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Manitowoc Grove GRT8100 Operator Manual – PDF DOWNLOAD
Manitowoc Grove GRT8100 Operator Manual – PDF DOWNLOAD
FILE DETAILS:
Manitowoc Grove GRT8100 Operator Manual – PDF DOWNLOAD
Language : English
Pages : 206
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Manitowoc Grove GRT8100 Operator Manual – PDF DOWNLOAD
Table of Contents.............................................................................................................. 5 SECTION 1...................................................................................................................... 11 Introduction............................................................................................................... 11 General................................................................................................................ 11 Customer Support................................................................................................... 11 New Owners..................................................................................................... 11 Noise/vibration Test results........................................................................................... 11 Noise Level Test Results........................................................................................... 11 Vibration Level Test Results....................................................................................... 12 Serial Number Location................................................................................................. 12 List Of Specifications................................................................................................. 14 General............................................................................................................ 14 Dimensions......................................................................................................... 14 Capacities......................................................................................................... 14 Torque Converter................................................................................................... 14 Transmission....................................................................................................... 14 Engine............................................................................................................. 14 Cummins QSB 6.7 - Tier 4F...................................................................................... 14 Cummins QSB 6.7 - Tier 3....................................................................................... 14 Axles.............................................................................................................. 14 Brakes............................................................................................................. 14 Wheels and Tires................................................................................................... 14 Swing Gearbox...................................................................................................... 14 Boom............................................................................................................... 14 Swivel Assembly.................................................................................................... 14 Hydraulic Pumps.................................................................................................... 15 Pump #1........................................................................................................ 15 Pump #2........................................................................................................ 15 Pump #3........................................................................................................ 15 Hoists............................................................................................................. 15 SECTION 2...................................................................................................................... 17 Safety Information......................................................................................................... 17 Safety Messages........................................................................................................ 17 General............................................................................................................ 17 Safety Alert Symbol................................................................................................ 18 Signal Words....................................................................................................... 18 General................................................................................................................ 18 Warning Signs...................................................................................................... 18 Accidents.............................................................................................................. 18 Operator Information................................................................................................... 19 Operator Qualifications................................................................................................ 19 Operational Aids....................................................................................................... 20 Rated Capacity Limiter (RCL) Systems (If Equipped)................................................................. 20 Anti-Two-Blocking Device........................................................................................... 21 Working Area Limiter (If Equipped)................................................................................. 21 Crane Stability/Structural Strength.................................................................................... 22 Load Charts........................................................................................................ 22 Work Site.......................................................................................................... 22 Wind Forces............................................................................................................ 23 Wind Speeds........................................................................................................ 23 Determination of 3-second wind gust speed at boom tip height:.................................................. 26 Size and Shape of the load:.................................................................................... 26 Determining Wind Drag Coefficient (Cd)......................................................................... 27 Maximum Permissible Wind Speed................................................................................. 28 Example and Sample Calculations (metric)................................................................... 30 Example 1: Crane Configuration:............................................................................ 30 Load example 1.1:.......................................................................................... 31 Load example 1.2:.......................................................................................... 31 Load example 1.3a:......................................................................................... 31 Load example 1.3b:......................................................................................... 31 Example and Sample Calculations (Non-metric)................................................................... 34 Example 2:................................................................................................. 34 Load example 2.1:.......................................................................................... 35 Load example 2.2:.......................................................................................... 35 Load example 2.3a:......................................................................................... 35 Load example 2.3b:......................................................................................... 35 Lifting Operations................................................................................................. 36 Counterweight...................................................................................................... 37 Outrigger Lift Off................................................................................................. 37 Multiple Crane Lifts............................................................................................... 37 Tilt-Up Panel Lifting.............................................................................................. 37 Pile Driving and Extracting............................................................................................ 38 Crane Equipment.................................................................................................... 38 Crane Inspection................................................................................................... 38 Electrocution Hazard................................................................................................... 39 Set-Up and Operation............................................................................................... 40 Electrocution Hazard Devices....................................................................................... 40 Electrical Contact................................................................................................. 41 Special Operating Conditions and Equipment......................................................................... 41 Grounding the Crane................................................................................................ 41 Personnel Handling..................................................................................................... 42 Environmental Protection............................................................................................... 43 Maintenance............................................................................................................ 43 Service and Repairs................................................................................................ 43 Lubrication........................................................................................................ 44 Tires.............................................................................................................. 45 Hoist Rope............................................................................................................. 45 Synthetic Hoist Rope............................................................................................... 45 Wire Rope.......................................................................................................... 45 Sheaves............................................................................................................ 46 Batteries.......................................................................................................... 47 Super Capacitor (If Equipped)...................................................................................... 47 General Maintenance................................................................................................ 47 Transporting the Crane................................................................................................. 48 Travel Operation....................................................................................................... 48 Work Practices......................................................................................................... 49 Personal Considerations............................................................................................ 49 Crane Access....................................................................................................... 49 Job Preparation.................................................................................................... 49 Working............................................................................................................ 50 Lifting............................................................................................................ 51 Hand Signals....................................................................................................... 52 Jib.................................................................................................................... 54 Parking and Securing................................................................................................... 54 Shut-Down.............................................................................................................. 54 Cold Weather Operation................................................................................................. 54 Temperature Effects on Hook Blocks..................................................................................... 55 Temperature Effects on Hydraulic Cylinders............................................................................. 55 Model Specific Information............................................................................................. 56 Crane Stability.................................................................................................... 56 Hoist Platform..................................................................................................... 57 Travel Position................................................................................................ 57 Overload Inspection.................................................................................................... 57 Boom Inspection.................................................................................................... 58 Superstructure Inspection.......................................................................................... 60 Carrier Inspection................................................................................................. 62 SECTION 3...................................................................................................................... 65 Operating Controls and Procedures.......................................................................................... 65 Controls and Indicators................................................................................................ 66 Steering column.................................................................................................... 66 Turn Signal Lever and Windshield Wiper/ Washer/Headlight/Horn Controls............................................. 67 Steering Column Tilt Lever......................................................................................... 67 Park Brake Control Switch.......................................................................................... 67 Headlights Switch.................................................................................................. 67 Drive Axle Selector Switch......................................................................................... 67 Hazard Lights Switch............................................................................................... 67 Increment/Decrement Switch......................................................................................... 68 Ignition Switch.................................................................................................... 68 Transmission Shift Lever........................................................................................... 68 Cab Overhead Controls.................................................................................................. 68 Skylight Window Latch.............................................................................................. 68 Skylight Wiper and Wiper Motor..................................................................................... 68 Skylight Sunscreen................................................................................................. 69 Dome Light......................................................................................................... 69 Cab Circulating Fan................................................................................................ 69 Right Side Window Latch............................................................................................ 69 Overhead Control Panel............................................................................................. 69 Skylight Wiper Switch.............................................................................................. 69 Heater/Air Conditioner Fan Speed Switch............................................................................ 69 Heater Control Switch.............................................................................................. 69 Air Conditioner Switch............................................................................................. 69 Work Lights Switch................................................................................................. 69 Crane Function Power Switch........................................................................................ 69 Exhaust System Cleaning Switch (Tier 4 Engine Only)................................................................ 69 Exhaust System Cleaning (Tier 4 Engines Only)...................................................................... 70 Inhibit Exhaust System Cleaning................................................................................ 70 Diesel Exhaust Fluid (Tier 4 Engines Only)......................................................................... 71 High Exhaust System Temperature.................................................................................... 71 Control Seat Assembly.................................................................................................. 72 Boom Lift/Main Hoist Control Lever (Dual Axis)..................................................................... 73 Swing/Telescope or Swing/Auxiliary Hoist Control Lever (Dual Axis)................................................. 73 Main Hoist Enable Switch........................................................................................... 73 Boom Up Bypass Switch.............................................................................................. 73 Lift Function Enable Switch........................................................................................ 73 Jog Dial........................................................................................................... 73 Outrigger Function Enable Switch................................................................................... 73 Differential Lock On/Off Switch (Optional)......................................................................... 73 Rear Steer Switch.................................................................................................. 73 Auxiliary Hoist Enable Switch...................................................................................... 74 Boom Telescope Enable Switch....................................................................................... 74 Swing Enable Switch................................................................................................ 74 Seat Slide Lever................................................................................................... 74 Air Conditioner/Heater Climate Unit................................................................................ 74 Seat Frame Slide Lever............................................................................................. 74 Armrest Adjustment Knobs........................................................................................... 74 Seat Height Adjustment Lever....................................................................................... 74 Limit Bypass Switch (Non-CE Certified Cranes)...................................................................... 74 Limit Bypass Switch (CE Certified Cranes).......................................................................... 75 Emergency Stop Switch.............................................................................................. 76 Level Indicator.................................................................................................... 76 Deadman Switches (Optional) (Dual Axis Control Levers only)........................................................ 76 Hoist High Speed Toggle Switches................................................................................... 76 Horn Button........................................................................................................ 76 Free Swing Button.................................................................................................. 76 Cab Door Release Lever............................................................................................. 76 Hoist Rotation Indicators (Not Shown).............................................................................. 76 Seat Switch (Not Shown)............................................................................................ 76 Main Hoist Control (Single Axis Option)............................................................................ 77 Boom Lift Control (Single Axis Option)............................................................................. 77 Telescope or Auxiliary Hoist Control (Single Axis Option).......................................................... 77 Swing Control (Single Axis Option)................................................................................. 77 Foot Pedal Controls.................................................................................................... 78 360° Swing Lock Pedal.............................................................................................. 78 Swing Brake Pedal.................................................................................................. 78 Telescope Control Pedal............................................................................................ 78 Service Brake Pedal................................................................................................ 78 Foot Throttle Pedal................................................................................................ 78 Miscellaneous Controls and Indicators.................................................................................. 78 Fuse and Relay Panels.............................................................................................. 78 Buzzer............................................................................................................. 78 Limit Bypass Switch (Non-CE Certified Cranes)...................................................................... 78 Limit Bypass Switch and Indicator (CE Certified Cranes)............................................................ 79 RCL Internal Light Bar (Optional).................................................................................. 80 Strobe Light or Beacon (Optional).................................................................................. 80 Backup Alarm (Not Shown)........................................................................................... 80 Emergency Exit..................................................................................................... 80 Crane Control System (CCS)............................................................................................. 81 Crane Control System (CCS) Display................................................................................. 81 Turntable Swing Lock Pin Control................................................................................... 81 Menu Control....................................................................................................... 81 CCS Main Screen Symbols and Icons.................................................................................. 82 CCS Menu Screen.................................................................................................... 83 CCS Operation Display.............................................................................................. 84 Menu Screen........................................................................................................ 84 Rated Capacity Limiter (RCL) System.................................................................................... 85 Mode of Operation.................................................................................................. 85 Outrigger Operation Menu........................................................................................... 86 Set Outriggers................................................................................................. 86 Raise Jacks.................................................................................................... 86 Telescope Operation Menus.......................................................................................... 87 Telescoping Configuration Screen............................................................................... 88 RCL Display Setup Screens...................................................................................... 88 All Modes Available and in Sequence........................................................................ 88 All Modes Enabled - A & B Out of Sequence.................................................................. 88 A & B Modes Disabled - X Mode In Sequence.................................................................. 88 A&B Modes Disabled - No Load Chart For Selected Rigging Code............................................... 89 A & B Modes Disabled When “A” Mode Confirmed............................................................... 89 RCL Display Operating Screen................................................................................... 89 Confirmed Telescoping Mode................................................................................. 89 Out of Sequence............................................................................................ 89 Operating Screen............................................................................................... 89 Telescoping Menu Screens....................................................................................... 90 Operating Display In Sequence. All except Mode M........................................................... 90 Operating Display Out Of Sequence. All modes except M...................................................... 90 Telescope Mode M........................................................................................... 91 RCL Setup Wizard................................................................................................... 91 Set Counterweight.............................................................................................. 92 Set Boom....................................................................................................... 93 Set Jib Length (if installed).................................................................................. 93 Set Jib Angle (if installed)................................................................................... 93 Hoist Selection................................................................................................ 93 Reeving Selection.............................................................................................. 94 Switch to RCL Home Screen Display.................................................................................. 94 CCS Working Range Limiter (WRL)........................................................................................ 95 Introduction....................................................................................................... 95 WRL Limitations.................................................................................................... 95 Accessing Limitation Screens.......................................................................................101 Height Limitation..................................................................................................102 Height Limitation Procedure by Crane Position..................................................................104 Height Limitation Procedure by Value...........................................................................105 Height Limitation Disable Procedure............................................................................105 Boom Up/Down Limitation............................................................................................105 Boom Up Limitation Procedure by Crane Position.................................................................107 Boom Down Limitation Procedure by Crane Position...............................................................108 Boom Up/Down Limitation Disable Procedure......................................................................108 Radius Limitation..................................................................................................108 Inner Radius Limitation Procedure by Crane Position............................................................110 Outer Radius Limitation Procedure by Crane Position............................................................111 Radius Limitation Disable Procedure............................................................................111 Swing Limitation...................................................................................................111 Swing Limitation Procedure by Crane Position...................................................................114 Swing Limitation Disable Procedure.............................................................................114 Wall Limitation....................................................................................................114 First Virtual Wall Procedure...................................................................................117 Subsequent Virtual Wall Procedure..............................................................................117 Wall Limitation Disable Procedure..............................................................................118 Delete Wall Limitation Procedure...............................................................................118 Economy Mode...........................................................................................................118 Terminology........................................................................................................118 Requirements.......................................................................................................118 Operation..........................................................................................................119 Benefits...........................................................................................................119 Crane Control System (CCS) Symbols and Icons...................................................................120 Operating Procedures...................................................................................................123 Pre-Starting Checks................................................................................................123 Fuel Supply....................................................................................................123 Engine Oil.....................................................................................................123 Engine Coolant.................................................................................................123 Batteries......................................................................................................123 Hydraulic Reservoir and Filter.................................................................................123 Wire Rope......................................................................................................123 Hook Block and Headache Ball...................................................................................123 Seats and Mirrors..............................................................................................123 Seat Belts.....................................................................................................123 Seat Belt Maintenance......................................................................................123 Cleaning Seat Belt Webbing.................................................................................123 Signal and Running Lights......................................................................................123 Service and Parking Brakes.....................................................................................123 Tires..........................................................................................................123 Wheels.........................................................................................................123 Safety Equipment...............................................................................................123 Daily Lubrication..............................................................................................123 Boom...........................................................................................................124 Air Cleaner....................................................................................................124 Air Intake Restriction Monitoring (AIRM) Communications System - Tier 4 Only...................................124 Cold Weather Operation.............................................................................................124 Component Coolant Heater.......................................................................................125 Radiator Shutters..............................................................................................125 Auxiliary Cab Heater...........................................................................................125 Battery Heater.................................................................................................126 Air Diverter...................................................................................................126 Super Capacitor................................................................................................126 Operation Below -40°C (-40°F)..................................................................................126 Crane Warm-up Procedures...........................................................................................126 Engine.........................................................................................................127 Transmission...................................................................................................127 Hoist..........................................................................................................127 Swing Drive and Turntable Bearing..............................................................................127 Axles..........................................................................................................127 Hydraulic Oil System...........................................................................................127 Engine Operation...................................................................................................128 Start-Up Procedure.............................................................................................128 Cold Engine....................................................................................................128 Idling Engine..................................................................................................129 Racing Engine..................................................................................................129 Shutdown Procedure.............................................................................................129 Battery Disconnect.............................................................................................129 Crane Travel Operation.............................................................................................129 Seat Belts.....................................................................................................129 Traveling — General............................................................................................129 Traveling — Towing/Pulling.....................................................................................130 Traveling — Being Towed/Pulled.................................................................................131 Traveling on Slopes............................................................................................131 Traveling with Elevated Boom...................................................................................132 Traveling with Boom Extension and/or Inserts Erected...........................................................132 33 ft (10.1 m)/56 ft (17.1 m) Extension....................................................................132 33 ft (10.1 m)/56 ft (17.1 m) Extension Plus 20 ft (6 m) Insert............................................132 Extended Travel................................................................................................133 Traveling — Forward............................................................................................133 Traveling — Reverse............................................................................................134 Steering.......................................................................................................134 Front Wheel Steering.......................................................................................134 Rear Wheel Steering........................................................................................134 Four Wheel Steering........................................................................................134 Crabbing...................................................................................................134 Four-Wheel Drive Operation.....................................................................................134 Differential Lock Operation (Optional).........................................................................135 General....................................................................................................135 Operation..................................................................................................135 Axle Oscillation Lockouts Operation............................................................................135 General Crane Operation............................................................................................136 Pump Drive.....................................................................................................136 Control Lever Operation........................................................................................136 Preload Check..................................................................................................136 Using Your Load Chart..........................................................................................136 Proper Crane Leveling..........................................................................................137 Level Indicator Adjustment.........................................................................................138 Crane Functions....................................................................................................138 Using Outriggers...............................................................................................138 Setting Outriggers.............................................................................................138 Outrigger Monitoring System (OMS) (Optional— Standard in North America and European Union Countries)...........139 Engaging the Mid Extend Lock Pin...............................................................................139 Stowing the Outriggers.........................................................................................139 Stowing Mid-Extend Lock Pin....................................................................................140 Swinging Superstructure........................................................................................140 Elevating and Lowering Boom....................................................................................140 Elevating Boom.............................................................................................140 Lowering Boom..............................................................................................141 Telescoping Boom...............................................................................................141 Telescope Control Pedal....................................................................................141 Extending Boom.............................................................................................141 Retracting Boom............................................................................................141 Activate telescope function with Telescope Enable Switch, then push on bottom of pedal to retract boom.....141 Lower and Raise Hoist Cable....................................................................................141 Lower Cable................................................................................................141 Raise Cable................................................................................................142 Hoist Speed Range Selection....................................................................................142 Stowing and Parking................................................................................................142 Unattended Crane...................................................................................................142 SECTION 4......................................................................................................................143 Set-Up and Installation....................................................................................................143 General................................................................................................................143 Hoist Platform.........................................................................................................143 Working Position...................................................................................................144 Installing Cable On Hoist..............................................................................................144 Anti Two Block (A2B) Switch............................................................................................145 Locking............................................................................................................145 Unlocking..........................................................................................................145 Checking Before Operation..........................................................................................146 Cranes with Main Hoist Only....................................................................................146 Machines with Main and Auxiliary Hoists........................................................................146 Cable Reeving..........................................................................................................147 Reeving Boom Cable.................................................................................................147 Dead-End Rigging/Wedge Sockets.........................................................................................147 Installing Wedge and Socket........................................................................................148 Bi-fold Swingaway, Off-settable Boom Extension.........................................................................153 Description........................................................................................................153 Boom Extension Rigging Mode........................................................................................153 Erecting Boom Extension............................................................................................153 Erecting Boom Extension Fly Section................................................................................155 Stowing Boom Extension.............................................................................................156 Setting Boom Extension Manual Offset...............................................................................158 Changing Offset from 0° to 20° or 40°..........................................................................158 Changing Offset from 40° to 20° or 0°..........................................................................159 Setting Boom Extension Hydraulic Offset............................................................................159 Erecting and Stowing Bi-fold Boom Extension with 6 m (20 ft) Insert....................................................162 Erecting...........................................................................................................162 Stowing............................................................................................................164 Connecting and Disconnecting Boom Extension............................................................................164 Connecting.........................................................................................................164 Making Hydraulic Connection Between Boom Extension and Main Boom...............................................164 Making Electrical Connection Between Boom Extension Base Section and Boom Nose.................................165 Making Electrical Connection Between Boom Extension Base Section and Boom Extension Fly Section................165 Disconnecting......................................................................................................165 Disconnecting Electrical Connection Between Boom Extension Base Section and Boom Nose..........................165 Disconnecting Electrical Connection Between Boom Extension Base Section and Boom Extension Fly Section.........165 Disconnecting Hydraulic Connection BetweenBoom Extension and Boom Base.........................................165 3.05 m (10 ft) Heavy Duty Boom Extension...............................................................................166 Description........................................................................................................166 Installing Heavy Duty Boom Extension...............................................................................166 Setting Heavy Duty Boom Extension Manual Offset....................................................................166 Changing Offset from 0° to 35° or 55°..........................................................................166 Changing offset from 55° to 35° or 0°..........................................................................166 Tilt-Up Panel Procedure Using the Heavy Duty Boom Extension........................................................166 Removing Heavy Duty Boom Extension.................................................................................167 Removable Counterweight................................................................................................168 Counterweight Control Panel........................................................................................168 Removing...........................................................................................................169 Installing.........................................................................................................169 Installing Optional Counterweight Slab.............................................................................170 Removing Optional Counterweight Slab...............................................................................170 SECTION 5......................................................................................................................171 Maintenance and Lubrication................................................................................................171 General................................................................................................................172 Environmental Protection...............................................................................................172 Lubricants and Lubrication Intervals...................................................................................172 Standard Lubricants................................................................................................173 Arctic Lubricants and Conditions...................................................................................175 Temperatures Below -9°C (15°F).................................................................................175 Cold Weather Package and Lubricants............................................................................175 Cylinder Rod Surface Protection........................................................................................178 Wire Rope Lubrication..................................................................................................178 Lubrication Points.....................................................................................................178 CraneLUBE..........................................................................................................178 Cummins Oil Registration List......................................................................................178 Safety.............................................................................................................178 Drive Train........................................................................................................180 Drive Train (Continued)............................................................................................181 Drive Train (Continued)............................................................................................183 Drive Train (Continued)............................................................................................184 Steering and Suspension............................................................................................185 Steering and Suspension (Continued)................................................................................186 Axles..............................................................................................................187 Turntable..........................................................................................................188 Turntable (Continued)..............................................................................................189 Cab Tilt...........................................................................................................189 Outriggers.........................................................................................................190 Lift Cylinder......................................................................................................191 Boom...............................................................................................................192 Boom (Continued)...................................................................................................193 Boom (Continued)...................................................................................................196 Hoist..............................................................................................................197 Hydraulic..........................................................................................................198 Rust Protection........................................................................................................199 Cleaning Procedures................................................................................................199 Inspection and Repair..............................................................................................200 Application........................................................................................................200 Areas of Application...............................................................................................200 Alphabetical Index.........................................................................................................203
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