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Manitowoc Grove GRT8120 User Manual
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A-1
GRT8120 OPERA
TOR MANUAL
Published 3-22-2021, Control # 702-02
APPENDIX 1
DECALS
Figure
A-1 shows the locations of the decals on the
GRT8120.
430
432
Table of Contents
Table of Contents
5
Section 1
17
Customer Support
18
New Owners
18
Noise/Vibration Test Results
19
Noise Level Test Results
19
Vibration Level Test Results
19
Serial Number Location
19
GRT8120 Crane Components
20
List of Specifications
22
General
22
Dimensions
22
Capacities
22
Transmission
22
Torque Converter
22
Engine
22
Cummins QSB 6.7L - Tier 4F
22
Cummins QSB 6.7L - Tier 3
22
Axles
22
Wheels and Tires
23
Boom
23
Outriggers
23
Swivel Assembly
23
Swing Gearbox
23
Hydraulic Pumps
23
Pump #1
23
Pump #2
23
Pump #3
23
Hoists
23
Section 2
25
Safety Messages
26
General
26
Safety Alert Symbol
26
Signal Words
26
Accidents
26
Operator Information
27
Operator Qualifications
27
Operational Aids
28
Rated Capacity Limiter (RCL) Systems
28
Anti-Two-Blocking Device
29
Working Area Limiter (if Equipped)
29
Crane Stability/Structural Strength
30
Load Charts
31
Work Site
31
Wind Forces
31
Wind Speeds
32
Determination of 3-Second Wind Gust Speed at Boom Tip Height
34
Size and Shape of the Load
34
Determining Wind Drag Coefficient (CD)
35
Maximum Permissible Wind Speed
36
Example and Sample Calculations (Non-Metric)
42
Lifting Operations
44
Multiple Crane Lifts
45
Lifting Multiple Loads
45
Tilt-Up Panel Lifting
45
Counterweight
46
Outrigger Lift off
46
Pile Driving and Extracting
46
Crane Equipment
47
Crane Inspection
47
Electrocution Hazard
47
Set-Up and Operation
48
Electrocution Hazard Devices
49
Electrical Contact
49
Special Operating Conditions and Equipment
50
Grounding the Crane
50
Personnel Handling
51
Environmental Protection
52
Maintenance
52
Service and Repairs
52
Hydraulic Fluid
52
Moving Parts
53
Before Maintenance or Repairs
53
After Maintenance or Repairs
53
Lubrication
53
Tires
53
Hoist Rope
54
Synthetic Hoist Rope
54
Wire Rope
54
Sheaves
56
Batteries
56
Super Capacitor (if Equipped)
56
General Maintenance
57
Transporting the Crane
57
Travel Operation
57
Work Practices
59
Personal Considerations
59
Crane Access
59
Job Preparation
59
Working
60
Lifting
60
Hand Signals
61
Boom Extension
63
Parking and Securing
63
Shut-Down
63
Cold Weather Operation
63
Temperature Effects on Hook Blocks
64
Temperature Effects on Hydraulic Cylinders
65
Crane Stability
67
Hoist Platform
67
Overload Inspection
67
Boom Inspection
68
Superstructure Inspection
70
Carrier Inspection
72
Operator Cab Overview
77
Steering Wheel and Column
78
Steering Wheel
79
Turn Signal Lever and Horn Controls
79
Parking Brake Switch
79
Headlights Switch
79
Drive Axle Selector Switch
79
Hazard Lights Switch
80
Transmission Shift Lever
80
Ignition Switch
80
Steering Column Tilt and Telescope Lock Lever
80
Right Overhead Control Panel
81
Heater/Air Conditioner Fan Speed Switch
82
Heater/Air Conditioner Temperature Control Switch
82
Fresh Air/Recirculation Air Switch
82
Boom-Mounted Lights Motor Switch (Optional)
82
Boom-Mounted Lights Switch (Optional)
82
Cab-Mounted Lights Switch
82
Front Window Wiper and Washer Switch
82
Skylight Wiper and Washer Switch
82
Increment/Decrement - Start/Stop Switch
82
Engine Wait-To-Start Indicator
83
Remote Control Enable/Disable Switch
83
Crane Function Enable/Disable Switch
83
Momentary Limit Bypass Switch (Non-CE Certified Cranes)
84
Limit Bypass Set-Up Switch (CE Certified Cranes)
84
Boom up Bypass Switch
85
Emergency Stop Button
86
Cab Dome Light
86
Left Overhead and Side Panel
87
Coat Hook
88
USB Charging Ports
88
Auxiliary Light and Switch
88
Mobile Phone Holder
88
Heater/Air Conditioner Vents
88
Right Lower Control Panel
89
Turntable Swing Lock Pin Control Handle
90
12-Volt Outlet
90
Engine On-Board Diagnostic (OBD) Connector
90
Rated Capacity Limiter Display Module and Operator Display Module
91
Rated Capacity Limiter Display Module (RDM)
92
Operator Display Module (ODM)
92
Navigation Control Pad
92
USB Diagnostic Connector
93
RCL Shutdown Warning Indicator (Non-CE Certified Cranes)
93
RCL Shutdown Warning Indicator (CE Certified Cranes)
93
RCL Early Warning Indicator
93
Anti-Two-Block (A2B) Indicator
93
Swing Brake Engaged Indicator
93
Brightness Sensor
93
Internal Temperature Warning Indicator
93
Operator Seat and Armrest Controls (Dual Axis)
94
Cup Holder
96
Boom Lift - Main Hoist - Telescope - Luffing Jib Controller (Dual Axis)
96
Deadman Switches (Optional) (Dual Axis)
96
Horn Button
96
Hoist Speed Toggle Switches
96
Jog Dial
96
Heater/Air Conditioner Vents
96
Main Hoist Enable/Disable Switch
96
Luffing Jib Enable/Disable Switch (Optional)
97
Boom Telescope Enable/Disable Switch
97
Boom Lift Enable/Disable Switch
97
Seat Lumbar Support Adjustment Lever
97
Seat Slide Lever
97
Auxiliary Hoist Enable/Disable Switch
97
Cab Tilt Switch
97
Swing Enable/Disable Switch
98
Outrigger Extend/Retract Switch
98
Differential Lock Switch (Optional)
98
Rear Steer Switch
98
Swing Brake Release Button
99
Swing/Telescope or Swing/Auxiliary Hoist Controller (Dual Axis)
99
Seat Backrest Adjustment Lever
99
Seat Adjustment Control Panel
99
Armrest Adjustment Buttons
100
Seat Heat Switch (Optional)
100
Seat Headrest (Not Shown)
100
Hoist Rotation Indicators
100
Seat Switch
100
Optional Single Axis Controllers
101
Swing Controller
102
Telescope or Auxiliary Hoist Controller
102
Boom Lift - Telescope - Luffing Boom Extension Controller
102
Main Hoist Controller
102
Hoist Rotation Indicators (Not Shown)
102
Foot Pedal Controls and Floor Mat
103
Swing Brake Pedal
104
Service Brake Pedal
104
Throttle Pedal
104
Floor Mat
104
Internal Rated Capacity Limiter Light Bar
105
Controls and Features at Front of Cab
106
Front Windshield/Emergency Exit
107
Sun Visor
107
Grab Handles
107
Foot Rests
107
Controls and Features at Rear of Cab
108
Radio (Optional)
109
Speakers (Optional)
109
Rear Window
109
Fan
109
Fire Extinguisher
109
User Manual Holder
109
Fuse and Relay Panel - Cab
110
Buzzer
111
Maintained Limit Bypass Switch (Non-CE Certified Cranes)
111
Right Window and Skylight Window
112
Skylight Window Latch (if Equipped)
113
Skylight Sun Shade
113
Right Side Window Latch
113
Controls and Features External to the Cab
114
Counterweight Removal Control Pads
114
Right Counterweight Cylinder Raise Button
114
Left Counterweight Cylinder Raise Button
114
Lock Cylinder Retract Button
115
Function Enable Button
115
Main Power LED Indicator
115
Horn Button
115
Lock Cylinder Extend Button
115
Left Counterweight Cylinder Lower Button
115
Right Counterweight Cylinder Lower Button
115
Bridging Switch (CE Certified Cranes)
116
External RCL Light Tower (Optional)
117
Strobe Light or Beacon
117
Backup Alarm
117
120V/240V Engine Block Heater and Outlet
118
Emergency Stop Buttons (Optional)
118
Battery Disconnect Switch
119
Fuse Box - Carrier
120
Fuse and Relay Box - Carrier
121
Cab Mounted Work Lights
122
Boom Mounted Work Lights (Optional)
122
Side Mounted Carrier Work Lights
122
Ladders and Grab Handles
123
Remote Control Unit
124
Overview
124
Storage and Charging
125
Controls and Features
126
Programming Port
127
Power Button
127
Color Display
127
Left Side Motion Button
127
Right Side Motion Button
127
Enable Buttons
127
Emergency Stop Button
127
Outrigger Beam Button
128
Outrigger Jack Button
128
Hoist Button
128
Boom Lift Button
128
Swing Button
128
Option Button
128
Engine Button
128
Horn Button
128
Information Button
128
Escape Button
129
Status Indicator
129
Battery Pack
129
Display Components
130
Pre-Starting Checks
134
Fuel Supply
134
Engine Oil
134
Engine Coolant
134
Batteries
134
Hydraulic Reservoir and Filter
134
Hoist Rope
134
Hook Block and Overhaul Ball
134
Seats and Mirrors
134
Cameras
134
Axle Oscillation Lock Outs Operation
135
Safety Equipment
135
Daily Lubrication
135
Boom
135
Air Intake Restriction Monitoring (AIRM) Communications System
135
Cold Weather Operation
135
Coolant Heater
136
Radiator Shutters
136
Auxiliary Cab Heater
136
Battery Heater
137
Air Diverter
137
Super Capacitor
137
Diesel Fuel
137
Engine Operation
138
Jump Starting Hazard
138
Charging the Batteries
138
Start-Up Procedure
138
Idling the Engine
139
Engine High Idle
139
Racing the Engine
139
Exhaust System Cleaning
139
Shutdown Procedure
140
Crane Warm-Up Procedures
141
Engine
141
Transmission
141
Hoist
141
Swing Drive and Turntable Bearing
141
Axles
142
Hydraulic Oil System
142
Driving the Crane
142
Seat Belts
142
Traveling - General
142
Traveling - Towing/Pulling
143
Traveling - Being Towed/Pulled
143
Traveling on Slopes
144
General Conditions
144
Slope Limitations - Fore/Aft Travel
144
Slope Limitations - Side Slope Travel
145
Traveling with Elevated Boom
145
Traveling with Boom Extension Erected
145
Extended Traveling
146
Traveling - Forward
146
Traveling - Reverse
147
Steering
147
Front Wheel Steering
147
Rear Wheel Steering
147
Four Wheel Steering
147
Crab Steering
147
Four-Wheel Drive Operation
148
Differential Lock Operation
148
General
148
Operation
148
Craning Functions
149
Controller Operation
149
Proper Crane Leveling
149
Using the Outriggers
149
Setting the Outriggers Manually
149
Setting the Outriggers Using the Auto-Level Feature
150
Outrigger Monitoring System (OMS) (Optional-Standard in North America and European Union Countries)
151
Stowing the Outriggers
151
Swinging the Boom and Superstructure
152
Raising and Lowering the Boom
152
Raising the Boom
152
Lowering the Boom
153
Telescoping the Boom
153
Extending the Boom
154
Retracting the Boom
155
Telescoping - Theory of Operation
156
Manual Telescoping
156
Semi-Automatic Telescoping
156
Extending with the Main Boom Configuration
157
Overview
157
Telescoping Process
158
Assignment for Display
160
Fixed Length and Intermediate Length
161
Main Boom Fixed Length
161
Main Boom Intermediate Length
161
Telescope Picture
161
Telescoping Sequence
161
Inspections Prior to Starting Operations
161
Enabling the Telescoping Mechanism
161
Function of the Controller
161
Disabling the Telescoping Mechanism
162
Manual Telescoping
162
Telescoping with Semi-Automation
168
Semi-Automatic Telescope Mode
168
Introduction
168
Semi-Auto Mode Basic Operating Procedures
170
Semi-Auto Mode for Shifting Cylinder Within Fully Retracted Boom
172
Semi-Auto Mode Requiring Boom to be Retracted
172
Semi-Auto Mode Screen Refresh
172
Semi-Auto Mode Warning Indications
173
Semi-Auto Mode Telescoping Function Shut-Down
173
Semi-Auto Mode Lost Boom Configuration
174
Reset Telescoping Configuration
174
Semi-Auto Mode Vs. Manual Mode
175
Boom Configurator
175
Lowering and Raising the Main Hoist Rope
177
Lowering the Main Hoist Rope
177
Raising the Main Hoist Rope
178
Lowering and Raising the Auxiliary Hoist Rope
178
Lowering the Auxiliary Hoist Rope
178
Raising the Auxiliary Hoist Rope
179
Selecting the Hoist Speed Range
179
Using the Remote Control Unit
180
Preparing for Remote Control Operation
180
Operating Remote Control
181
Superstructure Horn
181
Emergency Stop
181
Engine Start/Stop/Throttle
183
Outrigger Beams
185
Outrigger Jacks
187
Hoist Control (Main and Aux)
189
Boom Lift
191
Swing and 360° Swing Lock
193
OPT (Options)
195
Information
196
Navigating the Operator Display Module and Rated Capacity Limiter Display Module
197
Navigating the Operator Display Module and Rated
197
Capacity Limiter Display Module
197
Using the Operator Display Module (ODM)
198
Main Screen
199
Alerts Area
200
Active Screen Indicator Area
206
Crane Information Area
207
Crane Status Area
210
Frequently Used Quick Select Menu Area
215
Status Bar
216
Permanent Quick Select Menu Area
218
Menu Screen
219
Menu Screen
220
Camera Menu Group
224
Tele-Automation Menu Group
225
Semi-Automation Telescope Mode
225
Boom Configurator Mode
227
Crane Function Menu Group
229
Outrigger Extend/Retract
229
360° Swing Lock (Optional)
235
Boom Extension Deployment/Stowage
236
Working Range Limiter Menu Group
237
Introduction
237
WRL Limitations Overview
237
Accessing a WRL Limitation Screen
239
Boom Height Limitation
244
Boom Angle Limitation
246
Radius Limitation
249
Swing Angle Limitation
251
Virtual Walls Limitation
254
Emergency Program Menu Group
258
Manual Telescope Mode
258
Emergency Telescope Mode
260
Faults Menu Group
271
Crane Faults
271
Engine Faults
274
Information Menu Group
274
Operating Hours
274
Software Versions
276
User Settings Menu Group
277
Controller Curve
277
Controller Speed
279
ECO Mode
281
Boom Position Indicator Light
283
Exhaust System Cleaning (if Equipped)
283
Service Menu
285
Display Settings Menu Group
286
Units of Measure
286
Display Screen Brightness
286
Time Set
287
Using the Rated Capacity Limiter Display Module (RDM)
288
Enter Rigging Code
288
Entering Individual Components
288
Using the Rated Capacity Limiter Display
288
Module (RDM)
288
Entering the RCL Code
293
Checks before Operating the Crane
295
Displays During Crane Operation
297
RCL Early Warning
299
RCL Shutdown
299
Load Chart and Miscellaneous Alerts
300
Hoist Camera
304
Preload Check
306
Using the Load Chart
306
Stowing and Parking
308
Leaving Crane Unattended
308
Long-Term Storage
308
Section 5
309
Setup of Crane before and after Transporting
310
Hoist Camera
311
Lowering the Hoist Camera for Transport
311
Raising the Hoist Camera for Operation
311
Hoist Platform
312
Lowering the Hoist Platform Railings for Transport
312
Raising the Hoist Access Railings for Operation
312
Beacon Lights (Optional)
313
Lowering the Beacon Light for Transport
313
Raising the Beacon Light for Operation
313
Cab Mirrors
314
RCL Light Tower (Optional)
315
Retracting the RCL Light Tower for Transport
315
Extending the RCL Light Tower for Operation
315
Access Ladders
316
Raising the Access Ladder for Transport
316
Lowering the Access Ladder
316
Outrigger Floats
317
Stowing an Outrigger Float for Transport
317
Removing an Outrigger Float from Stowage
317
Hydraulic Hose Drum (Optional)
317
Boom Position Indicator Light and Anemometer (Optional)
317
Auxiliary Single-Sheave Boom Nose
317
Installing Cable on the Hoist
318
Anti-Two Block (A2B) Switch
318
Locking
319
Unlocking
319
Checking before Operation
319
Cranes with Main Hoist Only
319
Cranes with Main and Auxiliary Hoists
319
Hoist Rope Reeving
321
Possible Reeving Combinations
321
3-Sheave Hook Block
322
Hook Tackle
323
Auxiliary Boom Nose
323
Quick Reeving the Hook Block
325
Reeving Hoist Rope over the Boom
325
Reeving/Unreeving the Hoist Rope
325
Dead-End Rigging/Wedge Sockets
326
Installing Wedge and Socket
326
Boom Extension
328
General Warnings
329
Boom Extension Pin Interlock Mechanism
329
Front Boom Extension Mounting Pin
329
Boom Nose Installation Pins
329
Front Mounting Pin Handle
330
Boom Extension Mounting Brackets
331
Boom Extension Sensors
333
Lifting Points
333
About the Boom Extension Group in the ODM
334
Accessing the Boom Extension Deployment/Stowage Function
335
Boom Extension Alert and Warning Screens
336
Installing the Folding Boom Extension
338
Removing the Folding Boom Extension
342
Erecting the 17.6 M (57.6 Ft) Boom Extension
343
Erecting the Fly Section
347
Stowing the Fly Section
349
Stowing the 17.6 M (57.6 Ft) Boom Extension
350
Erecting the 10.5 M (34.5 Ft) Boom Extension Base Section Only
353
Stowing the 10.5 M (34.5 Ft) Boom Extension Base Section Only
356
Boom Extension Electrical Connections
359
Connecting Electrical Connection at Boom Nose
359
Disconnecting Electrical Connection at Boom Nose
359
Hydraulic Boom Extension Connections
360
Checking the Locking Device on the Hose Drum
360
Hydraulic Hose Installation
360
Retracting Hydraulic Hoses for Main Boom Operation
360
Establishing the Hydraulic Connection
361
Disconnecting the Hydraulic Connection
362
Reeving the Hoist Rope
363
Unreeving Hoist Rope
363
Offsetting the Mechanical Boom Extension
364
Mechanical Extension Angle Adjusting Mechanism
364
Setting the Offset Angle with an Auxiliary Crane
364
Setting the Offset Angle Without an Auxiliary Crane
365
Offsetting the (Optional) Hydraulic Boom Extension
365
Anti-Two Block Switch on the Boom Extension
366
10.5 M (34.5 Ft) Extension Anti-Two Block Installation
366
M (35 Ft) Extension Anti-Two Block Removal
366
17.6 M (57.6 Ft) Extension Anti-Two Block Installation
366
Folding Mast Sheave
367
Auxiliary Single Sheave Boom Nose
368
Identification
368
Installing/Removing Auxiliary Single-Sheave Boom Nose
368
Installing Auxiliary Single-Sheave Boom Nose
368
Installing/Removing Auxiliary Single-Sheave
368
Boom Nose
368
Removing the Auxiliary Single-Sheave Boom Nose
369
Rigging the Auxiliary Single-Sheave Boom Nose
370
Rigging in Transport Position
370
Rigging in Working Position
370
Attaching and Removing Hoist Cable
370
Rigging the Auxiliary Single-Sheave
370
Boom Nose
370
Anemometer/Boom Position Light (Optional)
371
Counterweight Removal and Installation
374
Counterweight Control Panel
375
Removing the Counterweight
376
Installing the Counterweight
377
General
380
Environmental Protection
380
Lubricants and Lubrication Intervals
380
Arctic Lubricants and Conditions
383
Arctic Conditions below -9°C (+15°F)
383
Cold Weather Package and Lubricants
383
Cylinder Rod Surface Protection
387
Wire Rope Lubrication
387
Lubrication Points
387
Cranelube
388
Cummins Oil Registration List
388
Safety
388
Drive Train
390
Steering and Suspension - Meritor Axles
396
Steering and Suspension - Kessler Axles
396
Steering and Suspension - Fifth Wheel Pivots
398
Axle Lubrication - Meritor Axles
400
Axle Lubrication - Kessler Axles
402
Turntable (Swing Drive) and Cab Tilt Lubrication
404
Outrigger Lubrication
408
Lift Cylinder Lubrication
410
Boom Lubrication
411
Boom Lubrication (Continued)
414
Hoist Lubrication
422
Hydraulics Lubrication
424
Rust Protection
426
Protecting Cranes from Rusting
426
Cleaning Procedures
427
Inspection and Repair
427
Application
428
Areas of Application
428
Appendix 1 - Decals
431
Word Index
441
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Manitowoc Grove GRT8120 Specifications
General
Brand
Manitowoc
Model
Grove GRT8120
Category
Construction Equipment
Language
English
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