the low end potentiometer is at its maximum setting
installer to configure the proportional output to conform to the "F". If this occurs, leave the low end proportional set at "F".
propor tional valves’ chara cteristics. Th is allo ws t he
5. Now set the potentiometer on the transmitter to maximum.
tr ansmitter proportional potentiometer to control the
This is done by fully pulling trigger.
proportional valve through its’ entire range of travel.
6. Set the "High End Proportional" to "0".
Once the receiver is installed properly, the following steps
should allow the installer to quickly match the receiver’s 7, Again activate the desired function. Be careful since now
proportional output to the proportional valve. the function activated will be at full speed!
Low End Proportional - 0 Least Trigger Setting F Highest 8. While maintaining transmission, slowly increment the
Trigger Setting "High End Proportional" hex switch until a noticeable
decrease in function speed is noticed. Now back up the
This pot is used to set starting movement on the trigger.
"High End Proportional" hex switch 1 to 2 settings.
High end proportional - 0 Highest Trigger Setting F Least
9. Failure to properly set the high end pot will result in a
Trigger Setting
decrease in the motion range of the trigg er whe n
1. Set the potentiometer on the transmitter to mini mum. This proportioning a function.
is done by releasing trigger.
The procedure is now complete and proportional control will
2. Set the "Low End Proportional" hex switch in the receiver function through the complete range of the transmitter
to "0". potentiometer.
3. With the receiver powered, activate the transmitter and
depress the desired function to control (i.e. boom up, boom
down, extend out, etc.)

10-4
600E OPTIONAL EQUIPMENT

Trouble Shooting , Repair And Replacement transmitter power is on, a function may be
activated.)
A few of the remote control components can be repaired, all
can be replaced. The following is a list of these items and 3. To verify that the power relay is engaged and that the
recommended method of repair or re placement. transmitter is transmitting, activate the emergency stop
on the transmitter. This will disable the power relay and
Circuit Bre ake rs the transmitter will transmit for 10 seconds.
There are two automatic resetting breakers in the system, a. The RF and Power Indicator LED’s will be on.
one 15 amp under the hood that protects the entire system During this time any toggle switch activated will only
and a 10 amp on the frame that protects the hand control. If a send the emergency stop signal.
breaker is opening, it is an indication that there is a short
b. To reset the receiver and transmitter, turn the
circuit somewhere in the system. It will generally stay open
transmitter power off and back on. At this time the
from 30 - 60 seconds.
rece ive rs RF I ndicato r LE D will be on for 10
Re lays se co nd s ( wi th ou t a ct iv at in g a to gg le on th e
transmitter) and you will hear the power relay
Three 12 VDC, normally open, automotive type relays are engage.
installed under the truck hood on the ignition start and throttle
advance circuits. One automotive type relay is installed in the 4. When a function is activated on the transmitter, two or
control console on the HCA-LMI override circuit. They are three LED’s are turned on in the receiver:
used so that current through the hand control does not • (1) RF Indicator LED
become excessive.
• (2) Output Status Indicator LED,
These relays will occasionally fail from physical damage,
corrosion or excessive current through the relay. Failure is • (3) Master Control LED (may or may not be utilized
evident when the relay will not close as power is applied to on the equipment).
the pilot terminal or will not open when power is removed 5. With power relay engaged, check each function by
from the pilot terminal. activating each toggle. Make sure that each of the
These relays cannot be repaired and must be replaced. receivers Output Status Indicator LED’s turn on.
a. If the appropriate Output Status Indicator LED
S ole noid Valve doesn’t come on, continue to the next step.
If the solenoid valve is inoperative, it is generally because of: 6. If the power relay doesn’t engage, there is a possibility
• Contamination in the valve. that the address codes are not matching. Compare the
12 position address switches in both transmitter and
• Not enough electrical power to operate solenoids. receiver and then repeat step 2.
T he v a lve ca n b e d isa ss e mb le d a nd cl ea ne d w he n a. If they both match and still the power relay doesn’t
contamination is suspected. engage, set all 12 of the dip switches to the "OFF"
If voltage drops below 1 0.5 V at the solenoid coil, the position in both the receiver and transmitter and
solenoids may not operate. Defective electrical equipment then repeat step 2.
on the truck will generally cause this low voltage condition. b. At this point if the radio controller works or not, call
Check the truck battery, voltage regulator and generator the factory to either be assigned a new address
(alternator) in this case. code or to have the radio controller shipped back to
Part ial or Comple t e Unit Failure the factory for repair.

If a unit fails completely or if just one or two outputs are not 7. With a function activated and all three indicator LED’s
working, check the following: "on" and there is no voltage registering on the voltmeter,
check the output fuse. There is a 7.5 Amp fast blow fuse
1. Remove cover on the receiver and refer to the Receiver on each output. There is an extra fuse and clip on the PC
Printed Circuit Board drawing . board. Remove and replace blown fuse. If fuse
repeatedly fails, you may have a dead short in your
2. With power to the receiver, the Power Indicator LED will
wiring harness or the electric coil or relay is failing. Do
be on.
not use anything other than the recommended fuse
a. Turn transmitter power on. At this time the receivers furnished on the receiver PC board
RF Indicator LED will be on for 10 seconds and you
will hear the power relay engage. (Anytime after 10

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OPTIONAL EQUIPMENT 600E

NOTE: If the transmitter face plate has been removed and g. To reset the receiver and transmitter, turn the
replaced, then three problems could have been transmitter power off and back on. At this time the
introduced. Troubleshoot as follows: rece ive rs RF I ndicato r LE D will be on for 10
se co nd s ( wi th ou t a ct iv at in g a to gg le on th e
a. Remove faceplate from transmitter. Make sure that
transmitter) and you will hear the power relay
leads to each lead screw on toggles are secure and
engage.
will not be at an angle where it would be touching
anything when replacing the faceplate. Troubleshooting Functional Test of R4
b. Disconnect wiring harness from PC board and then
1. Activate a function (boom up) on the transmitter, at this
reconnect the same way. Be sure that no wires are
time the receiver’s RF Indicator LED and the appropriate
loose at connector and that connector is secure on
Output Status Indicator LED will be on. And if the
connector pins. The wiring harness should be
function activated, such as the boom up motion does not
positioned between toggle housings or where it is
occur, check the following:
not hanging down creating a bind when replacing
the face plate. a. Be sure that the appropriate orange connector pin
matches the Output Status Indicator LED. There
c. With power to the receiver, the Power Indicator LED
should be 12 volts DC to that out put from the
will be on.
vehicle. If it is determined there is power to the
d. Turn transmitter power on. At this time the receivers output, then the wiring and hydraulic system should
RF Indicator LED will be on for 10 seconds and you be checked.
will hear the power relay engage. (Anytime after
b. If the appropriate Output Status Indicator LED is
transmitter power is on, a function may be
turned on and there is no power to the orange
activated.)
connector pin, this indicates that a circuit failure has
e. To verify that the power relay is engaged and that occurred and the radio controller must be repaired
t he t r a ns m it t e r is tr a n s mi t t in g , ac t iv a t e t h e at the factory.
emergency stop on the transmitter. This will disable
c. If crane function occurs when function switch is
the power relay and the transmitter will transmit for
activated and before trigger is pulled, readjust the
10 seconds.
low end proportional potentiometer in the receiver.
f. The RF and Power Indicator LED’s will be on.
During this time any toggle switch activated will only
send the emergency stop signal.

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600E OPTIONAL EQUIPMENT

JUMPER TO TURN ALL

ADDRESS CODES OFF
-1 SOFTWARE
JUMPER

PROGRAM CONNECTOR
(FACTORY USE ONLY)

TNAT-1
(PROCESSOR)
ADDRESS
TRANSMITTER
CODE
SOFTWARE LABEL
1,2,3,4,5,6,7,
8,9,10,11,12

(3 PIN PROPORTIONAL)
TRIGGER CONNECTION
Brown

Red

Brown
(5 PIN CONNECTOR)
POWER CONNECTOR
(Red wire to inside)
(8 PIN CONNECTOR)
FUNCTION CONNECTOR
(Brown wire to Inside)
E-STOP CONNECTOR
(Plug In Either Way)

Transmitter Board
(Address set at Factory)

10

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OPTIONAL EQUIPMENT 600E

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