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Manitowoc National Crane NBT30H-2, Service Manual

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Manitowoc National Crane NBT30H-2 Service Manual Download Page 7

National Crane

iii

NBT30H-2 

Micro Relay/fuse block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Directional Control Valve Solenoids  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Outrigger Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Front Outrigger Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Rear Outrigger Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Hydraulic Oil Cooler Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
RCL Communication Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
RCL CANbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

RCL Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Slew Potentiometer Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Boom Angle Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Boom Length Sensor Calibration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Rod Side Pressure Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Base Side Pressure Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Outrigger Length Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Load Chart and RCL Download  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

SECTION 4  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Maintenance

Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Removal from Truck  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Boom Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

2

nd

, 3

rd

, 4

th

 Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Disassembly of 2

nd

, 3

rd

, 4

th

 Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Additional Maintenance, Disassembled Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Extend/Retract Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

2

nd

/3

rd

/4

th

 Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Boom Cable Tensioning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Cable Tensioning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Cable Tension Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4- Section Boom w/ 2 Stage Cylinder Cable Positioning  . . . . . . . . . . . . . . . . . . . . 4-13
4- Section Boom w/ 1 Stage Cylinder Cable Positioning  . . . . . . . . . . . . . . . . . . . . 4-14
3- Section Boom w/ 1 Stage Cylinder Cable Positioning  . . . . . . . . . . . . . . . . . . . . 4-15
Cable Retention  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Boom Installation on the Truck  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

SECTION 5  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Hoist Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 5-3

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Hoist Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 5-4

Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Planetary Set  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Summary of Contents for National Crane NBT30H-2

Page 1: ...Service Manual National Crane NBT30H 2 ...

Page 2: ......

Page 3: ...rame Always furnish crane serial number when ordering parts or communicating service problems with your distributor or the factory 2019 Grove U S L L C 03 20 2019 Control 613 06 An untrained operator subjects himself and others to death or serious injury Do not operate this crane unless You are trained in the safe operation of this crane Manitowoc is not responsible for qualifying personnel You re...

Page 4: ...ust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Spark Arrestor Operation of this equipment may create sparks t...

Page 5: ...uds 1 26 Wire Rope 1 26 General 1 26 Environmental Conditions 1 26 Dynamic Shock Loads 1 26 Lubrication 1 26 Recommendations for Servicing Wire Rope 1 27 Wire Rope Inspection 1 27 Boom Extension and Retraction Cables 1 28 Wire Rope Replacement All Wire Rope 1 28 Seizing Wire Rope 1 28 SECTION 2 Hydraulic System Introduction 2 1 Hydraulic System General Overview 2 1 Hydraulic Symbols 2 3 Maintenanc...

Page 6: ...9 Hydraulic Oil Cooler Option 2 19 Hydraulic Valves 2 20 Directional Control Valve Manifold 2 21 Pilot Manifold Valve 2 21 Outrigger Manifolds 2 21 Holding Valves 2 21 Swing Gearbox 2 21 Hydraulic Pump Service 2 22 Description 2 22 Removal 2 22 Installation 2 22 Pump Startup 2 22 Pump Margin Pressure 2 23 Maximum Pump Pressure 2 23 Directional Control Valve 2 24 Lockout Pressure Adjustment 2 24 Te...

Page 7: ... Boom Disassembly 4 5 2nd 3rd 4th Boom Section Removal 4 5 Disassembly of 2nd 3rd 4th Boom Sections 4 5 Additional Maintenance Disassembled Boom 4 6 Boom Assembly 4 6 Extend Retract Cable Installation 4 8 Telescope Cylinder Installation 4 9 2nd 3rd 4th Boom Section Installation 4 10 Boom Cable Tensioning 4 11 Cable Tensioning 4 11 Cable Tension Sequence 4 12 4 Section Boom w 2 Stage Cylinder Cable...

Page 8: ...ng Bolts 6 8 Torque Values 6 10 Bearing Clearance 6 10 Bearing Replacement 6 11 Removal 6 11 Installation 6 12 Slew Potentiometer Adjustment 6 13 SECTION 7 Outriggers Description 7 1 Front Outrigger Assembly 7 1 Outrigger Beam Removal 7 2 Inspection 7 3 Outrigger Beam Installation 7 3 Extension Cylinder 7 4 Jack Cylinder 7 5 Wear Pad Adjustment 7 5 Rear Outriggers RSOD 7 6 RSOD Assembly 7 6 Extens...

Page 9: ...on and Repair 8 12 Application 8 12 Areas of Application 8 13 SECTION 9 Crane Installation General 9 1 Minimum Truck Requirements 9 1 Extension protection Schematic 9 1 Mounting Configuration 9 5 Tractor Mounting Configuration 9 5 PTO and Hydraulic Pump 9 5 Horsepower 9 5 Direct PTO Mount 9 5 PTO Ratio 9 5 Pump Rotation 9 6 Truck Frame Strength 9 7 Truck Preparation 9 11 Welding Precautions 9 11 P...

Page 10: ...nnections 9 25 CANBUS System Setup 9 26 Initial Crane Run In Procedure 9 26 RCL Calibration 9 26 Stability Test 9 26 Specifications 9 29 Hydraulic Pump 9 29 Hydraulic System 9 29 Reservoir 9 29 Hoist System 9 29 Crane Operating Speeds 9 30 Outrigger Speeds 9 30 SECTION 10 Schematics ...

Page 11: ...ies National Crane Figure 1 1 Before placing the crane into service all operators and persons working around the crane must thoroughly read and understand the contents of the Operator Manual Before moving a vehicle equipped with a crane information relating to transporting the vehicle must be read and observed This manual must be retained with the machine for use by subsequent operating personnel ...

Page 12: ... restored to proper operating condition and all tags have been removed by the person s who installed them Recognize and avoid pinch points while performing maintenance Stay clear of sheave wheels and holes in crane booms After maintenance or repairs Replace all guards and covers that have been removed Remove all tags connect the battery and perform a function check of all operating controls Perfor...

Page 13: ... Boom Nose 7 Boom Rest 8 Lift Cylinder 9 Hoist 10 Outrigger Beam 11 Outrigger Box 12 Rear Stabilizer Out and Down RSOD 13 Extension 14 Turret 15 Single Front Outrigger SFO 16 Hydraulic Tank 17 Hydraulic Pump 18 Radio Remote Receiver 19 Truck Frame 20 Truck Bed 21 Torsion Box T Box 22 Sheave 23 RSOD Foot Item Component 6 22 10 13 6 18 3 12 7 6 5 8 1 20 21 19 16 11 15 23 17 4 14 9 8596 2 2 8606 1 1 ...

Page 14: ...le lifting attachment for all removals requiring hoisting equipment Some removals require the use of lifting fixtures to obtain proper balance All supporting members chains and cables need to be parallel to each other and as near perpendicular as possible to the top of the object being lifted If a part resists removal check to be sure all nuts and bolts have been removed and that an adjacent part ...

Page 15: ...ble coat it with oil and wrap it in clean waxed paper Do not unwrap new bearings until time of installation The life of an antifriction bearing will be shortened if not properly lubricated Dirt in an antifriction bearing can cause the bearing to lock resulting in the shaft turning in the inner race or the outer race turning within the cage Double Row Tapered Roller Double row tapered roller bearin...

Page 16: ...d or grease If the machine is to be stored or not used for an extended period of time the batteries should be removed Store the batteries in a cool not subfreezing dry place preferably on wooden shelves Never store on concrete A small charge should be introduced periodically to keep the specific gravity rating at recommended level Jump Starting Hazard Do not attempt to jump start the crane All cra...

Page 17: ... a minimum of bending and twisting Tighten both couplings Due to manufacturing methods there is a natural curvature to a hydraulic hose The hose should be installed so any bend is with this curvature Visual Inspection of Hoses and Fittings 1 Visually inspect hoses and fittings once a month or every 250 hours for the following Leaks at hose fitting or in hose Damaged cut or abraded cover Exposed re...

Page 18: ...ce life 5 Hydraulic hose assemblies operating in climate zones A and B with high ambient temperatures could see hose service life reduced by 40 to 50 therefore it is recommended to replace these hoses after 4000 to 5000 hours of service life 6 Hydraulic hose assemblies operating in climate zones D and E should expect a degradation of mechanical properties such as elasticity therefore it is recomme...

Page 19: ...s 2 Align tube or hose to the mating fitting and check to see that the flare seats properly on the nose of the fitting 3 Finger tighten the nut onto the fitting If necessary a wrench should be used to seat the nut snugly against the fitting This is considered the Finger Tight condition 4 Using a permanent type ink marker make a mark on one of the flats of the nut and continue it onto the hex of th...

Page 20: ...than one full turn 6 Hold the fitting in the desired position and tighten the nut D following the F F F T method starting with step 4 Nonadjustable Straight Thread O ring Fitting Fitting to Port Refer to Table 1 4 for the following procedure 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign particles 2 Lubricate O ring with clean oil Figure 1 6 3 Turn f...

Page 21: ...ual inspection of these areas should be made part of an owner s planned preventive maintenance program Telescopic Boom wear pad retaining structures hydraulic cylinder attaching points boom pivot shaft retaining structures Outrigger pads beams boxes and attachment structures Main frame generally in the area of doubler plates and crossmembers at the junction of front and rear frame members on truck...

Page 22: ...d bolts and nuts of Grade 8 or Class 10 9 and higher may not be reused When referring to the applicable torque charts use values as close as possible to the torque values shown to allow for wrench calibration tolerance Torque Wrenches Flexible beam type wrenches even though they might have a pre set feature must be pulled at right angle and the force must be applied at the center of the handle For...

Page 23: ...que values for both ASME standard and metric fasteners The tables list the values for grade 5 and grade 8 zinc flake coated untreated black finish and stainless steel fasteners SAE Grade 1 and Grade 2 HHCS SAE Grade 5 HHCS SAE Grade 7 HHCS SAE Grade 8 HHCS Serrated Flange Head Socket Head Shoulder Screw Socket Head Capscrew FIGURE 1 8 ...

Page 24: ...16 14 UNC 5 38 4 37 4 36 5 8 54 3 52 9 51 5 1 2 13 UNC 5 58 6 57 1 55 7 8 82 8 80 7 78 6 9 16 12 UNC 5 84 5 82 4 80 3 8 119 4 116 5 113 5 5 8 11 UNC 5 116 6 113 7 110 8 8 164 8 160 7 156 6 3 4 10 UNC 5 206 8 201 7 196 5 8 292 3 284 9 277 6 7 8 9 UNC 5 333 8 325 4 317 1 8 471 6 459 8 448 0 1 8 UNC 5 500 3 487 8 475 3 8 707 0 689 3 671 6 1 1 8 7 UNC 5 624 0 608 4 592 8 8 1001 4 976 4 951 4 1 1 4 7 U...

Page 25: ... 5 66 0 64 4 62 7 8 93 3 90 9 88 6 9 16 18 UNF 5 94 3 91 9 89 6 8 133 2 129 9 126 6 5 8 18 UNF 5 132 1 128 8 125 5 8 186 7 182 0 177 3 3 4 16 UNF 5 231 0 225 2 219 4 8 326 4 318 2 310 1 7 8 14 UNF 5 367 7 358 5 349 3 8 519 6 506 6 493 6 1 12 UNF 5 547 4 533 7 520 0 8 773 5 754 2 734 8 1 1 8 12 UNF 5 700 0 682 5 665 0 8 1123 5 1095 4 1067 3 1 1 4 12 UNF 5 975 0 950 6 926 2 8 1564 8 1525 7 1486 5 1 ...

Page 26: ... 168 5 164 1 10 9 253 8 247 4 241 1 12 9 296 9 289 5 282 1 M18x2 5 8 8 246 2 240 1 233 9 10 9 350 7 341 9 333 2 12 9 410 4 400 1 389 9 M20x2 5 8 8 348 0 339 3 330 6 10 9 495 6 483 2 470 8 12 9 580 0 565 5 551 0 M22x2 5 8 8 474 4 462 6 450 7 10 9 675 7 658 8 641 9 12 9 790 7 770 9 751 2 M24x3 8 8 601 3 586 3 571 3 10 9 856 4 835 0 813 6 12 9 1002 2 977 1 952 1 M27x3 8 8 881 6 859 6 837 5 10 9 1255 ...

Page 27: ... 42 2 41 1 40 1 10 9 62 0 60 4 58 9 12 9 72 5 70 7 68 9 M12x1 0 8 8 79 5 77 5 75 5 10 9 116 7 113 8 110 9 12 9 136 6 133 2 129 8 M12x1 25 8 8 76 2 74 2 72 3 10 9 111 8 109 0 106 3 12 9 130 9 127 6 124 3 M12x1 5 8 8 72 9 71 1 69 2 10 9 107 1 104 4 101 7 12 9 125 3 122 1 119 0 M14x1 5 8 8 120 2 117 2 114 2 10 9 176 5 172 1 167 7 12 9 206 6 201 4 196 2 M16x1 5 8 8 184 4 179 8 175 2 10 9 270 9 264 1 2...

Page 28: ...8 951 4 927 6 903 8 10 9 1355 0 1321 1 1287 2 12 9 1585 6 1546 0 1506 3 M30x1 5 8 8 1369 2 1334 9 1300 7 10 9 1950 0 1901 3 1852 5 12 9 2281 9 2224 9 2167 8 M30x2 8 8 1324 6 1291 5 1258 4 10 9 1886 6 1839 4 1792 2 12 9 2207 7 2152 5 2097 3 M33x2 8 8 1784 5 1739 9 1695 3 10 9 2541 6 2478 0 2414 5 12 9 2974 2 2899 8 2825 4 M36x2 8 8 2340 1 2281 6 2223 1 10 9 3332 8 3249 5 3166 2 12 9 3900 2 3802 6 3...

Page 29: ...pact wrenches are not recommended Table 1 10 Inch Series Screws of STAINLESS STEEL 300 18 8 with Coarse Threads Torque Values for fasteners with lubrication these torque and preload values result in an 80 utilization of the yield strength Stainless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads and torque at low speeds without interruptions Do not use ...

Page 30: ...Inch and Series Designation Grade Torque ft lb Maximum Nominal Minimum 5 8 11 UNC 8 234 225 216 5 8 18 UNF 8 250 240 230 3 4 10 UNC 8 385 370 355 7 8 9 UNC 8 615 591 567 1 8 UNC 8 929 893 857 1 1 4 7 UNC 8 2043 1964 1885 Nominal Size Threads per Inch and Series Designation Grade Torque Nm Maximum Nominal Minimum M20X2 5 12 9 756 727 698 M24X3 10 9 1089 1047 1005 M24X3 12 9 1306 1256 1206 M27X3 10 ...

Page 31: ... 19 18 17 8 26 25 24 3 8 16 5 32 31 30 8 48 46 44 7 16 14 5 52 50 48 8 73 70 67 1 2 13 5 78 75 72 8 120 115 110 9 16 12 5 114 110 106 8 161 152 143 5 8 11 5 156 150 144 8 234 225 216 3 4 10 5 270 259 5 249 8 385 370 355 7 8 9 5 416 400 384 8 615 591 567 1 8 5 606 583 560 8 929 893 857 1 1 8 7 5 813 782 751 8 1342 1288 1234 1 1 4 7 5 1141 1097 1053 8 2043 1964 1885 1 3 8 6 5 1519 1461 1403 8 2496 2...

Page 32: ... 8 53 51 49 7 16 20 5 57 55 53 8 85 82 79 1 2 20 5 88 84 5 81 8 125 120 115 9 16 18 5 126 121 116 8 177 170 163 5 8 18 5 182 174 5 167 8 250 240 230 3 4 16 5 312 299 5 287 8 425 409 393 7 8 14 5 458 439 5 421 8 672 646 620 1 12 5 658 632 606 8 1009 970 931 1 14 5 670 644 5 619 8 945 908 5 872 1 1 8 12 5 882 848 814 8 1500 1440 1380 1 1 4 12 5 1251 1203 1155 8 2092 2008 5 1925 1 3 8 12 5 1704 1638 ...

Page 33: ...0 10 9 16 15 14 12 9 19 18 17 M8x1 25 8 8 27 26 25 10 9 38 36 5 35 12 9 45 43 5 42 M10x1 5 8 8 53 51 49 10 9 75 72 69 12 9 89 86 83 M12x1 75 8 8 93 89 85 10 9 130 125 120 12 9 156 150 144 M14x2 8 8 148 142 136 10 9 212 203 5 195 12 9 248 238 228 M16x2 8 8 230 221 212 10 9 322 310 298 12 9 387 372 357 M18x2 5 8 8 319 306 5 294 10 9 455 436 5 418 12 9 532 511 490 M20x2 5 8 8 447 430 413 10 9 629 605...

Page 34: ...roperty Class Torque Nm Maximum Nominal Minimum M8x1 8 8 29 28 27 10 9 41 39 5 38 12 9 49 47 45 M10x0 75 8 8 57 55 53 10 9 81 78 75 12 9 96 93 90 M10x1 25 8 8 57 55 53 10 9 81 78 75 12 9 96 93 90 M12x1 8 8 101 97 5 94 10 9 150 144 138 12 9 175 168 161 M12X1 25 8 8 100 96 92 10 9 147 141 5 136 12 9 172 165 5 159 M12x1 5 8 8 100 96 92 10 9 140 135 130 12 9 168 162 156 M14x1 5 8 8 160 153 5 147 10 9 ...

Page 35: ...924 888 5 853 12 9 1111 1068 1025 M24x2 8 8 836 803 5 771 10 9 1176 1130 5 1085 12 9 1410 1356 1302 M27x2 8 8 1225 1171 5 1130 10 9 1718 1652 5 1587 12 9 2063 1983 5 1904 M30x1 5 8 8 1530 1471 5 1413 10 9 2253 2166 5 2080 12 9 2637 2536 2435 M30x2 8 8 1661 1597 5 1534 10 9 2336 2246 5 2157 12 9 2800 2695 2590 M33x2 8 8 2141 2059 1977 10 9 3155 3034 2913 12 9 3692 3550 5 3409 M36x2 8 8 2795 2688 25...

Page 36: ...hoisting or swinging of a load Suspending loads while traveling over irregular surfaces such as railroad tracks potholes and rough terrain Moving a load that is beyond the cranes rated capacity Lubrication The object of rope lubrication is to reduce internal friction and to prevent corrosion New lubricant needs be added throughout the life of the rope It is important that lubricant applied needs t...

Page 37: ...m a National Consensus Standard as referenced by Federal Government Agencies Recommended inspection intervals depend on the machine environmental conditions frequency of lifts and exposure to shock loads The inspection intervals may also be predetermined by state and local regulatory agencies NOTE Wire rope is available from Manitowoc Crane Care Record any deterioration of the wire rope in the equ...

Page 38: ...ich can cause rapid deterioration of wire rope unusual cable sag stretch Be sure cables used in sets all have an equal tension applied Repeated need for adjustment of an individual cable is evidence of cable stretch and indicates the need for a more thorough inspection to determine and correct the cause Wire Rope Replacement All Wire Rope No precise rules can be applied to wire rope replacement be...

Page 39: ...ff the excess wire and pound the twist flat against the wire rope Figure 1 11 Method 2 Wind a length of soft annealed wire around the wire rope at least seven times Twist the two ends together in the center of the seizing Tighten the seizing by alternately prying and twisting Cut off both ends of the wire and pound the twist flat against the rope Figure 1 12 NOTE Non preformed wire rope should hav...

Page 40: ...1 30 03 20 2019 Control 613 06 INTRODUCTION NBT30H 2 SERVICE MANUAL ...

Page 41: ...Directional Control Valve Manifold 2 21 Pilot Manifold Valve 2 21 Outrigger Manifolds 2 21 Holding Valves 2 21 Swing Gearbox 2 21 Hydraulic Pump Service 2 22 Description 2 22 Removal 2 22 Installation 2 22 Pump Startup 2 22 Pump Margin Pressure 2 23 Maximum Pump Pressure 2 23 Directional Control Valve 2 24 Lockout Pressure Adjustment 2 24 Telescope Extend Pressure 2 24 Trouble Diagnosis 2 24 INTRO...

Page 42: ...c Oil Tank has three important functions storage cooling and supply of oil to the pumps Because piston rods take space in the cylinders the level of the oil in the tank will be higher when all the cylinders are retracted To understand how a hydraulic system works it is important to understand the following words Flow The flow through the system is caused by the pump The amount of fluid which is se...

Page 43: ...Enclosure of two or more functions contained in one unit Pressure Transducer Hydraulic electrical located in lift cylinder circuit for cranes RCL circuit 1 2 1 2 2 1 1 2 Filter Removes contamination from hydraulic fluid Filter with Bypass Valve Bypass valve allows hydraulic fluid to bypass the filter if the filter becomes clogged Accumulator Used to either develop flow or absorb shock Check Valve ...

Page 44: ...o tank with an unloader valve cartridge Closed Center Motor Spool Pressure compensated directional control valve for motor with open port for flow back to tank Allows flow back to tank when the crane is shut down Single Acting Cylinder Extended hydraulically and retracted with a spring Double Acting Cylinder Extended and retracted hydraulically Double Acting Telescope Cylinder Anchored rod pushes ...

Page 45: ...uid Then lubricate all components to aid in assembly Inspect all sealing elements O ring gaskets etc when disassembling and assembling the hydraulic system components Installation of new sealing elements is always recommended When installing metal hydraulic tubes tighten all bolts finger tight Then in order tighten the bolts at the rigid end the adjustable end and the mounting brackets After tubes...

Page 46: ...sure taken at these locations will give an indication of operating pressure or relief pressure Troubleshooting Procedures For good troubleshooting a step by step analysis of the problem and the possible cause is necessary First find the symptoms 1 Check with the operator Learn if there was a loss of power machine did not move the load or a loss of speed slow cycle time 2 Learn if the problem is co...

Page 47: ... control valve section Replace the bearings or pump Slow operating speeds All functions Low engine rpm Air leak in pump inlet line Air in oil foam in tank Leakage in the load sense relief valve Improper load sense relief valve setting Leakage in hydraulic swivel Control valve not fully actuated Improper primary pump pressure Faulty pump Increase engine rpm Tighten pump inlet line Replace O ring in...

Page 48: ...n hydraulic tank Leak in system Wrong type of oil Low oil level Bad seal in pump motor or cylinder Check O ring on pump inlet Check for leak in system and correct Use correct oil Check and add oil Overhaul or replace Short life of pump bearings shafts etc Dirt in oil Wrong type of oil Change oil and filter more frequently Use correct oil Pump leakage external Bad seal pump shaft Bad seals between ...

Page 49: ... the return line from the lift cylinder and raise the boom to maximum elevation 6 Connect the cylinder return line and lower the boom to its stowed position Replenish the reservoir hydraulic oil level as required 7 Disconnect the return line from an outrigger extension cylinder and fully extend the outrigger O RING FACE SEAL O RING BOSS B A O RING FACE REF O RING BOSS REF A B O RING FACE SEAL FITT...

Page 50: ...ponent has been replaced the reservoir level is too low or a leak develops in the suction line to the pump air can enter the system Air can cause noisy operation of the swing and hoist hydraulic motors Check the level of the hydraulic reservoir first if noisy operation occurs Inspect for leaks in the suction lines leading to the pumps Minute leaks may be hard to locate If a leak is not readily det...

Page 51: ... a pressure drop across an External Control Valve ECV As the ECV opens and closes the pressure delta across the valve changes Opening the ECV decreases the delta and closing the ECV increases the delta The LS control then increases or decreases pump flow to the system until the pressure delta becomes equal to the LS setting The advantage of the load sense control system is only the amount of flow ...

Page 52: ... of that circuit Valve Name Circuit Used In Physical Location Directional Control Valve Boom Lift Telescope and Swing Mounted inside operator console Holding Valves Boom Lift Telescope Hoist and Outriggers Port block on cylinder Hoist Motor Counter Balance Valve Hoist On hoist motor Front Outrigger Selector and Control Manifold Outrigger Manifold on front outrigger box RSOD Control Manifold Outrig...

Page 53: ...YDRAULIC SYSTEM FIGURE 2 2 Directional Control Valve Load Sense Relief Pilot Relief Boom Down Boom Up Telescope Extend Telescope Retract Hoist Up Hoist Down Swing Left Swing Right Inlet Port Outlet Port Option 1A 8732 1 Option 1B Telescope Extend Relief Telescope Extend Port ...

Page 54: ...ss bolts and remove console cover Radio Remote Control Optional If equipped with optional radio remote control all solenoid valves on each valve section are energized Figure 2 2 when the remote control enable switch is activated This closes the solenoid valves NOTE The normal de energized position of the pilot valves on the valve sections is closed pilot pressure is blocked and with the valve s pi...

Page 55: ...ng is reached Reservoir oil temperature is to be 60 71 C 140 160 F CHECKING RELIEF PRESSURE Preparation Start and warm up the engine until the hydraulic oil temperature reaches a minimum of 60 71 C 140 160 F Shut down the engine Relief pressure for the hoist hydraulic circuits is controlled by the load sense relief valve located on the directional control valve Figure 2 2 this relief valve is not ...

Page 56: ...ld be 19 65 MPa 2850 psi 6 Shut down the engine 7 Move the gauge to the retract line and plug the extend line 8 Start the engine 9 Pull the telescope control lever to retract 10 Relief pressure should be 20 5 MPa 2975 psi 11 Shut down the engine 12 Remove the pressure gauge and plug from the hoses 13 Reconnect the telescope cylinder hoses Swing The swing relief is preset and not adjustable To chec...

Page 57: ...down the engine and disconnect the pressure gauge and reconnect the outrigger extend line Center Front Outrigger 1 Disconnect the front outrigger extend and retract lines Figure 2 10 Cap the retract line and install a gauge in the extend line 2 Start engine and set at governed RPM 3 Depress the front outrigger extend retract switch to extend 4 Adjust the extend relief valve on the front outrigger ...

Page 58: ... 2 Hydraulic Oil Level Gauge 3 Hydraulic Temperature Gauge 4 Fill Cap 5 Access Cover 6 Shutoff Valve 7 Spin on Filters 8 Return Line 9 Suction Line 10 Sump Line from Directional Control Valve 11 Pump Manifold Case Drain 12 Outrigger Return 13 Case Drain from Pump 14 Drain Plug 15 Temperature Sensor 16 Breather Item Component 1 10 3 2 4 6 9 7 8 16 11 12 13 14 5 ...

Page 59: ... damage to the reservoir A sight gauge is located on the side of the reservoir to indicate hydraulic oil level A large access cover on the top of the reservoir provides access for cleaning The cover is secured to the top of the reservoir with screws and has a gasket to prevent leaking The access hole can also be used to fill the reservoir after it has been completely drained The dual spin on hydra...

Page 60: ...es develop at fittings and seals Spool seals are susceptible since they are subject to wear Seals may be damaged by temperatures that are too high or by dirt or paint accumulation on the spool Damaged seals must be replaced A component functioning at reduced efficiency may indicate that the valve section in the DCV for that component is leaking internally If preliminary a check reveals that adequa...

Page 61: ...ft or right 205 degrees will de energize the swing solenoids and block flow for operation of swinging Outrigger Manifolds The outrigger circuits are controlled by two manifolds located at the front and rear outrigger boxes The front manifold contains the extend retract valve for front and rear outriggers front outrigger component valves and the optional front jack valve The rear outrigger manifold...

Page 62: ...g strap 5 Reconnect the hydraulic lines as per removal tags 6 Fill the hydraulic tank to the full mark with hydraulic oil Pump Startup The pump startup procedure is as follows 1 Fill the pump housing with hydraulic fluid Pour the oil directly into the upper most case drain port 2 Open the shut off valve on the inlet line from the reservoir to the pump Check the line for properly tightened fittings...

Page 63: ...nd remove the diagnostic equipment 5 Check the maximum pump pressure and adjust as necessary Maximum Pump Pressure 1 Install a gauge at the pump pressure gauge port GP on the pump Figure 2 15 2 If the lift cylinder is not installed plug the extend hose larger of two hoses before proceeding to next step 3 Start the engine and throttle up to full RPM Slowly operate the lift cylinder and extend to ma...

Page 64: ...Extend Pressure 1 Install a gauge at the pump pressure gauge port GP on the pump Figure 2 15 2 If boom is not installed remove hose from tele extend port and plug the hose and cap the port before proceeding to next step 3 Start the engine 4 Idle RPM if the boom is attached and fully extend the boom 5 Hold at end of stroke 6 If no boom activate boom out 7 Throttle up to full RPM 8 The pressure shou...

Page 65: ... relief valve setting slows down system Adjust external relief valve setting following manufacturer s recommendations External relief setting must be above pressure compensation setting to operate properly Check pressure compensation and load sense control setting Low pressure compensation setting prevents the pump from achieving full stroke Low load sense setting limits output flow Adjust pressur...

Page 66: ...eservoir to proper level Hydraulic fluid viscosity above acceptable limits Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or the controls to operate properly Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures Check external system relief valve setting Eternal relief valve s...

Page 67: ...ack to pump control Adjust or replace relief valve System Pressure not Reaching pressure compensation setting Check pressure compensation control setting System pressure will not rise above pressure compensation setting Adjust pressure compensation to appropriate setting Check external relief valve External relief valve setting below pressure compensation setting presents pressure compensation Adj...

Page 68: ...w system to warm up before operating Inspect inlet screen Blocked or restricted inlet strainer screen causes high inlet vacuum Clean screen remove blockage Check inlet piping Kinked or obstruction in inlet hose Remove kink or obstruction Hydraulic fluid viscosity above acceptable limits High fluid viscosity causes high inlet vacuum Select fluid with appropriate viscosity for expected operating tem...

Page 69: ... contains all wiring interface between the truck and the crane including the electric outrigger controls MAINTENANCE General Electrical Understanding To aid in the understanding and troubleshooting of an electrical system review the terms and information that follows Electrical Energy power which comes from the movement of electrons Electrons are particles with a negative charge Electrons will col...

Page 70: ...ion in the pin or socket connectors Check the connectors to ensure that the pins and sockets are properly seated and engaged If the pins and sockets show any signs of corrosion use a good quality electrical contact cleaner or fine sandpaper to clean them When the pins or sockets show signs of arcing or burning it will probably be necessary to replace them Refer to Table 3 2 and Table 3 3 for listi...

Page 71: ...both crane console switches must be in the ON position set to RUN before the truck can be started from either the truck cab or the operator control console The switch has three positions STOP shuts down engine and crane power RUN activates truck engine ignition and crane power and START to start the truck engine NOTE The truck cab ignition and both console switches must be in the ON position set t...

Page 72: ...les the functions that cause a two block condition Normal functioning is restored by hoisting down or retracting the boom until the A2B weight is suspended freely The A2B system is incorporated into the crane RCL system A2B Cable Repair The A2B cable runs from the A2B reel through the boom to the boom tip Figure 3 2 To replace the A2B cable Retract the boom Run a small diameter rod from the front ...

Page 73: ...3 National Crane 03 20 2019 Control 613 06 3 5 NBT30H 2 SERVICE MANUAL ELECTRIC SYSTEM A2B Cable Reel FIGURE 3 2 A2B Switch A2B Cable A2B Weight Rear of Boom ...

Page 74: ...ove the access panel to gain access to the fuse compartment RCL master module computer interface connector and the RCL override keyswitch The optional radio remote module is stacked directly behind the RCL master module mounting FIGURE 3 3 1 Item Component 1 Access Panel 2 RCL Master Module 3 Fuse Compartment 4 Computer Interface Connector 5 RCL Override Keyswitch 6 Radio Remote Module Optional 5 ...

Page 75: ...The solenoids on the front outrigger manifold Figure 3 6 control the selection of the front outrigger components front center jack SFO the extend and retract functions of all outrigger components The solenoids on the front outrigger manifold provide the following functions The center front jack 4 solenoid extends or retracts the SFO when energized Any time the retract switch on the outrigger contr...

Page 76: ...m 4 Center Front Jack SFO Optional 5 Passenger Side Right Jack 6 Passenger Side Right Beam 7 Driver Side Left Jack 8 Extend 9 Retract 3 2 6 7 5 4 9 Front Outrigger Manifold 8 1 Item Solenoid 1 Driver Side Left Outrigger 2 Driver Side Left Beam 3 Passenger Side Right Beam 4 Passenger Side Right Outrigger FIGURE 3 7 1 2 3 4 Rear Outrigger Manifold Viewed from Rear of Vehicle ...

Page 77: ...Pa 35 psi check valve in the oil cooler limits the flow through the cooler Since hydraulic oil is thicker when it is cold less oil is routed through the cooler when it is cold than when it is hot The cooler electrical system is made up of the following Electric Fan Fan Relay Temperature Sensor The temperature sensor is located in the cooling core and energizes the fan relay when the hydraulic oil ...

Page 78: ... message is intended responds to the transmission All other nodes ignore the message Advantages to a CANBUS system are Reliability Self diagnostics Ease of Installation Elimination of a large bundle of wires Down loading to a laptop computer Protected safety interlocks EMI RFI tolerant RCL CANBUS The RCL has the following Nodes on the CANbus RCL Master Module RCL Display Module RCL Sensors Radio R...

Page 79: ...0H 2 SERVICE MANUAL ELECTRIC SYSTEM Fuse Relay Box Computer Interface Connector RCL Master Module RCL Angle Length Sensors and Termination Resistor Radio Remote Receiver Optional 8731 8703 8 8703 7 FIGURE 3 9 Radio Remote Module Operator Control Console ...

Page 80: ...able may be ordered from CraneCARE NOTE The software and cable can only be purchased by technicians that have attended the New Technology training course Refer to the NBT30H 2 Error Codes page 3 14 for detailed instructions to program or troubleshoot the RCL software CANbus RCL Specifications Leading error code digit in the diagnostics screen Figure 3 10 shown 1 is an indexing number for the error...

Page 81: ...3 National Crane 03 20 2019 Control 613 06 3 13 NBT30H 2 SERVICE MANUAL ELECTRIC SYSTEM Error Code Number Structure 8775 2 8775 1 Sample Diagnostics Screen FIGURE 3 10 ...

Page 82: ... J1939 General Truck Faults 10 Software Version Used to communicate software version changes 11 Event Chart RCL Event Recorder 12 Data Chart RCL Event Recorder 13 EEPROM Update of EEPROMs on another device 28 Voltage System Voltage at device Error Error Description Error Source 1 Open Output Status from Conductor 2 Short to Ground STG Output Status from Conductor 3 Short to Battery STB Output Stat...

Page 83: ...9 2 32 11 A07 1813 PS FRONT BEAM POTENTIOMETER String Pot sensor value is above OR_PS_Front_Full_Extend EEPROM value OMS_Adc_Tolerance OMS_Adc_High in RCL Module 19 2 32 12 A07 1813 PS FRONT BEAM POTENTIOMETER String Pot sensor value is below OR_PS_Front_Min_Extend EEPROM value OMS_Adc_Tolerance OMS_Adc_High in RCL Module 19 2 33 11 A08 1814 DS FRONT BEAM POTENTIOMETER String Pot sensor value is a...

Page 84: ... LEFT SOLENOID 19 3 36 8 B01 1158 SWING LEFT SOLENOID 19 3 36 9 B01 1158 SWING LEFT SOLENOID 19 3 37 1 B02 1157 SWING RIGHT SOLENOID 19 3 37 2 B02 1157 SWING RIGHT SOLENOID 19 3 37 3 B02 1157 SWING RIGHT SOLENOID 19 3 37 4 B02 1157 SWING RIGHT SOLENOID 19 3 37 5 B02 1157 SWING RIGHT SOLENOID 19 3 37 6 B02 1157 SWING RIGHT SOLENOID 19 3 37 7 B02 1157 SWING RIGHT SOLENOID 19 3 37 8 B02 1157 SWING RI...

Page 85: ...G BUZZER 19 3 39 8 B04 2152 WARNING BUZZER 19 3 39 9 B04 2152 WARNING BUZZER 19 6 40 10 RCL Module Module not responding over CAN bus 19 10 XX XX RCL MASTER SOFTWARE VERSION INDEX Major Revision ERROR NUMBER Minor Version If code is 19 10 5 15 then the software version is 5 15 19 11 41 15 RCL Module Event Recorder Event Chart Inability to log FLASH undefined 19 11 41 16 RCL Module Event Recorder E...

Page 86: ...ry Both the Event and Data chart info is cleared at the same time related to error 19 11 1 17 19 28 43 12 A12 803 System voltage low Voltage at RCL master is less than 10 0 V 18 V if 24 V system 19 28 43 11 A12 803 System voltage high Voltage at RCL master is greater than 16 0 V 30 V if 24 V system Device Group Index Error Pin Wire Description Possible Causes Comments Name Status Value RCL Module ...

Page 87: ...he sensors are displayed in the above Sensor Calibration Menu screen Sensor choices are Slew Angle Boom Angle Boom Length Tip Height Lift Cylinder Rod Pressure Lift Cylinder Piston Pressure Outrigger Length Use the scroll arrow keys to navigate and highlight the function keys Press the checkmark button to select function Press the main menu button to go back to the Main menu screen NOTE This butto...

Page 88: ... outriggers and level before starting the boom angle calibration procedure The boom angle needs to be measured accurately with an inclinometer to do an accurate calibration Select the boom angle icon from the Boom Angle Sensor Calibration menu to start the boom angle calibration Figure 3 14 Boom Angle Sensor Calibration Calibration positions are shown one at a time on the Boom Angle Sensor Calibra...

Page 89: ... display to reprogram the rod side pressure transducer Disconnect the electrical cable to base piston side transducer to temporarily remove it from the CANBUS Press the checkmark to confirm Reconnect the electrical cable to base piston side transducer Press checkmark to confirm Save the new Node ID by cycling the power to the rod side sensor using the ignition switch or by manually disconnecting r...

Page 90: ...libration Three calibration positions are shown on the Outrigger Length Sensor Calibration screen one at a time starting with the Fully Retract position Once the outriggers have been positioned and confirmed the next calibration position will be activated If an error message appears after a position has been confirmed the length sensors will need to be mechanically adjusted NOTE If sensors are not...

Page 91: ...function key use arrow keys to scroll Enable Chart Download At the Enable Chart Download Figure 3 21 Select the checkmark to enable Chart Downloading Mode A 30 second timer in the lower left corner of the screen will count down remaining time to initiate the download of the charts When the timer runs out chart downloading will be disabled until the process is repeated Once enabled the display will...

Page 92: ...ELECTRIC SYSTEM NBT30H 2 SERVICE MANUAL 3 24 03 20 2019 Control 613 06 ...

Page 93: ... the boom is used to raise and lower the boom The telescope cylinder is two stage double acting and attached to and extends the 1st 2nd and 3rd boom sections Extend cables are used to extend the 4th boom section Figure 4 1 The telescope cylinder retracts the 1st and 2nd boom sections Retract cables are used to retract the 3rd and 4th boom sections The extend cables for the 4th section are attached...

Page 94: ...CE MANUAL 4 2 03 20 2019 Control 613 06 Boom Nose Proportioning Cable 2nd Section 4th Section 3rd Section Retract Cables for the 4th Section FIGURE 4 1 Extend Cables for the 4th Section Retract Cables for the 3rd Section 1st Section ...

Page 95: ... for the 4th boom section extend cables 11 Attach point at the rear of the 4th boom section for the 4th boom section retract cables 12 Attach point at the rear of the 3rd boom section for the 3rd boom section retract cables 13 Extend sheaves at the font of the telescope cylinder 14 Attach point at the front of the 1st boom section for the 3nd boom section retract cables 15 Attach point at the fron...

Page 96: ...om CG and raise the boom until the weight is removed from the boom pivot pin Remove boom pivot pin keeper and pin Figure 4 4 and lift boom off the turret Lift Cylinder Removal This procedure assumes the boom has been removed 1 Tag and disconnect the hydraulic lines attached to the lift cylinder 2 Attach a lifting device to the lift cylinder 3 Remove the lift cylinder pivot pin at the turret 4 Lift...

Page 97: ...out of the 1st section to prevent damage to cable assemblies 7 Loosen and remove the two capscrews and lockwashers securing the spacer bar to the inside top front of the 1st section Remove the spacer bar 8 Loosen and remove four capscrews securing wear pads to the bottom front of the 1st section 9 Raise the 2nd 3rd 4th boom assembly inside the 1st section to allow for front bottom pad removal Tag ...

Page 98: ... the two capscrews cable guide wear pad and spacer bar from the front top of the 3rd section 15 Loosen and remove the four capscrews attaching the bottom pad plate to the 3rd section Slightly lift the 4th section and remove the pad plate 16 Slide the 4th section out of the 2nd section The side pads may need to be removed Tag and remove the side pads and shims if required 17 Loosen and remove all r...

Page 99: ... 4 8 5 Using an appropriate lifting device lift the 4th section to allow for wear pad pad plate installation in front of the 3rd section 6 Install the wear pad pad plate assembly and slide the sections together within 30 cm 12 inches of full retraction 7 Install the cable guide and upper spacer to the front of the 3rd section FIGURE 4 6 1 2 3 4 5 6 7 8 9 11 12 13 12 13 10 Item Component 1 Spacer 2...

Page 100: ...ap screws b Reeve the 4th section retract cable around cable sheave c Install the cable retainer pin into the anchor plate d Place the uncoiled cable in a safe area to prevent damage Figure 4 9 3 Place the retract cables anchored to the 4th section over the top of the retract sheaves on the 3rd section Install the keeper capscrew above the sheave to the hold retract cables in place 4 Reeve the cab...

Page 101: ...e wheels on the telescope cylinder The holes in the end of the pin must be located as shown in Figure 4 14 2 Reeve the retract cables around the telescope cylinder sheaves 3 Install the wear pads on the telescope cylinder NOTE Ensure the top wear pads do not fall off during cylinder installation Figure 4 14 4 Insert the telescope cylinder assembly to of the way into the 2nd section 5 At the base e...

Page 102: ... g Two cap screws 2nd 3rd 4th BOOM SECTION INSTALLATION 1 Slide the 2nd 3rd 4th section assemblies into the 1st section until 1 2 to 1 5 m 4 to 5 ft of the assembly is left 2 Install the lower wear pads at the front end of the 1st section and secure with cap screws Figure 4 17 3 Install the side wear pads and shims as required Secure with cap screws 4 Install the upper wear pad and secure with a f...

Page 103: ... and retract cables for each extendable section In addition sequencing of the sections during retraction requires retract cables of every section to be indexed relative to each other Cable Tensioning Tensioning Setup Procedure Tensioning must be done with the boom in the horizontal position When tightening loosening the first adjustment nuts on cables secure cable using the wrench flats at the fro...

Page 104: ...etract cables Four section boom with two stage cylinder Cable tensioning to be in the following order 1 321 retract cables 2 123 extend synchronizing cables 3 234 extend cables 4 432 retract cables Four section boom with one stage cylinder Cable tensioning to be in the following order 1 123 extend cables 2 321 retract cables 3 234 extend cables 4 432 retract cables Three section boom with one stag...

Page 105: ...g cable located at the top back of the base section may need to be loosened Retraction 1 Measure the retraction gaps between the first and second section and the second and third section If the retraction gap is greater between the first and second section than the retraction gap between the second and third section 2 Tighten the 123 synchronizing cable located at the back of the base section the ...

Page 106: ...t boom fully ensuring sections are bottomed out on section stops Ensure all sections are fully bottomed out and do not spring back Reference Tensioning Setup Procedure 321 and 123 cable balancing Extension 1 Measure the extension gaps between the first and second section and the second and third section If the extension gap between second and third section is less than the extension gap between th...

Page 107: ...ction gap between the second and third section 2 Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap measurements 3 Extend and retract the boom a few times and then repeat measuring the retraction gaps The fourth section should have moved in 4 Tightening until the retraction gap between the third and fourth section is equal to the re...

Page 108: ...ap between the second and the third are equal At this time the all extendable sections should extend and retract equally and bottom out against the stops simultaneously Cable Retention Cable Retention Hardware Nut configuration see Figure 4 23 will be First Nut ADJUSTMENT and Second Nut TORQUED NOTE OPTION 2 method used ONLY when space constraints prevent OPTION 1 usage When tightening loosening t...

Page 109: ...gure 4 4 6 Install the lift cylinder pivot pin in the bottom of the 1st boom section 7 Reinstall telescope cylinder hydraulic lines as per removal tags LIFT CYLINDER INSTALLATION 1 Attach a lifting device to the lift cylinder 2 Raise the lift cylinder to the truck bed under the boom 3 Line up the lift cylinder with the attach point on the turret and install the pivot pin Figure 4 4 4 Raise the rod...

Page 110: ...BOOM MAINTENANCE NBT30H 2 SERVICE MANUAL 4 18 03 20 2019 Control 613 06 ...

Page 111: ...ry Set 5 8 Motor 5 8 Troubleshooting 5 8 DESCRIPTION The NBT30H 2 hoist is composed of motor control valve a fixed displacement hydraulic motor a multiple disc brake and a pair of planetary gear sets The multiple disc brake is spring applied and hydraulically released through a port in the brake housing An overrunning clutch allows the hoist to raise the load without releasing the brake while at t...

Page 112: ...ble from the hoist drum 2 Tag and disconnect the hoist hydraulic lines Cap and plug all hydraulic openings 3 Attach a lifting device to the hoist and take up the slack 4 Remove the mounting bolts from the hoist 5 Remove the hoist from the crane with the lifting device Hydraulic Hoses Inspect the hydraulic hoses and replace as required Hoist Installation 1 Attach a lifting device to the hoist 2 Lif...

Page 113: ...planet set 4 from the cable drum Inspect the planet set for wear See Servicing The Planetary Set section for disassembly and repair 11 Remove the cable drum 5 and inspect the gear teeth for excessive wear Remove and replace the bearing 28 and seal 306 located in the drum 12 Inspect retaining ring 48 to insure it is still in groove and is not bent over 13 If necessary remove output shaft 32 from si...

Page 114: ... 8 Examine the bushing 39 in the brake housing for wear and replace if necessary 9 If brake housing 21 is removed from the hoist examine the journal on the brake housing where the seal 304 fits for wear If severely worn replace the brake housing 10 Carefully disassemble the brake driver clutch assembly noting the direction of lockup for the clutch 34 The clutch assembly must be re assembled with t...

Page 115: ...screws Make sure that the cover is aligned properly with the brake housing to orient the motor and vent as they should be 20 Check the brake release with a portable hydraulic pump Full release should be obtained at 250 psi 20 psi 1724 kPa 138 kPa Also check the brake for proper operation by applying 155 psi 1069 kPa to the brake port and adapting a torque wrench to the input shaft The torque in th...

Page 116: ... 72 55 73 52 45 45 9 305 11 20 40 77 35 75 45 35 70 30 303 24 310 302 10 308 309 19 17 14 15 18 38 9 39 15 17 13 307 28 32 2 21 34 14 63 62 50 5 8 33 3 306 6 36 4 6 16 43 306 28 304 26 12 105 101 108 102 106 2 1 103 108 106 107 104 207 205 201 207 204 203 206 202 69 42 301 301 35 44 30 31 7155 ...

Page 117: ...alance Block 43 2 Support Rod 44 1 Motor Assy 45 4 Fitting Adapter 49 1 Fitting Tee 50 1 Plate Side 52 4 Lockwasher 1 2 ID 55 4 Capscrew 58 4 Counterbalance Valve 61 4 NCC Label 62 6 Capscrew 63 2 Screw Buttonhead 64 1 Cord Set 65 1 Fitting Tee 66 1 Fitting Straight Adapter 69 1 Fitting Reducer 70 1 Hose Assy 72 1 Fitting Tee Adapter 73 1 Manifold Block 74 1 Valve Cart Solenoid 75 1 Hose Assy 77 3...

Page 118: ...ridge valves are not serviceable in the field Return them to an authorized distributor for service CAUTION Possible Equipment Damage If the pins are not lined up properly the thrust washers can be shattered during the pressing operation FIGURE 5 5 2 3 1 Metering Hole 7148 7147 TROUBLESHOOTING Problem Cause Solution Hoist does not hold load Excessive back pressure in the system Check the system for...

Page 119: ...ion The swing system consists of a hydraulic joystick controller directional control valve swing drive gearbox swing motor and swing brake The maximum rotation is 2 0 rpm The swing brake is automatically applied when the control lever is moved to the neutral position THEORY OF OPERATION Swing Drive The hydraulic power for the swing drive Figure 6 1 is supplied by the hydraulic piston pump Oil flow...

Page 120: ...GURE 6 1 1 3 2 Item Component 1 Pinion Gear 2 Swing Gearbox 3 Swing Motor 4 Swing Brake Release Line 5 Swing Speed Control 6 Swing Control Valve 7 Swing Brake 8 Oil Level Plug 9 Oil Fill Breather 10 Pinion Bearing Grease Fitting 11 Oil Drain Plug 4 5 7 8 9 10 6 11 ...

Page 121: ...e Input Planetary Gear 11b Race Output Planetary Gear 12 Output Sun Gear 13 Input Planetary Assembly 14 Brake Housing O Ring 15 Brake Assembly 16 Brake Mounting Capscrews 8 17 Drain Plug 18 Brake End Plate Output Planetary Gear Set 19 Retaining Washer 20 Output Planetary Pin 21 Washer 22 Needle Bearing 23 Spacer 24 Output Planet Gear Input Planetary Gear Set 25 Input Planet Gear 26 Retaining Washe...

Page 122: ...pins of the input planetary assembly 13 and with a small chain pull the planet set from the gear housing 9 Remove the output sun gear 12 and race 11b from the output planetary assembly 10 10 Using the eyebolt chain method outlined in step 6 remove the output planetary assembly 10 from the gear housing 11 Remove the lockwasher 8 and locknut 9 12 Remove the pinion shaft 2 from the housing 1 The unit...

Page 123: ...oad is determined by the rolling torque method This method involves increasing press load on the bearings 4 and 7 until drag or rolling resistance of 8 4 to 9 6 Nm 75 to 85 in lb is achieved when rotating the case This includes bearing as well as seal drag The torque is equal to a force of 8 4 to 9 6 Nm 75 to 85 in lb on a bolt screwed into one of the brake assembly mounting holes to rotate the ca...

Page 124: ...buted evenly 2 Alternately loosen the eight capscrews 19 one turn at a time until all internal spring force is relieved 3 Remove the brake end plate 18 from the brake housing 1 4 Inspect the brake end plate O Ring 13 and replace if necessary 5 Remove the brake springs 10 from the assembly FIGURE 6 3 Item Component 1 Brake Housing 2 Stator Plate 3 Friction Disc 4 Back up Ring 5 O Ring 6 O Ring 7 Ba...

Page 125: ...crews to recommended values refer to Fasteners and Torque Values page 1 12 NOTE Position the brake housing on the gearbox housing as per removal scribe mark 2 Start with a stator plate and install the stator plates and friction discs into the brake housing in the same order that they were removed NOTE Soak the friction discs in EP 90 oil before installation 3 Gently slide the brake piston 8 into t...

Page 126: ...tortion binding or complete separation of the turret from the frame Proper identification of bolt grade is important When marked as a high strength bolt grade 8 the serviceman must be aware of bolt classifications and that he is installing a high strength heat treated tempered component and the bolt must be installed according to specifications Special attention should be given to the existence of...

Page 127: ...06 6 9 NBT30H 2 SERVICE MANUAL SWING 8 25 12 4 28 14 21 9 22 29 3 19 11 9 23 16 30 15 10 18 2 6 14 29 23 8 1 16 21 27 12 4 19 10 2 25 5 13 28 22 7 30 17 15 20 26 11 3 18 9 24 FIGURE 6 6 17 24 6 20 27 5 13 26 1 FIGURE 6 7 Inner Race Outer Race ...

Page 128: ...eached the end of its useful life metal particles in the grease increased drive power required noise rough operation acceleration in the increase in bearing clearance Measure the internal clearance of the swing bearing to determine if it needs to be replaced Reference National Crane Technical Support Information TSI 10 1 Place the boom in the boom rest and set the outriggers 2 Put a magnetic base ...

Page 129: ... shut down the engine 4 Tag and disconnect the battery cables 5 Remove the boom and lift cylinder following the procedures outlined in See Boom Removal from Truck on page 4 4 6 Attach a suitable lifting device to the turret Remove any slack in the sling Do not pull up on the turret 7 Remove all bolts and washers from the outer race of the swing bearing FIGURE 6 9 1 2 3 4 5 6 7 8 DANGER Crushing Ha...

Page 130: ...efer to Inner Race Torquing page 6 10 3 Using an appropriate lifting device align the turret over the frame at the same position that it was before removal 4 Carefully lower the turret into position on the bearing plate 5 Install all bolts and washers to secure the outer race of the swing bearing to the T box frame Refer to Outer Race Torquing page 6 10 NOTE If a new bearing is installed a new pin...

Page 131: ...the RCL will not calibrate the swing position correctly 6 Reinstall the slew potentiometer in the turret 7 Slide the slew pot forward to make sure the slew pot gear is meshed with the swing bearing teeth 8 Back off the slew pot gear slightly so that there is a 3 1 to 4 7 mm 0 125 to 0 188 inch gap between the slew pot gear teeth and the swing bearing gear teeth 9 Tighten the bolts on the slew pot ...

Page 132: ...SWING NBT30H 2 SERVICE MANUAL 6 14 03 20 2019 Control 613 06 ...

Page 133: ...tiometer mounted inside each outrigger box The potentiometer is connected to the outrigger beam to monitor the extension of the beam retracted mid extended and full extended The front outriggers are the main support because they are located under the frame The front outriggers can be used in the fully retracted at the mid extended position or the fully extended position The outriggers are controll...

Page 134: ...g strap Figure 7 4 can be attached to the outrigger beam NOTE To prevent nicks and gouges to the bottom of the outrigger beam do not attach chains to the outrigger beam 6 4 9 10 1 7 5 FIGURE 7 1 3 2 8 Item Component 1 Stabilizer Cylinder 2 Outrigger Box Side Wear Pad One Side 3 Outrigger Box Bottom Wear Pads 4 Outrigger Box 5 Outrigger End Plate Outrigger Box 6 Extension Cylinder Bolts 7 Outrigger...

Page 135: ...r damaged hydraulic line Outrigger Beam Installation 1 Apply grease EP MPG to the bottom of the outrigger beam 2 Apply anti seize to wear pad and set screw threads 3 Adjust the bottom wear pads on the outrigger box until about 6 4 mm 0 25 in is protruding This keeps the beam off of the bottom of the outrigger box 4 Slide the beam into the outrigger box 5 Align the base of the extension cylinder ba...

Page 136: ...d end of the extension cylinder 5 from the keyhole on the jack end of the outrigger beam 4 Slide the extension cylinder out from the outrigger beam Be careful not to drop the cylinder NOTE The hydraulic hoses for the jack cylinder are removed with the extension cylinder Be careful not to damage the hydraulic hoses 5 Tag and disconnect the hydraulic hoses for the jack cylinder at the base of the ex...

Page 137: ... support tube with the retaining bolts 4 Reconnect the hydraulic hoses as per removal tags Wear Pad Adjustment There are seven adjustable wear pads on each outrigger Three wear pads are on the outrigger box and can be accessed from the outside Four wear pads are on the outrigger beam and are adjusted from inside the outrigger box Outrigger Beam Wear Pad Adjustment Wear pad adjustment is as follows...

Page 138: ...he outrigger beam NOTE To prevent damage to the bottom of the outrigger beam do not attach chains to the outrigger beam 3 Tag and remove the hydraulic hoses connected to the extension 5 Figure 7 9 and stabilizer 7 cylinders 4 Remove the bolts 1 that attach the extension cylinder barrel to the outrigger box 5 Pull the outrigger beam out of the outrigger box with the lifting device 6 Position the ou...

Page 139: ...g and disconnect the stabilizer cylinder hydraulic hoses 6 3 Remove the check valve 2 from the stabilizer cylinder 4 Remove the bolts on top of the stabilizer support tube and lower the stabilizer cylinder and foot out of the support tube 5 Remove the bolt on the bottom of the stabilizer foot and remove the stabilizer cylinder from the foot Installation 1 Place the stabilizer cylinder in the stabi...

Page 140: ...r example if three outriggers are fully extended and one is retracted the RCL defaults to the retracted chart Removal 1 Extend the outrigger beam slightly and shut down the engine 2 Remove the hardware that secures the outrigger cover plate 1 Figure 7 11 and remove the cover plate 3 Remove the OMS string potentiometer connector 2 from the attaching point on the outrigger beam Item Component 1 Stab...

Page 141: ... 1 Install the string potentiometer 5 on the inside of the outrigger cover plate 1 2 Connect the electrical cable 6 to the OMS string potentiometer 3 Attach the OMS string potentiometer connector 2 to the attaching point on the outrigger beam NOTE To prevent damage to the OMS string potentiometer do not allow the cable to retract freely 4 Install the outrigger cover plate to the outrigger box and ...

Page 142: ...OUTRIGGERS NBT30H 2 SERVICE MANUAL 7 10 03 20 2019 Control 613 06 ...

Page 143: ...pecified are for normal operation where moderate temperature humidity and atmospheric conditions prevail In areas of extreme conditions the service periods and lubrication specifications should be altered to meet existing conditions For information on extreme condition lubrication contact your local National Crane distributor or Manitowoc Crane Care Environmental Protection Dispose of waste proper...

Page 144: ...ab Heater The standard antifreeze coolant filled from the factory is intended to provide protection against freeze up down to 36 C 34 F and boil over up to 129 C 265 F using a 15 psi pressure cap Anti wear Additives Excessive wear in the system may cause a loss in volumetric efficiency and cause shutdowns for maintenance An efficient anti wear oil protects the components against rusting resists ox...

Page 145: ...esh oil Let the samples stand undisturbed for one or two hours Then compare the samples If the reservoir oil is heavily contaminated with water the sample will appear milky with only a small layer of transparent oil on top If the milky appearance is due to air foaming it will dissipate and the oil should closely match the fresh oil Remember replacement oil must meet ISO 17 14 or better cleanliness...

Page 146: ...ight without using proper fall protection as required by local state or federal regulations CAUTION Lubrication intervals are to be used only as a guide Actual intervals should be formulated by the operator to correspond accordingly to conditions such as continuous duty cycles and or hazardous environments CAUTION Lubrication intervals are to be used only as a guide Actual intervals should be form...

Page 147: ... or clean After first 40 Hrs Quarterly thereafter 3 Magnetic Plug Hydraulic oil reservoir Clean At oil filter service interval 4 Breather Hydraulic oil reservoir Clean Monthly 5 Sheave pins boom 5 places extension 1 block 1 rooster sheave 1 EP MPG Grease gun Weekly 6 Boom pivot pin EP MPG Grease gun Monthly 7 Lift cylinder pins 2 ea EP MPG Grease gun Monthly 8 Swing bearing EP MPG Grease gun Weekl...

Page 148: ...G See 8 7 Monthly or as required 14 Outrigger beams bottom sides LTG Brush or roller Monthly or as Required 15 Wire rope hoist cable EP OGL Brush or spray Semi Annually 16 Diffuser strainer hydraulic oil reservoir Clean Semi Annually with oil change 17 Swing motor pinion bearing EP MPG Grease gun Sparingly every 50 hours 18 Extend sheaves EP 3MG Grease gun Weekly 19 Retract sheaves Extend the boom...

Page 149: ... the access plate 6 located on the top rear of the 1st section Figure 8 2 3 Apply grease to the wear pads on the top of the 2nd section through the access holes 4 in the 1st section with a grease gun Figure 8 2 4 Extend the boom to line up the access holes on the 2nd section 3 with the wear pads on the 3rd section Apply grease to the 3rd section wear pads with a grease gun 5 Extend the boom to lin...

Page 150: ...suitable brush or putty knife 3 Extend and retract the outriggers several times until the grease is evenly spread 4 Repeat as necessary Hoist Brake Oil 1 3 FIGURE 8 2 2 4 5 6 Item Description 1 1st Boom Section 2 Access Holes for 4th Section Wear Pad 3 Access Holes for 3rd Section Wear Pad 4 Access Holes for 2nd Section Wear Pad 5 2nd Section Wear Pad 6 Access Plate DANGER Do not under any circums...

Page 151: ...and add new oil remove the vent plug Figure 8 5 and then screw a 1 pipe into the drain plug hole to allow the oil to drain Remove the drain plug with a hex head socket and drain hydraulic oil Remove the 1 drain pipe and install drain plug Fill hoist gearbox with oil To fill with oil rotate the drum so the fill level port Figure 8 5 is visible through the upper hole Install a 1 pipe with elbow into...

Page 152: ...uring inspection and maintenance procedures require special attention The object of rope lubrication is to reduce internal friction and to prevent corrosion The type and amount of lubrication applied during manufacture depends on the rope size type and anticipated use This lubrication provides the finished rope with protection for a reasonable time if the rope is stored under proper conditions Whe...

Page 153: ...ving them from the metal surface 2 the film creates a barrier to repel further moisture from coming in contact with the metal and 3 it penetrates crevices In addition to the factory applied Carwell coating National Crane owners must provide proper maintenance and care to help ensure long term protection of their crane against corrosion This procedure provides information and guidelines to help mai...

Page 154: ... surface Body putty may be applied as necessary to hide the defect then sand smooth Cover all bare metal with a primer that is compatible with the original paint finish and allow to dry thoroughly Prepare the surface prior to applying the finish coat of paint Apply a finish coat of paint using accepted blending techniques Use of original paint colors is recommended to insure the best color match p...

Page 155: ...e any questions Areas of Application The underside of the unit will have full coverage of the rust inhibitor These are the only areas that a full coat of the rust inhibitor is acceptable on the painted surfaces Areas include valves hose ends and fittings swivel pumps axles drive lines transmission and all interior surfaces of the frame Frame application areas are hose ends and fittings all unpaint...

Page 156: ...LUBRICATION NBT30H 2 SERVICE MANUAL 8 14 03 20 2019 Control 613 06 10 1 4 3 16 2 7 3 12 2 8 2 15 5 9 6 4 5 2 10 9 11 14 11 4 2 10 9 12 2 2 10 9 13 7 8606 2 8606 3 3 ...

Page 157: ...onnections 3 Pivot Shaft 4 Hose Connections 5 Mirror Mounting Hardware 6 Wire Rope 7 Boom Nose Pins Clips 8 Hook Block Downhaul Weight 9 O R Hose Connections 10 O R Pins Clips 11 Power Train Hardware 12 Entire Underside of Unit 13 Turntable Bearing Fasteners Pins 14 Valve Bank Hose Connections 15 Clips for Optional Jib 16 Hanger Hardware for Optional Jib Item Description ...

Page 158: ...LUBRICATION NBT30H 2 SERVICE MANUAL 8 16 03 20 2019 Control 613 06 ...

Page 159: ...tion provides information for proper mounting and initial check out of the crane Improper mounting can result in damage to the truck frame and drive train the hydraulic pump and cause crane instability The Federal Department of Transportation Laws relating to vehicle manufacture and modification such as lights brakes and axle loads must be met as well as State vehicle laws relating to weights and ...

Page 160: ...ame that minimizes or eliminates frame reinforcement or extension of the after frame AF Many frames are available that have the necessary AF section modulus SM and resistance to bending moment RBM so that reinforcing is not required The frame under the cab through the front suspension must have the minimum SM and RBM because reinforcing through the front suspension is often difficult because of en...

Page 161: ...ntrol 613 06 9 3 NBT30H 2 SERVICE MANUAL CRANE INSTALLATION Frame FIGURE 9 1 2nd Section 3rd Section Booms Typical Location of Serial Number Identification Tags Boom Nose Lift Cylinder Turret 1st Section Boom FORWARD RSOD Stabilizer ...

Page 162: ...Min 15422 kg 34000 lbs Bare Min 4513 kg 9950 lbs GAWR Min 8165 kg 18000 lbs 8744 1 192 Min 487 7 cm 256 Min 650 2 cm 105 Min 266 7cm 30 Min 762 cm Minimum Measurements for Tractor Mount Crane 9689 58 Min 147 cm 93 Min 236 cm 65 Min 165 cm 416 Min 762 cm 84 Min 213 cm 31 Min 79 cm 264 Min 670 5 cm 53 Min 135 cm 159 Min 404 cm 27 Min 68 cm Boom Extended 25 in to Stow 85 Min 215 cm 67 Min 170 cm Whee...

Page 163: ...ights and CG required for stability prior to installation of crane or accessories are 8619 kg 19000 Ib with a minimum moment of 345 637 cm kg 300000 in lb about centerline of rotation Tractor Mounting Configuration Wheelbase WB 6 50 m 264 in Cab to Axle Trunnion CT 2 33 m 92 in After Frame AF 2 13 m 84 in Gross Axle Weight Rating GAWR rear 20865 kg 46 000 Ib PTO AND HYDRAULIC PUMP Horsepower An ax...

Page 164: ... in a NBT30H 2 application must be the correct pump rotation configuration for the PTO Verify the direction the PTO output shaft rotates before selecting a clockwise CW or counter clockwise CCW rotation hydraulic pump Figure 9 4 Both CW or CCW rotation pumps are available Diesel Engine Optimum Speed Range RPM PTO Ratio 2400 RPM PUMP 2400 100 2200 109 2000 120 1800 133 1600 150 1500 160 CAUTION Rot...

Page 165: ...e rear of the truck frame to the front of the front outrigger boxes The truck frame strength required from the front of the outrigger boxes to the front stabilizer attachment point is variable and is listed in the table below Most truck frames have reduced section properties through the front suspension due to truck frame cut outs or because outer channel reinforcement stops short of the front sus...

Page 166: ...ction modulus obtained from the truck frame Add this to the section modulus of the channel obtained from Table A Angle Reinforcement Table B page 9 10 If the truck is reinforced with an angle refer to Table B for the data on the added strength provided by the angle Add this to the section modulus of the channel obtained from Table A Fish Plate Reinforcement Table C page 9 10 The frame can be stren...

Page 167: ... 128 8 8 144 9 7 159 in 3 cm 3 9 229 8 2 134 9 2 151 10 3 169 11 4 187 10 254 9 5 156 10 7 175 11 9 195 13 1 215 11 279 11 0 180 12 3 202 13 6 223 14 9 244 12 305 12 5 205 13 9 228 15 3 251 16 8 275 13 330 14 1 231 15 6 256 17 2 282 18 8 308 14 356 15 8 259 17 5 287 19 1 313 20 8 341 15 381 17 5 287 19 3 316 21 2 348 23 0 377 Thickness 5 16 in 7 94 mm D in mm W in mm 2 5 64 3 76 3 5 89 4 102 8 203...

Page 168: ... 0 82 9 5 241 5 6 92 5 8 95 6 0 98 6 2 102 10 5 267 6 8 111 7 1 116 7 3 120 7 5 123 11 5 292 8 1 133 8 4 138 8 6 141 8 9 146 12 5 318 9 5 156 9 8 161 10 1 166 10 4 170 13 5 343 11 0 180 11 4 187 11 7 192 12 0 197 14 5 368 12 6 206 13 0 213 13 4 220 13 7 224 Thickness 3 8 in 9 52 mm D in mm W in mm 2 75 70 3 25 83 3 75 95 4 25 108 7 5 191 4 3 70 4 5 74 4 6 75 4 8 79 in 3 cm 3 8 5 216 5 5 90 5 7 93 ...

Page 169: ... 93 6 4 105 7 0 115 7 7 126 in 3 cm 3 9 5 241 6 7 110 7 4 121 8 1 133 8 9 146 10 5 267 7 7 126 8 5 139 9 3 152 10 1 166 11 5 292 8 8 144 9 7 159 10 6 174 11 4 187 12 5 318 10 0 164 10 9 179 11 9 195 12 8 210 13 5 343 11 2 184 12 2 200 13 2 216 14 3 234 14 5 368 12 5 205 13 6 223 14 6 239 15 7 257 15 5 394 13 8 226 15 0 246 16 1 264 17 3 284 Thickness 1 4 in 6 35 mm D in mm W in mm 3 76 3 5 89 4 10...

Page 170: ...p is mounted on the PTO the rear mounting bar can be attached to a transmission bolt The rear of the pump must be supported regardless of the mounting method NOTE Some of the pipe fittings are sealed by means of two threaded tapered sections one male and one female When these two tapers meet you will note a sudden increase in the force required to screw the fittings together Further tightening doe...

Page 171: ...ounting anchors and bolt reinforcing in place See Figure 9 9 for recommended drilling and bolting procedure Use 0 625 in Grade 8 bolts drill holes to 15 5mm 0 61 in diameter drive fit bolts and torque according to torque chart in Fasteners and Torque Values page 1 12 The bolt hole clearance is 1 58 mm 1 16 in to 3 17 mm 1 8 in diameter larger than the bolt shank Ref Reinforcing The rivet hole clea...

Page 172: ... spring hanger brackets if they extend down below the existing truck frame If reinforcing angle is to be welded to truck frame cut out plug weld hole pattern as in Figure 9 8 Slide the reinforcing angle up from the bottom butt it to existing forward reinforcing and weld rear suspension reinforcing to forward reinforcing Replace as much of the spring hanger cut out areas as possible and butt weld t...

Page 173: ...een configured to meet the minimum truck PTO and frame strength requirements as described on page 9 1 through page 9 15 Mounting the crane to the truck frame is as follows Weld 152 6 Skip 152 6 Weld 152 6 Skip 152 6 Weld 304 12 Reinforcing under crane Cut outs Replace as much material as possible Butt weld Overload spring stop Remove and replace S k i p w e l d a l l b a r s w i t h a l t e r n a ...

Page 174: ...page 9 23 Complete the initial crane run in procedure CANBUS System Setup page 9 26 Calibrate the RCL and do the stability test RCL Calibration page 9 26 Mount the T Box 1 Position the truck so that the truck frame is level 2 Place the T box on the truck frame as determined by the information contained in the section titled Positioning the Crane On the Truck page 9 11 NOTE The top and bottom T box...

Page 175: ...rigger Anchor Brackets for the T Box and Frame Tubes for the Anchor Bolts T Box Reinforcing Plates Note The reinforcing plates must extend out past the RSOD mounting brackets Truck Frame 3 4 inch Grade 8 Bolts for the Crane Anchor Brackets For torque values refer to Fasteners and Torque Values page 1 12 FIGURE 9 13 Truck Frame T Box ...

Page 176: ...hor bar 8 Loosely bolt the anchor bars to the RSOD mounting bracket 9 Clamp the upper brackets to the anchor bars 10 Position the upper brackets on the T box and tack weld in place 11 Drill three holes in the anchor bar using the upper bracket holes as a template 12 Remove the anchor bars and weld the upper brackets and gussets in place 13 Bolt the anchor bars to the RSOD brackets and upper bracke...

Page 177: ...front anchor to fit inside the truck frame 3 Install the front anchor brackets and properly torque the bolts Install the Front Outriggers Install the front outriggers in the frame as described in Outrigger Beam Installation page 7 3 See page 9 25 for outrigger hydraulic connections 1 1 8 inch UNC Grade 8 Crane Anchor Bolts For torque values refer to Fasteners and Torque Values page 1 12 Square Spa...

Page 178: ...e 5 bolts Figure 9 16 Install the Rear Bumper Bolt the rear bumper to the truck frame with the 3 4 inch grade 5 bolts Figure 9 16 Ground clearance should be from 50 5 58 4 cm 20 23 in FIGURE 9 16 5 8 inch Grade 5 Bolts 3 4 inch Grade 5 Bolts Note Allow a 50 5 58 4 cm 20 to 23 in ground clearance Boom Rest Bumper Foot Throttle FIGURE 9 17 Turret Operator s Platform Throttle Connector 8746 ...

Page 179: ...st as described in SECTION 5 For hoist cable and wedge socket installation see SECTION 4 of the Operators Manual Install the RCL Reel The crane is shipped with the RCL reel temporarily attached to the top of the boom Figure 9 19 To mount the reel 1 Remove the RCL reel and mounting brackets from the top of the boom Figure 9 19 2 Bolt the C brackets to the bottom of the boom 3 Attach the mounting br...

Page 180: ...s away from the drive line and exhaust system Connect the truck interface harness as shown in Figure 9 22 NOTE The T box wiring harness contains three wires for the EET connection The number of wires required depends on the truck EET system Consult the truck manufacture for EET connection Run the battery harness to the truck battery and connect as shown in Figure 9 22 Mount with the Connectors on ...

Page 181: ...nstallation Connect the hydraulic hoses to the pump sections as marked Truck Battery Harness Wire Truck Function 51 Ground 5 Positive FIGURE 9 22 Truck Interface Harness Wire Truck Function 99 To Horn 901A To Truck Ignition 52 To Truck Start 396 PTO Mode Enable 54 PTO Indicator 2362 Remote Start 1289 H 1290 L J1939 Interface Connector 8763 1 2362 901 52 99 54 396 51N 5 51A 6A 30A 1290 1289 Truck B...

Page 182: ...Hydraulic line hookup is on the right side Left Front Outrigger 1 5 2 3 4 6 7 Front Outrigger Manifold Item Solenoid 1 Outrigger Enable 2 Center Front Outrigger SFO Optional 3 Passenger Side Stabilizer Right 4 Passenger Side Beam Right 5 Driver Side Beam Left 6 Driver Side Stabilizer Left 7 Extend Retract 8 Beam Extend Relief NOTE See page 3 7 for front outrigger manifold detail Center Front Jack ...

Page 183: ...2 Driver Side Beam Left 3 Passenger Side Beam Right 4 Passenger Side Stabilizer Right NOTE See page 3 9 for RSOD manifold detail From Front Outrigger Manifold JE BE JE Jack Extend JR Jack Retract BE Beam Extend BR Beam Retract Right Side Left Side JR BR BR BE JR JE 1 2 3 4 FRONT FIGURE 9 25 RSOD Hydraulic Line Connections RSOD Manifold ...

Page 184: ...respond with direction indicated on the control levers Refer to the appropriate sections in this manual to correct any problems NOTE Add oil to reservoir as required to keep air out of the system 6 Adjust the throttle for the engine RPM and PTO ratio to get proper pump shaft speed 7 After all cylinders have been cycled stow the crane and place the outriggers in the up position The oil level should...

Page 185: ...2 110 ft Boom Test load start position over the back Boom Length 14 m 46 ft Rated Radius 10 6 m 35 ft Rated Load 4286 4kg 9450 lbs Stability Test Load no jib stowed 9450 x 1 18 5058 0 kg 11151 Ib Includes weights of slings and hook block NOTE Be sure the weights lifted are accurate A 1 increase in load weight can result in a 10 increase in the required counterweight 4 Do the following for each tes...

Page 186: ...ated Load x 1 18 kg lb 100 ft 30 5 m Boom Over Back 13 4 44 9 1 30 5805 9 12800 6851 1 15104 Over Front 30 48 100 28 95 95 408 2 900 481 7 1062 Over Side 30 48 100 21 3 70 1224 7 2700 1471 9 3245 110 ft 33 5 m Boom Over Back 14 46 10 6 35 4286 4 9450 5058 0 11151 Over Front 35 5 110 25 9 85 635 0 1400 749 3 1652 Over Side 35 5 110 19 8 65 1474 1 3250 1766 2 3894 Includes the weight of slings and h...

Page 187: ...276 l 73 gal at full mark System capacity 442 9 l 117 gal Filtration 3 Micron Return Hoist System Wire Rope Standard Length 119 m 390 ft Diameter Rotation Resistant 14 mm 9 16 in Nominal Breaking Strength 17 463 kg 38 500 lb Permissible Line Pulls 3493 kg 7700 lb Wire Rope Optional Length 119 m 390 ft Diameter 14 mm 9 16 in 6X25 IWRC Nominal Breaking Strength 15 240 kg 33 600 lb Permissible Line P...

Page 188: ...c 10 Retract 60 sec 10 Outrigger Speeds Beam Extend Front 12 sec 3 Beam Extend Rear 6 sec 3 Beam Retract Front 10 sec 3 Beam Retract Rear 6 sec 3 Jack Extend Front 14 sec 3 Jack Extend Rear SFO 6 sec 3 Jack Retract Front 11 sec 3 Jack Retract Rear SFO 6 sec 3 High Speed Hoist Performance 1 part line Layer Hoist Pull lbs kg fpm mpm 1 5410 2454 199 61 2 4878 3573 220 67 3 4441 2014 242 74 4 4076 184...

Page 189: ...10 National Crane 10 1 NBT30H 2 SERVICE MANUAL SCHEMATICS SECTION 10 SCHEMATICS For your convenience the latest version of schematics available at the time of printing are placed in this section ...

Page 190: ...SCHEMATICS NBT30H 2 SERVICE MANUAL 10 2 ...

Page 191: ...ler Option 3 9 Hydraulic Pump 2 11 Hydraulic Symbols 2 3 Initial Crane Run In Procedure 9 26 Introduction 2 1 Lift Cylinder Installation 4 17 Lubrication 8 3 Maintenance 2 5 Maintenance 3 1 Maintenance 5 2 Maintenance 6 8 Micro Relay fuse block 3 6 Minimum Truck Requirements 9 1 Mounting Configuration 9 5 Mounting the Crane 9 15 Outrigger Manifolds 3 7 Outrigger Monitoring System OMS Optional Stan...

Page 192: ...and Brake 6 4 Theory of Operation 4 1 Theory of Operation 6 1 Torquing Swing Bearing Bolts 6 8 Troubleshooting 5 8 Truck Frame Strength 9 7 Truck Preparation 9 11 Valves 2 12 Weld Studs 1 26 Wire Rope Lubrication 8 10 Wire Rope 1 26 ...

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