Manitowoc National Crane NBT30H-2 Service Manual
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Manitowoc National Crane NBT30H-2 Service Manual

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Summary of Contents for Manitowoc National Crane NBT30H-2

  • Page 1 National Crane NBT30H-2 Service Manual...
  • Page 3 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 4 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well- ventilated area. •...

  • Page 5: Table Of Contents

    NBT30H-2 TABLE OF CONTENTS SECTION 1 ..........Introduction General .
  • Page 6 NBT30H-2 Draining and Flushing ..........2-9 Removing Air from the Hydraulic System .
  • Page 7 NBT30H-2 Micro Relay/fuse block........... 3-6 Directional Control Valve Solenoids .
  • Page 8 NBT30H-2 SECTION 6 ..........Swing Description .
  • Page 9 NBT30H-2 Low Temperature Grease ..........8-2 Extreme Pressure Multipurpose Gear Lubricant (EPGL) .
  • Page 10 NBT30H-2 Front Outrigger Hydraulic Line Connections ......9-24 RSOD Hydraulic Line Connections ........9-25 CANBUS System Setup .

  • Page 11: Section 1

    (HCAS), or a safe load indicator (SLI); Before placing the crane into service, all operators and Manitowoc refers to these systems as a rated capacity limiter persons working around the crane must thoroughly read and (RCL) throughout its Operator and Service Manuals.) understand the contents of the Operator Manual.

  • Page 12: Service And Repair

    The boom should be fully retracted and lowered and the If you are the new owner of a Grove crane, please register it load placed on the ground. with Manitowoc Crane Care so we have the ability to contact • Stop the engine and disconnect the battery.
  • Page 13 NBT30H-2 SERVICE MANUAL INTRODUCTION 8596-2 8606-1 FIGURE 1-2 Item Component Item Component Control Console Extension RCL Display Turret Operators Station Single Front Outrigger-(SFO) Rated Capacity Limiter (RCL) Reel Hydraulic Tank Boom Hydraulic Pump Boom Nose Radio Remote Receiver Boom Rest Truck Frame Lift Cylinder Truck Bed...

  • Page 14: General Maintenance

    INTRODUCTION NBT30H-2 SERVICE MANUAL GENERAL MAINTENANCE All supporting members (chains and cables) need to be parallel to each other and as near perpendicular as possible The suggestions listed below are helpful in analyzing and to the top of the object being lifted. correcting problems: CAUTION •...

  • Page 15: Hoses And Tubes

    NBT30H-2 SERVICE MANUAL INTRODUCTION Hoses and Tubes Installation When installing a new hose, loosely connect each end DANGER and make sure the hose takes up the designed position before tightening the connection. Clamps should be High Pressure/Temperature Hazard! tightened sufficiently to hold the hose without crushing Exercise extreme care around pressurized hydraulic and to prevent chafing.

  • Page 16: Gaskets

    INTRODUCTION NBT30H-2 SERVICE MANUAL When pressing bearings into a retainer or bore, uniformly batteries in a cool (not subfreezing), dry place, preferably on apply pressure to the outer race. If the bearing is pressed on wooden shelves. Never store on concrete. A small charge the shaft, uniformly apply pressure on the inner race.

  • Page 17: Hydraulic Systems

    If any of the above conditions exist, evaluate hose assemblies for correction or replacement. For replacement of hose assemblies, refer to your Manitowoc Crane Care Parts Manual. National Crane 03-20-2019 Control # 613-06...
  • Page 18 INTRODUCTION NBT30H-2 SERVICE MANUAL At the same service interval, visually inspect all other Hydraulic hose assemblies operating in a temperature hydraulic components and valves for the following: climate zone “C” Table 1-1 are recommended to be replaced after 8000 hours of service life. •...

  • Page 19: Hydraulic Fittings

    Follow the F.F.F.T. method, described above. Flats from Finger Tight (F.F.F.T.) Method Table 1-2: Tube and Swivel Nut/Hose Fittings Manitowoc recommends that the F.F.F.T. tightening method described here be used when assembling all hydraulic fittings. This method will minimize the risk of fitting damage or failure due to under or overtightening.
  • Page 20 INTRODUCTION NBT30H-2 SERVICE MANUAL BACK OFF Non-Adjustable Fitting to Port FIGURE 1-6 a0032 Adjustable Fitting to Port FIGURE 1-5 a0030 Turn fitting until finger tight. Inspect both mating parts for burrs, nicks, scratches, or Using the assembly torque method, tighten to given foreign particles.

  • Page 21: Electrical System

    NBT30H-2 SERVICE MANUAL INTRODUCTION Electrical System • Outrigger pads, beams, boxes attachment structures. Harnesses, Wires, and Connectors • Main frame: generally in the area of doubler plates and Visually inspect all electrical harnesses, cables, and crossmembers; at the junction of front and rear frame connectors every month or 250 hours for the following: members on truck cranes.

  • Page 22: Fasteners And Torque Values

    The use of handle and nuts being used. extensions will change applied torque to the bolt. The torque tables are provided by Manitowoc for reference • All handles must be parallel to the step wrench during when performing maintenance.
  • Page 23 NBT30H-2 SERVICE MANUAL INTRODUCTION Torque Values grade 5 and grade 8 zinc-flake coated, untreated (black) finish and stainless steel fasteners. The following tables list the torque values for both ASME standard and metric fasteners. The tables list the values for SAE Grade 1 SAE Grade 5 SAE Grade 7...
  • Page 24 INTRODUCTION NBT30H-2 SERVICE MANUAL Table 1-5 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-20 UNC 13.5 13.2 12.8 5/16-18 UNC 19.1 18.6 18.1 24.0 23.4 22.8...
  • Page 25 NBT30H-2 SERVICE MANUAL INTRODUCTION Table 1-6 Inch Series with Fine Threads (UNF) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-28 UNF 10.6 10.4 10.1 15.0 14.6 14.2 5/16-24 UNF 21.1 20.6 20.1...
  • Page 26 INTRODUCTION NBT30H-2 SERVICE MANUAL Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation M6x1.0 10.9 12.2 11.9 11.6 12.9 14.3 13.9 13.6 20.2 19.7 19.2 M8x1.25 10.9 29.6 28.9 28.2 12.9 34.7 33.8 33.0 40.0 39.0 38.0...
  • Page 27 NBT30H-2 SERVICE MANUAL INTRODUCTION Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 2089.8 2037.6 1985.3 M36x4 10.9 2976.4 2902.0 2827.6 12.9 3483.0 3395.9 3308.9 Table 1-8 Metric Series with Fine Threads – Zinc Flake Coated Nominal Size, Threads per Torque (Nm) Property...
  • Page 28 INTRODUCTION NBT30H-2 SERVICE MANUAL Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 386.0 376.3 366.7 M20x1.5 10.9 549.7 535.9 522.2 12.9 643.3 627.2 611.1 520.8 507.8 494.8 M22x1.5 10.9 741.7 723.2 704.7 12.9 868.0 846.3 824.6...
  • Page 29 NBT30H-2 SERVICE MANUAL INTRODUCTION Table 1-9 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads Size Torque (Nm) M2.5x0.45 M3x0.5 M4x0.7 M5x0.8 M6x1 M8x1.25 M10x1.5 Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength. Stainless steel fasteners tend to gall while being tightened.
  • Page 30 INTRODUCTION NBT30H-2 SERVICE MANUAL Table 1-11 Inch Series Bearing Bolts – Untreated (black finish) Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 5/8-11 UNC 5/8-18 UNF 3/4-10 UNC 7/8-9 UNC 1-8 UNC 1 1/4-7 UNC 2043 1964 1885...
  • Page 31 NBT30H-2 SERVICE MANUAL INTRODUCTION Inch Series with Coarse Threads (UNC) – Untreated (black finish) Table 1-13 Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-20 12.5 11.5 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 259.5 3/4-10 7/8-9 1 1/8-7 1342 1288 1234 1141 1097 1053...
  • Page 32 INTRODUCTION NBT30H-2 SERVICE MANUAL Table 1-14 Inch Series with Fine Threads (UNF) – Untreated (black finish) Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-28 14.5 13.5 5/16-24 3/8-24 7/16-20 84.5 1/2-20 9/16-18 174.5 5/8-18 299.5 3/4-16 439.5 7/8-14 1-12 1009 644.5 1-14 908.5...
  • Page 33 NBT30H-2 SERVICE MANUAL INTRODUCTION Metric Series with Coarse Threads – Untreated (black finish) Table 1-15 Torque (Nm) Property Size Class Maximum Nominal Minimum M4x0.7 10.9 12.9 M5x0.8 10.9 12.9 10.5 10.5 M6x1 10.9 12.9 M8x1.25 10.9 36.5 12.9 43.5 M10x1.5 10.9 12.9 M12x1.75...
  • Page 34 INTRODUCTION NBT30H-2 SERVICE MANUAL Torque (Nm) Property Size Class Maximum Nominal Minimum 1134 1090 1046 M27x3 10.9 1591 1530 1469 12.9 1910 1836.5 1763 1538 1479 1420 M30x3.5 10.9 2163 2080 1997 12.9 2595 2495 2395 2681 2578.5 2476 M36x4 10.9 3964 3812...
  • Page 35 NBT30H-2 SERVICE MANUAL INTRODUCTION Torque (Nm) Property Size Class Maximum Nominal Minimum 331.5 M18x1.5 10.9 12.9 M20X1 10.9 667.5 12.9 464.5 M20x1.5 10.9 12.9 M22x1.5 10.9 888.5 12.9 1111 1068 1025 803.5 M24x2 10.9 1176 1130.5 1085 12.9 1410 1356 1302 1225 1171.5...

  • Page 36: Weld Studs

    ANSI/ASME B30.5, federal regulations, and Manitowoc proper conditions. After the rope is put into service, periodic specifications. The inspection interval shall be determined by applications of a suitable rope lubricant are required.

  • Page 37: Recommendations For Servicing Wire Rope

    Use the daily inspection to monitor progressive only pre-assembled lengths of wire rope as supplied degradation and to identify damages that require wire rope from Manitowoc Crane Care. Do not build lengths from replacement such as: individual components. •...

  • Page 38: Boom Extension And Retraction Cables

    The information below is excerpted from a National equipment vibration. Consensus Standard as referenced by Federal Government Agencies and Manitowoc Crane Care recommendations to • boom nose sheaves, hook block sheaves, boom help determine when wire rope needs to be replaced. Wire...

  • Page 39: Introduction

    NBT30H-2 SERVICE MANUAL INTRODUCTION 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 portion in the groove.
  • Page 40 INTRODUCTION NBT30H-2 SERVICE MANUAL 1-30 03-20-2019 Control # 613-06...

  • Page 41: Hydraulic System General Overview

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Introduction....... 2-1 Maintenance .
  • Page 42 HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL in the system. Pressure is caused by resistance to the flow. To understand how a hydraulic system works, it is important This resistance can be external (for example, a load on a to understand the following words: cylinder or motor), or internal (the resistance of the Flow - The flow through the system is caused by the pump.

  • Page 43: Hydraulic Symbols

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYMBOLS The following pages show basic hydraulic symbols as used on the schematics. Description Symbol Description Symbol Hydraulic Reservoir - Stores, cools, and Filter - Removes contamination from cleans machines hydraulic fluid supply. hydraulic fluid. Hydraulic Return Lines - Terminated at (1) Filter with Bypass Valve - Bypass valve below fluid level (2) above fluid level.
  • Page 44 HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL Description Symbol Description Symbol Single Acting Cylinder - Extended Manually Operated - Valve shifted hydraulically and retracted with a spring. manually with check to allow flow back to tank. Double Acting Cylinder - Extended and retracted hydraulically.

  • Page 45: Maintenance

    Visually inspect hoses and fittings once a month or designated personnel who are properly trained. Use only every 250 hours for the following: Manitowoc supplied parts to repair the crane. Leaks at hose fitting or in hose Hydraulic System Maintenance Precautions...

  • Page 46: Troubleshooting Aids

    HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL At the same service interval, visually inspect all other the system. Instructions for installation of the flow meter hydraulic components and valves for the following: and the use of the flowmeter are normally included with the flowmeter.

  • Page 47: General Hydraulic System Troubleshooting

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM If the problem is two or three circuits, check each circuit NOTE: Do not remove the main relief valve from the circuit. separately. After a circuit is checked, use caps or plugs to The relief valve must be kept in the circuit to inhibit remove that circuit from the system.

  • Page 48: Parts Replacement

    Replace spring. Distortion or damage to valve spool. Replace valve section. PARTS REPLACEMENT Manitowoc Crane Care Parts Catalog for proper replacement parts. Parts found damaged or out of tolerance when maintenance is being performed need to be replaced. Refer to the...

  • Page 49: Service

    0.118 (3.00) 1 7/8-12 (37.82) NOTE: Contact your National Crane Distributor or Manitowoc Crane Care for O-Ring boss seal kits. SERVICE Remove the reservoir drain plug and drain the reservoir. Clean and install the drain plug and fill the reservoir with Hydraulic Oil Recommendations clean hydraulic oil.

  • Page 50: Removing Air From The Hydraulic System

    HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL Connect the outrigger return line and retract the operate all circuits and recheck the reservoir sight gauge. outrigger. Replenish the reservoir hydraulic oil level as Add hydraulic oil as required. necessary. Removing Air from the Hydraulic System Repeat step 7 and step 8 for the remaining outriggers.

  • Page 51: Hydraulic Pump

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM Load Sense Control WARNING The Load Sense (LS) control matches pump flow with system demand. The LS control senses the flow demand of High Pressure Hazard! the system as a pressure drop across an External Control Pressurized hydraulic fluid can cause serious injury.

  • Page 52: Valves

    HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL VALVES the circuit they are used in, and their physical location, refer to the table on page 2-12. The description of each valve General given here is for the valve itself. For information on how each valve functions in the individual circuits, refer to the This subsection provides descriptive information for all the description and operation procedures of that circuit.
  • Page 53 NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM Swing Left Hoist Down Telescope Extend Boom Down Option 1A Load Sense Relief Inlet Port Outlet Port Swing Right Hoist Up Telescope Extend Relief Telescope Retract Pilot Relief Telescope Boom Up Extend Port Option 1B FIGURE 2-2 8732-1 Directional Control Valve...

  • Page 54: Directional Control Valve

    HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL 8737 8730 Pilot Manifold Valve Directional Control Valve FIGURE 2-3 DIRECTIONAL CONTROL VALVE Radio Remote Control - (Optional) If equipped with optional radio remote control, all solenoid Description valves on each valve section are energized (Figure 2-2) The directional control valve (Figure 2-2 and 2-3) is located when the remote control enable switch is activated.

  • Page 55: Relief Pressures

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM RELIEF PRESSURES opens and the hydraulic oil is returned to the reservoir. Hydraulic circuits can be stalled by plugging the work hoses Description to the motor or cylinder prior to actuating the control valve. A pressure gauge placed in the proper line shows the pressure R e l i e f v a l v e s p r o t e c t h y dr a u l i c s y st e m s f r o m ov e r that the relief valve opens.

  • Page 56: Telescope In And Telescope Out Reliefs

    HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL Install a hydraulic pressure gauge to the pump gauge Move the gauge to the retract line and plug the extend port on the directional control valve (Figure 2-2). line. Idle machine with PTO engaged. Verify that the Start the engine.

  • Page 57: Outriggers Beam Extend

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM Outriggers Beam Extend Select an outrigger and remove the extend line from the outrigger extend cylinder. Pump Install a pressure gauge in the extend line (Figure 2-8). Manifold Start the engine and set the throttle to governed RPM. Activate the extend function for the selected outrigger.
  • Page 58 HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL Retract Relief Extend Relief FIGURE 2-10 FIGURE 2-11 Item Component Item Component Hydraulic Reservoir Suction Line Hydraulic Oil Level Gauge Sump Line from Directional Control Valve Hydraulic Temperature Gauge Pump Manifold Case Drain Fill Cap Outrigger Return Access Cover Case Drain from Pump...

  • Page 59: Supply Circuit

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM SUPPLY CIRCUIT A large access cover on the top of the reservoir provides access for cleaning. The cover is secured to the top of the Description reservoir with screws and has a gasket to prevent leaking. The access hole can also be used to fill the reservoir after it The supply pressure and return circuit routes hydraulic oil has been completely drained.

  • Page 60: Hydraulic Valves

    HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL optional remote controller. The DCV is located at the operator’s control console behind the console cover. Inspection Hydraulic Oil Cooler Inspect the DCV for visible damage, binding spools, and evidence of leakage. If excessive internal leakage is suspected during operation with a spool in its center position, it is possible that the area between the spool and working section bore of the valve body is worn beyond serviceable...

  • Page 61: Pilot Manifold Valve

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM equipment should make pressure adjustments when such allowed to shift and drain oil from these controls to tank. This adjustments are needed. will allow these controls to operate these functions again. Swinging left or right 205 degrees will de-energize the swing Directional Control Valve Manifold solenoids and block flow for operation of swinging.

  • Page 62: Hydraulic Pump Service

    HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL Hydraulic Pump Service Case Drain Rear Pump Mounting Strap To Directional From Tank Control Valve Pump Manifold To Tank Pump Load Sense To Front Outrigger Manifold Manifold FIGURE 2-14 Description Reconnect the hydraulic lines as per removal tags. Fill the hydraulic tank to the full mark with hydraulic oil.

  • Page 63: Pump Margin Pressure

    NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM NOTE: If the RCL is active or in override the pressure Operate the system under a light load for 5 to 10 should be in the 2413 kPa (350 psi) range. minutes. NOTE: If the pump does not build up pressure, shut down NOTE: The standby (margin) pressure is the system the engine and take corrective action.

  • Page 64: Directional Control Valve

    The following chart lists malfunctions which may occur during operation, the possible cause, and the possible solution. These are not all inclusive but are designed to help isolate the problem and should be checked before calling Manitowoc Crane Care. 8737 Lockout Pressure Pilot Manifold...
  • Page 65 NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM Troubleshooting Chart CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Insufficient hydraulic fluid causes Check fluid level in reservoir. Fill the reservoir to proper level. cavitation. Air in system causes noisy, Purge air and tighten fittings. Check for air in system. erratic control.
  • Page 66 HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL Troubleshooting Chart (Continued) CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Insufficient volume of hydraulic Check fluid level in reservoir. fluid will not meet cooling Fill reservoir to proper level. demands of system. Inspect heat exchanger. Check Insufficient air flow, high input air air flow and input air temperature, or undersized heat...
  • Page 67 NBT30H-2 SERVICE MANUAL HYDRAULIC SYSTEM Troubleshooting Chart (Continued) CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Activate pressure compensation Air in system causes erratic allowing system to bleed air. Check for air in system. operation. Check inlet line for leaks and eliminate source of air ingression. Sticking control spools cause Inspect spools for free movement Check control spools.
  • Page 68 HYDRAULIC SYSTEM NBT30H-2 SERVICE MANUAL Troubleshooting Chart (Continued) CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Low temperature increases Allow system to warm up before Check fluid temperature. viscosity. High fluid viscosity operating. causes high inlet vacuum. High inlet Vacuum Blocked or restricted inlet Caution Inspect inlet screen.

  • Page 69: Section 3

    NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS Description ....... 3-1 Outrigger Manifolds .

  • Page 70: Comparing Electrical System To A Hydraulic System

    ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL General Troubleshooting Because the system used on this machine is a negative ground system, current flows from the positive battery terminal and returns to the negative battery terminal. CAUTION In series circuit arrangements, the voltage is completely Electrical Shock Hazard! used in the circuit when the current is flowing.

  • Page 71: Troubleshooting Electrical System

    NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM Table 3-2 Deutsch Extraction Tool Table Description Deutsch Part Number National Crane Part Number 12 gauge wire 114010 9999100194 16 gauge wire 0411-204-1605 9999100195 8-10 gauge wire 114008 7902000012 4-6 gauge wire 114009 7902000009 20-24 gauge wire 0411-240-2005 9999102084 Table 3-3...

  • Page 72: Anti-Two-Block System Description

    ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL ANTI-TWO-BLOCK SYSTEM DESCRIPTION power supplied by the truck battery even when the truck ignition is in the OFF position. The anti-two-block system (A2B) helps prevent damage by NOTE: The RCL display is not intended for frequent sensing when the end of the hoist cable is near the boom tip removal as damage may occur to the electrical and disables the functions that cause a two block condition.
  • Page 73 NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM A2B Cable Reel Switch A2B Weight Rear of Boom A2B Cable FIGURE 3-2 National Crane 03-20-2019 Control # 613-06...

  • Page 74: Micro Relay/Fuse Block

    ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL MICRO RELAY/FUSE BLOCK panel to gain access to the fuse compartment, RCL master module, computer interface connector and the RCL override T h e r e i s o n e r e l a y / f u s e b l o c k l o c a t e d i n t h e f u s e keyswitch.

  • Page 75: Directional Control Valve Solenoids

    NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM DIRECTIONAL CONTROL VALVE OUTRIGGER MANIFOLDS SOLENOIDS There are two outrigger manifolds located on the crane. The front outrigger manifold is mounted on the center of the front The directional control valve (DCV) manifold is used to outrigger box (Figure 3-6) and the rear outrigger manifold is control the mode of operation of the valve.
  • Page 76 ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL Item Solenoid Beam Extend Relief Valve Beam Extend Relief Solenoid Driver Side (Left) Beam Center Front Jack (SFO) (Optional) Passenger Side (Right) Jack Passenger Side (Right) Beam Driver Side (Left) Jack Extend Retract FIGURE 3-6 Front Outrigger Manifold Item Solenoid...

  • Page 77: Rear Outrigger Manifold

    NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM Rear Outrigger Manifold oil is routed through the cooler when it is cold than when it is hot. The solenoids on the rear outrigger manifold control the rear The cooler electrical system is made up of the following: outrigger components.

  • Page 78: Rcl Communication Overview

    ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL RCL COMMUNICATION OVERVIEW • Elimination of a large bundle of wires • Down loading to a laptop computer The RCL needs to communicate with the various sensors, switches, and transducers on the crane in order to perform •...
  • Page 79 NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM Fuse/Relay Box RCL Master Computer Interface Module Connector Radio Remote Module Radio Remote 8703-7 8731 Receiver (Optional) Operator Control Console 8703-8 RCL Angle/Length Sensors and Termination Resistor FIGURE 3-9 National Crane 3-11 03-20-2019 Control # 613-06...

  • Page 80: Troubleshooting

    ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL Troubleshooting Refer to the NBT30H-2 Error Codes, page 3-14 for detailed instructions to program or troubleshoot the This machine incorporates a CANbus Multiplex system. In RCL software. order to effectively troubleshoot the electrical system, you CANbus RCL Specifications need a Windows-based PC, CAN-link service software (9999102409), and a connection cable (9999102296).
  • Page 81 NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM 8775-1 Sample Diagnostics Screen 8775-2 Error Code Number Structure FIGURE 3-10 National Crane 3-13 03-20-2019 Control # 613-06...
  • Page 82 ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL Error Codes Table 3-4 Device # Device Name Throttle Module (80021405) Remote Module (80068910) Hoist Sensor Module (80068909) Pressure Transducer, Base/Piston Pressure Transducer, Rod RCL Master Module (80068908) Boom Length Sensor RCL Display Module (80068741) ATB Switch Slew Sensor Boom Angle Sensor...
  • Page 83 NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM Error # Error Description Error Source Truck Fault Yellow J1939 Truck Fault Truck Fault Red J1939 Truck Fault Inability to log FLASH sector undefined Inability to log FLASH write failure Cleared by user (via RCL display) Cleared FLASH sectors E-Stop CAN and input...
  • Page 84 ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL Device Group Index Error Pin, Wire, Description Possible Causes/Comments String Pot sensor value is below B06, 1816, DS REAR OR_DS_Rear_Min_Extend EEPROM value (- BEAM POTENTIOMETER OMS_Adc_Tolerance - OMS_Adc_High) in RCL Module B01, 1158, SWING LEFT SOLENOID B01, 1158, SWING LEFT SOLENOID...
  • Page 85 NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM Device Group Index Error Pin, Wire, Description Possible Causes/Comments B03, 1198, CRANE FUNCTION ENABLED B03, 1198, CRANE FUNCTION ENABLED B03, 1198, CRANE FUNCTION ENABLED B03, 1198, CRANE FUNCTION ENABLED B03, 1198, CRANE FUNCTION ENABLED B04, 2152, WARNING BUZZER B04, 2152, WARNING BUZZER...
  • Page 86 ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL Device Group Index Error Pin, Wire, Description Possible Causes/Comments RCL Module: Event Recorder, Data Chart, Inability to log (FLASH write failure) RCL Module: Event User has accessed the event recorder login (via RCL Recorder, Data Chart, Display) and cleared memory.

  • Page 87: Rcl Sensor Calibration

    NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM I/O Screen #8:RCL Display Outputs The Tools Screen will appear, select the icon, the Name Status Value Sensor Calibration Menu will appear. Reference the operator Normal Buzzer manual for operating instructions. Truck Horn Normal The screen navigation is as follows: Tools Screen Normal Thumper...

  • Page 88: Boom Angle Sensor Calibration

    ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL Boom Angle Sensor Calibration Select the slew angle icon from the Slew Sensor Calibration Menu screen to begin the slew angle calibration, Level and set-up the truck on outriggers and level before Figure 3-13. starting the boom angle calibration procedure. The boom angle needs to be measured accurately with an inclinometer Slew Sensor Calibration to do an accurate calibration.

  • Page 89: Rod Side Pressure Sensor Calibration

    NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM Boom Length Sensor Calibration Two calibration steps are shown one at a time on the Rod Side Pressure Sensor Calibration screen. Once a step has been confirmed, the next step will be displayed. Follow instructions on display to reprogram the rod side pressure transducer.

  • Page 90: Outrigger Length Calibration

    Diagnostic Connector (1, Figure 3-19). Contact Manitowoc disconnecting the pressure transducers.
  • Page 91 NBT30H-2 SERVICE MANUAL ELECTRIC SYSTEM At the Main Sensor Calibration Menu, select function key (use arrow keys to scroll). Enable Chart Download FIGURE 3-21 8717-43 At the Enable Chart Download,(Figure 3-21) Select the 8703-7 FIGURE 3-19 checkmark to enable Chart Downloading Mode. Connect the laptop to the Diagnostic Connector (1, A 30 second timer in the lower left corner of the screen will Figure 3-19) with the interface cable.
  • Page 92 ELECTRIC SYSTEM NBT30H-2 SERVICE MANUAL 3-24 03-20-2019 Control # 613-06...

  • Page 93: Theory Of Operation

    NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE SECTION 4 BOOM MAINTENANCE SECTION CONTENTS Theory of Operation ......4-1 Boom Cable Tensioning ....4-11 Cable Tensioning.
  • Page 94 BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL Proportioning Cable Section Section Section Section Boom Nose Retract Cables for Retract Cables for Extend Cables for the 4 Section the 3 Section FIGURE 4-1 the 4 Section 03-20-2019 Control # 613-06...
  • Page 95 NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE FIGURE 4-2 Item Component Telescope cylinder attach point for the 3 boom section. Proportioning cable attach point. Attach point at the rear of the 2 boom section for the 4 boom section extend cables. Attach point at the rear of the 4 boom section for the 4 boom section extend cables.

  • Page 96: Boom Removal From Truck

    BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL Proportioning cable Sheave at Front of 2 Section. Proportioning Cable Boom Attach Point at Rear Pivot Pin of 3 Section FIGURE 4-3 Lift Cylinder Pivot Pin Turret BOOM REMOVAL FROM TRUCK The boom and hoist are removed from the truck as one assembly.

  • Page 97: Boom Disassembly

    NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE BOOM DISASSEMBLY Raise the 2 boom assembly inside the 1 section to allow for front bottom pad removal. Tag and The front of the boom is the sheave case end and the rear of remove the bottom wear pads. the boom is the hoist mount end.

  • Page 98: Additional Maintenance, Disassembled Boom

    BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL Loosen and remove the two capscrews securing the 16. Slide the 4 section out of the 2 section. The side lock bar to the extend cylinder collar. Remove the bar. pads may need to be removed. Tag and remove the side pads and shims if required.
  • Page 99 NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE Rear of 4 Section Cap Screws Right Side Wear Pad FIGURE 4-7 Install the 4 section boom into the 3 section. Slide in until about 150 cm (5 feet) of the 4 section extends from the 3 section.

  • Page 100: Extend/Retract Cable Installation

    BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL Install the front side wear pads and shims between the b. Reeve the 4 section retract cable around cable and 3 sections. sheave. NOTE: For boom reassembly with no new sections, Install the cable retainer pin into the anchor plate. reinstall shims per removal tags.

  • Page 101: Telescope Cylinder Installation

    NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE 12. Install the cable retainer to the top plate of the 2 section (Figure 4-11). Anchor Plate Assembly Cable Retainer section FIGURE 4-11 FIGURE 4-13 Telescope Cylinder Installation Wear Pad Install the sheave wheels on the telescope cylinder. The holes in the end of the pin must be located as shown in Plate (Figure 4-14).

  • Page 102: Nd /3 Rd /4 Th Boom Section Installation

    BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL Cap Screws FIGURE 4-15 Install the telescope cylinder the rest of the way into the boom assembly. Base End of 2 Section Insert the extend cable anchor assembly into the base end of the 2 section (Figure 4-16).

  • Page 103: Boom Cable Tensioning

    NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE BOOM CABLE TENSIONING Washer A boom assembly is considered properly timed when Cap Screw telescoping sections extend equally relative to each other Shim and bottom out simultaneously at full retraction and do not (as required) spring back out after retract pressure is returned to neutral.

  • Page 104: Cable Tension Sequence

    BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL 8860-5 8860-6 FIGURE 4-19 Cable Tension Sequence 234 extend cables 432 retract cables. Five section boom with two stage cylinder. Four section boom with one stage cylinder. Cable tensioning (See Figure 4-20) to be in the following order: Cable tensioning to be in the following order: 321 retract cables...

  • Page 105: 4- Section Boom W/ 2 Stage Cylinder Cable Positioning

    NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE 4- Section Boom w/ 2 Stage Cylinder Cable Positioning 1/2/3 EXTEND 2/3/4 EXTEND 1ST STAGE BASE 2ND STAGE 3RD STAGE 4th STAGE 8860-2 4/3/2 RETRACT 3/2/1 RETRACT FIGURE 4-20 Cable Tightening Sequence 4 Section Boom with Two Retraction Stage Extend Cylinder Measure the retraction gaps between the first and...

  • Page 106: 4- Section Boom W/ 1 Stage Cylinder Cable Positioning

    BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL The fourth section should have moved out. Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap Tightening until the extension gap between the third and measurements.

  • Page 107: 3- Section Boom W/ 1 Stage Cylinder Cable Positioning

    NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE Tightening until the retraction gap between the first and Tightening until the extension gap between the third and second section and the retraction gap between the fourth section is equal to the extension gap between the second and the third are equal.

  • Page 108: Cable Retention

    BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL Extend and retract the boom a few times and then Tighten the 321 retract cable located at the front bottom repeat measuring the extension gaps. of the base section the difference in the retraction gap measurements.

  • Page 109: Boom Installation On The Truck

    NBT30H-2 SERVICE MANUAL BOOM MAINTENANCE 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 tapped hole BOOM INSTALLATION ON THE TRUCK for the set screw is tangent to the end face of the wrench flat.
  • Page 110 BOOM MAINTENANCE NBT30H-2 SERVICE MANUAL 4-18 03-20-2019 Control # 613-06...

  • Page 111: Section 5

    NBT30H-2 SERVICE MANUAL HOIST SECTION 5 HOIST SECTION CONTENTS Description ....... 5-1 Disassembly .

  • Page 112: Maintenance

    HOIST NBT30H-2 SERVICE MANUAL MAINTENANCE Inspect the hoist daily for oil leaks, loose bolts, and worn hoist cable. Check the gearbox and brake oil every 500 hours. Do an oil change every 1000 hours. Refer to Lubrication, page 8-1. Inspect the hoist from the deck of the crane.

  • Page 113: Hoist Repair

    NBT30H-2 SERVICE MANUAL HOIST Reinstall the hydraulic hoses as per removal tags. Remove the input planet set (36) from the drum. Inspect the planet set for wear. See Servicing The Planetary Set HOIST REPAIR section for disassembly and repair. Remove the output sun gear (16) and thrust washer (6) Disassembly from the output planet assembly (4).

  • Page 114: Hoist Service

    HOIST NBT30H-2 SERVICE MANUAL 14. Position the side plate (1) over cable drum on rods (43). 10. Carefully disassemble the brake driver/clutch assembly Secure the side plate with the three capscrews (2). noting the direction of lockup for the clutch (34). The Tighten capscrews to 80 to 90 lb-ft (109 to 122 Nm).
  • Page 115 NBT30H-2 SERVICE MANUAL HOIST 18. Coat the new O-ring with light oil and install into the 20. Check the brake release with a portable hydraulic pump. groove on the brake cover (20). Full release should be obtained at 250 psi ± 20 psi (1724 kPa ±...
  • Page 116 HOIST NBT30H-2 SERVICE MANUAL 302 10 308 303 24 7155 FIGURE 5-4 03-20-19 Control # 613-06...
  • Page 117 NBT30H-2 SERVICE MANUAL HOIST Item Quantity Description Item Quantity Description Plate, Side Counterbalance Valve Capscrew NCC Label Snap Ring Capscrew Gear Set Screw, Buttonhead Drum Housing Cord Set Race, Bearing Fitting, Tee Gear, Input Sun Fitting, Straight Adapter Capscrew Fitting, Reducer Brake Piston Hose Assy Screw...

  • Page 118: Planetary Set

    HOIST NBT30H-2 SERVICE MANUAL Planetary Set Motor NOTE: See Figure 5-4 for item number identification. Remove the hose and the counterbalance block (42) from the motor assembly. Remove the spiral retaining rings from the planet pins. To remove the counterbalance block (42), loosen and Remove the pins from the carrier by carefully tapping remove the 4 capscrews (55).

  • Page 119: Section 6

    NBT30H-2 SERVICE MANUAL SWING SECTION 6 SWING SECTION CONTENTS Description ....... 6-1 Assembly .
  • Page 120 SWING NBT30H-2 SERVICE MANUAL Item Component Pinion Gear Swing Gearbox Swing Motor Swing Brake Release Line Swing Speed Control Swing Control Valve Swing Brake Oil Level Plug Oil Fill/Breather Pinion Bearing Grease Fitting Oil Drain Plug FIGURE 6-1 03-20-2019 Control # 613-06...
  • Page 121 NBT30H-2 SERVICE MANUAL SWING Breather Grease Fitting Fill Plug Level Plug Output Planetary Gear Set Input Planetary Gear Set 8741 FIGURE 6-2 Item Component Item Component Gearbox Housing Brake End Plate Pinion Shaft Output Planetary Gear Set Outboard Seal Retaining Washer Outboard Bearing Output Planetary Pin Outboard Bearing Race...

  • Page 122: Swing Gearbox And Brake

    SWING NBT30H-2 SERVICE MANUAL SWING GEARBOX AND BRAKE Remove the race (11a) from the input planetary assembly (13). The swing drive is a double planetary gear set with an Install three 1/4” eyebolts into the three planet pins of the integral brake.

  • Page 123: Pinion Shaft Repair

    NBT30H-2 SERVICE MANUAL SWING Pinion Shaft Repair Set the bearing preload by tightening locknut (9) onto pinion shaft (2) to 135 N·m (100 ft-lb). Proper bearing (See Figure 6-2 for reference numbers.) preload is determined by the rolling torque method. This method involves increasing press load on the bearings Remove the outboard race (5) and bearing (4) from the (4 and 7) until drag or rolling resistance of 8.4 to 9.6 Nm...

  • Page 124: Swing Brake

    SWING NBT30H-2 SERVICE MANUAL FIGURE 6-3 Item Component Item Component Brake Housing Spring Stator Plate Brake Driver Friction Disc Retaining Ring Back-up Ring End Plate O-Ring O-Ring Brake Housing O-Ring O-Ring Brake Mounting Capscrews (8) Back-up Ring Drain Plug Brake Piston Brake End Plate End Plate Capscrews (8) SWING BRAKE...

  • Page 125: Assembly

    NBT30H-2 SERVICE MANUAL SWING Connect a port-a-power or other hydraulic pressure source to the brake release port and slowly apply 2 mm (0.080 in) pressure until the brake piston (8) clears the brake 2.16 mm (0.085 in) housing (1). NOTE: Replace if the NOTE: Note the position of the dowel-pin hole with respect thickness is below...

  • Page 126: Swing Bearing

    SWING NBT30H-2 SERVICE MANUAL Bolt the brake end plate (18) to the brake housing (1) Maintaining proper torque value for bolts is extremely with the capscrews (19). Alternately tighten the important for structural strength, performance, and reliability capscrews one turn at a time until the cover is tight of the crane.
  • Page 127 NBT30H-2 SERVICE MANUAL SWING 27 5 13 26 FIGURE 6-6 Inner Race Outer Race FIGURE 6-7 National Crane 03-20-2019 Control # 613-06...

  • Page 128: Torque Values

    SWING NBT30H-2 SERVICE MANUAL Torque Values Put a magnetic base dial indicator opposite the boom on the top of the frame (Figure 6-8). Inner Race Torquing Place the dial on the top of the swing bearing The inner race bearing bolts are located on top of the inner (Figure 6-8).

  • Page 129: Bearing Replacement

    NBT30H-2 SERVICE MANUAL SWING FIGURE 6-9 BEARING REPLACEMENT Attach a suitable lifting device to the turret. Remove any slack in the sling. Do not pull up on the turret. Removal DANGER Fully extend and set the outriggers enough to take up the slack in the pads.

  • Page 130: Installation

    SWING NBT30H-2 SERVICE MANUAL Carefully lift the turret with bearing off the truck and set it on blocking that will not allow the turret to tilt or shift. Leave the lifting device attached. NOTE: If the current bearing is to be reinstalled, mark the position of the bearing on the turret before removal.

  • Page 131: Slew Potentiometer Adjustment

    NBT30H-2 SERVICE MANUAL SWING Slew Potentiometer FIGURE 6-11 Slew Potentiometer Adjustment Go to the RCL slew angle calibrate screen as described in the RCL service manual. The slew potentiometer (slew pot) located inside the turret, is Rotate the slew pot gear until the reading on the RCL is used by the RCL to determine swing position and limits the 0°...
  • Page 132 SWING NBT30H-2 SERVICE MANUAL 6-14 03-20-2019 Control # 613-06...

  • Page 133: Section 7

    NBT30H-2 SERVICE MANUAL OUTRIGGERS SECTION 7 OUTRIGGERS SECTION CONTENTS Description ....... 7-1 RSOD Assembly .

  • Page 134: Outrigger Beam Removal

    OUTRIGGERS NBT30H-2 SERVICE MANUAL FIGURE 7-1 Item Component Item Component Stabilizer Cylinder Extension Cylinder Bolts Outrigger Box Side Wear Pad (One Side) Outrigger Beam Top Wear Pads Outrigger Box Bottom Wear Pads Outrigger Beam Side Wear Pad (Both Sides) Outrigger Beam Outrigger Box Access Hole (Outrigger Beam) Outrigger End Plate (Outrigger Box)

  • Page 135: Inspection

    NBT30H-2 SERVICE MANUAL OUTRIGGERS FIGURE 7-3 Use lifting straps. Do not use chains. Blocking material must be capable of supporting the outrigger beam. FIGURE 7-4 Item Component Outrigger End Plate DANGER End Plate Bolt Crushing Hazard! Outrigger Hydraulic Tubes Extension Cylinder Bolts Blocking material must be able to support the outrigger beam and not allow the beam to tilt or slide.

  • Page 136: Extension Cylinder

    OUTRIGGERS NBT30H-2 SERVICE MANUAL Adjust the wear pads as described in Wear Pad Remove the rod end of the extension cylinder (5) from Adjustment, page 7-5. the keyhole on the jack end of the outrigger beam. Retract the outrigger after wear pad adjustment. Slide the extension cylinder out from the outrigger beam.

  • Page 137: Jack Cylinder

    NBT30H-2 SERVICE MANUAL OUTRIGGERS Installation outrigger beam and are adjusted from inside the outrigger box. Reconnect the hydraulic hoses for the jack cylinder to the base of the extension cylinder per removal tags. Outrigger Beam Wear Pad Adjustment Secure the jack hydraulic hoses to the extend cylinder Wear pad adjustment is as follows: with the clamps as shown in Figure 7-5.

  • Page 138: Rear Outriggers (Rsod)

    OUTRIGGERS NBT30H-2 SERVICE MANUAL console. When the outrigger extension is activated the selected beam or stabilizer is extended or retracted. Extension Cylinder Bolts RSOD Assembly The RSOD assembly consists of the following: • outrigger beams • jacks • required hoses and mounting hardware •...

  • Page 139: Extension Cylinder

    NBT30H-2 SERVICE MANUAL OUTRIGGERS Remove the extension cylinder from the outrigger beam. Installation Slide the extension cylinder into the outrigger beam. Install the extension cylinder wear pads. Install the cylinder rod pin. RSOD Stabilizers The RSOD stabilizers extend down to provide stability for crane operation.

  • Page 140: Outrigger Monitoring System (Oms) (Optional-Standard In North America)

    OUTRIGGERS NBT30H-2 SERVICE MANUAL OUTRIGGER MONITORING SYSTEM (OMS) (OPTIONAL—STANDARD IN NORTH AMERICA) Description The outrigger monitoring system (OMS) utilizes string potentiometers to monitor the outrigger’s extension beam positions together with the RCL. Four monitoring string potentiometers are used on the crane, one at the end of each outrigger extension beam to monitor if beams are at full, mid or retracted positions.

  • Page 141: Installation

    NBT30H-2 SERVICE MANUAL OUTRIGGERS NOTE: prevent damage string Attach the OMS string potentiometer connector (2) to potentiometer, do not allow the cable (3) to retract the attaching point on the outrigger beam. freely. NOTE: prevent damage string Disconnect the electrical cable (6) connector and secure potentiometer, do not allow the cable to retract to avoid damage.
  • Page 142 OUTRIGGERS NBT30H-2 SERVICE MANUAL 7-10 03-20-2019 Control # 613-06...

  • Page 143: Section 8

    Dispose of waste properly! Improperly disposing of waste can threaten the environment. Arctic Conditions Below -9°C (15°F) Potentially harmful waste used in Manitowoc cranes includes In general, petroleum based fluids developed especially for — but is not limited to — oil, fuel, grease, coolant, air...

  • Page 144: Chassis Grease

    This is a special high-graphite adhesive lubricant that helps suitability of a specific fluid, check with your authorized to eliminate fretting corrosion, is water resistant, and forms a National Cranes distributor or Manitowoc Crane Care. dry lubrication film which does not attract dust. Lubricant NOTE: All fluids and lubricants may be purchased by meets NLGI Class 1-2 specifications.

  • Page 145: Arctic Hydraulic Oil

    John Deere Standard JDM J20C. For colder operating conditions, the standard fluid may be Contact your National Crane distributor or Manitowoc Crane replaced with a petroleum based fluid developed especially Care if you have any questions.
  • Page 146 Chart (Figure 8-1). Lube description and symbols are found in tables below. Over lubrication of non-sealed fittings will not harm the fittings or components, but under lubrication shortens lifetime. Table 8-1 Manitowoc Lube Specification Symbol Description Cold Weather - Standard 40°C (-40°F)
  • Page 147 NBT30H-2 SERVICE MANUAL LUBRICATION Lubrication Points Grease Fitting Oil Fill/Breather Oil Fill Level FIGURE 8-1 8596-2 Table 8-2: Recommended Item Application Procedure Frequency Lubricant Check and Fill Check and Fill: Weekly, Fill as required Hydraulic oil reservoir HYDO Change Change: Semi-Annually After first 40 Hrs.
  • Page 148 LUBRICATION NBT30H-2 SERVICE MANUAL Table 8-2: Recommended Item Application Procedure Frequency Lubricant Check and Fill Check and Fill: Every 500 operating hours, or 3 months. 10a Hoist gearbox. GL-5 Change: After first 100 hours, Change then every 1000 hours or 6 months thereafter.

  • Page 149: Internal Cable Sheave Lubrication

    (National Crane P/N 955045). Repeat steps 3 - 6. Extend the boom about 2/3 and • Contact Manitowoc Crane Care to obtain this tip. retract to spread the grease. Lubrication of the extend and retract sheaves is as follows: Repeat steps 3 - 5. Fully extend and retract the boom to spread the grease.

  • Page 150: Outrigger Beam Lubrication

    LUBRICATION NBT30H-2 SERVICE MANUAL Item Description Boom Section Access Holes for 4 Section Wear Pad Access Holes for 3 Section Wear Pad Access Holes for 2 Section Wear Pad Section Wear Pad Access Plate FIGURE 8-2 Outrigger Beam Lubrication DANGER Do not, under any circumstances, work at an elevated height without using proper fall protection as required by local, state or federal regulations.

  • Page 151: Hoist Gearbox Oil

    +150° F). For operation outside this range, contact r a n g e , c o n ta c t M a n i t o w o c C r a n e C a r e f o r Manitowoc Crane Care for recommendations. recommendations.

  • Page 152: Hydraulic Oil Reservoir Level

    LUBRICATION NBT30H-2 SERVICE MANUAL Fill the swing gearbox with the appropriate amount and otherwise hidden during inspection and maintenance type of oil and then replace plug and vent. See procedures require special attention. “Lubrication” on page 8-3 of this manual. The object of rope lubrication is to reduce internal friction and Gearbox oil level inspection is achieved by removing the to prevent corrosion.

  • Page 153: Carwell© Rust Inhibitor

    To help protect against corrosion of your National Crane, In addition to the factory-applied Carwell coating, National Manitowoc Crane Care recommends washing the crane at Crane owners must provide proper maintenance and care to least monthly to remove all foreign matter. More frequent...

  • Page 154: Inspection And Repair

    To the extent any damage is structural in nature, Manitowoc Crane Care must be contacted and consulted as to what repairs may be required. CAUTION...

  • Page 155: Areas Of Application

    • Boom applications areas are: pivot pins, hose ends and Please contact Manitowoc Crane Care should you have any fittings, jib pins and shafts, all bare metal surfaces, questions. downhaul weight / hook block pins and fasteners.
  • Page 156 LUBRICATION NBT30H-2 SERVICE MANUAL 8606-3 8606-2 8-14 03-20-2019 Control # 613-06...
  • Page 157 NBT30H-2 SERVICE MANUAL LUBRICATION Item Description Item Description Hook Block/Downhaul Weight Hoist Plumbing Connections O/R Hose Connections All Hardware, Clips, Pins, Unpainted Hose O/R Pins, Clips Connections Power Train Hardware Pivot Shaft Entire Underside of Unit Hose Connections Turntable Bearing Fasteners, Pins Mirror Mounting Hardware Valve Bank, Hose Connections Wire Rope...
  • Page 158 LUBRICATION NBT30H-2 SERVICE MANUAL 8-16 03-20-2019 Control # 613-06...

  • Page 159: Section 9

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION SECTION 9 CRANE INSTALLATION SECTION CONTENTS General ........9-1 Install the Boom Rest.
  • Page 160 CRANE INSTALLATION NBT30H-2 SERVICE MANUAL required rating, the gross axle rating is reduced to its bending moment (RBM) so that reinforcing is not weakest component value. required. The frame under the cab through the front suspension must have the minimum SM and RBM •...
  • Page 161 NBT30H-2 SERVICE MANUAL CRANE INSTALLATION Typical Location of Serial Number Identification Tags FORWARD Turret Frame 1st Section Boom 2nd Section 3rd Section Booms Boom Nose RSOD Stabilizer Lift Cylinder FIGURE 9-1 National Crane 03-20-2019 Control # 613-06...
  • Page 162 CRANE INSTALLATION NBT30H-2 SERVICE MANUAL Front Stabilizer Minimum Measurement 360° Standard Mount Crane 762 cm 30 Min 360° Full capacity working area. SFO required 487.7 cm 192 Min 266.7cm 105 Min 650.2 cm 256 Min 8744-1 Bare Min 4513 kg (9950 lbs) Bare Min 4105 kg (9050 lbs) GAWR Min 8165 kg (18000 lbs) GAWR Min 15422 kg (34000 lbs)

  • Page 163: Mounting Configuration

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION MOUNTING CONFIGURATION PTO AND HYDRAULIC PUMP The mounting configuration shown in Figure 9-2 is based on Horsepower an 85% stability factor. The crane must be installed on the truck in accordance with factory requirements and a test An axial piston pump is furnished with this crane.

  • Page 164: Pump Rotation

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL 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. FIGURE 9-4 Diesel Engine Optimum PTO Ratio FRONT Speed Range 2400 RPM PUMP (RPM) 2400...

  • Page 165: Truck Frame Strength

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION View from Rear of Truck Engine CCW Engine CCW PTO CCW PTO CW FIGURE 9-5 TRUCK FRAME STRENGTH ha v e r ed uc ed s ec tion p rop ert i es t hro ug h th e fro nt suspension due to truck frame cut outs or because outer channel reinforcement stops short of the front suspension.
  • Page 166 CRANE INSTALLATION NBT30H-2 SERVICE MANUAL NOTE: All dimensions are centimeters (inches) (120) (108) (96) (84) (72) (60) (48) (36) (24) (12) FIGURE 9-6 The following tables determine the section modulus of the • Angle Reinforcement (Table B page 9-10) - If the truck truck frame.
  • Page 167 NBT30H-2 SERVICE MANUAL CRANE INSTALLATION to be spaced 127 mm (5 in) apart with welds at an interval of If you have any questions concerning frame strength or 102 mm (4 in). Do not weld on the flanges. reinforcing, contact National Crane before proceeding. Where thickness, depth or flange width vary, interpolation between tables or variables within a given table will provide the strength for the section.
  • Page 168 CRANE INSTALLATION NBT30H-2 SERVICE MANUAL TABLE B Section Modulus in Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95)

  • Page 169: Truck Preparation

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION TABLE D Section Modulus in Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89) 4 (102)

  • Page 170: Pto, Pump, And Reservoir

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL • Overhang - The amount of overhang allowed varies the pump must be supported regardless of the mounting from state to state. Check on your state requirements. method. • Federal Bridge Law - The Federal Bridge Law in effect NOTE: Some of the pipe fittings are sealed by means of currently states that in order to carry 24,493 kg (54,000...
  • Page 171 NBT30H-2 SERVICE MANUAL CRANE INSTALLATION FIGURE 9-7 Plan the location of the crane mounting anchors so they don’t Remove bolts, clamp on reinforcing, interfere with the bolts, etc. and mark the bolt hole location from the inside of the frame (Ref) Truck frame The bolt hole clearance is 1.58 mm (1/16 in) to 3.17...
  • Page 172 CRANE INSTALLATION NBT30H-2 SERVICE MANUAL 51 mm (2 in) 51 mm (2 in) 101 mm 203 mm (8 in) (4 in) FIGURE 9-9 If the frame through the rear suspension does not meet Slide the reinforcing angle up from the bottom, butt it to the minimum specifications for RBM and section existing forward reinforcing and weld rear suspension modulus, it can be reinforced by adding a reinforcing...

  • Page 173: Mounting The Crane

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION Reinforcing under crane Cut outs Replace as much material as possible. Butt weld Butt weld Overload spring stop. Remove and replace. Weld 152 (6) Skip 152 (6) Weld 152 (6) Skip 152 (6) Weld 304 (12) Truck frame (REF) 152 (6) 152 (6)

  • Page 174: Mount The T-Box

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL • Mount the torsion box (T-box) on the truck frame (Mount • Calibrate the RCL and do the stability test (RCL the T-Box, page 9-16). Calibration, page 9-26). • Attach the RSOD to the truck frame and T-box (Attach Mount the T-Box the RSOD, page 9-18).
  • Page 175 NBT30H-2 SERVICE MANUAL CRANE INSTALLATION Tubes for the Anchor Bolts Note: The reinforcing plates must extend out past the RSOD mounting brackets. Reinforcing Plates Anchor Brackets for the T-Box and Frame T-Box Mounting Brackets for RSOD Outrigger Truck Frame FIGURE 9-12 T-Box 3/4 inch Grade 8 Bolts for the Crane Anchor Brackets.

  • Page 176: Attach The Rsod

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL Attach the RSOD Use the holes in the brackets as a template and drill three 5/8 inch holes in each anchor bar. Position the RSOD on the truck frame so that there is Loosely bolt the anchor bars to the RSOD mounting about 30.4 cm (12 in) between the rear tire to the front of bracket.

  • Page 177: Mount The Frame Assembly

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION Mount the Frame Assembly page 1-12. Cut the anchor retaining bracket for the front anchor to fit inside the truck frame. Position the frame assembly on the T-box so that the Install the front anchor brackets and properly torque the mounting bolts can be routed through the tubes on the bolts.

  • Page 178: Install The Boom Rest

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL Install the Boom Rest Install the Rear Bumper Insert the boom rest into the brackets on back of the T-box Bolt the rear bumper to the truck frame with the 3/4 inch and secure with the 5/8 inch grade 5 bolts (Figure 9-16). grade 5 bolts (Figure 9-16).

  • Page 179: Mount The Operator Platforms And Install The Foot Throttles

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION Mount the Operator Platforms and Install the Install the RCL Reel Foot Throttles The crane is shipped with the RCL reel temporarily attached to the top of the boom (Figure 9-19). To mount the reel: Install the operator’s platform on both sides of the frame as shown in Figure 9-17.

  • Page 180: Connect The Slew Potentiometer

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL The bracket attached to the RCL reel must C-bracket be mounted on the top side of the C-bracket as shown Mounting Boom Mount with the Connectors on the Bottom Clearance between the RCL reel and adjacent components must be adequate so that no damage occurs...

  • Page 181: Install The Hydraulic System

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION Truck Battery Harness Wire Truck Function (-) Ground (+) Positive Tr u c k B a t t e r y Fuse Truck Interface Harness To Frame 1289 Wire # Truck Function / Tr u c k J1939 Harness 1290...

  • Page 182: Front Outrigger Hydraulic Line Connections

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL Front Outrigger Hydraulic Line Connections R = Retract Item Solenoid JE = Jack Extend Right Front Outrigger BE = Beam Extend Outrigger Enable Center Front Outrigger (SFO) (Optional) Passenger Side Stabilizer (Right) Passenger Side Beam (Right) Driver Side Beam (Left) Driver Side Stabilizer (Left) Extend/Retract...

  • Page 183: Rsod Hydraulic Line Connections

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION RSOD Hydraulic Line Connections Left Side From Front Outrigger Manifold Right Side JE = Jack Extend RSOD Manifold JR = Jack Retract BE = Beam Extend BR = Beam Retract NOTE: See page 3-9 for RSOD manifold detail.

  • Page 184: Canbus System Setup

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL CANBUS SYSTEM SETUP Program the RCL as outlined in the RCL manual. Run the truck engine at idle and activate the crane Before the engine is started from the crane for the first time, power switch. the CANbus system needs to be initialized.
  • Page 185 NBT30H-2 SERVICE MANUAL CRANE INSTALLATION Put the test unit on a firm level surface. Place cribbing • Rated Load 4286.4kg (9450 lbs) under the outrigger floats and RSOD feet. • Stability Test Load (no jib stowed): With the boom in the rest, raise and level the machine up 9450 x 1.18 = 5058.0 kg (11151 Ib)* on the outriggers with all tires clear of the ground according to procedures outlined in the Operator’s...
  • Page 186 CRANE INSTALLATION NBT30H-2 SERVICE MANUAL STABILITY TEST LOADS (No Jib on Side of Boom) Test Load Start Boom Length Rated Radius Rated Load Rated Load x 1.18 Position m (ft) m (ft) kg (lb) kg (lb) (Rotate 360°) 100 ft (30.5 m) Boom Over Back 13.4 (44) 9.1 (30)

  • Page 187: Specifications

    NBT30H-2 SERVICE MANUAL CRANE INSTALLATION SPECIFICATIONS Hydraulic Pump Type ................Variable displacement, axial piston with load sense Total Flow ..............180 LPM (47.5 GPM) at 2400 RPM Hydraulic System Requirements: Outrigger System ............53 lpm (14 gpm) Boom Up ............... 94 lpm (25 gpm) Boom Down..............

  • Page 188: Crane Operating Speeds

    CRANE INSTALLATION NBT30H-2 SERVICE MANUAL High Speed Hoist Performance (1 part line) Layer Hoist Pull (kg) (mpm) 5410 (2454) (61) 4878 (3573) (67) 4441 (2014) (74) 4076 (1849) (80) 3766 (1708) (87) NOTE: All ratings based on 34 gpm at 3500 psi (128.7 lpm at 24.1 MPa) Crane Operating Speeds Rotation 360°.................

  • Page 189: Section 10

    NBT30H-2 SERVICE MANUAL SCHEMATICS SECTION 10 SCHEMATICS For your convenience, the latest version of schematics available at the time of printing are placed in this section. National Crane 10-1...
  • Page 190 SCHEMATICS NBT30H-2 SERVICE MANUAL 10-2...
  • Page 191 Alphabetical Index Boom Section Installation ........4-10 Anti-two-Block System Description .
  • Page 192 Swing Brake ............6-6 Swing Gearbox and Brake .

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