Manitowoc NBT60XL Operator'S Manual Download Page 8

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TABLE OF CONTENTS

OPERATOR MANUAL NBT60XL

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Crane Remote Control (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Activating the Crane Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Camera System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Wind Speed Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set-Up

Outrigger Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Proper Leveling of the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Bubble Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Site Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Setting the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2

Jib Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Erecting And Stowing The Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Jib Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Deployment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Stowing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Jib Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
Jib Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
Jib Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10

Setting the Offset on the Telescopic Jib  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10
Setting the Offset on the Lattice Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10
Setting the Offset Mast  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-13
Anti-Two-Block Weight Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-14

Multi-part Line Reeving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Using Multiple Part Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-14
Possible Multi-Part Line Reeving Combinations . . . . . . . . . . . . . . . . . . . . . . . . . .  4-14
Lifting the Rated Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-20

Installing Rope on the Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Terminator Wedge Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Wedge Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Removable Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Procedure and Charts

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Reference

Only

Summary of Contents for NBT60XL

Page 1: ...Operator Manual National Crane NBT60XL 9731 10255 F o r R e f e r e n c e O n l y ...

Page 2: ...more information go to www P65warnings ca gov diesel Batteries battery posts terminals and related accessories can expose you to chemicals including lead and lead compounds which are known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling For more information go to www P65warnings ca gov California Spark Arrestor Operation of this equ...

Page 3: ...urnish crane serial number when ordering parts or communicating service problems with your distributor or the factory 2020 Grove U S L L C An untrained operator subjects himself and others to death or serious injury Do not operate this crane unless You have been trained in the safe operation of this crane Manitowoc is not responsible for qualifying personnel You read understand and follow the safe...

Page 4: ...THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 5: ...Operations 2 18 Counterweight 2 19 Outrigger Lift Off 2 19 Multiple Equipment Lifts 2 19 Tilt Up Panel Lifting 2 20 Pile Driving and Extracting 2 20 Equipment 2 21 Equipment Inspection 2 21 Electrocution Hazard 2 21 Set Up and Operation 2 22 Electrocution Hazard Devices 2 23 Electrical Contact 2 23 Special Operating Conditions and Equipment 2 24 Grounding the Equipment 2 24 Personnel Handling 2 24...

Page 6: ...ake Off PTO 3 4 Park Brake 3 4 Engine Speed Governor 3 4 Neutral Start Safety Switch 3 4 Crane Cab Controls 3 4 Crane Cab Operator Seat 3 4 Crane Cab Left Armrest 3 4 Outrigger Controls 3 4 Cab Outrigger Control Panel 3 5 Ground Station Outrigger Control Panels 3 5 Cab Outrigger Control 3 7 Outrigger Selector Valve 3 8 Emergency Stop Switch 3 8 Crane Level Indicator 3 8 Ground Station Outrigger Co...

Page 7: ...r Seat Heater 3 17 Main Hoist Speed 3 17 Auxiliary Hoist Speed 3 17 Hoist Rotation Indicator HRI System 3 17 Cab Tilt Switch 3 17 Adjustable Swing Speed Valve 3 17 Heater 3 18 Heater Cold Weather Fuel Mixture 3 18 Heater Coolant 3 19 Hydraulic Suction Pump Shut off Valve 3 19 Operating Procedures 3 19 Equipment Familiarization 3 19 Crane Cab Access 3 19 Accessing the Boom and Hoists 3 22 Equipment...

Page 8: ... Multiple Part Lines 4 14 Possible Multi Part Line Reeving Combinations 4 14 Lifting the Rated Load 4 20 Installing Rope on the Hoist 4 20 Wedge Sockets 4 21 Terminator Wedge Installation 4 21 Wedge Socket Installation 4 21 Removable Counterweights 4 23 Using the Counterweight Control Panels 4 23 Mounting the Top Counterweight on the Superstructure 4 24 Stowing the Top Counterweight on the Carrier...

Page 9: ...s 6 3 Environmental Conditions 6 3 Dynamic Shock Loads 6 4 Precautions and Recommendations During Inspection 6 4 Inspection 6 4 Wire Rope Replacement 6 5 Care of Wire Rope 6 5 Replacement Rope 6 6 Crane Adjustments and Repairs 6 6 Boom Extension Cable 6 6 Jib Jack Service and Maintenance 6 6 Lubrication 6 6 Rust Prevention 6 6 Hydraulic System 6 6 Oil Cooler 6 6 Tire Load And Inflation Table 6 7 S...

Page 10: ...mit 7 15 Setting Radius Limit 7 15 Deleting All Limits 7 16 Tools 7 16 Accessing the Tools Menu 7 16 Setting Units of Measure 7 16 Setting up the Hydraulic Filter Reminder 7 17 Setting RCL Screen Brightness 7 17 About Adjusting Joystick Output 7 17 System Configuration 7 18 Accessing the System Configuration Menu 7 18 Entering the System Configuration Password 7 18 Setting System Date and Time 7 1...

Page 11: ... your satisfaction with our products and customer support Your local distributor is the best equipped and most knowledgeable to assist you for parts service and warranty issues They have the facilities parts factory trained personnel and the information to assist you in a timely manner We request that you first contact them for assistance If you feel you need factory assistance please ask the dist...

Page 12: ...INTRODUCTION OPERATOR MANUAL NBT60XL 1 2 Published 11 01 2020 Control 710 00 FIGURE 1 1 10256 F o r R e f e r e n c e O n l y ...

Page 13: ...utrigger Beam 11 Outrigger Box 12 Telescoping Jib 13 Lattice Jib 14 Turret Bearing 15 Hoist Rope 16 Ground Outrigger Control 17 Hydraulic Pump 18 Cab Outrigger Control Inside Cab 19 Cab Seat 20 Access Steps 21 Hydraulic Tank 22 Outrigger Stabilizer 23 Counterweights 24 Cab Joysticks 25 Maintenance Platform 26 Hook Block 27 Counterweight Mounting Lugs Item Component 24 2 12 1 22 FIGURE 1 2 3 17 7 6...

Page 14: ...e distributor must be immediately advised of the incident and consulted on necessary inspections and repairs Should the distributor not be immediately available contact should be made directly with Manitowoc Crane Care The crane must not be returned to service until it is thoroughly inspected for any evidence of damage All damaged parts must be repaired or replaced as authorized by your local Nati...

Page 15: ...Repairs 2 26 Lubrication 2 27 Tires 2 27 Hoist Rope 2 28 Synthetic Hoist Rope 2 28 Wire Rope 2 28 Sheaves 2 29 Batteries 2 30 Engine 2 30 Transporting the equipment 2 30 Travel Operation 2 30 Work Practices 2 31 Personal Considerations 2 31 Equipment Access 2 31 Job Preparation 2 32 Working 2 32 Lifting 2 33 Hand Signals 2 34 jib 2 34 Parking and Securing 2 36 Shut Down 2 36 Cold Weather Operation...

Page 16: ...ose around you ACCIDENTS Following any accident or damage to equipment the National Crane distributor must be immediately advised of the incident and consulted on necessary inspections and repairs Should the distributor not be immediately available contact should be made directly with Manitowoc Product Safety at the address below The equipment must not be returned to service until it is thoroughly...

Page 17: ...merican National Standard or in any other applicable federal state or local laws Make sure that all personnel working around the equipment are thoroughly familiar with safe operating practices You must be thoroughly familiar with the location and content of all decals on the equipment Decals provide important instructions and warnings and must be read prior to any operational or maintenance functi...

Page 18: ... Capacity Limiter is inoperative or malfunctioning the designated person responsible for supervising the lifting operations shall establish procedures for determining load weights and shall ascertain that the weight of the load does not exceed the equipment ratings at the radius where the load is to be handled When a Boom Angle or Radius Indicator is inoperative or malfunctioning the radius or boo...

Page 19: ...ards of two blocking is the most important factor in preventing this condition An Anti Two Block System is intended to assist the operator in preventing dangerous two block conditions It is not a replacement for operator awareness and competence Never interfere with the proper functioning of operational aids or warning devices Working Area Limiter If Equipped This equipment may be equipped with a ...

Page 20: ... planning and operation Actual loads including necessary allowances should be kept below the capacity shown on the applicable Load Chart Load Chart capacities are based on freely suspended loads You must use the appropriate Load Chart when determining the capability of the equipment in the configuration required to perform the lift Maximum lifting capacity is available at the shortest radius minim...

Page 21: ...s a and b above the lift may also be limited by the projected wind area of the load Ap and by the wind drag coefficient Cd This limit can be determined by comparing the Actual wind resistance area with the Allowable wind resistance area Refer to Figure 2 1 for a simplified calculation method to determine permissible wind speed Maximum Wind Speed Beaufort Number Description m s km h mph Visible Ind...

Page 22: ...culate Awr load Ap X Cd Determine Cd of Load Ap maximum height X maximum length See Figure 2 2 Lifting is not permitted Cease Lifting Operations V z 20 1 m s 45 mph 13 4 m s V z 20 1 m s 30 mph V z 45 mph Use Main Boom on Fully Extended Outriggers ONLY V z 13 4 m s 30 mph Main Boom Allowable load Published Rated Capacity Allowable Load Published Rated Capacity X Capacity Reduction Factor from Load...

Page 23: ...his condition Size and Shape of the load These rated capacities are also based on the assumption that the Wind Resistance Area of load Awr load is not more than 0 0012 square meters per kilogram 0 0059 sq ft per pound of load See below Formulas 2 4 and 2 5 The load capacities shall be reduced to account for the larger wind resistance area of load and 3 second wind gust speed at boom tip height Use...

Page 24: ...ind Drag Coefficient Cd values If the exact Wind Drag Coefficient of a shape is not known use the maximum value of the shape s range Table 2 2 If the wind drag coefficient of the load cannot be estimated or determined it shall be assumed that Cd 2 4 Ap 24 m2 Ap 8 m2 Wind Wind 8 m 1 m 3 m 8 m 1 m 3 m Ap 250 ft2 Ap 75 ft2 Wind Wind 25 ft 3 ft 10 ft 25 ft 3 ft 10 ft 8384 1 FIGURE 2 2 F o r R e f e r ...

Page 25: ... for the load using Table 2 3 Table 2 3 Awr Ratio and Permissible Wind Speed V z Imperial units 8384 2 Shape Cd 1 1 to 2 0 0 3 to 0 4 0 6 to 1 0 0 8 to 1 2 0 2 to 0 3 0 05 to 0 1 Approximately 1 6 Turbine Blade or Complete Rotor Note Permissible and rated wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph For Ra...

Page 26: ...2 12 Published 11 01 2020 Control 710 00 SAFETY PRECAUTIONS NBT60XL OPERATOR MANUAL Rated Load Chart Example Metric FIGURE 2 3 8383 1 F o r R e f e r e n c e O n l y ...

Page 27: ...his table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed m s For Rated Capacity at 13 4 m s 12 2 11 4 10 6 10 0 9 5 For Allowable Capacity at 20 1 m s 18 3 17 0 15 9 15 0 14 2 Table 2 4 Example Capacity Reduction Factors for Wind Speed V z Greater than 13 4 m s Metric Only for lifting with main boom on fully extended outriggers with or w...

Page 28: ...12 040 kg YES Is Awr load less than Awr allow 13 08 m2 14 45 m2 YES Conclusion This load is permissible to lift in wind speed up to 20 1 m s Load example 1 3a With large wind resistance area of the load Awr load Load to be lifted of 14 000 kg Projected Wind Area Ap 21 85 m2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap X Cd 21 85 x 1 2 26 22 m2 Refer...

Page 29: ...city Reduction Factors for Wind Speed V z Greater than 30 mph Non metric Only for lifting with main boom on fully extended outriggers with or without stowed extension For wind speed Vz 3 second gust speed at boom tip height is greater 30 mph 45 mph the Reduced Capacity shall be calculated by multiplying the Published Rated Capacity by the following factors Main Boom Length in Feet Wind Speed Vz 30...

Page 30: ...2 16 Published 11 01 2020 Control 710 00 SAFETY PRECAUTIONS NBT60XL OPERATOR MANUAL Rated Load Chart Example Non metric FIGURE 2 4 8382 1 F o r R e f e r e n c e O n l y ...

Page 31: ...Wind Drag Coefficient of the load Cd load to be lifted of 19 500 lb Projected Wind Area Ap 70 ft2 Wind Drag Coefficient Cd 1 5 then the wind resistance area of load can be estimated as Awr load Ap x Cd 70 x 1 5 105 ft2 Refer to the above Lifting Limits at wind speed V z 30 mph and 45 mph Comparing the load and wind resistant area to the allowable Is the load to be lifted less than allowable load 1...

Page 32: ...o lift at a reduced wind speed calculated as follows Ratio 1 37 From Table 2 7 the maximum permissible wind speed at ratio of 1 37 rounded to next higher table value of 1 4 is 38 0 mph Lifting Operations Before lifting position the equipment on a firm surface properly extend and set the outriggers and level the equipment Depending on the nature of the supporting surface adequate cribbing may be re...

Page 33: ...ditional lifting instructions Always use enough parts of line to accommodate the load to be lifted Lifting with too few parts of line can result in failure of the hoist rope Counterweight On equipment that features removable counterweights make sure that the appropriate counterweight sections are properly installed for the lift being considered Do not add material to the counterweight to increase ...

Page 34: ...be inspected prior to and following the lifting operations for chaffing or scrubbing The total gross load shall not exceed 80 of the standard load chart The operator shall be responsible to control this as the RCL does not have a feature to set reduced lifting limits The auxiliary hoist line shall be considered part of the deducts to determine net allowable load The panel shall be lifted so that t...

Page 35: ...guides retainers shall be in place All jibs must be removed from the machine before pile driving or extraction begins All hoist hooks shall be equipped with a positive locking latch Equipment Inspection In addition to the equipment s frequent and periodic inspections dated daily records shall be maintained showing inspections were performed on the equipment during the time it was used for pile dri...

Page 36: ...y from the utility company or owner The rules in this Operator Manual must be followed at all times even if the electrical power lines or equipment have been de energized The safest way to avoid electrocution is to stay away from electrical power lines and electrical power sources It is not always necessary to contact a power line or power source to become electrocuted Electricity depending on mag...

Page 37: ...ards is limited by their physical size insulating characteristics and operating environment e g dust dirt moisture etc The insulating characteristics of these devices can be compromised if not kept clean free of contamination and undamaged Proximity sensing and warning devices are available in different types Some use boom nose localized sensors and others use full boom length sensors No warning m...

Page 38: ...l by sounding a warning signal when moving a load Do not allow the cover of the electromagnet power supply to be open during operation or at any time the electrical system is activated Shut down the equipment completely and open the magnet controls switch prior to connecting or disconnecting magnet leads Use only a non conductive device when positioning a load Lower the magnet to the stowing area ...

Page 39: ...0 for General Industry and 29CFR1926 1431 for Construction Use of National Crane equipment to handle personnel is acceptable provided The requirements of the applicable national state and local regulations and safety codes are met A determination has been made that use of the equipment to handle personnel is the least hazardous means to perform the work The equipment operator shall be qualified to...

Page 40: ...quipment with a Rated Capacity Limiter RCL and control lever lockout systems for all lifting operations Shut down the equipment while making repairs or adjustments Always perform a function check after repairs have been made to ensure proper operation Load tests should be performed when structural or lifting members are involved Follow all applicable safety precautions in this manual when performi...

Page 41: ...ted and lowered and the load placed on the ground Do not get under a raised boom unless the boom is blocked up safely Always block up the boom before doing any servicing that requires the boom to be raised Stop the engine and disconnect the battery Controls should be properly tagged Never operate the equipment if it is tagged out nor attempt to do so until it is restored to proper operating condit...

Page 42: ...contact with a live power line or has been used as a ground in an electric circuit e g welding may have wires that are fused or annealed and must be removed from service In standing ropes more than three 3 breaks in one rope lay in sections beyond the end connection or more than two 2 broken wires at an end connection Core deterioration usually observed as a rapid reduction in rope diameter is cau...

Page 43: ...rom a reel Apply back tension to the storage payoff reel of the new rope to ensure tight even spooling onto the hoist drum Operate the new rope first through several cycles at light load then through several cycles at intermediate load to allow the rope to adjust to operating conditions When using a wedge socket Always inspect socket wedge and pin for correct size and condition Do not use parts th...

Page 44: ...he equipment check the suitability of the proposed route with regard to the equipment height width length and weight Check load limits of bridges on the travel route and make sure that they are greater than the combined weight of the equipment and transporting vehicle When loading or unloading the equipment on a trailer or railroad car use a ramp capable of supporting the weight of the equipment M...

Page 45: ...and downshift to a low gear to permit compression braking by the engine and aid the application of the service brakes WORK PRACTICES Personal Considerations Always adjust the seat and lock it in position and fasten the seat belt securely before you start the engine Do not wear loose clothing or jewelry that can get caught on controls or moving parts Wear the protective clothing and personal safety...

Page 46: ...peration is in doubt operator shall stop the equipment functions in a controlled manner Lift operations shall resume only after safety concerns have been addressed or the continuation of equipment operations is directed by the lift supervisor Know the location and function of all equipment controls Make sure that all persons are away from the equipment and the Travel Select Lever is in the N Neutr...

Page 47: ... hoist is in motion Watch the path of the boom and load when swinging Avoid lowering or swinging the boom and load into ground personnel equipment or other objects Lift one load at a time Do not lift two or more separately rigged loads at one time even if the loads are within the equipment rated capacity Never leave the equipment with a load suspended Should it become necessary to leave the equipm...

Page 48: ...on is lost equipment movement must be stopped until communications are restored Keep your attention focused on the equipment s operation If for some reason you must look in another direction stop all equipment movement first Obey a signal to stop from anyone JIB To avoid death or serious injury follow the procedures in this manual during erection stowage and use of the jib Install and secure all p...

Page 49: ...NATIONAL CRANE Published 11 01 2020 Control 710 00 2 35 NBT60XL OPERATOR MANUAL SAFETY PRECAUTIONS 2 9580 FIGURE 2 6 F o r R e f e r e n c e O n l y ...

Page 50: ...r Check operating procedures in this manual for cold weather starting Don t touch metal surfaces that could freeze you to them Clean the equipment of all ice and snow Allow ample time for hydraulic oil to warm up In freezing weather park the equipment in an area where it cannot become frozen to the ground The drive line can be damaged when attempting to free frozen equipment If applicable to your ...

Page 51: ...situation will also occur in reverse If the equipment is set up in the morning with cool oil and the daytime ambient temperature heats the oil the cylinders will extend in similar proportions Table 2 8 and Table 2 9 have been prepared to assist you in determining the approximate amount of retraction extension that may be expected from a hydraulic cylinder as a result of change in the temperature o...

Page 52: ...view by the equipment owner Overload warnings do NOT indicate real time events Warnings could be sent 24 hours or more after the actual event Coeff 0 000774 1 C STROKE Temperature Change C m 5 10 15 20 25 30 35 40 45 50 55 1 5 6 12 17 23 29 35 41 46 52 58 64 3 12 23 35 46 58 70 81 93 104 116 128 4 5 17 35 52 70 87 104 122 139 157 174 192 6 23 46 70 93 116 139 163 186 209 232 255 7 5 29 58 87 116 1...

Page 53: ... 11 01 2020 Control 710 00 2 39 NBT60XL OPERATOR MANUAL SAFETY PRECAUTIONS 2 Boom Inspection 4 8 1 7 5 6 1 2 3 9 10 9 10 8836 1 8836 2 Illustration for reference only Your crane may be different F o r R e f e r e n c e O n l y ...

Page 54: ...ect all for damage 2 Collar Wear Pads Pad Retainers Inspect all for damage 3 Collar welds Inspect all for damage 4 Pinning Areas Inspect all for cracks 5 Telescopic Sections Inspect for bent or twisted sections Check the boom for straightness 6 Lift Cylinder Head Area Inspect for bends or cracked welds 7 Turret Base Section Inspect for cracked welds 8 Jib Section Inspect for bent or twisted sectio...

Page 55: ...01 2020 Control 710 00 2 41 NBT60XL OPERATOR MANUAL SAFETY PRECAUTIONS 2 Superstructure Inspection 7 6 9 10 8836 1 2 1 3 8 10 11 5 4 10 11 Illustration for reference only Your crane may be different F o r R e f e r e n c e O n l y ...

Page 56: ... Lift Cylinder Inspect for leaks 2 Wire Rope Inspect all for damage See topic in Introduction section of Service Manual 3 Turntable Bearing Check bolts for proper torque See topic in Swing section of Service Manual 4 Hoist Drums Inspect each for damage 5 Hoist Brakes Brakes must hold rated line pull 6 Bearing Main Boom Pivot Pin Inspect for deformation cracked welds 7 Lift Cylinder Lower Mount Ins...

Page 57: ...shed 11 01 2020 Control 710 00 2 43 NBT60XL OPERATOR MANUAL SAFETY PRECAUTIONS 2 Carrier Inspection 6 6 5 8836 1 2 1 5 4 3 4 2 1 5 Illustration for reference only Your crane may be different F o r R e f e r e n c e O n l y ...

Page 58: ...or leaks 2 Outrigger Pads Inspect for deformation and cracked welds Overload from 25 to 49 1 Stabilizer Cylinders Inspect for leaks 2 Outrigger Pads Inspect for deformation and cracked welds 3 Outrigger Beams Inspect for deformation and cracked welds 4 Outrigger Boxes Inspect for deformation and cracked welds 5 Welds Inspect for cracks 6 Paint Inspect for cracked paint which could indicate twisted...

Page 59: ...splay USB Port 3 14 Diagnostic Connector CCS RCL Module 3 14 Diagnostic Connector Display USB B Port 3 14 PC1 Interface Connector 3 14 Diagnostic Connector Crane USB B Port 3 15 Level Indicator 3 15 Engine Hi Low Switch 3 15 Crane Function Power Switch 3 15 Remote Power Switch Optional 3 15 Work Light Switch 3 15 Skylight Wiper Switch 3 15 Windshield Wiper Washer Switch 3 15 Air Conditioning Heate...

Page 60: ...y s to full capacity Slow charging is preferred to fast charging Fast charging saves time but risks overheating the battery s Slow charging at six 6 amps or less develops less heat inside the battery and breaks up the sulfate on the battery plates more efficiently to bring the battery up to full charge The use of a smart charger that automatically adjusts the charging amperage rate should be used ...

Page 61: ...ned ON The first switch to be turned to ignition is the controlling key switch Here is a summary of the main ignition states Ignition State 0 truck key off crane key off or interlocked Ignition State 1 truck key on Ignition State 2 Lower control active Used to run lower outrigger controls truck key off crane key on crane power off Ignition State 3 Crane control active truck key off crane key on cr...

Page 62: ...iable speed governor which overrides the engine speed governor If equipped two knobs in the cab select between crane operation and normal driving operation Neutral Start Safety Switch The truck must be equipped with a neutral start safety switch on transmission Check occasionally to ensure it is working correctly and repair if it is not CRANE CAB CONTROLS The following sections describe controls l...

Page 63: ...tains a level indicator and an emergency stop switch Outrigger beam functions can be controlled only from the side the ground station control panel is located Outrigger Selector Buttons There are four outrigger jack selector buttons located on each outrigger control panel Figure 3 1 and Figure 3 3 Pre selection of a button or a combination of buttons one or more beams or one or more jacks may be s...

Page 64: ...e may be different 11 9594 Item Description 1 Outrigger Midspan Selector Pin 2 Outrigger Beam Assy Long 3 Outrigger Beam Assy Short 4 Level Indicator 5 Outrigger Jack Cylinder 6 Ground Station Outrigger Controls 7 Outrigger Extend Retract Cylinder 8 Console Panel 9 Emergency Stop Switch 10 Cab Outrigger Controls Panel 11 Outrigger 75 Selector Pin NTC60XL Only Item Description F o r R e f e r e n c...

Page 65: ...am Selector Button The outrigger beam selector buttons Figure 3 2 and Figure 3 3 are used to operate the front or rear outrigger beams Both sides can be operated from the cab outrigger control panel NOTE The following details apply to both ground station control panels as indicated 10258 8232 5 FIGURE 3 2 3 6 2 4 7 1 1 1 2 2 1 5 2 Item Description 1 Outrigger Beam Selector Button 2 Outrigger Jack ...

Page 66: ...ith a visual indication for determining how level the crane is when operating the outriggers There are two additional level indicators located at each ground level control station NOTE To ensure a true reading always make sure the cab tilt is completely lowered Ground Station Outrigger Control Panel The following paragraphs describe the outrigger controls and indicators Figure 3 3 found on the gro...

Page 67: ...ncy stop switch only in the case of an emergency to shut down the engine do not use the emergency stop switch regularly as a means of turning off the machine FIGURE 3 3 9697 1 2 3 9 4 5 1 1 1 Item Description 1 Outrigger Beam Selector Button 2 Outrigger Jack Selector Button 3 Extend Button 4 Retract Button 5 Single Front Outrigger SFO Button if equipped 6 Enable Button 7 Module Power Indicator 8 C...

Page 68: ...anel Assembly 6 RCL Bypass Switch 7 Swing Brake Indicator 8 Minimum Indicator 9 Emergency Stop Switch 10 A C Heater Vent 11 Ignition Switch 12 Receptacle 12v 13 Display Diagnostic Connector 14 Crane Level Indicator 15 Truck Engine Hi Low Switch 16 Crane Function Power Switch 17 Remote Power Switch Optional 18 Work Light Switch 19 Skylight Wiper Switch 20 Windshield Wiper Switch 21 A C Heater Funct...

Page 69: ... Auxiliary Hoist Speed Switch HI OFF LOW 32 Swing Brake Control Switch 33 Horn Button 34 AC Heater Climate Control Unit 35 Single Axis Controller Boom Lift Lever 36 Single Axis Controller Main Hoist Lever 37 Single Axis Controller Boom Telescope Auxiliary Hoist Lever 38 Single Axis Controller Swing Control Lever 39 Seat only Slide Adjustment Lever 40 360 Swing Lock Pedal Optional 41 Cab Tilt Switc...

Page 70: ...eft joystick The operator can use this horn to provide a warning that the superstructure is rotating House Lock The house lock 42 Figure 3 4 is used to lock the superstructure from rotating when the boom is over the front or over the rear of the crane It consists of a push pull handle on the console and house lock control pin The house lock is useful for counterweight removal and assembly and shou...

Page 71: ...eing lifted and outrigger position The RCL continuously monitors these parameters and provides the operator with an updated readout of the crane status If a rated capacity condition is approached the RCL warns the operator with an alarm and locks out the crane functions RCL Override Switches There are two RCL Override Switches located in the crane cab The switch located on the front control panel ...

Page 72: ...engine and crane cab power The ignition switch has three positions OFF shuts down engine and cab power ON activates truck engine ignition and all cab power Start is truck engine start For more information about the ignition states see Crane Ignition and Control States page 3 3 12V Receptacle This 12 volt accessory outlet 12 Figure 3 4 is located on the lower part of the front control panel and is ...

Page 73: ... and truck ignition must all be OFF before the crane can be operated with a radio remote control The crane ignition switch must be in the ON position Work Light Switch The work light switch 18 Figure 3 4 is a two position rocker switch ON and OFF located on the right overhead console It turns the cab outside working lights on or off Skylight Wiper Switch The skylight wiper switch 19 Figure 3 4 is ...

Page 74: ...cy Pushing the lever forward will let out the hoist rope and pulling the lever back reels the rope in Moving the lever in a diagonal direction actuates the two functions simultaneously Dual Axis Controller Swing Tele Aux Hoist Optional The swing and telescope or auxiliary hoist swing tele or swing aux control lever 26 Figure 3 4 is located on the end of the left armrest The lever controls the swin...

Page 75: ...dicator HRI Display The HRI information appears on the operating screen of the RCL display The icon indicates the current hoist in operation and which direction the hoist is rotating For information about the HRI icons visible on the RCL display screen see Table 7 3 on page 7 4 Hoist Rotation Indicators HRI The Hoist Rotation Indicators for the auxiliary and main hoist are located on top of each h...

Page 76: ...under the cab seat Controls 25 26 27 Figure 3 4 for the heater are located on the overhead control panel in the crane cab Heater Cold Weather Fuel Mixture At temperatures below 20 F 7 C add a cold weather additive or mix kerosene with the diesel fuel at a 50 50 ratio Add the mixture to the heater diesel fuel tank 1 Figure 3 10 located on the outside of the cab FIGURE 3 8 9603 1 WARNING Explosion H...

Page 77: ...e is fully open To open the valve turn the handwheel 3 clockwise OPERATING PROCEDURES You need to be familiar with the safety precautions outlined in the section titled Safety Precautions page 2 1 before operating the crane Equipment Familiarization All members of the crew should become familiar with the location and operation of the controls the correct operating procedures the maximum lifting ca...

Page 78: ...3 with the ladder pin 1 Using the Movable Ladder to Access Decking Use the movable ladder 1 Figure 3 14 stowed on the right rear bumper to access different areas of the decking In the stowed position use the ladder to access to the rear of the crane and the hydraulic tank and hoist area of the superstructure The movable ladder 1 can also be used to access different locations on the decking from th...

Page 79: ...o the ladder pins 2 can be inserted in deck bushings 3 Insert the ladder pins 2 in the bushings in the deck Be sure the ladder pins are inserted securely in the bushings before using the ladder Stowing the Ladder on Rear Bumper for Transport To stow the ladder 1 in rear bumper stowage location for transport NOTE The ladder weighs approximately 11 kg 24 3 lbs 1 Lift and remove the ladder pins 2 Fig...

Page 80: ...aks or other conditions that requires immediate correction for safe operation The following checklist of items are suggested to ensure the crane is prepared for performing work operations Check For any unusual conditions such as pools of hydraulic fluid or lubricating oil under the chassis any outrigger which may have crept down or up and any signs of damage or improper maintenance The tires are i...

Page 81: ...rating the crane NOTE For temperatures below 9 C 15 F refer to arctic lubricants and conditions in the Operator and Service Manuals Before starting the crane ensure the appropriate lubricants are used to provide lubrication for the prevailing ambient temperatures in which the crane will operate in a list of lubricants and their temperature ranges can be found in the Lubrication section of your cra...

Page 82: ...ents and cylinders of the hydraulic system If there is any unusual sound coming from the crane s hydraulic pumps or motors stop the operation and engine immediately and contact a National Crane distributor From 10 C to 4 C 50 F to 40 F Crane operation with a load is allowed with medium engine RPM and medium function speed joystick position until the fluid reaches at least 10 C 50 F From 95 C to 10...

Page 83: ...automatic transmissions Otherwise Neutral common for manual and automated manual transmissions Set the truck park brake Wheel chocks may also be required Engage the power takeoff Turn the truck cab ignition switch to OFF Stowing and Parking When parking the crane it should be placed in the smallest most stable operational configuration that the job site practically allows by doing the following st...

Page 84: ...angle between the first section boom and the horizontal with the load The loaded boom angle combined with the boom length approximates the operating radius Working Area The area measured in a circular arc above the center line of rotation to the suspended load Freely Suspended Load The load hanging free with no direct external force applied except by the loadline Side Load Horizontal side force ap...

Page 85: ... area and set the outriggers See Outrigger Setup page 4 1 2 Program the RCL For more information see RCL Setup on page 7 8 Use the load chart to estimate the values 3 Position the boom nose over the load Do not try and drag the load with the boom or hoist 4 Perform the lift Use light variable movements of the controls when moving the load to avoid sudden stops 5 Retract and lower the boom after th...

Page 86: ...switch 9 Stow and secure the maintenance platform steps 10 Ensure the single front outrigger is fully retracted if equipped 11 Ensure the outrigger beams and jacks are fully retracted 12 Engage the mechanical travel lock at each outrigger beam 13 Remove the jack pads and place on the stowage brackets 14 Engage the mechanical travel lock at each outrigger beam 15 Turn off the ignition and all other...

Page 87: ...NBT60XL OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES 3 NATIONAL CRANE Published 11 01 2020 Control 710 00 3 29 FIGURE 3 18 F o r R e f e r e n c e O n l y ...

Page 88: ...CONTROLS AND OPERATING PROCEDURES OPERATOR MANUAL NBT60XL 3 30 Published 11 01 2020 Control 710 00 FIGURE 3 19 F o r R e f e r e n c e O n l y ...

Page 89: ...r SFO if equipped The standard Remote 1 Figure 3 20 and its stowage bracket are secured to the load chart binder bracket 2 Batteries If the standard remote control is not used for a long period it is recommended if using rechargeable batteries that they be charged before using the remote control When the standard Remote Control 1 is in the stowed position as shown in Figure 3 20 the remote control...

Page 90: ...To move the function more press and hold the button again When finished with the remote press the red STOP button This will only turn off the remote it will not shut off the machine If the remote is left turned on for more than 5 minutes the remote will shut itself off If any interference is present in the area and the remote does not function properly the radio s channel can be changed This is do...

Page 91: ...ns 7648 FIGURE 3 23 5 2 1 4 3 10 6 8 9 7 11 14 13 12 20 19 16 24 22 21 23 25 17 18 15 26 27 Item Description 1 Auxiliary Hoist Enable Disabled is Default 2 On Horn Button 3 Toggle Crane RCL Screen 4 Remote Frequency Change 5 Not Used 6 RPM Default is RPM 7 Turtle Mode Default is Normal 8 50 Default is 100 9 RCL Override 10 E Stop 11 Main Hoist High Speed 12 Auxiliary Hoist High Speed 13 Engine Sta...

Page 92: ...rily pressing the Frequency Change button 4 Once finished using the Crane Remote the Remote Power switch should be turned OFF and the crane cab ignition key should be turned to the OFF position The remote controller can be stored in the crane cab or the truck cab Use of rechargeable batteries or standard AA batteries is acceptable however the batteries can not be charged in the remote itself Activ...

Page 93: ...1 Actual Load Max Load Sample Screen Screen 2 Load Radius Screen 3 Boom Length Feedback Indicators Screen 4 Boom Angle Screen 5 Tip Height Screen 6 Reeving DANGER Be sure to turn off the remote by pressing the red stop button to de activate the controls in order to prevent crane from functioning if the controller switches are inadvertently depressed or bumped during storage Failure to comply with ...

Page 94: ...ONAL The cranes feature an optional wind speed indicator to measure wind speed at the end of the boom The wind speed indicator features a radio anemometer assembly and a wireless gateway router The anemometer 1 Figure 3 27 which captures wind speed data at the end of the boom or jib is battery powered and communicates wirelessly with the gateway router 2 located in the crane cab The gateway router...

Page 95: ...p 1 in the bushing 2 and keeper holes 4 Secure the pin 1 with the safety clip Changing the Anemometer Battery Use the following procedure to change the battery in the wireless anemometer For more information about acceptable battery types see Specifications on page 6 10 1 Lower the boom as necessary to access the anemometer 2 Remove the battery cover Figure 3 27 and old battery from the anemometer...

Page 96: ...ket 3 3 Install the anemometer mast 4 on the stowage bracket rod keeper 5 4 Install the bushing 2 over the mast 4 and rod keeper 5 Align the bushing and keeper holes so the safety pin can be installed 5 Install the safety clip in the bushing 2 and keeper holes 5 to secure the anemometer mast 4 Secure the pin 1 with the safety clip FIGURE 3 29 3 4 5 2 1 9699 9700 F o r R e f e r e n c e O n l y ...

Page 97: ...w to perform the following tasks Set the outriggers Erect the jib Stow the jib Remove the jib Use multi part reeving Install the hoist rope Install the anti two block weight Install a wedge socket Mount stow the removable counterweight OUTRIGGER SETUP Proper Leveling of the Crane ASME B30 5 specifies that if a crane is not level within 1 of grade the allowable capacities must be reduced It is esse...

Page 98: ...muddy Setting the Outriggers The outrigger setup procedure is as follows 1 Disengage the mechanical travel lock 1 Figure 4 1 that secures each outrigger beam in the fully retracted position during travel NOTE To ensure a true reading always make sure the cab tilt is completely lowered 2 Operate the ground station or cab outrigger control panel see Figure 3 1 3 Select the desired outrigger beam wit...

Page 99: ... necessary increase boom angle to maintain loaded radius When radius is between points listed on capacity chart the load shown at the next longer radius shall be used 5 Operate with jib by boom angle when main boom is not fully extended Do not exceed rated jib capacities at any reduced boom lengths When angle is between points listed on capacity chart the load shown at next lower boom angle shall ...

Page 100: ...ear personal protective equipment i e a hard hat eye protection gloves and metatarsal boots DANGER Boom angles are used to control speed at which jibs swing during erecting and stowage Improper boom angles will cause uncontrollable swing speeds of jib DANGER Before attempting to erect or stow the jib read and strictly adhere to all danger decals installed on the boom boom nose jib and stowage brac...

Page 101: ...This procedure will pull the jib out of the hook bracket 3 12 Using tag line swing jib into deployed position 13 Install upper left attachment pin 7 and spring clip A slight hammer strike may be necessary to install pins Always use proper eye protection during this step 14 Use the alignment jack 10 to align lower left side attachment pin 7 a Remove the jack handle 11 from the boom stowage bracket ...

Page 102: ...loadline in area to avoid possible damage from stow procedure 5 Disconnect A2B Rewire connector 12 Figure 4 3 at rear of the jib Re connect A2B RCL switch connector on boom tip Move weight chain assembly to boom tip see Figure 4 10 6 Lower the mast assembly 10 Figure 4 4 Secure with retaining clip and pin For more information see Setting the Offset Mast page 4 13 7 Attach tag line to sheave case e...

Page 103: ...tor Optional page 3 36 3 Perform steps 2 to 11 in the deployment procedure to position the jib at the boom tip For more information see Deployment Procedure page 4 5 NOTE When rigging the jib for the assist crane refer to the decal showing the jib balance point 4 Attach rigging to the jib and lift the jib with an assist crane With the assist crane supporting the jib remove the right side attachmen...

Page 104: ...wing Pin 6 Right Side Attachment Pins 7 Left Side Attachment Pins 8 Jib 9 Jib Retaining Pin 10 Alignment Jack 11 Jack Handle 12 A2B RCL Connector FIGURE 4 3 1 2 3 4 5 6 7 8 9 10 11 1 Stowed Position for pin when jib is erected 12 9628 9629 9630 9631 Retaining Pin Retaining Pin and Spring Clip 9626 9627 F o r R e f e r e n c e O n l y ...

Page 105: ...NATIONAL CRANE Published 11 01 2020 Control 710 00 4 9 NBT60XL OPERATOR MANUAL SET UP 4 FIGURE 4 4 1 6 11 10 9 8 2 3 4 7 14 12 13 5 17 16 15 18 9632 F o r R e f e r e n c e O n l y ...

Page 106: ...ng a Slowly lower the boom until the tip of the jib is on the ground and the offset pin 1 can be installed b Install the offset pin 1 and lock pin 2 c Deploy the offset mast in the extended up position See Setting the Offset Mast page 4 13 d Raise the boom and operate as desired Setting the Offset on the Lattice Jib The lattice boom can be set to the following positions 30 degree offset The offset...

Page 107: ...p position See Setting the Offset Mast page 4 13 6 Connect the RCL connector 7 Slowly elevate and telescope the boom at the same time until the offset shaft takes the full load of the jib Setting Offset from 0 to 15 1 If not done extend and set the outriggers See Setting the Outriggers on page 4 2 Swing the boom over rear of truck chassis CAUTION The mast assembly 10 Figure 4 4 must be positioned ...

Page 108: ... and lock pins 3 in the 0 offset position Secure with lock pin spring clips 5 Deploy the offset mast to the extended up position See Setting the Offset Mast page 4 13 6 Raise the boom and operate as needed Setting Offset from 15 to 0 1 If not done extend and set the outriggers See Setting the Outriggers on page 4 2 Swing the boom over rear of truck chassis 2 Slowly lower the boom until the tip of ...

Page 109: ...om the stowage bracket to secure the mast to the jib boom 7 Install the retaining clip 5 to secure pin to mast 8 Route hoist rope in groove in sheave wheel 7 and secure with retaining pin 6 CAUTION The mast assembly 1 Figure 4 9 must be positioned on top of the base section before attempting to use the jib at the 0 15 or 30 degree offset positions Failure to do so can cause damage to the mast and ...

Page 110: ...perating safety factor for the rope supplied with the machine Therefore any replacement rope must meet the rope specification in this manual Possible Multi Part Line Reeving Combinations The NBT60XL cranes support reevings of up to 11 line parts depending on the hook block and auxiliary sheave case used Possible components used for reeving include Anti Two Block For more information see Anti Two B...

Page 111: ...ng 1 Part Line Reeving 2 Part Line Reeving Overhaul Ball ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9639 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Connect to Overhaul Ball 9640 1 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9641 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheave Connect to boom nose 9642 F o r R e f e r e n c e O n l y ...

Page 112: ...bled View Reference Drawing 1 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9643 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheave Connect to Hook Block 9644 3 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9645 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheaves Connect to Boom Nose 9646 F o r R e f e r e n c e O n l y ...

Page 113: ...ts Assembled View Reference Drawing 3 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9647 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheaves Connect to Hook Block 9648 3 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9649 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheaves Connect to Boom Nose 9650 F o r R e f e r e n c e O n...

Page 114: ...bled View Reference Drawing 3 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9651 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheaves Connect to Hook Block 9652 5 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves 9653 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheaves Connect to Boom Nose 9654 F o r R e f e r e n c e O n l y ...

Page 115: ...5 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves Auxiliary Sheave Case 9655 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheaves Connect to Hook Block Sheave Case Aux 9656 5 Sheave Hook Block ATB Bottom Boom Nose Sheaves Top Boom Nose Sheaves Auxiliary Sheave Case 9657 Bottom Boom Nose Sheaves Top Boom Nose Sheaves Hook Block Sheaves Connect to Boom Nose Shve Cas...

Page 116: ...TE The end of the rope should be even with the bottom of the slot for the anchor wedge 4 Position the anchor wedge in the drum slot pull firmly on the free end 2 of the rope to secure the wedge NOTE If the wedge does not seat securely in the slot carefully tap 3 the top of the wedge with a mallet 5 Slowly rotate the drum ensuring the first layer of rope is evenly wound onto the drum 11 Part Line R...

Page 117: ...h center line of pin 3 Secure dead end section of rope 4 Tighten nuts on clip to recommended torque Figure 4 12 5 Do not attach dead end to live end or install wedge backwards 6 Use a mallet to seat Wedge and Rope as deep into socket as possible before applying first load Wedge Socket Installation 1 Inspect the wedge and socket Remove any rough edges and burrs 2 The end of the wire rope should be ...

Page 118: ...ope to the dead end or using a commercially available specialty wedge Typically it is recommended that the tail length of the dead end should be a minimum of 6 rope diameters but not less than 6 in 15 2 cm for standard 6 to 8 strand ropes and 20 rope diameters but not less than 6 in 15 2 cm for rotation resistant wire ropes When using method A place a wire rope clip around the dead end by clamping...

Page 119: ...re information about the optional cameras see Camera System Optional page 3 36 Using the Counterweight Control Panels Figure 4 16 shows the counterweight control panel A control panel is located on each side of the superstructure The FIGURE 4 14 Wedge Socket Specialty Clip Specialty Wedge DANGER Ensure that all mounting pins are properly installed and locked during and after operating the counterw...

Page 120: ...counterweight If this occurs rotate the cylinder rod using your hand or counterweight pin Raising the Counterweight Cylinders 1 Press and hold a Power Button 2 Press and hold the left and right Counterweight Removal Cylinder Raise Buttons 3 Release the left and right Counterweight Removal Cylinder Raise Buttons when the cylinders are at the fully raised position NOTE If the counterweight hits the ...

Page 121: ...nterweight cylinders For more information see Lowering the Counterweight Cylinders page 4 24 9 Attach the counterweight to cylinders using counterweight pins 6 Figure 4 18 10 Using the counterweight switch panel fully raise the counterweight cylinders For more information see Raising the Counterweight Cylinders page 4 24 NOTE The length of the left side superstructure attachment pin 5 is approxima...

Page 122: ...e lock Using the house lock will assist in aligning the counterweights For more information see House Lock page 3 12 The Counterweight Removal Slew Position Indicator yellow arrows 1 Figure 4 17 appears in the RCL display which indicates the rear of the superstructure is nearly directly above the counterweight stowage area on the carrier deck Ensure vertical alignment of counterweight to the count...

Page 123: ...unting the Top Counterweight on the Superstructure page 4 24 5 Set display in Operator s Console to the RCL Operating Mode Screen Figure 4 19 see Section 7 Rated Capacity Limiter 6 While watching the RCL display rotate superstructure so boom is over the rear of the crane and counterweights are over the counterweight stowage area Pull the House Lock handle on the console to engage the house lock Us...

Page 124: ... needed to level the counterweight and eliminate any relative motion between the upper and lower counterweight Tighten the jam nuts 9 to lock the counterweights into position 13 Repeat steps 4 to 12 as necessary for the remaining counterweight sections Stowing the Bottom Counterweight s 1 Position crane on a firm level surface 2 Fully extend and set the outriggers then level the crane see Setting ...

Page 125: ...ving the cab and performing a visual inspection If necessary retract the house lock and rotate the superstructure until alignment is achieved 6 Remove the superstructure pins 4 Figure 4 20 that secure the counterweight to superstructure NOTE It may be necessary to jog the cylinders up and down to remove the superstructure attachment pins 7 It may be necessary to jog the cylinders up and down to re...

Page 126: ...SET UP OPERATOR MANUAL NBT60XL 4 30 Published 11 01 2020 Control 710 00 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 127: ... 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 the environment Potentially...

Page 128: ...F and overheat temperature shutdown of 105 C 221 F 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 system serves as the power transmission medium system lubricant and coolant Selec...

Page 129: ...one or indicates a by pass condition the hydraulic oil must be sampled The hydraulic tank breather should also 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 comp...

Page 130: ...t 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 6829010993 EO 20W 20 Engine Oil Light non EP Oil Mil L 46152 6829005570 TES 295 TES295 Compliant Fluid 6829101690 NOTE Cold weather lubricants are not s...

Page 131: ...ND CHARTS 5 9669 13 5 5 18 15 7 10a 10b 14 8 19 6 11 12 14 1 3 2 4 21 9668 7449 1 13 Lubrication Points 19 22 25 23 24 26 27 26 27 9671 9670 26 27 Tilt Cab Illustrations for reference only Your crane may be different 4 places 9667 5 Telescoping Jib Lattice Jib FIGURE 5 1 F o r R e f e r e n c e O n l y ...

Page 132: ...s part of daily crane inspection check the gearbox for visible leaks Change After first 50 hours of operation every 500 hours thereafter For more information see Swing Gearbox Oil page 5 9 12 Swing gear teeth EP OGL Spray Can Monthly 13 Boom Inner Side and Bottom Wear Pads LTG See page 5 7 Monthly or as required 14 Outrigger beams bottom sides LTG Brush or roller spray can Monthly or as required 1...

Page 133: ... 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 putty knife 3 Extend and retract the outriggers several times until the grease is evenly spread 4 Repeat as necessary 22 Cab Heater Reservoir AFC Check and Fill Change Check and Fill Weekly Fill As Required Change Semi Annually 23 Hook Block Swivel Bearing ...

Page 134: ...hoist gearbox and brake holds a maximum of 5 44 liters 11 5 pints of oil Replace the Hoist Oil The hoist oil drain and fill plug is located on the drum The plug can be accessed through one of two access holes The bottom 6 o clock position access hole 3 Figure 5 3 is used when draining the oil The access hole on the side 3 o clock position is the used when filling the hoist with oil 4 When draining...

Page 135: ...lling the oil level should be approximately half way up in the sight glass 5 Using a 5 16 inch 8 mm Allen wrench install and tighten the drain and fill plug 4 Figure 5 4 Torque the drain and fill plug to 67 8 Nm 50 ft lb Swing Gearbox Oil The oil in the gearbox is recommended to be changed after first 50 hours of operation and every 500 hours thereafter 1 Remove the drain plug 1 Figure 5 5 and ven...

Page 136: ... typical ambient temperatures hydraulic oil is too thick to penetrate these cracks Normal machine operating temperatures will allow hydraulic oil to warm sufficiently to penetrate these cracks and if machines are operated daily protect the rods Machines that are stored transported or used in a corrosive environment high moisture rain snow or coastline conditions need to have the exposed rods prote...

Page 137: ...rial should be removed from the rope Clean with a stiff 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 a...

Page 138: ...conditions e g moisture held in mud where certain crane parts may become corroded even though other parts remain dry or in high humidity or when temperatures are just above the freezing point Cleaning Procedures To help protect against corrosion of National cranes Manitowoc Crane Care recommends washing the crane at least monthly to remove all foreign matter More frequent cleaning may be needed wh...

Page 139: ...nths Do not apply to recently primered and painted areas for at least 48 hours after paint is properly dried and cured For minor touch up areas a 24 hour period is needed for cure time before applying treatment NOTE Unit must be completely dry before applying treatment Do not allow product to puddle or build up on weather stripping rubber gaskets etc Unit should not have puddles or runs evident an...

Page 140: ...60XL 5 14 Published 11 01 2020 Control 710 00 7650 79 1 3 4 4 9 4 12 5 14 14 14 2 7 10 16 15 13 7 8 11 5 8 13 15 4 8 9 7650 80 6 3 FIGURE 5 8 17 16 12 8 6 8 8 8 Illustrations for reference only Your crane may be different F o r R e f e r e n c e O n l y ...

Page 141: ...ble 6 Wire Rope 7 Boom Nose Pins Clips 8 All Hardware Clips Pins Hose Connections not painted Outrigger Pins Clips 9 Downhaul Weight Hook block 10 Downhaul Weight Hook Block Tiedown 11 Mirror Mounting Hardware 12 Powertrain Hardware 13 Outrigger Hose Connections 14 Outrigger Pins Clips 15 Entire underside of unit 16 Turntable Bearing Fasteners 17 Outrigger Beam Hardware 18 Boom Extension Hardware ...

Page 142: ...LUBRICATION PROCEDURE AND CHARTS OPERATOR MANUAL NBT60XL 5 16 Published 11 01 2020 Control 710 00 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 143: ...s on performing maintenance on this crane Inspections The inspection intervals listed below are to be conducted on the unit to ensure safe and proper operation If replacing a missing fastener or tightening a loose fastener refer to the applicable torque chart in Section 1 of the Service Manual Should a deficiency be found a determination must be made as to whether the deficiency is a safety hazard...

Page 144: ...g 25 Hoist brake for proper operation at hoist capacity load 26 Control and drive mechanisms for excessive wear and or contamination from lubricants water or other foreign matter 27 All air hydraulic and working mechanisms before operating the PTO Perform maintenance per PTO manufacturer s specifications Weekly Inspections Check the following items 1 Battery water level 2 Tire pressure 3 Lubricati...

Page 145: ...ection of the extend and retract ropes sheaves and pins Stability Stability of unit throughout working area Check the stability procedure in Installation Section of the NBT60XL Service Manual annually or when any changes are made to crane or truck HOIST ROPE INSPECTION AND MAINTENANCE Hoist rope should be inspected frequently daily and periodically yearly in accordance with the following informati...

Page 146: ...ced Significant corrosion Broken or cut strands Number distribution and type of visible broken wires Core failure in rotation resistant ropes Prior electrical contact with a power line or other electric arc damage Significantly corroded cracked bent or worn end connections Only inspect the outer surface of a rope Never attempt to open the rope Pay particular attention to areas of the rope where we...

Page 147: ... broken wires in all strands in any one lay In rotation resistant ropes two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters Wear of one third the original diameter of outside individual wires Worn rope usually indicated by flat spots on the outer wires is unsafe for further use when less than two thirds the thickness of the out...

Page 148: ...urbine oil Avoid mixing types of oil Do not use brake fluid alcohol glycerin detergent motor oil or dirty oil Improper fluid can cause serious internal damage to the jack rendering it inoperative Adding Oil to the Jib Jack To add oil to the jib jack do the following 1 Set the jack in an upright level position 2 Lower the saddle and make sure the piston is fully depressed 3 Remove the oil filler pl...

Page 149: ... with other tire sizes or the same size tires rated differently Always check the tire sidewalls to verify the maximum capacity and inflation Inflation pressure and loading must not exceed the values shown on the wheel or rim Tire and Load Inflation Tables Letters in parenthesis denote the load range for which the bold face loads are a maximum International load index numbers are shown after the lo...

Page 150: ...s and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15 Drop Center Rims Tire and Rim Association Standard Radial Ply Metric Tires for Trucks Busses and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15 Drop Center Rims Tire and Rim Association Standard F o r R e f e r e n c e O n l y ...

Page 151: ...cks Busses and Trailers Used in Normal Highway Service Tires Used as Singles Mounted on 15 Drop Center Rims Tire and Rim Association Standard Radial Ply Tires for Trucks Busses and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15 Drop Center Rims Tire and Rim Association Standard F o r R e f e r e n c e O n l y ...

Page 152: ...released at 12 bar 175 psi Cab Air Conditioner 3 780 lpm at 259 9 bar 13 gpm at 3770 max psi Reservoir Capacity 598 1 l57 147 gal Reservoir Return Filter 5 micron Pump Suction Filter 250 micron Cab Tilt Cylinder Operating Pressure Maximum 137 9 bar 2000 psi Single Front Outrigger SFO if equipped Operating Pressure Maximum 206 84 bar 3000 psi Air Conditioner Air Conditioner Hydraulic System 3770 ps...

Page 153: ...d 10 3 sec Outrigger Jack Retract 10 3 sec Counterweights NBT60XL NTC60XL Weight 1 1 360 kg 3 000 lb Weight 2 1 360 kg 3 000 lb Weight 3 2268 kg 5000 lb Weight 4 2268 kg 5000 lb Weight Combined 7558 kg 16 000 lb For more information about counterweight combinations see Removable Counterweights on page 4 23 Anemometer Optional Measurement Range 0 to 241 4 kph 0 to 150 mph Radio Range clear line of ...

Page 154: ...View Camera 170 Horizontal General Specifications Capacity NBT60XL NTC60XL 54 4 metric tons 60 tons at 1 8 m 6 ft radius Overall Length 12 6 m 41 42 ft Overall Width 2 6 m 101 6 in Overall Height 3 95 m 155 5 in Boom Length 151 ft 5 section Retracted 11 3 m 37 ft Extended 46 0 m 151 ft Jib Length Telescoping 4 plate Construction Retracted 7 9 m 26 ft Extended 13 7 m 45 ft Jib Length Fixed Length L...

Page 155: ... Accessing the Operational Limits Screen 7 13 Setting the Slew Angle Limit 7 14 Setting the WADS Limit 7 14 Setting the Boom Angle Limit 7 15 Setting the Tip Height Limit 7 15 Setting Radius Limit 7 15 Deleting All Limits 7 16 Tools 7 16 Accessing the Tools Menu 7 16 Setting Units of Measure 7 16 Setting up the Hydraulic Filter Reminder 7 17 Setting RCL Screen Brightness 7 17 About Adjusting Joyst...

Page 156: ...load condition is sensed audible and visual warnings are generated and the crane function controls that worsen the overload condition boom down telescope out and hoist up main and auxiliary are disabled Components RCL display on the operator console RCL control module front console Length angle sensor with cable reel mounted on side of boom Lift cylinder pressure transducers integral to lift cylin...

Page 157: ...are used to set up operate calibrate and troubleshoot the Rated Capacity Limiter RCL system Table 7 1 shows the icons on the Main Menu screen 8717 2 1 FIGURE 7 2 Main Menu RCL Setup Tools Diagnostics Return to Operating Mode Screen Table 7 1 Main Menu Options Icon Description RCL Set Up Highlight and the press Select function key Figure 7 2 to configure the RCL system This screen includes configur...

Page 158: ...rtion of the screen is blank The warning cluster on the following sample screen shows all alert and limit symbols for illustration purposes only RCL Operating Mode Screen Sample Diagnostic Highlight and press the Select function key 3 Figure 7 2 to access the RCL diagnostic menu see page 7 20 This menu includes Machine Information and Warnings Crane Electrical Fault Monitoring Hour Meter Load Char...

Page 159: ...limits see Setting Radius Limit on page 7 15 Table 7 3 RCL Screen Symbols Continued Icon Description RCL WADS Limit The work area definition WADS limit is measured as a straight line from point A to point B anywhere in the work area This sets up a virtual wall that alerts the operator of a user set limit The WADS can be configured with three virtual walls For more information see Setting the WADS ...

Page 160: ...Pressing this button returns to the reeving configuration screen for number of parts of line selection LIMIT LIMIT Pressing enables the RCL Limits Menu screen and WADS options main menu TARE Pressing will enable disable TARE or zeros out the current load indicated on the screen to show the active weight of the load only TARE button icon flashes BLUE when active Reeved Parts Displays the number of ...

Page 161: ...crane with the RCL system overridden Use of the RCL system override to operate the crane in a non permissible range can result in death or injury to personnel and or damage to equipment and property Table 7 4 RCL and ATB Override Warnings Icon Description RCL Override Warning Red Indicates that the operator bypassed the RCL Use extreme caution when the RCL is bypassed ATB Override Warning Red Indi...

Page 162: ...rsonnel platform attached to the boom or the tip of the jib nose Select 1 no or 2 yes The Main Menu button here returns to the Main Menu If a personnel platform is selected and the machine is shut down the RCL restarts without having to complete the setup sequence This is to enable personnel platform with radio remote operation Step 2 Configuring the Boom If the crane is not configured with a jib ...

Page 163: ...etracted jib straight 0 midpoint offset 15 or full offset 30 Screen 4 2 Selected 2 on Screen 3 2 Select 1 or 2 is the extended jib straight 0 or offset 30 Step 3 Configuring the Counterweight s When the RCL system is configured at the factory it is determined if it is configured with the maximum counterweight configuration for the variant of crane Use screen 5 1 to adjust the RCL to reflect the cr...

Page 164: ...selection by using the up down arrow keys and selecting OK when complete If any of the Outrigger Length Monitoring Sensors are out of range or not functioning properly that beam will show at midspan position and will be colored in red Figure 7 7 To correct the sensor error recalibrate the outrigger sensor s and if needed replace the sensor s For more information about calibrating and replacing the...

Page 165: ...ded or 50 Extended When within Fully Extended 75 Extended NTC60XL only or 50 Extended range the appropriate left hand O R graphic changes from GRAY to BLUE Screen 6 3 If the user attempts to select OK before Fully Extended 75 NTC60XL only or 50 Extended condition is met the OK button is colored RED when depressed and the user can override the setup using the arrow keys If the user selects a setup ...

Page 166: ...orrect the configuration If the machine is shut down and restarted again within 2 hours the operator can select OK at Screen 9 Selecting OK automatically returns the RCL to the configuration used at shutdown Re configuration of the RCL is not required Screen 9 OPERATING MODE After the RCL is setup is complete the RCL Operating Mode screen is displayed The following RCL Operating Mode Sample has be...

Page 167: ...arily overrides the RCL system so long as the key is turned The key switch behind the operator s seat overrides the RCL system for as long as the key is in the ON Override position For more information see RCL Override Switches on page 3 13 OPERATIONAL LIMITS The operator sets operational limits to restrict crane operation to a defined area The operational limit icons are displayed in the warning ...

Page 168: ... form 3 virtual walls The points are taken from the rope fall length and highest point of the boom nose There needs to be at least two points for a virtual wall Points are stored as distance in feet RADIUS from the center of rotation and angle SLEW ANGLE from the center line of truck with the boom in the boom rest see Figure 7 8 1 Rotate the crane superstructure to the desired position the radius ...

Page 169: ...h no inputs Setting the Tip Height Limit Use the following procedure to set the limit for the maximum boom tip height The current boom tip height is always shown in the upper right hand corner RCL Limit 4 1 Move the crane boom to the desired boom tip height point it appears on the display screen 2 Select one of the following Select SET to store the current boom tip position as the MAX Select DEL t...

Page 170: ...Tools menu Select OK after making the selection MAIN Menu To access the Tools Menu Use the directional arrows to highlight the Tools icon Press the OK key The Tools Menu appears Tools Screen Setting Units of Measure The unit of measure can be changed for the measurements shown in Table 7 7 Yellow indicates the currently set value To change the unit of measure 1 Access the Tools menu 2 Use the arro...

Page 171: ...hutdown It is important to note that when a joystick setting is set to less than 100 full use of the crane joystick is still allowed but the maximum function speed is reduced according to the speed reduction Select function key 2 Tools on the MAIN Menu screen and the Tools menu appears Accessing the Joystick Output Setup Screen Select the Joystick Output Setup icon to display the Joystick Output S...

Page 172: ... Password A 5 digit password is required to access the system configuration screen After three failed attempts there is a three second timeout before the user can re enter the password After all numbers are entered the Select button turns green The up and down indicator in the time and password boxes correspond to button 4 OK to modify selection Use the Delete functional key to remove all entries ...

Page 173: ...ensors are located throughout the crane and are used to monitor the lifting parameters set by the crane operator When a sensor requires calibration its icon appears with a RED background in the RCL Table 7 12 shows the Sensor Calibration warning icons The sensors are calibrated at the factory before the crane is delivered but need to be calibrated in the following circumstances The sensor readings...

Page 174: ...12 Sensor Calibration Warnings Icon Description Slew Angle Indicates that the slew sensor needs to be calibrated Boom Angle Indicates that the boom angle sensor needs to be calibrated Boom Length Indicates that the boom length sensor needs to be calibrated Lift Cylinder Rod Pressure Transducer Indicates that the rod side transducer located on the lift cylinder needs to be calibrated Lift Cylinder ...

Page 175: ...generation first stage and all subsequent stages the general warning light is shown on the operating mode screen and the truck diesel particulate filter icon is highlighted YELLOW on the diagnostics screen Gray if not supported Module Fault Turns RED when any CANbus is missing including sensors and modules Engine Oil Pressure Warning If the truck engine oil pressure drops below 5 psi the general w...

Page 176: ...codes the button with the fault code icon and red X can be pressed Definitions of fault codes are available on the Manitowoc Diagnostics Code Mobile Application Enter the fault code in the application to retrieve the definition For more information see About the Manitowoc Diagnostic Code Mobile Application on page 7 23 The real time I O Diagnostics screens feature detailed information about the st...

Page 177: ... RCL Master Outputs RCL Display Inputs RCL Display Outputs Remotes Module Throttle Module Outputs To view real time I O diagnostics 1 Navigate to the Diagnostics Menu See Accessing the Diagnostics Menu on page 7 22 2 Press the I O function key The Real time Diagnostics screen appears 3 Use the directional button to scroll through the real time I O screens About the Manitowoc Diagnostic Code Mobile...

Page 178: ...The Diagnostic Code Application splash screen appears 3 Click NBT The NBT Boomtrucks screen appears 4 Complete the following using information from the error code displayed on the RCL Select Crane Type Select the NBT crane type from the dropdown list Device Enter the device number from the fault code Group Enter the group information from the fault code Component Enter the component information fr...

Page 179: ...lished 11 01 2020 Control 710 00 7 25 NBT60XL OPERATOR MANUAL RATED CAPACITY LIMITER 7 5 Click Continue The Fault code information is displayed 6 Click OK to return to the main screen 9616 F o r R e f e r e n c e O n l y ...

Page 180: ...RATED CAPACITY LIMITER OPERATOR MANUAL NBT60XL 7 26 Published 11 01 2020 Control 710 00 THIS PAGE BLANK F o r R e f e r e n c e O n l y ...

Page 181: ...ng Started 3 3 Heater 3 18 Hoist Rope Inspection And Maintenance 6 3 Hoist Rope 2 28 Hoist System Operation 3 25 Hydraulic System 6 6 Installing Rope on the Hoist 4 20 Jib Installation 4 7 Jib Maintenance 4 10 Jib Operation 4 5 Jib Removal 4 7 Jib Safety Information 4 3 jib 2 34 Lifting the Load 3 27 Load Chart 3 26 Lubrication Points 5 3 Maintenance 2 26 Model Specific Information 2 38 Multi part...

Page 182: ...erature Effects on Hook Blocks 2 36 Temperature Effects on Hydraulic Cylinders 2 36 Tire Load And Inflation Table 6 7 Tools 7 16 Transporting the equipment 2 30 Travel Operation 2 30 Truck Cab Controls 3 4 Wedge Sockets 4 21 Wind Forces 2 6 Wind Speed Indicator Optional 3 36 Wire Rope Lubrication 5 11 Work Practices 2 31 F o r R e f e r e n c e O n l y ...

Page 183: ...F o r R e f e r e n c e O n l y ...

Page 184: ...F o r R e f e r e n c e O n l y ...

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Manitowoc NBT60XL, Operator'S Manual

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