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Manitowoc Grove GRT8120, Operator'S Manual

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Manitowoc Grove GRT8120 Operator'S Manual Download Page 108

OPERATING CONTROLS AND FEATURES

GRT8120 OPERATOR MANUAL

3-34

Published 3-22-2021, Control # 702-02

CONTROLS AND FEATURES AT REAR OF 
CAB

Controls and features located at rear of the cab (Figure 3-17)
include the radio, fan, fire extinguisher, user manual holder,
fuse and relay panel, and limit bypass switch for non-CE
certified cranes.

FIGURE 3-17

Item

Description

Page

Item

Description

Page

1

Radio (Optional)

3-35

6

User Manual Holder

3-35

2

Speakers (Optional)

3-35

7

Fuse and Relay Panel

3-36

3

Rear Window

3-35

8

Buzzer (Not Shown)

3-37

4

Fan

3-35

9

Maintained Limit Bypass Switch 
(Non-CE Certified Cranes)

3-37

5

Fire Extinguisher

3-35

9838-16a

9

1

2

8

Not shown

4

7

2

3

5

6

Summary of Contents for Grove GRT8120

Page 1: ...Operator Manual Grove GRT8120 ...

Page 2: ...s 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 Opera...

Page 3: ...r when ordering parts or communicating service problems with your distributor or the factory An untrained operator subjects himself and others to death or serious injury You must not operate this crane unless You have been trained in the safe operation of this machine You read understand and follow the safety and operating recommendations contained in the manufacturer s manuals your employer s wor...

Page 4: ...THIS PAGE BLANK ...

Page 5: ...7 Boom 1 7 Outriggers 1 7 Swivel Assembly 1 7 Swing Gearbox 1 7 Hydraulic Pumps 1 7 Pump 1 1 7 Pump 2 1 7 Pump 3 1 7 Hoists 1 7 SECTION 2 Safety Information Safety Messages 2 2 General 2 2 Safety Alert Symbol 2 2 Signal Words 2 2 General 2 2 Accidents 2 2 Operator Information 2 3 Operator Qualifications 2 3 Operational Aids 2 4 Rated Capacity Limiter RCL Systems 2 4 Anti Two Blocking Device 2 5 Wo...

Page 6: ...8 Hydraulic Fluid 2 28 Moving Parts 2 29 Before maintenance or repairs 2 29 After maintenance or repairs 2 29 Lubrication 2 29 Tires 2 29 Hoist Rope 2 30 Synthetic Hoist Rope 2 30 Wire Rope 2 30 Sheaves 2 32 Batteries 2 32 Super Capacitor If Equipped 2 32 General Maintenance 2 33 Transporting the Crane 2 33 Travel Operation 2 33 Work Practices 2 35 Personal Considerations 2 35 Crane Access 2 35 Jo...

Page 7: ...ypass Switch Non CE Certified Cranes 3 10 Limit Bypass Set Up Switch CE Certified Cranes 3 10 Boom Up Bypass Switch 3 11 Emergency Stop Button 3 12 Cab Dome Light 3 12 Left Overhead and Side Panel 3 13 Coat Hook 3 14 USB Charging Ports 3 14 Auxiliary Light and Switch 3 14 Mobile Phone Holder 3 14 Heater Air Conditioner Vents 3 14 Right Lower Control Panel 3 15 Turntable Swing Lock Pin Control Hand...

Page 8: ... Hoist Rotation Indicators 3 26 Seat Switch 3 26 Optional Single Axis Controllers 3 27 Swing Controller 3 28 Telescope or Auxiliary Hoist Controller 3 28 Boom Lift Telescope Luffing Boom Extension Controller 3 28 Main Hoist Controller 3 28 Hoist Rotation Indicators Not Shown 3 28 Foot Pedal Controls and Floor Mat 3 29 Swing Brake Pedal 3 30 Service Brake Pedal 3 30 Throttle Pedal 3 30 Floor Mat 3 ...

Page 9: ...46 Fuse and Relay Box Carrier 3 47 Cab Mounted Work Lights 3 48 Boom Mounted Work Lights Optional 3 48 Side Mounted Carrier Work Lights 3 48 Ladders and Grab Handles 3 49 Remote Control Unit 3 50 Overview 3 50 Storage and Charging 3 51 Controls and Features 3 52 Programming Port 3 53 Power Button 3 53 Color Display 3 53 Left Side Motion Button 3 53 Right Side Motion Button 3 53 Enable Buttons 3 53...

Page 10: ... 8 Jump Starting Hazard 4 8 Charging the Batteries 4 8 Start Up Procedure 4 8 Idling the Engine 4 9 Engine High Idle 4 9 Racing the Engine 4 9 Exhaust System Cleaning 4 9 Shutdown Procedure 4 10 Crane Warm up Procedures 4 11 Engine 4 11 Transmission 4 11 Hoist 4 11 Swing Drive and Turntable Bearing 4 11 Axles 4 12 Hydraulic Oil System 4 12 Driving the Crane 4 12 Seat Belts 4 12 Traveling General 4...

Page 11: ...gnment for Display 4 30 Fixed Length and Intermediate Length 4 31 Main Boom Fixed Length 4 31 Main Boom Intermediate Length 4 31 Telescope Picture 4 31 Telescoping Sequence 4 31 Inspections Prior to Starting Operations 4 31 Enabling the Telescoping Mechanism 4 31 Function of the Controller 4 31 Disabling the Telescoping Mechanism 4 32 Manual Telescoping 4 32 Telescoping with Semi automation 4 38 S...

Page 12: ...u Area 4 85 Status Bar 4 86 Permanent Quick Select Menu Area 4 88 Menu Screen 4 90 Camera Menu Group 4 94 Tele automation Menu Group 4 95 Semi automation Telescope Mode 4 95 Boom Configurator Mode 4 97 Crane Function Menu Group 4 99 Outrigger Extend Retract 4 99 360 Swing Lock Optional 4 105 Boom Extension Deployment Stowage 4 106 Working Range Limiter Menu Group 4 107 Introduction 4 107 WRL Limit...

Page 13: ...a 5 3 Lowering the Hoist Camera for Transport 5 3 Raising the Hoist Camera for Operation 5 3 Hoist Platform 5 4 Lowering the Hoist Platform Railings for Transport 5 4 Raising the Hoist Access Railings for Operation 5 4 Beacon Lights Optional 5 5 Lowering the Beacon Light for Transport 5 5 Raising the Beacon Light for Operation 5 5 Cab Mirrors 5 6 RCL Light Tower Optional 5 7 Retracting the RCL Lig...

Page 14: ...Erecting the 10 5 m 34 5 ft Boom Extension Base Section Only 5 45 Stowing the 10 5 m 34 5 ft Boom Extension Base Section Only 5 48 Boom Extension Electrical Connections 5 51 Connecting Electrical Connection at Boom Nose 5 51 Disconnecting Electrical Connection at Boom Nose 5 51 Hydraulic Boom Extension Connections 5 52 Checking the Locking Device on the Hose Drum 5 52 Hydraulic Hose Installation 5...

Page 15: ...ditions 6 5 Arctic Conditions Below 9 C 15 F 6 5 Cold Weather Package and Lubricants 6 5 Cylinder Rod Surface Protection 6 9 Wire Rope Lubrication 6 9 Lubrication Points 6 9 CraneLUBE 6 10 Cummins Oil Registration List 6 10 Safety 6 10 Drive Train 6 12 Steering and Suspension Meritor Axles 6 18 Steering and Suspension Kessler Axles 6 18 Steering and Suspension Fifth Wheel Pivots 6 20 Axle Lubricat...

Page 16: ...TABLE OF CONTENTS GRT8120 A 12 THIS PAGE BLANK ...

Page 17: ...l wheel steer enables easy crane positioning and precise maneuvering on the job site The GRT8120 introduces new carrier design including flat aluminum decking for easy rigging and access multiple lockable storage compartments carrier electrical box centrally located and accessible to store batteries modules relays and fuses full LED lighting package including side mounted carrier work lights for i...

Page 18: ... is equipped with a seven section MEGAFORM boom with TWIN LOCK boom pinning system Additional reach is obtained by utilizing an optional swingaway boom extension Lifting is provided by a main hoist and an optional auxiliary hoist Customer Support Grove and our distributor network want to ensure your satisfaction with our products and customer support Your local distributor is the best equipped and...

Page 19: ...s for Hand Arm Vibration exposure when measured according to 89 392 EEC Community Legislation on Machinery per standard ISO 2631 1 Evaluation of Human Exposure to Work Body Vibration ISO 5349 Guidelines for the Measurement and Assessment of Human Exposure to Hand Transmitted Vibrations and ISO DIS 8041 Human Response Vibration Measuring Instrumentation SERIAL NUMBER LOCATION Refer to Figure 1 1 Wh...

Page 20: ...ION GRT8120 OPERATOR MANUAL 1 4 Published 3 22 2021 Control 702 02 GRT8120 CRANE COMPONENTS FIGURE 1 2 2 11 3 8 13 11 11 10 10 11 12 10086 1 10086 2 1 1 4 5 6 7 9 12 14 15 16 17 18 19 19 18 20 20 21 22 24 25 23 ...

Page 21: ...ning Condenser 18 Superstructure Valve Covers 6 Main Hoist 19 Boom Extension Sheaves 7 Auxiliary Hoist 20 Boom Extension Fly Section 8 Counterweight 21 Boom Extension Base Section 9 Tailpipe 22 Lift Cylinder 10 Outrigger Pads 23 Hydraulic Tank 11 Crane Steps and Grab Handles 24 Axle 1 Front Drive and Steer 12 Outrigger Jack Cylinders 25 Axle 2 Rear Drive and Steer 13 Diesel Exhaust Fluid DEF Tank ...

Page 22: ...nsmission includes Torque Converter 41 6 L 44 qt Diesel Exhaust Fluid DEF Tank 37 9 L 10 gal Transmission Gear Ratios Forward and Reverse Low Range 1st 12 59 1 2nd 6 06 1 3rd 2 22 1 High Range 4th 4 33 1 5th 2 08 1 6th 0 76 1 Maximum Drive Speed 24 1 km h 15 mph with counterweight installed Torque Converter Stall Ratio 1 82 1 Charge Pump Capacity 106 L min 28 gal min 2000 rpm Engine Cummins QSB 6 ...

Page 23: ...23 6 in Aluminum Optional 600 mm 23 6 in Max Individual Outrigger Pad Load 556 kN 125 000 lbf or 125 kip Swivel Assembly Electrical 20 Slip Rings Hydraulic 10 ports Water 2 ports Air Conditioning 2 ports Swing Gearbox Reduction Ratio 35 2 1 Continuous Torque 8191 N m 6042 lbf ft Max Pinion Torque 16382 N m 12083 lbf ft Hydraulic Pumps NOTE Pump flow rate output figures are theoretical Pump 1 Type ...

Page 24: ...INTRODUCTION GRT8120 OPERATOR MANUAL 1 8 Published 3 22 2021 Control 702 02 THIS PAGE BLANK ...

Page 25: ...trocution Hazard 2 23 Set Up and Operation 2 24 Electrocution Hazard Devices 2 25 Electrical Contact 2 25 Special Operating Conditions and Equipment 2 26 Grounding the Crane 2 26 Personnel Handling 2 27 Environmental Protection 2 28 Maintenance 2 28 Service and Repairs 2 28 Lubrication 2 29 Tires 2 29 Hoist Rope 2 30 Synthetic Hoist Rope 2 30 Wire Rope 2 30 Sheaves 2 32 Batteries 2 32 Super Capaci...

Page 26: ...uiring a false sense of security when using them They are there to assist not direct the operation Operational aids or warning devices can be mechanical electrical electronic or a combination thereof They are subject to failure or misuse and should not be relied upon in place of good operating practices You are the only one who can be relied upon to assure the safety of yourself and those around y...

Page 27: ...y are seated in a two man cab Do not remove the Load Chart this Operator Manual or any decal from this crane Inspect the crane every day before the start of each shift Make sure that routine maintenance and lubrication are being dutifully performed Don t operate a damaged or poorly maintained crane You risk lives when operating faulty machinery including your own If adjustments or repairs are nece...

Page 28: ...for the operational aids shall be followed If an operational aid should fail to work properly the crane user or owner must assure that repair or recalibration is accomplished as soon as is reasonably possible If immediate repair or recalibration of an operational aid is not possible and there are exceptional circumstances which justify continued short term use of the crane when operational aids ar...

Page 29: ...eved over the main boom nose and boom extension nose respectively An operator concentrating on the specific line being used may telescope or lower the boom allowing the other hoist line attachment to contact the boom or boom extension nose thus causing damage to the sheaves or causing the hoist rope to fail dropping the lifting device to the ground and possibly injuring personnel working below Cau...

Page 30: ... Capacity Limiter RCL System program for the outrigger position selected Before swinging the superstructure over the side when the outriggers are retracted check for backwards stability under the sub section titled Model Specific Information later in this section Long cantilever booms can create a tipping condition when in an extended and lowered position Retract the boom proportionally with refer...

Page 31: ...t could adversely effect the stability of the crane Be aware of the danger for people entering the working area Do not allow unnecessary personnel in the vicinity of the crane while operating WIND FORCES There are basic principles that must be followed while operating in windy conditions This information has been provided to assist in determining safe operation in windy conditions Always use extre...

Page 32: ...area of the load Ap and by the wind drag coefficient Cd This limit can be determined by comparing the Actual wind resistance area with the Allowable wind resistance area Refer to Figure 2 1 for a simplified calculation method to determine permissible wind speed Maximum Wind Speed Beaufort Number Description m s km h mph Visible Indicator Effects of wind as observed on land Zero 0 Calm 0 3 1 1 0 7 ...

Page 33: ...ficient of load Calculate Awr load Ap X Cd Determine Cd of Load Ap maximum height X maximum length See Figure 2 2 Lifting is not permitted Cease Lifting Operations V z 20 1 m s 45 mph 13 4 m s V z 20 1 m s 30 mph V z 45 mph Use Main Boom on Fully Extended Outriggers ONLY V z 13 4 m s 30 mph Main Boom Allowable load Published Rated Capacity Allowable Load Published Rated Capacity X Capacity Reducti...

Page 34: ...ted at this condition Size and Shape of the load These rated capacities are also based on the assumption that the Wind Resistance Area of load Awr load is not more than 0 0012 square meters per kilogram 0 0059 sq ft per pound of load See below Formulas 2 4 and 2 5 The load capacities shall be reduced to account for the larger wind resistance area of load and 3 second wind gust speed at boom tip he...

Page 35: ...and corresponding Wind Drag Coefficient Cd values If the exact Wind Drag Coefficient of a shape is not known use the maximum value of the shape s range Table 2 2 If the wind drag coefficient of the load cannot be estimated or determined it shall be assumed that Cd 2 4 Ap 24 m2 Ap 8 m2 Wind Wind 8 m 1 m 3 m 8 m 1 m 3 m Ap 250 ft2 Ap 75 ft2 Wind Wind 25 ft 3 ft 10 ft 25 ft 3 ft 10 ft 8384 1 FIGURE 2...

Page 36: ...eed V z for the load using Table 2 3 Table 2 3 Awr Ratio and Permissible Wind Speed V z Imperial units 8384 2 Shape Cd 1 1 to 2 0 0 3 to 0 4 0 6 to 1 0 0 8 to 1 2 0 2 to 0 3 0 05 to 0 1 Approximately 1 6 Turbine Blade or Complete Rotor Note Permissible and rated wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph...

Page 37: ...Grove Published 3 22 2021 Control 702 02 2 13 GRT8120 OPERATOR MANUAL SAFETY INFORMATION 2 Rated Load Chart Example Metric FIGURE 2 3 8383 1 ...

Page 38: ...ds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed m s For Rated Capacity at 13 4 m s 12 2 11 4 10 6 10 0 9 5 For Allowable Capacity at 20 1 m s 18 3 17 0 15 9 15 0 14 2 Table 2 4 Example Capacity Reduction Factors for Wind Speed V z Greater than 13 4 m s Metric Only for lifting with main boom on fully extended outriggers wi...

Page 39: ...owable load 10 000 kg 12 040 kg YES Is Awr load less than Awr allow 13 08 m2 14 45 m2 YES Conclusion This load is permissible to lift in wind speed up to 20 1 m s Load example 1 3a With large wind resistance area of the load Awr load Load to be lifted of 14 000 kg Projected Wind Area Ap 21 85 m2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap X Cd 21 8...

Page 40: ...han allowable load 8 000 kg 12 040 kg YES Is Awr load less than Awr allow 19 83 m2 14 45 m2 NO Conclusion This load is NOT permissible to lift in wind speed up to 20 1 m s but permitted to lift at a reduced wind speed calculated as follows Ratio 1 37 From Table 2 5 the maximum permissible wind speed at ratio of 1 37 rounded to next higher table value of 1 4 is 17 0 m s Conclusion This load is perm...

Page 41: ...Grove Published 3 22 2021 Control 702 02 2 17 GRT8120 OPERATOR MANUAL SAFETY INFORMATION 2 Rated Load Chart Example Non metric FIGURE 2 4 8382 1 ...

Page 42: ...ted wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph For Rated Capacity 30 mph 27 4 25 4 23 7 22 4 21 2 For Allowable Capacity 45 mph 41 1 38 0 35 6 33 5 31 8 Table 2 6 Example Capacity Reduction Factors for Wind Speed V z Greater than 30 mph Non metric Only for lifting with main boom on fully extended outrigg...

Page 43: ... allowable load 18 000 lb 20 160 lb YES Is Awr load less than Awr allow 108 ft2 119 ft2 YES Conclusion This load is permissible to lift in wind speed up to 45 mph Load example 2 3a With large wind resistance area of the load Awr load Load to be lifted of 22 000 lb Projected Wind Area Ap 180 ft2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap x Cd 180 x...

Page 44: ...keep the load as near to the crane and as close to the ground as possible Do not overload the crane by exceeding the capacities shown on the appropriate Load Chart Death or serious injury could result from the crane tipping over or failing structurally from overload The crane can tip over or fail structurally if The load and crane s configuration is not within the capacity as shown on the applicab...

Page 45: ...ufacturer s specifications and limitations 1926 753 e 2 Components of the multiple lift rigging assembly shall be specifically designed and assembled with a maximum capacity for total assembly and for each individual attachment point This capacity certified by the manufacturer or a qualified rigger shall be based on the manufacturer s specifications with a 5 to 1 safety factor for all components 1...

Page 46: ...raning activities be advised that the rated loads for these cranes as indicated on the crane s Load Chart do not exceed 85 of the tipping load on outriggers as determined by SAE J765 Cranes Stability Test Code An outrigger pad may lift off the ground during operation of the crane within the capacity limits of the Load Chart yet the crane will not have reached instability The balance point for stab...

Page 47: ... machine before pile driving or extraction begins All hoist hooks shall be equipped with a positive locking latch Crane Inspection In addition to the crane s frequent and periodic inspections dated daily records shall be maintained showing inspections were performed on the crane during the time it was used for pile driving or extraction All anti two block warning devices and RCL systems shall be i...

Page 48: ...nformation to the contrary from the utility company or owner The rules in this Operator Manual must be followed at all times even if the electrical power lines or equipment have been de energized The safest way to avoid electrocution is to stay away from electrical power lines and electrical power sources It is not always necessary to contact a power line or power source to become electrocuted Ele...

Page 49: ...the boom nose and a small portion of the boom Performance of boom cages and boom guards is limited by their physical size insulating characteristics and operating environment e g dust dirt moisture etc The insulating characteristics of these devices can be compromised if not kept clean free of contamination and undamaged Proximity sensing and warning devices are available in different types Some u...

Page 50: ...anes equipped with electromagnets you must take additional precautions Permit no one to touch the magnet or load Alert personnel by sounding a warning signal when moving a load Do not allow the cover of the electromagnet power supply to be open during operation or at any time the electrical system is activated Shut down the crane completely and open the magnet controls switch prior to connecting o...

Page 51: ...truction Use of a Grove crane to handle personnel is acceptable provided The requirements of the applicable national state and local regulations and safety codes are met A determination has been made that use of a crane to handle personnel is the least hazardous means to perform the work The crane operator shall be qualified to operate the specific type of hoisting equipment used in the personnel ...

Page 52: ...ts Always perform a function check after repairs have been made to ensure proper operation Load tests should be performed when structural or lifting members are involved Follow all applicable safety precautions in this manual when performing crane maintenance as well as crane operations Keep the crane free of mud dirt and grease at all times Dirty equipment introduces hazards wears out faster and ...

Page 53: ...the battery Controls should be properly tagged Never operate the crane if it is tagged out nor attempt to do so until it is restored to proper operating condition and all tags have been removed by the person s who installed them After maintenance or repairs Replace all guards and covers that have been removed Remove all tags connect the battery and perform a function check of all operating control...

Page 54: ...contact with a live power line or has been used as a ground in an electric circuit e g welding may have wires that are fused or annealed and must be removed from service In standing ropes more than three 3 breaks in one rope lay in sections beyond the end connection or more than two 2 broken wires at an end connection Core deterioration usually observed as a rapid reduction in rope diameter is cau...

Page 55: ...wire rope An inspection should include verification that none of the specified removal criteria for this usage are met by checking for such things as Surface wear nominal and unusual Broken wires number and location Reduction in diameter Rope stretch elongation Integrity of end attachments Evidence of abuse or contact with another object Heat damage Corrosion NOTE A more detailed rope inspection p...

Page 56: ...atteries Battery electrolyte must not be allowed to contact the skin or eyes If this occurs flush the contacted area with water and consult a doctor immediately When checking and maintaining batteries exercise the following procedures and precautions Wear safety glasses when servicing batteries If equipped disconnect battery with the battery disconnect switch before disconnecting the ground batter...

Page 57: ...ng or unloading the crane on a trailer or railroad car use a ramp capable of supporting the weight of the crane Make sure that the crane is adequately secured to the transporting vehicle Do not use the dead end lug 1 Figure 2 8 on the boom nose for tying down the boom during transport Damage to the lug and boom can result from usage as a tie down point Before transporting the crane on a road or hi...

Page 58: ...n to verify the area behind the crane is clear of obstructions and or personnel On cranes equipped with mirrors or camera systems make sure these components are in working order and are properly adjusted On cranes equipped with air operated brakes or hydraulically operated brakes do not attempt to move the crane until brake system air pressure or hydraulic pressure is at operating level Check load...

Page 59: ...ing in the hoist area Wear shoes with a highly slip resistant sole material Clean any mud or debris from shoes before entering the crane cab operator s station or climbing onto the crane superstructure Excessive dirt and debris on the handholds access steps or walking working surfaces could cause a slipping accident A shoe that is not clean might slip off a control pedal during operation Do not al...

Page 60: ...eight and superstructure area before removing the counterweight Keep unauthorized personnel clear of the working area during operation Only the crane operator shall occupy the crane when in operation You must always be aware of everything around the crane while lifting or traveling If you are unable to clearly see in the direction of motion you must post a look out or signal person before moving t...

Page 61: ...e load lines vertical Look before swinging your crane Even though the original setup may have been checked situations do change Never swing or lower the boom into the carrier cab if applicable Never push or pull loads with the crane s boom Never drag a load Do not subject crane to side loading A side load can tip the crane or cause it to fail structurally If the boom should contact an object stop ...

Page 62: ...ETY INFORMATION GRT8120 OPERATOR MANUAL 2 38 Published 3 22 2021 Control 702 02 FIGURE 2 10 Reprinted from ASME B30 5 2014 by permission of The American Society of Mechanical Engineers All Rights Reserved ...

Page 63: ...allowed values The boom should be retracted as far as is practical the crane configured in as stable a configuration as possible boom angle superstructure orientation boom extension angle etc In high winds the boom and boom extension should be lowered or secured Changing weather conditions including but not limited to wind ice accumulation precipitation flooding lightning etc should be considered ...

Page 64: ...ver store flammable materials on the crane If cold weather starting aids are provided on your crane use them The use of aerosol spray or other types of starting fluids containing ether volatiles can cause explosions or fire TEMPERATURE EFFECTS ON HOOK BLOCKS The Hook Block Working Load Limit WLL is valid between 60 C 140 F and the low temperature limit given on the hook block identification plate ...

Page 65: ...t in the load not moving smoothly Proper boom lubrication and wear pad adjustment is important to permit the boom sections to slide freely Slow movement of the boom may be undetected by the operator unless a load is suspended for a long period of time To minimize the effects of thermal contraction or Stick slip it is recommended that the telescope control lever is activated periodically in the ext...

Page 66: ... 18 58 20 90 23 22 50 2 58 5 16 7 74 10 32 12 90 15 48 18 06 20 64 23 22 25 80 55 2 84 5 68 8 51 11 35 14 19 17 03 19 87 22 70 25 54 28 38 60 3 10 6 19 9 29 12 38 15 48 18 58 21 67 24 77 27 86 30 96 Length change in inches Stroke Ft X Temperature Change F X Coeff in 3 in 3 F X 12 in ft Coeff 0 000774 1 C STROKE Temperature Change C m 5 10 15 20 25 30 35 40 45 50 55 1 5 6 12 17 23 29 35 41 46 52 58...

Page 67: ... be stopped immediately and Crane Care must be contacted for corrective action The following illustrations may not be an exact representation of your crane and are to be used for reference only NOTE If your crane is equipped with CraneSTAR an overload warning will be posted to the web site for review by the crane owner Overload warnings do NOT indicate real time events Warnings could be sent 24 ho...

Page 68: ...SAFETY INFORMATION GRT8120 OPERATOR MANUAL 2 44 Published 3 22 2021 Control 702 02 Boom Inspection 1 3 4 1 2 1 5 6 1 7 8 9 10 9 10 Illustration for reference only Your crane may be different ...

Page 69: ...l for damage Overload from 25 to 49 1 Sheaves Inspect all for damage 2 Luffing Mechanism Cylinder Inspect for damage leaks 3 Collar wear pads Inspect all for damage 4 Collar welds Inspect all for cracks 5 Telescopic Sections Inspect for bent or twisted sections Check the boom for straightness 6 Lift Cylinder Head Area Inspect for bends or cracked welds 7 Turntable Inspect for cracked welds 8 Locki...

Page 70: ...SAFETY INFORMATION GRT8120 OPERATOR MANUAL 2 46 Published 3 22 2021 Control 702 02 Superstructure Inspection 1 6 3 4 5 2 7 8 9 10 Illustration for reference only Your crane may be different ...

Page 71: ... of Service Manual Overload from 25 to 49 1 Lift Cylinder Inspect for leaking 2 Turntable Bearing Check bolts for proper torque See topic in Swing section of Service Manual 3 Wire Rope Inspect all for damage See topic in Introduction section of Service Manual 4 Hoist Drums Inspect each for damage 5 Hoist Brakes Brakes must hold rated line pull 6 Bearing Main Boom Pivot Pin Inspect for deformation ...

Page 72: ...SAFETY INFORMATION GRT8120 OPERATOR MANUAL 2 48 Published 3 22 2021 Control 702 02 Carrier Inspection 5 6 3 1 1 1 2 2 2 3 3 4 4 Illustration for reference only Your crane may be different ...

Page 73: ...s Inspect for leaking 2 Outrigger Pads Inspect for deformation and or cracked welds Overload from 25 to 49 1 Jack Cylinders Inspect for leaking 2 Outrigger Pads Inspect for deformation and or cracked welds 3 Outrigger Beams Inspect for deformation and or cracked welds 4 Outrigger Boxes Inspect for deformation and or cracked welds 5 Welds Inspect for cracks 6 Paint Inspect for cracked paint which c...

Page 74: ...SAFETY INFORMATION GRT8120 OPERATOR MANUAL 2 50 Published 3 22 2021 Control 702 02 THIS PAGE BLANK ...

Page 75: ...onnector 3 16 Rated Capacity Limiter Display Module and Operator Display Module 3 17 Rated Capacity Limiter Display Module RDM 3 18 Operator Display Module ODM 3 18 Navigation Control Pad 3 18 USB Diagnostic Connector 3 19 RCL Shutdown Warning Indicator Non CE Certified Cranes 3 19 RCL Shutdown Warning Indicator CE Certified Cranes 3 19 RCL Early Warning Indicator 3 19 Anti Two Block A2B Indicator...

Page 76: ... Raise Button 3 40 Lock Cylinder Retract Button 3 41 Function Enable Button 3 41 Main Power LED Indicator 3 41 Horn Button 3 41 Lock Cylinder Extend Button 3 41 Left Counterweight Cylinder Lower Button 3 41 Right Counterweight Cylinder Lower Button 3 41 Bridging Switch CE Certified Cranes 3 42 External RCL Light Tower Optional 3 43 Strobe Light or Beacon 3 43 Backup Alarm 3 43 120V 240V Engine Blo...

Page 77: ...tion Page 1 Steering Wheel and Column 3 4 7 Operator Seat and Armrest Controls 3 20 2 Right Overhead Control Panel 3 7 8 Foot Pedal Controls 3 29 3 Left Overhead and Side Panel 3 13 9 Internal RCL Light Bar Optional 3 31 4 Right Lower Control Panel 3 15 10 Front Cab Controls and Features 3 32 5 Operator Display Module 3 17 11 Rear Cab Controls and Features 3 34 6 Rated Capacity Limiter Display Mod...

Page 78: ... 2 3 in The steering column includes the ignition switch as well as levers and switches for operating the crane Figure 3 2 Item Description Page 1 Steering Wheel 3 5 2 Turn Signal Lever and Horn Controls 3 5 3 Parking Brake Switch 3 5 4 Headlights Switch 3 5 5 Drive Axle Selector Switch 3 5 6 Hazard Lights Switch 3 6 7 Transmission Shift Lever 3 6 8 Ignition Switch 3 6 9 Steering Column Tilt and T...

Page 79: ...re outriggers can be operated Headlights Switch The Headlights Switch 4 Figure 3 2 is located on the front of the steering column This three position rocker switch OFF Park Headlight controls the operation of the instrument lights and switch LEDs as well as the headlights marker lights and taillights on the front and rear of the crane Push bottom of switch to cause the headlights marker lights and...

Page 80: ...wheel drive low range To use the three low gears set Drive Axle Selector Switch 5 Figure 3 2 to four wheel drive To use the three high gears set Drive Axle Selector Switch to two wheel drive NOTE The transmission will not shift into forward or reverse gear without first pushing and holding the Service Brake Pedal Refer to Traveling Forward page 4 16 and Traveling Reverse page 4 17 for more detaile...

Page 81: ...onditioner Temperature Control Switch 3 8 11 Remote Control Enable Disable Switch 3 9 3 Fresh Air Recirculation Air Switch 3 8 12 Crane Function Enable Disable Switch 3 9 4 Boom Mounted Lights Motor Switch Optional 3 8 13 Momentary Limit Bypass Switch Non CE Certified Cranes 3 10 5 Boom Mounted Lights Switch Optional 3 8 13 Limit Bypass Set up Switch CE Certified Cranes 3 10 6 Cab Mounted Lights S...

Page 82: ...e switch controls the work lights mounted to the boom base section Push top of the switch to cause the lights to come on Push bottom of switch to cause the lights to go off Cab Mounted Lights Switch The Cab Mounted Lights Switch 6 Figure 3 3 is located on the right overhead control panel The switch controls the work lights mounted on the bottom front of the superstructure cab Push top of switch to...

Page 83: ...led Indicator shows green in the Status Bar Figure 4 73 of the Operator Display Module ODM Always position switch to the disabled position when Remote Control Unit is not in use If Remote Control Unit is enabled and one of the crane function enable disable switches in the cab is pushed the Remote Control Unit will be disabled Refer to Remote Control Unit page 3 50 for an overview of the Remote Con...

Page 84: ...s are bypassed Bypass 1 Pressed Indicator is on Figure 4 206 RCL Bypass Active Indicator is on Figure 4 206 RCL Shutdown Warning Indicator is flashing 5 Figure 3 6 Anti Two Block Indicator is flashing 7 Figure 3 6 3rd Wrap Alert is flashing Figure 4 68 Working Range Limiter WRL indicator is flashing Figure 4 71 Low Boom Angle Alert is flashing Figure 4 68 29 C Temperature Limiter Alert is flashing...

Page 85: ... and released the swing left right boom up down hoist up down and telescope extend retract functions operate at normal speeds when actuated The following indicators come on to indicate the limiters are bypassed Bypass 1 Pressed Indicator Figure 4 206 is on RCL Bypass Active Indicator Figure 4 206 is on RCL Shutdown Warning Indicator 5 Figure 3 6 is flashing Working Range Limiter WRL Indicator Figu...

Page 86: ...ergency Stop Button is pushed in the Emergency Stop Active Alert in the Alerts Area Figure 4 68 of the Operator Display Module ODM comes on red Rotate and pull out Emergency Stop Button to allow engine to be re started and resume normal operation Cab Dome Light The Cab Dome Light 16 Figure 3 3 is located on the right overhead control panel The dome light has a touch control feature Touch the light...

Page 87: ... left overhead and side panel Figure 3 4 includes a coat hook USB charging ports auxiliary light cell phone holder and heater air conditioner vents FIGURE 3 4 9838 8 Item Description Page 1 Coat Hook 3 14 2 USB Charging Ports 3 14 3 Auxiliary Light and Switch 3 14 4 Mobile Phone Holder 3 14 5 Heater Air Conditioner Vents 3 14 1 3 2 4 5 ...

Page 88: ... An Auxiliary Light and Switch 3 Figure 3 4 is located on the left overhead and side panel The auxiliary light switch is a two position switch Push top of switch to cause the light to come on Push bottom of switch to cause the light to go off The auxiliary light can be adjusted by hand if necessary Mobile Phone Holder A Mobile Phone Holder 4 Figure 3 4 is located on the left overhead and side pane...

Page 89: ...TROL PANEL The right lower control panel Figure 3 5 includes the turntable swing lock pin control handle 12 volt outlet and on board diagnostic OBD connector FIGURE 3 5 Item Description Page 1 Turntable Swing Lock Pin Control Handle 3 16 2 12 Volt Outlet 3 16 3 Engine On Board Diagnostic OBD Connector 3 16 9838 9 1 3 2 ...

Page 90: ...counterclockwise to unlock the swing lock 2 Pull rearward on the control handle to cause the swing lock pin to pull out of the socket 3 Turn control handle clockwise to lock it in position NOTE Before driving the crane always make sure that the boom is centered over the front or rear of the carrier and that the turntable swing lock pin is engaged 12 Volt Outlet The 12 Volt Outlet 2 Figure 3 5 is l...

Page 91: ...s screen brightness sensor and USB diagnostic connector Item Description Page Item Description Page 1 Rated Capacity Limiter Display Module RDM 3 18 6 RCL Early Warning Indicator 3 19 2 Operator Display Module ODM 3 18 7 Anti Two Block A2B Indicator 3 19 3 Navigation Control Pad 3 18 8 Swing Brake Engaged Indicator 3 19 4 USB Diagnostic Connector 3 19 9 Brightness Sensor 3 19 5 RCL Shutdown Warnin...

Page 92: ...asure metric imperial screen display brightness and time 24 hour or AM PM Refer to Using the Operator Display Module ODM page 4 68 for more information regarding the use of the module in the operation of the crane Navigation Control Pad The Navigation Control Pads 3 Figure 3 6 on the RDM and ODM allow the operator to navigate through the function screens of the related module The control buttons o...

Page 93: ... when the RCL senses a lift that is between 90 to 100 of crane capacity for the programmed configuration Anti Two Block A2B Indicator The Anti Two Block Indicator 7 Figure 3 6 is located immediately below and to the right of the ODM screen The A2B Indicator comes on red when a two block condition occurs When a two block condition occurs the crane control system will lock out the hoist up boom down...

Page 94: ...trol 702 02 OPERATOR SEAT AND ARMREST CONTROLS DUAL AXIS The operator seat and armrest controls Figure 3 9 include most of the controls for performing craning operations FIGURE 3 9 9838 11a 3 14 17 18 7 8 9 6 16 15 1 2 10 21 20 4 11 5 23 24 19 3 5 7 24 26 Not shown 13 12 28 27 22 27 25 ...

Page 95: ... Switch 3 24 6 Jog Dial 3 22 20 Swing Brake Release Button 3 25 7 Heater Air Conditioner Vents 3 22 21 Swing Telescope or Swing Auxiliary Hoist Controller Dual Axis 3 25 8 Main Hoist Enable Disable Switch 3 22 22 Seat Backrest Adjustment Lever 3 25 9 Luffing Jib Enable Disable Switch Optional 3 23 23 Seat Adjustment Control Panel 3 25 10 Boom Telescope Enable Disable Switch 3 23 24 Armrest Adjustm...

Page 96: ...on The Horn Button 4 Figure 3 9 is located on the upper front of the right controller Push button to operate the horn Hoist Speed Toggle Switches The Hoist Speed Toggle Switches 5 Figure 3 9 are thumb operated three position center spring return switches located on top of each controller Push and release switch closest to the operator to change hoist speed to high push and release switch again to ...

Page 97: ...ause the engine speed to decrease to 800 rpm Seat Lumbar Support Adjustment Lever The Seat Lumbar Support Adjustment Lever 12 Figure 3 9 is located at the right side of the seat backrest The lever can be set to three lumbar support positions Rotate lever clockwise to increase the lumbar support Rotate lever counterclockwise to reduce the lumbar support Seat Slide Lever The Seat Slide Lever 13 Figu...

Page 98: ...that is located on the left armrest Use Differential Lock Switch to engage the differential lock for additional traction The Differential Lock can be activated for a maximum of 30 seconds at a time NOTE Crane must be in Four Wheel Drive to engage the Differential Lock refer to Drive Axle Selector Switch page 3 5 Push and hold the Differential Lock Switch to engage the Differential Lock Release the...

Page 99: ... or right for 360 degree continuous rotation of the superstructure in the desired direction Push controller forward to extend the boom Pull controller rearward to retract the boom If equipped with an auxiliary hoist push controller forward to lower the hoist rope Pull controller rearward to raise the hoist rope Move controller in a diagonal direction to operate the two functions at the same time S...

Page 100: ... is located at the top of the seat backrest Pull up to raise the head rest Push down to lower the head rest Hoist Rotation Indicators Hoist Rotation Indicators 27 Figure 3 9 for auxiliary and main hoists are located at mid stick facing the operator on each dual axis hoist controller 2 21 Figure 3 9 The Hoist Rotation Indicator pulses on the auxiliary or main hoist controller 2 21 when its related ...

Page 101: ...owing single axis controllers Figure 3 13 are available as an option on the GRT8120 crane FIGURE 3 13 Item Description Page 1 Swing Controller 3 28 2 Telescope or Auxiliary Hoist Controller 3 28 3 Boom Lift Telescope Luffing Boom Extension Controller 3 28 4 Main Hoist Controller 3 28 5 Hoist Rotation Indicators Not Shown 3 28 9838 28 4 3 2 1 5 5 ...

Page 102: ...oller rearward to raise the boom When Telescope function is enabled push controller forward to extend the boom Pull controller rearward to retract the boom When crane is equipped with an optional luffing boom extension the luffing boom extension function is also operated by the Boom Lift Telescope Controller Operator must enable the luffing boom extension function using the related Enable Disable ...

Page 103: ...D FEATURES 3 FOOT PEDAL CONTROLS AND FLOOR MAT The foot pedal controls Figure 3 14 include the swing brake pedal service brake pedal and throttle pedal FIGURE 3 14 Item Description Page 1 Swing Brake Pedal 3 30 2 Service Brake Pedal 3 30 3 Throttle Pedal 3 30 4 Floor Mat 3 30 9838 13 3 2 1 4 ...

Page 104: ...edal to apply the service brakes Braking increases or decreases proportionately with the amount of foot pressure applied to the pedal Throttle Pedal The Throttle Pedal 3 Figure 3 14 is located on the right side of the floor Push Throttle Pedal to increase engine speed Engine speed increases or decreases proportionately with the amount of foot pressure applied to the pedal Floor Mat A Floor Mat 4 F...

Page 105: ...stem to warn the operator of an approaching overload condition that could cause equipment damage personal injury or death The lights in the light bar come on in the following manner Green LEDs when the eight green LEDs are on the load being lifted is less than 90 of crane RCL programmed capacity Yellow LEDs when the yellow LEDs are on the load being lifted is between 90 to 100 of crane RCL program...

Page 106: ...TURES AT FRONT OF CAB Controls and features located at the front of the cab Figure 3 16 include the front windshield emergency exit sun visor grab handles and foot rests FIGURE 3 16 Item Description Page 1 Front Windshield Emergency Exit 3 33 2 Sun Visor 3 33 3 Grab Handles 3 33 4 Foot Rests 3 33 1 2 4 9838 31 3 ...

Page 107: ...n visor can be folded down to reduce sunlight coming into the cab through the front windshield The sun visor can be rotated 90 to reduce sunlight coming into the cab through the door Grab Handles Grab Handles 3 Figure 3 16 are located around the entrance to the cab to help with entering and exiting the cab Always maintain a three point contact with the crane when entering and exiting Foot Rests Fo...

Page 108: ...her user manual holder fuse and relay panel and limit bypass switch for non CE certified cranes FIGURE 3 17 Item Description Page Item Description Page 1 Radio Optional 3 35 6 User Manual Holder 3 35 2 Speakers Optional 3 35 7 Fuse and Relay Panel 3 36 3 Rear Window 3 35 8 Buzzer Not Shown 3 37 4 Fan 3 35 9 Maintained Limit Bypass Switch Non CE Certified Cranes 3 37 5 Fire Extinguisher 3 35 9838 1...

Page 109: ...o open push outward on the handle located at the bottom of the window Fan The Cab Circulating Fan 4 Figure 3 17 is located at the right rear side of the cab The fan is situated on a swivel that allows it to be adjusted The switch on the fan base controls the fan It has high low and off positions Fire Extinguisher A Fire Extinguisher 5 Figure 3 17 is located at the left rear as seated in the operat...

Page 110: ...lished 3 22 2021 Control 702 02 Fuse and Relay Panel Cab The Fuse and Relay Panel 7 Figure 3 17 is located behind the operator seat in the right side upper compartment The cab fuse and relay panel contains the fuses and relays listed in Figure 3 18 FIGURE 3 18 9904 ...

Page 111: ...ystems and their crane function lockouts RCL System boom up down telescope extend hoist up Anti Two Block System boom up down telescope extend hoist up 3rd Wrap Limiter System hoist down Working Range Limiter WRL System Carrier Avoidance System 29 C Temperature Limiter System optional The following indicators come on to indicate the limiters are bypassed Bypass 3 Pressed Indicator is on Figure 4 2...

Page 112: ...he right window and skylight window Figure 3 19 can be opened for ventilation The skylight sun shade can be adjusted to multiple positions to allow varying amounts of light into the cab FIGURE 3 19 9838 17 Item Description Page 1 Skylight Window Latch If Equipped 3 39 2 Skylight Sun Shade 3 39 3 Right Side Window Latch 3 39 1 3 2 ...

Page 113: ...t Sun Shade The Skylight Sun Shade 2 Figure 3 19 reduces direct sunlight coming into the cab The sun shade is self retracting and can be set to screen all sunlight coming into the cab The sun shade can also be adjusted to reduce sunlight in the cab by moving it rearward and securing it into the notches provided Right Side Window Latch The window on the right side of the cab can be opened for venti...

Page 114: ... Green LED left position indicates function is enabled Yellow LED middle position indicates an error condition Red LED right position indicates the requested function is not available or the counterweight removal system is not enabled The crane engine must be running with the parking brake in the ON position and no other crane functions enabled for the system to be fully operational Use the functi...

Page 115: ...be operated The operator must first release the Enable button and then quickly push and release it again to re activate the function buttons Main Power LED Indicator The Main Power LED Indicator 5 Figure 3 21 flashes green to indicate that Main Power is on Horn Button The Horn Button 6 Figure 3 21 is always active and can be pushed at any time without first pushing the Keypad Enable button 4 Lock ...

Page 116: ...ndicators come on to indicate the limiters are bypassed Bypass 3 Pressed Indicator is on only when pushed and held Figure 4 206 RCL Bypass Active Indicator is on Figure 4 206 Working Range Limiter WRL Indicator is on Figure 4 71 Low Boom Angle Indicator is flashing Figure 4 68 Upon pushing the Bridging Switch the swing left right function pressure is reduced to 25 The boom down hoist up and telesc...

Page 117: ...s on the load being lifted is less than 90 of crane RCL programmed capacity Yellow LED when the yellow LED is on the load being lifted is between 90 to 100 of crane RCL programmed capacity Red LED when the red LED is on the load being lifted is greater than 100 of crane RCL programed capacity Strobe Light or Beacon The standard Strobe Light or Beacon 1 Figure 3 24 is located at the right side of t...

Page 118: ... optional 240V engine block heater and outlet is available in place of the 120V version Emergency Stop Buttons Optional The optional Emergency Stop Buttons 1 Figure 3 26 are located on the left and right sides of the carrier Push in the red button to stop the engine and all crane functions When the Emergency Stop Button is pushed in the Emergency Stop Active Alert in the Alerts Area Figure 4 68 of...

Page 119: ... batteries Always disconnect batteries using the Battery Disconnect Switch if crane is scheduled to be inactive for over 24 hours The Battery Disconnect Switch has an integral lock feature that allows the switch to be held in the ON position battery connected or OFF position battery disconnected when used with a padlock useful for lockout tagout programs NOTE To avoid possible engine fault codes a...

Page 120: ... FEATURES GRT8120 OPERATOR MANUAL 3 46 Published 3 22 2021 Control 702 02 Fuse Box Carrier The Fuse Box is located on the left side of the carrier in the battery box and includes fuses listed in Figure 3 28 FIGURE 3 28 10251 ...

Page 121: ... 47 GRT8120 OPERATOR MANUAL OPERATING CONTROLS AND FEATURES 3 Fuse and Relay Box Carrier The Fuse and Relay Box is located on the left side of the carrier in the battery box and includes fuses and relays listed in Figure 3 29 FIGURE 3 29 10250 ...

Page 122: ...the Boom Mounted Lights Switch Optional page 3 8 Optional motorized Boom Mounted Work Lights are adjusted by the Boom Mounted Lights Motor Switch Optional page 3 8 Side Mounted Carrier Work Lights Two carrier work lights 1 Figure 3 32 are located on each side of the carrier These four lights can be adjusted by hand to illuminate the desired area around the crane during low light or nighttime groun...

Page 123: ...at the left and right sides of the crane as well as at the front and rear of the crane Use these ladders and grab handles to climb and access the carrier deck or the cab Always maintain a three point contact to the crane when using the ladders and grab handles FIGURE 3 33 9838 32 2 2 2 1 LEFT SIDE FIGURE 3 34 9838 33 RIGHT SIDE 2 2 1 FIGURE 3 35 9838 34 FRONT 1 2 2 FIGURE 3 36 9838 35 REAR 1 2 2 ...

Page 124: ...ift Swing 360 Swing Lock Horn Engine Start Stop Engine Throttle Control Hydraulic Luffing Boom Extension optional Boom Extension Stowage Actuators When using the Remote Control Unit all limiters and their crane function lockouts are inoperable to include the following RCL System boom up down telescope extend hoist up Anti Two Block System boom up down telescope extend hoist up 3rd Wrap Limiter Sys...

Page 125: ...mote Control Unit in the dashboard in front of the steering column 1 Figure 3 38 For long term storage store the Remote Control Unit behind the seat or in the netting to the right of the seat Keep the spare battery pack in the charger which is located behind the seat 1 Figure 3 39 The charger is always on and will charge the battery pack whether the engine is operating or not The charger is equipp...

Page 126: ...OPERATING CONTROLS AND FEATURES GRT8120 OPERATOR MANUAL 3 52 Published 3 22 2021 Control 702 02 Controls and Features FIGURE 3 40 8 9 10 9864 1 11 12 13 14 15 16 17 3 18 1 2 4 5 6 6 7 19 Not Shown ...

Page 127: ...n the display screen The speed of the crane function operation is controlled by how far down the pushbutton switch is pushed For the crane function to operate the left or right side Enable Button 6 Figure 3 40 must also be pushed at the same time that the Right Motion Button is pushed Enable Buttons The Enable Buttons 6 Figure 3 40 are two position pushbutton switches Either the left or right side...

Page 128: ...ered Swing Button The Swing Button 12 Figure 3 40 is a momentary pushbutton switch Push the button to cause the swing function screen to appear in the Remote Control Unit display From this function screen the boom and superstructure can be swung left and right Option Button The Option Button 13 Figure 3 40 is a momentary pushbutton switch Push the Option Button several times to cause the luffing j...

Page 129: ...n switch Push button to cause the crane function screen that currently appears in the display to change back to the main screen Status Indicator The Status Indicator 18 Figure 3 40 is a bi colored LED that indicates the status of the Remote Control Unit The following statuses are possible Battery Pack The Battery Pack 19 Figure 3 40 is installed into the back of the Remote Control Unit Green slow ...

Page 130: ...Right Enable Indicator Green enable button is pushed function can be operated 8 DEG or RPM Indicator When applicable shows the position of the superstructure in degrees or the rotational speed of the selected motion 9 E Stop Indicator White E Stop button pulled out operation is allowed Red E Stop button pushed in operation is not allowed 10 Crane Fault Indicator White no active crane fault exists ...

Page 131: ... Transmission 4 11 Hoist 4 11 Swing Drive and Turntable Bearing 4 11 Axles 4 12 Hydraulic Oil System 4 12 Driving the Crane 4 12 Seat Belts 4 12 Traveling General 4 12 Traveling Towing Pulling 4 13 Traveling Being Towed Pulled 4 13 Traveling on Slopes 4 14 General Conditions 4 14 Slope Limitations Fore Aft Travel 4 14 Slope Limitations Side Slope Travel 4 15 Traveling with Elevated Boom 4 15 Trave...

Page 132: ...p 4 51 Engine Start Stop Throttle 4 53 Outrigger Beams 4 55 Outrigger Jacks 4 57 Hoist Control Main and Aux 4 59 Boom Lift 4 61 Swing and 360 Swing Lock 4 63 OPT options 4 65 Information 4 66 Navigating the Operator Display Module and Rated Capacity Limiter Display Module 4 67 Using the Operator Display Module ODM 4 68 Main Screen 4 69 Alerts Area 4 70 Active Screen Indicator Area 4 76 Crane Infor...

Page 133: ...e Operating the Crane 4 165 Displays During Crane Operation 4 167 RCL Early Warning 4 169 RCL Shutdown 4 169 Limit Bypass Alert Indicators 4 170 Load Chart and Miscellaneous Alerts 4 170 Hoist Camera 4 174 Preload Check 4 176 Using the Load Chart 4 176 Stowing and Parking 4 178 Leaving Crane Unattended 4 178 Long term Storage 4 178 ...

Page 134: ...formation of the hook opening including twist Be sure safety latch is free and aligned Seats and Mirrors Adjust seat and mirrors for clear vision and safe driving Cameras Make sure hoist rear view and side view cameras function properly and are properly adjusted Make sure cameras are kept clean Seat Belts Seat Belt Maintenance Seat belt assemblies are maintenance free however they should be period...

Page 135: ... AIRM Communications System This system calculates real time air filter restriction at operational flow rate using the temperature and pressure input from the TBAP sensor which is included on the Direct Flow air cleaner When the air filter becomes dirty and should be replaced a maintenance fault is generated and the Engine Warning Indicator in the Alerts Area 1 Figure 4 67 of the Operator Display ...

Page 136: ...le gas or vapors are found or can be formed example at fuel stations and chemical factories At locations where explosive dust is found or can be formed example coal wood or grain dust There is a risk of suffocation when using the heater Do not operate heater in enclosed spaces example garages To activate heater make sure fuel supply valve from heater fuel reservoir is turned to the ON position Mak...

Page 137: ...d be activated 2 hours before starting the crane to allow sufficient time to preheat batteries and provide easy start up conditions Make sure battery heater coolant valve is turned OFF in ambient temperatures above 9 C 15 F Air Diverter An air diverter directs warmed air collected from under the engine hood when temperature is below 9 C 15 F to preheat the air intake going to the engine Make sure ...

Page 138: ...e of an emergency white kerosene can be added to the fuel to bring the pour point down to the required temperature This will prevent clogging of filters and small passages by wax crystals The addition of kerosene is NOT recommended for general use 4 Make sure battery disconnect switch handle is in the ON position 5 Make sure emergency stop switch is not pressed 6 Make sure parking brake is set to ...

Page 139: ...ntrol system will automatically return the engine idle speed to its usual setting when one of the following conditions occur Transmission is shifted to forward or reverse Parking brake is disengaged Brake pedal is pressed Controller is actuated Engine coolant temperature rises above 79 C 175 F Exhaust System Cleaning Switch is set to the Manual Cleaning position Exhaust system cleaning process is ...

Page 140: ...nual cleaning process at the next opportune time Refer to section titled Exhaust System Cleaning If Equipped page 4 153 for procedures to manually clean the exhaust As a warning the High Exhaust System Temperature HEST strobe light 1 Figure 4 1 near the exhaust pipe 2 Figure 4 1 will flash during exhaust system cleaning Shutdown Procedure 1 Allow engine to run at fast idle speed for about five min...

Page 141: ...ne speed to return to idle 3 Repeat Step 2 until the temperature of the transmission sump reaches 20 C 68 F Hoist Warm up procedures are recommended at every startup and required at ambient temperatures below 4 C 40 F Warm up Procedures Standard Hydraulic Oil 1 Without operating the hoist function warm the hydraulic oil see Hydraulic Oil System page 4 12 2 Once hydraulic system is warm operate the...

Page 142: ...atures from 95 C to 10 C 200 F to 50 F Crane operation with a load is allowed with no restrictions Hydraulic oil temperature above 95 C 200 F No crane operation is allowed Let hydraulic oil cool by running engine at idle with no functions actuated DRIVING THE CRANE Seat Belts 1 Before fastening the seat belt always adjust driver s seat to position in which you will drive 2 Pull belt across your la...

Page 143: ...rain being traversed Traveling Being Towed Pulled Grove recommends connecting to a pintle hook if equipped or evenly attaching to the tie down lugs when being towed by another vehicle WARNING Tipping Hazard Avoid holes rocks extremely soft surfaces and any other obstacles which might subject crane to undue stresses or possible overturn Do not drive crane with boom off center because automatic osci...

Page 144: ...fluids must be filled to the specified levels Axle differentials and planetary hub fluids must be filled to the specified levels No loads may be supported by the boom i e no pick and carry loads while traversing a slope All cribbing or other non standard accessories must be removed from the crane Avoid holes rocks extremely soft surfaces and any other obstacles that might subject crane to undue st...

Page 145: ...ed fashion Do not exceed a speed of 16 kph 15 mph with boom over front with counterweight installed Inflate tires to recommended pressure for travel operations When using towing attachments boom must remain horizontal Fully retract all boom sections Refer to Traveling with Boom Extension Erected page 4 15 if boom extension is in the erected position Position boom over front or rear of crane Engage...

Page 146: ...orward propulsion and first 1 gear are selected NOTE If Service Brake Foot Pedal is not pressed before shifting to a gear the gear selection will flash in the Operator Display Module ODM until the Transmission Shift Lever is returned to the neutral N position Transmission will not shift 6 Release Service Brake Foot Pedal and press Foot Throttle Pedal until maximum first gear speed is reached Rotat...

Page 147: ... side of the switch activates the rear steer cylinders steering crane in the selected direction Four Wheel Steering Four wheel steering is accomplished with the steering wheel and Rear Steer Switch With the boom over the front of the crane turn steering wheel to the left and push Rear Steer Switch to the left to turn crane to the left Turn steering wheel to the right and push Rear Steer Switch to ...

Page 148: ...gaging the differential lock function 1 Lock unlock differentials only when vehicle is standing still or moving at a constant low speed with wheels not slipping 2 When traveling with differentials locked do not deviate from a straight path more than absolutely necessary 3 Locked differentials cause crane s turning radius to increase creating an understeer condition Use caution good judgment and dr...

Page 149: ...t be reduced Therefore whether lifting on rubber or outriggers it is essential the crane is level to within 1 of grade The digital Inclination indicator provided in the Operator Display Module ODM is calibrated to be accurate within 0 1 of grade To properly level the crane the boom must be positioned over front of the crane fully lowered to horizontal and fully retracted and the cab must be in its...

Page 150: ...sing the Auto Level Feature Start with outrigger beams and jacks retracted NOTE ECO mode does not work when operating the outriggers 1 Enable the outrigger functions by doing the following Shift transmission to neutral Engage the parking brake Engage four wheel drive Disable all crane functions Fully lower cab 2 Position the outrigger pads directly out from each outrigger to where the outriggers w...

Page 151: ...the RCL then the OMS indicates to the RCL the horizontal position of each of the four outrigger beams If the outrigger beam configuration programmed by the operator does not match that which is detected by the Outrigger Monitoring System an outrigger beam over ride warning screen will appear refer to Outrigger Span page 4 161 The RCL does not lock out the crane or select a different load chart bas...

Page 152: ...d apply the swing brake using the Swing Brake Pedal refer to Swing Brake Pedal page 3 30 Single Axis Controller Optional 1 Push the Swing Enable Disable Switch on left armrest to enable the swing function The Swing Enable Indicator will come on green 2 Push outer controller on left armrest forward and hold to swing right rotates turntable clockwise or pull controller rearward and hold to swing lef...

Page 153: ...r The operator inputs the telescoping sequence or tele picture into the Operator Display Module ODM by entering the locking position for each of the six telescoping sections The Crane Control System CCS determines the order of operations required to achieve the entered telescoping sequence To increase the boom length the user moves the controller in the extend direction To decrease the boom length...

Page 154: ...access code In the Emergency Mode the operator has control over the locking and unlocking functions of the telescoping cylinder The operator can also retract or extend the telescoping cylinder The operator or technician may also see the sensor information for the complete telescoping system The operator must use the telescope controller with the automatic and manual telescope modes in the ODM to t...

Page 155: ...the desired length let controller return to the center neutral position to stop retracting the boom Dual Axis Controller Crane Equipped with Auxiliary Hoist 1 Push the Telescope Enable Disable Switch on right armrest to enable the telescope function The Telescope Enable Indicator in the Status Bar area Figure 4 73 of the Operator Display Module ODM will come on green 2 Push controller on right arm...

Page 156: ... ways Manual Telescoping For manual telescoping the operator must initiate some locking and unlocking processes at the right time Semi automatic Telescoping When telescoping with semi automation the operator enters a telescoping sequence or tele picture and the Crane Control System CCS controls all of the locking and unlocking processes automatically This mode can also be used for intermediate len...

Page 157: ...III 1 to 3 Each telescopic section is equipped with two section locking pins 7 which are extended by spring force The section locking pins 7 are pushed into the cutouts 4 of the telescopic section at the locking points the telescopic section is locked The telescoping cylinder is attached to the base section 9 with the piston rod 8 The telescoping cylinder has two cylinder locking pins 5 at the bot...

Page 158: ...nder locking pins 5 extend the telescoping cylinder is locked 3 Unlocking the telescopic section A Figure 4 8 When a telescope section is locked at the 50 92 or 100 position the telescoping cylinder extends until the locking pins 7 for that section are clear When a section is fully retracted and locked at the 0 position there is no liftoff process The boom section is supported at the front of the ...

Page 159: ...ction to a locking point The locking pins 7 Figure 4 9 of the mechanism 10 extend into the cutouts 4 The telescopic section is automatically set down The telescoping cylinder retracts until the locking pins 7 Figure 4 10 are positioned on the above telescopic section 1 The weight of the load is now on the telescopic sections and not on the telescoping cylinder 8849 120 FIGURE 4 9 8849 121 FIGURE 4...

Page 160: ... of the main boom in the menus The following elements are displayed Figure 4 11 0 Base section 1 Telescopic section 1 2 Telescopic section 2 3 Telescopic section 3 4 Section locking pin on the telescopic section 5 Cylinder locking pins on the telescoping cylinder 6 Section pin cutouts holes 7 Cylinder pin engagement cutouts holes 9093 FIGURE 4 11 ...

Page 161: ...ayed telescoping status from the current status of the telescoping mechanism and the previously saved locking and unlocking procedures Normally CCS detects differences between the current and the displayed telescoping and displays the corresponding error message If a malfunction results in saved values being deleted CCS can no longer calculate the current telescoping and may not issue an error mes...

Page 162: ...oping To telescope manually the operator must initiate some locking and unlocking processes The locking and unlocking processes are carried out automatically The following sections describe the operating procedures Checking the initial position page 4 32 Unlocking the telescoping cylinder page 4 33 Extending retracting the telescoping cylinder without tele section page 4 34 Locking the telescoping...

Page 163: ...lay 5 lock symbol will show orange when the telescope cylinder is at the locking point Position of the Locking Pins The current positions of the locking pins are Figure 4 16 The area 3 shows an enlarged cut out The current settings are shown in different colors Unlocking the Telescoping Cylinder Unlocking the telescoping cylinder is required for the telescoping cylinder to be moved separately with...

Page 164: ...l 1 green Telescoping cylinder unlocked symbol 2 red Extending Retracting Move the controller in the corresponding telescoping direction The telescoping cylinder extends retracts The display 1 Figure 4 21 shows the length as a percentage that a telescope section is extended to as well as the length in millimeters that the telescope cylinder is extended to Near a locking point the symbols 3 Figure ...

Page 165: ...escopic section locked symbol 1 green NOTE Lock command available symbol 4 orange Telescoping cylinder unlocked symbol 2 red Lock 1 Move the telescoping cylinder to the desired locking point e g to telescopic section 1 Figure 4 24 Wait until the display shows the desired telescopic section 1 and the symbols 2 are shown 2 Select the symbol 3 3 Confirm the selection the locking pins will extend symb...

Page 166: ...f symbol 1 is not red after approx 10 seconds this means that the locking pins are under load To relieve the load carefully retract and extend a little If removing the load does not cause unlocking you must lock the telescopic section Locking the Tele Section page 4 37 and restart unlocking Telescoping the Tele Section The tele section can be telescoped once it is unlocked Prerequisites Telescopin...

Page 167: ...ele Section Every telescopic section can be locked at the fixed lengths refer to Main Boom Fixed Length page 4 31 Prerequisites Telescoping mechanism on symbol 3 Figure 4 29 green Telescopic section unlocked symbol 1 red Telescoping cylinder locked symbol 2 green Lock 1 Telescope to the desired fixed length e g telescopic section 6 to 100 1 Figure 4 30 If the symbol 3 is displayed the telescopic s...

Page 168: ... Introduction The Semi auto Mode is typically the standard method for telescoping the pinned boom It is important to understand that a pinned boom has a telescoping cylinder that can disconnect and reconnect unlock lock to boom sections as well as disconnect and connect unlock lock boom sections to each other This is accomplished by a pinning mechanism or pinning head at the near end of the barrel...

Page 169: ... 33 at some point in the telescoping process will flash The flashing is an indication that an unlocking or locking event will occur if the operator holds the controller in the direction of that arrow for at least 1 second If this event begins then the screen will change to the dots as described for Figure 4 32 so that the operator knows that an automated motion or action is again occurring The RCL...

Page 170: ...For example if Enter is used on the 50 button then all the values in the top row of the display will be set to 50 thus requesting the final boom configuration of 50 50 50 50 50 50 Semi auto Mode Basic Operating Procedures The following steps would be expected for extending the boom in Semi auto Mode Enter the Semi auto screen on the Operating Display Module The icon for this screen is 1 Figure 4 3...

Page 171: ... the T6 boom section retract to the T5 boom section lock to the T5 boom section and then unlock the T5 boom section When the T5 boom section is unlocked the left and right telescoping direction arrows will appear again as is shown in Figure 4 33 The operator can telescope the next boom section T5 The T5 boom section operating process is the same as for the T6 boom section described above When the ...

Page 172: ...cylinder is locked to the desired boom section that boom section will be automatically unlocked as if it is to be operated Use the controller to retract for at least 1 second The boom section will re lock and the boom should still be fully retracted and locked and the telescoping cylinder will be in the position desired such as locked to T1 boom section Semi auto Mode Requiring Boom to be Retracte...

Page 173: ...sing faults that eventually cause the telescoping function to shut down refer to the section in the document Semi auto Mode telescoping function shut down There are sensors in the telescoping cylinder that detect elevated pressure conditions for extending the boom particularly for telescoping with significant hook loads If the pressure is beyond a threshold depending on the distance the telescopin...

Page 174: ...be used to reset or teach the telescoping configuration Enter the request reset telescoping screen on the Operating Display Module ODM Figure 4 43 shows the icon for this screen The request reset telescoping screen appears as shown in Figure 4 44 This screen is for entering a confirmation code The confirmation code is L O S T When these letters are entered on the screen then an Enter button can be...

Page 175: ...nal boom configuration values for the Semi auto Mode When one of the unlock or lock icons becomes available to be selected changes from the basic gray color to the focus color then the operator can request the unlock command or the lock command The top unlock icon is for the boom section unlocking and at the proper time the lock icon would be used to again lock the boom section the lock icon will ...

Page 176: ...ol system begins to work that selection and can begin unlocking the boom As an example the RCL rigging information can be set as follows including using the check mark to activate this selection Outriggers at 100 extension Counterweight of 13 245 kg 29 200 lb 4 parts of line on main hoist no aux nose Boom extension stowed 1 Enter the Boom Configurator screen should appear similar to Figure 4 48 2 ...

Page 177: ...ed then the value to enter on the Boom Configurator screen would be the following Pmodified 10 000 0 75 Pmodified 13 333 Thus enter the value of 13 5 klbs for the Boom Configurator Lowering and Raising the Main Hoist Rope NOTE When load is stopped at desired height the automatic brake will engage and hold the load as long as the controller remains in neutral Lowering the Main Hoist Rope Dual Axis ...

Page 178: ...en load is stopped at desired height the automatic brake will engage and hold the load as long as the controller remains in neutral Lowering the Auxiliary Hoist Rope Dual Axis Controllers 1 Push the Auxiliary Hoist Enable Disable Switch on left armrest to enable the auxiliary hoist function The Auxiliary Hoist Enable Indicator in the Status Bar area Figure 4 73 of the ODM will come on green 2 Push...

Page 179: ...ry hoist controller is pulled rearward to raise the rope the Hoist Rotation Indicator 5 Figure 3 13 pulses and the Auxiliary Hoist Raise Indicator Figure 4 73 in the Status Bar area of the ODM comes on to indicate to the operator that the auxiliary hoist is operating Selecting the Hoist Speed Range On dual axis controllers and single axis controllers optional the high speed hoist function can be e...

Page 180: ...tem hoist down Working Range Limiter WRL System Carrier Avoidance System 29 C Temperature Limiter System optional Preparing for Remote Control Operation 1 Position the crane in the desired location 2 Apply the parking brake 3 Shift the transmission to neutral 4 Stop the engine with the ignition switch the engine will be re started with the remote control 5 Set the ignition switch to RUN position 6...

Page 181: ...ton on the Remote Control Unit Battery power is too low 12 Set the Remote Control to OFF by doing the following a If desired stop the engine with the Remote Control Unit See Engine Start Stop Throttle page 4 53 b Set the Remote Control Unit to OFF by pressing the Power Button on the Remote Control Unit c Disable the Remote Control Unit by pressing the bottom of the Remote Control Enable Disable Sw...

Page 182: ...OPERATING PROCEDURES GRT8120 OPERATOR MANUAL 4 52 Published 3 22 2021 Control 702 02 FIGURE 4 54 ...

Page 183: ...ine speed hold down either enable button and the left motion button at the same time The engine s speed is shown in the RPM screen 8 When the remote control unit is on engine speed cannot be controlled from the throttle pedal and increment decrement switch in the crane cab Exiting Start Stop Throttle Screen To exit this screen press the ESC button on the remote control unit The main screen appears...

Page 184: ...OPERATING PROCEDURES GRT8120 OPERATOR MANUAL 4 54 Published 3 22 2021 Control 702 02 FIGURE 4 55 1a 1b 1c 1d 1e 1f ...

Page 185: ...ion button at the same time Release both buttons to stop the beams at the desired position 3 To EXTEND the selected beams hold down either enable button and the right motion button at the same time Release both buttons to stop the beams at the desired position 4 To exit this screen press the ESC button on the remote control The main screen appears Item Indicator Name Description 1 Outrigger Beams ...

Page 186: ...OPERATING PROCEDURES GRT8120 OPERATOR MANUAL 4 56 Published 3 22 2021 Control 702 02 FIGURE 4 56 1a 1b 1c 1d 1e 1f 1g ...

Page 187: ...time Release both buttons to stop the jacks at the desired position 3 To EXTEND the selected jacks hold down either enable button and the right motion button at the same time Release both buttons to stop the jacks at the desired position 4 To exit this screen press the ESC button on the remote control The main screen appears Item Indicator Name Description 1 Outrigger Jacks Function 1a All four ja...

Page 188: ...OPERATING PROCEDURES GRT8120 OPERATOR MANUAL 4 58 Published 3 22 2021 Control 702 02 FIGURE 4 57 ...

Page 189: ...n the remote control unit The main screen appears Item Indicator Name Description 1 Main Hoist Function 1 Green main hoist can be operated 2 Reel Out lower 2a Blue main hoist cannot be operated until either enable button is held down 2b Green hoist rope can be reeled out from main hoist with left motion button 3 Reel In raise 3a Blue main hoist cannot be operated until either enable button is held...

Page 190: ...OPERATING PROCEDURES GRT8120 OPERATOR MANUAL 4 60 Published 3 22 2021 Control 702 02 FIGURE 4 58 ...

Page 191: ...tton at the same time Release both buttons to stop the boom 4 The boom angle is shown in the DEG screen 5 5 To exit this screen press the ESC button on the remote control unit The main screen appears Item Indicator Name Description 1 Boom Lift Function 1 Green boom can be operated 2 Boom Down 2a White boom cannot be operated until either enable button is held down 2b Green boom can be lowered with...

Page 192: ...OPERATING PROCEDURES GRT8120 OPERATOR MANUAL 4 62 Published 3 22 2021 Control 702 02 FIGURE 4 59 0 179 9 180 90 90 100 FRONT ...

Page 193: ... 360 swing lock hold down either enable button and the right motion button at the same time Exiting Swing 360 Swing Lock Screen To exit this screen press the ESC button on the remote control The main screen appears Item Indicator Name Description 1 Swing Function 1 Green swing can be operated 2 Swing Left 2a Blue cannot swing left until either enable button is held down 2b Green can swing left wit...

Page 194: ...OPERATING PROCEDURES GRT8120 OPERATOR MANUAL 4 64 Published 3 22 2021 Control 702 02 FIGURE 4 60 50 0 5a 5b 6a 6b 5 4a 5a 6a 4 6 7 4b 5b 6b ...

Page 195: ...extension stowage actuator screen 2 See Figure 4 60 2 To RETRACT the rear actuator hold down either enable button and the left motion button at the same time 3 To EXTEND the rear actuator hold down either enable button and the right motion button at the same time NOTE Speed in either direction is proportional to how far the motion button is depressed 4 Repeat the above steps for the front boom ext...

Page 196: ...ure 4 61 The information screen shows the following Remote control unit s software version 1 You will need to know the software version when communicating with your Grove dealer or Manitowoc Crane Care Crane Serial Number 2 The remote control must remain with the crane it was supplied with The serial number in the information screen must match the serial number on the crane FIGURE 4 61 ...

Page 197: ...ed by the Jog Dial at that time The Active Screen Toggle Button 3 Figure 4 63 is used to switch between controlling the ODM or RDM The ODM has a Main Screen and a Menu Screen The operator can return to the Main Screen by pressing the Escape Button 1 Figure 4 62 and Figure 4 63 or return to the Menu Screen by pressing the Menu Button 3 Figure 4 62 and 4 Figure 4 63 The RDM has a Setup Screen and a ...

Page 198: ...ton 6 Figure 4 62 on the ODM Navigation Control Pad is used to get more information about a crane control system CCS fault code USING THE OPERATOR DISPLAY MODULE ODM NOTE Refer to Operator Display Module ODM page 3 18 for additional information The Operator Display Module ODM has two primary screens 1 Main Screen For detailed information on the Main Screen of the ODM refer to the section titled Ma...

Page 199: ...e Jog Dial to select the ODM screen control then press the Escape Button 2 or Press the Escape Button 3 Figure 4 66 on the Navigation Control Pad at the ODM The Main Screen is separated into seven areas as shown in Figure 4 67 FIGURE 4 66 1 2 3 FIGURE 4 67 1 10254 39a 5 6 7 2 3 Item Description Page 1 Alerts Area 4 70 2 Active Screen Indicator Area 4 76 3 Crane Information Area 4 77 4 Crane Status...

Page 200: ...al Red Critical At the same time the alert can show constant on or flashing to indicate an additional level of importance Name Symbol Description Crane Fault Active Alert Indicates there is at least one active crane fault that has been viewed New Crane Fault Active Alert Indicates there is at least one active crane fault that has not been viewed Low Fuel Level Alert Indicates the fuel level is low...

Page 201: ...d Alert Indicates the engine coolant temperature input from the engine ECM is invalid Engine Oil Pressure Warning Alert Indicates the engine oil pressure is too low Safely stop the lifting operations land and secure any load being lifted If possible retract and lower boom Shut down and secure crane Engine Fault Active Alert Indicates there is at least one active engine fault that has been viewed N...

Page 202: ...Auxiliary Hoist Indicates the minimum number of wraps of rope required has been reached on the auxiliary hoist When the indicator comes on red the warning buzzer will sound The crane system will lock out the hoist down and telescope out crane functions Engine Wait To Start Alert Indicates the outside ambient temperature is low and preheating of the air inside the air intake manifold is required Do...

Page 203: ...erations Tilting the cab while the parking brake is released Starting the engine while the parking brake is released Shifting the transmission to forward or reverse while the parking brake is engaged Operating the outrigger function while the parking brake is released Releasing the parking brake while rigging code 9810 Stationary On Rubber is active in the RCL Auto level Sensor Warning Alert Indic...

Page 204: ...n is not in four wheel drive low range Differential lock is engaged for more than 60 seconds There is a malfunction in the differential lock system High Exhaust System Temperature Alert Indicates the exhaust temperature is above 640 C 1184 F during the active exhaust system cleaning process Indicator remains on until the temperatures falls below 625 C 1157 F Indicator also is on constant during th...

Page 205: ...irements When the indicator comes on red the warning buzzer will sound Do not drive crane until brake pressure malfunction is corrected Low Steering System Pressure Alert Indicates the hydraulic pressure in the steering system is below normal operating requirements When the indicator comes on red the warning buzzer will sound Do not drive crane until steering pressure malfunction is corrected Name...

Page 206: ...g indicator can appear in the Active Screen Indicator Area 1 Figure 4 69 of the ODM Main Screen Name Symbol Description Active Screen Indicator Indicates the ODM screen is being controlled by the Jog Dial Refer to Navigating the Operator Display Module and Rated Capacity Limiter Display Module page 4 67 FIGURE 4 69 1 10254 39a ...

Page 207: ...of the ODM Main Screen 10254 39a FIGURE 4 70 1 3 7 8 9 6 4 2 5 Item Description Item Description 1 Direction Gear Indicator 6 Transmission Oil Temperature Indicator 2 Engine Speed Indicator 7 Speedometer 3 Engine Coolant Temperature Indicator 8 Battery Charging Voltage Indicator 4 Diesel Exhaust Fluid DEF Level Indicator 9 Hydraulic Oil Temperature Indicator 5 Diesel Fuel Level Indicator ...

Page 208: ...and lower the boom Shut down and secure the crane 4 Diesel Exhaust Fluid Level Indicator Shows the DEF level as a percentage Yellow Indicator Indicates the DEF tank is between 5 to 10 full Red Indicator Indicates the DEF tank is 5 or less full 5 Diesel Fuel Level Indicator Shows the fuel level as a percentage Yellow Bar Indicates the fuel tank is between 11 to 21 full Red Bar Indicates the fuel ta...

Page 209: ...tage when the engine is off and the charging voltage when the engine is running Red Indicator Indicates the battery voltage is less than 20V or greater than 30V 9 Hydraulic Oil Temperature indicator Shows the hydraulic oil temperature in the selected unit of measure C F If indicator is yellow or red safely stop crane operation and let hydraulic oil cool by running engine at idle with no functions ...

Page 210: ...tors make up the Crane Status Area Figure 4 71 of the ODM Main Screen Item Description 1 Parking Brake Indicator 2 Marker Light Headlight Indicator 3 Suspension Control Indicator 4 Economy ECO Mode Indicator 5 Two Wheel Drive Four Wheel Drive Indicator 6 Working Range Limiter WRL Indicator FIGURE 4 71 1 2 6 5 4 10254 39a 3 ...

Page 211: ...refer to Headlights Switch page 3 5 3 Suspension Control Indicator Indicates the suspension is unlocked and the rear axle is free to oscillate from side to side Indicates the suspension is locked and axle oscillation is prevented 4 Economy ECO Mode Indicator Indicates ECO mode is disabled Indicates ECO mode is enabled refer to ECO Mode page 4 151 but is not active Indicates ECO mode is enabled and...

Page 212: ...eight limit setpoint WRL Boom Angle Stop Indicator Red Indicates the boom angle is at a boom angle limit setpoint The warning buzzer is on constant For cranes that are equipped with the WRL Lock Out Function the boom up or boom down crane function is locked out depending upon which limit is reached 6 WRL Boom Height Enabled Indicator Green Indicates the boom height limit is defined WRL Boom Height...

Page 213: ...r Amber Indicates the swing angle is within 10 of a swing angle limit setpoint The warning buzzer slowly beeps when the swing angle is within 10 of the swing angle limit setpoint and changes to a fast beep when the swing angle is within 5 of the swing angle limit setpoint For cranes that are equipped with the WRL Lock Out Function when the swing angle is within 10 of the swing angle lock out setpo...

Page 214: ...en set The warning buzzer slowly beeps when the boom tip is within 6 m 20 ft of a virtual wall and changes to a fast beep when the boom tip is within 1 5 m 5 ft of a virtual wall WRL Virtual Walls Stop Indicator Indicates the boom tip is at a virtual wall that has been set The warning buzzer is on constant For cranes that are equipped with the WRL Lock Out Function the telescope out boom down and ...

Page 215: ...t the top left corner and descending to the bottom right corner as shown by the red arrows in Figure 4 72 During the operation of the crane the function icons that appear in this area will change as their usage changes Use the Navigation Control Pad or Jog Dial to select one of the function icons in this area These six function icons can also be found in the Menu Screen of the ODM Selecting one of...

Page 216: ... function indicator can have the following status Blue Indicator Indicates the crane function is disabled Yellow Indicator Constant On Indicates the crane function is enabled but is in a standby mode due to the operator not being seated causing seat switch to open refer to Seat Switch page 3 26 The crane function is re enabled by either sitting in the operator seat or by actuating a dead man switc...

Page 217: ...oist Lower Indicator Green Indicates the main hoist rope is being let out Main Hoist High Speed Indicator Green Indicates the main hoist function and the high speed function are enabled Auxiliary Hoist Raise Indicator Green Indicates the auxiliary hoist rope is being reeled in Auxiliary Hoist Lower Indicator Green Indicates the auxiliary hoist rope is being let out Auxiliary Hoist High Speed Indic...

Page 218: ...requently used in the operation of the crane These six function icons are constantly shown and cannot be changed Use the Navigation Control Pad or Jog Dial to select one of the function icons These six function icons can also be found in the Menu Screen of the ODM Selecting one of the six icons in the Permanent Quick Select Menu Area or in the Menu Screen will open the same function screen 10254 3...

Page 219: ...etract function screen page 4 99 3 Camera 1 Function Icon Opens the Right Side Camera View function screen page 4 94 4 Semi automatic Telescope Mode Function Icon Opens the Semi automatic Telescope Mode function screen page 4 95 5 Manual Telescope Mode Function Icon Opens the Manual Telescope Mode function screen page 4 128 6 Emergency Telescope Mode Function Icon Opens the Emergency Telescope Mod...

Page 220: ...ode 6 Boom Configurator Mode 7 Crane Function Menu Group 8 Outrigger Extend Retract 9 360 Superstructure Lock Unlock 10 Boom Extension Deployment Stowage 11 Working Range Limiter Menu Group 12 Swing Angle Limitation 13 Boom Angle Limitation 14 Boom Height Limitation 15 Radius Limitation 16 Virtual Walls 17 Emergency Program Menu Group 18 Manual Telescope Mode 19 Emergency Telescope Mode 20 Telesco...

Page 221: ...Grove Published 3 22 2021 Control 702 02 4 91 GRT8120 OPERATOR MANUAL OPERATING PROCEDURES 4 THIS PAGE BLANK ...

Page 222: ...G PROCEDURES GRT8120 OPERATOR MANUAL 4 92 Published 3 22 2021 Control 702 02 10 1 2 FIGURE 4 76 5 6 7 17 12 9 8 13 14 15 16 18 19 20 21 22 23 24 3 25 26 27 28 10254 2 29 30 31 32 35 36 37 38 33 34 10254 1 4 11 ...

Page 223: ... Menu Group Icon 4 99 27 Software Versions Icon 4 146 9 Outrigger Extend Retract Icon 4 99 28 User Settings Menu Group Icon 4 147 10 360 Superstructure Lock Unlock Icon 4 105 29 Controller Curve Icon 4 147 11 Boom Extension Deployment Stowage Icon 4 106 30 Controller Speed Icon 4 149 12 WRL Menu Group Icon 4 107 31 ECO Mode Icon 4 151 13 Swing Angle Limitation Icon 4 121 32 Boom Position Indicator...

Page 224: ...d to select which camera view is displayed on the Camera View Screen Figure 4 79 Use the Jog Dial or Arrow Buttons on the Navigation Control Pad to select the desired camera view icon Press the Jog Dial or the OK Button to show the Camera View Screen To exit the Camera View Screen press the Main Screen Button 1 Figure 4 78 or Menu Screen Button 2 FIGURE 4 77 10254 3 1 2 3 4 FIGURE 4 78 1 2 1 2 FIG...

Page 225: ... is opened Telescope Diagram Display Current relation of the telescopic sections to each other section of top view Figure 4 82 The image shown in Figure 4 82 shows the status of the section and cylinder pins Green 1 indicates that the pin is locked Yellow 2 shows that it is in an intermediate position and Red is unlocked Additionally if the hazard triangle 3 is present an error exists Telescoping ...

Page 226: ... Sections Display Current extended length of the main boom 1 Figure 4 84 Unit of measurement Displayed depending on setting m meters or ft feet 1 6 Display of telescopic sections 1 to 6 Figure 4 85 FIGURE 4 84 10254 13 1 FIGURE 4 85 10254 13 1 6 Display of telescopic sections 1 to 6 Figure 4 86 1 Pre selection telescoping 0 2 Pre selection telescoping 50 3 Pre selection telescoping 92 4 Pre select...

Page 227: ...ct symbol 1 Figure 4 91 and confirm menu is opened 1 6 Display of telescopic sections 1 to 6 Figure 4 85 1 Start telescoping with Retract Figure 4 89 2 Start telescoping with Extend 10254 13 FIGURE 4 88 FIGURE 4 89 10254 6a 1 2 1 Confirm request to use entered telescoping values Figure 4 90 2 Once a new set of values are entered for telescoping the question mark appears until the OK is confirmed T...

Page 228: ...plan criteria 9 For the row in the table that is highlighted this is the boom configuration tele picture 10 For the row in the table that is highlighted this is a schematic view of the boom configuration 11 Up arrow when selected and select Enter the highlighted row moves up in the table 12 Down arrow when selected and select Enter the highlighted row moves down in the table 13 OK button when sele...

Page 229: ...een is also used to retract and stow the outriggers as well as operate the side mounted carrier work lights NOTE The outriggers are to be deployed with the boom centered over the front axle In this configuration the direction the operator is facing is considered the front of the crane The steering wheel symbol 6 Figure 4 94 shown on the Outrigger Extend Retract function screen corresponds to the f...

Page 230: ...con 2 Right Front Beam Jack 9 O R Beams Icon 3 Right Rear Beam Jack 10 O R Jacks Icon 4 Left Rear Beam Jack 11 O R Jacks x4 Icon 5 Percentage Outrigger Beam is Extended 12 Auto level Icon 6 Steering Wheel to indicate front of crane 13 Side Mounted Carrier Work Lights On Off Icon 7 Inclination Indicator FIGURE 4 94 10269 1 1 2 4 5 6 11 8 7 9 10 12 3 5 5 5 13 ...

Page 231: ... and Figure 4 96 When a button at the Jog Dial or Navigation Control Pad is pushed and held the corresponding O R beam image turns orange to indicate that it is actively moving An arrow will appear to indicate whether the beam is extending or retracting In the following example Figure 4 96 the top image shows the Left Front O R beam is extending and the bottom image shows the Left Front O R beam i...

Page 232: ... to the retract position then press and one or more of the four buttons at the Jog Dial or Navigation Control Pad NOTE The O R jack positions correspond to the four buttons at the Jog Dial and the ODM Navigation Control Pad Figure 4 97 and Figure 4 98 When a button at the Jog Dial or Navigation Control Pad is pressed and held the corresponding O R jack image turns orange to indicate that it is act...

Page 233: ...ntrol Pad NOTE While the Outrigger Jack Extend Retract x4 icon is active individual outrigger jacks can be extended or retracted by positioning the Outrigger Extend Retract Switch to the desired direction then pressing and holding one of the four buttons at the Jog Dial or Navigation Control Pad Figure 4 99 The O R jack positions correspond to the four buttons at the Jog Dial and the ODM Navigatio...

Page 234: ...e Auto level Button on the screen With the two buttons pressed the auto level system will adjust the height of the jacks automatically as it levels the crane Several adjustments may be necessary After an adjustment is made the auto level system will pause for a short time as it does a levelness check of the crane The operator can watch the leveling process by viewing the inclination indicator 2 Fi...

Page 235: ...Swing Lock Optional Select the 360 Swing Lock icon 1 Figure 4 104 under the Crane Function Group to show the 360 Superstructure Lock Unlock function screen The 360 Superstructure Lock Unlock function screen Figure 4 105 is used to lock the superstructure in position any where throughout its 360 rotation The function screen Figure 4 105 shows the current swing angle 1 the Lock and Unlock Icons for ...

Page 236: ...ion Control Pad select the Unlock icon 3 Figure 4 105 3 Press the Jog Dial or the OK Button to start the locking process When the lock is disengaged the Unlock Status Indicator 4 Figure 4 105 will appear Boom Extension Deployment Stowage Select the Boom Extension Deployment Stowage icon 1 Figure 4 107 under the Crane Function Group to show the Boom Extension Deployment Stowage function screen The ...

Page 237: ... radius limits can be defined for minimum and maximum radius working zones Virtual Wall s Limitation Icon 6 Up to five virtual walls can be defined to be jobsite objects or warning zones WRL Limitations Overview For each of the limitations the limitation must first be ENABLED within the WRL feature of the Crane Control System software This is done with particular screens and buttons on the Operati...

Page 238: ... the swing speed When a limitation is active and the boom has reached the requested limit position the ODM shows a red colored alert indicator for the limitation again with a symbol for the particular type of limitation refer to Figure 4 108 for the WRL Menu Icons In this condition audible alarms as well as stopping of crane functions if Lock Out Function is used will also be apparent For example ...

Page 239: ...wn as a group and one of the limitations can then be selected to work with that limitation screen To move to the Icon you wish to select use the Arrow Keys on the Navigational Control Pad or the Jog Dial to move to the corresponding Function Icon you wish to set the limitation on as shown in Figure 4 108 LIMITATION POSITION ALARM INDICATOR Swing Angle Limitation 10 deg before limit Slow beeping Am...

Page 240: ...represents the Boom Height Limitation Symbol represents the Working Radius Limitation Symbol represents the Virtual Walls Limitation Menu This Symbol is an audible alert selection If this symbol is shown the audible alert is functioning Hitting OK can change this symbol to the Lock Out Option shown as the next Symbol below This Symbol is a Lock Out Warning Symbol If this symbol is shown the option...

Page 241: ...p when the swing angle is within 5 of the swing angle limit set point For cranes that are equipped with the WRL Lock Out Function when the swing angle is within 10 of the swing angle lock out set point the swing function commanded by the controller may be reduced or suspended depending upon the weight of the load and the swing speed Warning Due to the free swing characteristic of the crane s super...

Page 242: ...eight Indicator Active Working Range Limiter WRL Boom Height Indicator Enabled Working Range Limiter WRL Boom Height Indicator Stop Working Range Limiter WRL Radius Icon Active Working Range Limiter WRL Radius Icon Enabled Working Range Limiter WRL Radius Icon Stop Working Range Limiter WRL Wall Icon Active Working Range Limiter WRL Wall Icon Enabled Symbol Description ...

Page 243: ...s considered defined Accept Crane Position Point B symbol If the limitation is enabled this symbol allows the acceptance of the current crane position in terms of hook radius and swing angle to be the second point Point B of a line that defines the position and orientation of the virtual wall If this symbol is highlighted as shown here with orange background and the crane position is accepted with...

Page 244: ...The Boom Height can be typed in or set by boom position NOTE The Limitation is dependent on the accuracy of the Tip Height Calculation which can be 5 Setting the Boom Height Limitation Using Crane Position To set parameters and enable the Boom Height Limitation the following steps can be used 1 Set the RDM screen parameters first Refer to Using the Rated Capacity Limiter Display Module RDM page 4 ...

Page 245: ... top left side of the ODM screen 4 Enable the limitation by using the Jog Dial 5 Figure 4 63 or the Arrow Keys 4 Figure 4 62 and move to the Enable Disable Switch 1 Figure 4 109 NOTE The Switch 1 Figure 4 109 is the Enable Disable Switch and is a toggle switch Click OK 5 Figure 4 62 or the Jog Dial 5 Figure 4 63 to toggle the switch Click OK NOTE The alarm will sound if boom tip is above the limit...

Page 246: ...e 4 110 you will see that the highlighted Icon in orange for the Enable Disable Switch Symbol for the maximum boom angle is selected since it has the orange color highlighting Table 4 9 lists the WRL Limitation Screen Symbols NOTE The Boom Angle can be typed in or set by a boom position Setting the Boom Angle Limitation Menu The Boom Angle Limitation Menu allows the operator to set the upper and o...

Page 247: ...ect the Boom Angle Limitation Menu 3 Figure 4 108 NOTE The Boom Angle Limitation Icon 8 Figure 4 110 is shown on the top left side of the ODM screen 4 Move the Boom to the desired position This position will indicate the boom angle current value B 5 position 5 Enable the Lower Boom Limitation Angle by using the Jog Dial 5 Figure 4 63 or the Arrow Keys 4 Figure 4 62 to move and select the Enable Di...

Page 248: ... The Switch 4 Figure 4 110 is the Enable Disable Switch and is a toggle switch Click OK 5 Figure 4 62 or the Jog Dial 5 Figure 4 63 to set the switch 5 Use the Jog Dial 5 Figure 4 63 or the Right Arrow Key 4 Figure 4 62 to move and select the Minimum Boom Angle Symbol 6 Figure 4 110 Limitation B Enable the value entry by clicking on OK 5 Figure 4 62 Enter a value by using the Jog Dial 5 Figure 4 6...

Page 249: ... subsequent actions Table 4 9 lists the WRL Limitation Screen Symbols NOTE The Working Radius can be typed in or set by boom position WRL Working Radius Limit Menu The Working Radius Menu allows the operator to set minimum and maximum working radii limits FIGURE 4 111 8882 9c Working Radius Limitation Screen Example Only Display Values May Vary 1 2 3 4 8 5 6 7 Item Description Refer to 1 Minimum R...

Page 250: ...an be used 1 Set the RDM screen parameters first Refer to Using the Rated Capacity Limiter Display Module RDM page 4 158 2 Using the Jog Dial 5 Figure 4 63 go to the ODM Main Menu Screen Then choose the Working Range Limiter WRL Group Menu Icon 5 Figure 4 108 3 Select the Working Radius Limitation Menu Screen 5 Figure 4 108 NOTE The Working Radius Limitation Icon 8 Figure 4 111 is shown on the top...

Page 251: ...th the color orange typically meaning that the object is selected and can be affected by subsequent actions In Figure 4 112 the orange Icon Item 3 symbol is selected since it has the orange color highlighting Table 4 9 lists all of the symbols for the Limitation Menus that are available on the WRL Limitation Screens Setting the Swing Angle Limitation The Swing Angle Menu allows the operator to set...

Page 252: ...on is now defined and enabled Setting Swing Angle Limitation by Value To set parameters and enable the Swing Angle Menu using a typed in value as the limitation the following steps can be used 1 Set the RDM screen parameters first Refer to Using the Rated Capacity Limiter Display Module RDM page 4 158 2 Using the Jog Dial 5 Figure 4 63 go to the ODM Main Menu Screen Then choose the Working Range L...

Page 253: ... to highlight the Switch Enable Disable Symbol 3 Figure 4 112 Enable is I and Disable is O 3 Use the OK Button 5 Figure 4 62 or the Jog Dial 5 Figure 4 63 to toggle to disable the limitation Swing Angle Limitation with Lock Out Function Enabled For cranes that are equipped with the WRL Lock Out Function when the swing angle is within 10 of the swing angle lock out set point Value previously define...

Page 254: ...Arrow 4 Figure 4 62 Function Keys on the Display or the Jog Dial 5 Figure 4 63 changes the object highlighted on the screen As the arrow keys are pressed the highlight will move between the objects with the color orange typically meaning that the object is selected and can be affected by subsequent actions In Figure 4 113 one can see that the wall Point A Symbol is selected since it has the orange...

Page 255: ... B or Item 3 Figure 4 113 NOTE The two points may not be so close to each other that a virtual wall is not clearly defined The two points should be at least 10 ft apart 6 Use the Right Arrow 4 Figure 4 62 Function key to highlight the Accept Crane Position Point B Symbol 3 Figure 4 113 7 Use an OK Button 5 Figure 4 62 to accept the current crane position to be Point B The location of the point sho...

Page 256: ... Figure 4 62 to accept the current crane position to be Point A as shown in Figure 4 113 The location of the point should now be shown on the screen with a label that shows the wall number and the letter a as shown in the yellow highlight in the sample Figure 4 114 7 Position the crane so that the hook is located at the position to define the second point of the Virtual Wall Point B or Item 3 Figu...

Page 257: ...ws 4 Figure 4 62 to alter the Virtual Walls number to the desired value Use an OK Button 5 Figure 4 62 to finish entering the value 5 Use the Left Arrow and or Right Arrow 4 Figure 4 62 keys or the Jog Dial 5 Figure 4 63 to highlight the Enable Disable Switch Symbol 4 Figure 4 113 6 Use an OK Button 5 Figure 4 62 to toggle the symbol to the Limitation being disabled Delete Virtual Walls Limitation...

Page 258: ...he telescoping operation To open Select symbol 1 and confirm menu is opened Figure 4 116 Telescoping Cylinder Locked Released Locking releasing the Telescoping Cylinder FIGURE4 115 1024 4 1 2 3 4 FIGURE 4 116 8882 2e 1 Display Yellow Locking pins intermediate position Figure 4 117 Green Telescoping cylinder locked Red Telescoping cylinder unlocked To lock Telescopic section locked Select symbol 1 ...

Page 259: ... section unlocked To lock Select symbol 2 Figure 4 120 and confirm telescopic section locked To unlock Select symbol 1 and confirm telescopic section is unlocked FIGURE 4 119 10254 44a FIGURE 4 120 10254 44a 1 2 Display Current extended length of the telescoping cylinder Figure 4 121 Unit of measurement Displayed depending on setting mm millimeters or ft feet and percent Display Current extended l...

Page 260: ...ocked there and then the telescoping cylinder can be retracted to the hole The standard emergency program will only allow extending the telescoping cylinder if the boom length is not longer than this particular configuration i e T1 at first locking position and all other boom sections fully retracted and locked If the boom is completely retracted then the telescoping cylinder can be manipulated be...

Page 261: ...n made the Telescoping emergency program is started The emergency program has a time limit The display 1 Figure 4 128 shows the remaining time for operating the emergency program It runs for approx 1000 seconds or 16 minutes The telescoping mechanism can be operated with the emergency program within this time If the time is not sufficient then you must restart the emergency program FIGURE 4 126 88...

Page 262: ...ion the H position for H E L P until a selection is shown prior to the letter A then the digits 0 to 9 will appear Item Description Refer to 1 Enter the password HELP to access the Telescoping emergency program with basic controls To enter the password highlight a letter select Enter to alter the letter dial the new letter and select Enter again 1 2 Select the check mark after entering the passwor...

Page 263: ...re arranged in the same manner The next row S2117N S2118N and S2116N are indicators for the tele cylinder being aligned with a boom section S2117N is shown to the left when the tele cylinder is nearly aligned for instance within 50 mm or 2 inches of the connection and S2117N is ON then the cylinder needs to extend slightly moving the right controller to the right if using the standard joystick arr...

Page 264: ...ylinder operations refer to Items 1 and 2 Item 4 is the indicator for a command to release or re extend pins This command works for both the cylinder pin retracting and the section pin retracting they are connected to the same double acting hydraulic actuation cylinder so it can only release the pins that had been previously retracted whichever they were The arrow buttons on the display or the jog...

Page 265: ...ele cylinder to the configuration where the tele cylinder pinning head can be serviced from the access hole in the base section not to fully retract the boom after failures of sensors or mechanical components NOTE The speed is restricted to approx 30 of the maximum speed Error on Length Indicator If the precision length sensor for the tele cylinder does not show a reasonable value then the second ...

Page 266: ...131 The telescoping cylinder is locked to a telescoping boom section no unlock symbol shown near the graphical representation of the tele cylinder refer to Item 1 in Figure 4 129 The telescoping boom section is unlocked the unlock symbol is shown near the graphical representation of the section pins refer to Item 2 in Figure 4 129 In the top row of the proximity switches S2110N is on the others in...

Page 267: ... section is actually aligned with a pinning hole The screen should appear as shown in Figure 4 132 In particular S2111N should be ON FIGURE 4 132 8854 259a 1 CAUTION Machine Damage Hazard If you select Lock during telescoping the locking pins on the telescopic section are slid out immediately and they can damage or tear the electrical or hydraulic components in the main boom Table 4 1 Locking poin...

Page 268: ...N is on but the others are on or off depending on the location of the tele cylinder with respect to telescoping boom sections You can now move the telescoping cylinder into the next telescopic section refer to Table 4 3 for the expected value for the precision length sensor Item 2 in Figure 4 128 when the tele cylinder is near a connection to a boom section WARNING Risk of Damage to Main Boom You ...

Page 269: ... aligned with a pinning location hole in the boom section The screen should appear as shown in Figure 4 132 You can now operate this telescopic section refer to Retracting and Locking a Telescopic Section page 4 137 Tables for Approaching the Locking Points The extent to which the telescoping cylinder has to be extended in order to reach a locking point depends on whether you want to lock the tele...

Page 270: ... cylinder such as when the switch is malfunctioning or disconnected but this should only be done with physical verification of the location of the telescoping cylinder with respect to the boom nose If the telescoping cylinder impacts the boom nose the boom system will be damaged With the telescoping cylinder not moving and with the controller not being used then the bypass switch Figure 4 138 can ...

Page 271: ... the On position Additional information about the fault can be accessed by first highlighting a fault code then pressing the Additional Information Button 1 Figure 4 141 at the ODM Navigation Control Pad The Additional Information screen Figure 4 142 gives the operator details about the location of the system that is at fault along with an explanation A list of all fault codes and their definition...

Page 272: ...e Application splash screen appears 3 Click CCS The CCS screen appears 4 Complete the following using information from the error code displayed on the ODM Select Crane Type Select the crane model from the dropdown list Component Enter the component information from the fault code Condition Enter the condition information from the fault code Device Enter the device number from the fault code Index ...

Page 273: ...ve Published 3 22 2021 Control 702 02 4 143 GRT8120 OPERATOR MANUAL OPERATING PROCEDURES 4 5 Click Continue The Fault code information is displayed 6 Click OK to return to the main screen 10158 FIGURE4 145 ...

Page 274: ...cannot be cleared by the operator without first correcting the malfunction then cycling the ignition key to the Off position and back to the On position Information Menu Group The Information Menu Group includes the following function icons Operating Hours page 4 144 Software Versions page 4 146 Operating Hours Select the Operating Hours icon 1 Figure 4 148 under the Information Menu Group to show...

Page 275: ... 4 149 9902 21 Item Description Item Description 1 Swing Operating Hours 6 Engine Operating Hours 2 Boom Telescope Operating Hours 7 Transmission Operating Hours 3 Boom Lift Operating Hours 8 Boom Pinning Count 4 Main Hoist Operating Hours 9 Reset All Icon 5 Auxiliary Operating Hours 1 2 4 5 6 8 7 9 3 ...

Page 276: ...at is to be reset hours will turn to an orange hour glass 2 Press the Jog Dial or OK Button on the Navigation Control Pad to reset the hours to zero 0 NOTE Allow up to 8 seconds for the trip meter to reset to 0 0 hours To reset all crane function operating hours and counts to zero 0 select the Reset All icon 9 Figure 4 149 icon will turn orange on the Operating Hours function screen and then press...

Page 277: ... page 4 153 Service Menu page 4 155 Controller Curve Select the Controller Curve icon 1 Figure 4 152 under the User Settings Menu Group to show the Controller Sensitivity function screen The Controller Sensitivity function screen Figure 4 153 allows the operator to adjust the sensitivity of the controllers FIGURE 4 152 10254 4 1 FIGURE 4 153 9902 24 1 2 4 5 3 Item Description Item Description 1 Sw...

Page 278: ...row Buttons on the Navigation Control Pad select the controller function icon that is to be adjusted icon will turn orange 2 Press the Jog Dial or OK Button on the Navigation Control Pad to make the controller function icon active icon background will turn gray 3 Using the Jog Dial or the Up Down Arrow Buttons select one of the five possible sensitivity curves Figure 4 156 4 Press the Jog Dial or ...

Page 279: ... Speed icon 1 Figure 4 157 under the User Settings Menu Group to show the Controller Speed function screen The Controller Speed function screen Figure 4 158 allows the operator to adjust the crane function speeds relative to the position of the controllers Adjustment is made as a percentage of full rated speed FIGURE 4 157 10254 4 1 ...

Page 280: ... the desired setting Adjustments are made in 1 increments decrements To quickly make large adjustments hold down the Jog Dial while rotating it 4 Press the Jog Dial or OK Button to accept the new setting Select the Reset All icon 5 Figure 4 158 on the Controller Speed function screen and press the Jog Dial or the OK Button to set all function speeds to the factory default setting of 100 NOTE A cra...

Page 281: ...the ECO Mode function to on or off The Idle Speed 1 Time Delay Setting 2 is used to specify the period of time the craning functions must be inactive controllers in neutral position before the engine speed is reduced from the operator specified working engine speed to the idle speed of 950 rpm The Idle Speed 2 Time Delay Setting 3 is used to specify the period of time the craning functions must be...

Page 282: ...a craning function is operated controller is moved out of neutral position Engine speed will stay at the Working Engine Speed while craning functions are operated Engine speed will automatically decrease to the idle speed of 950 rpm after all craning functions have stopped controllers in neutral position and the time period that was specified in the Idle Speed 1 Time Delay Setting 2 Figure 4 160 h...

Page 283: ...The Boom Position Indicator Light function screen Figure 4 163 allows the operator to switch the boom Position indicator light on and off Switching on Select symbol 1 Figure 4 163 and confirm Switching off Select symbol 2 and confirm Exhaust System Cleaning If Equipped Select the Exhaust System Cleaning icon 1 Figure 4 164 under the User Settings Menu Group to show the Exhaust System Cleaning func...

Page 284: ...un at this speed for up to 45 minutes As a warning the strobe light 1 Figure 4 166 near the exhaust pipe 2 will flash during exhaust system cleaning Pressing the service brake pedal or throttle pedal during cleaning or selecting the Inhibit Cleaning Process Icon 2 Figure 4 165 will interrupt the manual cleaning process Make sure the crane and surrounding area are monitored during manual cleaning I...

Page 285: ... Press the Jog Dial or OK Button on the Navigation Control Pad to set the cleaning process to inhibit Inhibit Cleaning Process Icon changes to green The Inhibit Exhaust System Cleaning Indicator comes on in the Alerts Area of the ODM and the active and manual modes of exhaust system cleaning are prevented Service Menu Select the Service Menu icon 1 Figure 4 168 under the User Settings Menu Group t...

Page 286: ...ial or Arrow Buttons on the Navigation Control Pad to select the desired unit of measure then press the Jog Dial or the OK Button to accept the new setting Display Screen Brightness Select the Display Screen Brightness icon 1 Figure 4 171 under the Display Settings Menu Group to show the Display Screen Brightness function screen The Display Screen Brightness function screen Figure 4 172 allows the...

Page 287: ...Offsets To set the time and time format do the following 1 Using the Jog Dial or Arrow Buttons on the Navigation Control Pad select the UTC Offset field 1 Figure 4 174 2 Press the Jog Dial or the OK Button 3 Turn the Jog Dial or press the Up Down Arrow Buttons until the correct UTC Offset is shown 4 Press the Jog Dial or OK Button to accept the value 5 Using the Jog Dial or Arrow Buttons select th...

Page 288: ...y boom nose installed in the RCL The predicted radius will be that of the main boom nose and the mass of the auxiliary boom nose will be considered part of the load Enter Rigging Code For a complete rigging code input operator must enter confirm and accept the rigging code and the reeving There are two ways of entering the current rigging mode Either enter the individual components 1 Figure 4 176 ...

Page 289: ...g on Input Mode Select one of the desired components 1 Figure 4 177 to 4 The corresponding symbol goes orange Confirm the selection Direction arrows appear on the display Input mode is switched on Selecting Values With the input mode switched on you can select values that are permissible according to the Lifting Capacity Table The selection process is described using reeving as an example Select a...

Page 290: ...irm a symbol 1 for the next component symbol orange Accept the displayed rigging mode Select and confirm the symbol 2 refer to Accepting the Rigging Code page 4 163 Enter the other components of the current rigging mode in the same way Counterweight Select and confirm the symbol 1 Figure 4 182 Use the buttons 2 or 3 to select the required counterweight combination e g 0 0 klb Confirm the selection...

Page 291: ...183 to select the rigged boom system Confirm each selection Outrigger Span Select and confirm the symbol 1 Figure 4 184 Use the buttons 2 or 3 to select the rigged outrigger span Confirm the selection 2 Main boom 3 Main boom with boom extension 4 Angle of the manual boom extension 5 Length of boom extension FIGURE 4 183 5 2 3 4 1 10254 50a FIGURE 4 184 1 8849 36a 10254 51a ...

Page 292: ... 2 Verifying that the chosen outrigger beam position is the one to use even though it doesn t match the OMS in which case the screen transitions to the main viewing screen Swing Range Select and confirm the symbol 1 Figure 4 186 Use the buttons 2 or 3 to select the required swing range e g 360 Confirm the selection DANGER When the OMS system is overridden the RCL will not provide protection from o...

Page 293: ...ode Now you can enter the reeving and accept the rigging mode Selecting the Hoist and Entering the Reeving Entering the reeving does not have an effect on any other component that has already been entered Position the slider bar 3 Figure 4 188 over the top of the hoist that is to be used Example screen shot in Figure 4 188 shows the Main Hoist is selected Confirm the selection Use the buttons 4 Fi...

Page 294: ...d and locked then a Telescoping Mode Number may be selected 1 Figure 4 190 Entering this option allows the up down or jog dial to be used to select from an available list of these mode numbers After this selection and using the check mark again on the rigging screen the telescoping function will commence for the requested telescoping status based on the mode number WARNING Overload Tipover Hazard ...

Page 295: ...er rigging mode 3 menu You can start working with the crane if the correct rigging mode of the crane is displayed Example of how to Switch over the Hoists The load is planned to be raised with the auxiliary hoist for example However the hoist indicator 2 Figure 4 194 for the main hoist is on and the indicator 2 for the auxiliary hoist is off WARNING Overload Tipover Hazard The RCL is an operator a...

Page 296: ...the auxiliary hoist indicator The hoist indicator will now be displayed above the auxiliary hoist icon 1 Figure 4 194 10254 48a FIGURE 4 194 1 2 WARNING Overload Hazard When operating the crane with two hoists reeved ensure that the hoist in use is identified in the RCL configuration Failure to do so may result in overload of the hoist line or crane Death or Serious Injury could occur ...

Page 297: ...ed outrigger cylinders on the largest outrigger span The value is displayed either in meters m or in feet ft depending on the setting Current Lattice Extension Angle Lifting lowering lattice extension Shows the current lattice extension angle 1 Figure 4 196 in relation to the main boom in degrees Lattice extension can be angled Shows the angle of the lattice extension corresponding to the RCL code...

Page 298: ...sitive 0 to 180 Currently Raised Load The display Figure 4 200 shows the sum of the payload lifting gear hook block Maximum Load The display Figure 4 201 shows the maximum load that can be lifted in the current rigging mode with the current working radius Degree of Utilization The degree of utilization shows the weight of the current load as a percentage of the maximum possible load Display 2 Figu...

Page 299: ...04 Greater than 100 indicator 5 will illuminate solid Lamp 6 will illuminate Display 3 shows the current degree of utilization e g 100 the bar is red The value on display 1 is equal to or greater than the value on display 2 Canceling a Shutdown Turn off the buzzer tone if necessary Leave the shutdown range by moving the crane according to the following table 1 In some cases the RCL will also switc...

Page 300: ...it Bypass Switch Non CE Certified Cranes page 3 10 2 Limit Bypass Set Up Switch CE Certified Cranes page 3 10 A Limit Bypass Switch is also located in the cab behind the operator s seat on non CE certified cranes and on the outside rear of the cab on CE certified cranes 3 Maintained Limit Bypass Switch Non CE Certified Cranes page 3 37 4 Bridging Switch CE Certified Cranes page 3 42 When a Limit B...

Page 301: ...Grove Published 3 22 2021 Control 702 02 4 171 GRT8120 OPERATOR MANUAL OPERATING PROCEDURES 4 FIGURE 4 206 10254 56a 1 2 3 4 5 6 7 8 10 12 13 11 9 ...

Page 302: ...ve been bypassed by way of the Limit Bypass Switch located behind the operator s seat on non CE certified cranes or inside a key locked single door enclosure attached to the outside rear of the operator s cab on CE certified cranes Refer to Maintained Limit Bypass Switch Non CE Certified Cranes page 3 37 or Bridging Switch CE Certified Cranes page 3 42 for more information on the switch s operatio...

Page 303: ...ad Chart Alert Indicates there is no load chart available for the boom extension but the boom extension has been chosen in the RCL 12 Curve Chart Point Error Alert Indicates there is no load chart found for the given crane configuration off chart 13 Status Light Bar Alert CE cranes Indicates the system setting for CE cranes is disabled but the system setting for the outside light bar is enabled Ac...

Page 304: ...operating the Outrigger Position View will show on the Main Screen Select and confirm the Hoist Camera View Icon 3 Figure 4 207 to enable or disable the hoist camera view The Hoist Camera View can also be set to show continuously in full screen on the RDM Figure 4 209 The full screen view of the hoist camera is enabled in the Menu Screen of the RDM The operator can access the Menu Screen from the ...

Page 305: ...21 Control 702 02 4 175 GRT8120 OPERATOR MANUAL OPERATING PROCEDURES 4 From the Menu Screen select and confirm the Hoist Camera Icon 1 Figure 4 209 to open the full screen view of the hoist camera 2 FIGURE 4 209 10254 58a 2 1 ...

Page 306: ... Grove crane is the Load Chart Manual in the crane operator s cab NOTE Refer to Figure 4 210 for terms to know in determining lifting capacities The Load Chart Manual contains crane lifting capacities in all allowable lifting configurations and must be thoroughly understood by the operator The left column is the load radius which is the distance from axis of crane rotation to load center of gravit...

Page 307: ... kg 5000 lb needs to be lifted to a height of 9 1 m 30 ft at a radius of 15 2 m 50 ft maximum The range diagram indicates the boom must be extended to 18 9 m 62 ft to reach a height of 9 1 m 30 ft at a radius of 15 2 m 50 ft First check the crane for load handling devices In our example the crane is equipped with a auxiliary boom nose rooster sheave and a five ton overhaul ball The rooster sheave ...

Page 308: ...ld be left while unattended shall be determined by a qualified designated individual familiar with the job site configuration conditions and limitations LONG TERM STORAGE Guidelines for tires on cranes parked for long periods 1 If possible set crane up on outrigger jacks that are not fully extended to allow for thermal expansion and remove the load from the tires If the crane cannot be placed on o...

Page 309: ... 25 About the Boom Extension Group in the ODM 5 26 Installing the Folding Boom Extension 5 30 Removing the Folding Boom Extension 5 34 Erecting the 17 6 m 57 6 ft Boom Extension 5 35 Erecting the Fly Section 5 39 Stowing the Fly Section 5 41 Stowing the 17 6 m 57 6 ft Boom Extension 5 42 Erecting the 10 5 m 34 5 ft Boom Extension Base Section Only 5 45 Stowing the 10 5 m 34 5 ft Boom Extension Bas...

Page 310: ...cidental opening during transportation After transporting the crane place these components into their working positions 10086 1 3 2 4 6 6 7 7 8 FIGURE 5 1 5 10 Item Description Page 1 Hoist Camera page 5 3 2 Hoist Platform page 5 4 3 Beacon Lights Optional page 5 5 4 Cab Mirrors page 5 6 5 RCL Light Tower Optional page 5 7 6 Access Ladders page 5 8 7 Outrigger Floats page 5 9 8 Hydraulic Hose Drum...

Page 311: ...ractable lock 2 in the locked position to secure the hoist camera in the transport position 3 Lower the rear and side hoist platform railings For more information see Hoist Platform page 5 4 Raising the Hoist Camera for Operation 1 Raise the side and rear hoist platform railings For more information see Hoist Platform page 5 4 2 Pull the retractable lock 2 Raise the hoist camera 1 3 Push the retra...

Page 312: ... to secure the railing in the lowered position 6 Remove pins 4 and lower the side railing 2 Use pins to secure the railing in the lowered position Raising the Hoist Access Railings for Operation 1 Remove pins 4 and raise the side railing 2 Use pins 4 to secure the railing in the raised position 2 Remove pins 3 and raise the rear railing 1 Use pins 3 to secure the railing in the working position 3 ...

Page 313: ...ar of the superstructure The beacons must be lowered for transport and raised for operation Lowering the Beacon Light for Transport 1 Loosen the wing nut 2 Lower the beacon light 1 2 Tighten the wing nut 2 to secure the beacon light 1 in the transport position Raising the Beacon Light for Operation 1 Loosen the wing nut 2 Raise the beacon light 1 2 Tighten the wing nut 2 to secure the beacon light...

Page 314: ... for the top 1 and side 2 cab mirrors The operator can use the top cab mirror to view the hoists and the side mirror to view behind the left side of the cab The cab mirrors must be retracted for stowed and moved to working position for operation Working Position Transport Position Working Position Transport Position 1 2 FIGURE 5 5 9930 9929 9931 9932 ...

Page 315: ...d position Align the retract position hole 5 in the tower post with the hole in the mounting bracket 3 Install the pin 3 in the mounting bracket 4 and tower post Secure the pin with the retaining clip 2 Extending the RCL Light Tower for Operation 1 Remove the retaining clip 2 and pin 3 from the mounting bracket 4 2 Slide the RCL light tower 1 up to the extended position Align the extend position h...

Page 316: ...must be lowered during operation Raising the Access Ladder for Transport 1 Remove retaining clips 3 and pins 2 2 Raise the ladder 1 in to transport position 3 Install pins 2 Install retaining clips 3 to secure the pins Lowering the Access Ladder 1 Remove retaining clips 3 and pins 2 2 Lower the ladder 1 3 Install pins 2 Install retaining clips 3 to secure the pins 1 3 2 Working Position FIGURE 5 7...

Page 317: ...ighs approximately 30 kg 65 0 lbs 1 Hold the handle 4 and remove pins 3 from posts 2 2 Remove the outrigger float 1 from stowage posts 2 on the outrigger box 3 Install pins 3 in stowage posts 2 Hydraulic Hose Drum Optional If installed on the boom the hydraulic hose drum must be secured before transport For more information see Checking the Locking Device on the Hose Drum page 5 52 Boom Position I...

Page 318: ...edge in wedge block Pull firmly on inside hoist side of cable to secure the wedge 5 If wedge does not seat securely in slot carefully tap cable and top of wedge 7 with a mallet 6 Slowly rotate drum and evenly wind first layer of cable 7 Install remainder of cable as required ANTI TWO BLOCK A2B SWITCH Two anti block switches must be installed to allow crane operation If a single hoist rope has been...

Page 319: ...st rope With odd numbers of rope lines the lifting limit switch weight shall be attached to the rope line with the lowest operating speed If the crane is operated with a main boom extension or lattice insert the connecting cable must be mounted between the connector on the boom extension or lattice insert and the connector on the main boom The main boom A2B switch weight must be disconnected and m...

Page 320: ...n 4 Slowly lower the boom to bring about a potential two block situation As soon as the hook block raises the weight the acoustic alarm should sound the A2B indicator should display and boom lower should switch off Lower the hook block slightly to eliminate this condition 5 Slowly extend telescope out the boom to bring about a potential two block situation As soon as the hook block raises the weig...

Page 321: ...TMS9000 2 depends on the rope pull the reeving and friction force It is lower than the load bearing capacity of the hook block NOTE Please note that the maximum load bearing capacities already include the weight of the hook block and the lifting gear You must subtract these weights in order to obtain the actual payload NOTE The recommended hook blocks are designed to be of sufficient weight to ove...

Page 322: ...2 02 SET UP AND INSTALLATION GRT8120 OPERATOR MANUAL 3 sheave hook block 1 sheave hook block Reeving A 7 parts line B 6 parts line C 5 parts line D 4 parts line FIGURE 5 13 Reeving A 3 parts line B 2 parts line C 1 parts line FIGURE 5 14 ...

Page 323: ...702 02 5 15 GRT8120 OPERATOR MANUAL SET UP AND INSTALLATION 5 Hook tackle Auxiliary Boom Nose Reeving A 1 part line FIGURE 5 15 FIGURE 5 16 9137 Reeving A 1 part line B 2 part line C 12 part line FIGURE 5 17 9137 1 FIGURE 5 18 9137 2 C ...

Page 324: ...5 16 Published 3 22 2021 Control 702 02 SET UP AND INSTALLATION GRT8120 OPERATOR MANUAL FIGURE 5 19 Boom Extension Shown at 20 Offset 8996 3 Boom Extension Shown at 45 Offset 8996 4 ...

Page 325: ...re the auxiliary hoist rope is over the rope guide For more information see Reeving Hoist Rope Over the Boom page 5 17 2 Remove the retaining rods 1 Figure 5 22 3 Guide the rope over the upper boom nose sheave 2 4 Guide the rope over the lower boom nose sheave 3 5 Install the hook tackle or the hook block 6 Reinstall all the retaining rods 1 and secure with retaining clips CAUTION Reeve only the m...

Page 326: ...e it manufactures Other hoist ropes and rigging accessories are available from various vendors Different hoist rope manufacturers have differing requirements for construction handling cutting seizing installation termination inspection and replacement of hoist ropes they produce Their advice should be sought for each specific type of hoist rope a crane user intends to install on a mobile crane Whe...

Page 327: ...ope the dead end tail length must be a minimum of 20 rope diameters but not less than 15 2 cm 6 in When using method A place a hoist rope clip around the dead end by clamping a short extra piece of rope to the rope dead end DO NOT CLAMP LIVE END U bolt should bear against the dead end Clip saddle should bear against the short extra piece Torque U bolts to values listed in NOTE Use of swivels is no...

Page 328: ...ffset mechanism for offsets of 0 to 45 degrees All boom extensions are built specifically for the crane with which they were sold Each extension is stamped with the crane s serial number To use a single boom extension on several Grove cranes contact Manitowoc Crane Care or your authorized Grove Distributor DANGER To prevent serious injury or death always wear personal protective equipment i e a ha...

Page 329: ...3 is extended When the front mounting pin is retracted no signal is sent to the control system Boom Nose Installation Pins The boom nose installation pins 4 Figure 5 26 are used as a pivot to erect the boom extension on to the boom nose and stow the boom extension on the side of the boom base section Mechanical interlock pins 6 lock and unlock the installation pins 4 based on the position of the f...

Page 330: ... pin 3 Handle up The front mounting pin 3 is extended in the front mounting bracket and the boom nose installation pins 4 are unlocked Handle down The front mounting pin 3 is retracted and the installation pins 4 are locked The handle is also used to manually release the front boom extension mounting pin interlock so that the boom extension can be removed from the crane FIGURE 5 26 2 1 3 5 Install...

Page 331: ...ounting bracket 1 Figure 5 27 The boom extension base section is pinned to the fly section The fly section is secured to the side of the main boom with the electrically actuated pin 2 Front Boom Extension Mounting Bracket Located nearest the boom nose is the front boom extension mounting bracket 6 Figure 5 27 The boom extension base section is secured to the side of the main boom with the electric...

Page 332: ...om Extension Mounting Bracket 2 Rear Boom Extension Pin 3 Rear Mounting Pin Sensor 4 Rear Boom Extension Side Sensor 5 Boom Nose Sensor 6 Front Boom Extension Mounting Bracket 7 Front Mounting Pin Sensor 8 Front Boom Extension Side Sensor 9 Middle Fly Section Mounting Bracket 10088 2a 10088 1 10088 5b 10088 4b 1 2 3 4 10088 3a 6 7 8 5 9 ...

Page 333: ...b For more information see Boom Extension Pin Interlock Mechanism page 5 21 Front Side Sensor 8 Figure 5 27 Sends a signal to the crane control system when the boom extension base section is against the front stowage bracket Boom Nose Sensor 5 Figure 5 27 Sends a signal to the crane control system when the boom extension or auxiliary boom nose is in the erected position Signals from the sensors ap...

Page 334: ...bout the Alerts Area Active Screen Indicator Area and Status Bar see Using the Operator Display Module ODM page 4 68 Table 5 2 Boom Extension Group Icons Item s Icon Description 1 and 2 Boom Extension Rear or Front Mounting Pin Locked Selected 1 and 2 Boom Extension Rear or Front Mounting Pin Unlocked Selected 1 and 2 Boom Extension Rear or Front Mounting Pin Unlocked Unselected 5 3 4 2 1 FIGURE 5...

Page 335: ...Boom Extension Deployment Stowage icon 1 Figure 5 30 3 Press the OK button on the ODM navigation pad or press down on the jog dial to select the Boom Extension Deployment Stowage icon The Boom Extension Deployment Stowage function screen Figure 5 29 1 and 2 Boom Extension Rear or Front Mounting Pin Locked Unselected 1 Rear Boom Extension Mounting Pin pin 1 2 Front Boom Extension Mounting Pin pin 2...

Page 336: ...entify an inconsistency relative to normal operation one of two possible warning screens will appear If a screen shows with three question marks Figure 5 31 the system has identified that either Pin 1 or Pin 2 is not in the proper locked unlocked condition for the activity taking place This can result in damage to the boom extension or boom extension stowage system DANGER Boom Extension Hazard Usi...

Page 337: ...Alert anyone near the crane to move away from the boom extension 3 Determine if the extension is properly secured and supported at all required locations and then determine if the issue causing the error can be resolved safely before continuing If additional assistance is needed contact your Grove Distributor or Manitowoc Crane Care for help DANGER Falling Boom Extension Hazard If the fly section ...

Page 338: ... Using the Outriggers page 4 19 3 Fully retract and lower the boom to horizontal 4 Attach a tag line to the end of the boom extension base section with the nose sheave 5 Make sure the connecting link 1 Figure 5 33 is in place that connects the fly section to the boom extension base section 6 Make sure the attachment pin 1 Figure 5 34 and retaining clip are in place that connects the ends of the fl...

Page 339: ...tension installation pins 4 in the holes in the boom nose using an impact driver turning the jack screw 3 counterclockwise 11 Lower the front mounting pin handle 1 Figure 5 36 to lock the boom extension installation pins 12 Remove pins 5 Figure 5 39 and retaining clips 6 from the stowage bracket Secure the boom extension to the boom nose using four pins 5 inserted through the boom extension anchor...

Page 340: ...ydraulic Boom Extension Connections page 5 52 16 Remove the slings from the boom extension 17 Raise the mast sheave assembly For more information see Folding Mast Sheave page 5 59 18 Reeve the hoist rope For more information see Reeving the Hoist Rope page 5 55 19 Remove the anti two block switch from the auxiliary boom nose For more information see Anti Two Block A2B Switch page 5 10 Install the ...

Page 341: ...Grove Published 3 22 2021 Control 702 02 5 33 GRT8120 OPERATOR MANUAL SET UP AND INSTALLATION 5 FIGURE 5 39 10088 7b 3 4 4 6 5 1 1 1 1 2 2 2 2 ...

Page 342: ...liary crane attach the auxiliary crane to the boom extension attaching points For more information about attaching points for the sling see Lifting Points page 5 25 7 Attach a tag line to the end of the boom extension base section with the nose sheave 8 Lower the mast sheave assembly For more information see Folding Mast Sheave page 5 59 9 Disconnect and stow the boom extension electrical connecti...

Page 343: ...1 5 If erecting a hydraulic boom extension connect hydraulic hoses For more information see Hydraulic Boom Extension Connections page 5 52 6 If erecting an optional hydraulic boom extension make sure the angle indicator 1 Figure 5 41 is aligned If the arrows are not aligned adjust the boom extension offset as needed to align the arrows For more information see Offsetting the Optional Hydraulic Boo...

Page 344: ...tension base section together 10 Tie a tag line to the end of the boom extension base section The tag line will assist when swinging the boom extension to the boom nose 11 Retract the retaining pin 1 Figure 5 45 from the bracket 2 to release the rear boom extension ramp 3 from the stowed position Fully swing the rear boom extension ramp 3 into the erected position Make sure the pin 4 locks into po...

Page 345: ...ess and hold the OK on the ODM control pad or press down on the jog dial The lock status icon turns yellow indicating the pin is retracted Figure 5 49 14 Visually confirm that the rear mounting pin is unlocked 15 Using the tag line swing the boom extension out on the rear ramp so the boom extension installation pins 4 Figure 5 39 align with the holes in the boom nose attachment fittings 16 With an...

Page 346: ... installation pins are locked NOTE The front mounting pin Pin 2 will not unlock unless the right side boom extension installation pins are fully engaged If the front boom extension pin Pin 2 does not unlock make sure the right side boom extension installation pins are fully engaged and the interlock pins are inserted through the pins 19 Slightly raise and or lower the boom to help control the boom...

Page 347: ...ve assembly For more information see Folding Mast Sheave page 5 59 24 Erect the boom extension fly section following the procedures under Erecting the Fly Section page 5 39 Erecting the Fly Section Use this procedure to erect the boom extension fly section NOTE This procedure assumes the boom extension is erected and fly extension is folded on the boom extension base section 1 Make sure the connec...

Page 348: ...cation b Connect the plugs 1 Figure 5 58 to the sockets making sure the plug wire number corresponds to the socket number 6 Slightly raise and or lower the boom to help control the boom extension Using the tag line swing the fly section around and engage the fly section attachment fittings 1 Figure 5 59 with the base section anchor fittings 2 7 Remove the pin 3 Figure 5 59 from its holder on the b...

Page 349: ...on mast sheave assemblies For more information see Reeving the Hoist Rope page 5 55 3 Install the anti two block switch on the end of the boom extension base section For more information see Anti Two Block Switch on the Boom Extension page 5 58 4 If installed disconnect and remove wind speed indicator and boom position light assembly from the end of the fly section For more information see Anemome...

Page 350: ...more information about installing the counterweight see Counterweight Removal and Installation page 5 66 3 Fully retract and lower the boom to horizontal 4 If necessary adjust the boom extension offset to 0 depending on the type of boom extension If stowing a mechanical boom extension make sure the offset is set to 0 For more information see Offsetting the Mechanical Boom Extension page 5 56 or If...

Page 351: ...ti two block switch on the auxiliary boom nose For more information see Anti Two Block A2B Switch page 5 10 9 Stow the mast sheave assembly For more information see Folding Mast Sheave page 5 59 10 Attach a tag line to the end of the boom extension base section 11 Make sure the boom extension installation pins 4 Figure 5 39 are engaged 12 Remove the four pins 5 Figure 5 39 and retaining clips 6 th...

Page 352: ...played in the intermediate installation position 16 Make sure the ODM shows that the front mounting pin Pin 2 is extended Visually confirm that the front mounting pin is securely installed and the handle is in the up position before continuing 17 Lower the boom to a horizontal position 18 Turn the jack screw 3 Figure 5 39 clockwise with the impact wrench extension and 14 mm impact socket to retrac...

Page 353: ... 23 Remove tag line 24 Disconnect boom extension electrical connections For more information see Boom Extension Electrical Connections page 5 51 25 If stowing a hydraulic boom extension disconnect hydraulic hoses For more information see Hydraulic Boom Extension Connections page 5 52 Erecting the 10 5 m 34 5 ft Boom Extension Base Section Only Use the following procedure to erect the boom extensio...

Page 354: ...page 5 57 6 In the ODM verify that the front Pin 2 and rear Pin 1 boom extension pins are securely installed Visually confirm that the pins are installed 7 Attach a tag line to the tip of the boom extension base section near the sheave The tag line will assist when swinging the boom extension to the boom nose 8 Detach the fly section from the boom extension base section by removing the retaining c...

Page 355: ...pad or press down on the jog dial The lock status indicator icon turns yellow indicating Pin 2 is retracted 15 Visually confirm that the front boom extension pin Pin 2 in the ODM is unlocked The boom extension interlock handle should be in the down position When the handle is in the down position the front mounting pin is retracted and the boom installation pins are locked NOTE The front mounting ...

Page 356: ...w the boom extension base section to the side of the main boom NOTE This procedure assumes only the boom extension base section is erected and the fly section is secured to the side of the main boom NOTE The boom extension base section cannot be stowed if the fly section is not first stowed on the side of the main boom 1 Make sure the crane is set up on fully extended outriggers For more informati...

Page 357: ... 6 on the boom extension stowage bracket 12 Slightly raise and or lower the boom to help control the boom extension Using the tag line swing the boom extension to the intermediate position on the side of the base section of the boom Make sure the wheels engage on the front and rear boom extension ramps 13 Raise and lower the boom as needed to move the boom extension in against the main boom so the...

Page 358: ...sition 18 Remove the pin from its holder on the boom extension base section Attach boom extension base section to fly section by installing the pin 2 Figure 5 70 and securing it with the retaining clip 1 19 Attach the fly section to the boom extension base section using the connecting link 1 Figure 5 71 Secure connecting link with pin 3 and retaining clip 2 20 Disconnect electrical connections For...

Page 359: ... the socket 4 This connects the extension to the main boom circuit 2 Wind the cable around the storage location 3 such that it will not be damaged during crane operation Disconnecting Electrical Connection at Boom Nose Use the following procedure to disconnect the boom extension electrical connector 1 Figure 5 72 from the electrical connector on the boom nose Be sure to stow the boom extension ele...

Page 360: ...sengage it from the hole Locking the Drum 1 Turn the hose drum until a hole is aligned with the latch 2 Figure 5 73 2 Rotate the latch 2 counterclockwise to position B until the latch fully engages the hole Hydraulic Hose Installation 1 Unlock the hose drum 2 Remove the hinged pins 1 Figure 5 74 and fold up the guide sheaves 2 3 Remove the strain relief 3 from its main boom mounting bracket 4 and ...

Page 361: ...ulic Connection 1 If necessary bring the connections 1 Figure 5 76 into the position for boom extension operations 2 Remove the hose line 2 from the clamp 4 3 Feed the hose lines towards the left hand side through the lower opening 3 in the boom extension base section under the boom head 4 Remove the protective caps to the connections 1 and attach the hose lines observe color code FIGURE 5 74 1 2 ...

Page 362: ...ERATOR MANUAL Disconnecting the Hydraulic Connection 1 Remove the hose lines 2 Figure 5 77 from the connections 1 2 Close off the hose lines and the connections 1 with the protective caps 3 Secure hoses in holder 3 on the boom extension base section 7567 38 1 2 3 FIGURE 5 77 ...

Page 363: ...tall the overhaul ball or the hook block Unreeving Hoist Rope 1 Unreeve the hook block or unpin the overhaul ball 2 Remove the retaining clips and rope retaining pins 1 Figure 5 78 3 Take the hoist rope off the nose sheave 2 and mast sheave 3 and place it on the ground on the left side 4 Replace all rope retaining pins 1 Secure with retaining clips CAUTION Falling Objects Hazard Always make sure s...

Page 364: ...with the retaining clip If offset is to be 45 remove pin and store in the operator cab 4 Lower the boom extension with the auxiliary crane and remove the lifting gear When setting a 45 offset if the boom extension now touches the ground at the current angle the angle will set itself when the main boom is raised WARNING Crushing Hazard Always secure the adjustable boom extension with an auxiliary c...

Page 365: ...lining the Crane In order to set the offset angle of the adjustable extension you must set it down on the ground by extending and lowering the main boom over the rear Depending on the space available the condition of the terrain or a limitation on the telescoping due to the current rigging mode it may be that the nose of the boom extension cannot be set on the ground by telescoping and lowering th...

Page 366: ...or 17 6 m 57 6 ft extension operation the anti two block switch must be removed 1 Remove the anti two block connector from the socket 2 Install the cap on the storage socket 3 Remove the retaining clip from the mounting pin and remove the anti two block switch assembly The anti two block switch can now be moved to another location and connected 17 6 m 57 6 ft Extension Anti Two Block Installation ...

Page 367: ...he handle 2 Figure 5 82 and pull out the pin 1 3 Fold the mast sheave 1 up and fasten it in this position with the pin 2 Figure 5 83 4 Secure the pin 2 using the retaining clip Stowing Mast Sheave 1 Remove the retaining clip from the pin 2 Figure 5 83 2 Hold the mast sheave by the handle 3 and pull out the pin 2 3 Fold the mast sheave 1 down and fasten it in position with the pin 2 4 Secure the pi...

Page 368: ... attached to the lifting eye 3 on the auxiliary boom nose and lift it to the front of the main boom head 3 Align the auxiliary single sheave boom nose so that the attachment lugs 1 Figure 5 85 line up to the boom nose attachment lugs 2 4 Secure the auxiliary single sheave boom nose to the main boom nose using pins 3 5 Secure the pins 3 with retaining clips 4 6 Depending on the application bring th...

Page 369: ...3 Figure 5 85 In the transport position the auxiliary single sheave boom nose is positioned to the side of the main boom head and is fastened with two pins 1 Attach an auxiliary crane to the lifting eye of the boom nose 2 Remove the retaining clips and remove all the pins out of the bores and lugs 3 Lift the auxiliary single sheave boom nose from the head of the main boom FIGURE 5 85 8994 1 1 2 3 ...

Page 370: ... sheave boom nose to the front of the main boom head so the pin 7 can be inserted and secured with a retaining clip 3 Remove the retaining clip and take out the pin 6 4 Swing the auxiliary boom nose into position in front of the main boom head Insert pins 3 into the lugs and secure with the retaining clips The auxiliary single sheave boom nose is now in working position Attaching and Removing Hois...

Page 371: ...es in such a way that they will not be damaged during crane operation Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised Switching the boom position indicator light on and off CAUTION Machine Damage Always remove the anemometer and boom position indicator light before on road driving This prevents the specified overall height being exceeded at ...

Page 372: ...boom position indicator light before driving on the road Switch off the boom position indicator light Remove the plug and close the sockets 4 Figure 5 88 and 5 with the protective caps Wind the cables on to the holders 2 Remove the rod 1 from the holder 3 For transportation fasten the retaining pins to the rod 1 FIGURE 5 88 8851 46 ...

Page 373: ... 02 5 65 GRT8120 OPERATOR MANUAL SET UP AND INSTALLATION 5 FIGURE 5 89 2 1 3 4 5 6 Item Description 1 Mounting Arm 2 Holder 3 Clamps 4 Anemometer Connector 5 A2B Switch Connector 6 Boom Position Light Connector 10012 10013 10023 4 6 5 5 2 ...

Page 374: ...n clips Counterweight is lowered or lifted from two centering pins located on the rear deck DANGER Falling counterweight can crush and cause death or serious injury Ensure all mounting pins are properly installed and locked during and after operating the counterweight removal system DANGER Travel is not permitted with removable counterweight on carrier deck FIGURE 5 90 1 2 4 5 6 7 8658 1 3 Item De...

Page 375: ...or system not enabled NOTE The horn button 3 is always active Enable does not have to be pressed before using the horn The Enable button 2 must be pressed and released before selecting a function The function must be selected within five seconds after pressing the Enable button or the system will time out and the Enable button must be pressed again If the Enable button is pressed and held for more...

Page 376: ...d release Enable button 2 Press and hold Left 8 and Right 9 Counterweight Cylinder Lift buttons until cylinder rods are completely retracted Reinstall retaining pins and lock pins NOTE Do not leave cylinder rods extended Corrosion or other damage may occur 10 Release turntable lock Rotate superstructure 90 for clear access to rear deck NOTE Counterweight weighs 13 245 kg 29 200 lb 11 Lift counterw...

Page 377: ...se Enable button 2 Press and hold Left 8 and Right 9 Counterweight Cylinder Lift buttons until counterweight engages superstructure and lock cylinder holes are aligned with lock cylinder rods on both sides NOTE Operate left or right cylinder as needed to align lock cylinder holes with lock cylinder pins 10 Press and release Enable button 2 Press and hold Lock Cylinder Extend button 5 until lock cy...

Page 378: ...5 70 Published 3 22 2021 Control 702 02 SET UP AND INSTALLATION GRT8120 OPERATOR MANUAL THIS PAGE BLANK ...

Page 379: ... CraneLUBE 6 10 Cummins Oil Registration List 6 10 Safety 6 10 Drive Train 6 12 Steering and Suspension Meritor Axles 6 18 Steering and Suspension Kessler Axles 6 18 Steering and Suspension Fifth Wheel Pivots 6 20 Axle Lubrication Meritor Axles 6 22 Axle Lubrication Kessler Axles 6 24 Turntable Swing Drive and Cab Tilt Lubrication 6 26 Outrigger Lubrication 6 30 Lift Cylinder Lubrication 6 32 Boom...

Page 380: ...water Always drain waste fluids into leak proof containers that are clearly marked with what they contain Always fill or add fluids with a funnel or filling pump Immediately clean up any spills LUBRICANTS AND LUBRICATION INTERVALS Use lubricants as listed in this section of the Operator Manual See also your GRT8120 Service Manual for maintenance and lubrication instructions Grove recommends the us...

Page 381: ...l SAE EO 15W 40 6829104182 Conoco Fleet Supreme EC Mobil Delvac 1300 Super Mobil Delvac MX ESP 15W 40 CJ 4 Hydraulic Transmission Oil 6829006444 Phillip 66 PowerTran XP Exxon Mobil 424 ISO 46 68 Must meet John Deere Standard JDM J20C Extreme Pressure Swing Drive Gearbox Brake Assembly Oil 6829100213 Mobil Mobilgear 600XP 150 Gear Oil Texaco Meropa 150 Phillips 66 Extra Duty Gear Oil AGMA EP 4 AGMA...

Page 382: ...DEF Extreme Pressure 3 Moly Grease EM 3MG 6829015304 Citgo Lithoplex CM2 Mobil Mobilgrease CM P Phillips 66 Megaplex XD3 Ipiranga IPIFLEX LI COMP MOLY 2 Gray NLGI 2 NLGI 2 NLGI 1 NLGI 2 GC LB Certified GC LB Certified BECHEM PAL1 01373458 BECHEM RHUS SW 2 03325216 NLGI 1 2 Table 6 1 Standard Lubricants Down to 9 C 15 F Lubricant Fluid Grove Spec Recommended Lubricant Type Grade Classification ...

Page 383: ...or or Manitowoc Crane Care Regardless of temperature and oil viscosity always follow the cold weather start up and operating procedures as described in Section 4 Operating Procedures to ensure adequate lubrication during system warm up and proper operation of all crane functions Cold Weather Package and Lubricants Grove recommends specific Cold Weather lubricants for use in ambient temperatures do...

Page 384: ... Chevron All Weather THF Texaco TDH Oil SS Must Meet John Deere Std JDM J20C J20D Transmission Oil 6829006993 Exxon Mobil UNIVIS HVI 26 ISO 26 Hoist Gear Oil Swing Drive Gearbox Brake Assembly Oil 6829103636 Petro Canada ENDURATEX Synthetic EP 150 Mobil SHC629 Phillips 66 Syncon EP Plus ISO 150 AGMA No 4 EP Extreme Pressure Multipurpose Grease Cold Weather EP MPG 6829104275 Mobil Mobilith SHC 220 ...

Page 385: ...co Duragear EP 75W 90 GL 5 Engine Oil SAE 80056036 Shell Rotella T6 Mobil Delvac 1 ESP Caterpillar Cat DE0 ULS Cold Weather 0W 40 CJ 4 Hydraulic Oil 6829101559 Petro Canada Duratran Synthetic THF Chevron All Weather THF Texaco TDH Oil SS Must Meet John Deere Std JDM J20C J20D Transmission Oil 6829006993 Exxon Mobil UNIVIS HVI 26 ISO 26 Swing Drive Gearbox Brake Assembly Oil 6829103636 Petro Canada...

Page 386: ...mix AdBlue TerraCair Ultrapure DEF Extreme Pressure 3 Moly Grease 6829104275 Mobil Mobilith SHC 220 Petro Canada Precision Synthetic EP1 NLGI 2 Windshield Washer fluid 90037773 Splash De icer Diesel Fuel 80069407 NOCO Kerosene 3 UN1223 III 1 NLOCK08 BECHEM PAL1 01373458 BECHEM RHUS SW 2 03313195 NLGI 2 Table 6 3 Cold Weather Lubricants in Arctic Conditions Down to 40 C 40 F Lubricant Fluid Grove S...

Page 387: ...ew lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost For more detailed information concerning the lubrication and inspection of wire rope refer to Wire Rope in Section 1 Introduction of the Service Manual LUBRICATION POINTS A regular frequency of lubrication must be established for all lubrication points Normally this is based on ...

Page 388: ...ols mini tab and Oil Registration Lists link within the Service Tools list This will load a list of the different Cummins Engineering Specification numbers Select the one that applies to your engine and view the registered oils Safety To lubricate many of the locations on the crane the engine must be started Parts of the crane to include the boom superstructure outriggers and the like must be retr...

Page 389: ...ated Anti Freeze Coolant 6829101130 6829101130 6829104212 D Liquid Coolant Conditioner LCC 6829012858 6829012858 6829012858 E Tractor Hydraulic Fluid 6829006444 6829101559 6829101559 F Engine Oil SAE 6829104182 15W 40 80056036 0W 40 80056036 0W 40 G Open Gear Lube 6829102971 6829102971 6829102971 H Extreme Pressure Gear Lube 6829100213 6829103636 6829103636 J Hydraulic Oil 6829006444 6829006993 68...

Page 390: ...case REPLACE filter 3B FILL oil to FULL 3C See NOTE 8 Engine Crankcase CUMMINS QSBT3 275 HP with Filter F 20 L 5 3 gal Every 10 hours of service or daily whichever interval comes first CHECK oil level ADD oil to FULL See NOTE 8 Every 500 hours of service See NOTE 9 when using sulfur fuel that is 5000 ppm it is not recommended DRAIN crankcase REPLACE filter See NOTE 9 FILL oil to FULL See NOTE 8 NO...

Page 391: ...t causing engine damage it is important to drain the engine crankcase and replace your engine oil filter 3B using the following time line as your guide If using 500 5000 ppm sulfur fuel in the engine then drain the crankcase and replace your engine oil filter every 400 hours of service If using 5000 ppm sulfur fuel in the engine then drain the crankcase and replace your engine oil filter every 250...

Page 392: ...r See NOTE 14 CLEAN magnetic drain plug INSTALL magnetic plug in drain port FILL transmission sump to FULL on DIPSTICK See NOTE 15 Thereafter PERFORM DRAIN procedure to include REPLACING transmission and torque converter filter every 500 hours of service or 3 months whichever interval comes first DRAINtransmission sump See NOTE 13 REPLACE filter See NOTE 14 FILL transmission sump to FULL on DIPSTI...

Page 393: ...on the DIPSTICK for the Transmission and Torque Converter sump and FILL with transmission fluid through the DIPSTICK opening FILL to FULL on DIPSTICK b OPERATE engine at 850 rpm to prime torque converter and lines c CHECK fluid LEVEL with engine running at 850 rpm and torque converter fluid at 65 C to 93 C 150 F to 200 F d ADD transmission fluid as necessary FILL to FULL on DIPSTICK Item Lube Poin...

Page 394: ...rainer 8A Driveline Slip Figure 6 3 A Brush on Every 500 hours of service or 3 months whichever interval comes first BRUSH ON grease to coat the driveline slip surface 8B Driveline Slip Figure 6 3 A Brush on Every 500 hours of service or 3 months whichever interval comes first BRUSH ON grease to coat the driveline slip surface 9 Fuel Water Separator Figure 6 3 Every 10 hours daily DRAIN water trap...

Page 395: ... OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 3 SIDE VIEW OF CARRIER FRONT 10024 02 6 7 8A 8B 9 RIGHT SIDE OF CARRIER TRANSMISSION DIPSTICK 10024 02c 6A FIGURE 6 4 LEFT REAR SIDE OF CARRIER LEFT UNDERSIDE OF CARRIER 10 11 12 10024 02b 10024 02a ...

Page 396: ...E 18 Figure 6 6 A Until grease extrudes Every 500 hours or 3 months whichever interval comes first LUBRICATE 2 fittings per axle 4 service points 25 Steering Cylinder Pivot Pins See NOTE 18 Figure 6 6 A Until grease extrudes Every 50 hours or weekly whichever interval comes first LUBRICATE 4 fittings per axle 8 service points 26 Tie Rod Pivot Pins Figure 6 6 Maintenance Free NO SERVICE 27 King Pin...

Page 397: ...Grove Published 3 22 2021 Control 702 02 6 19 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 10024 03 FIGURE 6 5 MERITOR AXLE 20 21 23 22 FIGURE 6 6 10024 04 KESSLER AXLE 25 24 26 27 ...

Page 398: ...RICATE 2 service points See NOTE 19 NOTE 19 Use grease fittings provided DO NOT USE non semi synthetic lubricant Use of non approved lubricant may damage components CAUTION Possible Equipment Damage Use specified semi synthetic or synthetic lubricants as listed in this section of your GRT8120 Operator Manual See also your GRT8120 Service Manual for maintenance and lubrication instructions Use of n...

Page 399: ...Grove Published 3 22 2021 Control 702 02 6 21 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 7 10024 05 FIFTH WHEEL PIVOTS 28 ...

Page 400: ...o provide sufficient lubrication final fluid level MUST BE LEVEL with the filler plug hole at the Wheel End with fluid even slightly dripping from the hole CLEAN magnetic plug then INSTALL magnetic plug in drain port NOTE 21 Before operating crane in cold weather arctic ambient temperatures below 9 C 15 F Standard bearing lubricant must be fully purged and replaced with Cold Weather lubricant meet...

Page 401: ...6 23 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 8 MERITOR DRIVE AXLE FRONT VIEW 10024 06 31 31 30 FIGURE 6 9 MERITOR AXLE SIDE VIEW AXLE HUB PLANETARY DRAIN AND FILL PORTS 10024 06a 31A OIL FILL 31B OIL DRAIN LEGEND 31A 31B ...

Page 402: ...ll level indicated on axle hub To provide sufficient lubrication final fluid level MUST BE LEVEL with the filler plug hole at the Wheel End with fluid even slightly dripping from the hole CLEAN magnetic plug then INSTALL magnetic plug in drain port NOTE 25 Before operating crane in cold weather arctic ambient temperatures below 9 C 15 F Standard bearing lubricant must be fully purged and replaced ...

Page 403: ...Grove Published 3 22 2021 Control 702 02 6 25 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 10 KESSLER DRIVE AXLE FRONT VIEW 10024 07 33 33 32 KESSLER DRIVE AXLE DETAIL VIEW 10024 07a ...

Page 404: ...0 hours of service Thereafter every 50 hours of service or 1 week whichever interval comes first CHECK oil level FILL swing drive gearbox to BOTTOM of FILL HOLE 1 service point See NOTE 29 After first 50 hours of service Thereafter every 1000 hours or 12 months which ever comes first DRAIN swing drive gearbox FILL to BOTTOM of FILL HOLE 1 service point See NOTE 29 42 Turntable Bearing Figure 6 11 ...

Page 405: ...aring grease using Table 6 2 Cold Weather Lubricants in Arctic Conditions Down to 29 C 20 F If temperatures below 9 C 15 F are rare and intermittent then greases from Table 6 1 Standard Lubricants Down to 9 C 15 F are acceptable NOTE 32 DO NOT USE non semi synthetic lubricant Use of non approved lubricant may damage components Item Lube Point Description Figure No Approved Lubricant Approximate Ca...

Page 406: ... See NOTE 33 52 Cab Door Track and Rollers Figure 6 13 Light Oil Every 6 months LUBRICATE top and bottom door track and rollers 2 service points 53 Air Conditioner Condenser Filter Figure 6 14 Every 1000 hours or 6 months whichever interval comes first CHECK and CLEAN condenser filter 1 service point NOTE 33 USE grease fittings provided NOTE 34 DO NOT USE non semi synthetic lubricant Use of non ap...

Page 407: ...21 Control 702 02 6 29 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 UNDERSIDE OPERATOR CAB DOOR TRACK AND ROLLERS 10024 10 52 FIGURE 6 13 FIGURE 6 14 10024 09 REAR OF OPERATOR CAB AIR CONDITIONER CONDENSER FILTER 53 ...

Page 408: ... I D of each cylinder support tube and wear bands Every 50 hours or 1 week of service whichever interval comes first BRUSH ON I D of 4 service points See NOTE 35 See NOTE 36 63 Jack Cylinder Barrels Figure 6 15 L Brush on Every 50 hours or 1 week of service whichever interval comes first BRUSH ON 4 service points See NOTE 35 See NOTE 36 64 Extend Cylinder Supports Figure 6 15 L Brush on Every 50 h...

Page 409: ...Grove Published 3 22 2021 Control 702 02 6 31 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 15 OUTRIGGER BOX 10024 13 62 60 60 61 61 63 62 61 64 10024 13a OUTRIGGER BOX INTERIOR REF REF ...

Page 410: ... ambient temperatures below 9 C 15 F Standard grease must be fully purged and replaced with Cold Weather grease meeting Grove U S L L C specifications as shown in Table 6 4 Approved Lubricant Reference Table page 6 11 in this Operator Manual See also your GRT8120 Service Manual for specified maintenance and lubrication instructions CAUTION Possible Equipment Damage Use specified semi synthetic or ...

Page 411: ...e 6 to the 0 pinning location 8 Raise boom to 70 Boom Lubrication READ FIRST IMPORTANT CRANE SET UP INFORMATION 1 With crane set on a firm level surface and a minimum 29 200 lb counterweight installed fully extend the outriggers and level the crane 2 Center the boom over the front of the crane engage the turntable swing lock pin and disable the swing function 3 Fully retract the boom and set boom ...

Page 412: ...e sure that grease is properly distributed 6 When Tele 4 greasing is complete retract and lock Tele 4 to the 0 pinning location 7 Raise boom to 70 Telescope Section 3 Tele 3 1 Make sure that the tele cylinder is locked to Tele 3 2 Extend and lock Tele 3 to the 100 pinning location 3 Extend and lock Tele 2 to the 50 pinning location 4 Lower the boom to 0 and perform the following greasing in this p...

Page 413: ... Grease the rear upper wear pads of Tele 1 on both sides at the grease fittings 1 Figure 6 17 through the openings in the base section c Grease locking pins on both sides 2 Figure 6 17 NOTE To grease the rear upper wear pads of Tele 1 at the or 89 pinning locations extend and lock Tele 1 to these pinning locations and repeat Step 3b greasing 4 While in the horizontal position extend and retract Te...

Page 414: ...n line 12 service points See NOTE 42 See NOTE 43 NOTE 42 DO NOT USE non semi synthetic lubricant Use of non approved lubricant may damage components NOTE 43 Extend boom for access to telescopic slide front faces that contact wear pads inside the boom Follow the Tele Section positioning and lubrication instruction given in the section titled READ FIRST IMPORTANT CRANE SET UP INFORMATION page 6 33 I...

Page 415: ...37 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 18 HOOK BLOCKS OVERHAUL BALL OVERHAUL CYLINDER 10024 16 10024 20 10024 18 10024 17 10024 15 10024 19 80 81 82 83 84 84 FIGURE 6 19 TELESCOPIC SECTION SLIDE FRONT FACES 10024 21 85 ...

Page 416: ...ach fitting Every 250 hours or 3 months whichever interval comes first LUBRICATE 2 service points See NOTE 46 93 Tele 2 Lock Pin Figure 6 20 N 1 or 2 pumps each fitting Every 250 hours or 3 months whichever interval comes first LUBRICATE 2 service points See NOTE 46 94 Tele 3 Lock Pin Figure 6 20 N 1 or 2 pumps each fitting Every 250 hours or 3 months whichever interval comes first LUBRICATE 2 ser...

Page 417: ...ove Published 3 22 2021 Control 702 02 6 39 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 LEFT SIDE BOOM REAR UPPER WEAR PADS AND LOCK PINS 88 89 90 91 FIGURE 6 20 93 92 97 95 94 86 87 96 10024 22 ...

Page 418: ... of service whichever interval comes first CHECK 2 service point CHECK sheave for dry points of operation and grease leaks See NOTE 47 102 Boom Nose Sheaves Figure 6 21 A Every 250 hours or 3 months of service whichever interval comes first CHECK 7 service points CHECK sheave for dry points of operation and grease leaks See NOTE 47 103 Auxiliary Boom Nose Sheave Figure 6 21 A Every 250 hours or 3 ...

Page 419: ...3 22 2021 Control 702 02 6 41 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 10024 23 BOOM EXTENSION SCREW 10024 24 FIGURE 6 21 BOOM EXTENSION TELE CYLINDER WEAR PAD 10024 25 101 102 102 103 99 99 105 100 98 104 ...

Page 420: ... of service whichever interval comes first LUBRICATE 2 service points 107 Interlock Pins Figure 6 22 A Brush on Every 250 hours or 3 months of service whichever interval comes first LUBRICATE 2 service points 108 Boom Extension Swing Pin Figure 6 22 A Brush on Every 250 hours or 3 months of service whichever interval comes first LUBRICATE 1 service point 109 Rear Boom Extension Ramp Pin Figure 6 2...

Page 421: ...Grove Published 3 22 2021 Control 702 02 6 43 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 22 10299 109 106 107 108 106 107 10024 24a ...

Page 422: ...nterval comes first BRUSH ON 2 service points See NOTE 48 See NOTE 50 112 Hoist Bearings Figure 6 23 A Until grease extrudes from entire bearing circumference Every 250 hours or 3 months of service whichever interval comes first LUBRICATE 2 service points See NOTE 48 See NOTE 51 NOTE 48 DO NOT USE non semi synthetic lubricant Use of non approved lubricant may damage components NOTE 49 Check oil le...

Page 423: ...Grove Published 3 22 2021 Control 702 02 6 45 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 FIGURE 6 23 HOIST DRUMS MAIN and AUXILIARY HOIST DRUM RIGHT SIDE HOIST DRUM LEFT SIDE 111 112 110 ...

Page 424: ... 90 C 150 F to 200 F NOTE 56 Hydraulic oil SHALL MEET or EXCEED ISO 4406 class 17 14 cleanliness level reference SAE J1165 Working in harsh environmental conditions can dramatically affect the performance and condition of hydraulic oil filters and breathers Therefore specific intervals for servicing changing hydraulic oil filters and hydraulic tank breathers cannot be set Thus it is imperative for...

Page 425: ...Grove Published 3 22 2021 Control 702 02 6 47 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 HYDRAULIC TANK FIGURE 6 24 9900 26a 114 116 115 ...

Page 426: ...ous ways 1 it eliminates the moisture containing salt dirt and other pollutants by lifting and removing them from the metal surface 2 the film creates a barrier to repel further moisture from coming in contact with the metal and 3 it penetrates crevices In addition to the factory applied treatment Grove crane owners must provide proper maintenance and care to help ensure long term protection of th...

Page 427: ...automotive type scratch remover It is recommended that a good coat of automotive wax be applied to this area afterwards Any area scratched through to bare metal should be touched up and repaired as soon as possible to prevent flash rusting To repair a major scratch down to bare metal or minor damage follow these procedures NOTE Manitowoc Crane Care recommends a qualified body repair technician pre...

Page 428: ...ommended Carwell treatment is available in 16 ounce spray bottles from Manitowoc Crane Care order part number 8898904099 After treatment application is complete wash or clean film residue from lights windshield grab handles ladders steps and all crane access areas as necessary Contact your local Grove distributor or Manitowoc Crane Care should you have any questions Areas of Application Refer to F...

Page 429: ...2021 Control 702 02 6 51 GRT8120 OPERATOR MANUAL MAINTENANCE AND LUBRICATION 6 7650 75 Figure 6 25 Picture may not be same model as your crane it is for reference only 2 1 5 2 8 12 6 5 11 10 13 3 4 18 14 1 7 9 1 9 15 16 17 ...

Page 430: ...earing Fasteners 3 Hook Block Overhaul Ball 14 Powertrain Hardware Inside Compartment 4 Boom Extension Hanger Hardware 15 Valve Bank 5 Pivot Shaft 16 Hoist Hose Connections 6 Hose Connections Inside Turntable 17 Tension Spring 7 All Hardware Clips Pins Hose Connections not painted Outrigger Pins Clips 18 Wire Rope 8 Outrigger Hose Connections 19 Counterweight Mounting Hardware 9 Hook Block Tiedown...

Page 431: ...A 1 GRT8120 OPERATOR MANUAL Published 3 22 2021 Control 702 02 APPENDIX 1 DECALS Figure A 1 shows the locations of the decals on the GRT8120 ...

Page 432: ...ssurized fluid can cause serious injury or death Do not open radiator while hot 7376102517 DANGER ROTATING FAN BLADES KEEP HANDS CLEAR 7376011364 ENGINE DAMAGE Improper filling of engine coolant system can result in engine damage Shut down engine Fill slowly Flows exceeding 12 l min 3 gpm can give false level Wait 1 min and recheck See service manual 12 L min CAUTION 7376102516 DANGER BURN HAZARD ...

Page 433: ... D DANGER 7376102946 To avoid death or serious injury Never mix gasoline alcohol or gasohol with diesel fuel This mixture can cause an explosion G7 Use only ultra low sulfur fuel Failure to do so may cause damage to the catalyst 80021918 G7 USE ISO 22241 1 QUALITY DIESEL EXHAUST FLUID DEF ONLY 2XR 36 2X R11 5 80116980 G7 CUTOUT To avoid possible engine fault codes and undesirable operation ensure ...

Page 434: ...en the boom is secured for transport boom shall not be constrained All securement must allow for reasonable freedom of movement G7 80061893 7376102910 G7 G7 80025216 Attention Special lubricant has been installed in this component For more information please refer to lubrication decal on Hydraulic Reservoir or lubrication chart in Operator s Manual UNDER COVER ON T T AT EACH HOIST HOOK BLOCK BOTH ...

Page 435: ... 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 California Proposition 65 California Spark Arrestor 81007557 REV C DOOR WHEN IT S COMPLETELY OPEN DEATH OR SERIOUS INJURY MAY RESULT WITH IMPROPER USE Lug for counterweigh...

Page 436: ...RATURE DRIVE LIGHTS PARK LIGHTS ENGINE STOP LOW FUEL LEVEL LOW BOOM INDICATOR WORKING RANGE LIMITER TELESCOPE CYLINDER AT BOOM NOSE INDICATOR TRANSMISSION WARNING TRANSMISSION TEMPERATURE WARNING CRANE FAULTS P BOOM LIGHTS WINDSHIELD WASHER WORK LIGHTS SKYLIGHT WIPER SWING BOOM RIGHT SWING BOOM LEFT WAIT TO START TELESCOPE SEMI AUTO TELESCOPE MANUAL TELESCOPE EMERGENCY TELESCOPE UNKNOWN CAB POSITI...

Page 437: ...ergized and grounded BEFORE performing any work If contact is ever accidentally made with a power line and any part of this crane its rigging or load NEVER touch the crane or even approach or come near the crane Electrocution CAN OCCUR even without direct contact with the crane DANGER 80037260 ELECTROCUTION HAZARD EACH SIDE OF ALL O R BEAMS FRONT REAR O R BEAMS FRONT REAR O R BEAMS EACH SIDE OF AL...

Page 438: ...ANGER RCL Override Switch 30 E Stop 31 Serial Number 32 Window Cling Serial Number 100 DANGER Tip 2 Blocking Hazard 101 CAUTION Trans Damage 102 No Step 103 DANGER Super Structure Swing Hazard 104 Symbol ID 105 Armrest Adjustment 106 CAUTION Armrest Position 107 Cab Fuse and Relay Board 108 CraneStar Logo 109 Pin Swing Lock 110 No Step 111 CAUTION Pin Swing Lock 112 Emergency Exit 113 CAUTION 4 Wh...

Page 439: ...Boom Nose 183 CAUTION Dead End Lug 184 CAUTION Disconnect Anti 2 Block 185 DANGER Auxiliary Nose Anti 2 Block 186 Boom Extension Stinger Electrical Connect 187 Boom Extension Wiring Connect 2 188 Boom Extension Wiring Connect 3 189 Boom Extension Wiring Connect 200 GRT8120 ID 201 GRT8120 202 Grove 6 5 Gray 203 Grove 7 7 Gray 204 Grove 5 White 205 Chevron Outrigger Jack 206 Manitowoc Gray Red 3 207...

Page 440: ...GRT8120 OPERATOR MANUAL A 10 Published 3 22 2021 Control 702 02 THIS PAGE BLANK ...

Page 441: ...m Base Section Erecting 5 45 10 5m Base Section Stowing 5 48 17 6m Erecting 5 35 17 6m Stowing 5 42 About the ODM 5 26 Accessing ODM Screen 5 27 Anti Two Block Switch 5 58 Electrical Connections 5 51 Fly Section Erecting 5 39 Fly Section Stowing 5 41 Hydraulic Connections Optional 5 52 Installing 5 30 Jack 5 31 5 39 5 48 Lifting Points 5 25 Mast Sheave Assembly 5 32 5 34 5 39 5 43 5 48 5 49 Mounti...

Page 442: ...isable Switch 3 7 3 9 Crane Leveling Proper 4 19 Crane Warm Up Procedures 4 11 Cup Holder 3 21 3 22 D Dead End Rigging 5 18 Deadman Switches Dual Axis 3 21 3 22 Decals A 1 Degree Indicator 3 56 Diagnostics Manitowoc Mobile Application 4 141 Diagrams Reeving 5 13 Dial Jog 3 21 3 22 Differential Lock Operation 4 18 Differential Lock Switch Optional 3 21 3 24 Disconnect Switch Battery 3 45 Display Re...

Page 443: ... or RPM 3 56 Emergency Stop On Remote Control Unit 3 56 Enable 3 56 Engine Wait To Start 3 7 3 9 Internal Temperature Warning 3 17 3 19 Left Motion Command 3 56 Parking Brake On Remote Control Unit 3 56 RCL Early Warning 3 17 3 19 RCL Shutdown Warning CE Certified Cranes 3 17 3 19 RCL Shutdown Warning Non CE Certified Cranes 3 17 3 19 Right Motion Command 3 56 Status On Remote Control Unit 3 53 3 ...

Page 444: ...iggers 4 19 Setting the Outriggers Using Auto Level 4 20 Stowing the Outriggers 4 21 Using the Outriggers 4 19 P Panel Fuse and Relay In Cab 3 34 3 36 Left Overhead and Side 3 13 Right Overhead Control 3 7 Parking Brake Indicator On Remote Control Unit 3 56 Parking Brake Switch 3 4 3 5 Parking the Crane 4 178 Pedal Service Brake 3 29 3 30 Swing Brake 3 29 3 30 Throttle 3 29 3 30 Pin Interlock Mech...

Page 445: ...ng the Boom and Superstructure 4 22 Switch Auxiliary Hoist Enable Disable 3 21 3 23 Auxiliary Light 3 13 3 14 Battery Disconnect 3 45 Boom Lift Enable Disable 3 21 3 23 Boom Mounted Lights Optional 3 7 3 8 Boom Mounted Lights Motor Optional 3 7 3 8 Boom Telescope Enable Disable 3 21 3 23 Boom Up Bypass 3 7 3 11 Bridging CE Certified Cranes 3 42 Cab Mounted Lights 3 7 3 8 Cab Tilt 3 21 3 23 Crane F...

Page 446: ... 35 Using the Load Chart 4 176 Using the Operator Display Module ODM 4 68 Using the Rated Capacity Limiter Display Module RDM 4 158 Using the Remote Control Unit 4 50 V Vents Heater Air Conditioner 3 13 3 14 3 21 3 22 Visor Sun 3 32 3 33 W Wait To Start Indicator Engine 3 7 3 9 Warm Up Procedures Crane 4 11 Wedge Sockets 5 18 Window Latch Right Side 3 38 3 39 Window Latch Skylight 3 38 3 39 Window...

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