Manitowoc National Crane NBT40-1 Series Service Manual
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Manitowoc National Crane NBT40-1 Series Service Manual

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  • Page 1 National Crane NBT40-1 Series Service Manual...
  • Page 2 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. • If in an enclosed area, vent the exhaust to the outside.
  • Page 3 SERVICE MANUAL This manual has been prepared for and is considered part of the NBT40-1 Series Cranes This Manual is divided into the following sections: SECTION 1 INTRODUCTION SECTION 2 HYDRAULIC SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION 4 BOOM MAINTENANCE SECTION 5 HOIST SECTION 6...
  • Page 4 THIS PAGE BLANK...
  • Page 5 NBT40-1 SERVICE MANUAL SECTION 1 ..........Introduction General .
  • Page 6 NBT40-1 SERVICE MANUAL Radio Remote Manifold (optional) ........2-7 Tool Circuit Manifold (optional) .
  • Page 7 NBT40-1 SERVICE MANUAL Hydraulic Oil Cooler........... . 3-14 Hydraulic Temperature Sensor Warning Light.
  • Page 8 NBT40-1 SERVICE MANUAL Swing Brake............6-2 Swing Gearbox and Brake .
  • Page 9 NBT40-1 SERVICE MANUAL Multipurpose Extreme-Pressure Gear Lubricant (EPGL) ..... 8-2 Open Gear Lubricant ..........8-2 Antifreeze/Coolant (for Cab Heater) .
  • Page 10 NBT40-1 SERVICE MANUAL Stability Test ............9-33 Counterweight .
  • Page 11 NBT40-1 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Fasteners and Torque Values .
  • Page 12 If you are the new owner of a National crane, please register Basic Nomenclature it with Manitowoc Crane Care so we have the ability to The nomenclature used to describe parts of a National Crane c o n t a c t y o u i f t h e n e e d a r i s e s . G o t o h t t p s : / / crane are described in Figure 1-2.
  • Page 13 NBT40-1 SERVICE MANUAL INTRODUCTION 9022-1 7474-4 7474-5 7474-3 7474-2 FIGURE 1-2 Item Component Item Component Crane Cab Outrigger Box Crane Cab Console Boom Angle Indicator Operator’s Seat Downhaul Weight, Hook Block Boom Boom Nose Turret Boom Rest Single Front Outrigger (SFO), Front Outrigger Jack Lift Cylinder Hydraulic Tank...
  • Page 14 INTRODUCTION NBT40-1 SERVICE MANUAL GENERAL MAINTENANCE All supporting members (chains and cables) need to be parallel to each other and as perpendicular as possible to the The suggestions listed below are helpful in analyzing and top of the object being lifted. correcting problems: CAUTION •...
  • Page 15 NBT40-1 SERVICE MANUAL INTRODUCTION Bearings driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part. Antifriction Bearings Gaskets When an antifriction bearing is removed, cover it to keep out dirt and abrasives.
  • Page 16 INTRODUCTION NBT40-1 SERVICE MANUAL Keep the System Clean Remove the batteries if the machine is not used for an extended period of time. Store the batteries in a warm, dry When removing components of a hydraulic system, cover all place, preferably on wooden shelves. Never store on openings on both the component and the crane.
  • Page 17 NBT40-1 SERVICE MANUAL INTRODUCTION Fatigue of Welded Structures Adhesive/Sealant Application Highly stressed welded structures are subject to cracking Bead Application (fatigue) when repeatedly subjected to varying stresses caused by twisting, shock, bending, and overloads. Inspect equipment periodically for weld fatigue. The frequency of inspections depends on the age of the equipment, the severity of the application, and the experience of the FIGURE 1-3...
  • Page 18 INTRODUCTION NBT40-1 SERVICE MANUAL Torque Wrenches • Torque wrenches must be those specified, and forces must be applied at the handle grip. The use of handle Flexible beam types of wrenches, even though they might extensions will change applied torque to the bolt. have a pre-set feature, must be pulled at a right angle, and •...
  • Page 19 NBT40-1 SERVICE MANUAL INTRODUCTION Table 1-2. 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 20 INTRODUCTION NBT40-1 SERVICE MANUAL Table 1-3. 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 21 NBT40-1 SERVICE MANUAL INTRODUCTION 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 22 INTRODUCTION NBT40-1 SERVICE MANUAL Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 2,089.8 2,037.6 1,985.3 M36x4 10.9 2,976.4 2,902.0 2,827.6 12.9 3,483.0 3,395.9 3,308.9 Table 1-5. Metric Series with Fine Threads – Zinc Flake Coated Nominal Size, Threads per Torque (Nm) Property...
  • Page 23 NBT40-1 SERVICE MANUAL INTRODUCTION 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 24 INTRODUCTION NBT40-1 SERVICE MANUAL Table 1-6. 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 The torque values shown are for fasteners installed with lubrication. When using lubricated fasteners, the torque values result in an 80% utilization of the yield strength.
  • Page 25 NBT40-1 SERVICE MANUAL INTRODUCTION Table 1-8. 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 2,043 1,964 1,885...
  • Page 26 INTRODUCTION NBT40-1 SERVICE MANUAL Table 1-10 .Inch Series with Coarse Threads (UNC) – Untreated (black finish) 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 1,342 1,288 1,234 1,141 1,097 1,053...
  • Page 27 NBT40-1 SERVICE MANUAL INTRODUCTION Table 1-11 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 1,009 644.5 1-14 UNS 908.5...
  • Page 28 INTRODUCTION NBT40-1 SERVICE MANUAL Table 1-12. Metric Series with Coarse Threads – Untreated (black finish) 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 29 NBT40-1 SERVICE MANUAL INTRODUCTION Torque (Nm) Property Size Class Maximum Nominal Minimum 1,134 1,090 1,046 M27x3 10.9 1,591 1,530 1,469 12.9 1,910 1,836.5 1,763 1,538 1,479 1,420 M30x3.5 10.9 2,163 2,080 1,997 12.9 2,595 2,495 2,395 2,681 2,578.5 2,476 M36x4 10.9 3,964 3,812...
  • Page 30 INTRODUCTION NBT40-1 SERVICE MANUAL Table 1-13. Metric Series with Fine Threads – Untreated (black finish) Torque (Nm) Property Size Class Maximum Nominal Minimum M8x1 10.9 39.5 12.9 M10x0.75 10.9 12.9 M10x1.25 10.9 12.9 97.5 M12x1 10.9 12.9 M12X1.25 10.9 141.5 12.9 165.5 M12x1.5*...
  • Page 31 NBT40-1 SERVICE MANUAL INTRODUCTION Torque (Nm) Property Size Class Maximum Nominal Minimum 803.5 M24x2 10.9 1,176 1,130.5 1,085 12.9 1,410 1,356 1,302 1,225 1,171.5 1,130 M27x2 10.9 1,718 1,652.5 1,587 12.9 2,063 1,983.5 1,904 1,530 1,471.5 1,413 M30x1.5 10.9 2,253 2,166.5 2,080 12.9...
  • Page 32 The following information includes inspection, replacement, Cranes may be equipped with synthetic hoist rope or wire and maintenance guidelines for wire rope as established by rope. Hoist rope may be purchased through Manitowoc ANSI/ASME B30.5, federal regulations, and National Crane Crane Care.
  • Page 33 NOTE: Wire rope is available from Manitowoc Crane Care. from Manitowoc Crane Care. Do not build lengths from individual components. Record any deterioration of the wire rope in the equipment inspection log. Determination of wire rope replacement must •...
  • Page 34 INTRODUCTION NBT40-1 SERVICE MANUAL Monthly Inspections Boom Extension and Retraction Cables Inspect the total length of wire rope monthly or more often if Periodic Inspection necessitated by adverse conditions. Only inspect the outer It is recommended that inspection of all boom extension and surface of the wire rope.
  • Page 35 Consensus Standard as referenced by Federal Government 1/64 inch for diameters up to and including 5/16 inch Agencies and Manitowoc Crane Care recommendations to help determine when wire rope needs to be replaced. Wire 1/32 inch for diameters 3/8 and 1/2 inch inclusive...
  • Page 36 INTRODUCTION NBT40-1 SERVICE MANUAL Seizing Wire Rope 9023-33 It is important to seize the ends of rotation-resistant wire ropes to prevent the displacement and unraveling of the individual wires and strands at the ends. All preformed and non-preformed styles of wire rope need to be seized prior to cutting.

  • Page 37: Table Of Contents

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Maintenance ....... . . 2-4 Hydraulic Valves .
  • Page 38 HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL Table 2-1 Hydraulic Symbols Description Symbol Description Symbol Hydraulic Reservoir - Stores, cools, and Filter - Removes contamination from cleans machine’s hydraulic fluid supply hydraulic fluid Hydraulic Return Lines - Terminated at: (1) below fluid level, (2) above fluid level Filter with Bypass Valve - Bypass valve allows hydraulic fluid to bypass the filter if the filter becomes clogged...
  • Page 39 NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM 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 Double-Acting Telescope Cylinder - Anchored rod pushes Pneumatic Operated - Valve shifted by barrel out when check valve is unseated...

  • Page 40: Maintenance

    Parts found damaged or out of tolerance when maintenance personnel who are properly trained. Use only National Crane is being performed need to be replaced. Replacement parts supplied parts to repair the crane. may be purchased through Manitowoc Crane Care parts department. Hydraulic System Maintenance Precautions SERVICE Contaminants in a hydraulic system affect operation and result in serious damage to the system components.

  • Page 41: Removing Air From The Hydraulic System

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Remove the reservoir drain plug and drain the reservoir. and forward. Replenish the reservoir hydraulic oil level Clean and install the drain plug and fill the reservoir with as necessary. clean hydraulic oil. CAUTION CAUTION Hydraulic oils must be of the same specifications or Hydraulic oil supply lines must be connected to the discoloration (milkiness) may occur.

  • Page 42: System Description

    HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL as practical, and allow the boom to remain in this • Hydraulic Remote Controllers (HRC) position overnight. This should allow trapped air to find • Pilot Manifold its way to the holding valve so that telescoping the boom •...

  • Page 43: Rcl Lockout Manifold

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM RCL Lockout Manifold system, releases the spring-applied brake in the swing gearbox, and provides enabling of the aerial lift configuration The RCL lockout manifold is located in the turret and (optional). disa bles crane fun ction s whe n the RCL senses an impending tipping condition.

  • Page 44: Hydraulic Oil Cooler

    HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL Hydraulic Oil Cooler HYDRAULIC VALVES The hydraulic oil cooler is located in front of the hydraulic This section provides descriptive information for all the reservoir mounted to the boom rest. Heated hydraulic oil hydraulic valves used on this crane. For a listing of all valves, returning to the hydraulic tank flows through a bypass valve the circuit they are used in, and their physical location, see to the hydraulic oil cooler and returns to the hydraulic tank.
  • Page 45 NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Valve Locations 9021-10 9021-2 9010-13 9021-9 Item Component Item Component Tool Circuit Manifold RCL Lockout Manifold Swing and Air Conditioner Control Valve Holding Valve Directional Control Valve (DCV) Standard Swing Motor Manifold Pilot Manifold (crane power/AC/swing brake/ Dual-Mode Swing Motor Manifold aerial) (if equipped)
  • Page 46 HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL 9021-4 9021-8 9021-1 9021-6 9021-3 9021-5 9021-10 Item Component Item Component Pressure Intensifier (if equipped, located on aerial Swing Brake Valve lift platform) Remote Controllers (if equipped) Front Outrigger Manifold Rear Outrigger Manifold Outrigger Pressure-Reducing Valve Hydraulic Joystick (X 2) Pump Manifold Telescope Valve (if equipped)
  • Page 47 NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Directional Control Valve - 4 Section Valve (with Aux. Hoist) 9013-4 FIGURE 2-3 Directional Control Valve Item Numbers Item Description Item Description Item Description Boom Relief Valve - Up Aux Hoist Relief Valve - Gauge Port Main Hoist Relief Valve - Up Tele Cyl Relief Valve - Load Sense Bleed-Off...
  • Page 48 HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL 75881-1 FIGURE 2-4 Swing Control Valve Item List & Port/Hosing Item Description Item Description Item/Port Description HRC - Swing 1 (R) Swing Relief Valve - Swing Hose - A/C Pressure Motor Swing Relief Valve - Swing Hose - Return to Tank Hose - Swing Motor Load Sense Port - Swing Motor...

  • Page 49: Relief Valve Pressure Setting Procedures

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM RELIEF VALVE PRESSURE SETTING Release the control lever after taking each reading and while making adjustments. When the proper PROCEDURES pressure setting has been attained, tighten the adjustment screw lock nut and recheck the Description pressure.
  • Page 50 HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL Relief Valve Pressure Settings Valve To Be Set Pressure Setting Tolerance Valve Adjustment Location Telescope Retract Relief (with aerial lift) 112 bar (1,625 psi) ±7 bar (100 psi) Main Directional Valve Telescope Retract Relief (without aerial lift) 155 bar (2,250 psi) ±7 bar (100 psi) Main Directional Valve...

  • Page 51: System Pressure Check

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM System Pressure Check Boom Lift Up and Boom Lift Down See Figure 2-3 for the following procedure. Hoist Up and Hoist Down With the engine off, install a pressure check diagnostic See Figure 2-5 for the following procedure. quick disconnect (Parker PD240) with gauge onto the With the engine off, install a pressure check diagnostic test nipple at the GP gauge port of the DCV.
  • Page 52 HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL Telescope In and Telescope Out Outriggers See Figure 2-3 for the following procedure. With the engine off, install a pressure check diagnostic quick disconnect (Parker PD240) with gauge onto the NOTE: The telescope cylinder hoses can be disconnected test nipple at the GP gauge port of the DCV (see and capped for this procedure.

  • Page 53: Hydraulic Reservoir And Filter

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Start the engine and run at idle. Retract the SFO until the A magnetized drain plug (11) in the bottom of the reservoir cylinder is at the end of its stroke and hold the switch in collects metal particles from the hydraulic oil.

  • Page 54: Hydraulic Filter Replacement

    HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL 9013-2 Item Component Item Component Filter Element Fill Cap Hydraulic Reservoir Magnetized Drain Plug Breather Outrigger Drain Swivel Drain Access Cover Filter Head Pump Case Drain Capscrew (qty 6) Suction to Pump Filter Cap Temperature Gauge Filter Element Gauge Hydraulic Oil Level Gauge Filter Bowl...

  • Page 55: Hydraulic Oil Cooler

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Oil Cooler Item Component The hydraulic oil cooler (4, Figure 2-7) is located on the boom rest (7). The hydraulic oil cooler return circuit is parallel Hydraulic Reservoir with the reservoir return circuit (6). The hydraulic oil cooler Hydraulic Oil Cooler Inlet inlet (2) and return/out (3) circuits run through the bypass block (5) on top of the hydraulic reservoir (1).

  • Page 56: Directional Control Valve (Dcv)

    HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL A component functioning at reduced efficiency may indicate Check the valve for rust. Rust or dirt collecting on the valves that the control valve for that component is leaking internally. can prevent free movement of the spool and keep it from the If preliminary check-out reveals that adequate volume is true center position.

  • Page 57: Hydraulic Remote Controllers

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Remote Controllers Do not try to repair or set the valve pressure. If a holding valve is suspect, replace it with a new valve. The crane functions are controlled by hydraulic remote controllers (HRC) on the armrest of the operator’s seat. The Swing Gearbox controllers operate from pilot pressure, which is generated The standard Glide Swing gearbox is locked in place by an...

  • Page 58: Hydraulic Pump

    HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL HYDRAULIC PUMP See “Pump Startup” on page 2-22 before starting the engine. Description Pump Startup Hydraulic system pressure is supplied by an axial piston If the hydraulic pump is removed for maintenance or hydraulic pump mounted to the truck power take-off (PTO) or replacement, the following startup procedure should be truck chassis.

  • Page 59: Pump Margin Pressure Setting

    NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-3. Pressure Settings Pump Margin Pressure Maximum Pump Pressure Load Sense Relief Valve Pressure 26 ±4 bar (375 ±50 psi) 345-0+4 bar (5,000 -0+50 psi) 288 ±7 bar (4,175 ±100 psi) Pump Margin Pressure Setting Crane Preparation Start the engine and run at idle.

  • Page 60: Troubleshooting

    1.720 (43.69) 0.118 (3.00) 1 7/8-12 NOTE: Contact your National Crane distributor or Manitowoc Crane Care for O-ring boss seal kits. TROUBLESHOOTING possible solution. These are not all inclusive but are designed to help isolate the problem and should be checked...
  • Page 61 NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-5. Troubleshooting CONDITION POSSIBLE CAUSE POSSIBLE SOLUTION Low hydraulic oil level Fill reservoir. Reservoir-to-pump suction lines broken or Check that all connections are tight and there are restricted. Air entering at suction lines. no cracks. Clean, tighten, repair, or replace parts as Pump not priming.
  • Page 62 HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL CONDITION POSSIBLE CAUSE POSSIBLE SOLUTION Pump not operating at proper speed or Check PTO ratio, pump size, and engine speed for displacement. proper oil flow. Low hydraulic fluid supply. Check and fill as required. Poor hydraulic system Relief valve sticking.
  • Page 63 NBT40-1 SERVICE MANUAL HYDRAULIC SYSTEM CONDITION POSSIBLE CAUSE POSSIBLE SOLUTION Attempting to swing up too much of incline. Level machine. Turn circuit relief valves sticking. Clean and check circuit pressure. Swing bearing drag. Lubricate thoroughly as rotating boom. Swing does not function Check for a minimum of 14 bar (200 psi) brake pilot (Standard System).
  • Page 64 HYDRAULIC SYSTEM NBT40-1 SERVICE MANUAL CONDITION POSSIBLE CAUSE POSSIBLE SOLUTION Use dry lubricant or replace lube plugs in wear Boom sections need lubrication. pads. Wear pads not shimmed correctly. Re-shim as described in boom assembly section. Boom chatters during Boom hot from high extend duty cycle. Slow duty cycle to cool boom and pads.
  • Page 65 NBT40-1 SERVICE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION CONTENTS Description ........3-1 Micro Relay Fuse Box 2 .

  • Page 66: Dielectric Grease

    ELECTRICAL SYSTEM NBT40-1 SERVICE MANUAL Dielectric Grease Dielectric grease was applied to the following connections at the factory when the crane was assembled. When servicing electrical connections, dielectric grease must be re-applied to these connections. Rubber Seal • All Deutsch Connectors •...

  • Page 67: General Troubleshooting

    Manitowoc Crane Care for more information. when the overhaul ball, hook block, or wire rope becket is Manitowoc Crane Care recommends you have as part of near the boom tip and disables the functions that cause a your service tool kit inventory the Orchestra (CAN-Link) two-block condition.

  • Page 68: Fuse And Relay Panel

    ELECTRICAL SYSTEM NBT40-1 SERVICE MANUAL (4). The A2B switch assembly cable is attached to the anti- NOTE: The slew encoder is on the CAN cable and internal two-block weight (5). to the electrical slip ring. The RCL cable (3, Figure 3-2) runs from the bottom of the The two lift cylinder pressure transducers are integral to the reel (2) to the end of the boom, then splits, with one cable lift cylinder, and CAN cables are routed from each sensor to...
  • Page 69 NBT40-1 SERVICE MANUAL ELECTRICAL SYSTEM 9014-6 7600-2 FIGURE 3-3 Item Component Item Component Fuse and Relay Panel Fuse Box #1 Buzzer, 3rd wrap indicator ACC Relay RCL Bypass Key Switch Crane Relay Fuse Box #3 Remotes Relay Fuse Box #2 HVAC Relay National Crane Published 7-01-2021 Control # 655-02...

  • Page 70: Micro Relay Fuse Box 2

    ELECTRICAL SYSTEM NBT40-1 SERVICE MANUAL Micro Relay Fuse Box 1 Micro Relay Fuse Box 2 9014-2 9014-1 FIGURE 3-4 FIGURE 3-5 Micro Relay Fuse Box 1 Micro Relay Fuse Box 2 Micro relay fuse block 1 (6, Figure 3-3) is located on the left Micro relay fuse block 2 (5, Figure 3-3) is located in the side of the fuse relay panel and contains the following middle of the fuse relay panel and contains the following...

  • Page 71: Micro Relay Fuse Box 4

    NBT40-1 SERVICE MANUAL ELECTRICAL SYSTEM Micro Relay Fuse Box 3 • R1 - Lower Control Interlock Relay • R2 - A92.2 Interlock Relay • R3 - Crane Function Interlock Relay • R4 - LMI Lockout Relay • R5 - Crane Power and Remote Power Relay •...
  • Page 72 ELECTRICAL SYSTEM NBT40-1 SERVICE MANUAL Micro Relay Fuse Box 4 Micro Relay Fuse Box 4 Micro relay fuse block 4 (1, Figure 3-7) is located at the rear of the crane, below the counterweight and windshield wash reservoir (2) and is installed with the radio remote option. Micro relay fuse box 4 contains the following components.

  • Page 73: Vec Module

    NBT40-1 SERVICE MANUAL ELECTRICAL SYSTEM 9023-4 9023-5 Item Component Item Component Truck Ignition Relay Vehicle Electrical Center (VEC) Oil Cooler Relay Diode (2 used) Not Used Circuit Breaker 1 (CB1) - 20 Amp Engine Start Relay Circuit Breaker 2 (CB2) - 20 Amp Not Used Circuit Breaker 3 (CB3) - 30 Amp Crane Ignition Relay...

  • Page 74: Crane Manifold Solenoids

    ELECTRICAL SYSTEM NBT40-1 SERVICE MANUAL 7587-3 Item Solenoid Valve Boom Down Hoist Down Hoist Up Telescope Extend Auxiliary Hoist Up (Optional) Auxiliary Hoist Down (Optional) Swing Brake Release Air Conditioning Aerial A92 Relieving Valve 9013-5 Crane Power/HRC Enable RCL Lockout Manifold Pilot Manifold FIGURE 3-10 CRANE MANIFOLD SOLENOIDS...
  • Page 75 NBT40-1 SERVICE MANUAL ELECTRICAL SYSTEM Before replacing a relay or solenoid, check the connector for non-electrolytic grease. Non-electrolytic grease insulates the corrosion. Clean the connector with fine sand paper and connection and prevents relay operation. l u b r i c a t e w i t h e l e c t r o l y t i c g r e a s e . D o n o t u s e a Problem Cause Solution...

  • Page 76: Outrigger Manifolds

    ELECTRICAL SYSTEM NBT40-1 SERVICE MANUAL OUTRIGGER MANIFOLDS of the front outrigger box (Figure 3-11), and the rear outrigger manifold is mounted at the center of the rear of the truck There are two outrigger manifolds located on the carrier under the T-box (Figure 3-12). frame.

  • Page 77: Rear Outrigger Manifold

    NBT40-1 SERVICE MANUAL ELECTRICAL SYSTEM Rear Outrigger Manifold The solenoids on the rear outrigger manifold control the selection of the rear outrigger components. See Figure 3-12 (1 through 4) for solenoid identification. 7601-3 Item Solenoid Driver Side Stabilizer 7601-1 Driver Side Beam Passenger Side Beam Passenger Side Stabilizer FIGURE 3-12...

  • Page 78: Hydraulic Oil Cooler

    ELECTRICAL SYSTEM NBT40-1 SERVICE MANUAL HYDRAULIC OIL COOLER The temperature sensor (2) is located in the cooling core and energizes the fan relay when the hydraulic oil reaches 49°C The hydraulic oil cooler (3, Figure 3-13) is mounted on the (120°F).
  • Page 79 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE SECTION 4 BOOM MAINTENANCE SECTION CONTENTS Four-Section Boom ......4-1 Five-Section Cable Tensioning .

  • Page 80: Boom Removal

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 1/2/3 EXTEND SHEAVE CASE 2/3/4 EXTEND BASE BOOM REAR TEL #1 BOOM SECTION TEL #2 BOOM TEL #3 BOOM SECTION 8860-2 4/3/2 RETRACT 3/2/1 RETRACT FIGURE 4-1 See Figure 4-1, Figure 4-9, and Figure 4-13 for boom boom pivot pin and lower the counterweight until it rests removal, disassembly, assembly, and cable tensioning.

  • Page 81: Four-Section Boom Disassembly

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Four-Section Boom Disassembly Option 1 7 6 14 13 Option 2 BASE BOOM SECTION View B View A 9015-4 Item Description Item Description Item Description Nut (Adjustment) Inspection Cover Base Boom Section Washer TEL #1 Boom Section Capscrew 1/2/3 Extend Cables Nut (Positive Lock)
  • Page 82 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 9015-13 4, 5 1, 2 Item Description Capscrew Washer Cam Plate Capscrew Washer Wear Pad Retaining Plate Top Wear Pad FIGURE 4-3 See Figure 4-3 for the following steps. Remove the capscrews (4), washers (5), and wear pad retaining plate (6).
  • Page 83 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE 9015-6 Item Description Lock Washer Capscrew Capscrew Jam Nut Back Plate Wear Pad Back Plate Wear Pad Upper Plate Shim Capscrew Lock Washer Flat Washer Socket Head Capscrews Bottom Wear Pad Capscrew Shim Shim Upper Side Wear Pad Lock Nut Retract Cable Capscrew...
  • Page 84 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 9015-8 Item Description TEL #1 Boom Section Rear Wear Pad Shim Capscrew Retract Cable Guide Roller Setscrew Retract Sheave Pin Retract Sheave Bearing Base End 10 Spacer 11 Snap Ring 12 Capscrew 13 Retract Cable Keeper Bracket 14 Cable Anchor Assembly 15 Capscrew 16 Bottom Wear Pad...
  • Page 85 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Option 1 9015-10 Option 2 Front Rear 8 9 10 TEL #1 BOOM SECTION CONTINUED Item Description Item Description Item Description 2/3/4 Extend Cables Steel Pad Bearing Nut (Adjustment) Shim Sheave Nut (Positive Lock) Cable Guide Cable Anchor Assembly Capscrew Cable Assembly...
  • Page 86 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL View A View B Rear TEL #2 BOOM SECTION Front Item Description Item Description Item Description Boom Section Rear Lock Washer Cable Keeper Bracket Keeper Wear Pads Cable Keeper Shim Capscrew Capscrew Capscrew Sheave Wear Pad Capscrew Lock Washer Shim...
  • Page 87 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Rear Front TEL #3 BOOM SECTION Item Description Item Description Item Description Capscrew Capscrew Cam Plate Lock Washer Cable Sheave Pin Keeper Capscrew Spacer Wear Pad Keeper Bearing Plate Capscrew Loadline Sheave Retract Anchor Capscrew Spacer Wear Pads Shim...

  • Page 88: Additional Maintenance (Disassembled Boom)

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 39. Lower the cylinder to the original position. Attach a sling Lubricate all cable assemblies as required. Lubricate all or chain to the front of the TEL #3 boom section and pull cable assemblies before reinstalling them in the boom. the TEL #3 boom section out of the TEL #2 boom Inspect all sheave pins for nicks, gouges, or pitting due section approximately one foot.
  • Page 89 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Install the center bearing (5) and loadline sheave (6) Raise and support the TEL #3 boom section in the front with the grease fitting facing either side. of the TEL #2 boom section. Install the top bearing (5) and loadline sheave (6) to TEL #3 and TEL #2 Boom Section the left-hand side of the boom with the spacer (7) to See Figure 4-7 for the following steps.
  • Page 90 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Install the bearings (5) into the 2/3/4 extend cylinder front of the TEL #2 boom section. Install the 4/3/2 retract sheaves (6). anchor (18) into the anchor plates at the rear of the TEL #3 boom section. b.
  • Page 91 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Install the two side wear pads (2) and shims (3) onto the Slide the pins (with sheaves) into the slots in front of pins at the rear of the TEL #2 boom section. Shim the sheave anchor assembly (20). Fold back and according calibration instructions...
  • Page 92 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 18. Install the wear pad (7) on top of the 2/3/4 extend cable NOTE: Do not twist the cables. Twisting the cables will result in damage or failure of the cable. When anchor assembly (4), then install the 2/3/4 extend cable initially assembling the threaded ends of the anchor assembly in the slots of the rear of the TEL #1 cables, thread the first nut on past the flat so...
  • Page 93 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE 24. Route the 3/2/1 retract cables between the bottom of the NOTE: Apply multipurpose grease (MPG) to all wear pads TEL #1 boom section and the bottom pad shims. and contact surfaces. 25. Install two side wear pads (2) and shims (3) onto the rear Rotate the base section cylinder shaft so the of the TEL #1 boom section.
  • Page 94 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL NOTE: Do not twist the cables. Twisting the cables will See Figure 4-2 for the following steps. result in damage or failure of the cable. When 14. Attach the base section cylinder rod to the base section initially assembling threaded ends of cables, thread hoist mount with washers (3) and capscrews (2).

  • Page 95: Four-Section Cable Tensioning

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Four-Section Cable Tensioning Mark the front of each section with a chalk line as indicated in Figure 4-9. After boom assembly or if the interior proportioning cables Extend and retract the boom several times to establish appear loose, cable tensioning may be necessary.

  • Page 96: Cable Retention

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Retraction Continue tightening until the retraction gap between the first and second sections and the retraction gap between Measure the retraction gaps between the first and the second and third sections are equal. second sections and the second and third sections. Tighten the extend cables to 61.01 Nm (45 ft-lb).

  • Page 97: Four-Section Top And Bottom Pad Replacement (Assembled Boom)

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Four-Section Top and Bottom Pad Torque Values for Second Lock Nut Replacement (Assembled Boom) Table 4-1 Inspect the top and bottom wear pads periodically for signs of abrasion or excessive wear. Inch Series with Coarse Threads (UNC) Excessive wear is wear that is in excess of 4.76 mm (0.188 Minimum Nut Cable End...
  • Page 98 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Top Wear Pad Replacement 9015-1 Item Description Inspection Hole Capscrew Washer 2, 3, 4 Cam Plate Washer option 1 Capscrew Wear Pad Retaining Plate Top Wear Pad option 2 Shim 1/2/3 Extend Cable Nut (Adjustment) Back Plate Nut (Positive Lock) Nut (Torqued)
  • Page 99 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Bottom Wear Pad Replacement VIEW A Item Description Capscrew Bottom Wear Pad VIEW C VIEW B 9015-2 FIGURE 4-12 See Figure 4-12 for the following steps. bottom wear pads (2, View A and B) and remove the bottom wear pads.

  • Page 100: Five-Section Boom

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL ‘FIVE-SECTION BOOM The 3/2/1 retract cables directly oppose the 1/2/3 extend cables to ensure that the TEL #1 and TEL #2 boom sections See Figure 4-13 for the following information. extend and retract equally at all times. A two-section, rod fed, double-acting cylinder is attached to The 4/3/2 retract cables directly oppose the 2/3/4 extend and supports the base, TEL #1, and TEL #2 boom sections.

  • Page 101: Boom Removal

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Boom Removal the counterweight retaining hardware from the boom pivot pin and lower the counterweight until it rests on the See Figure 4-13, Figure 4-21, Figure 4-18, Figure 4-20, and rear outrigger box. Figure 4-21 for Boom Removal, Disassembly, Assembly and Attach a lifting device to the rod end of the lift cylinder, Cable Tensioning.

  • Page 102: Five-Section Boom Disassembly

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Five-Section Boom Disassembly option 1 option 2 6 14 View B View A BASE BOOM SECTION 9020-1 Item Description Item Description Item Description Inspection Cover Nut (Adjustment) Base Boom Section TEL #1 Boom Section Washer Capscrew Nut (Positive Lock) 1/2/3 Extend Cables...
  • Page 103 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE 9020-1 BASE BOOM SECTION Continued 4, 5 1, 2 Item Description Capscrew Washer Cam Plate Capscrew Washer Wear Pad Retaining Plate Top Wear Pad FIGURE 4-15 NOTE: All top wear pads must be tagged, inspected, and Remove the capscrews (4) and washers (5) and remove reassembled exactly as they have been removed.
  • Page 104 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 9020-3 BASE BOOM SECTION Continued Item Description Item Description Item Description Shim Shim Capscrew Lock Washer Upper Side Wear Pad Capscrew Lock Washer Lock Nut Flat Washer Capscrew Jam Nut Socket Head Capscrews 3/2/1 Retract Cable Back Plate Bottom Wear Pad Capscrew...
  • Page 105 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE See Figure 4-16 for the following steps. (23) that retain the 3/2/1 retract cable anchor plates (24) to the bottom front of the base boom section. 11. Remove and tag the nut (1), lock washer (2), and capscrew (3) on the front end of the base boom section 15.
  • Page 106 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Option 1 Option 2 25 26 VIEW A VIEW B 9020-4 TEL #1 BOOM SECTION Item Description Item Description Item Description Wear Pad TEL #1 Boom Section Cable Anchor Capscrew Wear Pad Rear Wear Pad Capscrew Shim Flathead Screw...
  • Page 107 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE See Figure 4-17 for the following steps. 23. Remove and tag the cable guide (33) and hardware (30—32 and 34) located on the top front of the TEL #1 17. Remove the capscrew (4) and guide roller (5) from each boom section.
  • Page 108 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Option 1 9020-8 Option 2 41 42 VIEW A VIEW A 59 58 VIEW B TEL #2 BOOM SECTION Item Description Item Description Item Description Boom Section Rear Wear Pad Guide Roller Wear Pad Wear Pad Capscrew Shim Shim...
  • Page 109 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE See Figure 4-18 for the following steps. the TEL #4 boom section and drape outside of rear end of the TEL #2 boom section. 28. Remove the capscrews (19), retract cable keeper bracket (20), and cable keeper (21) from the lower rear See Figure 4-19 for the following steps.
  • Page 110 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 9020-6 TEL #3 BOOM SECTION Item Description Item Description Item Description Bearing Wear Pad Boom Section Rear Shim Cable Anchor Assembly Wear Pad Wear Pad Sheave Pin Shim Shim Flat Washer Cam Plate Wear Pad Snap Ring Flat Washer Wear Pad Assembly...
  • Page 111 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE 49. Attach a sling or chain to the front of the TEL #4 boom 51. Remove the grease fittings (29) from the sheave pin (31) section and pull the TEL #4 boom section out at the front of the TEL #3 boom section. Remove the ten approximately six feet.

  • Page 112: Additional Maintenance (Disassembled Boom)

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Additional Maintenance (Disassembled NOTE: For reference, the front of the boom is the sheave case end, rear is hoist mount end, and the left and Boom) right are viewed from rear to front. Clean all boom sections and inspect for wear, dents, TEL #4 Boom Section bent or crooked boom sections, gouged metal, broken welds and any abnormal conditions.
  • Page 113 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Install the bottom rear wear pads (12), shims (13), and Install the 3/4/5 extend sheave assembly (42) inside the capscrews (11) to the rear of the TEL #4 boom section front of the TEL #3 boom section. (1).
  • Page 114 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Install the upper capscrew (11), washer (13), and nut Raise and support the TEL #3 TEL #4 boom sections (14) only. Swing the wear pad (12) and position the 3/4/5 and install them into the TEL #2 boom section extend cables between the opening of the cable approximately fifteen feet.
  • Page 115 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE NOTE: Install cables in their natural untwisted condition. d. Install a bearing (24) into both sheaves (23) and Do not twist the cables. Twisting the cables will brush with chassis grease. Install the sheaves on result in damage or failure of the cable.
  • Page 116 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Install the two top wear pad retaining plates (8), wear Slide the pin assembly into the slots in the front of pads (9), capscrews (10), and flat washers (11) onto the the sheave case assembly (48). Fold back and rear of the TEL #2 boom section (1).
  • Page 117 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE NOTE: Apply multipurpose grease (MPG) to all wear pads 20. Route three 3/2/1 retract cables around the 3/2/1 retract and contact surfaces. cable keeper (21) and install them on the cable keeper bracket (20) with capscrew (19) onto the 3/2/1 retract 12.
  • Page 118 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL TEL #1 and Base Boom Section Install the side wear pads (8), wear pad backup plates (7), and back plates (6) to both sides of the base boom See Figure 4-17 for the following steps. section.

  • Page 119: Five-Section Cable Tensioning

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE 16. Tighten the cables per the five-section cable tensioning the cable ends to prevent cable twist. Excess twisting of the procedure. See “Five-Section Cable Tensioning” on cables can cause premature failure. page 41. Ensure the boom is completely assembled and fully 17.
  • Page 120 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Extend and retract the boom a few times and then Extend and retract the boom a few times and then repeat measuring the extension gaps. repeat measuring the extension gaps. NOTE: The second section should have moved out. NOTE: The fourth section should have moved out.

  • Page 121: Cable Retention

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Retraction Extend and retract the boom a few times and then repeat measuring the retraction gaps. Measure the retraction gaps between the fourth and fifth sections and between the third and fourth section. The fifth section should have moved in. If the retraction gap is greater between the fourth and fifth Continue tightening until the retraction gap between the section than the retraction gap between the third and fourth...

  • Page 122: Five-Section Top And Bottom Pad Replacement (Assembled Boom)

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL Five-Section Top and Bottom Pad Torque Values for Second Nut Replacement (Assembled Boom) Table 4-2 Inspect the top and bottom wear pads periodically for signs of abrasion or excessive wear. Inch Series with Coarse Threads (UNC) Excessive wear is wear in excess of 4.78 mm (3/16 in) from Minimum Nut Cable End...

  • Page 123: Boom Calibration

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Extend the boom approximately (41.75 in) (10.44 in per Bottom Pad Replacement section) so that the upper wear pads on the TEL #1 Lower the boom until the boom lift cylinder is bottomed boom section are visible through the hole in the top plate out and extend the boom out approximately eight feet.

  • Page 124: Inner Side Wear Pads

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL cylinder anchor bars, take a measurement directly in front of these bars. 9023-38 9023-40 CYLINDER CYLINDER CYLINDER ANCHOR ANCHOR ANCHOR BARS BARS OUTER SECTION BARS OUTER SECTION FIGURE 4-25 FIGURE 4-27 The top rear wear pads also act as the top side pads. These pads are anchored in place by means of offset With the inside/outside calipers, measure the outside retainers that are bolted onto the inner boom top plates.

  • Page 125: Rear, Bottom Wear Pads

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Rear, Bottom Wear Pads 9023-44 With a tape measure, measure the inside height of the outer section (H ) at the front and back of the boom and record the smallest measurement. If the section has cylinder anchor bars, take a measurement directly in front of these bars.

  • Page 126: Hydraulic Cylinder

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 9023-46 = 492.3 mm (19.38 in) AT FRONT 492.3 mm (19.38 in) AT BACK NEAR CYLINDER ANCHOR BARS FIGURE 4-33 = 17.88 19.38 -17.88 - 0.75 -twp - 0.50 -twp 0.25 Clearance - 0.19 Bottom shims 0.06 Final Clearance HYDRAULIC CYLINDER...

  • Page 127: Cylinder Reassembly

    NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Using hydraulic power (porta power or crane circuit) Install the O-ring and backup rings on the inner diameter extend the hydraulic cylinder sections approximately of the base section piston and thread onto the base 609.6 mm (24 in). If the sections do not move equally, section cylinder shaft assembly until snug, making retain the moving section to allow for equal extension of certain that the piston counterbore is seated over the...

  • Page 128: Jib Boom

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL JIB BOOM 3/4 in GRADE 5 9023-49 (TYP 4 PLCS) Jib Stowage Bracket Adjustment 9.7 mm (0.38 in) It is extremely important for the safety of the crane operator and all others working near the crane that the jib boom extension be properly secured to the jib stowage bracket 1.5 mm 9.7 mm...
  • Page 129 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE proper alignment. Position the top ear so it holds the top of the jib in toward the boom and the bottom ear so that it STOWAGE BRACKET holds the bottom of the jib away from the bottom of the boom, see Figure 4-41.

  • Page 130: Jib Jack Service And Maintenance

    BOOM MAINTENANCE NBT40-1 SERVICE MANUAL 7462-30 Ear Assemblies FIGURE 4-44 FIGURE 4-43 7462-28 S-Pin Adding Oil 10. Try to remove the jib pins. If the pins are too tight, the With the saddle fully lowered and the piston depressed, stow hook assembly or front bars will need to be set jack in its upright level position and remove oil filler adjusted.
  • Page 131 NBT40-1 SERVICE MANUAL BOOM MAINTENANCE Troubleshooting Table 4-3. Symptom Possible Cause(s) Corrective Action Will not lift load. 1. No oil in system 1. Add oil to reservoir tank through oil filler hole. 2. Release valve not closed 2. Turn handle clockwise tightly. Will lift load only partway.
  • Page 132 BOOM MAINTENANCE NBT40-1 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-54 Published 7-01-2021 Control # 655-02...
  • Page 133 NBT40-1 SERVICE MANUAL HOIST SECTION 5 HOIST SECTION CONTENTS Description ........5-1 Troubleshooting .

  • Page 134: Hoist Removal

    HOIST NBT40-1 SERVICE MANUAL Hoist Removal Remove the hoist (4 or 7) from the crane with the lifting device. Hydraulic Hoses CAUTION Inspect the hoist hydraulic tubes and hoses (17, 18, and 23) The combined weight of the hoist and 137 m (450 ft) of for cracks or damage that may cause leaks.
  • Page 135 NBT40-1 SERVICE MANUAL HOIST FIGURE 5-1 7582 Item Component Item Component Item Component Cover Elbow Tube, Lower Flatwasher Union Tube, Raise HHCS Washer Adapter Main Hoist Washer Motor Washer (8 places) Elbow, 90 HHCS (8 places) 5/8-11UNC Boom Brake Auxiliary Hoist Washer Case Drain Hose Cable, 5/8...

  • Page 136: Hoist Rotation Indicator (Hri) System

    HOIST NBT40-1 SERVICE MANUAL Hoist Rotation Indicator (HRI) System HRI Display The HRI display (1, Figure 5-3) is located in the front The HRI system consists of an LED display that indicates the overhead panel. direction the hoist(s) are rotating, pressure switches that monitor hydraulic pilot pressure, and a control module To replace the display, remove the overhead panel.

  • Page 137: Drum Rotation Indicator

    NBT40-1 SERVICE MANUAL HOIST To replace the control module, tag and disconnect the wires The DRI transducer and integral 3rd Wrap Indicator is from the module (see Figure 5-5). The module is mounted to programmed to notify the operator when there are three the bulkhead using double-sided adhesive tape.

  • Page 138: Programming The 3Rd Wrap Indicator

    HOIST NBT40-1 SERVICE MANUAL Series A 8640-2 Series B 8640-8 FIGURE 5-7 8640-1 Installation To install the DRI, use the following procedure: Install shaft assembly into 3rd wrap indicator. Apply silicone sealant on the setscrew to prevent oil getting into electronics. Tighten setscrew.

  • Page 139: Shipping Mode (Series A Only)

    NBT40-1 SERVICE MANUAL HOIST NOTE: Use an Allen Wrench or other small tool with a flat, blunt end approximately 1.5mm or (1/16") in width and at least 76 mm (3") in length. Use of a pointed or sharp tool can cause faulty setting or damage to the HMS.

  • Page 140: Troubleshooting

    HOIST NBT40-1 SERVICE MANUAL To use Shipping Mode: Remove the brake subassembly from the hoist by removing eight capscrews (9) holding the brake housing Install the wire rope on the drum. Refer to the to the side plate (27). Reinstall two of these capscrews appropriate winch manual for more information.
  • Page 141 NBT40-1 SERVICE MANUAL HOIST Attach the base (56), and support rod (2) to the side 13. Install five pins (51) between the ring gear (25) and the plate (29) with twelve capscrews (1, 57, and 87) and two drum (5). nuts (58).
  • Page 142 HOIST NBT40-1 SERVICE MANUAL 9012 FIGURE 5-10 5-10 Published 7-01-2021 Control # 655-02...
  • Page 143 NBT40-1 SERVICE MANUAL HOIST Hoist Parts List Item Description Item Description Item Description Capscrew Retaining Ring Straight Adapter Support Rod Output Sun Gear Tee Fitting Counterbalance Block Thrust Bushing 90 deg Adapter Output Planet Gearset Friction Disk 90 deg Adapter Carrier Stator Plate Capscrew...

  • Page 144: Brake

    HOIST NBT40-1 SERVICE MANUAL Brake slide the driver/clutch assembly onto the sun gear spline. See Figure 5-10 and the Hoist Parts List on page 5-11 for 12. Install the stator plates (19) and friction disks (18) into the following brake service steps. the brake housing, starting with a stator and alternating Evenly remove the four capscrews (11) holding the friction discs and stator plates.

  • Page 145: Planetary Set

    NBT40-1 SERVICE MANUAL HOIST Planetary Set Motor See Figure 5-10 and the Hoist Parts List on page 5-11 for See Figure 5-12 and the Hoist Parts List on page 5-11 for the following procedure. the following procedure. Remove the spiral retaining rings (4-4 and 36-4) from Remove and tag lines.

  • Page 146: Troubleshooting

    HOIST NBT40-1 SERVICE MANUAL TROUBLESHOOTING Problem Cause Solution Check the system for restrictions and reduce the Excessive back pressure in the system. back pressure. The hoist does not hold Brake discs are worn out. Replace brake discs. the load. Inspect the clutch and driver for wear and replace Hoist clutch is slipping.
  • Page 147 NBT40-1 SERVICE MANUAL SWING SECTION 6 SWING SECTION CONTENTS Description ........6-1 Maintenance.
  • Page 148 SWING NBT40-1 SERVICE MANUAL 8766-1 Dual-Mode Swing Motor Manifold Item Description Swing Motor Adjustable Speed Valve Brake Coolant Out Standard Swing Motor Manifold Service Brake Apply Breather Brake Coolant In Parking Brake Release Fill Screw & Flatwasher, 3/4 in Gearbox Control Clockwise 7582-1 Control Counterclockwise...
  • Page 149 NBT40-1 SERVICE MANUAL SWING 9023-8 Outer Planetary Gear Inner Planetary Gear FIGURE 6-2 Item Component Item Component Gear Housing Capscrew (qty 8) Output Shaft Drain Plug (qty 2) Oil Seal Plate Lower Bearing Retaining Washer Lower Bearing Race Output Planetary Pin Upper Bearing Race Washer Upper Bearing...

  • Page 150: Swing Gearbox And Brake

    SWING NBT40-1 SERVICE MANUAL SWING GEARBOX AND BRAKE • Retaining ring pliers • Gear puller The swing drive is a double planetary gear reducer with an integral brake. The planetary gear reducer is designed for • Ratchet wrench (1/2 in drive) long life in heavy-duty applications such as crane rotation.

  • Page 151: Input Planetary Repair

    NBT40-1 SERVICE MANUAL SWING Shaft Repair CAUTION See Figure 6-2 for the following procedure. The lock nut is no longer retaining the output shaft. Care The lower bearing (4) may be removed from the output should be taken when moving the gear housing because shaft (2) using a gear puller.

  • Page 152: Swing Brake

    SWING NBT40-1 SERVICE MANUAL Set the bearing preload by tightening the lock nut (9) 19. Fill the gear housing with 3.8 L (1 gal) of EP 80-90 gear onto the output shaft (2) to a torque of 135 Nm (100 ft lb). grease.
  • Page 153 NBT40-1 SERVICE MANUAL SWING 11. Remove the bearing (4) and the oil seal (3) from the brake housing. 9023-9 FIGURE 6-3 Item Component Item Component O-ring Stator Plate (qty 6) Brake Housing Friction Disc (qty 4) Oil Seal Back-up Ring Bearing O-ring Back-up Ring...

  • Page 154: Assembly

    SWING NBT40-1 SERVICE MANUAL Assembly time until the cover is tight against the brake housing. Tighten the capscrews to a torque of 41 Nm to 47 Nm See Figure 6-3 for the following procedure. (30 ft-lb to 35 ft-lb). Assembly is in reverse order of disassembly with the SWING BEARING following additional instructions.

  • Page 155: Swing Bearing Capscrews

    NBT40-1 SERVICE MANUAL SWING existence of lubricant and plating that will cause variation When using step wrenches, calculated wrench settings are from dry torque values. When a high-strength capscrew is valid only when the following conditions are met. removed, or untorqued, the capscrew must be replaced with •...
  • Page 156 SWING NBT40-1 SERVICE MANUAL 7582-2 28 36 FIGURE 6-5 9023-11 9023-12 FIGURE 6-6 6-10 Published 7-01-2021 Control # 655-02...

  • Page 157: Bearing Clearance

    NBT40-1 SERVICE MANUAL SWING Outer Race Tightening Procedure Place the dial on the top of the turret bearing plate (1, Figure 6-8). The outer race capscrews (1, Figure 6-7) are located on top of the bearing. Power the boom down onto the boom rest. Set the dial indicator at zero.

  • Page 158: Bearing Replacement

    SWING NBT40-1 SERVICE MANUAL 9023-64 FIGURE 6-9 BEARING REPLACEMENT Slowly rotate the boom back to 20° off the front position. Elevate the boom slightly and shut down the engine. Removal Tag and disconnect the battery cables. Fully extend and set the outriggers enough to take up Remove the boom and lift cylinder, following the the slack in the pads.

  • Page 159: Installation

    NBT40-1 SERVICE MANUAL SWING Carefully lower the turret into position on the bearing plate. Be careful not to damage the swivel assembly. DANGER Ensure the lifting device is capable of supporting the 9023-14 boom assembly. 13. Remove the remaining capscrews and washers that secure the swing bearing outer race to the carrier.

  • Page 160: Slew Potentiometer Adjustment

    SWING NBT40-1 SERVICE MANUAL 9023-16 9023-15 FIGURE 6-11 Slew Potentiometer Adjustment Tighten the three screws (3) to secure the slew potentiometer to the mounting plate. Install the electrical See Figure 6-11 for the following procedure. swivel cover. The slew potentiometer is a component of the hydraulic and Release the swing brake and swing the turret to electric swivel assembly, which is mounted inside the approximately 10°...
  • Page 161 NBT40-1 SERVICE MANUAL SWING swivel assembly is the electrical swivel section (1, NOTE: Slew sensor calibration requires Orchestra Figure 6-12) and contains the slew sensor (2, Figure 6-12). software (version 2.4.7 or later), Windows-based PC, and diagnostic cable 80009992. See “Tooling fo r Trou ble shoo tin g”...

  • Page 162: Testing

    EEPROM window. Position the swing lock (5) onto the turret and secure it with four capscrews (9), bushings (10), and flat washers 12. Export the EEPROM data for Manitowoc Crane Care (11). and/or dealer records.
  • Page 163 NBT40-1 SERVICE MANUAL SWING 7589-2 9,11 7589-1 7589-3 View A FIGURE 6-14 Item Description Item Description Clevis Pin Capscrew (qty 4) Cotter Pin Bushing (qty 4) Washer Flat Washer (qty 4) Cable Spring (qty 2) Swing Lock Stop Capscrew Shim Lock Nut Capscrew (qty 2) Swing Bearing Ring Gear...

  • Page 164: House Lock

    SWING NBT40-1 SERVICE MANUAL HOUSE LOCK Insert the house lock cable into the house lock bracket (5) and securely tighten the lock nuts (3). The house lock holds the turret in place, preventing any type Align the yoke (2) with the hole in the house lock pin (1) of movement in either a counterclockwise or clockwise and install the clevis pin (not shown).
  • Page 165 NBT40-1 SERVICE MANUAL OUTRIGGERS SECTION 7 OUTRIGGERS SECTION CONTENTS Description ........7-1 Outrigger Calibration .
  • Page 166 OUTRIGGERS NBT40-1 SERVICE MANUAL 9023-17 Item Description Top Cable Adjustment Outer-Jackbeam Midbeam Outrigger Box Lock Pin Bottom Cable Adjustment Outrigger Float Stabilizer Extend Cylinder Anchor Capscrew Hydraulic Line FIGURE 7-1 Published 7-01-2021 Control # 655-02...

  • Page 167: Description

    NBT40-1 SERVICE MANUAL OUTRIGGERS 9023-18 Item Description Trunnion Extend/Retract Cable Top Cable Adjustment Hydraulic Hoses Hydraulic Hose Sheaves on the nose of the Extend Cylinder Cable sheaves on the Nose of the Extend Cylinder Bottom Cable Adjustment Hydraulic Tubes To Stabilizer Cylinder Extend Cylinder Anchor Bracket...

  • Page 168: Outrigger Beam Assembly

    OUTRIGGERS NBT40-1 SERVICE MANUAL Removal Remove the holding valve to allow extend cylinder rod movement. Raise the midbeam and outer jackbeam assembly against the outrigger box. Remove and tag the bottom wear pad and shims from the outrigger box. Mark the position and remove the retaining nuts from the proportioning cable stops at the bottom of the outrigger box.

  • Page 169: Assembly

    NBT40-1 SERVICE MANUAL OUTRIGGERS 21. Pull the outer jackbeam out of the midbeam and place it Install wear rings into the stabilizer leg. on adequate blocking. If necessary, remove and tag the Insert the stabilizer cylinder into the stabilizer tube. wear pads and shims from the outer jackbeam.

  • Page 170: Cable Tensioning

    OUTRIGGERS NBT40-1 SERVICE MANUAL OUTRIGGER CALIBRATION 21. Push the midbeam and outer-jackbeam assembly into the main outrigger box until the butt plate of the extend cylinder reaches the end of the outrigger box. Bolt the butt end of the extend cylinder to the end of the outrigger INSIDE OUTSIDE box.
  • Page 171 NBT40-1 SERVICE MANUAL OUTRIGGERS 9023-59 2 PLCS TOP 9023-60 FIGURE 7-9 Subtract the largest outside width (W Figure 7-8) of the inner section and the thickness of the two pads (t 1 PLC BOTTOM Figure 7-9) from the inside width of the outer section (W Figure 7-7).
  • Page 172 OUTRIGGERS NBT40-1 SERVICE MANUAL Table 7-1. Side Wear Pad Clearance Dimension (in) (inside width, smallest) 306.3 12.06 (outside width, largest) 279.4 (side wear pad thickness, 26.4 1.04 total) Clearance = W 0.02 Side Clearance Specification 0 to 1.5 0 to 0.06 INNER SECTION Top and Bottom Pads 9023-63...

  • Page 173: Outrigger Monitoring System (Oms)

    NBT40-1 SERVICE MANUAL OUTRIGGERS OUTRIGGER MONITORING SYSTEM (OMS) Install Fully retract the outrigger beam. The OMS aids the operator in accurately programming the rated capacity limiter (RCL) by automatically identifying the Install the string potentiometer to the outrigger box cover position of each outrigger beam.
  • Page 174 OUTRIGGERS NBT40-1 SERVICE MANUAL Startup During Operation Upon turning the operator cab key switch to the ignition Once boom functions are permitted, the boom functions position, the outrigger jack monitoring system begins to operate normally as per operating instructions. The outrigger sense the configuration of the machine.
  • Page 175 However, certain fluids, such as halogenated Potentially harmful waste used in Manitowoc Crane cranes hydrocarbons, nitro hydrocarbons, and phosphate ester includes — but is not limited to — oil, fuel, grease, coolant,...

  • Page 176: Lubricants

    NBT40-1 SERVICE MANUAL Open Gear Lubricant NOTE: All fluids and lubricants may be purchased by contacting the Manitowoc Crane Care Parts This is a special high-graphite adhesive lubricant that helps Department. to eliminate fretting corrosion, is water resistant, and forms a Regardless of temperature and oil viscosity, always use dry lubrication film which does not attract dust.

  • Page 177: Arctic Hydraulic Oil

    For colder operating conditions, the standard fluid may be level and must meet John Deere Standard JDM J20C. replaced with a petroleum-based fluid developed especially Contact your National Crane distributor or Manitowoc Crane for colder environments. Care if you have any questions.
  • Page 178 LUBRICATION NBT40-1 SERVICE MANUAL Table 8-1 Manitowoc Lube Specification Symbol Description Cold Weather - Standard 40°C (-40°F) Antifreeze/Coolant (for Cab Heater) 6829101130 6829104212 EP-MPG Extreme Pressure Multipurpose Grease 6829003477 6829104275 GL-5 GL-5 Gear Lubricant 6829012964 6829014058 HYDO Hydraulic Oil 6829006444...
  • Page 179 NBT40-1 SERVICE MANUAL LUBRICATION Lubrication Points Grease Tube 9013-3 Opposite side 8839-1 FIGURE 8-1 Recommended Item Application Procedure Frequency Lubricant Weekly as Required Hydraulic Oil Reservoir Hydraulic Oil Change/Check and Fill Semi-Annually After First 40 Hrs. As indicated Oil Filter, Hydraulic Oil Reservoir Change or Clean by Gauge Thereafter.
  • Page 180 LUBRICATION NBT40-1 SERVICE MANUAL Recommended Item Application Procedure Frequency Lubricant Chassis Grease After First 100 Operating Hours #200S Silver Weekly Pump Drive U-Joint (qty 2) (if equipped) Grease Gun or Direct Apply Streak Special Semi-Annually when Disassembled or Pump Spline Shaft (direct mount) Multi-Lube (light) Check and fill...
  • Page 181 NBT40-1 SERVICE MANUAL LUBRICATION Recommended Item Application Procedure Frequency Lubricant 24 Hook Block Sheaves EP-MPG Grease Gun Monthly 25 Turntable Swing Lock Pin EP-MPG Spray Monthly Check and fill w/ 4 ounces Polyalkylene Anytime A/C Is Disconnected or 26a Air Conditioning above 6 ounces in (PAG) Oil Serviced...

  • Page 182: Lubrication

    LUBRICATION NBT40-1 SERVICE MANUAL Internal Cable Sheave Lubrication contact surfaces at the top of all boom sections with a grease gun or a brush. Raise the boom to 75°. DANGER Extend and retract the boom several times until the Do not, under any circumstances, work at an elevated grease is evenly spread.

  • Page 183: Hoist Gearbox Oil

    Hoist gear lubricants are satisfactory for operation in temperatures from -23°C to 66°C (-10°F to +150°F). For operation outside this range, contact Manitowoc Crane Care for recommendations. National Crane Published 7-01-2021 Control # 655-02...

  • Page 184: Swing Gearbox And Brake Oil

    3.3 L (3.50 qt) of gear lube oil. Gearbox lubricants are satisfactory for standard operation in temperatures from -23°C to 82°C (-10°F to +180°F). For operation outside this range, contact Manitowoc Crane Care for recommendations. 9013-1 FIGURE 8-6...

  • Page 185: Air Conditioning

    NBT40-1 SERVICE MANUAL LUBRICATION AIR CONDITIONING • Have sufficient adhesive strength to remain on the rope • Be of a viscosity capable of penetrating the interstices When servicing the air conditioner, evacuate the system between wires and strands prior to disconnecting any components connected to the pressurized system.

  • Page 186: Carwell® Rust Inhibitor

    To help protect against corrosion of National cranes, In addition to the factory-applied treatment, National crane Manitowoc Crane Care recommends washing the crane at owners must provide proper maintenance and care to help least monthly to remove all foreign matter. More frequent ensure long-term protection of their crane against corrosion.

  • Page 187: Inspection And Repair

    Use of pressure pots to apply the treatment to the unit To the extent any damage is structural in nature, being processed is recommended. Manitowoc Crane Care must be contacted and consulted • Carwell® treatment is available in 16-ounce spray as to what repairs may be required.

  • Page 188: Areas Of Application

    • Frame application areas are: hose ends and fittings, all necessary. unpainted fasteners and hardware, all bare metal Please contact Manitowoc Crane Care if you have any surfaces, outrigger pads, and back-up alarm hardware. questions. • Superstructure applications are: hose end and fittings,...
  • Page 189 NBT40-1 SERVICE MANUAL LUBRICATION 8839-5 8839-4 FIGURE 8-8 National Crane 8-15 Published 7-01-2021 Control # 655-02...
  • Page 190 LUBRICATION NBT40-1 SERVICE MANUAL Item Description Hoist Plumbing Connections Tension Spring Counterweight Pins Boom Rest Valvebank, Hose Connections Inside Turntable Boom Extension Hardware (optional) Pivot Shaft Boom Nose Pins, Clips Downhaul Weight/Hook Block Mirror Mounting Hardware Powertrain Hardware O/R Hose Connections O/R Pins, Clips Entire Underside of Unit Turntable Bearing Fasteners...
  • Page 191 NBT40-1 SERVICE MANUAL CRANE INSTALLATION SECTION 9 CRANE INSTALLATION SECTION CONTENTS General ........9-1 Truck Preparation .

  • Page 192: Minimum Truck Requirements

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL MINIMUM TRUCK REQUIREMENTS determine allowable axle weights for every individual axle and axle group. Many factors must be considered in the selection of a proper • Truck Frame—Select a truck frame that will minimize or truck for a NBT40-1 series crane.
  • Page 193 NBT40-1 SERVICE MANUAL CRANE INSTALLATION Typical Serial Number Location 9023-27 FIGURE 9-1 Item Description Item Description Sub-base Turret Base Boom Section TEL #3 Boom Section TEL #1 Boom Section TEL #4 Boom Section TEL #2 Boom Section Lift Cylinder National Crane Published 7-01-2021 Control # 655-02...

  • Page 194: Mounting Configurations

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL MOUNTING CONFIGURATIONS NBT36-1 Configuration — Standard Torsion Box and 103 ft Boom Front 1,229.9 cm (40 ft 4.2 in) Stabilizer 389.1 cm 360° (12 ft 9.2 in) 68.6 cm (27 in) 382 cm 459 cm (150.3 in) (181 in) 193 cm...

  • Page 195: Nbt36-1 Configuration - Standard Torsion Box And 127 Ft Boom

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION NBT36-1 Configuration — Standard Torsion Box and 127 ft Boom Front Stabilizer 1,220 cm (40 ft 0.3 in) 389.3 cm 360° (12 ft 9.2 in) 68.6 cm (27 in) 381.8 cm 459 cm (181 in) (150.3 in) 182.9 cm (72 in)

  • Page 196: Nbt40-1 Configuration - Standard Torsion Box And 103 Ft Boom

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL NBT40-1 Configuration — Standard Torsion Box and 103 ft Boom Front 1,207 cm (39 ft 7.2 in) Stabilizer 386.9 cm 360° (12 ft 8.3 in) 68.6 cm (27 in) 205.7 cm 192.8 cm (81 in) (72 in) 505 cm (199 in)

  • Page 197: Nbt40-1 Configuration - Standard Torsion Box And 127 Ft Boom

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION NBT40-1 Configuration — Standard Torsion Box and 127 ft Boom Front 1,208.5 cm (39 ft 7.8 in) Stabilizer 387.1 cm (12 ft 8.4 in) 360° 68.6 cm (27 in) 205.7 cm 194.3 cm (81 in) (76.5 in) 505 cm (199 in)

  • Page 198: Nbt40-1 Configuration - Standard Torsion Box And 142 Ft Boom

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL NBT40-1 Configuration — Standard Torsion Box and 142 ft Boom Front 1,208.5 cm (39 ft 7.8 in) Stabilizer 388.1 cm (12 ft 8.8 in) 360° 68.6 cm (27 in) 205.7 cm 233.4 cm (81 in) (91.9 in) 505 cm (199 in)

  • Page 199: Nbt40-1 Configuration - Extended Torsion Box And 127 Ft Boom

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION NBT40-1 Configuration — Extended Torsion Box and 127 ft Boom 1,245.4 cm (40 ft 10.3 in) 360° 387.1 cm (12 ft 8.4 in) 68.6 cm (27 in) 205.7 cm 170.2 cm (81 in) (67 in) 9017-15 505 cm (199 in)

  • Page 200: Nbt40-1 Configuration - Extended Torsion Box And 142 Ft Boom

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL NBT40-1 Configuration — Extended Torsion Box and 142 ft Boom 1,245.4 cm (40 ft 10.3 in) 388.1 cm 360° (12 ft 8.8 in) 68.6 cm (27 in) 205.7 cm 170.2 cm (81 in) (67 in) 505 cm (199 in) 9017-6...

  • Page 201: Nbt45-1 Configuration - Extended Torsion Box And 127 Ft Boom

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION NBT45-1 Configuration — Extended Torsion Box and 127 ft Boom 1,294.8 cm (42 ft 5.8 in) 360° 387.1 cm (12 ft 8.4 in) 205.7 cm (81 in) 686 cm 194.3 cm (27 in) (76.5 in) 505 cm (199 in) 9017-9...

  • Page 202: Nbt45-1 Configuration - Extended Torsion Box And 142 Ft Boom

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL NBT45-1 Configuration — Extended Torsion Box and 142 ft Boom 1,293.4 cm (42 ft 5.2 in) 360° 388.1 cm (12 ft 8.8 in) 205.7 cm (81 in) 686 cm 192.8 cm (27 in) (75.9 in) 490 cm (193 in) 9017-11...

  • Page 203: Nbt45-1 Configuration - Extended Torsion Box And 161 Ft Boom

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION NBT45-1 Configuration — Extended Torsion Box and 161 ft Boom 1,378.3 cm (45 ft 2.6 in) 360° 388.1 cm (12 ft 8.8 in) 205.7 cm (81 in) 68.6 cm 192.8 cm (27 in) (75.9 in) 477 cm (188 in) 9017-13...

  • Page 204: Pto Requirements

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL PTO REQUIREMENTS The following PTO ratio and engine speed combinations provide the proper pump shaft speed, which is the Horsepower recommended maximum rpm for the NBT40-1 hydraulic pump. The PTO must meet the minimum requirements shown in The engine must be operated within a specific rpm range to hydraulic specifications.

  • Page 205: Truck Frame Strength

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION • Be rigid enough to allow excessive boom movement due to truck frame deflection when lifting over the front of the unit • Be strong enough to resist the loading induced by the 9023-21 crane •...

  • Page 206: Section Modulus Tables

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL 9023-23 NOTE: All dimensions are centimeters (inches). (120) (108) (96) (84) (72) (60) Distance From SFO Attachment Point (48) centimeters (Inches) (36) (24) (12) FIGURE 9-14 SECTION MODULUS TABLES • Angle Reinforcement (Table B on page 18)—If the truck is reinforced with an angle, see Table B for the data The following tables (A, B, C, and D) determine the section on the added strength provided by the angle.
  • Page 207 NBT40-1 SERVICE MANUAL CRANE INSTALLATION Where thickness, depth or flange width vary, interpolation If you have any questions concerning frame strength or between tables or variables within a given table will provide reinforcing, contact National Crane before proceeding. the strength for the section. TABLE A Section Modulus cm Thickness 6.35 mm (1/4 in)
  • Page 208 CRANE INSTALLATION NBT40-1 SERVICE MANUAL TABLE B Section Modulus cm Thickness 4.76 mm (3/16 in) Thickness 6.35 mm (1/4 in) W mm (in) W mm (in) D mm D mm (in) (in) 70 (2.75) 83 (3.25) 95 (3.75) 70 (2.75) 83 (3.25) 95 (3.75) (4.25) (4.25) 191 (7.5) 36 (2.2)
  • Page 209 NBT40-1 SERVICE MANUAL CRANE INSTALLATION TABLE C Section Modulus cm D mm (in) TH mm (in) 203 (8) 229 (9) 254 (10) 279 (11) 305 (12) 330 (13) 356 (14) 381 (15) 406 (16) 4.76 33 (2.0) 41 (2.51) 51 (3.10) 61 (3.75) 73 (4.46) 86 (5.24) (0.1875) (6.08) (6.98)
  • Page 210 CRANE INSTALLATION NBT40-1 SERVICE MANUAL TABLE D Section Modulus cm Thickness 6.35 mm (0.25 in) Thickness 4.76 mm (0.1875 in) W mm (in) W mm (in) D mm D mm (in) (in) 76 (3) 89 (3.5) 102 (4) 114 (4.5) 76 (3) 89 (3.5) 102 (4) 114 (4.5)

  • Page 211: Truck Preparation

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION TRUCK PREPARATION CAUTION Plan the installation thoroughly before any work is done. Rotating the pump in the wrong direction damages the Plan the location of the crane on the truck frame for the final pump. front and rear axle weights and boom overhang.

  • Page 212: Reinforcement After-Frame Extension

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL If using a drive shaft type of mount, connect the PTO b. Mark the approximate location of the crane drive shaft to the pump and PTO. Drill a 7.9 mm x 3 mm mounting anchors (5) on the reinforcement so that (0.31 in dia.
  • Page 213 NBT40-1 SERVICE MANUAL CRANE INSTALLATION 50.8 mm (2 in) 9023-25 127 mm (5 in) 50.8 mm (2 in) 101.6 mm (4 in) 101.6 mm (4 in) 203.2 mm (8 in) Item Description Crossmember bolt holes. Shift the plug weld holes slightly to clear the crossmember holes.
  • Page 214 CRANE INSTALLATION NBT40-1 SERVICE MANUAL 9023-28 6 - 6 12 - 6 152.4 mm (6 in) 152.4 mm (6 in) Item Description 152.4 mm Reinforcement Angle (6 in) Spring Stop (2 per spring) Spring Hangers (4 per spring) Reinforcing Under Crane Cut Out Reinforcement Pieces (quantity varies) Existing Truck Frame Lower Reinforcement Bar...

  • Page 215: Mounting The Crane

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION Cut out the marked areas in the long leg of the b. If the AF is too short, the frame needs to be reinforcement angle as deep as necessary. Install lengthened. Use channels fabricated from 689 MPa the reinforcement angle up from the underside of (100,000 psi) yield material that are the same size as the truck frame.
  • Page 216 CRANE INSTALLATION NBT40-1 SERVICE MANUAL See Figure 9-20 for the following steps. Weld the two end plates to the cross bar. NOTE: Position the rear strap plate with the bend in the 10. Position the welded cross bar assembly to the truck plate inward or outward depending on the width of frame, in the center of both strap plates (6), and tack the truck frame.
  • Page 217 NBT40-1 SERVICE MANUAL CRANE INSTALLATION 7609 View B View C 9724 View A 406.4 mm (16 in) min. to 431.8 (17 in) max. 134.9 mm to 312.7 mm (5.31 in to 12.31 in) 711.2 mm (28 in) min. to 812.8 (32 in) max. 216 mm (8.5 in) 7610-1...
  • Page 218 CRANE INSTALLATION NBT40-1 SERVICE MANUAL 4.8 mm (0.19 in) 7.9 mm 7.9 mm (0.31 in) 6.4 mm (0.31 in) 9726 (0.25 in) 9725 View G 9.7 mm (0.38 in) No Weld, Both Sides 25.4 mm (1 in) FIGURE 9-20 9727 View F Item Description...

  • Page 219: Truck Interface Electrical Connection

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION Truck Interface Electrical Connection Route wire 901 (crane ignition signal) of the crane main wire harness through the truck’s firewall, and into the See Figure 9-21 for the following steps. truck cab behind the dashboard. Install socket 7826000087 onto wire 901 and install it into plug Make the required electrical connections between the crane 7709000815 cavity 2.
  • Page 220 CRANE INSTALLATION NBT40-1 SERVICE MANUAL 10. Install the throttle activation relay (1, Figure 9-23) to the engine side of the firewall. Connect the orange throttle Item Description activation wire (2) to terminal 87 of the relay. Splice the power feed wire (3) from terminal 86 of the relay to wire Engine Warning Indicator 901.

  • Page 221: Hydraulic Pump Connection

    ® Cummins INSITE Remote Throttle Parameters If there is a different resistance reading, contact Heading Parameter New Value Manitowoc Crane Care for more information. Remote Accelerator Remote Accelerator Enable Pedal or Lever Pedal or Lever Remote Accelerator Remote Accelerator...
  • Page 222 CRANE INSTALLATION NBT40-1 SERVICE MANUAL Make sure driveline meets minimum 10. If using the configuration shown in Figure 9-27 be sure requirements for maximum pump horsepower. See to position the case drain port (2) at the highest point “Specifications” on page 9-38. above ground level.

  • Page 223: Rcl Calibration

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION While watching the pressure gauge, start the truck Set the throttle according to engine rpm and PTO ratio to engine and idle until the gauge registers the pressure. achieve the proper hydraulic pump speed. System pressure must be within 51.7 bar to 55.1 bar After all the cylinders have been run through six (750 psi to 800 psi).
  • Page 224 CRANE INSTALLATION NBT40-1 SERVICE MANUAL Table 9-3 extension. The stability test can be performed with or without the jib stowed on the side of the main Model Boom Length Loaded Radius boom. 40103-1 (std t-box) Be sure to select the correct load capacity chart; the charts are titled—with stowed extension or 40103-1 (ext t-box) without extension.

  • Page 225: Counterweight

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION Over the side: NOTE: The NBT36-1 model crane is not equipped with a counterweight. • Assemble the first stability test load as described above near the crane. Use only the counterweight plate combinations as shown in the following counterweight Table 9-4 and Figure 9-29.

  • Page 226: Counterweight Removal

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL Counterweight Removal Counterweight Installation Position the crane on a firm, level surface. Fully extend Position the crane on a firm level surface. Fully extend and set the outriggers. and set the outriggers. Position the superstructure over the front of the machine Position the superstructure over the front of the machine and engage the turntable lock.
  • Page 227 NBT40-1 SERVICE MANUAL CRANE INSTALLATION Table 9-4 Model Description Figure 9-29 View NBT36-1 NBT40-1 Standard 454 kg (1,000 lb) NBT40-1 + 1,000 Option 907 kg (2,000 lb) NBT45-1 Standard 2,041 kg (4,500 lb) NBT45-1 + 1,000 Option 2,494 kg (5,500 lb) NBT45-1TM 454 kg (1,000 lb) 1,2, and 3...

  • Page 228: Specifications

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL SPECIFICATIONS PTO Minimum Torque Rating ..........644 Nm (475 lb-ft) PTO Minimum Horsepower Rating........67 kW (90 hp) per 1,000 rpm of PTO shaft speed 148 KW (199 hp) per 2,200 rpm of PTO shaft speed Hydraulic Hydraulic Pump ..............

  • Page 229: Counterweight

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION Hoist Line Pull/Layer Layer Low Speed kN (lb) High Speed kN (lb) 66.7 (15,000) 33.4 (7,516) 60.2 (13,529) 30.1 (6,765) 54.7 (12,299) 27.4 (6,150) 50.2 (11,275) 25.1 (5,637) 46.3 (10,407) 23.1 (5,204) Line Speed (no load at high engine idle speed) Layer Low Speed m/sec (ft/sec) High Speed m/sec (ft/sec)

  • Page 230: General

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL General NBT36-1................32.6 metric tons (36 tons) at 2.13 m (7 ft) radius NBT40-1................36.3 metric tons (40 tons) at 2.13 m (7 ft) radius NBT45-1................40.8 metric tons (45 tons) at 2.13 m (7 ft) radius *NBT36-1 103 ft.

  • Page 231: Dimensional Drawing

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION DIMENSIONAL DRAWING NBT40-1 and NBT45-1 Extended T-Box R2622 Counterweight Tail Swing 8839-2 R1919 Cab Swing Retracted 951.2 cm (31 ft 2 in) 952 cm (31 ft 3 in) 1,043.1 cm (34 ft 3 in) 1,170.7 cm (38 ft 5 in) Extended 3,139.5 cm (103 ft) 3,869.7 cm (127 ft) 4,318.8 cm (141 ft 8 in) 4,897 cm (160 ft 8 in)

  • Page 232: Nbt40-1 And Nbt45-1 Standard T-Box

    CRANE INSTALLATION NBT40-1 SERVICE MANUAL NBT40-1 and NBT45-1 Standard T-Box R2622 Counterweight Tail Swing 9017-19 R1919 Cab Swing Retracted 951.2 cm (31 ft 2 in) 952 cm (31 ft 3 in) 1,043.1 cm (34 ft 3 in) 1,170.7 cm (38 ft 5 in) Extended 3,139.5 cm (103 ft) 3,869.7 cm (127 ft) 4,318.8 cm (141 ft 8 in)

  • Page 233: Nbt36-1 Extended T-Box

    NBT40-1 SERVICE MANUAL CRANE INSTALLATION NBT36-1 Extended T-Box R2622 Counterweight Tail Swing 9017-20 R1919 Cab Swing Retracted 951.2 cm (31 ft 2 in) 952 cm (31 ft 3 in) 1,043.1 cm (34 ft 3 in) 1,170.7 cm (38 ft 5 in) Extended 3,139.5 cm (103 ft) 3,869.7 cm (127 ft) 4,318.8 cm (141 ft 8 in) 4,897 cm (160 ft 8 in) 251.6 cm...
  • Page 234 CRANE INSTALLATION NBT40-1 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 9-44 Published 7-01-2021 Control # 655-02...
  • Page 235 NBT40-1 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 236 SCHEMATICS NBT40-1 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 10-2...

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