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Manitowoc Grove GRT880 Operator Manual CTRL643-01
Manitowoc Grove GRT880 Operator Manual CTRL643-01 – PDF DOWNLOAD
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Manitowoc Grove GRT880 Operator Manual CTRL643-01 – PDF DOWNLOAD
Language : English
Pages : 202
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Manitowoc Grove GRT880 Operator Manual CTRL643-01 – 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 3......................................................................................... 14 Cummins QSB 6.7 Tier 4 Final................................................................................... 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 Earthing 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 Engine Speed (RPM) Increase/Decrease Switch........................................................................ 68 Ignition Switch.................................................................................................... 68 Transmission Shift Lever........................................................................................... 68 Cab Overhead Controls.................................................................................................. 68 Skylight Window Latch.............................................................................................. 68 Skylight Wiper and Wiper Motor..................................................................................... 69 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........................................................................................ 70 Exhaust System Cleaning Switch (Tier 4 Engine Only)................................................................ 70 Exhaust System Cleaning (Tier 4 Engines Only)...................................................................... 71 Inhibit Exhaust System Cleaning................................................................................ 71 Diesel Exhaust Fluid (Tier 4 Engines Only)......................................................................... 71 High Exhaust System Temperature.................................................................................... 71 Control Seat Assembly - Dual Axis Joysticks............................................................................ 72 Boom Lift/Main Hoist Joystick (Dual Axis).......................................................................... 73 Swing/Telescope or Swing/Auxiliary Hoist Joystick (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 Joysticks 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 Control Seat Assembly - Single Axis Joysticks.......................................................................... 77 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 (Optional)................................................................................. 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)...................................................................... 79 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 Menu........................................................................................... 87 RCL Display Setup Screens...................................................................................... 88 B Mode Available and in Sequence........................................................................... 88 B Mode Enabled and out of Sequence......................................................................... 88 RCL Display Operating Screen................................................................................... 88 Confirmed Telescoping Mode................................................................................. 88 Out of Sequence............................................................................................ 88 Operating Screen............................................................................................... 88 Telescoping Menu Screens....................................................................................... 89 Operating Display In Sequence - except Mode M.............................................................. 89 Operating Display Out Of Sequence - except Mode M.......................................................... 89 Telescope Mode M........................................................................................... 90 RCL Setup Wizard................................................................................................... 90 Set Counterweight.............................................................................................. 91 Set Boom....................................................................................................... 91 Set Jib Length (if installed).................................................................................. 91 Set Jib Angle (if installed)................................................................................... 92 Hoist Selection................................................................................................ 92 Reeving Selection.............................................................................................. 92 Switch to RCL Home Screen Display.................................................................................. 93 CCS Working Range Limiter (WRL)........................................................................................ 94 Introduction....................................................................................................... 94 WRL Limitations.................................................................................................... 94 Accessing Limitation Screens.......................................................................................101 Height Limitation..................................................................................................102 Height Limitation Procedure by Crane Position..................................................................103 Height Limitation Procedure by Value...........................................................................104 Height Limitation Disable Procedure............................................................................104 Boom Up/Down Limitation............................................................................................105 Boom Up Limitation Procedure by Crane Position.................................................................106 Boom Down Limitation Procedure by Crane Position...............................................................107 Boom Up/Down Limitation Disable Procedure......................................................................107 Radius Limitation..................................................................................................108 Inner Radius Limitation Procedure by Crane Position............................................................110 Outer Radius Limitation Procedure by Crane Position............................................................110 Radius Limitation Disable Procedure............................................................................110 Swing Limitation...................................................................................................111 Swing Limitation Procedure by Crane Position...................................................................113 Swing Limitation Disable Procedure.............................................................................113 Wall Limitation....................................................................................................114 First Virtual Wall Procedure...................................................................................116 Subsequent Virtual Wall Procedure..............................................................................116 Wall Limitation Disable Procedure..............................................................................117 Delete Wall Limitation Procedure...............................................................................117 Economy Mode...........................................................................................................117 Terminology........................................................................................................117 Requirements.......................................................................................................117 Operation..........................................................................................................118 Benefits...........................................................................................................118 Crane Control System (CCS) Symbols and Icons...................................................................119 Operating Procedures...................................................................................................122 Pre-Starting Checks................................................................................................122 Fuel Supply....................................................................................................122 Engine Oil.....................................................................................................122 Engine Coolant.................................................................................................122 Batteries......................................................................................................122 Hydraulic Reservoir and Filter.................................................................................122 Wire Rope......................................................................................................122 Hook Block and Headache Ball...................................................................................122 Seats and Mirrors..............................................................................................122 Seat Belts.....................................................................................................122 Seat Belt Maintenance......................................................................................122 Cleaning Seat Belt Webbing.................................................................................122 Signal and Running Lights......................................................................................122 Service and Parking Brakes.....................................................................................122 Tires..........................................................................................................122 Wheels.........................................................................................................122 Safety Equipment...............................................................................................122 Daily Lubrication..............................................................................................122 Boom...........................................................................................................123 Air Cleaner....................................................................................................123 Air Intake Restriction Monitoring (AIRM) Communications System - Tier 4 Only...................................123 Cold Weather Operation.............................................................................................123 Component Coolant Heater.......................................................................................124 Radiator Shutters..............................................................................................124 Auxiliary Cab Heater...........................................................................................124 Battery Heater.................................................................................................125 Air Diverter...................................................................................................125 Super Capacitor................................................................................................125 Operation Below -40°C (-40°F)..................................................................................125 Crane Warm-up Procedures...........................................................................................125 Engine.........................................................................................................126 Transmission...................................................................................................126 Hoist..........................................................................................................126 Swing Drive and Turntable Bearing..............................................................................126 Axles..........................................................................................................126 Hydraulic Oil System...........................................................................................126 Engine Operation...................................................................................................127 Start-Up Procedure.............................................................................................127 Cold Engine....................................................................................................127 Idling Engine..................................................................................................128 Racing Engine..................................................................................................128 Shutdown Procedure.............................................................................................128 Battery Disconnect.............................................................................................128 Crane Travel Operation.............................................................................................128 Seat Belts.....................................................................................................128 Traveling — General............................................................................................128 Traveling — Towing/Pulling.....................................................................................129 Traveling — Being Towed/Pulled.................................................................................130 Traveling on Slopes............................................................................................130 Traveling with Elevated Boom...................................................................................131 Traveling with Boom Extension and/or Inserts Erected...........................................................131 33 ft (10.1 m)/56 ft (17.1 m) Extension....................................................................131 33 ft (10.1 m)/56 ft (17.1 m) Extension Plus 20 ft (6 m) Insert............................................131 Extended Travel................................................................................................132 Traveling — Forward............................................................................................132 Traveling — Reverse............................................................................................133 Steering.......................................................................................................133 Front Wheel Steering.......................................................................................133 Rear Wheel Steering........................................................................................133 Four Wheel Steering........................................................................................133 Crabbing...................................................................................................133 Four-Wheel Drive Operation.....................................................................................133 Differential Lock Operation (Optional).........................................................................134 General....................................................................................................134 Operation..................................................................................................134 Axle Oscillation Lockouts Operation............................................................................134 General Crane Operation............................................................................................135 Pump Drive.....................................................................................................135 Joystick Operation.............................................................................................135 Preload Check..................................................................................................135 Using Your Load Chart..........................................................................................135 Proper Crane Leveling..........................................................................................136 Level Indicator Adjustment.........................................................................................137 Crane Functions....................................................................................................137 Using Outriggers...............................................................................................137 Setting Outriggers.............................................................................................137 Outrigger Monitoring System (OMS) (Optional— Standard in North America and European Union Countries)...........138 Engaging the Mid Extend Lock Pin...............................................................................138 Stowing the Outriggers.........................................................................................138 Stowing Mid-Extend Lock Pin....................................................................................139 Swinging Superstructure........................................................................................139 Elevating and Lowering Boom....................................................................................139 Elevating Boom.............................................................................................139 Lowering Boom..............................................................................................140 Telescoping Boom...............................................................................................140 Telescope Control Pedal....................................................................................140 Extending Boom.............................................................................................140 Retracting Boom............................................................................................140 Activate telescope function with Telescope Enable Switch, then push on bottom of pedal to retract boom.....140 Lower and Raise Hoist Cable....................................................................................140 Lower Cable................................................................................................140 Raise Cable................................................................................................141 Hoist Speed Range Selection....................................................................................141 Stowing and Parking................................................................................................141 Unattended Crane...................................................................................................141 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..........................................................................................145 Cranes with Main Hoist Only....................................................................................145 Machines with Main and Auxiliary Hoists........................................................................146 Cable Reeving..........................................................................................................146 Reeving Boom Cable.................................................................................................147 Dead-End Rigging/Wedge Sockets.........................................................................................147 Installing Wedge and Socket........................................................................................147 Bi-fold Swingaway, Off-settable Boom Extension.........................................................................153 Description........................................................................................................153 Erecting Boom Extension............................................................................................153 Erecting Boom Extension Fly Section................................................................................155 Stowing Boom Extension.............................................................................................155 Setting Boom Extension Manual Offset...............................................................................158 Changing Offset from 0° to 20° or 40°..........................................................................158 Changing Offset from 40° to 20° or 0°..........................................................................158 Erecting and Stowing Bi-fold Boom Extension with 6 m (20 ft) Insert....................................................161 Erecting...........................................................................................................161 Stowing............................................................................................................163 Connecting and Disconnecting Boom Extension............................................................................163 Connecting.........................................................................................................163 Making Electrical Connection Between Boom Extension Base Section and Boom Nose.................................163 Making Electrical Connection Between Boom Extension Base Section and Boom Extension Fly Section................163 Disconnecting......................................................................................................163 Disconnecting Electrical Connection Between Boom Extension Base Section and Boom Nose..........................163 Disconnecting Electrical Connection Between Boom Extension Base Section and Boom Extension Fly Section.........163 Removable Counterweight................................................................................................164 Counterweight Control Panel........................................................................................164 Removing...........................................................................................................165 Installing.........................................................................................................165 SECTION 5......................................................................................................................167 Maintenance and Lubrication................................................................................................167 General................................................................................................................168 Environmental Protection...............................................................................................168 Lubricants and Lubrication Intervals...................................................................................168 Standard Lubricants................................................................................................169 Arctic Lubricants and Conditions...................................................................................171 Temperatures Below -9°C (15°F).................................................................................171 Cold Weather Package and Lubricants............................................................................171 Cylinder Rod Surface Protection........................................................................................174 Wire Rope Lubrication..................................................................................................174 Lubrication Points.....................................................................................................174 CraneLUBE..........................................................................................................174 Cummins Oil Registration List......................................................................................175 Safety.............................................................................................................175 Drive Train........................................................................................................176 Drive Train (continued)............................................................................................177 Drive Train (Continued)............................................................................................179 Drive Train (Continued)............................................................................................180 Steering and Suspension............................................................................................181 Steering and Suspension (Continued)................................................................................182 Axles..............................................................................................................183 Turntable..........................................................................................................184 Turntable (Continued)..............................................................................................185 Cab Tilt...........................................................................................................185 Outriggers.........................................................................................................186 Lift Cylinder......................................................................................................187 Boom...............................................................................................................188 Boom (Continued)...................................................................................................189 Boom (Continued)...................................................................................................192 Hoist..............................................................................................................193 Hydraulic..........................................................................................................194 Rust Protection........................................................................................................195 Cleaning Procedures................................................................................................195 Inspection and Repair..............................................................................................196 Application........................................................................................................196 Areas of Application...............................................................................................196 Alphabetical Index.........................................................................................................199
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