Manitowoc Grove GRT8120

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5-70 Published 3-22-2021, Control # 702-02

SET-UP AND INSTALLATION GRT8120 OPERATOR MANUAL

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Table of Contents5
Section 117
Customer Support18
New Owners18
Noise/Vibration Test Results19
Noise Level Test Results19
Vibration Level Test Results19
Serial Number Location19
GRT8120 Crane Components20
List of Specifications22
General22
Dimensions22
Capacities22
Transmission22
Torque Converter22
Engine22
Cummins QSB 6.7L - Tier 4F22
Cummins QSB 6.7L - Tier 322
Axles22
Wheels and Tires23
Boom23
Outriggers23
Swivel Assembly23
Swing Gearbox23
Hydraulic Pumps23
Pump #123
Pump #223
Pump #323
Hoists23
Section 225
Safety Messages26
General26
Safety Alert Symbol26
Signal Words26
Accidents26
Operator Information27
Operator Qualifications27
Operational Aids28
Rated Capacity Limiter (RCL) Systems28
Anti-Two-Blocking Device29
Working Area Limiter (if Equipped)29
Crane Stability/Structural Strength30
Load Charts31
Work Site31
Wind Forces31
Wind Speeds32
Determination of 3-Second Wind Gust Speed at Boom Tip Height34
Size and Shape of the Load34
Determining Wind Drag Coefficient (CD)35
Maximum Permissible Wind Speed36
Example and Sample Calculations (Non-Metric)42
Lifting Operations44
Multiple Crane Lifts45
Lifting Multiple Loads45
Tilt-Up Panel Lifting45
Counterweight46
Outrigger Lift off46
Pile Driving and Extracting46
Crane Equipment47
Crane Inspection47
Electrocution Hazard47
Set-Up and Operation48
Electrocution Hazard Devices49
Electrical Contact49
Special Operating Conditions and Equipment50
Grounding the Crane50
Personnel Handling51
Environmental Protection52
Maintenance52
Service and Repairs52
Hydraulic Fluid52
Moving Parts53
Before Maintenance or Repairs53
After Maintenance or Repairs53
Lubrication53
Tires53
Hoist Rope54
Synthetic Hoist Rope54
Wire Rope54
Sheaves56
Batteries56
Super Capacitor (if Equipped)56
General Maintenance57
Transporting the Crane57
Travel Operation57
Work Practices59
Personal Considerations59
Crane Access59
Job Preparation59
Working60
Lifting60
Hand Signals61
Boom Extension63
Parking and Securing63
Shut-Down63
Cold Weather Operation63
Temperature Effects on Hook Blocks64
Temperature Effects on Hydraulic Cylinders65
Crane Stability67
Hoist Platform67
Overload Inspection67
Boom Inspection68
Superstructure Inspection70
Carrier Inspection72
Operator Cab Overview77
Steering Wheel and Column78
Steering Wheel79
Turn Signal Lever and Horn Controls79
Parking Brake Switch79
Headlights Switch79
Drive Axle Selector Switch79
Hazard Lights Switch80
Transmission Shift Lever80
Ignition Switch80
Steering Column Tilt and Telescope Lock Lever80
Right Overhead Control Panel81
Heater/Air Conditioner Fan Speed Switch82
Heater/Air Conditioner Temperature Control Switch82
Fresh Air/Recirculation Air Switch82
Boom-Mounted Lights Motor Switch (Optional)82
Boom-Mounted Lights Switch (Optional)82
Cab-Mounted Lights Switch82
Front Window Wiper and Washer Switch82
Skylight Wiper and Washer Switch82
Increment/Decrement - Start/Stop Switch82
Engine Wait-To-Start Indicator83
Remote Control Enable/Disable Switch83
Crane Function Enable/Disable Switch83
Momentary Limit Bypass Switch (Non-CE Certified Cranes)84
Limit Bypass Set-Up Switch (CE Certified Cranes)84
Boom up Bypass Switch85
Emergency Stop Button86
Cab Dome Light86
Left Overhead and Side Panel87
Coat Hook88
USB Charging Ports88
Auxiliary Light and Switch88
Mobile Phone Holder88
Heater/Air Conditioner Vents88
Right Lower Control Panel89
Turntable Swing Lock Pin Control Handle90
12-Volt Outlet90
Engine On-Board Diagnostic (OBD) Connector90
Rated Capacity Limiter Display Module and Operator Display Module91
Rated Capacity Limiter Display Module (RDM)92
Operator Display Module (ODM)92
Navigation Control Pad92
USB Diagnostic Connector93
RCL Shutdown Warning Indicator (Non-CE Certified Cranes)93
RCL Shutdown Warning Indicator (CE Certified Cranes)93
RCL Early Warning Indicator93
Anti-Two-Block (A2B) Indicator93
Swing Brake Engaged Indicator93
Brightness Sensor93
Internal Temperature Warning Indicator93
Operator Seat and Armrest Controls (Dual Axis)94
Cup Holder96
Boom Lift - Main Hoist - Telescope - Luffing Jib Controller (Dual Axis)96
Deadman Switches (Optional) (Dual Axis)96
Horn Button96
Hoist Speed Toggle Switches96
Jog Dial96
Heater/Air Conditioner Vents96
Main Hoist Enable/Disable Switch96
Luffing Jib Enable/Disable Switch (Optional)97
Boom Telescope Enable/Disable Switch97
Boom Lift Enable/Disable Switch97
Seat Lumbar Support Adjustment Lever97
Seat Slide Lever97
Auxiliary Hoist Enable/Disable Switch97
Cab Tilt Switch97
Swing Enable/Disable Switch98
Outrigger Extend/Retract Switch98
Differential Lock Switch (Optional)98
Rear Steer Switch98
Swing Brake Release Button99
Swing/Telescope or Swing/Auxiliary Hoist Controller (Dual Axis)99
Seat Backrest Adjustment Lever99
Seat Adjustment Control Panel99
Armrest Adjustment Buttons100
Seat Heat Switch (Optional)100
Seat Headrest (Not Shown)100
Hoist Rotation Indicators100
Seat Switch100
Optional Single Axis Controllers101
Swing Controller102
Telescope or Auxiliary Hoist Controller102
Boom Lift - Telescope - Luffing Boom Extension Controller102
Main Hoist Controller102
Hoist Rotation Indicators (Not Shown)102
Foot Pedal Controls and Floor Mat103
Swing Brake Pedal104
Service Brake Pedal104
Throttle Pedal104
Floor Mat104
Internal Rated Capacity Limiter Light Bar105
Controls and Features at Front of Cab106
Front Windshield/Emergency Exit107
Sun Visor107
Grab Handles107
Foot Rests107
Controls and Features at Rear of Cab108
Radio (Optional)109
Speakers (Optional)109
Rear Window109
Fan109
Fire Extinguisher109
User Manual Holder109
Fuse and Relay Panel - Cab110
Buzzer111
Maintained Limit Bypass Switch (Non-CE Certified Cranes)111
Right Window and Skylight Window112
Skylight Window Latch (if Equipped)113
Skylight Sun Shade113
Right Side Window Latch113
Controls and Features External to the Cab114
Counterweight Removal Control Pads114
Right Counterweight Cylinder Raise Button114
Left Counterweight Cylinder Raise Button114
Lock Cylinder Retract Button115
Function Enable Button115
Main Power LED Indicator115
Horn Button115
Lock Cylinder Extend Button115
Left Counterweight Cylinder Lower Button115
Right Counterweight Cylinder Lower Button115
Bridging Switch (CE Certified Cranes)116
External RCL Light Tower (Optional)117
Strobe Light or Beacon117
Backup Alarm117
120V/240V Engine Block Heater and Outlet118
Emergency Stop Buttons (Optional)118
Battery Disconnect Switch119
Fuse Box - Carrier120
Fuse and Relay Box - Carrier121
Cab Mounted Work Lights122
Boom Mounted Work Lights (Optional)122
Side Mounted Carrier Work Lights122
Ladders and Grab Handles123
Remote Control Unit124
Overview124
Storage and Charging125
Controls and Features126
Programming Port127
Power Button127
Color Display127
Left Side Motion Button127
Right Side Motion Button127
Enable Buttons127
Emergency Stop Button127
Outrigger Beam Button128
Outrigger Jack Button128
Hoist Button128
Boom Lift Button128
Swing Button128
Option Button128
Engine Button128
Horn Button128
Information Button128
Escape Button129
Status Indicator129
Battery Pack129
Display Components130
Pre-Starting Checks134
Fuel Supply134
Engine Oil134
Engine Coolant134
Batteries134
Hydraulic Reservoir and Filter134
Hoist Rope134
Hook Block and Overhaul Ball134
Seats and Mirrors134
Cameras134
Axle Oscillation Lock Outs Operation135
Safety Equipment135
Daily Lubrication135
Boom135
Air Intake Restriction Monitoring (AIRM) Communications System135
Cold Weather Operation135
Coolant Heater136
Radiator Shutters136
Auxiliary Cab Heater136
Battery Heater137
Air Diverter137
Super Capacitor137
Diesel Fuel137
Engine Operation138
Jump Starting Hazard138
Charging the Batteries138
Start-Up Procedure138
Idling the Engine139
Engine High Idle139
Racing the Engine139
Exhaust System Cleaning139
Shutdown Procedure140
Crane Warm-Up Procedures141
Engine141
Transmission141
Hoist141
Swing Drive and Turntable Bearing141
Axles142
Hydraulic Oil System142
Driving the Crane142
Seat Belts142
Traveling - General142
Traveling - Towing/Pulling143
Traveling - Being Towed/Pulled143
Traveling on Slopes144
General Conditions144
Slope Limitations - Fore/Aft Travel144
Slope Limitations - Side Slope Travel145
Traveling with Elevated Boom145
Traveling with Boom Extension Erected145
Extended Traveling146
Traveling - Forward146
Traveling - Reverse147
Steering147
Front Wheel Steering147
Rear Wheel Steering147
Four Wheel Steering147
Crab Steering147
Four-Wheel Drive Operation148
Differential Lock Operation148
General148
Operation148
Craning Functions149
Controller Operation149
Proper Crane Leveling149
Using the Outriggers149
Setting the Outriggers Manually149
Setting the Outriggers Using the Auto-Level Feature150
Outrigger Monitoring System (OMS) (Optional-Standard in North America and European Union Countries)151
Stowing the Outriggers151
Swinging the Boom and Superstructure152
Raising and Lowering the Boom152
Raising the Boom152
Lowering the Boom153
Telescoping the Boom153
Extending the Boom154
Retracting the Boom155
Telescoping - Theory of Operation156
Manual Telescoping156
Semi-Automatic Telescoping156
Extending with the Main Boom Configuration157
Overview157
Telescoping Process158
Assignment for Display160
Fixed Length and Intermediate Length161
Main Boom Fixed Length161
Main Boom Intermediate Length161
Telescope Picture161
Telescoping Sequence161
Inspections Prior to Starting Operations161
Enabling the Telescoping Mechanism161
Function of the Controller161
Disabling the Telescoping Mechanism162
Manual Telescoping162
Telescoping with Semi-Automation168
Semi-Automatic Telescope Mode168
Introduction168
Semi-Auto Mode Basic Operating Procedures170
Semi-Auto Mode for Shifting Cylinder Within Fully Retracted Boom172
Semi-Auto Mode Requiring Boom to be Retracted172
Semi-Auto Mode Screen Refresh172
Semi-Auto Mode Warning Indications173
Semi-Auto Mode Telescoping Function Shut-Down173
Semi-Auto Mode Lost Boom Configuration174
Reset Telescoping Configuration174
Semi-Auto Mode Vs. Manual Mode175
Boom Configurator175
Lowering and Raising the Main Hoist Rope177
Lowering the Main Hoist Rope177
Raising the Main Hoist Rope178
Lowering and Raising the Auxiliary Hoist Rope178
Lowering the Auxiliary Hoist Rope178
Raising the Auxiliary Hoist Rope179
Selecting the Hoist Speed Range179
Using the Remote Control Unit180
Preparing for Remote Control Operation180
Operating Remote Control181
Superstructure Horn181
Emergency Stop181
Engine Start/Stop/Throttle183
Outrigger Beams185
Outrigger Jacks187
Hoist Control (Main and Aux)189
Boom Lift191
Swing and 360° Swing Lock193
OPT (Options)195
Information196
Navigating the Operator Display Module and Rated Capacity Limiter Display Module197
Navigating the Operator Display Module and Rated197
Capacity Limiter Display Module197
Using the Operator Display Module (ODM)198
Main Screen199
Alerts Area200
Active Screen Indicator Area206
Crane Information Area207
Crane Status Area210
Frequently Used Quick Select Menu Area215
Status Bar216
Permanent Quick Select Menu Area218
Menu Screen219
Menu Screen220
Camera Menu Group224
Tele-Automation Menu Group225
Semi-Automation Telescope Mode225
Boom Configurator Mode227
Crane Function Menu Group229
Outrigger Extend/Retract229
360° Swing Lock (Optional)235
Boom Extension Deployment/Stowage236
Working Range Limiter Menu Group237
Introduction237
WRL Limitations Overview237
Accessing a WRL Limitation Screen239
Boom Height Limitation244
Boom Angle Limitation246
Radius Limitation249
Swing Angle Limitation251
Virtual Walls Limitation254
Emergency Program Menu Group258
Manual Telescope Mode258
Emergency Telescope Mode260
Faults Menu Group271
Crane Faults271
Engine Faults274
Information Menu Group274
Operating Hours274
Software Versions276
User Settings Menu Group277
Controller Curve277
Controller Speed279
ECO Mode281
Boom Position Indicator Light283
Exhaust System Cleaning (if Equipped)283
Service Menu285
Display Settings Menu Group286
Units of Measure286
Display Screen Brightness286
Time Set287
Using the Rated Capacity Limiter Display Module (RDM)288
Enter Rigging Code288
Entering Individual Components288
Using the Rated Capacity Limiter Display288
Module (RDM)288
Entering the RCL Code293
Checks before Operating the Crane295
Displays During Crane Operation297
RCL Early Warning299
RCL Shutdown299
Load Chart and Miscellaneous Alerts300
Hoist Camera304
Preload Check306
Using the Load Chart306
Stowing and Parking308
Leaving Crane Unattended308
Long-Term Storage308
Section 5309
Setup of Crane before and after Transporting310
Hoist Camera311
Lowering the Hoist Camera for Transport311
Raising the Hoist Camera for Operation311
Hoist Platform312
Lowering the Hoist Platform Railings for Transport312
Raising the Hoist Access Railings for Operation312
Beacon Lights (Optional)313
Lowering the Beacon Light for Transport313
Raising the Beacon Light for Operation313
Cab Mirrors314
RCL Light Tower (Optional)315
Retracting the RCL Light Tower for Transport315
Extending the RCL Light Tower for Operation315
Access Ladders316
Raising the Access Ladder for Transport316
Lowering the Access Ladder316
Outrigger Floats317
Stowing an Outrigger Float for Transport317
Removing an Outrigger Float from Stowage317
Hydraulic Hose Drum (Optional)317
Boom Position Indicator Light and Anemometer (Optional)317
Auxiliary Single-Sheave Boom Nose317
Installing Cable on the Hoist318
Anti-Two Block (A2B) Switch318
Locking319
Unlocking319
Checking before Operation319
Cranes with Main Hoist Only319
Cranes with Main and Auxiliary Hoists319
Hoist Rope Reeving321
Possible Reeving Combinations321
3-Sheave Hook Block322
Hook Tackle323
Auxiliary Boom Nose323
Quick Reeving the Hook Block325
Reeving Hoist Rope over the Boom325
Reeving/Unreeving the Hoist Rope325
Dead-End Rigging/Wedge Sockets326
Installing Wedge and Socket326
Boom Extension328
General Warnings329
Boom Extension Pin Interlock Mechanism329
Front Boom Extension Mounting Pin329
Boom Nose Installation Pins329
Front Mounting Pin Handle330
Boom Extension Mounting Brackets331
Boom Extension Sensors333
Lifting Points333
About the Boom Extension Group in the ODM334
Accessing the Boom Extension Deployment/Stowage Function335
Boom Extension Alert and Warning Screens336
Installing the Folding Boom Extension338
Removing the Folding Boom Extension342
Erecting the 17.6 M (57.6 Ft) Boom Extension343
Erecting the Fly Section347
Stowing the Fly Section349
Stowing the 17.6 M (57.6 Ft) Boom Extension350
Erecting the 10.5 M (34.5 Ft) Boom Extension Base Section Only353
Stowing the 10.5 M (34.5 Ft) Boom Extension Base Section Only356
Boom Extension Electrical Connections359
Connecting Electrical Connection at Boom Nose359
Disconnecting Electrical Connection at Boom Nose359
Hydraulic Boom Extension Connections360
Checking the Locking Device on the Hose Drum360
Hydraulic Hose Installation360
Retracting Hydraulic Hoses for Main Boom Operation360
Establishing the Hydraulic Connection361
Disconnecting the Hydraulic Connection362
Reeving the Hoist Rope363
Unreeving Hoist Rope363
Offsetting the Mechanical Boom Extension364
Mechanical Extension Angle Adjusting Mechanism364
Setting the Offset Angle with an Auxiliary Crane364
Setting the Offset Angle Without an Auxiliary Crane365
Offsetting the (Optional) Hydraulic Boom Extension365
Anti-Two Block Switch on the Boom Extension366
10.5 M (34.5 Ft) Extension Anti-Two Block Installation366
M (35 Ft) Extension Anti-Two Block Removal366
17.6 M (57.6 Ft) Extension Anti-Two Block Installation366
Folding Mast Sheave367
Auxiliary Single Sheave Boom Nose368
Identification368
Installing/Removing Auxiliary Single-Sheave Boom Nose368
Installing Auxiliary Single-Sheave Boom Nose368
Installing/Removing Auxiliary Single-Sheave368
Boom Nose368
Removing the Auxiliary Single-Sheave Boom Nose369
Rigging the Auxiliary Single-Sheave Boom Nose370
Rigging in Transport Position370
Rigging in Working Position370
Attaching and Removing Hoist Cable370
Rigging the Auxiliary Single-Sheave370
Boom Nose370
Anemometer/Boom Position Light (Optional)371
Counterweight Removal and Installation374
Counterweight Control Panel375
Removing the Counterweight376
Installing the Counterweight377
General380
Environmental Protection380
Lubricants and Lubrication Intervals380
Arctic Lubricants and Conditions383
Arctic Conditions below -9°C (+15°F)383
Cold Weather Package and Lubricants383
Cylinder Rod Surface Protection387
Wire Rope Lubrication387
Lubrication Points387
Cranelube388
Cummins Oil Registration List388
Safety388
Drive Train390
Steering and Suspension - Meritor Axles396
Steering and Suspension - Kessler Axles396
Steering and Suspension - Fifth Wheel Pivots398
Axle Lubrication - Meritor Axles400
Axle Lubrication - Kessler Axles402
Turntable (Swing Drive) and Cab Tilt Lubrication404
Outrigger Lubrication408
Lift Cylinder Lubrication410
Boom Lubrication411
Boom Lubrication (Continued)414
Hoist Lubrication422
Hydraulics Lubrication424
Rust Protection426
Protecting Cranes from Rusting426
Cleaning Procedures427
Inspection and Repair427
Application428
Areas of Application428
Appendix 1 - Decals431
Word Index441

Manitowoc Grove GRT8120 - Page 378

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