Manitowoc Grove GRT9165

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Grove Published 7-23-2020, Control # 668-02 5-13

GRT9165 OPERATOR MANUAL SET-UP AND INSTALLATION

FIGURE 5-12

Counterweight Base Section

LH Counterweight Section

RH Counterweight Section

Counterweight Fully Assembled

3483 kg (7678 lb)

25764 kg (56800 lb)

Lifting Points

18785 kg (41414 lb)

Lifting Points

9921

9922

9923

9924

Main Page

Table of Contents5
Section 117
Customer Support18
New Owners18
Noise/Vibration Test Results19
Noise Level Test Results19
Vibration Level Test Results19
Serial Number Location19
GRT9165 Crane Components20
List of Specifications22
General22
Dimensions22
Capacities22
Transmission22
Torque Converter22
Engine22
Cummins QSB 6.7L - Stage V/Tier 4F22
Cummins QSB 6.7L - Non-Certified22
Axles22
Boom23
Outriggers23
Swivel Assembly23
Hydraulic Pumps23
Pump #123
Pump #223
Pump #323
Pump #423
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
Model Specific Information67
Hoist Platform67
Overload Inspection67
Boom Inspection68
Superstructure Inspection70
Carrier Inspection72
Operator Cab Overview77
Steering Wheel and Column78
Steering Wheel79
Standard Driving Configuration79
Alternate Driving Configuration79
Turn Signal Lever and Horn Controls80
Parking Brake Switch81
Headlights Switch81
Drive Axle Selector Switch81
Alternate Driving Configuration81
Turn Signal Lever and Horn Controls81
Hazard Lights Switch82
Transmission Shift Lever82
Ignition Switch82
Steering Column Tilt and Telescope Lock Lever83
Right Overhead Control Panel84
Heater/Air Conditioner Fan Speed Switch85
Heater/Air Conditioner Temperature Control Switch85
Fresh Air/Recirculation Air Switch85
Boom-Mounted Lights Motor Switch (Optional)85
Boom-Mounted Lights Switch (Optional)85
Cab-Mounted Lights Switch85
Front Window Wiper and Washer Switch85
Skylight Wiper and Washer Switch85
Increment/Decrement - Start/Stop Switch85
Heater/Air Conditioner Temperature Control85
Engine Wait-To-Start Indicator86
Engine Brake Switch (Optional)86
Remote Control Enable/Disable Switch86
Crane Function Enable/Disable Switch86
Momentary Limit Bypass Switch (Non-CE Certified Cranes)87
Limit Bypass Set-Up Switch (CE Certified Cranes)87
Boom up Bypass Switch88
Steering Reversal Switch88
Emergency Stop Button89
Cab Dome Light89
Left Overhead and Side Panel90
Coat Hook91
USB Charging Ports91
Auxiliary Light and Switch91
Cell Phone Holder91
Heater/Air Conditioner Vents91
Right Lower Control PANEL92
Turntable Swing Lock Pin Control Handle93
12-Volt Outlet93
Engine On-Board Diagnostic (OBD) Connector93
Rated Capacity Limiter Display Module and Operator Display Module94
Rated Capacity Limiter Display Module (RDM)95
Operator Display Module (ODM)95
Navigation Control Pad95
USB Connector96
RCL Shutdown Warning Indicator (Non-CE Certified Cranes)96
RCL Shutdown Warning Indicator (CE Certified Cranes)96
RCL Early Warning Indicator96
Anti-Two-Block (A2B) Indicator96
Swing Brake Engaged Indicator97
Brightness Sensor97
Internal Temperature Warning Indicator97
Operator Seat and Armrest Controls (Dual Axis)98
Cup Holder100
Main Hoist - Boom Lift - Telescope - Luffing Boom Extension Controller (Dual Axis)100
Deadman Switches (Optional) (Dual Axis)100
Horn Button100
Hoist Speed Toggle Switches100
Jog Dial100
Heater/Air Conditioner Vents100
Main Hoist Enable/Disable Switch100
Luffing Boom Extension Enable/Disable Switch (Optional)101
Boom Telescope Enable/Disable Switch101
Boom Lift Enable/Disable Switch101
Seat Lumbar Support Adjustment Lever101
Seat Slide Lever101
Auxiliary Hoist Enable/Disable Switch101
Cab Tilt Switch101
Swing Enable/Disable Switch102
Outrigger Extend/Retract Switch102
Differential Lock Switch102
Rear Steer Switch102
Standard Driving Configuration103
Alternate Driving Configuration104
Free Swing Button104
Auxiliary Hoist - Swing Controller (Dual Axis)105
Seat Backrest Adjustment Lever105
Seat Adjustment Control Panel105
Armrest Adjustment Buttons105
Seat Heat Switch (Optional)105
Seat Headrest (Not Shown)105
Hoist Rotation Indicators106
Seat Switch106
Optional Single Axis Controllers107
Swing Controller108
Auxiliary Hoist Controller108
Boom Lift - Telescope - Luffing Boom Extension Controller108
Main Hoist Controller108
Hoist Rotation Indicators (Not Shown)108
Foot Pedal Controls109
Swing Brake Pedal110
Service Brake Pedal110
Throttle Pedal110
Floor Mat110
Internal Rated Capacity Limiter Light Bar (Optional)111
Internal Rated Capacity Limiter Light Bar111
3-View Camera Display112
Controls and Features at Front of Cab113
Front Windshield/Emergency Exit114
Sun Visor114
Grab Handles114
Foot Rests114
Controls and Features at Rear of Cab115
Radio (Optional)116
Speakers (Optional)116
Rear Window116
Fan116
Fire Extinguisher116
User Manual Holder116
Fuse and Relay Panel - Cab117
Buzzer118
Maintained Limit Bypass Switch (Non-CE Certified Cranes)118
Right Window and Skylight Window119
Skylight Window Latch (if Equipped)120
Skylight Sun Shade120
Right Side Window Latch120
Controls and Features External to the Cab121
Outrigger Removal Control Box121
Pin Enable Switch121
Pin Control Switch121
Bridging Switch (CE Certified Cranes)121
External RCL Light Tower (Optional)123
Strobe Light or Beacon123
Backup Alarm123
120V/240V Engine Block Heater and Outlet124
Emergency Stop Buttons (Optional)124
Battery Disconnect Switch125
Fuse and Relay Box #1 - Carrier126
Fuse Box #2 - Carrier127
Cab-Mounted Working Lights128
Motorized Boom-Mounted Working Lights128
Ladders and Grab Handles128
Auxiliary Ladder (Optional)129
Remote Control Unit130
Overview130
Storage and Charging131
Controls and Features132
Programming Port133
Power Button133
Color Display133
Left Side Motion Button133
Right Side Motion Button133
Enable Buttons133
Emergency Stop Button133
Outrigger Beam Button134
Outrigger Jack Button134
Hoist Button134
Boom Lift Button134
Swing Button134
Option Button134
Engine Button134
Horn Button134
Information Button134
Escape Button135
Status Indicator135
Battery Pack135
Display Components136
Pre-Starting Checks140
Fuel Supply140
Engine Oil140
Engine Coolant140
Batteries140
Hydraulic Reservoir and Filter140
Hoist Rope140
Hook Block and Overhaul Ball140
Seats and Mirrors140
Seat Belts140
Safety Equipment141
Daily Lubrication141
Boom141
Air Intake Restriction Monitoring (AIRM) Communications System141
Cold Weather Operation141
Coolant Heater142
Radiator Shutters142
Auxiliary Cab Heater143
Battery Heater143
Air Diverter143
Super Capacitor143
Diesel Fuel144
Engine Operation144
Jump Starting Hazard144
Charging the Batteries144
Start-Up Procedure144
Idling the Engine145
Engine High Idle145
Racing the Engine145
Exhaust System Cleaning145
Shutdown Procedure146
Suspension Height146
Crane Warm-Up Procedures147
Engine147
Transmission147
Hoist147
Swing Drive and Turntable Bearing147
Axles148
Hydraulic Oil System148
Driving the Crane148
Seat Belts148
Traveling - General148
Traveling - Towing/Pulling149
Traveling - Being Towed/Pulled149
Traveling on Slopes150
General Conditions150
Slope Limitations - Fore/Aft Travel150
Slope Limitations - Side Slope Travel151
Traveling with Elevated Boom152
Traveling with Boom Extension Erected152
Extended Traveling153
Traveling - Forward153
Traveling - Reverse154
Steering154
Front Wheel Steering154
Rear Wheel Steering155
Six-Wheel Steering155
Crab Steering155
Four-Wheel Drive Operation155
Differential Lock Operation155
General156
Operation156
Craning Functions156
Controller Operation156
Proper Crane Leveling156
Using the Outriggers157
Setting the Outriggers Manually157
Setting the Outriggers Using the Auto-Level Feature158
Outrigger Monitoring System (OMS)158
Engaging the Outrigger MID-Extend Lock Pin159
Stowing the Outriggers159
Swinging the Boom and Superstructure160
Stowing the Outrigger MID-Extend Lock Pin160
Raising and Lowering the Boom161
Raising the Boom161
Lowering the Boom162
Telescoping the Boom162
Extending the Boom163
Retracting the Boom164
Telescoping - Theory of Operation164
Manual Telescoping164
Semi-Automatic Telescoping164
Extending with the Main Boom Configuration164
Overview164
Telescoping Process165
Assignment for Display168
Fixed Length and Intermediate Length169
Main Boom Fixed Length169
Main Boom Intermediate Length169
Telescoping169
Telescoping Sequence169
Inspections Prior to Starting Operations169
Switching on the Telescoping Mechanism169
Function of the Controller169
Switching off the Telescoping Mechanism170
Manual Telescoping170
Telescoping with Semi-Automation175
Semi-Automatic Telescope Mode176
Introduction176
Semi-Auto Mode Basic Operating Procedures178
Semi-Auto Mode for Shifting Cylinder Within Fully Retracted Boom180
Semi-Auto Mode Requiring Boom to be Retracted180
Semi-Auto Mode Screen Refresh180
Semi-Auto Mode Warning Indications180
Semi-Auto Mode Telescoping Function Shut-Down181
Semi-Auto Mode Lost Boom Configuration181
Reset Telescoping Configuration182
Semi-Auto Mode Vs. Manual Mode183
Boom Configurator184
Lowering and Raising the Main Hoist Rope186
Lowering the Main Hoist Rope186
Raising the Main Hoist Rope186
Lowering and Raising the Auxiliary Hoist Rope187
Lowering the Auxiliary Hoist Rope187
Raising the Auxiliary Hoist Rope188
Selecting the Hoist Speed Range188
Using the Remote Control Unit189
Preparing for Remote Control Operation189
Operating Remote Control191
Superstructure Horn191
Emergency Stop191
Engine Start/Stop/Throttle193
Outrigger Beams195
Outrigger Jacks197
Hoist Control (Main and Aux)199
Boom Lift201
Swing and 360° Swing Lock203
OPT (Options)205
Information206
Navigating the Operator Display Module and Rated Capacity Limiter Display Module207
Using the Operator Display Module (ODM)208
Main Screen209
Alerts Area210
Active Screen Indicator Area216
Crane Information Area217
Crane Status Area220
Frequently Used Quick Select Menu Area225
Status Bar226
Permanent Quick Select Menu Area228
Menu Screen229
Tele-Automation Menu Group232
Semi-Automation Telescope Mode232
Boom Configurator Mode234
Crane Function Menu Group236
Outrigger Extend/Retract236
Counterweight Removal/Installation242
360° Swing Lock (Optional)242
Boom Extension Deployment/Stowage243
Suspension Raise/Lower243
Boom Removal/Installation244
Working Range Limiter Menu Group246
Introduction246
WRL Limitations Overview246
Accessing a WRL Limitation Screen248
Boom Height Limitation253
Boom Angle Limitation255
Radius Limitation258
Swing Angle Limitation260
Virtual Walls Limitation263
Emergency Program Menu Group267
Manual Telescope Mode267
Emergency Telescope Mode269
Tables for Approaching the Locking Points278
Telescoping Cylinder Boom Nose Switch279
Faults Menu Group280
Crane Faults280
Engine Faults281
Information Menu Group282
Operating Hours282
Software Versions284
Legal Notice284
User Settings Menu Group285
Controller Curve285
Controller Speed288
ECO Mode289
Exhaust System Cleaning (if Equipped)291
Service Menu292
Display Settings Menu Group293
Units of Measure293
Display Screen Brightness293
Time Set294
Using the Rated Capacity Limiter Display Module (RDM)295
Enter Rigging Code295
Entering Individual Components295
Entering the RCL Code299
Checks before Operating the Crane300
Displays During Crane Operation302
RCL Early Warning303
RCL Shutdown304
Limit Bypass Alert Indicators305
Load Chart and Miscellaneous Alerts305
Preload Check309
Using the Load Chart309
Stowing and Parking311
Leaving Crane Unattended311
Long-Term Storage311
Section 5313
Setup of Crane before and after Transporting314
Hoist Camera315
Lowering the Hoist Camera for Transport315
Raising the Hoist Camera for Operation315
Hoist Platform316
Lowering the Hoist Platform Railings for Transport316
Raising the Hoist Access Railings for Operation316
Beacon Lights (Optional)317
Lowering the Beacon Light for Transport317
Raising the Beacon Light for Operation317
Cab Mirrors318
RCL Light Tower (Optional)319
Retracting the RCL Light Tower for Transport319
Extending the RCL Light Tower for Operation319
Access Ladders320
Raising the Access Ladder for Transport320
Lowering the Access Ladder320
Auxiliary Ladder320
Stowing the Auxiliary Ladder for Transport322
Installing the Auxiliary Ladder322
Auxiliary Ladder Rear Maintenance Location322
Outrigger Floats322
Stowing an Outrigger Float for Transport323
Removing an Outrigger Float from Stowage323
Hydraulic Hose Drum (Optional)323
Boom Position Indicator Light and Anemometer (Optional)323
Auxiliary Single-Sheave Boom Nose323
Boom Lift Cylinder323
Installing Cable on the Hoist323
Counterweight Removal and Installation324
General Warnings324
Counterweight Sections Lifting Points324
Assembling the Counterweight for Operation326
Disassembling the Counterweight for Transport326
Installing the Counterweight on the Carrier Platform328
Removing the Counterweight from the Carrier Platform329
Installing and Removing the Counterweight On/From the Superstructure331
Overview of the Counterweight ODM Screen331
Automatic Mode334
Entering Automatic Mode334
Pausing Automatic Mode334
Canceling Automatic Mode334
Lowering the Counterweight on to the Carrier (Automatic Mode)334
Installing the Counterweight on to the Superstructure (Automatic Mode)336
Manual Mode338
Removing the Counterweight (Manual Mode)338
Installing the Counterweight (Manual Mode)339
Outrigger Removal and Installation341
Bleed Valve Operation341
Outrigger Box Removal341
Outrigger Box Installation342
Anti-Two Block (A2B) Switch344
Locking344
Unlocking344
Checking before Operation344
Cranes with Main Hoist Only344
Cranes with Main and Auxiliary Hoists345
Hoist Rope Reeving346
Possible Reeving Combinations346
Quick Reeving the Hook Block354
Reeving Hoist Rope over the Boom354
Adjusting the Upper Head Sheave354
Reeving/Unreeving the Hoist Rope355
Dead-End Rigging/Wedge Sockets356
Installing Wedge and Socket356
Boom Extension357
Set-Up and Installation357
General Warnings358
Boom Extension Configurations358
Boom Extension Pin Interlock Mechanism359
Front Boom Extension Mounting Pin359
Boom Nose Installation Pins359
Front Mounting Pin Handle360
Boom Extension Mounting Brackets360
Boom Extension Sensors362
Lifting Points362
Lattice Insert362
Fly Section362
Boom Extension Base Section363
About the Boom Extension Group in the ODM363
Accessing the Boom Extension Group in the ODM365
Installing the Boom Extension365
Removing the Boom Extension368
Erecting the 17.8 M Boom Extension369
Erecting the Fly Section374
Stowing the Fly Section376
Stowing the 17.8 M Boom Extension376
Erecting the 10.9 M Boom Extension Base Section Only379
Stowing the 10.9 M Boom Extension Base Section Only382
Boom Extension and Lattice Insert Electrical Connections384
Connecting Electrical Connection to Main Boom385
Disconnecting Electrical Connection from Main Boom385
Connecting Electrical Connection to Lattice Insert385
Disconnecting Electrical Connection from Lattice Insert385
Hydraulic Boom Extension Connections385
Checking the Locking Device on the Hose Drum385
Unlocking the Drum386
Locking the Drum386
Extending Hoses for Hydraulic Boom Extension Operation386
Retracting Hydraulic Hoses for Main Boom Operation388
Connecting the Hydraulic Hoses for Operation388
Disconnecting Hydraulic Hoses388
Reeving the Hoist Rope389
Unreeving Hoist Rope389
Offsetting the Boom Extension389
Setting a Manual Offset Angle of 0°, 15°, 30°, or 50390
Setting the (Optional) Hydraulic Boom Extension Offset391
Anti-Two Block Switch on the Boom Extension391
Boom Extension Base Section391
Boom Extension Fly Section392
Lattice Insert (Optional)393
Attaching the Lattice Insert on the Boom Nose393
Installing the Boom Extension on the Lattice Insert395
Removing the Boom Extension from the Lattice Insert396
Removing the Lattice Insert from the Boom Nose397
Boom Extension-To-Lattice Insert Hydraulic Connections397
Removing the Lattice Insert from the Boom397
Nose397
Connecting the Boom Extension Hydraulics to the Lattice Insert398
Disconnecting the Boom Extension Hydraulics from the Lattice Insert398
Auxiliary Single Sheave Boom Nose398
Installing Auxiliary Single-Sheave Boom Nose399
Removing the Auxiliary Single-Sheave Boom Nose399
Rigging the Auxiliary Single-Sheave Boom Nose for Transport399
Removing the Auxiliary Single-Sheave Boom399
Nose399
Rigging in Transport Position400
Rigging in Working Position400
Reeving the Hoist Rope400
Anemometer/Boom Position Light (Optional)400
Installing the Anemometer/Boom Position Light400
Removing Anemometer/Boom Position Light400
Installing the Anemometer/Boom Position400
Light400
General404
Environmental Protection404
Lubricants and Lubrication Intervals404
Arctic Lubricants and Conditions407
Arctic Conditions below -9°C (+15°F)407
Cold Weather Package and Lubricants407
Cylinder Rod Surface Protection411
Wire Rope Lubrication411
Lubrication Points411
Cranelube412
Cummins Oil Registration List412
Safety412
Drive Train414
Steering and Suspension424
Axle Lubrication426
Superstructure Lubrication428
Superstructure and Cab Tilt Lubrication432
Outrigger Lubrication434
Lift Cylinder Lubrication436
Boom Lubrication440
Hoist Lubrication448
Hydraulics Lubrication450
Rust Protection452
Protecting Cranes from Rusting452
Cleaning Procedures452
Inspection and Repair453
Application453
Areas of Application453

Manitowoc Grove GRT9165

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