Crane Load Monitoring Retrofit System for Legacy Mobile Cranes

Manitowoc introduces an upgrade system enabling older Grove cranes to adopt modern lift management and wireless sensor monitoring technology through retrofit installation.  www.manitowoc.com Load monitoring and lift control systems play a central role in crane safety and operational efficiency, particularly when handling variable loads and boom configurations. In this context, Manitowoc introduced the upFLEX Rated Capacity Limiter (RCL), an aftermarket upgrade system designed to retrofit older Grove rough-terrain and truck cranes with updated lift management technology. Retrofit system updates load management in existing crane fleets Many mobile cranes remain in operation for decades, creating demand for retrofit technologies that bring older machines closer to current digital control standards. The upFLEX Rated Capacity Limiter (RCL) addresses this need by replacing earlier iFLEX RCL systems used in Grove cranes manufactured between 2002 and 2023. The upgrade system provides a standardized lift management interface for operators working across mixed crane fleets. It is compatible with a wide range of Grove rough-terrain cranes and truck cranes that previously used earlier iFLEX systems. The design introduced a new 7-inch operator console with updated interface controls that allow operators to switch between working screens and operating modes through a unified display layout. By standardizing the operator interface across older crane models, the system helped simplify training and improve operational consistency. Plug-and-play integration through CAN-BUS connectivity The retrofit system connects directly to the crane’s CAN-BUS network using the machine’s onboard Ethernet connection. This architecture allows the unit to be installed without major mechanical modifications to the crane control system. Because the device integrates directly with existing communication networks, installation is designed as a plug-and-play upgrade, reducing the time required to modernize older machines. Such connectivity supports the broader adoption of digital construction equipment technologies that rely on electronic load monitoring and data exchange between machine components. Wireless sensor monitoring through APEX indicator Alongside the new load management system, Manitowoc also introduced the APEX stand-alone indicator, designed to work with wireless sensors on Grove cranes. The indicator provides a wireless connection to two critical safety sensors: the anti-two-block sensor and the wind speed sensor. Sensor status is displayed graphically to the operator inside the crane cab, allowing continuous monitoring of these parameters during lifting operations. These sensors play an important role in preventing lifting incidents. The anti-two-block system helps detect situations where the hook block approaches the boom tip, while wind speed monitoring helps operators evaluate environmental conditions that may affect lift stability. Replacement of earlier iFLEX load monitoring systems The upFLEX RCL replaces several earlier systems previously installed on Grove cranes, including iFLEX5 (LI5G), iFLEX5 (CGMK), and iFLEX2 (LSQG). By allowing existing cranes to upgrade to a more recent load monitoring system, the retrofit solution enables equipment owners to extend the operational life of mobile cranes while updating safety monitoring and operator interface capabilities. Manitowoc presented the retrofit technologies at CONEXPO CON/AGG 2026, held March 3–7, 2026, in Las Vegas, Nevada, USA, where they were demonstrated as part of the company’s crane technology portfolio. www.manitowoc.com Edited by industrial journalist, Aishwarya Mambet. Powered by Induportals Media Publishing