Built around the National Crane 600E-2, 647E2 and 638E2 cranes, this 184-page service manual PDF (OEM publication 114-09) fits all three models, with mounting configurations called out for each. Hydraulic and electrical schematics close the book, tracing circuits from the control valves and unloader through anti-two block, HCA and outrigger monitoring wiring, while the troubleshooting chapter pairs a hydraulic system chart with an HCA flow chart. Truck installation fills close to a quarter of the pages: frame section modulus tables, PTO horsepower requirements, counterweighting methods and CAN bus setup. Check swing bearing clearance against the 0.090 in limit, and torque wear pad retainer capscrews to 110 ft-lb (149 N-m). Guess a pad thickness, and you pull the boom twice. Bookmarks take you straight to each chapter, and the pages print clean enough to sit on your bench and soak up hydraulic oil.
What's Inside This National Crane 600E-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 11-34 | General (Supplemental Information, New Owner, Cleanliness) |
| Hydraulic System | 35-42 | Hydraulic System Description (Hydraulic System Maintenance Precautions, Label Parts When Disassembling, Hydraulic Oil Recommendations) |
| Electric System | 43-74 | Anti-Two Block System Description, Anti-Two Block Operation |
| Boom | 75-100 | Three Section Boom Operation (Special Boom Inspection), Three Section Boom Maintenance (Three Section Cable Tensioning), Hoist Removal, Boom Removal |
| Hoist | 101-102 | Hoist Removal, Hoist Installation |
| Swing | 103-116 | Swing Gearbox and Brake (Disassembly and Assembly Instructions, Swing Drive Disassembly, Tulsa Swing Drive Assembly Procedure), Rotation Stop-Mechanical (Rotation Stop Adjustment) |
| Lubrication | 117-130 | General (Surface Protection for Cylinder Rods, Lubricants, Arctic Conditions Below 0°F) |
| Troubleshooting | 131-136 | Hydraulic System Troubleshooting Chart, Jib Load Limiting Device Troubleshooting, Jib Jack Troubleshooting (Systematic Troubleshooting), HCA Troubleshooting Flow Chart |
| Crane Installation | 137-178 | Crane to Truck Installation, Minimum Truck Requirements |
| Schematics | 179-184 | Hydraulic Schematics, Electrical Schematics |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Solenoid resistance | 12 ohm | p. 136 |
| Top rear pad thickness | 0.75 inch (19.05 mm) | p. 81 |
| Bottom front 1st section pad thickness | 1 inch (25.4 mm) | p. 81 |
| Torque for Second Nut (Metric Series) | M16x2: 26 Nm, M20x2.5: 66 Nm | p. 95 |
| Swing bearing clearance limit | 0.090 in | p. 111 |
| Swing drive pinion backlash shim thickness | 0.008 in (0.203 mm) | p. 114 |
| Slew pot gear to swing bearing gear teeth gap | 0.125 - 0.188 in (3.1 - 4.7 mm) | p. 115 |
| Hoist brake fill capacity | 0.23 liter (0.25 quart) | p. 123 |
| Motor counterbalance valves setting | 600 psi | p. 132 |
| Main Relief Valve Adjustment (Crane Valve) | 32 ft-lb (43 Nm) | p. 39 |
| Main Relief Valve Adjustment (Hoist Valve) | 25 ft-lb (34 Nm) | p. 39 |
| Hoist Gearbox Oil Capacity | 1.42 liters (1.50 quarts) | p. 124 |
National Crane 600E-2 Common Problems This Manual Covers
National Crane 600E-2 hoist will not lift load, or hoist gearbox heats up during operation
Check the hoist entries in the hydraulic troubleshooting chart on page 131, then verify the motor counterbalance valves setting of 600 psi listed on page 132. Check the hoist gearbox oil level against the 1.42 liters (1.50 quarts) capacity on page 124, and confirm the hoist brake is filled to 0.23 liter (0.25 quart).
Manual Section: Hydraulic System Troubleshooting p. 131Hydraulic system shows poor performance, no flow from pump, cylinder drift, or no response to control
Check the reservoir oil level first; the hydraulic reservoir holds 66 gallons (250 L) per page 176. Work through the hydraulic troubleshooting chart on page 131 for pump flow, control response and cylinder drift. Inspect the hydraulic filter, then remove air from the hydraulic system following the procedure in the Hydraulic System section.
Manual Section: Hydraulic System Troubleshooting p. 131Three section boom chatters, or boom will not extend, during the telescope function
Inspect the boom wear pads following page 81 and replace any pad with uneven wear beyond 3/32 inch (2.38 mm). Torque the retainer capscrews to 110 ft-lb (149 N-m). Shim the pads in 0.03 inch (.8 mm) steps per page 82 to hold 0.03 to 0.09 inch (.8 to 2.3 mm) clearance between the inner and outer boom.
Manual Section: Boom p. 81Swing bearing shows excessive clearance during inspection, and swing drive pinion backlash is out of adjustment
Measure swing bearing clearance following page 111 and compare it against the 0.090 in limit. When reinstalling, torque the inner and outer race bolts to 80% of specified torque first, then bring them to final torque per the Fasteners and Torque Values table. Set swing drive pinion backlash with 0.008 in (0.203 mm) shims per page 114.
Manual Section: Swing p. 111HCA overload system trips and does not reset, leaving the crane locked out of normal operation
Follow the HCA troubleshooting flow chart on page 136 in order instead of swapping parts. Measure the solenoid resistance with a meter and compare it to the 12 ohm value given there. Trace the circuit against the electrical schematics starting on page 179 before you condemn the solenoid.
Manual Section: HCA Troubleshooting Flow Chart p. 136Anti-two block system fails continuity check with damaged or corroded internal wire connectors
Test continuity through the anti-two block internal wire and inspect each connector for corrosion or damage. Repair the internal wire following the procedure on page 44, then retest continuity end to end. Check the circuit against the Electric System wiring diagram on page 68 before putting the crane back to work.
Manual Section: Anti-two Block Internal Wire Repair p. 44Frequently Asked Questions
What is the torque spec for the 1/2-13 hoist brake mounting bolts on a National Crane 600E-2?
The hoist mounting capscrews must be torqued to 220 ± 20 ft-lb (300 ± 30 N.m). p. 101
What is the procedure for resetting the jib load limiting device if the load cell is not calibrated?
To set the zero point, remove all force from the load cell, power down the unit, and set switch position 8 to ON. Power the system and press the button on the board to set the zero point. To set the gain, set switch position 8 to OFF and set the switch to the correct code matching the load cell gain found on the tag accompanying the load cell. p. 134
What is the torque specification for the 5/8-11 UNC Grade 8 bearing bolts on the National Crane 600E-2?
The nominal torque for 5/8-11 UNC Grade 8 bearing bolts (untreated, black finish) is 240 ft/lb, with a maximum of 250 ft/lb and a minimum of 230 ft/lb. p. 24
What is the recommended oil change interval for the hoist gearbox on a National Crane 600E-2?
The oil in the hoist gearbox and brake sections should be changed every 1000 hours or every 6 months of usage. p. 123
What is the required torque for the swing bearing bolts on a National Crane 600E-2?
Swing bearing bolts must be torqued to the final torque specified in the 'Fasteners and Torque Values' table on page 1-7. The inner and outer race bolts should first be torqued to 80% of the specified value using a star pattern, then returned to bolt number 1 and torqued to the final value. p. 111
Will this National Crane 600E-2 Service Manual download right away?
Straight to your device: 184 pages of searchable Service Manual, downloadable the moment payment goes through.
Is printing allowed for this National Crane 600E-2 Service Manual?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
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