Manitowoc National Crane NBT60 Boom Truck Manuals

Manuals and User Guides for Manitowoc National Crane NBT60 Boom Truck. We have 2 Manitowoc National Crane NBT60 Boom Truck manuals available for free PDF download: Service Manual, Operator's Manual

Manitowoc National Crane NBT60 Service Manual (250 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 10 MB

Table of Contents
5
Section Contents
11
Supplemental Information
11
Safety Information
11
General
11
Basic Nomenclature
12
General Maintenance
14
Cleanliness
14
Removal and Installation
14
Disassembly and Assembly
14
Pressing Parts
14
Locks
14
Shims
14
Bearings
15
Gaskets
15
Hydraulic Systems
15
Electrical
16
Fatigue of Welded Structures
17
Loctite
17
Fasteners and Torque Values
17
Weld Studs
30
Special Boom Inspection
31
Hoist Cable Inspection and Maintenance
31
Hoist Rope
31
Keeping Records
31
Wire Rope
31
General
31
Environmental Conditions
31
Dynamic Shock Loads
31
Lubrication
31
Recommendations for Servicing Wire Rope
32
Wire Rope Inspection
32
Boom Extension and Retraction Cables
33
Wire Rope Replacement (All Wire Rope)
33
Seizing Wire Rope
34
Synthetic Hoist Rope
35
Section Contents
37
Maintenance
37
Hydraulic Oil Recommendations
37
Draining and Flushing
37
Hydraulic System
37
Description
39
Removing Air from Hydraulic System
41
Parts Replacement
41
Directional Control Valve (DCV)
41
Maintenance
41
Supply Pressure and Return Circuit
43
Description
43
Maintenance
44
Troubleshooting Chart
45
Hydraulic Filter Replacement
48
Hydraulic Oil Cooler
50
Description
50
Oil Cooler Service and Maintenance
50
Hydraulic Pump
51
Description
51
Load Sense Control
51
System Circuit Flow
51
Removal
52
Installation
52
Pump Startup Procedure
52
Pump Margin Pressure Setting
54
Main Relief Pressure Setting
54
Setting Maximum Pump Pressure
55
Load Sense Relief Valve (LSRV) Pressure Setting (Directional Control Valve)
55
Hydraulic System Setup Procedure
57
Getting Started
58
Hoists
59
Boom up
59
Boom down
59
Telescope Extend
59
Telescope Retract
59
Swing Clockwise/Counter Clockwise
61
Swing Backpressure
61
Cab A/C
61
Pilot Supply
61
Swing Brake Release
62
Swing Brake Apply
62
Gear Box Coolant
62
Outrigger Extend and Retract
62
Counterweight Removal Cylinders
63
Tilt Cab Cylinder
63
Single Front Outrigger (SFO) - Optional
64
Valves
65
General
65
Removal
67
Installation
67
Functional Check
67
Outrigger Manifolds
67
Holding Valves
67
Jump Starting the Crane
69
Section Contents
69
Charging
69
Welding Precautions
69
Electric System
69
Maintenance
70
General
70
Diagnostic
70
General Troubleshooting
70
Troubleshooting the Electrical Swivel
70
Connector Troubleshooting
70
Ignition Switch
71
Rated Capacity Limiter (RCL) System Description
71
RCL and Anti-Two Block (A2B) System Description
71
Rated Capacity Limiter (RCL) System
71
Description
71
RCL Communication Overview
72
Cab Module, Fuse, Relay Panel
73
Directional Control Valve
76
Directional Control Valve (DCV) Solenoids
77
Outrigger Manifolds
77
Front Outrigger Manifold
77
Rear Outrigger Manifold
79
Hydraulic Oil Cooler
79
Theory of Operation
81
Boom Maintenance
81
Special Boom Inspection
82
Boom Removal
82
Maintenance
82
Boom Disassembly
83
Additional Maintenance, Disassembled Boom
85
Boom Assembly
85
Boom Cable Tensioning
99
Five Section Cable Tensioning
99
Cable Tension Sequence
100
Section Boom W/ 2 Stage Cylinder Cable Positioning
101
Cable Retention
103
Boom Calibration
104
Top, Rear Wear Pads
104
Inner Side Pads
105
Bottom Rear Pads
105
Multi-Stage Extend Cylinder
107
Cylinder Disassembly
107
Cylinder Reassembly
107
Jib Boom
108
Jib Stowage Bracket Adjustment
108
Jib Jack Service and Maintenance
110
Lift Circuit
112
Description
112
Theory of Operation
112
Maintenance
112
Lift Cylinder Removal
114
Lift Cylinder Installation
114
Section Contents
117
Removal
119
Hydraulic Hose
119
Hoist Installation
119
Warm-Up Procedure
119
Hoist Rotation Indicator (HRI) Display System
119
Description
119
Drum Rotation Indicator
120
Removal
120
Programming the Minimum Wrap Indicator
122
Shipping Mode (Series a Only)
122
Troubleshooting
123
For Series "A
123
Series "B" Circuit Breaker Reset Instructions
123
Hoist Repair
123
Disassembly
123
Assembly
123
Brake
127
Planetary Set
128
Motor
128
Troubleshooting
128
Counterweight Cylinder
129
Removal
129
Installation
129
Section Contents
131
Description
131
Theory of Operation
131
Swing Drive
131
Swing Brake
131
Description
132
Swing Gearbox and Brake
135
Oil Change
135
Disassembly and Assembly Instructions
135
Tools Required
135
Parts Required to Rebuild
135
Disassembly
136
Assembly
136
Servicing the Brake
137
Servicing the Bearing and Pinion
138
Planetary Gear Set
138
Swing Brake
139
Swing Bearing
139
Description
139
Maintenance
140
General
140
Torquing Swing Bearing Bolts
140
Swing Bearing Bolts
140
Inner Race Torquing
140
Bearing Clearance
142
Bearing Replacement
143
Removal
143
Installation
144
Slew Encoder
145
Section Contents
147
Description
147
Theory of Operation
148
Outrigger Controls
148
Outrigger Selector Valve
148
Maintenance
151
Outrigger Beam
155
Description
155
Theory of Operation
155
Maintenance
155
Extension Cylinder
159
Description
159
Outrigger Jack Cylinder
160
Description
160
Maintenance
160
Outrigger System Valves
162
Description
162
Single Front Outrigger (SFO) Cylinder (Optional)
163
Description
163
Maintenance
163
Lubrication
165
General
165
Environmental Protection
165
Lubricants
165
Arctic Conditions below -9°C (15°F)
165
Chassis Grease
166
Low Temperature Grease
166
Extreme Pressure Multipurpose Gear Lubricant (EPGL)
166
Open Gear Lubricant
166
Antifreeze/Coolant (for Cab Heater)
166
Anti-Wear Additives
166
Hydraulic Oil
166
Standard Hydraulic Oil
166
Lubricants
166
Arctic Hydraulic Oil
167
Hydraulic Oil Inspection
167
Lubrication
167
Lubrication Chart
168
Side and Bottom Boom Wear Pad Lubrication
171
Top Boom Wear Pad Lubrication
171
Outrigger Beam Lubrication
171
Hoist Brake Oil
172
Hoist Gearbox Oil
172
Swing Gearbox and Brake Oil
173
Hydraulic Oil Reservoir Level
173
Surface Protection for Cylinder Rods
174
Wire Rope Lubrication
174
Carwell® Rust Inhibitor
175
Protecting Cranes from Rusting
175
Cleaning Procedures
175
Inspection and Repair
176
Application
176
Areas of Application
177
Section 9
181
Minimum Truck Requirements
181
Mounting Configurations
184
PTO Requirements
189
Pump Rotation
189
PTO Ratio
189
PTO Horsepower Requirements
190
Truck Frame Strength
191
Section Modulus Tables
192
Truck Preparation
195
Welding Precautions
195
Positioning Crane on Truck
195
PTO, Pump, Reservoir
195
Reinforcing after Frame Extension
196
Mounting the Crane
201
T-Box Installation
201
Rear Bumper and Light Installation
203
Decking and Ladder Installation
205
Single Front Outrigger Installation (SFO) -Optional
209
Truck Interface Electrical Connection
231
Fuel Level Select EEPROM
239
Hydraulic Pump Connection
239
Initial Crane Run in Procedure
240
Stability Test
240
Specifications
242
Hydraulic
242
Air Conditioner
242
Hoist System
242
NBT60 Crane Operating Speeds
243
Counterweight
243
General
243
Section 10
245

Manitowoc National Crane NBT60 Operator's Manual (168 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 6 MB

Table of Contents
5
Section 1

11
- Basic Nomenclature
  11
- New Owner
  11
- Supplemental Information
  11
Section 2

15
- Safety Messages
  15
  - General
    15
  - Safety Alert Symbol
    16
  - Signal Words
    16
- Accidents
  16
- General
  16
- Operator Information
  16
- Operator Qualifications
  17
- Operational Aids
  18
- Crane Stability/Structural Strength
  19
  - Load Charts
    20
  - Work Site
    20
- Wind Forces
  20
  - Wind Speeds
    21
  - Lifting Operations
    34
  - Counterweight
    35
  - Outrigger Lift off
    35
  - Multiple Crane Lifts
    35
  - Tilt-Up Panel Lifting
    35
- Pile Driving and Extracting
  36
  - Crane Equipment
    36
  - Crane Inspection
    36
- Electrocution Hazard
  37
  - Set-Up and Operation
    38
  - Electrocution Hazard Devices
    38
  - Electrical Contact
    39
  - Special Operating Conditions and Equipment
    39
  - Grounding the Crane
    39
- Personnel Handling
  40
- Environmental Protection
  41
- Maintenance
  41
  - Service and Repairs
    41
  - Lubrication
    42
  - Tires
    43
- Hoist Rope
  43
  - Synthetic Hoist Rope
    43
  - Wire Rope
    43
  - Sheaves
    44
  - Batteries
    45
  - Engine
    45
- Transporting the Crane
  45
- Travel Operation
  46
- Work Practices
  47
  - Personal Considerations
    47
  - Crane Access
    47
  - Job Preparation
    47
  - Working
    47
  - Lifting
    48
  - Hand Signals
    49
- Boom Extension
  51
- Cold Weather Operation
  51
- Parking and Securing
  51
- Shut-Down
  51
- Temperature Effects on Hook Blocks
  52
- Temperature Effects on Hydraulic Cylinders
  52
- Model Specific Information
  53
- Overload Inspection
  53
  - Boom Inspection
    55
  - Superstructure Inspection
    57
  - Carrier Inspection
    59
Section 3

61
- Crane Theory of Operation
  62
  - Crane Software Overview
    62
- Jump Starting the Crane
  62
  - Charging
    62
  - Getting Started
    62
  - Crane Ignition and Control States
    63
- Truck Cab Controls
  63
  - Truck Cab Ignition Switch
    63
  - Power Take off (PTO)
    63
  - Park Brake
    64
  - Engine Speed Governor
    64
  - Neutral Start/Safety Switch
    64
- Outrigger Controls
  64
- Cab Outrigger Control
  67
  - Outrigger Selector Valve
    68
  - Emergency Stop Switch
    68
  - Crane Level Indicators
    69
- Crane Controls
  70
  - Swing Brake Pedal
    73
  - Boom Telescope Pedal (Standard with Aux Hoist)
    73
  - Foot Throttle Pedal
    73
  - Display Panel
    73
  - RCL Bypass Switch
    73
  - Minimum Wrap Indicator
    74
  - Emergency Stop Switch
    74
  - Ac/Heater Vent
    74
  - Crane Ignition Switch
    74
  - 12V Receptacle
    74
  - Diagnostic Connector
    74
  - Buzzer Alarm
    74
  - Engine Hi/Low Switch
    74
  - Crane Function Power Switch
    74
  - Remote Power Switch (Optional)
    74
  - Skylight Wiper Switch
    75
  - Windshield Wiper/Washer Switch
    75
  - Air Conditioning/Heater Controls
    75
  - Dual Axis Controller (Boom Lift/Main Hoist)
    75
    
    Dual Axis Controller (Swing/Tele/Aux Hoist)
    75
    
    Seat Back Adjustment
    75
    
    Seat Slide Adjustment Lever
    75
    
    Seat/Controls Assembly Slide Adjustment Lever
    75
    
    Main Hoist Speed
    75
    
    Aux Hoist Speed
    75
    
    Swing Brake Indicator
    76
    
    Swing Horn Button
    76
    
    Single Axis Controller (Boom Lift/Hoist)
    76
    
    Single Axis Controller (Swing/Boom Tele)
    76
    
    Cab Tilt Switch
    76
  - Swing Lock
    76
    
    360° Positive Swing Lock
    76
    
    Swing Lock Control (Pin Type)
    76
    
    Adjustable Swing Speed Valve
    77
  - Heater
    77
    
    Heater Cold Weather Fuel Mixture
    77
    
    Heater Coolant
    78
  - Operating Procedures
    78
    
    Equipment Familiarization
    78
    
    Crane Cab Access
    78
    
    Equipment Checks
    78
    
    Cold Weather Operation
    79
  - Crane Warm-Up Procedures
    79
    
    Engine
    79
    
    Transmission
    79
    
    Hoist
    80
    
    Swing Drive and Turntable Bearing
    80
    
    Axles
    80
    
    Hydraulic Oil System
    80
    
    Anti-Two Block Check
    80
    
    RCL Check
    81
  - Hoist System Operation
    81
  - Work Site Location
    81
    
    Before Leaving the Truck Cab
    81
    
    Stowing and Parking
    81
    
    Unattended Crane
    82
    
    Before Making the Lift
    82
  - Load Chart
    82
    
    Using the Load Chart
    82
  - Lifting the Load
    83
  - Shut down and Preparation for Road Travel
    83
  - Standard Remote Control
    87
    
    Batteries
    87
    
    Operation
    88
  - Crane Remote Control (Optional)
    89
    
    Crane Remote Control Activation
    90
Section 4

93
- Proper Leveling of the Crane
  93
- Bubble Level Adjustment
  93
- Site Selection
  94
- Setting the Outriggers
  94
- JIB Safety Information
  95
- Erecting and Stowing the JIB
  95
- General Warnings
  95
- JIB Operation
  96
  - Jib Deployment Procedure
    96
  - Stowing Procedure
    99
  - Jib Removal
    100
- Jib Maintenance
  101
  - Setting the Offset
    101
  - Setting the Offset Mast
    101
  - Anti-Two-Block Weight Installation
    104
- Multi-Part Line Reeving
  104
  - Using Multiple Part Lines
    104
  - Lifting the Rated Load
    104
- Installing Cable on the Hoist
  106
- Wedge Sockets
  106
  - Terminator Wedge Installation
    106
  - Wedge Socket Installation
    107
- Removable Counterweight
  109
  - Mounting the Counterweight
    109
  - Stowing the Counterweight
    111
Section 5

113
- General
  113
  - Environmental Protection
    113
  - Lubricants
    113
  - Arctic Conditions below -9°C (15°F)
    113
  - Chassis Grease
    114
  - Low Temperature Grease
    114
  - Extreme Pressure Multipurpose Gear Lubricant (EPGL)
    114
  - Open Gear Lubricant
    114
  - Antifreeze/Coolant (for Cab Heater)
    114
  - Anti-Wear Additives
    114
  - Hydraulic Oil
    114
  - Standard Hydraulic Oil
    114
  - Lubricants
    114
  - Arctic Hydraulic Oil
    115
  - Hydraulic Oil Inspection
    115
- Lubrication
  115
  - Side and Bottom Boom Wear Pad Lubrication
    119
  - Top Boom Wear Pad Lubrication
    119
  - Outrigger Beam Lubrication
    119
  - Hoist Brake Oil
    119
  - Hoist Gearbox Oil
    120
  - Swing Gearbox and Brake Oil
    120
  - Hydraulic Oil Reservoir Level
    121
  - Surface Protection for Cylinder Rods
    121
  - Wire Rope Lubrication
    122
- Carwell® Rust Inhibitor
  123
  - Protecting Cranes from Rusting
    123
  - Cleaning Procedures
    123
  - Inspection and Repair
    124
  - Application
    124
  - Areas of Application
    125
Section 6

129
- Crane Inspection and Maintenance
  129
  - Inspections
    129
  - Inspections
    130
  - Special Boom Inspection
    131
  - Stability
    131
- Hoist Rope Inspection and Maintenance
  131
  - Keeping Records
    131
  - Environmental Conditions
    131
  - Dynamic Shock Loads
    131
  - Precautions and Recommendations During Inspection
    132
  - Inspection
    132
  - Wire Rope Replacement
    133
  - Care of Wire Rope
    133
- Replacement Rope
  133
- Crane Adjustments and Repairs
  134
  - Boom Extension Cable
    134
  - Jib Jack Service and Maintenance
    134
  - Lubrication
    134
  - Rust Prevention
    134
- Hydraulic System
  134
  - Oil Cooler
    134
- Tire Load and Inflation Table
  135
- Specifications
  138
  - Hydraulic
    138
  - Air Conditioner
    138
  - Hoist System
    138
  - NBT60 Crane Operating Speeds
    139
  - Counterweight
    139
  - General
    139
Section 7

142
- RCL System Description
  142
  - RCL Display
    143
  - Alert and Limit Symbols
    144
  - RCL Override Warning
    144
- RCL Setup
  147
  - Boom Configuration
    147
  - Counterweight Configuration
    148
- Hoist & Reeving Configuration
  150
  - Confirmation
    150
- Operating Mode
  150
  - TARE Function
    151
- Operational Limits
  152
  - Slew Angle Limit
    152
  - WADS Limit
    152
  - Boom Angle Limit
    153
  - Tip Height Limit
    153
  - Radius Limit
    153
  - Delete All Limits
    154
- Tools
  154
  - Joystick Output
    154
  - RCL Sensor Calibration
    155
  - Slew Sensor Calibration
    156
  - Boom Angle Calibration
    157
  - Boom Length Calibration
    157
  - Rod Side Pressure Sensor Calibration
    157
  - Base Side Pressure Sensor Calibration
    157
  - Outrigger Span/Length
    158
  - CWT Switch Panel Calibration
    158
  - Load Chart and RCL Upload
    158
- Diagnostic
  159
- About the Manitowoc Diagnostic Code Application
  161
  - About the Manitowoc Diagnostic Code
    161
  - Application
    161

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Manitowoc National Crane NBT60 Boom Truck Manuals

Manitowoc National Crane NBT60 Service Manual (250 pages)

Table of Contents

Manitowoc National Crane NBT60 Operator's Manual (168 pages)

Table of Contents

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

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