Manitowoc National Crane NBT40-1 Series User manual

Service Manual
National Crane NBT40-1
Series
For
Reference
Only

The original language of this publication is English.
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.
• Do not modify or tamper with the exhaust
system.
• Do not idle the engine except as
necessary.
For more information, go to
www.P65warnings.ca.gov/diesel
Batteries, battery posts, terminals, and
related accessories can expose you to
chemicals, including lead and lead
compounds, which are known to the State of
California to cause cancer and birth defects or
other reproductive harm. Wash hands after
handling. For more information, go to
www.P65warnings.ca.gov
California Spark Arrestor
Operation of this equipment may create
sparks that can start fires around dry
vegetation. A spark arrestor may be required.
The owner/operator should contact local fire
agencies for laws or regulations relating to fire
prevention requirements.
For
Reference
Only

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 SWING
SECTION 7 OUTRIGGERS
SECTION 8 LUBRICATION
SECTION 9 CRANE INSTALLATION
SECTION 10 SCHEMATICS
The crane serial number is the only method your distributor or the factory has of providing you with correct parts and service
information.
The crane serial number is identified on the builder’s decal attached to the crane frame. Always furnish a crane serial
number when ordering parts or communicating service problems with your distributor or the factory.
© 2021 Grove U.S.L.L.C.
Published 7-01-2021 Control # 655-02
Untrained operators subject themselves and others to death or
serious injury. Do not operate this crane unless:
•You are trained in the safe operation of this crane. National Crane is
not responsible for qualifying personnel.
•You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
•You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
•The Operator Manual and Load Chart are in the holder provided on the
crane.
DANGER
!
1
4
5
6
7
8
2
3
9
10
For
Reference
Only

THIS PAGE BLANK
For
Reference
Only

National Crane TOC-1
NBT40-1 SERVICE MANUAL
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Loctite®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Hoist Cable Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Recommendations for Servicing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Wire Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Monthly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Yearly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Boom Extension and Retraction Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Wire Rope Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Label Parts when Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Directional Control Valve (DCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
RCL Lockout Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Swing and Air Conditioning Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Outrigger Control Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Reservoir with Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Remote Controllers (HRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pilot Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
For
Reference
Only

NBT40-1 SERVICE MANUAL
TOC-2
Radio Remote Manifold (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Tool Circuit Manifold (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pressure Intensifier Manifold (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pump Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Swing Motor Manifold (with Remotes Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hydraulic Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Relief Valve Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
System Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Hydraulic Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Hydraulic Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Hydraulic Oil Cooler Service & Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Directional Control Valve (DCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Hydraulic Remote Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Outrigger Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Crane Function Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Pump Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Pump Margin Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Maximum Pump Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Load Sense Relief Valve Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Jump Starting Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Charging the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Connector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tooling for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Troubleshooting the Electrical Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
RCL System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
RCL and A2B System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Fuse and Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Micro Relay Fuse Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Micro Relay Fuse Box 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Micro Relay Fuse Box 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Micro Relay Fuse Box 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
VEC Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Crane Manifold Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Outrigger Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Front Outrigger Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Rear Outrigger Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
For
Reference
Only

National Crane TOC-3
NBT40-1 SERVICE MANUAL
Hydraulic Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Hydraulic Temperature Sensor Warning Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Outrigger Monitoring System (OMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Outrigger Jack Monitoring System (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Maintenance
Four-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Four-Section Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Additional Maintenance (Disassembled Boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Four-Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Cable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Four-Section Top and Bottom Pad Replacement (Assembled Boom) . . . . . . . . . . 4-19
‘Five-Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Five-Section Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Additional Maintenance (Disassembled Boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Five-Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Five-Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Cable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Five-Section Top and Bottom Pad Replacement (Assembled Boom) . . . . . . . . . . 4-44
Boom Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Inner Side Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Rear, Bottom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
Jib Stowage Bracket Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Warm-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hoist Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hoist Rotation Indicator (HRI) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Drum Rotation Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Programming the 3rd Wrap Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Shipping Mode (Series A Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
For Series “A” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Series “B” Circuit Breaker Reset Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Hoist Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Planetary Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
For
Reference
Only

NBT40-1 SERVICE MANUAL
TOC-4
Swing Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Swing Gearbox and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Disassembly and Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Parts Required to Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Input Planetary Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Output Planetary Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Shaft Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Case Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Torquing Swing Bearing Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Bearing Capscrews. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Slew Potentiometer Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Slew Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
House Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outriggers
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Outrigger Beam Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Outrigger Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Side Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Top and Bottom Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Outrigger Monitoring System (OMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
String Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Outrigger Jack Monitoring System (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
SECTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Arctic Conditions Below -9°C (15°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Chassis Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Low Temperature Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
For
Reference
Only

National Crane TOC-5
NBT40-1 SERVICE MANUAL
Multipurpose Extreme-Pressure Gear Lubricant (EPGL) . . . . . . . . . . . . . . . . . . . . . 8-2
Open Gear Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Antifreeze/Coolant (for Cab Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Anti-wear Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Standard Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Arctic Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Hydraulic Oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Side and Bottom Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Top Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Outrigger Beam Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Hoist Brake Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Hoist Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Swing Gearbox and Brake Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Protecting Cranes from Rusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crane Installation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Minimum Truck Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Mounting Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
NBT36-1 Configuration — Standard Torsion Box and 103 ft Boom . . . . . . . . . . . . . 9-4
NBT36-1 Configuration — Standard Torsion Box and 127 ft Boom . . . . . . . . . . . . . 9-5
NBT40-1 Configuration — Standard Torsion Box and 103 ft Boom . . . . . . . . . . . . . 9-6
NBT40-1 Configuration — Standard Torsion Box and 127 ft Boom . . . . . . . . . . . . . 9-7
NBT40-1 Configuration — Standard Torsion Box and 142 ft Boom . . . . . . . . . . . . . 9-8
NBT40-1 Configuration — Extended Torsion Box and 127 ft Boom. . . . . . . . . . . . . 9-9
NBT40-1 Configuration — Extended Torsion Box and 142 ft Boom. . . . . . . . . . . . 9-10
NBT45-1 Configuration — Extended Torsion Box and 127 ft Boom. . . . . . . . . . . . 9-11
NBT45-1 Configuration — Extended Torsion Box and 142 ft Boom. . . . . . . . . . . . 9-12
NBT45-1 Configuration — Extended Torsion Box and 161 ft Boom. . . . . . . . . . . . 9-13
PTO Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Direct PTO Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
PTO Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Truck Frame Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Positioning the Crane on the Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
PTO, Pump, and Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Reinforcement After-frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Mounting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Truck Interface Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Hydraulic Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
RCL Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Initial Crane Run-in Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
For
Reference
Only

NBT40-1 SERVICE MANUAL
TOC-6
Stability Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Hydraulic Intensifier Valve - Optional. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Boom Weight - including hoist/rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
NBT40-1 and NBT45-1 Extended T-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
NBT40-1 and NBT45-1 Standard T-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
NBT36-1 Extended T-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
SECTION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Schematics
For
Reference
Only

National Crane Published 7-01-2021 Control # 655-02 1-1
NBT40-1 SERVICE MANUAL INTRODUCTION
1
10
SECTION 1
INTRODUCTION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Supplemental Information . . . . . . . . . . . . . . . . . . . . . 1-1
New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 1-4
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . 1-4
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . 1-7
Loctite® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . .1-7
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Hoist Cable Inspection and Maintenance . . . . . . . . .1-22
Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Keeping Records. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Environmental Conditions . . . . . . . . . . . . . . . . . . . . .1-22
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . .1-22
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Recommendations for Servicing Wire Rope . . . . . . .1-23
Wire Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . .1-23
Monthly Inspections . . . . . . . . . . . . . . . . . . . . . . . . .1-24
Yearly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
Boom Extension and Retraction Cables . . . . . . . . . .1-24
Wire Rope Replacement (All Wire Rope) . . . . . . . . .1-25
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
GENERAL
This manual has been compiled to assist you in properly
operating and maintaining your Model NBT40-1 Series
National Crane (see Figure 1-1).The NBT40-1 series
includes crane models NBT36-1, NBT40-1and NBT45-1.
Before placing the crane into service, all operators and
persons working around the crane must thoroughly read and
understand the contents of the Operator’s Manual. Before
moving a vehicle equipped with a crane, information relating
to transporting the vehicle must be read and observed.
This manual must be retained with the machine for use by
subsequent operating personnel.
Information in this manual does not replace federal, state, or
local regulations, safety codes, or insurance requirements.
For detailed information concerning the operation and
maintenance of the RCL system installed on the equipment,
see the manufacturer’s manual supplied with the equipment.
Manufacturers of rated capacity limiters may refer to them in
their manuals as a load moment indicator (LMI), a hydraulic
capacity alert system (HCAS), National Crane refers to these
systems as a rated capacity limiter (RCL) throughout its
Operator and Service Manuals.)
The NBT40-1 SERIES has been designed for maximum
performance with minimum maintenance. With proper care,
years of trouble-free service can be expected.
National Crane and our Distributor Network want to ensure
your satisfaction with our products and customer support.
Your local distributor is the best equipped and most
knowledgeable to assist you for parts, service, and warranty
issues. They have the facilities, parts, factory-trained
personnel, and information to assist you in a timely manner.
We request that you first contact them for assistance. If you
feel you need factory assistance, please ask the distributor’s
service management to coordinate the contact on your
behalf.
Supplemental Information
Supplemental Information regarding Safety & Operation,
Specifications, Service & Maintenance, Installation, and
parts for options such as remote controls, augers, varying
control configurations, platforms, grapples, etc. are included
in separate manuals. Most optional content is being added to
this standard manual such as the platform and remotes. The
RCL and optional the hydraulic pressure intensifier are
included as separate manuals.
Whenever a question arises regarding your National Crane
product or this publication, please consult your National
Crane Distributor for the latest information. Your National
Crane Distributor is equipped with the proper tools,
necessary parts, and trained service personnel to maintain
and service your equipment.
A Safety Compact Disc or a USB flashdrive which includes
sections on Operation, Service and a Safety Video for
National Crane operators and owners is supplied when the
equipment is purchased new. Additional copies are available
from your local distributor.
For
Reference
Only

1-2 Published 7-01-2021 Control # 655-02
INTRODUCTION NBT40-1 SERVICE MANUAL
New Owner
If you are the new owner of a National crane, please register
it with Manitowoc Crane Care so we have the ability to
contact you if the need arises. Go to https://
www.manitowoccranes.com/home/Parts_Services/
ServiceAndSupport/ChangeOfOwnershipForm
Basic Nomenclature
The nomenclature used to describe parts of a National Crane
crane are described in Figure 1-2. This nomenclature is used
throughout this manual.
FIGURE 1-1
9009 FIGURE 1-1
For
Reference
Only

National Crane Published 7-01-2021 Control # 655-02 1-3
NBT40-1 SERVICE MANUAL INTRODUCTION
1
10
FIGURE 1-2
Item Component
1 Crane Cab
2 Crane Cab Console
3 Operator’s Seat
4 Boom
5 Boom Nose
6 Boom Rest
7 Lift Cylinder
8 Hoist Cable
9 Hoist (9a Auxiliary, 9b Main)
10 Sheave
11 Outrigger Beam
12 Outrigger Jack
13 Outrigger Float
14 Outrigger Box
15 Boom Angle Indicator
16 Downhaul Weight, Hook Block
17 Jib
18 Turret
19 Single Front Outrigger (SFO), Front Outrigger
Jack
20 Hydraulic Tank
21 Hydraulic Pump (not shown)
22 Hydraulic Remote Controller (HRC)
23 Truck Frame
24 Truck Bed
25 Torsion Box Frame, T-Box Frame
Item Component
5
10
19
8
16
54
7
6
24
20 23
25
21 14 12
1
2
18
11
13
1
12
9
17 5
14
9a 9b
15
22
3
9022-1
7474-4
7474-2
7474-5
7474-3
8
For
Reference
Only

1-4 Published 7-01-2021 Control # 655-02
INTRODUCTION NBT40-1 SERVICE MANUAL
GENERAL MAINTENANCE
The suggestions listed below are helpful in analyzing and
correcting problems:
•Determine the problem
•List possible causes
•Devise checks
•Conduct checks in a logical order to determine the
cause
•Consider the remaining service life of components
against the cost of parts and labor to replace them
•Make the repair
•Test the equipment to ensure the problem is fixed
NOTE: Safety is the number one consideration when
working around machines. Safety is a matter of
understanding the job to be done and applying good
common sense. It is not just a list of do’s and don’ts.
Stay clear of all moving parts.
Cleanliness
Cleanliness is important in preserving the life of the machine.
Keep dirt out of working parts and compartments. Keep
filters and seals clean. Whenever hydraulic, fuel, lubricating
oil lines, or air lines are disconnected, clean the adjacent
area as well as the point of disconnect. Cap and plug each
line or opening to prevent entry of foreign material.
Clean and inspect all parts. Be sure all passages and holes
are open. Cover all parts to keep them clean. Be sure parts
are clean when they are installed. Leave new parts in their
containers until ready for assembly. Clean the rust
preventive compound from all machined surfaces of new
parts before installing them.
Removal and Installation
Do not attempt to manually lift heavy parts that require
hoisting equipment. Do not put heavy parts in an unstable
position.
When raising a portion or a complete crane, ensure the
weight is supported by blocks rather than by lifting
equipment.
When using hoisting equipment, follow the hoist
manufacturer’s recommendations. Use lifting devices that
achieve the proper balance of the assemblies being lifted.
Unless otherwise specified, use an adjustable lifting
attachment for all removals requiring hoisting equipment.
Some removals require the use of lifting fixtures to obtain
proper balance.
All supporting members (chains and cables) need to be
parallel to each other and as perpendicular as possible to the
top of the object being lifted.
If a part resists removal, check to be sure all nuts and bolts
have been removed and that an adjacent part is not
interfering.
Disassembly and Assembly
Complete each step in turn when disassembling and
assembling a component. Do not partially assemble one part
and start assembling some other part. Make all adjustments
as recommended. Always check the job after it is complete
to see that nothing has been overlooked. Recheck the
various adjustments by operating the machine before
returning to service.
Pressing Parts
When one part is pressed into another, use an anti-seize
compound or a molybdenum disulfide base compound to
lubricate the mating surfaces.
Assemble tapered parts dry. Before assembling parts with
tapered splines, be sure the splines are clean, dry, and free
from burrs. Position the parts together by hand to mesh the
splines before applying pressure.
Parts which are fitted together with tapered splines are
always very tight. If they are not tight, inspect the tapered
splines and discard the part if the splines are worn.
Locks
Lock washers, flat metal locks, or cotter pins are used to lock
nuts and bolts. For flat metal locks, bend one end of the lock
around the edge of the part and the other end against one
flat surface of the nut or bolt head.
Always use new locking devices on components which have
moving parts.
Use a steel flat washer between aluminum housings and
lock washers.
Shims
When shims are removed, tie them together and identify
them as to location. Keep shims clean and flat until they are
reinstalled.
CAUTION
The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
becomes less than 90°. Eyebolts and brackets should
never be bent and should only have stress in tension.
For
Reference
Only

National Crane Published 7-01-2021 Control # 655-02 1-5
NBT40-1 SERVICE MANUAL INTRODUCTION
1
10
Bearings
Antifriction Bearings
When an antifriction bearing is removed, cover it to keep out
dirt and abrasives. Wash bearings in nonflammable cleaning
solution and allow them to drain dry. The bearing may be
dried with compressed air, but do not spin the bearing.
Discard the bearings if the races and balls or rollers are
pitted, scored, or burned. If the bearing is serviceable, coat it
with oil and wrap it in clean waxed paper. Do not unwrap new
bearings until the time of installation. The life of an antifriction
bearing is shortened if not properly lubricated. Dirt can cause
an anitfriction bearing to lock, which results in the shaft
turning in the inner race or the outer race turning within the
cage.
Double Row, Tapered Roller
Double row, tapered roller bearings are precision fit during
manufacture, and components are not interchangeable. The
cups, cones, and spacers are etched with the same serial
number and letter designator. If no letter designators are
found, wire the components together to ensure correct
installation. Reusable bearing components should be
installed in their original positions.
Heating Bearings
Bearings which require expansion for installation should be
heated in oil not to exceed 121°C (250°F). When more than
one part is heated to aid in assembly, they must be allowed
to cool and then pressed together again. Parts often
separate as they cool and contract.
Installation
Lubricate new or used bearings before installation. Bearings
that are to be preloaded must have a film of oil over the entire
assembly to obtain accurate preloading. When installing a
bearing, spacer, or washer against a shoulder on a shaft, be
sure the chamfered side is toward the shoulder.
When bearings are pressed into a retainer or bore, apply
pressure to the outer race uniformly. If the bearing is pressed
on the shaft, apply pressure on the inner race uniformly.
Preload
Preload is an initial load placed on the bearing at the time of
assembly. Consult the disassembly and assembly
instructions to determine if the bearing can be preloaded.
Be careful in applying preload to bearings requiring end
clearance. Otherwise, bearing failure may result.
Sleeve Bearings
Do not install sleeve bearings with a hammer. Use a press
and be sure to apply the pressure directly in line with the
bore. If it is necessary to drive on a bearing, use a bearing
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.
Gaskets
Be sure the holes in the gaskets correspond with the
lubricant passages in the mating parts. If it is necessary to
make gaskets, select material of the proper type and
thickness. Be sure to cut holes in the right places. Blank
gaskets can cause serious damage.
Hydraulic Systems
Visual Inspection
Do a visual inspection daily on all hydraulic components for
missing hose clamps, shields, guards, excessive dirt buildup,
and leaks. Do a monthly or 250-hour inspection for the items
listed in the inspection procedure below.
Valves and Manifolds
Inspect valves and manifolds for leaking ports or sections.
Hoses and Fittings
Inspect all hoses and fittings for the following:
•Cut, kinked, crushed, flattened, or twisted hoses
•Leaking hoses or fittings
•Cracked, blistered, or hoses charred by heat
•Damaged or corroded fittings
•Fitting slippage on hoses
If any of the above conditions exist, evaluate and replace as
necessary.
The climate in which the crane operates affects the service
life of the hydraulic components. The climate zones are
defined in the table on page 1-6. Recommended
replacement of hoses is as follows:
•Climate zones A and B with high ambient temperatures
and duty cycles after 4,000 to 5,000 hours of service
•Climate zone C after 8,000 hours of service
•Climate zones D and E after 4,000 to 5,000 hours of
service
Cleanliness
Contaminants in a hydraulic system affect operation and
result in serious damage to the system components.
DANGER
Pressurized hydraulic fluid can cause serious injury.
Depressurize the hydraulic system before loosening
fittings.
!
For
Reference
Only

1-6 Published 7-01-2021 Control # 655-02
INTRODUCTION NBT40-1 SERVICE MANUAL
Keep the System Clean
When removing components of a hydraulic system, cover all
openings on both the component and the crane.
If evidence of foreign particles is found in the hydraulic
system, flush the system.
Disassemble and assemble hydraulic components on a
clean surface.
Clean all metal parts in a nonflammable cleaning fluid. Then
lubricate all components to aid in assembly.
Sealing Elements
Inspect all sealing elements (O-ring, gaskets, etc.) when
disassembling and assembling the hydraulic system
components. Installation of new elements is recommended.
Hydraulic Lines
When disconnecting hoses, tag each one to ensure proper
identification during assembly.
When installing metal tubes, tighten all bolts finger-tight.
Then, tighten the bolts in the following order: at the rigid end,
the adjustable end, and the mounting brackets. After tubes
are mounted, install the hoses. Connect both ends of the
hose with all bolts finger-tight. Position the hose so it does
not rub the machine or another hose and has a minimum of
bending and twisting. Tighten bolts in both couplings.
Due to manufacturing methods there is a natural curvature to
a hydraulic hose. Reinstall the hose so any bend is with this
curvature.
Electrical
Batteries
Clean the batteries with a solution of baking soda and water.
Rinse with clear water and dry. Clean the battery terminals
with fine sandpaper and coat the terminals with dielectric
grease. Do not use a non-dielectric grease.
Remove the batteries if the machine is not used for an
extended period of time. Store the batteries in a warm, dry
place, preferably on wooden shelves. Never store on
concrete. A small charge should be introduced periodically to
keep the specific gravity rating at the recommended level.
When disconnecting wires, tag each one to ensure proper
identification during reassembly.
Connectors, Harnesses, Wires, and Connectors
Visually inspect all electrical harnesses, cables, and
connectors every month or 250 hours for the following:
•Damaged, cut, blistered, or cracked insulation
•Exposed bare wires
•Kinked or crushed wires and cables
•Cracked or corroded connectors, battery terminals, and
ground connections
If any of the above conditions exist, evaluate and replace as
necessary.
The climate in which the crane operates affects the service
life of the electrical components. The climate zones are
defined in the table on page 1-6. Recommended
replacement of harness and cables is as follows:
•Climate zones A and B with high ambient temperatures
and duty cycles after 8,000 hours of service
•Climate zone C after 10,000 hours of service
•Climate zones D and E after 10,000 hours of service
•Saltwater conditions after 8,000 hours of service
CAUTION
Disconnect batteries prior to working on the electrical
system.
Table 1-1.Climate Zone Classification
Zone Classification
A (Tropical Moist) Latitude 15°–25° North and South (All months average above 18°C [64°F])
B (Dry or Arid) Latitude 20°–35° North and South (Deficient of precipitation most of the year)
C (Moist Mid-Latitude) Latitude 30°–50° North and South (Temperate with mild winters)
D (Moist Mid-Latitude) Latitude 50°–70° North and South (Cold winters)
E (Polar) Latitude 60°–75° North and South (Extremely cold winters and summers)
For
Reference
Only

National Crane Published 7-01-2021 Control # 655-02 1-7
NBT40-1 SERVICE MANUAL INTRODUCTION
1
10
Fatigue of Welded Structures
Highly stressed welded structures are subject to cracking
(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
operators and the maintenance personnel. The following are
known high-stress areas and should be inspected as part of
a preventive maintenance program:
•Hydraulic cylinder and boom pivot attaching points
•Outrigger pads, beams, boxes, and attachment
structures
•On the frame in the area of doubler plates and
crossmembers
•Turntable bearing connection (where bearing is bolted to
the crane turret)
•Counterweight support structures (where applicable)
•Hydraulic cylinder end connections
The above is provided only as a guide, and your inspection
plan should not be limited to the areas listed. A visual
inspection of all weldments is good practice.
Loctite®
Follow the directions on the Loctite container. There are
different Loctite types for different applications. The following
types of Loctite adhesives are available from the parts
department of the local National Crane distributor.
Application of Medium-Strength Loctite
NOTE: The fastener can be reused, and the adhesive can
be reapplied over cured adhesive residue.
The following procedure covers the proper application and
curing method for medium-strength Loctite adhesive/sealant
(Loctite #243). Clean dirt and oil from the threaded surfaces,
both male and female.
Adhesive/Sealant Application
1. Apply a bead several threads wide in the approximate
area of threaded contact (see Figure 1-3).
2. In a blind hole application, apply several drops of
adhesive in the bottom of the hole so that the adhesive is
forced up when the bolt is installed.
3. After installation, fixturing occurs within five (5) minutes.
The time required to achieve full strength is 24 hours.
Fasteners and Torque Values
Use bolts of the correct length. A bolt which is too long may
bottom before the head is tight against the part it is to hold. If
a bolt is too short, there may not be enough threads engaged
to hold the part securely. Threads can be damaged. Inspect
them and replace fasteners, as necessary.
Torque values should correspond to the type of bolts, studs,
and nuts being used.
The torque tables are provided by National Crane for
reference when performing maintenance.
Use of proper torque values is extremely important. Improper
torquing can seriously affect performance and reliability.
Identification of fastener grade is always necessary. When
marked as a high-strength bolt (grade 5, 8, etc.), the
mechanic shall be aware that he/she is working with a highly
stressed component, and the fastener should be torqued
accordingly.
NOTE: Some special applications require variation from
standard torque values. Reference should always
be made to component overhaul procedures for
recommendations.
Special attention should be given to the existence of
lubricant, plating, or other factors that might require variation
from standard torque values.
The use of lubricants on zinc-flake coated parts is prohibited
since this will change the required torque value.
When maximum recommended torque values have been
exceeded, the fastener should be replaced.
Previously installed bolts and nuts of grade 8 or class 10.9
and higher may not be reused.
When referring to the applicable torque charts, use values as
close as possible to the torque values shown to allow for
wrench calibration tolerance.
DANGER
Loctite type adhesives contain chemicals that may be
harmful if misused. Read and follow the instructions on
the container.
!
Bead Application
FIGURE 1-3
9023-29
For
Reference
Only

1-8 Published 7-01-2021 Control # 655-02
INTRODUCTION NBT40-1 SERVICE MANUAL
Torque Wrenches
Flexible beam types of wrenches, even though they might
have a pre-set feature, must be pulled at a right angle, and
the force must be applied at the center of the handle. Force
value readings must be made while the tool is in motion.
Rigid handle types, with torque limiting devices that can be
pre-set to required values, eliminate dial readings, and
provide more reliable, less variable readings.
NOTE: If multipliers and/or special tools are used to reach
hard-to-get-at areas, ensure torque readings are
accurate.
Torque wrenches are precision instruments and must be
handled with care. To ensure accuracy, calibrations must be
made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
damaged, it should immediately be removed from service
until recalibrated. When using a torque wrench, any erratic or
jerking motion can result in the application of excessive or
improper torque. Always use a slow, even movement and
stop when the predetermined value has been reached.
When using step wrenches, calculated wrench settings are
valid only when the following conditions are met:
•Torque wrenches must be those specified, and forces
must be applied at the handle grip. The use of handle
extensions will change applied torque to the bolt.
•All handles must be parallel to the step wrench during
final tightening. Multiplier reaction bars may be
misaligned no more than 30 degrees without causing
serious error in torque.
•Multiplier bar handles must be propped or supported
within the outer 1/4 of the handle length, or serious
under or over tightening will occur.
To convert pounds-foot (lb-ft) of torque to newton meters
(Nm), multiply the pounds-foot quantity by 1.3558.
To convert pounds-inch (lb-in) of torque to newton meters
(Nm), multiply the pounds-inch quantity by 0.11298.
Torque Values
The following tables list the torque values for both ASME
standard and metric fasteners. The tables list the values for
grade 5 and grade 8 zinc-flake coated, untreated (black)
finish, and stainless steel fasteners.
SAE Grade 1
and Grade 2
HHCS
SAE Grade 5
HHCS
SAE Grade 7
HHCS
SAE Grade 8
HHCS
Serrated
Flange Head
Socket Head
Shoulder
Screw
Socket Head
Capscrew
FIGURE 1-4
For
Reference
Only

National Crane Published 7-01-2021 Control # 655-02 1-9
NBT40-1 SERVICE MANUAL INTRODUCTION
1
10
Table 1-2. Inch Series with Coarse Threads (UNC) – Zinc Flake Coated
Nominal Size, Threads per
Inch, and Series
Designation
Grade
Torque (ft/lb)
Maximum Nominal Minimum
1/4-20 UNC 5 6.6 6.4 6.2
8 9.3 9.0 8.8
5/16-18 UNC 5 13.5 13.2 12.8
8 19.1 18.6 18.1
3/8-16 UNC 5 24.0 23.4 22.8
8 33.9 33.1 32.2
7/16-14 UNC 5 38.4 37.4 36.5
8 54.3 52.9 51.5
1/2-13 UNC 5 58.6 57.1 55.7
8 82.8 80.7 78.6
9/16-12 UNC 5 84.5 82.4 80.3
8 119.4 116.5 113.5
5/8-11 UNC 5 116.6 113.7 110.8
8 164.8 160.7 156.6
3/4-10 UNC 5 206.8 201.7 196.5
8 292.3 284.9 277.6
7/8-9 UNC 5 333.8 325.4 317.1
8 471.6 459.8 448.0
1-8 UNC 5 500.3 487.8 475.3
8 707.0 689.3 671.6
1 1/8-7 UNC 5 624.0 608.4 592.8
8 1,001.4 976.4 951.4
1 1/4-7 UNC 5 880.5 858.5 836.5
8 1,413.1 1,377.8 1,342.5
1 3/8-6 UNC 5 1,154.5 1,125.6 1,096.7
8 1,852.8 1,806.5 1,760.2
1 1/2-6 UNC 5 1,532.0 1,493.7 1,455.4
8 2,458.8 2,397.3 2,335.8
For
Reference
Only

1-10 Published 7-01-2021 Control # 655-02
INTRODUCTION NBT40-1 SERVICE MANUAL
Table 1-3. Inch Series with Fine Threads (UNF) – Zinc Flake Coated
Table 1-4. Metric Series with Coarse Threads – Zinc Flake Coated
Nominal Size, Threads per
Inch, and Series
Designation
Grade
Torque (ft/lb)
Maximum Nominal Minimum
1/4-28 UNF 5 7.5 7.3 7.1
8 10.6 10.4 10.1
5/16-24 UNF 5 15.0 14.6 14.2
8 21.1 20.6 20.1
3/8-24 UNF 5 27.2 26.5 25.8
8 38.4 37.5 36.5
7/16-20 UNF 5 42.9 41.8 40.7
8 60.6 59.1 57.6
1/2-20 UNF 5 66.0 64.4 62.7
8 93.3 90.9 88.6
9/16-18 UNF 5 94.3 91.9 89.6
8 133.2 129.9 126.6
5/8-18 UNF 5 132.1 128.8 125.5
8 186.7 182.0 177.3
3/4-16 UNF 5 231.0 225.2 219.4
8 326.4 318.2 310.1
7/8-14 UNF 5 367.7 358.5 349.3
8 519.6 506.6 493.6
1-12 UNF 5 547.4 533.7 520.0
8 773.5 754.2 734.8
1 1/8-12 UNF 5 700.0 682.5 665.0
8 1,123.5 1,095.4 1,067.3
1 1/4-12 UNF 5 975.0 950.6 926.2
8 1,564.8 1,525.7 1,486.5
1 3/8-12 UNF 5 1,314.4 1,281.5 1,248.6
8 2,109.5 2,056.7 2,004.0
1 1/2-12 UNF 5 1,723.9 1,680.8 1,637.7
8 2,766.8 2,697.6 2,628.4
Nominal Size, Threads per
Inch, and Series
Designation
Property
Class
Torque (Nm)
Maximum Nominal Minimum
M4x0.7 10.9 3.6 3.5 3.4
12.9 4.2 4.1 4.0
M5x0.8 10.9 7.2 7.0 6.8
12.9 8.4 8.2 8.0
For
Reference
Only