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Manitowoc National Crane NBT40 Series, Service Manual

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Manitowoc National Crane NBT40 Series Service Manual Download Page 6

NBT40 SERVICE MANUAL

TOC-2

System Pressure Check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-13
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-13
Boom Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-13
Telescope In and Telescope Out Reliefs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-13
Outriggers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-13
Swing Valve Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-14
Center Front Stabilizer (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-14
Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-15
Hydraulic Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-16
Hydraulic Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-17
Oil Cooler Service & Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-17
Hydraulic Valves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-17
Main Control Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18
Hydraulic Remote Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18
Outrigger Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18
Swing Gearbox  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18
Crane Function Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18

Hydraulic Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-19
Pump Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-19
Pump Margin Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-20
Maximum Pump Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-20
Load Sense Relief Valve Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-20

Trouble Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-22

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Connector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Tooling For Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Troubleshooting the Electrical Swivel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2

RCL system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2

RCL & ATB System Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2

Cab Module, Fuse, Relay Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3

Micro Relay Fuse Box #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-5
Micro Relay Fuse Box #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-5
Micro Relay Fuse Box #3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-6

VEC Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-7

Crane Manifold Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-8

Outrigger manifolds  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-9

Front Outrigger Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
Rear Outrigger Manifold  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10

Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11
Hydraulic Temperature Sensor Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11

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

Four Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Boom Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Additional Maintenance, Disassembled Boom  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Four Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Cable Tightening Sequence  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3

Reference Only

Summary of Contents for National Crane NBT40 Series

Page 1: ...Service Manual National Crane NBT40 Series R e f e r e n c e O n l y ...

Page 2: ...R e f e r e n c e O n l y ...

Page 3: ... furnish crane serial number when ordering parts or communicating service problems with your distributor or the factory 2017 Manitowoc Published 8 01 2017 Control 287 11 Untrained operators subject themselves 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 read under...

Page 4: ...ed area vent the exhaust to the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel 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 handl...

Page 5: ...ion 1 22 Recommendations for Servicing Wire Rope 1 23 Wire Rope Inspection 1 23 Boom Extension and Retraction Cables 1 24 Wire Rope Replacement All Wire Rope 1 24 Seizing Wire Rope 1 25 SECTION 2 Hydraulic System Maintenance 2 4 General 2 4 Hydraulic System Maintenance Precautions 2 4 Label Parts When Disassembling 2 4 Welding Precautions 2 4 Parts Replacement 2 4 Service 2 4 Hydraulic Oil Recomme...

Page 6: ... 20 Load Sense Relief Valve Pressure Setting 2 20 Trouble Diagnosis 2 22 SECTION 3 Electric System Description 3 1 Maintenance 3 1 General 3 1 General Troubleshooting 3 1 Connector Troubleshooting 3 1 Tooling For Troubleshooting 3 1 Troubleshooting the Electrical Swivel 3 2 Ignition Switch 3 2 RCL system description 3 2 RCL ATB System Description 3 2 Cab Module Fuse Relay Panel 3 3 Micro Relay Fus...

Page 7: ...d 1st Section Boom 4 29 Five Section Cable Tensioning 4 36 Cable Tightening Sequence 4 37 Cable Retention 4 38 Five Section Top bottom Pad Replacement Assembled Boom 4 39 Boom Calibration 4 41 Inner Side Pads 4 41 Rear Bottom Pads 4 42 Multi stage Extend Cylinder 4 43 Cylinder Reassembly 4 44 Jib Boom 4 44 Jib Stowage Bracket Adjustment 4 44 Jib Jack Service and Maintenance 4 47 SECTION 5 Hoist De...

Page 8: ...11 Bearing Replacement 6 12 Removal 6 12 Installation 6 13 Slew Potentiometer Adjustment 6 14 Testing 6 14 Swing Lock 6 14 Removal 6 15 Installation 6 15 SECTION 7 Outriggers Description 7 1 Outrigger Beam Assembly 7 1 Removal 7 4 Assembly 7 5 Cable Tensioning 7 6 Outrigger Calibration 7 6 Side Pads 7 6 Top And Bottom Pads 7 8 Outrigger Monitoring System OMS Optional Standard in North America 7 8 ...

Page 9: ...m NBT40 and NBT459 4 Configuration With Pusher Axle 58 000 lb GVWR 103 127 ft Boom NBT40 and NBT459 5 Configuration With Extended T Box NBT40 127 and NBT45 127 9 6 Configuration With Tag Axle 60 000 lb GVWR 142 FT Boom NBT40 and NBT459 8 Configuration With Tag Axle 94 000 GVWR 103 ft Boom NBT45TM 9 10 Configuration With 103 127 ft Boom NBT36 9 11 PTO Requirements 9 12 Horsepower 9 12 Direct PTO Mo...

Page 10: ...NBT40 SERVICE MANUAL TOC 6 Boom Weight 9 34 Dimensional Drawing 9 35 SECTION 10 Schematics R e f e r e n c e O n l y ...

Page 11: ... the operation and maintenance of the RCL system installed on the crane see the manufacturer s manual supplied with the crane Manufacturers of rated capacity limiters may refer to them in their manuals as a load moment indicator LMI a hydraulic capacity alert system HCAS a safe load indicator SLI or an ECS5 Manitowoc refers to these systems as a rated capacity limiter RCL throughout its Operator s...

Page 12: ...fety and Maintenance for National Crane operators and owners is supplied when the crane is purchased new Additional copies are available from your local distributor Basic Nomenclature The nomenclature used to describe parts of a National Crane are described in Figure 1 2 This nomenclature is used throughout this manual FIGURE 1 1 R e f e r e n c e O n l y ...

Page 13: ...er Beam 12 Outrigger Jack 13 Out Rigger Float 14 Outrigger Box 15 Boom Angle Indicator 16 Hoist Cable 17 Jib 18 Turret 19 Stabilizer Front Outrigger SFO Front Outrigger Jack 20 Hydraulic Tank 21 Hydraulic Pump not shown 22 Hydraulic Remote Controller HRC 23 Truck Frame 24 Truck Bed 25 Torsion Box Frame T Box Frame 26 Sheave Item Component 5 26 19 8 16 5 4 7 6 24 20 23 25 21 14 12 1 2 18 11 13 1 12...

Page 14: ... attachment for all removals requiring hoisting equipment Some removals require the use of lifting fixtures to obtain proper balance All supporting members chains and cables need to be parallel to each other and as near perpendicular as possible to the top of the object being lifted If a part resists removal check to be sure all nuts and bolts have been removed and that an adjacent part is not int...

Page 15: ...is an initial load placed on the bearing at the time of assembly Consult the disassembly and assembly instructions to determine if the bearing can be preloaded Be careful in applying preload to bearings requiring end clearance Otherwise bearing failure may result Sleeve Bearings Do not install sleeve bearings with a hammer Use a press and be sure to apply the pressure directly in line with the bor...

Page 16: ... machine is not used for an extended period of time Store the batteries in a warm dry place preferably on wooden shelves Never store on concrete A small charge should be introduced periodically to keep the specific gravity rating at recommended level When disconnecting wires tag each one to ensure proper identification during reassembly Connectors Harnesses Wires and Connectors Visually inspect al...

Page 17: ...on apply several drops of adhesive in the bottom of the hole so that the adhesive is forced up when the bolt is installed 3 After installation fixturing occurs within five 5 minutes The time required to achieve full strength is 24 hours Fasteners And Torque Values Use bolts of the correct length A bolt which is too long may bottom before the head is tight against the part it is to hold If a bolt i...

Page 18: ...STOP when the predetermined value has been reached When using step wrenches calculated wrench settings are valid only when the following conditions are met Torque wrenches must be those specified and forces must be applied at the handle grip The use of handle extensions will change applied torque to the bolt All handles must be parallel to the step wrench during final tightening Multiplier reactio...

Page 19: ...6 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 UN...

Page 20: ...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 3 8 12 UNF 5 1314 4 ...

Page 21: ... 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 22: ... 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 1 257 3 12 9 317 0 309 ...

Page 23: ...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 24: ...t recommended Table 1 6 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 excessive pressure Im...

Page 25: ...Threads per 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 M27X3 10 9 1591 1530 14...

Page 26: ... 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 2396 2296 1 1 2 6 5 2...

Page 27: ... 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 UNS 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 163...

Page 28: ... 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 9 629 605 581 12 9 756 727 69...

Page 29: ...ON 1 10 M27x3 8 8 1134 1090 1046 10 9 1591 1530 1469 12 9 1910 1836 5 1763 M30x3 5 8 8 1538 1479 1420 10 9 2163 2080 1997 12 9 2595 2495 2395 M36x4 8 8 2681 2578 5 2476 10 9 3964 3812 3660 12 9 4639 4461 4283 Size Property Class Torque Nm Maximum Nominal Minimum R e f e r e n c e O n l y ...

Page 30: ...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 9 229 220 211 12 9 268 257 246 M16x1 5 8 8 248 238 5 229 10 9 348 335 322 12 9 418 402 386 M18x1 5 8 8 345 331 5 318 10 9 491 471 451 12 9 575 552 529 M20X1 8 8 471 453 435 10 9 694 667 5 641 12 9 812 781 7...

Page 31: ... 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 2581 10 9 4118 3960 3802 12 9 4818 4634 4450 Size Property Class Torque Nm M...

Page 32: ... be determined by a qualified person and shall be based on expected rope life as determined by experience severity of environment percentage of capacity lifts frequency of operation and exposure to shock loads Periodic inspections need not be at equal calendar intervals and should be performed at shorter time intervals as the wire rope approaches the end of its useful life A periodic inspection sh...

Page 33: ...assembled lengths of wire rope as supplied from Manitowoc CraneCARE Do not build lengths from individual components Replace an entire wire rope assembly Do not attempt to rework damaged wire rope or wire rope ends Never electroplate wire rope assemblies Do not weld wire rope assemblies or components unless recommended by the wire rope manufacturer Do not allow welding spatter to come in contact wi...

Page 34: ...owing guidelines for reduction of rope diameter below nominal diameter severely corroded or broken wires at end connections severely corroded cracked bent worn or improperly applied end connections deterioration in areas such as sections in contact with saddles equalizer sheaves or other sheaves where rope travel is limited sections of wire rope at or near terminal ends where corroded or broken wi...

Page 35: ... wire rope need to be seized prior to cutting Seizings must be placed on both sides of the point where the wire rope is to be cut The two methods for seizing wire ropes are described below Method 1 Using a length of soft annealed wire place one end in the groove between two strands of the wire rope Turn the long end of the annealed wire at right angles to the wire and wrap it tightly over the port...

Page 36: ...1 26 Published 8 01 2017 Control 287 11 INTRODUCTION NBT40 SERVICE MANUAL THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 37: ...2 14 Hydraulic Reservoir and Filter 2 15 Hydraulic Filter Replacement 2 16 Hydraulic Oil Cooler 2 17 Oil Cooler Service Maintenance 2 17 Hydraulic Valves 2 17 Main Control Valve 2 18 Hydraulic Remote Controllers 2 18 Outrigger Manifolds 2 18 Holding Valves 2 18 Swing Gearbox 2 18 Crane Function Power Switch 2 18 Hydraulic Pump 2 18 Description 2 18 Removal 2 18 Installation 2 19 Pump Start up 2 19...

Page 38: ... 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 Creates back pressure Orifice In line fixed restriction Adjustabl...

Page 39: ...nk 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 barr...

Page 40: ...hen in order tighten the bolts at the rigid end the adjustable end and the mounting brackets After tubes are mounted install the hoses Connect both ends of the hose with all bolts finger tight Position the hose so it does not rub the machine or another hose and has a minimum of bending and twisting Tighten bolts in both couplings Due to manufacturing methods there is a natural curvature to a hydra...

Page 41: ...the line to the swing motor then drive the swing motor in the opposite direction until the boom is centered and forward Replenish the reservoir hydraulic oil level as necessary When hydraulic oils are changed recheck the reservoir hydraulic oil level after brief system operation and add hydraulic oil as required Ensure the crane is level and in the travel mode of operation when the hydraulic syste...

Page 42: ...ense standby pressure of 2413 2757 kPa 350 400 psi Main Control Valve The main control valve is located in the turret and has three sections The main control valve and controls the hoist lift and telescope Section one controls the boom up and down and contains a lift relief valve that protects the lift down circuit lift up is protected by the system relief valve Section two controls the hoist and ...

Page 43: ...vides descriptive information for all the hydraulic valves used on this crane For a listing of all valves the circuit they are used in and their physical location refer to the table below Refer to Figure 2 1 for control valve and manifold locations The description of each valve given here is for the valve itself For information on how each valve functions in the individual circuits refer to the de...

Page 44: ...ont Outrigger Solenoid Manifold 7 Outrigger Pressure Reducing Valve 8 Swing Speed Control Valve Item Component 5 FIGURE 2 1 4 1a 3 2 5 6 8 Item Component 1a Main Control Valve lift telescope hoist 1b Main Control Valve Optional Aux Hoist 2 Swing Control Valve 3 Pilot Valve Air Conditioner Swing Brake 4 Dump Valve 1b R e f e r e n c e O n l y ...

Page 45: ...lief Valve 13 Standby Pressure 4 Main Hoist Relief Valve down 9 Load Sensing Relief 14 Check Valve 4 places 5 Tele Cyl Relief Valve retract 10 Pilot Supply Port Description Port Description Port Description A Outlet swivel port 4 G Tele Cyl extend B4 Hose Dump Valve B1 B Inlet swivel port 3 H Tele Cyl retract J1 Plugged C Lift Cyl extend J Main Hoist Raise J2 Hose Dump Valve B2 D Lift Cyl retract ...

Page 46: ...y Pressure 3 Tele Cyl Relief Valve extend 8 Load Sensing Relief Valve 13 Check Valve 4 places 4 Tele Cyl Relief Valve retract 9 Pilot Supply 5 Main Hoist Relief Valve down 10 Gauge Port Port Description Port Description Port Description A Outlet swivel port 4 G Tele Cyl extend J2 Hose Dump Valve B2 B Inlet swivel port 3 H Tele Cyl retract J3 Plugged C Lift Cyl extend B1 Hose Dump Valve B4 D Lift C...

Page 47: ...ve w Aux Hoist A C J4 N Hose A C Pressure B Swing Control Valve w out A C J5 P Hose Swing Motor 1 Swing Relief Valve Swing Motor X3 Hose Pilot Manifold A2 R Outlet Swivel 4A 2 Swing Relief Valve Swing Motor X4 Hose Pilot Manifold P T Inlet Swivel 3A 3 Load Sense Port Swing Motor L Hose A C Return 4 A C Relief Valve M Hose Swing Motor T P R L M N R T M P 2 1 A 1 4 3 X3 J4 J5 X4 B 2 3 J4 J5 75881 1 ...

Page 48: ...for long periods of time Reservoir oil temperature is to be 140 160 F Preparation Run the engine until the hydraulic oil temperature reaches a minimum of 49 C 60 C 120 F 140 F Shut down the engine Relief Valve Pressure Settings CAUTION Do not overtighten the adjustment screw or locknut Do not hold the relief valve open for more than one minute at a time DANGER Do not attempt to loosen the fittings...

Page 49: ... boom stops or stop the engine disconnect and cap the boom up hydraulic line 5 Set the boom up relief valve on the main control valve Figure 2 2 Figure 2 3 to 24821 689 kPa 3600 100 psi 6 Shutdown the engine 7 Reconnect the boom up hydraulic line to the lift cylinder Telescope In and Telescope Out Reliefs 1 Remove the extend and retract work port hoses 1 Figure 2 6 from the telescope cylinder Cap ...

Page 50: ...e 7 Start engine and set throttle to governed rpm 8 Activate the swing function and check for a pressure of 21373 kPa 689 0 3100 200 0 psi 9 Shut down the engine 10 Replace swing relief valve s in the swing control valve Figure 2 4 if pressure measured is not within specification Center Front Stabilizer if equipped 1 Disconnect the front stabilizer retract 1 Figure 2 9 and extend lines 2 Cap the r...

Page 51: ...oir to indicate hydraulic oil level A filler cap on the top of the reservoir is for filling the reservoir The filler cap includes a strainer for catching contaminants and gaskets to prevent leaking A breather cap vent which is part of the filler cap allows air to enter or leave the reservoir The breather must be kept clean to prevent damage to the reservoir A large access cover on the top of the r...

Page 52: ... by comparing their part numbers with the part numbers of the used filter element 7 Discard the used filter element Element Installation 1 Install the new element into the filter bowl housing 2 Install the filter cap and twist to lock in place 3 Tighten the six bolts to secure the filter cap 4 Activate the hydraulic system and check for leaks Make repairs as needed 1 5 4 6 7 9 10 8 FIGURE 2 10 2 3...

Page 53: ...ooling fan for proper operation Any obstructions to air flow needs to 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 Hydraulic Valves Inspection Inspect the control valve for visible damage binding spools and evidence of leakage If excessive i...

Page 54: ... front and rear outrigger boxes The front manifold contains the extend retract valve front outrigger component valves and the optional front jack valve The rear outrigger manifold contains the rear outrigger component valves The valves are operated by solenoids that are controlled by switches on the outrigger control boxes located on the side of the truck bed An optional hand held outrigger contro...

Page 55: ...en the shut off valve on the hydraulic line from the reservoir to the pump 4 Fill the pump housing with hydraulic fluid Pour the oil directly into the upper most case drain port 5 Fill the inlet line from the pump to the reservoir with hydraulic oil Check the line for properly tightened fittings and be certain it is free of restrictions and air leaks 6 Inspect the case drain line for leaks and res...

Page 56: ...g screw Loosen locknut and turn PC adjustment screw 1 Figure 2 13 clockwise to increase the setting each turn gains 99 9 bar 1450 psi Tighten lock nut 16 2 nm 12 lb ft to secure setting Reset the LSRV setting see Load Sense Relief Valve Pressure Setting Load Sense Relief Valve Pressure Setting 1 Perform this procedure after setting the pump s maximum pressure setting or checking the Load Sense Rel...

Page 57: ...2 NBT40 SERVICE MANUAL HYDRAULIC SYSTEM National Crane Published 8 01 2017 Control 287 11 2 21 FIGURE 2 14 1 2 7590 R e f e r e n c e O n l y ...

Page 58: ... 19 18 097 2 46 7 8 14 1 3 16 12 07 1 78 739 18 77 750 12 924 23 47 116 2 95 1 1 16 12 1 7 16 12 07 1 78 926 23 52 1 000 16 1 171 29 74 116 2 95 1 5 16 12 1 11 16 12 07 1 78 1 176 29 87 1 250 20 1 475 37 46 118 3 00 1 5 8 12 2 12 07 1 78 1 489 37 82 1 500 24 1 720 43 69 118 3 00 1 7 8 12 NOTE Contact your National Crane Distributor or Manitowoc Crane Care for O Ring boss seal kits CONDITION POSSIB...

Page 59: ...in circuit Adjust hydraulic component Faulty hydraulic cylinder motor or valve Replace faulty component No response to control Crane function power switch off Turn crane function power switch on Load too heavy Check Capacity Chart RCL inoperative Insure RCL is programmed properly and Anti Two Block Overload solenoids are powered PTO not engaged Engage PTO Low hydraulic fluid supply Check and fill ...

Page 60: ...rake not properly applying Check dynamic brake pressure Must modulate between 0 3 4 MPa 0 500 PSI Turn does not function Glide Swing System Attempting to swing up too much of incline Level machine Turn circuit relief valves sticking Clean and check circuit pressure Swing bearing drag Lubricate thoroughly as upper is rotated Swing brake on Select swing brake control switch on and check swing brake ...

Page 61: ...lifting Relief valve setting too low Check and adjust if required Motor worn Replace motor Sprag clutch defective Clean or replace Sprag clutch Load block too close to boom tip two block system shut down Lower load or retract boom Check two block system repair if defective Brake worn out Repair or replace brake Anti two block system defective Repair anti two block system Hoist gearbox heats Gearbo...

Page 62: ...idly Move joystick slowly and smoothly to start and stop swing Turn pulsates continuously and is slow Low pilot circuit pressure Check and adjust pilot pressure to 3 45 MPa 500 PSI Turn will not start smoothly or increases decreases speed drastically near full joystick throw Improper or defective valve spool springs or burrs on valve spool Swing should start to rotate at 0 7 1 MPa 100 140 PSI and ...

Page 63: ... open circuit or for voltage if you suspect a power problem Check the electrical schematic for the most accurate wiring information 3 Replace faulty components and wiring 4 Test the repaired circuit and verify that the circuit works properly Connector Troubleshooting The cause of an electrical problem may be a loose or corroded connection in a connector Check the connectors to ensure that the pins...

Page 64: ...oom down telescope out are disabled A RCL override key switch is located behind the operator s seat Turn the key switch ON to override the RCL The RCL memory always has power supplied by the truck battery even when the truck ignition is in the OFF position NOTE Consult the RCL manual in the event of an RCL malfunction RCL ATB System Description The anti two block system ATB is part of the RCL syst...

Page 65: ...he operator s seat Remove the two screws securing the access panel to gain access to the fuse blocks relays cab control module interface connectors and the cab RCL module NOTE The cab control modules and RCL module are not serviceable contact Crane Care Customer Service with any service or repair questions about the modules FIGURE 3 1 1 3 2 4 5 6 7569 10 7569 11 7569 2 7 R e f e r e n c e O n l y ...

Page 66: ... Numbers FIGURE 3 2 1 3 10 8 7569 5 7 9 1 2 3 5 4 7600 6 2 5 6 4 7600 2 Item Component 1 Access Panel 2 Buzzer Minimum Wrap Indicator 3 RCL Bypass Key Switch 4 Fuse Box 3 5 Fuse Box 2 6 Fuse Box 1 7 ACC Relay 8 Crane Relay 9 Remote Relay 10 HVAC Relay Item Component R e f e r e n c e O n l y ...

Page 67: ...Switch 7 5 amp F5 Air Condition Power Relay 15 amp F6 RCL Power and Override Switch Circulation Fan Switch 15 amp F7 Horn Horn Relay and Horn Switch 10 amp F8 Heater and Air Conditioner Controls 10 amp F9 Spare 30 amp F10 HVAC Power Relay 30 amp Fuse Box 2 Micro Relay Fuse Box 2 The micro relay fuse block 5 Figure 3 2 is located in the middle of the fuse relay panel and contains the following comp...

Page 68: ...wing components Figure 3 5 R1 Not Used R2 Not Used R3 Not Used R4 Rated Capacity Limiter RCL Relay R5 Crane Power and Remote Power F1 Spare 7 5 amp F2 Hoist Speed Switch 7 5 amp F3 Spare 5 amp F4 Spare 10 amp F5 MWI Lockout Solenoid 5 amp F6 Swing Brake Power Hoist Thumper 5 amp F7 RCL Lockout Solenoid 10 amp F8 Hoist DRI MWI Sensor 3 amp F9 Spare 15 amp F10 Outrigger Power 15 amp FIGURE 3 5 7602 ...

Page 69: ...emperature switch closes Throttle control relay 3 switches the throttle control from the truck to the crane The radio remote option disables this relay when the truck is started with the radio remote The engine start relay 4 energizes the engine starter circuit from the crane cab ignition or radio remote Item 5 not used Crane Ignition relay 6 disables the crane ignition switch when the truck is ru...

Page 70: ...n The crane manifold solenoids are located on the crane manifold valve A Figure 3 7 and provide for the following operations 7 Crane Function Power enables all crane functions when energized 8 Air Conditioner runs the air conditioner compressor when energized if not used this port is plugged 9 Swing Brake applies the swing park brake when energized FIGURE 3 7 6 5 4 3 2 1 7 8 C A 9 7587 3 7587 2 1 ...

Page 71: ...rcuit however only one function at a time can be working When the crane function power switch is turned ON the outrigger manifolds are disabled Figure 3 8 Item List Fault Check RCL A2B Solenoids fail to energize RCL relay R4 in the mini fuse block Fuse F9 in the mini fuse block Faulty RCL override switches Fuse F7 in micro fuse block Faulty crane power switch Minimum Wrap Indicator Switch solenoid...

Page 72: ...t switch on the outrigger control is depressed the SFO is first up The component solenoids 2 through 5 control the front outrigger components See Figure 3 8 for solenoid identification The extend 7 retract 8 solenoids control the extend and retract functions for all outrigger components on both front and rear outriggers Rear Outrigger Manifold The solenoids on the rear outrigger manifold control t...

Page 73: ...r 2 and fan relay The temperature sensor 2 is located in the cooling core and energizes the fan relay when the hydraulic oil reaches 49 C 120 F The fan relay is in the VEC module Figure 3 6 and turns the fan on when energized If the fan does not run when the hydraulic oil is hot check the temperature sensor relay and fan motor NOTE The fan runs constantly if the sensor fails HYDRAULIC TEMPERATURE ...

Page 74: ...ELECTRIC SYSTEM NBT40 SERVICE MANUAL 3 12 Published 8 01 2017 Control 287 11 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 75: ...pport the 4th stage boom The 4 3 2 retract cables Figure 4 1 are attached to the base of the 4th stage boom are reeved around sheaves at the base of the 3rd stage boom and attach to the tip of the 2nd stage boom The 1 2 3 extend cables Figure 4 1 attach to the base of the 1st stage boom are reeved around sheaves at the tip of the 2nd stage boom and attach to the base of the 3rd stage boom The 3 2 ...

Page 76: ...ight distribution and raise the boom until weight is removed from the boom pivot pin Remove boom pivot pin keeper and boom pivot pin Lift boom free of turret Additional Maintenance Disassembled Boom 1 Clean all boom sections and inspect for wear dents bent or crooked boom sections gouged metal broken welds or any abnormal conditions Repair or replace as required 2 Inspect all sheaves for excessive...

Page 77: ...ables at back of 2nd section to 30 51 Nm 22 5 ft lb each To reach 2 3 4 extend cables extend the boom out approximately 610 mm 24 in 115 mm 4 56 in per section and tighten through hole in back of base section 4 Equally torque 3 2 1 retract cables at front of base section to 4 07 Nm 3 ft lb start with two inside cable ends then the two next outside cable ends then the two outside cable ends 5 Torqu...

Page 78: ...revent cable twist After the cable adjustment procedure is completed for the entire boom assembly The second torqued nut must be installed on all retract and extend cables The second nut should be hand tightened until it comes in contact with the back of the first nut Hold the first adjustment nut stationary and a torque wrench to tighten the second torqued nut against the first adjustment nut to ...

Page 79: ...ADE Nut Type TORQUE ft lbf 1 2 13 SAE 2 Hex Jam HALF 12 5 8 11 SAE 2 Hex Jam HALF 31 3 4 10 SAE 2 Hex Jam HALF 47 7 8 9 SAE 2 Hex Jam HALF 63 1 8 SAE 2 Hex Jam HALF 199 1 7 SAE 2 Hex Jam HALF 203 1 6 SAE 5 Hex Jam FULL 250 1 5 ASTM B Hex Jam FULL 250 1ST STAGE 1 2 3 EXTEND CABLE 2 3 4 EXTEND CABLES 4TH STAGE 3RD STAGE 2ND STAGE 4 3 2 RETRACT CABLES 3 2 1 RETRACT CABLES FIGURE 4 4 R e f e r e n c e...

Page 80: ...heir original location previously marked on the threaded cable ends 6 Extend the boom approximately 31 5 in 10 44 in per stage so that upper wear pads on 2nd stage boom are visible through hole in the top plate of the 1st stage boom 7 Remove countersunk capscrews from the top base of the 2nd stage boom wear pad retaining plates and slide wear pad retaining plates towards the center of boom Mark th...

Page 81: ... 3rd and 4th on a suitable horizontal surface NOTE Use caution not to pinch or crush retract cables while lifting or supporting 2nd stage boom 13 Tag and remove rear wear pads and shims from base of 2nd stage boom if replacing 14 Remove capscrew 66 and retract cable guide roller 32 from each side of the bottom base of the 2nd stage boom 15 Remove the two square head setscrews 117 which retain 3 4 ...

Page 82: ... anchor 78 and store in an area where they will not be damaged during further boom disassembly 30 Mark the location of the nuts which secure the 4 3 2 retract cables 53 to the tip of the 2nd stage boom and loosen nuts 12 113 and remove plate 26 and capscrew 27 from the threaded cable end 31 Pull the 4 3 2 retract 2 3 4 extend pin 77 with cables 29 as an assembly out of slot in the bottom base of t...

Page 83: ... pin 90 in left side of the upper sheave case NOTE Install spacers 92 between sheaves and between sheaves and side plates b Install small spacer 92 c Install sheaves assembly 94 95 near the sheave case side plates with the grease fitting 93 facing the side plate to allow for greasing d Install spacer 91 e Install center sheave assembly 94 95 with grease fitting 93 facing either side f Install top ...

Page 84: ...Coat bearing with multi purpose grease and install 2 3 4 extend sheaves into extend cylinder 5 c Install pin assembly 142 through cylinder sheave case securing with keeper plate 150 and two bolts 81 d Install two wear pads 144 and 145 each side on front tip of extend cylinder with capscrew 143 13 Reeve 2 3 4 extend cables 29 over 2 3 4 extend cylinder sheaves 83 at the front of the telescope cylin...

Page 85: ...a loop and find the center of cable length a Slide this center loop from front to back through the cable anchor slot at base top of the 3rd stage boom 3 b Slide the keeper sheave 71 into this slot from back to front so raised portion of sheave slides into slot of cable anchor plate c Pull this loop of cable forward to lock 1 2 3 sync extend cable 10 to 3rd stage boom d Place the sheave case assemb...

Page 86: ...age boom 2 while guiding 2 3 4 extend cables 29 into anchor assembly 30 Install nuts 31 and spacer 152 on threaded ends of 2 3 4 extend cables spacer is used on center cable only NOTE Do not twist cables Twisting of cables will result in damage or failure of cable When initially assembling threaded ends of cables thread the first nut on past the flat so adjustment can be made later 20 Lock cable a...

Page 87: ...ear pad backup plate 22 back plate 70 NOTE Apply multipurpose grease MPG to all wear pads and contact surfaces 9 Install adjusting bolt 104 and jam nut 97 on lower front side of 1st stage boom Install wear pad retaining hardware 28 40 61 in wear pad pocket 10 Install upper wear pad assembly 164 163 160 with hardware 162 161 at upper tip of 1st stage boom NOTE It may be necessary to support the com...

Page 88: ...ontrol 287 11 21 Extend boom and align all boom sections 22 Install access cover 124 with hardware 125 126 to top rear of 1st stage boom 23 Install boom angle pendulum 121 and bearing 120 to left side of 1st stage boom with hardware 122 56 R e f e r e n c e O n l y ...

Page 89: ...63 160 15 14 13 17 10 46 130 12 113 27 167 26 64 129 106 105 41 42 37 36 114 36 37 118 8 11 117 32 5 31 132 152 27 39 30 19 43 38 66 153 156 157 154 155 16 101 56 21 23 168 161 25 24 28 1 63 22 70 97 104 98 162 122 56 120 121 164 163 160 166 19 115 113 27 12 130 165 49 20 124 131 9 8 10 5 73 125 126 111 56 76 40 61 53 29 109 35 156 155 118 8 11 To Base of 3rd Stage To Rear Base of 4th Stage R e f ...

Page 90: ...5 14 13 167 158 152 154 155 156 156 155 38 108 107 51 65 74 72 27 48 10 71 50 49 41 42 79 80 69 37 53 36 34 35 36 37 64 19 153 155 154 94 81 21 82 91 89 81 21 127 128 95 94 95 92 95 93 92 96 82 21 81 110 89 92 94 95 92 90 81 93 21 82 41 42 67 68 4 156 93 93 92 93 95 92 94 89 156 157 155 29 43 107 112 78 53 60 99 99 60 64 69 77 43 To Tip of 1st Stage To Tip of 2nd Stage 5 R e f e r e n c e O n l y ...

Page 91: ... Thread Adapter 8 Flatwasher 3 4 9 Hex Nut 3 4 10 10 Cable Assembly 11 Socket Hd SS 3 4x0 75 12 Hex Jam Nut 5 8 11 13 Shim 14 Shim 15 Wear Pad 16 Plate 17 Wear Pad 18 Plug 19 Cable Assembly 20 Capscrew Hex Hd l 1 2 13 x1 50 G8 21 Lock Washer 3 8 22 Back Plate 23 Capscrew Hex Hd 3 8 16 x0 75 G5 24 Capscrew Hex Hd 3 8 16 G5 25 Hex Lock Nut 3 8 16 26 Plate Assembly 27 Capscrew Socket Flat Hd 3 8 16 x...

Page 92: ... Cable Anchor Assembly 79 Shim 80 Wear Pad 81 Capscrew Hex Hd l 3 8 16 x0 88 G8 82 Keeper 4 Section Boom Item Description 83 Sheave 84 Bearing 89 Hitch Pin 0 75x7 90 Sheave Pin 91 Spacer 92 Spacer 93 Grease Fitting 94 Sheave 95 Bearing 96 Sheave Pin 97 Hex Jam Nut M20 98 Cable Block 99 Retaining Ring 1 50 100 Shim 101 Shim 102 Shim 103 Capscrew Hex Hd 3 8 16 x1 5 G5 104 Capscrew Hex Hd M20x50 8 8 ...

Page 93: ... x0 63 150 Keeper 151 Capscrew Socket Flat Hd 5 16 18 x0 75 152 Spacer 153 Wear Pad Plate 154 Cam Plate Rear Wear Pad 155 Flatwasher 10 156 Capscrew Hex Hd M10x16 157 Wear Pad 158 Wear Pad 160 Keeper Side Wear Pad 161 Capscrew Hex Hd M6x70 8 8 162 Flatwasher 6 163 Side Wear Pad 164 Keeper Side Wear Pad 165 Wear Pad Left 166 Wear Pad Right 167 Capscrew Socket Flat Hd 1 2 13 cx1 168 Cable Protector ...

Page 94: ... retract cables Figure 4 6 directly oppose the 1 2 3 extend cables to ensure that the 2nd and 3rd stage booms extend and retract equally at all times The 4 3 2 retract cables Figure 4 6 directly oppose the 2 3 4 extend cables to ensure that the 3rd and 4th stage booms extend and retract equally at all times The 5 4 3 retract cables Figure 4 6 directly oppose the 3 4 5 extend cables to ensure that ...

Page 95: ...d disconnect the hydraulic lines to the telescope cylinder Cap all lines and openings 4 Loosen and remove two capscrews 11 8 and hardened washers which anchor the 1st stage extend cylinder rod 6 to the base of the 1st stage boom 5 Mark the location of the nuts and washer 9 8 which secure the 1 2 3 extend cables 10 to the rear base of the 1st stage boom base section 1 Remove nuts and washers from 1...

Page 96: ...ting 3rd stage boom 25 Tag and remove wear pads and shims from base of 3rd stage boom if replacing 26 Remove the 1 2 3 extend cable 10 from top of 3rd stage boom Slide the top center rear sheave 71 toward the rear of boom and remove Pull the cable loop forward and remove from sheave keeper Cable is now free at base of boom Push the two sheaves at the front tip of the 2nd stage boom forward and rem...

Page 97: ...l surface NOTE Use caution not to pinch or crush retract cables while lifting or supporting 4th stage boom 42 If necessary tag and remove wear pads and shims from the base of the 4th stage boom 43 Remove the 5 4 3 retract 2 3 4 extend pin 78 from the bottom base of the 4th stage boom Remove the 5 4 3 retract cables 77 from the anchor plates at the bottom base of the 5th stage boom and store in an ...

Page 98: ... b Install small spacer 122 c Install sheaves 120 121 near the sheave case side plates with the grease fitting 95 facing the side plate to allow for greasing d Install small spacer 122 e Install center sheave s 120 121 with grease fitting 95 facing either side f Install top sheaves 120 121 to the left hand side of the boom with the spacer 123 to the right hand side g Install keeper plates 125 to b...

Page 99: ...Install related hardware 146 21 56 to secure from the top front of the 4th stage boom NOTE Shim according to calibration instructions in this section or as pads were originally removed and tagged d Push the 5th stage boom completely into the 4th stage boom while keeping 3 4 5 extend cables 96 taunt e Scribe a mark in the tip of the 5th stage boom in front of side wear pads on the 4th stage boom fo...

Page 100: ...l top wear pad 52 with shims 138 and cable guide 76 with 75 wear pad and related hardware 146 21 56 on the top front of 3rd stage boom 3 Shim according to calibration instructions in this section 10 Push 4th 5th stage booms completely into 3rd stage boom and scribe a mark in the tip of the 4th stage boom in front of the side wear pad on the 3rd stage for retract sequencing Keep 3 4 5 extend cables...

Page 101: ...es toward tip of boom 3 Install 4 3 2 retract cable keeper 82 into anchor plates at the base of the fourth stage boom 22 Assemble and install the 4 3 2 retract 1 2 3 extend pin assembly into anchor plate at the bottom base of the 3rd stage boom 3 a Install one retainer 37 and one washer 36 inside of each sheave b Install bushing 35 into double groove sheave 34 and brush with chassis grease and ins...

Page 102: ...oss cables NOTE Do not twist cables Twisting of cables will result in damage or failure of cable When initially assembling threaded ends of cables thread the first nut on past the flat so adjustment can be made later 11 Install lower side wear pads 15 shims 13 14 with capscrew 26 on front inside of 2nd stage boom 12 Install upper wear pad assembly 180 179 178 with capscrew 176 washer 177 at upper ...

Page 103: ...d contact surfaces 27 Install two top wear pad mounting plates 152 wear pads 173 with capscrew 198 washer 196 onto the base of the 2nd stage boom 2 NOTE Apply multipurpose grease MPG to all wear pads and contact surfaces 28 Install adjustment cam plate 200 capscrews 199 and flatwashers 196 2nd and 1st Section Boom 29 Install one bottom wear pad 167 and shims 141 140 with capscrew 167 onto the base...

Page 104: ...nd tighten clamping hardware 42 Attach 1st stage cylinder rod to 1st stage hoist mount with washer 8 and shoulder bolt 11 that has been torqued and Loctite applied 43 It is important in this step to have the nuts loose on the 3 2 1 retract cables 19 at the bottom tip of the 1st stage boom Install the 1 2 3 sync extend cables 10 into the holes at the base of the 1st stage boom install washer 8 and ...

Page 105: ...8 179 180 15 14 13 17 10 46 168 12 151 27 186 26 64 167 141 140 41 42 37 36 148 36 37 155 8 11 154 149 6 31 170 87 27 39 30 53 95 38 74 152 198 173 200 196 16 136 56 21 23 204 177 25 24 61 1 18 22 28 111 70 130 176 159 56 157 158 178 179 180 185 19 150 151 27 12 168 184 203 202 201 203 49 20 160 169 9 8 10 6 73 161 162 133 56 76 62 63 53 29 27 8176 1 8176 2 35 199 196 155 8 11 R e f e r e n c e O ...

Page 106: ...1 146 176 177 3 59 178 179 52 138 180 77 107 32 151 12 168 187 15 14 13 186 172 152 73 188 191 200 196 198 193 192 198 196 191 144 145 51 65 74 72 27 48 86 10 71 50 49 96 41 42 142 143 69 37 53 36 34 35 36 37 64 6 11 8 183 7 6 118 32 153 114 119 29 116 32 101 112 165 113 153 113 166 115 118 116 118 109 29 19 8176 3 8176 4 R e f e r e n c e O n l y ...

Page 107: ...7 109 21 163 128 121 120 121 122 95 121 122 164 125 21 109 60 127 122 120 121 122 126 125 95 21 109 41 134 135 110 103 5 181 77 106 97 98 100 89 90 91 99 94 93 92 101 27 146 21 56 105 104 59 139 102 96 40 95 27 97 189 108 41 42 67 68 69 132 78 131 79 80 64 132 88 133 56 82 81 83 152 84 85 29 73 77 4 200 196 197 195 194 173 196 197 8176 5 8176 6 95 95 53 188 R e f e r e n c e O n l y ...

Page 108: ...6 18uncx0 75 33 Wear Pad 34 Sheave 35 Bearing 36 Flatwasher 2 00x3 0x0 7 37 Retaining Ring 2 00 38 Pin 39 Wear Pad 40 Socket Flat Head Capscrew M10x12 10 9 41 Shim 42 Wear Pad 43 Grease Fitting 44 Sheave Anchor Assembly 45 Bearing 46 Sheave 47 Pin 48 Hex Head Capscrew 1 2 13uncx2 00 G5 49 Lock Washer 1 2 50 Keeper 51 Cable Anchor Assembly 52 Plate 53 R4 Cable Assembly 54 Cable Guide 55 Hex Head Ca...

Page 109: ...eper 126 Sheave Pin 127 Hitch Pin 0 75x7 128 Link 130 Cable Block Five Section Boom Item Description 131 Retaining Ring 1 5 132 Flatwasher 1 5x2 25x0 7 133 Hex Nut 3 8 16unc 134 Wear Pad 135 Shim 136 Shim 137 Shim 138 Shim 139 Shim 140 Shim 141 Wear Pad 142 Shim 143 Wear Pad 144 Bracket 145 Hex Head Capscrew 5 16 18uncx0 5 G5 146 Hex Head Capscrew 3 8 16uncx1 5 G5 148 Sheave 149 Roller 150 Plate A...

Page 110: ...ed by approximately 6 inches 6 Measure the retraction gaps between each boom section and scribed line and note values 7 Extend and retract the boom a few times and then repeat measuring the extension gaps 8 Adjust all corresponding cables according to following instructions Cable Tightening Sequence NOTE When adjusting cable hold the cable end and turn the nut Do not turn the cable Turning the cab...

Page 111: ... in step 4 and torque 1 2 3 extend cables as in step 5 Repeat until 2nd section bottoms out correctly b If 3rd section is bottoming out first equally loosen 3 2 1 retract cables and tighten 1 2 3 extend cables and retract the boom a few feet Torque 3 2 1 retract cables as in step 4 and torque 1 2 3 extend cables as in step 5 Repeat until 3rd section bottoms out correctly c If 4th section is bottom...

Page 112: ...e back of the first nut Hold the first adjustment nut stationary and a torque wrench to tighten the second torqued nut against the first adjustment nut to the values indicated in TORQUE VALUES for Second Nut Third positive lock nut installation is to be placed on each of the extend cables The retract cables do not require the third positive lock nut The third nut should be hand tightened until the...

Page 113: ...n in excess of 3 32 in deeper than the inside edge of the pad If any of these conditions are found the top and bottom pads may be replaced without disassembly of the boom Also if the boom extension operates erratically or during replacement of top and bottom pads it is recommended that Cable end Thread Size Minimum Nut Strength GRADE Nut Type TORQUE ft lbf 1 2 13 SAE 2 Hex Jam HALF 12 5 8 11 SAE 2...

Page 114: ...that base of the 4th stage boom passes the hole in the side plate of the 3rd stage boom and base of the 5th stage boom passes the hole in the side plate of the 4th stage boom Raise the 4th and 5th stage boom tips to relieve pressure on wear pads on the top base of the 4th and 5th stage booms 10 Remove countersunk capscrews from the bottom of the top plate on the base of the 4th stage boom that att...

Page 115: ...pper inner section to obtain a 0 00 0 06 clearance between these wear pads Wo and inside width Wi of outer section Stamp wear pad retainers with R right or L left and with 2 3 4 or 5 boom stage in position as shown Stamp top plate of boom sections with R or L corresponding to and in same general location as stamp on wear pad mounting plates as shown Inner Side Pads 1 With a pair of inside outside ...

Page 116: ...ord the smallest measurement If the section has cylinder anchor bars take a measurement directly in front of these bars 2 With the tape measure measure the outside height of the inner section Ho at bottom rear pad location Record the largest measurement 3 Measure the thickness of the top wear pads and record twp 4 Subtract the largest outside height Ho of the inner section and the thickness of the...

Page 117: ...supports and place drain pan under holding valve 2 Using hydraulic power porta power or crane circuit extend cylinder sections approximately 24 in If stages Hi Ho twp twp Clearance Bottom shims Final Clearance 19 38 17 88 0 75 0 50 0 25 0 19 0 06 Hi 19 38 AT FRONT 19 38 AT BACK NEAR CYLINDER ANCHOR BARS H0 17 88 FIGURE 4 22 1ST STAGE 2ND STAGE 3RD STAGE FIGURE 4 23 R e f e r e n c e O n l y ...

Page 118: ...counterbore is seated over shaft assembly properly Take care not to damage the O ring while installing piston Using the proper size spanner wrench tighten piston onto 1st stage cylinder shaft assembly to 600 lb ft 4 Install setscrew into piston using Loctite Type 243 according to Loctite recommendations and torque to 8 lb ft Loctite and install second set screw on top of first setscrew and torque ...

Page 119: ... side of the first boom section Figure 4 25 3 Extend the boom approximately one foot 4 Using an overhead hoist lift the jib assembly and align and pin the jib to the boom sheave head Figure 4 26 5 With jib pinned to the sheave head swing the jib parallel to the boom and secure to the jib stowage bracket Figure 4 27 6 Slowly retract the boom until the jib ears are within 0 50 in of the ear assembli...

Page 120: ... out securely in the ear assemblies Figure 4 31 If the stow pins are not aligned properly the hook assembly and front bars will have to be positioned as shown so the jib cannot slide forward or backward as the boom is elevated 10 Try to remove the jib pins If the pins are too tight the stow hook assembly or front bars will have to be adjusted 11 Torque all capscrews to their specified torque value...

Page 121: ...n The oil will run slowly because air must enter as oil drains out 4 Be careful to prevent dirt or foreign matter from entering the system 5 Replace with proper oil as described above Lubrication Add proper lubrication oil to all pivoting sections every three months Rust Prevention Check ram every three months for any sign of rust or corrosion Clean as needed and wipe with an oil saturated cloth N...

Page 122: ...BOOM MAINTENANCE NBT40 SERVICE MANUAL 4 48 Published 8 01 2017 Control 287 11 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 123: ...s both the main and auxiliary hoist hoist cover and hydraulic motor some NBT40 models are configured with only a main hoist and some models with both the main and auxiliary hoists The following removal installation disassembly assembly and adjustments procedures in this section applies to both the main and auxiliary hoist MAINTENANCE Inspect the hoist daily for oil leaks loose bolts and worn hoist...

Page 124: ...2 13 Figure 5 1 from the hoist 6 Remove the hoist 4 7 Figure 5 1 from the crane with the lifting device Hydraulic Hoses Inspect the hoist hydraulic hoses 17 18 23 Figure 5 1 for cracks or damage that may cause leaks Replace hoses as needed Hoist Installation The following removal procedure applies to both the main and auxiliary hoist 1 Attach a lifting device to the hoist 4 7 Figure 5 1 2 Lift the...

Page 125: ...nent Item Component 1 Cover 9 Elbow 2 Flatwasher 10 Union 3 HHCS 11 Washer 4 Main Hoist 12 Washer 5 Washer 8 places 13 Nut 6 HHCS 8 places 5 8 11UNC 14 Boom 7 Auxiliary Hoist 15 Washer 8 Cable 5 8 16 Union FIGURE 5 1 8 8 7 4 6 18 17 23 11 5 14 6 20 13 12 2 3 24 1 19 22 21 15 16 15 10 9 5 16 7582 R e f e r e n c e O n l y ...

Page 126: ...el Figure 5 3 To replace the display remove the overhead panel Disconnect the electrical connector and pry the display off of the panel Clean the panel where the display was affixed with isopropyl alcohol remove the paper from the adhesive back of the new display and stick it into the panel Connect the wires to the display Replace the panel and secure with the hardware HRI Control Module The contr...

Page 127: ...of the hoist and transmits a rotation signal to a solenoid thumb thumper located in the hoist control lever on the operator s seat The DRI transducer and integral Minimum Wrap Indicator MWI is programmed to notify the operator when there are three wraps of wire rope or 8 wraps of synthetic hoist rope left on the hoist drum Removal 1 Loosen the collar on the connector and unplug the DRI cable 1 Fig...

Page 128: ... down 6 Tighten the set screw 1 Figure 5 8 after the DRI is positioned as desired 7 Plug in the DRI cable and tighten the collar to secure the connector Programming the Minimum Wrap Indicator The minimum wrap indicator MWI needs to be programmed to alert the operator when the cable is down to the third wrap of wire rope or eight wraps of synthetic hoist rope To program the MWI you need to 1 Run th...

Page 129: ...EM to set the set points on the cable before shipping to a job site This prevents the need to recalibrate the set points when the winch is installed on the machine NOTE The drum rotation indication commonly a thumper handle remains operational while the HMS is in shipping mode To use Shipping Mode 1 Install the wire rope on the drum Refer to the appropriate winch manual for more information 2 See ...

Page 130: ...l integrity and the gear teeth for excessive wear then replace if necessary 3 Attach the output shaft Item 32 to the side plate Item 29 with six capscrews Item 9 making sure the vent Item 30 is oriented properly then torque them to specification see Torque Specifications Chart on page 15 of this manual 4 Install the retaining ring Item 3 onto the shaft Item 32 5 Attach the spacer Item 60 base Item...

Page 131: ...this manual 16 Install a new o ring Item 7 5 on the face of the motor and re install the motor counterbalance valve assembly Install four capscrews Item 9 and torque them to specification see Fasteners And Torque Values on page 1 7 of this manual 17 Reconnect the tubing Item 22 to the brake housing Item 21 18 Fill both the gearbox and the brake section with the proper amount and type of lubricants...

Page 132: ...rew 9 14 Capscrew 50 4 Flange 10 1 Brake Piston 51 1 Pind 11 4 Capscrew 52 5 Retaining Ring 12 1 Tubing 54 1 DRI MWI Minimum Wrap Indicator 13 1 Brake Driver 56 1 Base 14 2 Race 57 1 Capscrew 15 2 Retaining Ring 58 4 Nut 16 1 Output Sun Gear 63 4 Screw 17 2 Bushing 64 2 Cordset 18 7 Friction Disk 65 1 Cable packer 19 8 Stator Plate 65 1 2 Bearing 20 1 Brake Cover 65 2 2 Arm 21 1 Brake Housing 65 3...

Page 133: ...5 10 National Crane Published 8 01 2017 Control 287 11 5 11 NBT40 SERVICE MANUAL HOIST FIGURE 5 10 R e f e r e n c e O n l y ...

Page 134: ...oper direction in order for the hoist to function properly Inspect the surface on the input and brake drivers Items 13 38 where the clutch Item 34 runs If there is any pitting or spalling on the drivers then both it and the clutch must be replaced 10 Re assemble the driver clutch assembly making sure that the clutch is installed properly 11 Install a new seal Item 7 7 into the brake housing If the...

Page 135: ...hey are not cut or flattened 4 Motors and cartridge valves are not serviceable in the field Return them to an authorized distributor for service CAUTION If the pins are not lined up properly the thrust washers can be shattered during the pressing operation FIGURE 5 12 2 3 1 Metering Hole 7148 TROUBLESHOOTING Problem Cause Solution Hoist does not hold load Excessive back pressure in the system Chec...

Page 136: ...HOIST NBT40 SERVICE MANUAL 5 14 Published 8 01 2017 Control 287 11 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 137: ...sition and the turret swings freely after the SWING control lever is released and coasts to a stop NOTE When equipped with a radio remote control the swing brake is automatically applied whenever the swing control lever is in the neutral position The swing system consists of a hydraulic remote controller directional control valve swing drive gearbox swing motor swing brake and swing brake pedal Th...

Page 138: ...he brake When the SWING BRAKE selector switch is positioned to OFF the regulated pressure is directed from the pressure reducing sequence valve to the brake release port overcoming the brake spring pressure and releasing the swing brake Swing Gear Box Assembly Figure 6 1 Item List FIGURE 6 1 4 1 2 3 5 6 7 8 10 9 11 13 4 12 7582 1 14 15 Item Description Item Description 1 Motor 9 Fill 2 Adjustable ...

Page 139: ... Upper Bearing 8 Lock Washer 9 Locknut 10 Output Planetary Assembly 11 Thrust Washer 12 Output Sun Gear 13 Input Planetary Assembly 14 Input Sun Gear 15 Brake Assembly 16 Cap Screw 8 17 Drain Plugs 18 Plate 19 Retaining Washer 20 Output Planetary Pin 21 Washer 22 Needle Bearing 23 Spacer 24 Output Planet Gear 25 Input Planet Gear 26 Retaining Washer 27 Input Planetary Pin 28 Washer 29 Needle Beari...

Page 140: ...brake and a hydraulic motor bolted on the input end of the assembly is approximately 275 lbs 124 kg Tools Required Scribe or small punch Oil drain pan Eye bolts 1 4 Retaining ring pliers Gear puller Ratchet wrench 1 2 drive 9 16 socket 1 2 drive Socket for pinion nut Whittet Higgins P N BAS 14 Soft hammer brass or plastic Press Drift rod 1 4 to 3 8 diameter Torque wrench 1 2 drive approximately 10...

Page 141: ... a gear puller 2 Remove old seal 3 and discard Grease pack the lower bearing 4 with lithium grease or EP lube and install into the bearing race 5 in the gear housing 1 The old bearing 4 may be reused only if it was removed to replace the seal and was not the cause of the seal failure Use a press fixture or a hammer and a large flat ended bar or rod to press the new seal 3 into the gear housing 1 u...

Page 142: ... torque to 30 ft lb 40 N m 18 Put pipe sealant on one of the pipe plugs 17 and install the plug in the lower hole of the gear housing 1 19 Fill the gear housing 1 with 1 gallon 3 8 L of EP 80 90 gear grease 20 Put pipe sealant on the other pipe plug 17 and install the plug in the top hole in the gear housing 1 SWING BRAKE The brake is manufactured for two specific types of holding torque requireme...

Page 143: ...Item Component 1 O ring 3 Housing 4 Seal 5 Bearing 6 Backup Ring 7 O ring 8 O ring 9 Backup Ring 10 Brake Piston 11 Retaining Ring 12 Brake Driver 13 Retaining Ring 14 Stator Plates 15 Friction Discs 16 Backup Ring 17 O ring 18 O ring 19 Backup Ring 20 Park Brake Piston 21 Springs 22 O ring 23 Cover 24 Capscrews 8 Item Component R e f e r e n c e O n l y ...

Page 144: ...cate the o ring 22 with hydraulic oil and install on the brake cover 23 11 Carefully set the brake cover on top of the piston springs so they remain upright on the brake piston Start the eight capscrews 24 into the brake housing by hand Alternately tighten the capscrews one turn at a time until the cover is tight against the brake housing Torque the capscrew to 30 35 ft lb 41 47 N m SWING BEARING ...

Page 145: ...ications Torque the swing bearing bolts according to the procedures outlined in this section When using step wrenches calculated wrench settings are valid only when the following conditions are met 1 Torque wrenches must be those specified and forces must be applied at the handle grip The use of handle extensions will change applied torque to the bolt 2 All handles must be parallel to the step wre...

Page 146: ...287 11 FIGURE 6 5 17 16 15 14 13 12 11 10 18 20 21 22 23 24 25 26 27 19 35 34 33 32 31 30 29 28 36 8 9 10 11 12 14 15 13 23 22 21 20 19 17 16 18 24 25 26 27 28 30 31 29 7 7 6 5 4 3 2 1 1 2 6 5 4 3 8 9 32 33 34 35 36 7582 2 1 FIGURE 6 6 R e f e r e n c e O n l y ...

Page 147: ...n TSI 10 1 Place the boom over the front and set the outriggers 2 Put a dial indicator 2 Figure 6 8 opposite the boom on the T box frame 3 3 Place the dial on the top of the turret bearing plate 1 Figure 6 8 4 Power the boom down onto the boom rest 5 Set the dial indicator at zero 6 Raise the boom about 76mm 3 in above the boom rest 7 Record the deflection indicated on the dial 8 Repeat steps 4 th...

Page 148: ...table bolts between the marks 5 Slowly rotate the boom back to 20 off front position 6 Elevate the boom slightly and shut down the engine 7 Tag and disconnect the battery cables 8 Remove the boom and lift cylinder following the procedures outlined in Section 4 of this manual 9 Tag and disconnect all hydraulic lines from the swivel on the carrier side Cap or plug all lines and openings 10 Disconnec...

Page 149: ...ing plate Be careful not to damage the swivel assembly 5 Install all bolts and washers that are not covered by the swing motor Refer to Outer Race Torquing in Figure 6 5 NOTE If a new bearing is installed a new pinion gear 1 Figure 6 10 must also be used Align the high point maximum eccentricity 2 Figure 6 10 on the bearing with the high point on the new pinion gear 6 Install the swing drive pinio...

Page 150: ... indicates 0 6 0 1 8 Tighten the three screws 3 Figure 6 11 to secure the slew potentiometer to the mounting plate Install the electrical swivel cover 9 Disengage the swing brake and swing approximately 10 to the left counterclockwise Slowly swing back to over the front and set the swing brake NOTE If the turret swings past the house lock pin engaged position step 8 must be repeated 10 If the angl...

Page 151: ...ide movement between the swing lock 5 Figure 6 12 and the swing lock mounting blocks welded to the turret 3 Attach the cable 4 Figure 6 12 to the swing lock 5 with clevis pin 1 cotter pin 2 and washer 3 4 Adjust the cable 4 Figure 6 12 using the following instructions a Engage swing lock assembly with turret bearing ring so that maximum tooth engagement is achieved b View A Figure 6 12 shows a sid...

Page 152: ...SWING NBT40 SERVICE MANUAL 6 16 Published 8 01 2017 Control 287 11 FIGURE 6 12 1 14 2 4 15 3 5 7 8 6 9 11 10 12 A 15 13 7589 3 7589 1 7589 2 R e f e r e n c e O n l y ...

Page 153: ...be used in the fully retracted at the mid extended position or the fully extended position When the outrigger extension is activated it extends or retracts the outrigger beam and or stabilizer cylinders The outrigger beams can be extended to the mid extend position by rotating the lock pin into the lock position The spring loaded lock pin is injected into the hole when the beam reaches the mid ext...

Page 154: ...ished 8 01 2017 Control 287 11 Lock Pin FIGURE 7 1 1ST Section Beam 2ND Section Beam Extend Cylinder Anchor Bolts Top Cable Adjustment Outrigger Box Outrigger Float Bottom Cable Adjustment Stabilizer Hydraulic LInes R e f e r e n c e O n l y ...

Page 155: ...l on the Nose of the Extend Cylinder Cable Sheaves on the Nose of the Extend Cylinder Hydraulic Tubes to Stabilizer Cylinder Cable Sheaves on 2ND Section Hydraulic Hose Hydraulic Hoses Extend Retract Cables Trunnion Anchor Brackets Top Cable Adjustment Bottom Cable Adjustment Extend Cylinder R e f e r e n c e O n l y ...

Page 156: ... assembly 11 Lift the extend cylinder trunnion out of anchor pockets in the 1ST section beam Figure 7 2 12 Remove the snap rings from the shaft in the rear of the 1ST section beam Remove the shaft and sheaves from beam Route the cables back through the opening in the bottom plate of the 2ND section after sheave removal 13 Disconnect the internal hydraulic hoses from the anchor brackets at the rear...

Page 157: ... extend cylinder Install the cables and hoses and drape excess in area to avoid damage 12 Insert extend cylinder into 1ST 2ND outrigger assembly Use caution to avoid pinching the cables and hoses 13 Lift the cylinder up to allow cable anchor access and install the fittings in the anchor plate assembly Attach stabilizer cylinder hoses 14 Assemble the proportioning cable stop into cable anchor and i...

Page 158: ... cables 6 Check the outriggers for proper proportioning when extended and position retracted OUTRIGGER CALIBRATION Side Pads 1 With a pair of inside outside calipers measure the inside width of the outer section outrigger Wi Figure 7 7 at the front pad location and three ft back from the front of the section and record the smallest measurement NOTE Method of Calibration is the same for section the...

Page 159: ...n installing 1st 2nd outriggers into outrigger boxes subbase EXAMPLE Wi 8 75 Wo 7 81 twp 0 38 twp 0 38 Clearance 0 19 Left Side Shim 0 06 Right Side Shim 0 06 0 06 Wi 12 12 AT FRONT 12 06 AT BACK WO 10 94 AT TOP REAR PAD LOCATION WO 11 00 AT TOP FORWARD PAD LOCATION WO 10 94 AT BOTTOM REAR PAD LOCATION 1ST SECTION 2ND SECTION FIGURE 7 10 R e f e r e n c e O n l y ...

Page 160: ...nstalled See example 5 Install the inner outrigger section into the outer outrigger section Nominal front bottom pad and shim thickness 0 75 in which should allow the inner outrigger section to extend parallel with the outer outrigger section If adjustment is necessary raise the inner section outrigger up and adjust the lower front shims to level the outrigger section extension Shim the top front ...

Page 161: ...ometer remove string potentiometer Install 1 Fully retract outrigger 2 Using screws mount the string potentiometer to the outrigger box cover 3 Connect electrical connector to string potentiometer 4 Attach spring clip to attaching point on outrigger beam 5 Mount outrigger box cover on outrigger box 6 Calibrate string potentiometers refer to Calibrate page 7 9 Calibrate Calibrating the string poten...

Page 162: ...OUTRIGGERS NBT40 SERVICE MANUAL 7 10 Published 8 01 2017 Control 287 11 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 163: ...ate 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 properly Improperly disposing of waste can threaten...

Page 164: ...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 oxidation and helps prevent wear Hydraulic Oil Oil in a hydraulic sy...

Page 165: ... be inspected to assure that it is not restricting air flow into and out of the reservoir To inspect the hydraulic oil fill a small glass container with a sample of the reservoir oil and another glass container with fresh 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...

Page 166: ...tifreeze Coolant for Cab Heater 6829101130 6829104212 EP MPG Extreme Pressure Multipurpose Grease 6829003477 6829104275 GL 5 GL 5 Gear Lubricant 6829012964 6829014058 HYDO Hydraulic Oil 6829006444 6829006993 EP OGL Open Gear Lubricant CEPLATTYN 300 Spray NLGI Grade 1 2 6829102971 6829102971 AGMA EP 4 Extreme Pressure Gear Lubricant 6829100213 6829103636 WRL Wire Rope Lubricant 6829015236 682901099...

Page 167: ...rvoir Hydraulic Oil Check fill change Weekly As Required Semi Annually 2 Oil filter Hydraulic oil reservoir Change or clean After first 40 Hrs As indicated by gauge thereafter 3 Magnetic Plug Hydraulic oil reservoir Clean At oil filter service interval 4 Breather Hydraulic oil reservoir Clean Monthly 5 Sheave pins boom nose 5 plcs jib 1 pl hook block 1 pl Aux Boom Nose 1 pl EP MPG Grease gun Weekl...

Page 168: ... Special Multi Lube light Grease Gun Weekly 17b Extend Sheaves 4th Section 127 ft and 142 ft booms each side Chassis Grease 200S Silver Streak Special Multi Lube light Grease Gun Weekly 18 Retract Sheaves extend boom until retract sheave zerks are visible through access holes at center of boom Chassis Grease 200S Silver Streak Special Multi Lube light Grease Gun Weekly 19 Wire Rope Jib Extension C...

Page 169: ...boom to 75 6 Extend and retract the boom several times until the grease is evenly spread 7 Repeat as necessary Outrigger Beam Lubrication Recommended lubricant is EP 3MG grease 1 Fully extend and set the outriggers Refer to Figure 8 2 2 Apply grease to all wear pads and contact surfaces at the side and bottom of all beam sections and lower surface of the stabilizer jacks with a suitable brush or p...

Page 170: ...ll level plug 1 Fill Hoist Gearbox with Oil To fill with oil rotate the drum so the gearbox fill level port 1 Figure 8 4 is visible through the upper hole Remove fill level plug 1 with a hex socket Install a 1 pipe with elbow into the fill hole 1 to assist with adding oil Remove the vent plug 3 to assist with adding the oil Fill gear box with 3 3 l 3 50 qt of oil or until oil is at the bottom leve...

Page 171: ...8 National Crane Published 8 01 2017 Control 287 11 8 9 NBT40 SERVICE MANUAL LUBRICATION FIGURE 8 4 8640 1 2 3 1 R e f e r e n c e O n l y ...

Page 172: ...e oil level is even with the upper mark If the oil level is high drain oil until the oil level is even with the upper mark AIR CONDITIONING When servicing air conditioner evacuate system prior to disconnecting any components connected to the pressurized lines Follow the specifications listed on section titled Air Conditioner page 9 32 After servicing ensure air conditioning system is re charged wi...

Page 173: ...iff wire brush and solvent compressed air or live steam Lubricate the rope immediately after the rope is cleaned Techniques that can be used include 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...

Page 174: ...t common causes of corrosion include the following Road salts chemicals dirt and moisture trapped in the hard to reach areas Chipping or wear of paint cased by minor incidents or moving components Damage caused by personal abuse such as using the decks to transport rigging gear tools or cribbing and Exposure to harsh environmental hazards such as alkaline acids or other chemicals that can attack t...

Page 175: ...nd marks in areas of low visibility Consider touching up the spots with a brush technique to cover the bare metal This will retard the effects of corrosion and enable you to do the repair at a later time during a normal maintenance interval Spots should be touched up with quality paint Primers tend to be porous using a single coat of primer only will allow air and water to penetrate the repair ove...

Page 176: ...the frame Frame application areas are hose ends and fittings all unpainted fasteners and hardware all bare metal surfaces outrigger pads and back up alarm hardware Superstructure applications are hose end and fittings wire rope on hoist roller tensioning springs on hoists all unpainted fasteners and hardware valves slew ring fasteners and all bare metal surfaces Boom applications areas are pivot p...

Page 177: ...onal Crane Published 8 01 2017 Control 287 11 8 15 NBT40 SERVICE MANUAL LUBRICATION 7650 52 1 3 4 5 9 7 12 4 10 14 17 2 8 10 15 14 13 8 11 11 3 17 4 10 4 15 7 7650 53 6 16 FIGURE 8 8 R e f e r e n c e O n l y ...

Page 178: ...t painted O R Pins Clips 5 Valvebank Hose Connections inside turntable 6 Boom Extension Hardware Optional 7 Pivot Shaft 8 Boom Nose Pins Clips 9 Headache Ball Hook block 10 O R Pins Clips 11 Mirror Mounting Hardware 12 Powertrain Hardware 13 O R Hose Connections 14 Entire underside of unit 15 Turntable Bearing Fasteners 16 Wire Rope 17 Outrigger Beam Hardware Item Description R e f e r e n c e O n...

Page 179: ...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 dimensional restrictions such as overall length overhang etc The final manufacturer of the vehicle must certify that the axle ratings have ...

Page 180: ...fter frame AF section modulus S M and resistance to bending moment RBM so that reinforcing is not required The front hydraulic jack is used for a 360 working range around the truck The frame under the cab through the front suspension must have the minimum S M and RBM because reinforcing through the front suspension is often difficult because of engine radiator mounts and steering mechanics See Tru...

Page 181: ...3 NBT40 SERVICE MANUAL CRANE INSTALLATION Typical Serial Number Location 1 2 3 4 5 FIGURE 9 1 7 6 8 1 Sub Base 5 Turret 2 1st Section Boom 6 4th Section Boom 3 2nd Section Boom 7 5th Section Boom 4 3rd Section Boom 8 Lift Cylinder R e f e r e n c e O n l y ...

Page 182: ... and tag weight required for stability truck with tag axle raised 20 250 lb gross 9 450 lb front axle 10 800 rear axle Less Weight required if equipped with auxiliary hoist or additional swinging counterweight Additional options or heavier bare chassis weights will require additional axles or a GVWR in excess of 60 000 lb in some states special permits for overload are required Estimated Final Wei...

Page 183: ...nce with factory requirements and a test performed to determine actual stability and counterweight requirements since individual truck chassis vary NOTE If bare truck weights are not met counterweight will be required A summary of mounting and truck requirements are listed as follows Working area 360 Gross Axle Weight Rating GAWR front 20 000 lb Gross Axle Weight Rating GAWR rear 40 000 lb Gross V...

Page 184: ...ith subbase and an 85 percent stability factor The complete unit must be installed in accordance with factory requirements and a test performed to determine actual stability and counterweight requirements contact the factory for details Transmission neutral safety interlock switch is required Configuration With Extended T Box NBT40 127 and NBT45 127 Mounting configuration with pusher axle 58 000 l...

Page 185: ...gal fuel and two persons in cab Add 1820 lb for 31 55 ft jib 1105 lb for aux hoist with rooster sheave and 180 lb downhaul weight Figure 9 4 shows the 360 working area See Truck Frame Strength section for truck frame strength required for mounting crane Gross Vehicle Weight Rating GVWR is dependent on all components of the vehicle axles tires springs frame etc meeting manufacturers recommendations...

Page 186: ... lb rear axle Estimated Final Weight with the following machine configuration NBT40 60 250 lb and NBT 45 63 750 lb 142 ft Boom 400 lb 3 part block Steel Decks 100 gal fuel two persons in cab Add 785 lb for 26 ft jib 1105 lb for aux hoist with rooster sheave and 180 lb downhaul weight Less Weight required if equipped with auxiliary hoist or additional swinging counterweight Additional options or he...

Page 187: ...h subbase and an 85 percent stability factor Complete unit must be installed in accordance with factory requirements and a test performed to determine actual stability and counterweight requirements contact factory for details Transmission neutral safety interlock switch is required The speeds shown above are optimum operating speeds The engine must be operated at a speed such that the horsepower ...

Page 188: ...lowing machine configuration NBT45TM Wet 70 000 lb 103 ft Boom 400 lb 3 part block 100 gal fuel and two men in cab Add 1590 lb for 31 55 ft jib 1105 lb for aux hoist with rooster sheave and 180 lb downhaul weight Figure 9 6 shows the 360 working area that can be achieved with front stabilizer optional on Series NBT45TM 240 stable without SFO The front stabilizer is essential when extending the boo...

Page 189: ... axles or a GVWR in excess of 54 000 lb In some states special permits for overload are required Estimated Final Average Weight 51 880 lb Includes basic crane without jib 100 gallon fuel tank and two workers in cab Figure 9 4 shows the 360 working area that can be achieved with the front stabilizer standard on the NBT36 The front stabilizer is essential when extending the boom and lifting loads ov...

Page 190: ...mum speed for the NBT40 pump The speeds shown below are optimum operating speeds The engine must be operated at a speed such that the horsepower developed is adequate to run the pump under pressure and provide the required flow Select as slow as an engine speed as possible to reduce fuel usage while ensuring PTO ratio does not exceed engine torque capacity especially at low engine speeds Pump Rota...

Page 191: ...xes 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 suspension In these cases it is imperative that the truck frame is ...

Page 192: ...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 16 The frame can be strengthened by adding a fish plate of suitable thickness and depth equal to the frame The section modulus of the fish plate can be obtained from Table C and ...

Page 193: ...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 9 mm D in mm W in mm 2 5 64 3 76 3 5 89 4 102 8 203 8 4 138 9 5 156 10 7 175 11 9 195 in 3 cm 3 9 229 10 0 164 11 3 185 12 6 206 13 9 228 10 254 11 6 190 13 1 215 14 6 239 16 0 262 11 ...

Page 194: ...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 5 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 5 9 97 6 0 ...

Page 195: ...7 2 282 13 5 343 15 2 249 16 5 270 17 8 292 19 2 315 14 5 368 16 9 277 18 3 300 19 7 323 21 2 347 15 5 394 18 7 306 20 2 331 21 7 356 23 3 382 Thickness 5 16 in 7 9 mm D in mm W in mm 3 76 3 5 89 4 102 4 5 114 8 5 216 9 8 161 10 8 177 11 9 195 12 9 211 in 3 cm 3 9 5 241 11 5 188 12 6 206 13 8 226 15 0 246 10 5 267 13 3 218 14 5 238 15 8 259 17 1 280 11 5 292 15 1 247 16 5 271 18 0 295 19 4 318 12 ...

Page 196: ...te the pump no more than 42 inches 106 cm from the PTO Do not exceed a 15 angle on the drive line The drive line U joint yokes on both ends of the drive shaft must be parallel with each other The drive lines need be sized so they can safely carry the maximum pump horsepower requirements Drive lines are furnished by National Crane 5 Plan the location of the pump mounting bracket and drive line so t...

Page 197: ... rivets are used to secure truck frame cross members Place the reinforcing 1 Figure 9 11 on the truck frame 4 and clamp in place Mark the location of rivets 3 by striking the outside of the reinforcing 4 over the rivet area with a hammer so that the rivets make an impression on the inside of the reinforcing Mark the approximate location of the crane mounting anchors 5 on the reinforcing 1 so that ...

Page 198: ...the crossmember holes 2 Planned location of mounting plate Plug weld locations can be shifted to clear plate 3 Clearance holes for rivets on weld or on reinforcement Can be filet welded around to eliminate plug weld holes 4 1 25 4 diameter holes for plug welds NOTE All Figure 9 12 dimensions are inches 1 4 4 8 2 5 2 4 3 2 FIGURE 9 12 8 Typ 4 2 Min 2 Min FIGURE 9 13 R e f e r e n c e O n l y ...

Page 199: ...ow the existing truck frame 8 If reinforcing angle 1 Figure 9 14 is welded to truck frame cut out plug weld hole pattern as in Figure 9 12 Slide the reinforcing angle 1 Figure 9 14 up from the bottom butt it to existing forward reinforcing 4 and weld 9 rear suspension reinforcing to forward reinforcing Replace as much of the spring hanger 5 cut out areas as possible Use the drop off material from ...

Page 200: ...If the AF is too long cut off the excess and remove any crossmembers from back of truck frame If the AF is too short the frame needs to be lengthened Use channels fabricated from 100 000 psi yield material that are the same size as the truck frame Weld these channels to the ends of the existing truck frame channels Bevel the ends of the channels to get 100 weld joints with Grade 90 weld material F...

Page 201: ...e 3 to locate holes in the truck frame 6 6 Locate and weld the rear strap plate 5 Figure 9 16 and collar plate 8 to the T box frame 7 See detail C Figure 9 16 for locator dimensions and weld requirements Position rear strap plate 5 with the bend in the plate inward or outward depending on the width of the truck frame 7 Cut the cross bar 10 Figure 9 16 to fit inside the truck frame 6 be sure to inc...

Page 202: ...CRANE INSTALLATION NBT40 SERVICE MANUAL 9 24 Published 8 01 2017 Control 287 11 FIGURE 9 15 1 1 2 4 6 1 3 2 8 5 7 4 3 7609 A C B A B 7610 1 5 0 to12 0 4 x 8 50 20 0 to 32 0 R e f e r e n c e O n l y ...

Page 203: ... harness away from the drive line and exhaust system The accessory and ignition wires are tied into the back of the ignition switch in the truck cab If there are two ignition wires when tying into the truck ignition tie into both wires Be sure the wires are not pinched or cut 8 5 FIGURE 9 16 11 1 in 254 mm No Weld 0 38 in 380 mm 7 5 in 19 cm 10 7 6 11 7610 5 76010 6 C 9 4 5 8 O R e f e r e n c e O...

Page 204: ...k ground NOTE The type of throttle supplied with the truck determines if three leads or six leads 1 Figure 9 17 are required FIGURE 9 17 3 1 2 4 4 4 7608 5 Truck Interface Harness Item 1 Figure 9 17 Wire Truck Function 473 475 Throttle Leads 473 475 for three lead 477 479 Throttle Leads 473 479 for six lead 476 Throttle Remote Signal 901 Ignition Switch 52 Start Switch 112 Accessory Switch 1331 En...

Page 205: ...ust system 7 Position the pump so that hydraulic lines can be connected without sharp bends especially the large suction line from the reservoir 8 For drive line installation install the pump mount to the truck frame 9 Lubricate the splines on the pump shaft and drive coupling with heavy lithium grease 10 If using the configuration shown in Figure 9 18 be sure to position the case drain port 2 at ...

Page 206: ... Add oil to reservoir as required to keep air from reentering the system 3 Set the throttle according to engine RPM and PTO ratio to get the proper pump shaft speed 4 After all the cylinders have been run through six complete cycles stow the crane with the outriggers retracted The oil level should be visible at the full mark of the sight gage 5 The lift and stability test must now be performed The...

Page 207: ... R fully extended capacity at 79 ft 32 m boom length 60 ft 18 3 m radius 6 450 lb 2925 7 kg per capacity chart Stability Test Load with extension stowed 6450 lb x 1 176 7585 2 lb 2925 7 kg x 1 176 3440 6 kg 6 Over the side Assemble the first stability test load as described above near the crane Measure the load radius from the center of rotation directly to one side of the machine Extend the boom ...

Page 208: ...table for the proper crane counterweight combination The NBT36 model crane is not equipped with a counterweight Use only the counterweight plate combinations as shown in the following counterweight table and Figure 9 20 Each counterweight plate can be identified by the part number and weight steel stamped 1 Figure 9 19 into the side of the plate Counterweight Removal 1 Position the crane on a firm...

Page 209: ... lifting device attach straps to each bolt lift and place the counterweight inside the crane support weldment 4 With the lifting device still attached align the two counterweight and crane support weldment holes and install two bolts 1 Figure 9 20 lockwashers 2 nuts 3 Counterweight Table Model Plate Part Number Description Figure 9 20 Letter Call Out NBT36 N A N A N A NBT40 Standard 80018805 1000 ...

Page 210: ...18 gpm at 3100 200 00 psi Swing Park Brake Hydraulic released disc released at 175 psi 12 bar Reservoir Capacity 100 gal 351 3 L Reservoir Return Filter 5 micron Reservoir Suction Filter 25 micron Air Conditioner Air Conditioner Hydraulic System 3500 100 psi Minimum Evacuation Time 30 minutes Refrigerant Charge Levels 2 0 pounds Additional Pag Oil Required Above 6 ounces in Compressor 4 0 ounces H...

Page 211: ...0 SERVICE MANUAL CRANE INSTALLATION Line Speed no load at high engine idle speed Layer Low Speed m sec ft sec High Speed m sec ft sec 1 43 9 144 87 5 287 2 48 5 159 97 2 319 3 53 3 175 107 0 351 4 58 2 191 116 7 383 5 63 1 207 126 5 415 R e f e r e n c e O n l y ...

Page 212: ...ons 32 6 metric tons at 7 ft 2 13 m radius NBT40 40 tons 36 3 metric tons at 7 ft 2 13 m radius NBT45 45 tons 40 8 metric tons at 7 ft 2 13m radius NBT36 127 ft Boom 35 550 lbs 16 125 21 kg NBT40 127 ft Boom 37 300 lbs 16 919 kg NBT45 127 ft Boom 40 950 ibs 18 574 61 kg Boom Weight 103 ft Boom 12 425 lbs 5 636 kg 127 ft Boom 12 985 lbs 5 890 kg 142 ft Boom 14 338 lbs 6 504kg 161 ft Boom 17 526 lbs...

Page 213: ...9 National Crane Published 8 01 2017 Control 287 11 9 35 NBT40 SERVICE MANUAL CRANE INSTALLATION DIMENSIONAL DRAWING FIGURE 9 21 7488 5 7488 3 R e f e r e n c e O n l y ...

Page 214: ...CRANE INSTALLATION NBT40 SERVICE MANUAL 9 36 Published 8 01 2017 Control 287 11 7488 4 7488 6 R e f e r e n c e O n l y ...

Page 215: ...nal Crane 10 1 NBT40 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 R e f e r e n c e O n l y ...

Page 216: ...SCHEMATICS NBT40 SERVICE MANUAL 10 2 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 217: ...equirements 9 1 Mounting Configurations 9 5 Mounting the Crane 9 22 Multi stage Extend Cylinder 4 39 Outrigger Beam Assembly 7 1 Outrigger Calibration 7 6 Outrigger manifolds 3 9 Outrigger Monitoring System OMS Optional Standard in North America 7 8 Parts Replacement 2 4 PTO Requirements 9 11 RCL Calibration 9 27 RCL system description 3 2 Reinforcing after Frame Extension 9 18 Relief Valve Pressu...

Page 218: ...NBT40 SERVICE MANUAL APL 2 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 219: ...R e f e r e n c e O n l y ...

Page 220: ...R e f e r e n c e O n l y ...

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