Page 1 GHC55 Operating and Maintenance Manual GHC 55 Read this manual completely before using for the first time! ȀȀȀ ! Translation of the original Published 01-05-2016, Control # 565-02...
Page 2 GHC55 Use of the Read this manual carefully all the way through before you work with  manual the machine. Always keep this manual in the cab for future use.  In the event of sale, disposal or loan, the manual must accompany ...
Page 3 GHC55 Presentation of listings Text. Text. Listings are marked with bullet points.  – Text. Text. Sub-points in listings or procedures are marked with dashes. Target group The machine has been developed for demanding tasks. Persons working on or with the machine must be trained or instructed for this purpose.
Page 4 GHC55 7: Setup tasks  Chapter 6 contains procedures for mounting and dismounting components, for example, MOUNTING THE FLY BOOM 8: Transport:  Dimensions and weights of the machine are found in chapter 7. 9: Maintenance:  Chapter 8 presents procedures for ensuring the functionality of the machine.
Page 5 Table of Contents GHC55 Safety ........1-1 1.1 Presentation of safety information .
Page 6 Table of Contents GHC55 3.5.1 Procedure when reaching the limit value "wind in operation" 3-8 3.5.2 Procedure when reaching the limit value "wind not in operation" 3-8 3.6 Hooks ........3-9 3.7 Dimensions of the basic machine .
Page 7 Table of Contents GHC55 5.2.6 Working diagram ....5-15 5.2.7 Winch parameters ....5-16 5.3 Load moment limitation .
Page 8 Table of Contents GHC55 6.5.1 DEF/system for reducing nitrogen oxide (Tier 4f engines) 6-21 6.5.2 Exhaust aftertreatment system regeneration (Tier 4f engines) 6-23 6.5.3 Control panel - automatic air conditioning . 6-26 6.5.4 Camera system ..... 6-29 6.6 Load moment limitation (LML) .
Page 9 Table of Contents GHC55 7.1.1 Mounting/Removing ....7-2 7.1.2 Stowing ......7-4 7.2 Setup operating mode .
Page 10 Table of Contents GHC55 8.7 Lifting the machine ..... . . 8-14 Maintenance ....... . . 9-1 9.1 Cleaning tasks .
Page 11 Table of Contents GHC55 9.12.1Lubricating the slewing ring bearing race . 9-69 9.12.2Lubricating the slewing ring gearing ..9-71 9.12.3Tightening the slewing ring bolts ..9-75 9.13 Telescopic boom ......9-77 9.13.1Lubricating the telescopic boom .
Page 12 Table of Contents GHC55 11.7 Residual Useful Life of Winches ... . . 11-1 11.8 Installing Large Roller Bearings, Slewing Gears and Flange Connections 11-1 11.9 PFEIFER Pouch Lock System ....11-1 11.10List of Operating Fluids and Lubricants .
Page 13 Safety - Presentation of safety information GHC55 Safety 1.1 Presentation of safety information This operating manual contains warnings to alert you to hazardous situations. Safety This is the safety alert symbol. alert symbol It is used to alert you to potential injury hazards. Observe all safety information that follow this symbol to avoid possible injury or death.
Page 14 Safety - Danger sources GHC55 1.2 Danger sources The machine has been built in accordance with the state of the technology and the recognized safety regulations. Nevertheless, there may be dangers during its use to personnel, machines and other material assets, if... the machine is not used as intended, ...
Page 15 Safety - Intended use GHC55 Intended use always requires that: all instructions, safety notices, and rules for avoiding hazards in the  operating manual are complied with during operation and during assembly, disassembly, service, maintenance, and fault diagnosis, the acoustic and visual warning signals are perceived and ...
Page 16 Safety - Intended use GHC55 Embankments and The crane must be set up with a sufficient safety distance to excavations embankments and excavations. The distance depends on the type of ground. Personal injury and material damage due to the machine WARNING slipping! The machine slips off of the embankment.
Page 17 Safety - Impermissible use GHC55 Impermissible use Impermissible The operational safety of the machine is only ensured if used as operating methods intended and according to this operating manual. The capacity information specified in Chapter 3 T must ECHNICAL DATA not be exceeded.
Page 18 Safety - Crane categorization GHC55 Crane categorization As specified in the standard, the crane is a mobile crane for assembly operation. Overall crane The crane is categorized in crane group A1 and is designed and calculated for collective class Q1 and operating class U2 in accordance with ISO 4301 Part 1 and 2.
Page 19 Safety - Requirements on personnel GHC55 Owner The owner (entrepreneur/enterprise) is whoever operates the product and uses it in accordance with its intended use or allows the product to be operated by suitable and instructed personnel. Operating personnel Operating personnel are those persons authorized by the owner to operate the product.
Page 20 Safety - Work operation GHC55 1.8 Work operation Danger to life due to uncontrolled movement of loads and DANGER machine parts! Persons on or next to the machine will be injured due to uncontrolled movements of the machine or of the load. Always engage the running gear parking brake before switching off the machine.
Page 21 Safety - Work operation GHC55 Danger to life when the work area set in a working area limitation WARNING is exceeded! If machine motions are executed quickly when an optional work area limitation is used, the set work area can be exceeded. This can cau- se severe or fatal injury.
Page 22 Safety - Work operation GHC55 Danger of injury due to crushing between the machine and WARNING stationary fixtures! Persons can be crushed between the cab and and a stationary fixture. Maintain a minimum distance of 500 mm between the machine and the stationary fixture.
Page 23 Safety - Work operation GHC55 Personal protective Operating personnel are obligated to wear the personal protective equipment equipment prescribed by national regulations when working on the machine (for example hard hat, hearing protection, protective gloves, safety footwear). At working heights of 2.00 m or more, Grove recommends the use of a safety harness to prevent falling.
Page 24 Safety - Work operation GHC55 Vibration The machine operator is protected against mechanical vibration with a shock-cushioning seat that can be adjusted for the operator's weight. The seat height and backrest are adjustable. The optimal work position can be set for each individual driver. The alarm values for hand-arm vibration (2.5 m/s ) and for full-body vibration (0.5 m/s ) are not...
Page 25 Safety - Work operation GHC55 Safety distances to overhead lines Nominal voltage (volts) Safety distance m (ft) for the USA to 750 V 4 (1.22), with lowered boom over 750 V to 50 kV 6 (1.83), with lowered boom over 50 kV to 345 kV 10 (3.05), with lowered boom over 345 kV to 750 kV 16 (4.87), with lowered boom...
Page 26 Safety - Work operation GHC55 1.8.1 Boarding or exiting the crane safely Enter and exit machine only when it is at a standstill. Use the access  steps and/or ladders intended for this purpose: – If necessary, clean access steps and ladders prior to use. –...
Page 27 Safety - Work operation GHC55 1.8.3 Regulations for applications planning When planning an application, the following anticipatory inspections must be performed by the owner: Inspection for conformity of the anticipated application with the  technical data of the machine, for example, with the anticipated crane application: Required safe working load, working radius, hook height Inspection of the external conditions, for example, effects of wind,...
Page 28 Safety - Work operation GHC55 1.8.4 Ramming tasks or pulling sheet pile walls Strong vibration can occur when performing pile driving tasks and pulling sheet pile walls. This can cause premature material fatigue and cracks in load-bearing steel constructions. Vibrations on the pile driver must not be permitted to transfer to the boom.
Page 29 Safety - Work operation GHC55 1.8.5 Deployment on a pontoon If the following requirements are met, the machine can be deployed on a pontoon. General requirements Secure the machine on the pontoon to prevent it from shifting.  Attach sturdy stops on the pontoon (Fig. 1). Alternatively, lash the machine using the optional eyes on the undercarriage (Fig.
Page 30 Safety - Work operation GHC55 Deployment scenarios The following deployment scenarios are possible. Additional require- ments must be met. 1) The pontoon is stabilized and in a horizontal position: – The standard load charts without incline apply. 2) The pontoon is stabilized, however, inclined up to a maximum of 4°: –...
Page 31 Safety - Work operation GHC55 1.8.6 Start-up A thorough inspection of the machine must be performed prior to every start-up. Comply with Chapter 1 S  AFETY Before start-up, carry out checks in accordance with Section 4.2. Check protective devices for completeness, functionality, and ...
Page 32 Safety - Work operation GHC55 1.8.7 Operation Comply with Chapter 1 S  AFETY Before start-up, carry out checks in accordance with Section 4.2. The following applies to all tasks: Only carry out the task if the work  area has a firm, level ground with sufficient load-bearing capacity. Do not drag loads over the ground.
Page 33 Safety - Work operation GHC55 1.8.9 Decommissioning If wind speeds exceed the permissible values, depending on the  equipment status, crane operation must be stopped (in accordance with Chapter 3.5). Before exiting the cab:  – Completely lower the cab. –...
Page 34 Safety - Maintenance GHC55 Do not climb onto equipment parts (for example boom sections,  ballast parts) that are hanging from a crane. 1.9 Maintenance Danger to life due to sudden movement or unintentional DANGER starting of the machine! Persons on or in the work area of the machine will be caught and injured by the machine.
Page 35 Safety - Transport GHC55 If necessary, use the optional battery disconnect switch to interrupt  the current supply. Before performing any work in the area of the battery, cover the  battery with insulating material. Do not place tools on the battery. Reattach all protective devices after completion of maintenance ...
Page 36 Safety - Responsibilities of the owner GHC55 1.11 Responsibilities of the owner Recurring Inspection by an expert checks The machine must be thoroughly inspected by an expert: before start-up and before operating the machine after significant  modifications at least once a year ...
Page 37 Safety - Protective devices GHC55 Ensure that the operators have the necessary qualifications for the  intended tasks. Ensure that the content of this manual is read and completely  understood. In accordance with the EC Machinery Directive, a manual must be available in the language of the destination country. If necessary, purchase the manual in the appropriate official language from Grove.
Page 38 Safety - Machine labelling GHC55 1.13Machine labelling The machine is provided with specific warning and information signs. Do not remove the signs.  Ensure that all signs and labels are undamaged and legible.  Clean soiled labels with soap and water if necessary, do not use fuel ...
Page 39 Safety - Warning and information signs GHC55 1.14 Warning and information signs Information The overviews and descriptions of the warning and information signs on the machine are located in the appendix of the manual. ()*+ Ȁ - ),*.*+ Ȁ /)01. 2 * Ȁ...
Page 40 Safety - Warning and information signs GHC55 This Page Blank 1 - 28 Published 01-05-2016, Control # 565-02...
Page 41 Overview - Overall machine GHC55 Overview 2.1 Overall machine Ȁ & " Ȁ ȀȀ Fig. 4 Components of the machine Clamping tongs Bottom hook block Luffing cylinder Soil drill Telescopic boom Winches Undercarriage Counterweight Uppercarriage Grove 2 - 1 Published 01-05-2016, Control # 565-02...
Page 42 Overview - Undercarriage GHC55 Undercarriage Fig. 5 Components of the undercarriage Idler (forward direction of Track roller travel) Access ladder, folding Drive wheel (reverse direction of travel) Carrier roller Crawler track 2 - 2 Published 01-05-2016, Control # 565-02...
Page 43 Overview - Cab GHC55 2 3 4 Fig. 6 Components of the cab Visual and acoustic Safety lever warning system LML Camera Heating/air-conditioning display system Pedals Control panel, top right SENCON diagnostic and Radio control system Control panel, right Beacon Control levers, left and right Grove...
Page 44 Overview - Uppercarriage GHC55 Uppercarriage " Ȁ %% #& Fig. 7 Service access door, left Battery 24 V power socket Fuel prefilter with Dipstick water separator Battery disconnect switch Combination cooler 2 - 4 Published 01-05-2016, Control # 565-02...
Page 45 Overview - Uppercarriage GHC55 " Ȁ ## $% Fig. 8 Service access door, left Slewing ring lubrication Lubricating strip Slewing gear DEF tank (Tier 4f engines) Grove 2 - 5 Published 01-05-2016, Control # 565-02...
Page 46 Overview - Winch GHC55 Winch Ȁ Fig. 9 Winch layout Winch Lowering limit switch Winch motor with lowering brake valve 2 - 6 Published 01-05-2016, Control # 565-02...
Page 47 Overview - Winch GHC55 Ȁ Fig. 10 Winch positions Winch 1 Winch 2 Allocation of Winch 1: Main boom, auxiliary jib, fly boom attachments to winches Winch 2: Main boom Grove 2 - 7 Published 01-05-2016, Control # 565-02...
Page 48 Overview - Winch GHC55 This Page Blank 2 - 8 Published 01-05-2016, Control # 565-02...
Page 49 Technical data - Basic machine GHC55 Technical data The technical data of the basic machine is listed in Section 3.1. Section 3.6 specifies the load ratings of the machine. Note Shipping dimensions and weights for the basic machine are provided in Section 8.5 T .
Page 50 Technical data - Basic machine GHC55 The speed limitation sticker of the diesel engine must be undamaged and free from soiling. Permitted inclinations of engine: Left Right Front Rear 30° 30° 30° 30° Information If the inclination is excessive, the oil level in the engine can no longer be guaranteed to be sufficient.
Page 51 Technical data - Basic machine GHC55 Modifications to Any modifications of the delivered device on delivered device Engine,  Engine cooling system including ventilation ducts,  Air filter system,  Exhaust aftertreatment system,  Exhaust system  will result in the invalidation of the certification for the diesel engine exhaust emissions and invalidation of the operating certificate for the machine, and also the invalidation of any claims made against Grove.
Page 52 Technical data - Permissible ground pressure GHC55 Permissible ground pressure Risk of personal injury and material damage due to the machine WARNING falling over! If the machine's ground pressure exceeds the load-bearing capacity of the ground at the operation site, then the ground may give in, causing the machine to fall over.
Page 53 Technical data - Permissible ground pressure GHC55 Determining the load- The following table provides an orientation for the load-bearing bearing capacity of the capacity of the ground. The guidelines in the following table must be ground taken into consideration for applications planning. The load-bearing capacity of the ground must be at least as high as the maximum ground pressure.
Page 54 Technical data - Diesel fuel GHC55 3.3 Diesel fuel The Grove factory filling for diesel fuel conforms to EN 590 with a sulphur content of <10 mg/kg. Information The use of sulphur-free fuel in accordance with EN 590 or ASTM D975 S15 is strictly required for engines subject to EU Stage IV and US EPA Tier 4 Final emission standards.
Page 55 Technical data - Engine oil GHC55 Engine oil The Grove factory filling for engine oil is selected for use with sulphur- free diesel fuel with a sulphur content of <15 mg/kg. Information The use of low-ash ACE E9-08 or API CJ-4 engine oils is strictly required for engines subject to EU Stage IIIb and US EPA Tier 4 Final emission standards.
Page 56 Technical data - Permissible wind speeds GHC55 Permissible wind speeds When operating the crane, the displayed wind speed should always be compared with the permissible wind speed. Wind speed can be measured with the optional anemometer. The necessary safety measures (for example, setting down the boom) must be undertaken before the preset limit values are reached.
Page 57 Technical data - Hooks GHC55 Hooks The machine can be equipped with different winches and the associat- ed hooks. The following technical data relates to the possible features of the machine type. Winch tensile force: 50 kN Hoisting rope diameter: 16 mm (0.63 in) Capacity Hook weight in kg (lbs) 80 (176)
Page 58 Technical data - Dimensions of the basic machine GHC55 Dimensions of the basic machine ȀȀ !" Fig. 12 Dimensions of the basic machine – 1 Dimensions Dimensions in mm (inches) in mm (inches) 6 799 (267.7) 2 757 (108.5) 2 466 (97.1) 3 179 (125.2) 3 891 (153.2) 1 254 (49.4)
Page 59 Technical data - Dimensions of the basic machine GHC55 ȀȀ ! " Fig. 13 Dimensions of the basic machine – 2 Dimensions Dimensions in mm (inches) in mm (inches) 2 600 (102.4) 4 100 (161.4) 900 (35.4) 900 (35.4) 3 500 (137.8) 5 000 (196.9) 1 034 (40.7) Grove...
Page 60 Technical data - Working diagram - main boom GHC55 Working diagram - main boom ȀȀ !" Fig. 14 Work range of the machine depending on boom length and the boom angle 3 - 12 Published 01-05-2016, Control # 565-02...
Page 61 Technical data - Weights GHC55 Weights Weight in kg (lbs) Machine with counterweight 45 300 (99 869) Fly boom 6.5 m 600 (1 323) Fly boom 13 m 850 (1 874) 3.10Working loads Information The load ratings apply for  –...
Page 62 Technical data - Working loads GHC55 Wind  Lateral loads  Oscillating loads  Jerking or sudden stopping of the load  Inexperience of operating personnel  Driving with load.  Permissible rope winch Per strand in crane operation: At rope diameter 16 mm 5,000 kg / 11,000 lbs Load capacity reduced with fly boom (6.5 m)
Page 63 Technical data - Conversion factors GHC55 3.11 Conversion factors Pressure 1 bar 100 Kpa 14.5 psi 10 psi 68.95 Kpa 0.6895 bar Flow 1 l/min 0.0353 cfm 0.2642 gal/min (US) 1 gal/min (Brit.) 0.1605 cfm 1 gal/min (US) 3.78541 l/min Length 1 mm 0.03934 in...
Page 64 Technical data - Conversion factors GHC55 This Page Blank 3 - 16 Published 01-05-2016, Control # 565-02...
Page 65 Start-up - GHC55 Start-up Safety at Thoroughly inspect the device before every use. start-up Prior to start up, perform the inspection tasks as specified in  Section 4.2. Check protective devices for completeness, functionality, and  proper fastening. Wear personal protective equipment (for example hard hat, hearing ...
Page 66 Start-up - Initial start-up GHC55 Initial start-up The initial start-up of the machine is carried out by Grove or by a trained and authorized specialist. If the machine was shut down for a prolonged period (> 6 months), contact GROVE Cranecare before start-up. 4.2 Checks before start-up Familiarize yourself with the machine and its equipment.
Page 67 Start-up - Checks before start-up GHC55 Is the load weight known?  Is an experienced person available for signaling, if required?  Are the machine and sling devices appropriate for the loads to be  attached? Observe the instructions in Section 3 T ECHNICAL DATA Are danger zones (overhead lines, ditches, etc.) marked and ...
Page 68 Start-up - Switching on the battery disconnect switch GHC55 Switching on the battery disconnect switch Open the left service access door (1) in Fig. 15. Turn the battery disconnect switch (2) in Fig. 15 to position I. Close the service door. Ȁ...
Page 69 Start-up - Machine start GHC55 Machine start After switching the machine off, wait for at least 15 seconds before  a restarting it. Keep the service doors closed.  Before starting the engine, ensure that no one is in the danger zone. ...
Page 70 Start-up - Machine start GHC55 4.4.1 Fastening the seat belt Danger of injury due a defective seat belt! WARNING If there is collision or jerky machine movements personnel can be thrown against cab parts and injured. Check belt for signs of wear before starting up the machine. Replace the belt immediately if damaged.
Page 71 Start-up - Machine start GHC55 Opening the seat belt ȀȀ !" Fig. 17 Opening the seat belt Pull the release (1) in Fig. 17 on the belt buckle (2) in Fig. 17 upward. – The belt buckle opens. Grove 4 - 7 Published 01-05-2016, Control # 565-02...
Page 72 Start-up - Machine start GHC55 4.4.2 Starting the engine Danger of poisoning due to exhaust gases! WARNING Inhaling exhaust gases results in unconsciousness or death. Never leave the machine unattended with the engine running. Only run the engine outdoors or in well-ventilated areas. Danger of severe injury due to unintentional activation of the WARNING joystick or pedals!
Page 73 Start-up - Machine start GHC55 Select the operating mode on the SENCON. Push the button 1 on the right joystick. – The horn sounds. Ȁ Turn the ignition key to position II. Fig. 20 Horn Ignition key position Ignition key position Meaning Enable fuel pump Ignition OFF...
Page 74 Start-up - Machine start GHC55 Automatic idle and Automatic idle and EcoMode are configured on the SENCON. EcoMode Symbol Name Description Automatic idle Automatic idle automatically lowers the engine speed for pauses in work. This saves fuel and protects the Ȁ...
Page 75 Start-up - Machine start GHC55 4.4.3 Selecting setup status The machine operating parameters for the desired use are configured in the Load Moment Limitation window. The Load Moment Limitation window automatically appears after the ignition is turned on and the SENCON starts. Switch on the battery disconnect switch.
Page 76 Start-up - Machine start GHC55 Set additional operating parameters as needed until the setup status on the SENCON matches that of the machine. 4.4.4 Bringing the machine to operating temperature Machine damage and danger of injury! WARNING Operating the machine without allowing it sufficient time to warm up can damage the engine and other components.
Page 77 Start-up - Machine start GHC55 4.4.5 Jump start The machine is equipped with a 24 volt starting system. Ensure that the external power source has the same voltage. Danger of explosion due to improper handling of the battery! WARNING An exploding battery causes personal injury and material damage. Avoid creating sparks by fire, naked light, or smoking.
Page 78 Start-up - Switching off engine GHC55 4.5 Switching off engine Danger of acid burns due to escaping battery acid! WARNING Escaping battery acid burns skin, eyes or clothing. Avoid any contact with the skin, eyes or clothing. Rinse off acid splashes and spills with clean water immediately. If there is contact with the eyes, seek the attention of a physician.
Page 79 Start-up - Decommissioning the machine GHC55 Decommissioning the machine Information Check the seals every 6 months. Proceed as follows if the machine is to be decommissioned for a prolonged period: Choose a storage location that is as dry and dust-free as possible.
Page 80 Start-up - Preservation and storage GHC55 Preservation and storage Proceed as follows if the machine will be preserved or stored for a longer period of time: Select the storage location where the possibility of hazards can be excluded. Set down the attachment on wooden planks to prevent freeze Perform the maintenance for 2000 hours of operation (annual interval).
Page 81 Start-up - Starting up the machine after long-term storage GHC55 Starting up the machine after long-term storage Proceed as follows to recommission a preserved machine: Remove the corrosion protection agent in a suitable manner, for example using a high-pressure cleaner with a suitable cleaning additive (be careful around sensitive components and electronic components!).
Page 82 Start-up - Starting up the machine after long-term storage GHC55 This Page Blank 4 - 18 Published 01-05-2016, Control # 565-02...
Page 83 SENCON 2.0 - GHC55 SENCON 2.0 Ȁ ! ȀȀ ! " About this chapter This chapter describes the SENCON 2.0 diagnostic and control system. The SENCON provides up-to-date operating data on the machine and can statistically evaluate this data as needed. It can also configure various machine parameters and run error diagnostics.
Page 84 SENCON 2.0 - Overview of controls GHC55 5.1 Overview of controls +,() Ȁ-) ' () "#$%" "#$%" "#$%" '()* " & #$%& #$%& ' () ' () & ' (),- Ȁ,! -. Ȁ-/ ' 01 2,Ȁ-3 4,5-3 Ȁ ! ȀȀ Ȁ! Fig.
Page 85 SENCON 2.0 - Overview of controls GHC55 5.1.1 Quick selection icons Symbol Name Description Automatic idle Automatic idle automatically lowers the engine speed for pauses in work. This saves fuel and protects the Ȁ !" environment. #$% & # Automatic idle has three stages: Stage 1: 1,440 rpm after 5 seconds of inactivity.
Page 86 SENCON 2.0 - Overview of controls GHC55 Symbol Name Description Uppercarriage slewing The slewing speed of the uppercarriage can be speed reduced for more precise movement. Settings Reduced slewing speed. Normal slewing speed. Show quick selection Hidden quick selection icons are displayed. icons 5.1.2 Menu icons Symbol...
Page 87 SENCON 2.0 - Start screen GHC55 5.2 Start screen +,() Ȁ-) &'( "#$%" "#$%" "#$%" '()* Ȁ & !"# !"# &'( &'( &'(+,-+.,/ -,0&12 3+-,4 5+6,4 Ȁ ! --%-6 Fig. 24 Start screen Operating status Load capacity scale Winch parameters Notification icons, joystick assignment and slew uppercarriage Configured LML operating mode parameters, see Chapter 5.3 Diesel engine notification and warning icons...
Page 88 SENCON 2.0 - Start screen GHC55 5.2.1 Operating status The displays (1) in Fig. 24 on the start screen show the most commonly needed operating status values at a glance. The operating status display can appear in different colors: Gray: Operating status is within normal range. ...
Page 89 SENCON 2.0 - Start screen GHC55 Symbol Name Description Current fuel consumption DEF level (Tier 4f Gray: engines) DEF level normal.  Orange: Refill DEF tank at the next  opportunity. Red: Refill DEF tank immediately.  Hydraulic oil temperature Gray: Hydraulic oil temperature normal.
Page 90 SENCON 2.0 - Start screen GHC55 5.2.2 Telescopic boom and slew uppercarriage notification icons Symbol Possible Explanation statuses Winch 1 is operated with the left joystick. Winch 2 is operated with the right joystick. Switch position: Ȁ Ȁ Winch 2 is operated with the left joystick. Winch 1 is operated with the right joystick.
Page 91 SENCON 2.0 - Start screen GHC55 Symbol Possible Explanation statuses Slewing gear freewheel disengaged. Slewing gear freewheel engaged. Slewing gear freewheel not available. If an uppercarriage inclination of more than 0.3° is set in the Load moment limitation window, the slewing gear freewheel cannot be engaged.
Page 92 SENCON 2.0 - Start screen GHC55 5.2.3 Diesel engine notification and warning icons Symbol Description Status Serious diesel engine Gray: error Diesel engine is functioning properly.  Ȁ !" Red: Park machine at a safe location immediately.  Contact your Grove Service Partner. ...
Page 93 SENCON 2.0 - Start screen GHC55 Symbol Description Status DEF quality (Tier 4f Gray: engines) DEF quality normal.  Orange: Drain DEF tank.  Refill DEF.  Preheating Gray: Diesel engine ready.  Orange: Diesel engine preheating.  Battery Gray: Battery charging.
Page 94 SENCON 2.0 - Start screen GHC55 5.2.4 Load moment limitation notification and warning icons Symbol Possible Explanation statuses Gray: Load moment limitation functioning properly.  Orange: LML error  Check error number in the diagnostics windows.  Contact your Grove Service Partner. ...
Page 95 SENCON 2.0 - Start screen GHC55 Symbol Possible Explanation statuses Gray: Lifting limit switch off.  Red: Lifting limit switch on.  Red: Lifting limit switch bypassed.  5.2.5 Overall machine notification and warning icons Symbol Possible Explanation statuses Gray: No error.
Page 96 SENCON 2.0 - Start screen GHC55 Symbol Possible Explanation statuses The emergency stop is deactivated. All machine functions are available. The emergency stop is activated. The machine is shut down. 5 - 14 Published 01-05-2016, Control # 565-02...
Page 97 SENCON 2.0 - Start screen GHC55 5.2.6 Working diagram " & ȀȀ Ȁ! Fig. 25 Working diagram Wind speed Telescopic boom length Telescopic boom angle Working radius Machine inclination Telescopic boom height Track width The direction of movement of the work equipment is shown as a triangle in the working diagram.
Page 98 SENCON 2.0 - Start screen GHC55 Symbol Name Description Track width monitoring Gray: Track width permitted for the selected oper-  ating mode Red: Track width not permitted for the selected  operating mode 5.2.7 Winch parameters Ȁ "" ! # Fig.
Page 99 SENCON 2.0 - Load moment limitation GHC55 5.3 Load moment limitation The load moment limitation operating parameters for the desired operating mode are configured in the Load moment limitation window. The Load moment limitation window automatically appears after the ignition is turned on and the SENCON starts. Opening LML settings Press the HOME button.
Page 100 SENCON 2.0 - Load moment limitation GHC55 Information If the current load capacity is greater than a specified load, the load change lock (10) in Fig. 27 prevents the LML operating parameters from being modified. When the load change lock is active, a closed lock icon appears.
Page 101 SENCON 2.0 - Load moment limitation GHC55 5.3.1 Entering uppercarriage inclination The maximum uppercarriage inclination while in operation is entered in the Uppercarriage inclination window. Ȁ !"#$"%#& Ȁ !"#'"$#& Ȁ !"#("$#& $$'$) Fig. 28 Uppercarriage inclination Press the SCROLL wheel. –...
Page 102 SENCON 2.0 - Load moment limitation GHC55 5.3.2 Entering undercarriage ballast The weight of the attached undercarriage ballast is entered in the Undercarriage ballast window. Ȁ"# ȀȀ ! Ȁ Fig. 29 Undercarriage ballast Press the SCROLL wheel. – The selected LML parameter is outlined in black. Turn the SCROLL wheel until the Undercarriage ballast LML parameter is selected.
Page 103 SENCON 2.0 - Load moment limitation GHC55 5.3.3 Entering winch reeving The reeving number of the selected winch is entered in the Winch reeving window. Ȁ !" #$ %&'()*+ , !-&' !" +$ ,- $%& "! '"( Ȁ !"# ) * "# ./ '' 0* !! 2.
Page 104 SENCON 2.0 - Load moment limitation GHC55 5.3.4 Setting travel speed The maximum travel speed of the machine is set in the Travel speed window. Ȁ"#$ %& Ȁ'( "#$ %& ȀȀ Ȁ! Fig. 31 Travel speed Press the SCROLL wheel. –...
Page 105 SENCON 2.0 - Load moment limitation GHC55 5.3.5 Entering track width The track width of the machine is entered in the Track width window. " ȀȀ Ȁ! Fig. 32 Track width Press the SCROLL wheel. – The selected LML parameter is outlined in black. Turn the SCROLL wheel until the Track width LML parameter is selected.
Page 106 SENCON 2.0 - Load moment limitation GHC55 5.3.6 Entering attachments and configuring setup program Attachments and boom extensions on the machine are entered in the Attachments and setup program window. Ȁ !"#$%&"'() !*+&" , -. , -. , -23 , -23 "...
Page 107 SENCON 2.0 - Load moment limitation GHC55 Press the SCROLL wheel. Configure other LML parameters as needed. Press the SET button. – The LML parameters are saved. The start screen appears. Grove 5 - 25 Published 01-05-2016, Control # 565-02...
Page 108 SENCON 2.0 - Load moment limitation GHC55 5.3.7 Entering counterweight The attached counterweight is entered in the Counterweight window. " # $%& ȀȀ ! ! Fig. 34 Counterweight Press the SCROLL wheel. – The selected LML parameter is outlined in black. Turn the SCROLL wheel until the Counterweight LML parameter is selected.
Page 109 SENCON 2.0 - Setting language GHC55 5.4 Setting language Language settings The language of the display text is set in the window. Opening language settings Press the HOME button. Press the Device settings menu button. Ȁ !"# "$%&$''(!"& Ȁ ! "#$$ %&...
Page 110 SENCON 2.0 - Setting brightness GHC55 5.5 Setting brightness The brightness of the display and buttons is configured in the brightness window. Opening brightness settings Press the HOME button. Press the Device settings menu button. Turn the SCROLL wheel one step to the right. Ȁ...
Page 111 SENCON 2.0 - Setting brightness GHC55 Set brightness Press the SCROLL wheel. – A black selection box shows the selected brightness setting. Turn the SCROLL wheel to select the desired brightness setting. 1 Display  2 buttons  Press the SCROLL wheel to set the brightness. –...
Page 112 SENCON 2.0 - Setting date and time GHC55 5.6 Setting date and time The date and time are configured in the Date and time window Opening the date and time settings Press the HOME button. Press the Device settings menu button. Turn the SCROLL wheel two steps to the right.
Page 113 SENCON 2.0 - Setting date and time GHC55 Setting date and time Press the SCROLL wheel. – A black selection box indicates the selected field. Turn the SCROLL wheel until the field you want to edit is outlined in black. Press the SCROLL wheel.
Page 114 SENCON 2.0 - Configuring units GHC55 5.7 Configuring units The displayed units of measurement are configured in the System of units window. Opening the unit settings Press the HOME button. Press the Device settings menu button. Turn the SCROLL wheel three steps to the right. Ȁ...
Page 115 SENCON 2.0 - Configuring units GHC55 Configuring units of measurement Press the SCROLL wheel. – A black selection box indicates the selected unit setting. Press the SCROLL wheel. – The selection window for the unit being configured appears. Turn the SCROLL wheel to select the desired value. Press the SET button.
Page 116 SENCON 2.0 - USB GHC55 5.8 USB The USB window can only be used by personnel authorized by Grove for diagnostics and configuration purposes. Ȁ ! Ȁ !"#$%&#!''#"!&! ($)&*!+ #%,"!& -!+!. & +#%,"!& /,"!& #0$123%+!&4$1 5%++ 1&#6 7 '###########8+47 + 999:: Fig.
Page 117 SENCON 2.0 - Histogram GHC55 5.10 Histogram The Histogram window measures the speed curve over a specific time period. The measured speed curve is displayed in a histogram. Opening the histogram Press the HOME button. Press the Info menu button. ()**+ Ȁ...
Page 118 SENCON 2.0 - Login information GHC55 5.11 Login information The Login information window can only be used by personnel authorized by Grove for diagnostics and configuration purposes. Ȁ ! "#$ %& $ "'()"(*' % + &$ "'( , &+ Ȁ -'+ .&...
Page 119 SENCON 2.0 - General information GHC55 5.12 General information The General information window displays general information on the machine and the SENCON. Opening General information Press the HOME button. Press the Info menu button. Turn the SCROLL wheel two steps to the right. Ȁ...
Page 120 SENCON 2.0 - Diagnostics GHC55 5.13 Diagnostics The Active faults engine, Active faults machine and Active faults RCL diagnostic windows display the current machine status and errors. Some error messages can be corrected by the operator. Troubleshooting steps can be found in the overview at the end of this chapter.
Page 121 SENCON 2.0 - Diagnostics GHC55 5.13.1 Active faults engine The Active faults engine window displays the diesel engine errors that have occurred. Opening Active faults engine Press the HOME button. Press the Diagnostics menu button. Ȁ !"#$%&'()!*%+,-",$ !"# ' ( )*+,-.,/0 Ȁ...
Page 122 SENCON 2.0 - Diagnostics GHC55 5.13.2 Active faults machine The Active faults machine window displays the overall machine errors that have occurred. Opening Active faults machine Press the HOME button. Press the Diagnostics menu button. Turn the SCROLL wheel one step to the right. Ȁ...
Page 123 SENCON 2.0 - Diagnostics GHC55 Overview of status messages SENCON Description Remedy icon 1011001 Hydraulic oil Let diesel engine go to idle.    temperature too high Check cooler for contamination   and clean as needed. 1011002 Hydraulic oil return filter Contact your Grove Service ...
Page 124 SENCON 2.0 - Diagnostics GHC55 SENCON Description Remedy icon Intake manifold Let diesel engine go to idle.    temperature too high. Switch off the diesel engine.   Let diesel engine cool down.   Check combination cooler for ...
Page 125 SENCON 2.0 - Diagnostics GHC55 SENCON Description Remedy icon 1761 DEF level low (Tier 4f Add DEF.    engines)   4096   3364 DEF quality bad (Tier 4f Check DEF quality with    engines) refractometer.
Page 126 SENCON 2.0 - Diagnostics GHC55 5.13.3 Active faults RCL The Active faults RCL window displays the LML errors that have occurred. Opening Active faults machine Press the HOME button. Press the Diagnostics menu button. Turn the SCROLL wheel two steps to the right. Ȁ...
Page 127 Operation - Safety instructions GHC55 Operation 6.1 Safety instructions Comply with Chapter 1 S  AFETY Before start-up, execute checks in accordance with Section 4.2. Persons who work on or with the machine must be trained or  instructed for this purpose. Work only if the work area is level and solid enough.
Page 128 Operation - Safety instructions GHC55 Machine failure due to lightning strike! NOTICE Lightning strike can result in malfunction or total failure of the vehicle electronics. Make sure the controls and safety features are working properly before starting the machine back up. Risk of damage to the machine when freeing jammed loads.
Page 129 Operation - Cab GHC55 6.2 Cab Ȁ " Fig. 48 Cab components Work light Sliding door Front windshield - pop-out Emergency hammer Door lock and handle The comfort cab offers you a comfortable and safe workstation. You can individually adapt certain components to your own requirements. Emergency exit In an emergency, you can exit via the side windows or windshield.
Page 130 Operation - Cab GHC55 Sliding door The sliding door (5) in Fig. 49 can be held open with a catch on the side panel of the cab. Pulling on the release lever (5a) in Fig. 49 on the inside of the door releases the locking mechanism. Fig.
Page 131 Operation - Cab GHC55 Opening and closing the windshield Press both buttons (2a) in Fig. 50. Push the windshield forward to open it. To close the windshield, push the buttons (2a) in Fig. 50 and pull on the handles (2b) in Fig. 50 until the windshield locking mechanism engages.
Page 132 Operation - Cab GHC55 Turning the spotlight on and off Turn the switch (1) in Fig. 52 to position I. – This turns on the spotlight (2) in Fig. 52. Turn the switch (1) in Fig. 52 to position 0. –...
Page 133 Operation - Cab GHC55 Note Refer to the radio manufacturer's operating manual for more information. 6.2.1 Driver seat Danger of accident due to incorrect use of the driver seat! WARNING Risk of personal injury as a consequence of malfunctions of the driver seat.
Page 134 Operation - Cab GHC55 Fig. 54 Driver seat Weight adjustment Height adjustment Seat tilt adjuster (option) Seat depth adjuster (option) Armrest tilt adjuster (option) Arm rests (option) Headrest/seatback extension Seat heater Lumbar support Backrest adjustment Horizontal suspension (option) Length adjustment 6 - 8 Published 01-05-2016, Control # 565-02...
Page 135 Operation - Cab GHC55 6.2.2 Tilting the cab Risk of death from shearing and crushing when tilting the cab. WARNING Persons can be crushed between the cab and the undercarriage. Make sure no one is underneath, behind or on top of the cab when tilting it. Start the diesel engine.
Page 136 Operation - Operating elements in the cab GHC55 6.3 Operating elements in the cab 2 3 4 Fig. 56 Components of the cab Visual and acoustic Safety lever warning system - LML Camera display Heating/air-conditioning system Pedals Control panel, top right SENCON CONTROL Radio System...
Page 137 Operation - Operating elements in the cab GHC55 6.3.1 Emergency stop switch The emergency stop switch (1) in Fig. 57 is located on the bottom right control panel and immediately shuts down the machine when pressed. Fig. 57 Emergency stop switch Positions: Pulled = machine On Pushed = machine Off...
Page 138 Operation - Operating elements in the cab GHC55 Fig. 59 Safety lever released (pushed forward) When the safety lever is released (see illustration) All hydraulic functions are available.  All work maneuvers can be carried out.  6 - 12 Published 01-05-2016, Control # 565-02...
Page 139 Operation - Operating elements in the cab GHC55 6.3.3 Assignment of the joysticks and pedals Risk of damage to the machine due to improper handling of the NOTE slewing gear holding brake. Using the slewing gear holding brake during work can damage the machine.
Page 140 Operation - Operating elements in the cab GHC55 6.3.4 Storage compartment, right of the driver seat " Ȁ Fig. 60 Right storage compartment Hour meter Soil drill on/off (option) Drill speed, slow/fast (option) Open soil drill lock (option) Preselect clamping tons/supplemental hydraulic system (option) Ashtray 6 - 14...
Page 141 Operation - Operating elements in the cab GHC55 Danger to life from preselected supplemental hydraulic system! DANGER Danger to life from preselected supplemental hydraulic system! The clamping tongs will fully close when the Preselect clamping tongs/supplemental hydraulic system switch is set to the Supple- mental hydraulic system position.
Page 142 Operation - Operating elements in the cab GHC55 6.3.5 Control panels, right Emergency stop Winch 1/Winch 2 Release - winch 1 Release - winch 2 Ȁ Luff/telescope boom switch Rapid motion winch 1/2 Release travel mode Travel slow/fast " Speed governor Start/stop engine Automatic climate control Auxiliary heating system timer (option)
Page 143 Operation - Operating elements in the cab GHC55 Ȁ Ȁ Ȁ " "" & #$ % $& % !! #'( Fig. 62 Right control panel next to driver seat Storage compartment LML bypass key switch LML bypass push-button Ignition lock - start engine = Enable the fuel pump = Ignition OFF = Ignition ON (Ignition switch-off after 20 minutes!)
Page 144 Operation - Operating elements in the cab GHC55 6.3.6 Control panel, top right Fig. 63 Top control panel Roof work light Beacon Boom headlight Slewing ring lubrication (option) Uppercarriage headlights Central lubrication system (option) Windshield wiper - windshield Diesel filter heating on/off (option) Windshield washer system Radio operation on/off (option) Windshield wiper - glass roof panel...
Page 145 Operation - Slewing ring lubrication (option) GHC55 6.4 Slewing ring lubrication (option) ȀȀ ! Fig. 64 Position of lubricant reservoir for slewing ring lubrication system Information Clean the lubrication point thoroughly down to the bare metal before the first application of lubricant to ensure that the lubricant creates an uninterrupted lubricant film across the surface! Switch off the diesel engine.
Page 146 Operation - Central lubrication system (option) GHC55 6.5 Central lubrication system (option) The central lubrication system automatically lubricates the bearing race of the rotary connection, the pivot point on the luffing cylinder and telescopic boom on the uppercarriage. The lubrication cycle is pre-set at the factory. Information The preset lubricating cycle can be shortened.
Page 147 Operation - Central lubrication system (option) GHC55 6.5.1 DEF/system for reducing nitrogen oxide (Tier 4f engines) Risk of serious damage to parts due to crystallizing DEF. NOTICE If DEF is not immediately removed, it crystallizes and can cause serious damage. Immediately and thoroughly clean the parts of the machine that come into contact with DEF with water.
Page 148 Operation - Central lubrication system (option) GHC55 Information Check the quality of the DEF with a refractometer before starting up machines that have been in storage. Observe SENCON error messages and refill or replace the DEF as needed. See the DEF manufacturer's MSDS for more information. Preheating DEF DEF is preheated at temperatures around 0 °C using the coolant circuit of the diesel engine.
Page 149 Operation - Central lubrication system (option) GHC55 6.5.2 Exhaust aftertreatment system regeneration (Tier 4f engines) Severe material damage and injury due to burning! WARNING Exhaust becomes very hot during regeneration. Severe burns can occur by coming into contact with exhaust or the exhaust system. Allow the exhaust system to cool down after regeneration.
Page 150 Operation - Central lubrication system (option) GHC55 or near the exhaust system. Turn off automatic idle on the SENCON.  Automatic idle is programmed to turn the engine off if there has been no hydraulic activity for five minutes. Turn off EcoMode on the SENCON. ...
Page 151 Operation - Central lubrication system (option) GHC55 Information The exhaust aftertreatment system can only be regenerated if the load status of the exhaust aftertreatment system is sufficient for the regeneration process. If the load status is sufficient, the following indicator light illuminates on the SENCON: Information The escalation levels pertaining to the load status of the exhaust...
Page 152 Operation - Central lubrication system (option) GHC55 6.5.3 Control panel - automatic air conditioning The machine is equipped with air conditioning automation that enables exact heating or cooling. Safety instructions Maintenance and repair tasks must only be executed by trained ...
Page 153 Operation - Central lubrication system (option) GHC55 Information Press the A/C button (4) in Fig. 66 two times to switch on the heating/ air conditioning. Information Keep windows and cab door closed to ensure effective air conditioning. The air conditioner regulates the temperature depending on the ambient temperature.
Page 154 Operation - Central lubrication system (option) GHC55 Switching on the air conditioning Start the diesel engine. system Turn on the blower (1) in Fig. 66 on the right control panel. Open the air nozzles in the cab to prevent the evaporator from icing up.
Page 155 Operation - Central lubrication system (option) GHC55 6.5.4 Camera system MC7115P-3 +MC7000-MH2 MD3072B-Quad+MD-KG MKW30 MKW20 MKWW10 MC7115P-3 MODE SELECT SELECT Fig. 67 Elements of the camera system Depending on the configuration, the machine is equipped with a camera system. Each camera has a 115° image angle ...
Page 156 Operation - Load moment limitation (LML) GHC55 6.6 Load moment limitation (LML) Safety instructions The load moment limitation is a safety device.  The LML may only be bypassed in case of emergency or in the event  of component failure to shut down the machine in a safe condition. Have the malfunction remedied as quickly as possible.
Page 157 Operation - Load moment limitation (LML) GHC55 6.6.2 Audible and visual warning device statuses Operating Load Speed reduction Warning device outside cab status to < 25% Visual Acoustic Normal Load < 90% Continuous green — light Approaching Load greater Continuous —...
Page 158 Operation - Load moment limitation (LML) GHC55 6.6.3 Operation The LML is operated and adjusted via the SENCON. 6.6.4 Mode selection The operating mode is selected automatically depending on the inputs of the user according to the current operating status. Information Make sure the operating parameters configured on the SENCON ...
Page 159 Operation - Load moment limitation (LML) GHC55 6.6.5 Bypassing the load moment limitation (LML) With the LML bypassed – All crane functions can be executed. – No shutdown occurs if the maximum load moment is reached. – All limit switches are bypassed. –...
Page 160 Operation - Load moment limitation (LML) GHC55 6.6.6 Operating modes table Specific operating modes can be disabled depending on the machine equipment. Upper Carbody Track carriage Inclination counter Main boom / Offset counter LML code [°] weight Attachment [°] [Position] weight Setting up 00153394...
Page 161 Operation - Load moment limitation (LML) GHC55 Main boom HA-S Auxiliary boom nose HA-HAB Main Boom with personnel basket SA-HAB Boom extention 6.5 m (21 ft 4 in) personnel basket 6.5 m (21 ft 4 in) boom extension SA13 13 m (42 ft 8 in) bi-fold boom extension 100% full span 4.1 m (13.5 ft) 50% mid span 3.3 m (10.8.ft) 0% retracted span 2.6 m (8.5 ft)
Page 162 Operation - Load moment limitation (LML) GHC55 6.6.7 Safety components Pressure sensors on the luffing cylinder (LML)  Angle transmitter/spring cable drum on the boom (LML)  Lifting limit switch – boom  Lifting limit switch – fly boom  Lowering limit switch on the winch ...
Page 163 Operation - Load moment limitation (LML) GHC55 Lifting limit switch Risk of damage to machine due to bottom hook block colliding NOTICE with boom head. If the lifting limit switch chain is shortened, it can cause a delayed response in the lifting limit switch. In this case the rope will not be stopped at the right time and the bottom hook block collides with the boom head.
Page 164 Operation - Load moment limitation (LML) GHC55 Risk of damage to machine due to bottom hook block colliding NOTICE with boom head. If the chain of the lifting limit switch is shortened, this can result a delayed reaction of the lifting limit switch. In this case the rope will not be stopped at the right time and the bottom hook block collides with the boom head.
Page 165 Operation - Load moment limitation (LML) GHC55 Lowering limit switch/ rope end limiter (E) Fig. 73 Lowering limit switch on the winch The rope end limiter ensures that sufficient rope always remains wound on the winch. If the cable is retracted beyond the set minimum rope remaining length, the "winch up"...
Page 166 Operation - Special equipment GHC55 Special equipment 6.7.1 Remote radio control (option) Ȁ !" Ȁ ! " Ȁ ! " Ȁ ! " &# $%& ))**+ Fig. 74 Remote radio controls Diesel engine on/off Crane working speed, slow/fast Emergency STOP LML audible signals on/off Increase/reduce speed Crane mode/drive mode...
Page 167 Operation - Special equipment GHC55 1 Diesel engine on/off This button turns the diesel engine on and off. 2 Emergency STOP The machine can be immediately taken out of service with the emergency stop switch. The horn (9) has to be sounded in order to restart remote radio control after an emergency stop.
Page 168 Operation - Special equipment GHC55 9 Horn/remote start Sound the horn to release the remote radio control. Sounding the horn is necessary before starting tasks because the operator could be far away from the machine due to the remote radio control, and may possibly not be aware that other persons are in the danger zone of the machine.
Page 169 Operation - Special equipment GHC55 Ȁ !" #$%& #$%& #$%& * '( )* ( +, " " Ȁ Ȁ Ȁ ! " Fig. 75 Joystick assignment of remote radio control Left joystick Center joystick Right joystick Lower winch 2 Extend boom Lower winch 1 Drive left crawler forward Drive right crawler forward...
Page 170 Operation - Special equipment GHC55 Enabling the remote radio control Switch on the ignition. Press the Radio remote control on/off switch on the top control panel toward the symbol. Exit the cab. Sound the horn on the remote radio control. Start the diesel engine with the Diesel engine on/off switch on the remote radio control.
Page 171 Operation - Special equipment GHC55 Status displays The status displays show operating status values. If an operating status value is outside the normal range, a warning indicator (2) in Fig. 76 appears next to it. The warning indicator appears as a rectangle. The following statuses are possible: Display Description...
Page 172 Operation - Special equipment GHC55 Operating statuses The most frequently required operating status values are shown on the display. The icons indicating the operating statuses are shown on the right and left edges of the screen. Ȁ !" Ȁ ! " Ȁ...
Page 173 Operation - Special equipment GHC55 Name Statuses Actual safe working load Coolant temperature No warning: – Coolant temperature normal Half of the field filled: – Reduce load on diesel engine Entire field filled: – Lower attached loads. – Run diesel engine at idle speed Hydraulic oil No warning: temperature...
Page 174 Operation - Special equipment GHC55 Notification and If machine parameters are outside of normal tolerances, a rectangular warning messages warning indicator appears under the appropriate icon. Ȁ !" Ȁ ! " Ȁ ! " Ȁ ! " &'# (& # $% ))* +, Fig.
Page 175 Operation - Special equipment GHC55 Depletion level of the No warning: exhaust – Automatic exhaust aftertreatment system cleaning activated. aftertreatment system – Depletion level of exhaust aftertreatment system normal. One field filled: – Depletion level of exhaust aftertreatment system high. –...
Page 176 Operation - Special equipment GHC55 Safe working load No warning: warning – Safe working load normal One field filled: – Safe working load about to be exceeded Two fields filled: – Safe working load exceeded. LML bypassed No warning: – LML active One field filled: –...
Page 177 Operation - Special equipment GHC55 6.7.2 Diesel filter heater (option) The machine is equipped with a heatable diesel filter. Information Once the fuel temperature drops below 5 °C, Grove recommends acti- vating the diesel filter heater. The SENCON displays the current fuel temperature.
Page 178 Operation - Special equipment GHC55 6.7.3 Beacon Fig. 80 Location of the beacon Beacon 6 - 52 Published 01-05-2016, Control # 565-02...
Page 179 Operation - Work implementation GHC55 6.8 Work implementation Safety instructions Prior to start up, perform the inspection tasks as specified in  Chapter 1 S AFETY Operation and work must only be carried out by trained personnel.  Ensure that nobody other than the slinger and banksman is in the ...
Page 180 Operation - Work implementation GHC55 6.8.1 Crane operation During crane operation, there is always a connection between the load and the hydraulic system. Once the operating elements are released, the load remains in the momentary position (lifting/lowering friction- locked, see Section 6.8.7 ). Safety notice Only work in crane operation with the LML switched on.
Page 181 Operation - Work implementation GHC55 6.8.2 Securing bottom hook block for drive mode Risk of damage to the machine due to bottom hook block NOTICE swinging while driving. If the bottom hook block begins swinging while driving, machine components may be damaged. Secure the bottom hook block.
Page 182 Operation - Work implementation GHC55 ȀȀ ! Fig. 81 Securing the bottom hook block from swinging 6 - 56 Published 01-05-2016, Control # 565-02...
Page 183 Operation - Work implementation GHC55 6.8.3 Moving the machine Machine motion Activity Position of hand levers Stop the machine. Release both hand levers.  Travel forward in a straight line. Push both levers forward.  Travel in reverse in a straight Pull both hand levers back.
Page 184 Operation - Work implementation GHC55 Machine motion Activity Position of hand levers Travel forward to the right. Push the left hand lever  forward. Release the right hand lever.  Travel in reverse to the left. Release the left hand lever. ...
Page 185 Operation - Work implementation GHC55 Machine motion Activity Position of hand levers Slew right at standstill. Push the left hand lever  forward. Pull the right hand lever  back. Grove 6 - 59 Published 01-05-2016, Control # 565-02...
Page 186 Operation - Work implementation GHC55 6.8.4 Travel with suspended load Safety instructions Secure the load against swinging.  Keep the load as close to the ground as possible.  Pay attention to the permitted wind speeds.  Turn the boom in the direction of travel. ...
Page 187 Operation - Work implementation GHC55 6.8.5 Moving on inclines and ramps The machine can move on inclines and ramps up to 20° (36%). Prerequisites Set boom angle to 20°.  Place the uppercarriage in the direction of travel (sprocket back, ...
Page 188 Operation - Work implementation GHC55 6.8.6 Slewing the uppercarriage Danger to life due to moving parts in the work area of the DANGER machine! Persons in the work area of the machine will be caught and injured by moving machine parts. Ensure that no one is in the work area while the machine is in operation.
Page 189 Operation - Work implementation GHC55 Slewing gear When the green Slewing gear holding brake engaged symbol is holding brake displayed on the SENCON, the slewing gear holding brake is active. The slewing gear holding brake activates once the ignition is turned on or the safety lever is pulled.
Page 190 Operation - Work implementation GHC55 Uppercarriage slewing Releasing the joystick to the center position when the slewing gear with freewheel freewheel is engaged and the uppercarriage is slewing allows the uppercarriage to continue slewing without losing speed. The slewing gear freewheel protects the slewing gear from excessive strain, such as can occur with swinging loads.
Page 191 Operation - Work implementation GHC55 Push the left joystick to the left. – The uppercarriage is slewed to the left. Push the left joystick to the right. – The uppercarriage is slewed to the right. Ȁ Ȁ Ȁ Ȁ Ȁ Ȁ...
Page 192 Operation - Work implementation GHC55 Symbol Possible Explanation statuses Slewing gear freewheel disengaged. Slewing gear freewheel engaged. Slewing gear freewheel not available. If an uppercarriage inclination of more than 0.3° is set in the Load moment limitation window, the slewing gear freewheel cannot be engaged.
Page 193 Operation - Work implementation GHC55 Stopping slewing Slewing can be slowed down and stopped in the following ways: without freewheel Releasing the joystick to the center position.  Stepping on the slewing gear brake pedal.  Note Gently moving the left joystick in the opposite direction increases braking.
Page 194 Operation - Work implementation GHC55 6.8.7 Lifting and lowering loads Danger to life due to suspended loads! DANGER Persons on or next to the machine will be injured due to uncontrolled load movements. Always lower the load when work is interrupted. Never leave the operator cab when a load is suspended.
Page 195 Operation - Work implementation GHC55 Information The lift speed depends on the: Speed of the drive engine  Deflection of the right joystick  Switching joystick assignment for winch control Press the Winch 1/Winch 2 switch to the left. – Winch 2 is operated with the left joystick. –...
Page 196 Operation - Work implementation GHC55 6.8.8 Hook operation with both winches Danger to life! WARNING Danger to life if the permissible safe working loads and LML programs are not observed. Severe material damage and personal injury extending to loss of life are possible. Only lift loads weighing less than/or equal to the permissible safe working load of the auxiliary jib or the fly boom in the appropriate working radius (auxiliary-boom safe working load 100% of the load!).
Page 197 Operation - Work implementation GHC55 Fig. A Lift the load on the auxiliary jib or fly boom. The hoisting rope on the main boom remains unloaded at first but the rope must not become slack. Then lift the load via the main boom until the load is horizontal.
Page 198 Operation - Work implementation GHC55 Fig. C The load is suspended on the main boom. Lift the load using the auxiliary jib or the fly boom. The load moment will increase. The machine can tip or the boom system can be overloaded. Fig.
Page 199 Operation - Work implementation GHC55 6.8.10 Extending/retracting the boom The boom is extended and retracted using the left control lever. In order to be able to extend or retract the boom, the Luff/telescope boom switch has to be to the right. Ȁ...
Page 200 Operation - Work implementation GHC55 6.8.11 Turning on the supplemental hydraulic system (option) Danger to life from preselected supplemental hydraulic system! DANGER Danger to life from preselected supplemental hydraulic system! The clamping tongs will fully close when the Preselect clamping tongs/supplemental hydraulic system switch is set to the Supple- mental hydraulic system position.
Page 201 Operation - Work implementation GHC55 6.8.12 Operating the clamping tongs (option) Danger to life from preselected supplemental hydraulic system! DANGER Danger to life from preselected supplemental hydraulic system! The clamping tongs will fully close when the Preselect clamping tongs/supplemental hydraulic system switch is set to the Supple- mental hydraulic system position.
Page 202 Operation - Work implementation GHC55 Ȁ " Fig. 91 Control elements for clamping tongs Turning the clamping To turn the clamping tongs off, press the Preselect clamping tongs/ tongs off supplemental hydraulic system switch to the center position. 6 - 76 Published 01-05-2016, Control # 565-02...
Page 203 Operation - Work implementation GHC55 6.8.13 Operating the soil drill (option) Telescope the undercarriage fully outward. Attach the maximum counterweight. Enter the cab. Start the diesel engine and push the safety lever forward. Select Setup operating mode on the SENCON. Slew the soil drill into working position.
Page 204 Operation - Work implementation GHC55 6.8.14 Refuel the machine The machine can be refueled in two ways: Manually  Using a refueling pump (option)  Danger of health impairment and environmental damage due WARNING to escaping fuel! Serious health impairments occur if there is contact with the body. Serious environmental damage occurs if fuel spills into the soil or bodies of water.
Page 205 Operation - Work implementation GHC55 Manually Lower attached loads to the ground. Switch off the diesel engine. Use the walkway on the right side of the machine to climb up to the diesel filler neck. Open the cover (1) in Fig. 93 of the fuel filler neck. Clean the wide-mesh screen (2) in Fig.
Page 206 Operation - Work implementation GHC55 Using a refueling pump (option) Information Ensure that the maximum suction lift of 3 m is not exceeded. Machine damage due to a longer period of dry running! Ensure NOTICE that the pump does not run dry for more than 30 s. If necessary, switch off the fuel pump with the red button (3).
Page 207 Operation - Work implementation GHC55 Check the intake filter (4) in Fig. 95 for contamination and damage. Replace the intake filter if necessary. Attach the fueling hose (3) in Fig. 95 to the intake port on the fuel pump and insert it into external fuel tank. Turn on the fuel pump by pressing the green button (1) in Fig.
Page 208 Operation - Work implementation GHC55 6.8.15 Checking the DEF level and refilling (Tier 4f engines) Risk of machine damage from contact with DEF. NOTE Machine parts, especially hoses and cables, can be damaged beyond repair by DEF. Do not pour on hoses or cables.
Page 209 Operation - Work implementation GHC55 ȀȀ ! " Fig. 96 Location of the DEF tank in the machine Check the DEF tank (1) in Fig. 96 for contamination and clean as needed. Carefully open the sealing cover (2) in Fig. 96 of the DEF tank. Refill the DEF tank with the DEF filling unit.
Page 210 Operation - Work implementation GHC55 This Page Blank 6 - 84 Published 01-05-2016, Control # 565-02...
Page 211 Setup tasks - GHC55 Setup tasks Safety during setup Use personal protective equipment in accordance with applicable  accident prevention regulations. When disassembling components or equipment, always use load  suspension equipment with a sufficient load bearing capacity at the attachment points.
Page 212 Setup tasks - Walkways GHC55 7.1 Walkways 7.1.1 Mounting/Removing The walkways at the cab entrance, in front of the cab and on the right side of the uppercarriage must be installed before starting any work with the machine. Installing a walkway is described below. Install walkways with the undercarriage retracted.
Page 213 Setup tasks - Walkways GHC55 Insert the walkway in the bracket. Screw the walkway to the frame (1) in Fig. 97. Observe the specified tightening torque of the screws. Make sure the walkway is fastened securely. Information Walkways are removed in the reverse sequence. For transport, the walkways must be removed together with the step grid holder.
Page 214 Setup tasks - Walkways GHC55 7.1.2 Stowing The machine is equipped with stowable walkways on the cab and up- percarriage. Fig. 98 Stowing walkways – removing pins Unlock and remove the rear pins (1) in Fig. 98. Fig. 99 Stowing walkways Stow the walkway.
Page 215 Setup tasks - Setup operating mode GHC55 Setup operating mode Operating modes are configured on the SENCON. The operating mode Setup 1 is used for the following setup tasks: Reeving  Setting up the auxiliary jib  Setting up the fly boom (SA8/SA15) ...
Page 216 Setup tasks - Setup operating mode GHC55 Required operating parameters for Setup 1 Uppercarriage inclina- 0.3° tion Ȁ ! "# $"% # & Track width A (3.8 m/12.5 ft) Ȁ Undercarriage ballast 0 t (0 Ibs) Ȁ ! Counterweight 8.9 t (19 621 Ibs) Ȁ...
Page 217 Setup tasks - Changing the track width GHC55 7.3 Changing the track width General information You can change the track width of the machine. Always extend the running gear to the maximum track width  and secure it during maintenance and servicing. Reduce the track width of the running gear in order to transport ...
Page 218 Setup tasks - Changing the track width GHC55 7.3.2 Extending the running gear " ȀȀ ! " Fig. 101 Unbolting the undercarriage for telescoping Remove the spring cotter pins (2) in Fig. 101 and the bolts (1) in Fig. 101 on the locking rods at the positions shown. Enter the cab.
Page 219 Setup tasks - Changing the track width GHC55 Information Drive the machine a short distance forward and backward to facilitate the telescoping process. Switch off the diesel engine. Pull the safety lever back. Exit the cab. ȀȀ ! " Fig. 102 Bolting the undercarriage Bolt the locking rods (1) in Fig.
Page 220 Setup tasks - Changing the track width GHC55 7.3.3 Retracting the running gear " ȀȀ ! " Fig. 103 Unbolting the undercarriage for telescoping Remove the spring cotter pins (2) in Fig. 103 and the bolts (1) in Fig. 103 on the locking rods at the positions shown. Enter the cab.
Page 221 Setup tasks - Changing the track width GHC55 Information Drive the machine a short distance forward and backward to facilitate the telescoping process. Switch off the diesel engine. Pull the safety lever back. Exit the cab. ȀȀ ! " Fig. 104 Bolting the retracted undercarriage Insert the bolts (1) in Fig.
Page 222 Setup tasks - Access ladders GHC55 7.4 Access ladders Danger of crushing due to moving machine parts! WARNING Persons will caught and injured by extending track wheel carriers. Use a banksman for assistance. Ensure that no unauthorized persons are present in the danger zone during all work.
Page 223 Setup tasks - Setting up the slewing range safeguard GHC55 7.5 Setting up the slewing range safeguard The slewing range safeguard indicates the slewing range of the uppercarriage in work operation. When in working mode, all persons must stay clear of the slewing range. Pull the locking bolt (1) in Fig.
Page 224 Setup tasks - Setting up the slewing range safeguard GHC55 Pull out the bolt (1) in Fig. 108. Pull out the slewing range safeguard to its full length. Insert the bolt (1) in Fig. 108 at the position shown. ȀȀ ! Fig.
Page 225 Setup tasks - Connections for clamping tongs and supplemental hydraulic system on the boom head (option) GHC55 7.6 Connections for clamping tongs and supplemental hydraulic system on the boom head (option) Safety notice Any work involving the clamping tongs and the soil drill require the maximum counterweight to be fitted and the undercarriage to be completely telescoped out.
Page 226 Setup tasks - Attaching clamping tongs (option) GHC55 7.7 Attaching clamping tongs (option) Enter the cab. Start the diesel engine and push the safety lever forward. Select Setup operating mode on the SENCON. Completely retract the telescopic boom. Raise the bottom hook block. Leave a distance of 0.5 m between bottom hook block and lifting limit switch.
Page 227 Setup tasks - Slewing the soil drill (option) into working position GHC55 7.8 Slewing the soil drill (option) into working position Enter the cab. Start the diesel engine and push the safety lever forward. Select Setup operating mode on the SENCON. Retract the boom almost completely.
Page 228 Setup tasks - Slewing the soil drill into transport position (option) GHC55 7.9 Slewing the soil drill into transport position (option) Enter the cab. Start the diesel engine and push the safety lever forward. Select Setup operating mode on the SENCON. Release the Soil drill on switch and push it toward the symbol.
Page 229 Setup tasks - Attaching the fly boom (6.5 m) GHC55 7.10Attaching the fly boom (6.5 m) Risk of falling. WARNING Climbing on the boom can result in a fall causing serious injury or death. Use a ladder with a minimum height of 1.40 m to insert/remove the bolts. Do not climb onto the boom.
Page 230 Setup tasks - Attaching the fly boom (6.5 m) GHC55 Align the fly boom to the telescopic boom head. The bores of the fly boom (2) in Fig. 111 and the telescopic boom (1) in Fig. 111 must be aligned. ȀȀ...
Page 231 Setup tasks - Attaching the fly boom (6.5 m) GHC55 Remove the bolt (2) in Fig. 113 from the retainer (1) in Fig. 113. Fold up the deflection sheave (3) in Fig. 113. Bolt down and secure the deflection sheave with the bolt (2) in Fig.
Page 232 Setup tasks - Attaching the fly boom (6.5 m) GHC55 Run the hoist rope over the deflection sheave and the head pulley sheave on the fly boom. Remove the bypass plug (1) in Fig. 114 from the lower socket (2) in Fig. 114 and insert it into the upper socket (3) in Fig. 114. ȀȀ...
Page 233 Setup tasks - Attaching the fly boom (6.5 m) GHC55 Attach the bypass flag of the lifting limit switch to the telescopic boom head. ȀȀ ! " Fig. 115 Attaching the bypass flag to the telescopic boom Remove the lifting limit switch cable of the fly boom (1) in Fig.
Page 234 Setup tasks - Attaching the fly boom (6.5 m) GHC55 Insert the lifting limit switch cable of the fly boom (1) in Fig. 117 into the lower socket (2) in Fig. 117 on the telescopic boom. ȀȀ ! " Fig. 117 Inserting the fly boom lifting limit switch cable into the telescopic boom Attach the lifting limit switch weight and chain to the lifting limit switch of the fly boom.
Page 235 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 7.11 Folding the fly boom (6.5 m) into working position Safety instructions Ensure that the fly boom is correctly bolted to the basic body and  secured. This procedure requires at least 10 m of space on the right side of ...
Page 236 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Release and remove the bolt (1) in Fig. 119 on the ramp. ȀȀ Ȁ! Fig. 119 Unbolting the ramp Fold out the ramp (1) in Fig. 120. Insert the bolt (2) in Fig. 120 at the position shown and secure it with the retaining spring (3) in Fig.
Page 237 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 WARNING Danger of fatal injury due to the fly boom swinging around! The fly boom can swing off its support at high speed and severely injure anybody in its swing range. Observe the deadweight of the fly boom.
Page 238 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Use the rope to move the fly boom (1) in Fig. 122 around until the bolt openings on the right of the fly boom align with those of the telescopic boom.
Page 239 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Bolt the fly boom to the telescopic boom at the bolting positions (1) in Fig. 124 and secure with retaining springs (2) in Fig. 124. " ȀȀ Ȁ! Fig.
Page 240 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Use the rope to pull the fly boom into working position. ȀȀ Ȁ! Fig. 126 Pulling the fly boom into working position Bolt and secure the fly boom to the main boom (1) in Fig. 127. ȀȀ...
Page 241 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Release and remove the bolt (1) in Fig. 128 on the ramp. Ȁ ! " Fig. 128 Unbolting the ramp Fold in the ramp (1) in Fig. 129 and secure it with the bolt (2) in Fig.
Page 242 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Remove the bolt (2) in Fig. 130 from the retainer (1) in Fig. 130. Fold up the deflection sheave (3) in Fig. 130. Bolt down and secure the deflection sheave with the bolt (2) in Fig.
Page 243 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Remove the bypass plug (1) in Fig. 131 from the lower socket (2) in Fig. 131 and insert it into the upper socket (3) in Fig. 131. ȀȀ...
Page 244 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Remove the lifting limit switch cable of the fly boom (1) in Fig. 133 from the socket. ȀȀ ! " Fig. 133 Fly boom lifting limit switch cable Insert the lifting limit switch cable of the fly boom (1) in Fig.
Page 245 Setup tasks - Folding the fly boom (6.5 m) into working position GHC55 Attach the lifting limit switch weight and chain to the lifting limit switch of the fly boom. Reeve the bottom hook block. See Section 11.16 R EEVING DIAGRAM Grove 7 - 35...
Page 246 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 7.12 Folding the fly boom (6.5 m) into transport position Safety instructions Ensure that the fly boom is correctly bolted to the basic body and  secured. This procedure requires at least 10 m of space on the right side of ...
Page 247 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Remove the bypass flag of the lifting limit switch on the telescopic boom. ȀȀ ! " Fig. 136 Removing the bypass flag from the telescopic boom head Remove the bypass plug (1) in Fig.
Page 248 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Release and remove the bolt (2) in Fig. 138 on the deflection sheave (3) in Fig. 138. Fold the deflection sheave down. Insert and secure the bolt in the retainer (1) in Fig. 138. ȀȀ...
Page 249 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Insert and secure the bolt (1) in Fig. 140 on the ramp. Ȁ ! " Fig. 140 Bolting the ramp Attach a rope (1) in Fig. 141 to the fly boom. ȀȀ...
Page 250 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Release and remove the vertical bolt (1) in Fig. 142 on the basic body. ȀȀ ! " Fig. 142 Releasing the fly boom safeguard Release and remove the bolt (1) in Fig. 143 on the ramp. ȀȀ...
Page 251 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 WARNING Danger of fatal injury due to the fly boom swinging around! The fly boom can swing off its support at high speed and severely injure anybody in its swing range. Observe the deadweight of the fly boom.
Page 252 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Use the rope to move the fly boom around until the lock openings on the fly boom align with those of the telescopic boom (1) in Fig. 145. "...
Page 253 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Release and drive out the bolts (1) in Fig. 146 on the right side of the boom. Insert and secure the bolts in the parking position. " ȀȀ...
Page 254 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Secure the fly boom to the ramp with the bolt (1) in Fig. 148. ȀȀ ! " Fig. 148 Securing the fly boom to the ramp Release and remove the bolt (1) in Fig. 149. Fold in the ramp (2) in Fig.
Page 255 Setup tasks - Folding the fly boom (6.5 m) into transport position GHC55 Insert and secure the bolt (1) in Fig. 150 on the ramp. ȀȀ Ȁ! Fig. 150 Bolting the ramp in transport position Release the rope from the fly boom. Reeve the hoist rope on the telescopic boom.
Page 256 Setup tasks - Folding the fly boom from 0° to 40° GHC55 7.13 Folding the fly boom from 0° to 40° Note When folding in the fly boom, it slides approx. 1.5 m (4.9 ft) on the support toward the machine. ȀȀ...
Page 257 Setup tasks - Folding the fly boom from 0° to 40° GHC55 Release and remove both bolts (1) in Fig. 152 from the fly boom. ȀȀ ! Fig. 152 Removing the bolts from the fly boom Insert and secure both bolts at the positions shown (1) in Fig.
Page 258 Setup tasks - Folding the fly boom from 40° to 0° GHC55 7.14 Folding the fly boom from 40° to 0° Information When setting the boom down, the fly boom slides approx. 1.5 m (4.9 ft) on the support away from the machine. ȀȀ...
Page 259 Setup tasks - Folding the fly boom from 40° to 0° GHC55 Remove both bolts (1) in Fig. 155 on the fly boom from the positions shown. Do not push the fly boom into the ground. ȀȀ ! " Fig. 155 Removing the bolts from the fly boom Insert and secure both bolts (1) in Fig.
Page 260 Setup tasks - Attaching the fly boom extension (6.5 m) (option) GHC55 7.15 Attaching the fly boom extension (6.5 m) (option) Danger of falling! WARNING Climbing on the boom can result in a fall causing serious injury or death. Use a ladder with a minimum height of 1.40 m to insert/remove the bolts. Do not climb onto the boom.
Page 261 Setup tasks - Attaching the fly boom extension (6.5 m) (option) GHC55 Attach the fly boom extension to an auxiliary crane (min. load capacity: 2,000 kg (4,400 lbs)) with suitable lifting gear. Hoist the fly boom extension to the fly boom head. Align the fly boom extension with the fly boom head.
Page 262 Setup tasks - Attaching the fly boom extension (6.5 m) (option) GHC55 Remove the lifting gear from the fly boom extension and move the auxiliary crane out of the work area. Retract the hoist rope of winch 1 over the deflection sheave on the fly boom and the boom head of the fly boom extension.
Page 263 Setup tasks - Folding the fly boom extension (6.5 m) into transport position GHC55 Attach the lifting limit switch weight and chain to the lifting limit switch of the fly boom extension. Reeve the bottom hook block. See Section 11.16 R EEVING DIAGRAM 7.16 Folding the fly boom extension (6.5 m) into...
Page 264 Setup tasks - Folding the fly boom extension (6.5 m) into transport position GHC55 Release and remove the bolt (1) in Fig. 162 on the fly boom extension. " ȀȀ ! Fig. 162 Releasing the bolt on the fly boom extension Attach a rope (1) in Fig.
Page 265 Setup tasks - Folding the fly boom extension (6.5 m) into transport position GHC55 WARNING Danger of fatal injury due to the fly boom swinging around! The fly boom can swing off its support at high speed and severely injure anybody in its swing range. Observe the deadweight of the fly boom.
Page 266 Setup tasks - Folding the fly boom extension to working position GHC55 Insert the fly boom extension to the fly boom with the bolt (1) in Fig. 166 and secure with a spring cotter pin (2) in Fig. 166. " ȀȀ...
Page 267 Setup tasks - Folding the fly boom extension to working position GHC55 Attach a rope (1) in Fig. 167 to the boom head of the fly boom extension. " ȀȀ ! Fig. 167 Attaching a rope for pulling the fly boom extension around Release and remove the bolts (1) in Fig.
Page 268 Setup tasks - Folding the fly boom extension to working position GHC55 WARNING Danger of fatal injury due to the fly boom swinging around! The fly boom can swing off its support at high speed and severely injure anybody in its swing range. Observe the deadweight of the fly boom.
Page 269 Setup tasks - Folding the fly boom extension to working position GHC55 Bolt the fly boom extension to the fly boom with the bolt (1) and secure with spring cotter pins. ȀȀ ! " Fig. 171 Bolting the fly boom extension into working position Remove the lifting limit switch cable of the fly boom extension (1) in Fig.
Page 270 Setup tasks - Folding the fly boom extension to working position GHC55 Insert the lifting limit switch cable of the fly boom extension (1) in Fig. 173 into the socket on the fly boom head. ȀȀ ! " Fig. 173 Inserting the fly boom extension lifting limit switch cable into the fly boom head Retract the hoist rope over the deflection sheave and the boom...
Page 271 Setup tasks - Attaching the auxiliary jib GHC55 7.18 Attaching the auxiliary jib Start the diesel engine. Select Setup operating mode on the SENCON. Fully retract the telescopic boom and lower it to installation height. Place the bottom hook block on the ground. Unreeve the hoist rope.
Page 272 Setup tasks - Attaching the auxiliary jib GHC55 Reeving the hoist rope Guide the hoist rope of winch 1 over the sheave of the telescopic boom and over the sheave of the auxiliary jib. Remove the bypass plug (1) in Fig. 176 from the lower socket on the telescopic boom and insert it into the upper power socket.
Page 273 Setup tasks - Attaching the auxiliary jib GHC55 Insert the rope guard (1) in Fig. 178 into the auxiliary jib sheave and secure it with spring cotter pins (2) in Fig. 178. ȀȀ ! " Fig. 178 Attaching the rope guard to the auxiliary jib Attach the bottom hook block.
Page 274 Setup tasks - Attaching the auxiliary jib GHC55 This Page Blank 7 - 64 Published 01-05-2016, Control # 565-02...
Page 275 Transport - GHC55 Transport Preliminary tasks Transport on a lowbed trailer requires the following preliminary tasks to be performed: Select a suitable transport vehicle.  Note the dimensions of the machine as specified in Section 8.5 . Clean machine.  Bring the telescopic boom into transport position.
Page 276 Transport - Controls for unloading the machine GHC55 Controls for unloading the machine & Ȁ Ȁ " "" #& #$ % $& % !! #&, Fig. 179 Controls for unloading the machine Safety lever Luff/telescope boom switch Joystick, left Release travel mode Hand lever, left crawler Travel slow/fast Hand lever, right crawler...
Page 277 Transport - Switching on the battery disconnect switch GHC55 Switching on the battery disconnect switch Open the left service access door (1) in Fig. 180. Turn the battery disconnect switch (2) in Fig. 180 to position I. Close the service door. Ȁ...
Page 278 Transport - Unload machine GHC55 8.3.1 Configuring the setup program in the SENCON Completely lower the lowbed of the trailer. Remove the lashings. Turn on the battery disconnect switch Enter the cab. Turn the ignition key to position I. – The SENCON is switched on. Ȁ...
Page 279 Transport - Unload machine GHC55 Roll the SCROLL wheel (1) in Fig. 183 until the setting (2) in Fig. 183 is outlined in black. Press the SCROLL wheel. 5623 Ȁ" 3 ' () % ./- % % ./- % % ./- % 1234 456 7 456 7...
Page 280 Transport - Unload machine GHC55 Roll the SCROLL wheel until the setting (1) in Fig. 184 is outlined in black. Press the button on the SENCON. – The setup program is selected. <= 9: Ȁ> : ) 6 ',) ) 6 ',) ) 6 ',) 8 9: ;...
Page 281 Transport - Unload machine GHC55 Press the button on the SENCON. – The setup program is configured. – The working diagram displays. Ȁ-) +,() )* + " # $ % " " # $ % " " # $ % " '()* &...
Page 282 Transport - Unload machine GHC55 8.3.2 Moving the machine off the transport vehicle Turn the ignition key to position II. – The diesel engine is started. Unlock the Luff/telescope boom switch and press it to the left. Press the Winch 1/Winch 2 switch to the right. Press the Release winch switch to the right.
Page 283 Transport - Unload machine GHC55 Press the button (1) in Fig. 186 on the right joystick. – The horn sounds. Ȁ Fig. 186 Horn Push the safety lever forward. ȀȀ !" Fig. 187 Pushing the safety lever Lift the boom into the 30° position. –...
Page 284 Transport - Unload machine GHC55 Risk of damage to the machine due to improper operation of the NOTICE load hook when the lifting limit switch is bypassed. If the load hook is lifted too quickly while the lifting limit switch is bypassed or if the safety distance to the boom head is not maintained, the load hook can strike the boom head.
Page 285 Transport - Lashing points GHC55 Lashing points The lashing points on the machine are marked with a green symbol on a white background. auf weißem Grund gekennzeichnet. The lashing points for transporting the machine are located on inside of the front and rear track wheel carriers and on the middle bridge.
Page 286 Transport - Transport dimensions and weights GHC55 Transport dimensions and weights " Ȁ & **+,* Fig. 190 Transport dimensions Dimensions Dimensions in inches (mm) Dimensions in inches (mm) 35.4 (900) 225.7 (5 734) 102.4 (2 600) 47.6 (1 209) 137.8 (3 500) 104.7 (2 660) 267.7 (6 799) 108.5 (2 757)
Page 287 Transport - Locking the uppercarriage GHC55 Locking the uppercarriage Place the uppercarriage in the direction of travel. Apply parking and holding brake of the slewing gear. Fig. 191 Locking rod Bolt and secure the locking bar (1) in Fig. 191 to the undercarriage and the uppercarriage.
Page 288 Transport - Lifting the machine GHC55 Lifting the machine Safety instructions Only lash the machine at the designated lifting points. The lifting  points are marked green and have a green load hook symbol. Ensure that the lifting equipment has a sufficient safe working load ...
Page 289 Transport - Lifting the machine GHC55 Lifting data Fig. 192 Lifting data The lifting data applies to the following machine configuration: Counterweight 8.9 t No. winches Bottom hook block 35 t Base plates 3-grouser, 900 mm Overall weight 45.7 t Grove 8 - 15 Published 01-05-2016, Control # 565-02...
Page 290 Transport - Lifting the machine GHC55 This Page Blank 8 - 16 Published 01-05-2016, Control # 565-02...
Page 291 Maintenance - GHC55 Maintenance Risk of death due to machine moving suddenly or starting WARNING unintentionally. Persons on or near the machine can suffer serious injury or death by the machine moving suddenly or starting unintentionally.  Park the machine on secure ground. Move the machine away from the edge of any trenches or pits.
Page 292 Maintenance - GHC55  Use only original Grove spare parts.  Do not lift heavy components manually, use lifting equipment instead.  Disconnect the power with the battery disconnect switch.  When working near the battery, cover it with insulating material. ...
Page 293 Maintenance - Cleaning tasks GHC55 9.1 Cleaning tasks Clean the machine every month, especially before maintenance or repair. Shorten the cleaning intervals depending on operating conditions and contamination. Danger of injury due to falling. WARNING Danger of falling when performing work above body height. Park the machine.
Page 294 Maintenance - Cleaning tasks GHC55 Lubricate all bearing points to prevent water ingress. Close all openings where water is not allowed to ingress:  Exhaust pipe  Air filter  Air conditioning system external air filter Protect all components that must not be cleaned with water from the direct water jet: ...
Page 295 Maintenance - Cleaning tasks GHC55 Apply water with cleaning agent and let it soak in. Remove firmly adhering contamination with a sponge or brush. Rinse off the machine with clean water. Clean the cab windows and mirrors with a commercial glass cleaner.
Page 296 Maintenance - Oils and lubricants GHC55 9.2 Oils and lubricants Risk of damage to machine components due to mixing different NOTICE lubricants and operating fluids. Mixing different types of oils, lubricants or operating fluids can damage machine components.  Only use the same type of oils, lubricants and operating fluids. ...
Page 297 Maintenance - Oils and lubricants GHC55 9.2.1 Disposing of lubricants and operating fluids Risk of environmental damage due to improper disposal NOTICE of lubricants and operating fluids. Lubricants and operating fluids that are not properly disposed of contaminate ground water. ...
Page 298 Maintenance - Coolant GHC55 9.3 Coolant Health hazard due to nitrosamines. WARNING Mixing of nitrite-based coolants with amine-based agents produces harmful nitrosamines.  Avoid skin contact with coolants.  Avoid inhaling the vapors.  Use skin protection products. Risk of engine damage due to overheating. NOTICE Adding unapproved coolants and coolant additives can damage the radiator and cause the engine to overheat.
Page 299 Maintenance - Coolant GHC55 Information Observe the coolant sticker near the radiator. If the ambient temperature on site is below -37 °C (-34 °F), check the engine manufacturer's operating manual or consult your Grove Service Partner before starting up the machine. Information If only a small amount (up to max.
Page 300 Maintenance - Coolant GHC55 Information  Use clean, pH-neutral, filtered and softened fresh water. Grove recommends distilled water.  Cummins specifies the use of distilled water.  Do not use ditch water, industrial drain water, salt water, sea water or rain water. ...
Page 301 Maintenance - Coolant GHC55 Risk of scalding from coolant steam. CAUTION Opening the coolant tank will cause hot coolant to evaporate. Persons in the vicinity can be scalded.  Let the engine cool down before draining coolant. Information Collect draining coolant and dispose of it in accordance with regulations.
Page 302 Maintenance - Coolant GHC55 Changing coolant Switch off the diesel engine. Let the diesel engine and combination cooler cool down. Carefully open the sealing cap of the expansion tank to equalize the pressure. Completely drain the cooling system before filling. Flush the cooling system several times with clean water.
Page 303 Maintenance - Welding GHC55 9.4 Welding Safety instructions  Welding may only be performed by an authorized and qualified welding specialist.  Cover vulnerable components with fireproof material.  Drilling and welding is prohibited on the following components: – Boom parts –...
Page 304 Maintenance - Diesel engine GHC55 9.5 Diesel engine Risk of injury due to rotating parts or hot engine parts. WARNING Persons can be injured by moving or hot engine parts when the engine is running.  Only perform maintenance and repairs with the engine off and the cooling system cooled down.
Page 305 Maintenance - Diesel engine GHC55 9.5.1 Cummins diesel engine QSB4.5, Tier 4f Engine oil Risk of environmental damage due to improper disposal of used oil. NOTICE Used oil that has not been properly disposed of contaminates ground water. Make sure used oil does not seep into the soil or reach bodies of water. ...
Page 306 Maintenance - Diesel engine GHC55 Add engine oil to the filler neck (1) in Fig. 193 as needed according to the engine manufacturer's instructions. Changing the engine oil and oil filter Warm up the diesel engine. Park the machine on a level surface. Open the left rear service door.
Page 307 Maintenance - Diesel engine GHC55 Air filter Risk of engine damage from cleaning with compressed air. NOTICE Cleaning with compressed air can allow contaminants to get into and damage the engine. Do not use compressed air to clean the inside of the housing. ...
Page 308 Maintenance - Diesel engine GHC55 Carefully remove the contaminated main filter (A) in Fig. 195. – Make sure no absorbed dirt gets in the housing. – Check the filter for any uneven contamination pattern, which can indicate an inadvertent release of dust or sealing problems.
Page 309 Maintenance - Diesel engine GHC55 Replace the service cover and secure it with the locking clamps. Fig. 197 Closing the air filter service cover Check the entire line system for cracks and holes, especially between the air filter and the engine. Make sure all clamps and connections are seated properly.
Page 310 Maintenance - Diesel engine GHC55 Air intake system Information Regularly checking the air intake system is the only way to ensure maximum protection of the drive motor against damage and destruction due to dust. Checking the air intake system ȀȀ ! " Fig.
Page 311 Maintenance - Diesel engine GHC55 9.5.2 Cummins diesel engine QSB4.5, Tier IIIa Engine oil Safety instructions  Proceed with the utmost caution when draining hot oil.  Old oil must not seep into the ground or waterways. Dispose of oil and oil filters in accordance with statutory regulations.
Page 312 Maintenance - Diesel engine GHC55 Place the machine in a horizontal position. Run engine for approximately 2 minutes until the system is filled with oil. Shut down drive engine. Open rear right maintenance door. Pull out oil dipstick (1) in Fig. 199 and wipe it off with a clean, lint-free cloth.
Page 313 Maintenance - Diesel engine GHC55 Air filter Danger of burn injuries due to unsuitable cleaning agents! WARNING Persons suffer burn injuries when cleaning the air filter with hot or flammable cleaning agents. Never use gasoline, soap or hot liquids to clean the air filter. Only clean the air filter when the engine is shut off and cooled down.
Page 314 Maintenance - Diesel engine GHC55 Clean filter element, replace if necessary Open the locking clamps (2) in Fig. 200 of the air filter cover (1) and remove the air filter cover. Remove replacement cartridge (3). Clean the replacement cartridge: – Blow out from inside to outside using dry compressed air (max.
Page 315 Maintenance - Diesel engine GHC55 Cleaning the air filter pre-separator Information If dust escapes when pressing the dust discharge valve, the pre- separator of the air filter must be cleaned. Fig. 201 Cleaning the air filter pre-separator Set down loads and turn off the engine. Open the service hatch (1).
Page 316 Maintenance - Diesel engine GHC55 Diesel preliminary filter Fig. 202 Position and overview of the diesel preliminary filter Item Description Housing - filter cartridge Vent screw Drain valve Screw cap 9 - 26 Published 01-05-2016, Control # 565-02...
Page 317 Maintenance - Diesel engine GHC55 Dewatering the diesel preliminary filter Danger of injury due to rotating parts or hot engine parts! WARNING Persons will be injured due to moving parts or hot parts of the running engine. Only execute maintenance tasks when the drive engine is shut down and the cooling system has cooled down.
Page 318 Maintenance - Diesel engine GHC55 Unscrew the screw cap (4) from the housing (1) and pull out the filter element that is fastened on it – Unclip the filter element from the screw cap. – Replace the O-ring of the screw cap (new O-ring is provided with the spare filter element) –...
Page 319 Maintenance - Diesel engine GHC55 Screw the screw cap (4) with new filter element into the housing (1) to the stop. Ensure tightening torque of 50 Nm! Dispose of old filter element and O-rings. Close maintenance door. Diesel fine filter Replacement Information See the operating manual provided by the engine manufacturer for...
Page 320 Maintenance - Combination cooler GHC55 Combination cooler Risk of injury from rotating, sharp or hot parts. WARNING Persons can be injured by moving, sharp or hot parts on or near the combination cooler.  Only perform maintenance when the drive motor is off and the cooling system has cooled down.
Page 321 Maintenance - Combination cooler GHC55 Let the diesel engine and combination cooler cool down. Carefully open the sealing cap (2) in Fig. 203 of the expansion tank (1) in Fig. 203 to equalize the pressure. Check the antifreeze and coolant level. Add coolant as needed.
Page 322 Maintenance - Water separator GHC55 9.7 Water separator Risk of injury from hot exhaust aftertreatment system. WARNING Persons can be injured when the exhaust aftertreatment system is hot.  Only perform maintenance when the drive motor is off and the cooling system has cooled down.
Page 323 Maintenance - Water separator GHC55 Drain water Place a container under the hose connected to the drain plug (3) in Fig. 204. Open the drain plug. Drain water and dirt until fuel comes out. Close the drain plug. Dispose of the fluid in the container properly. Grove 9 - 33 Published 01-05-2016, Control # 565-02...
Page 324 Maintenance - Water separator GHC55 Changing Depending on filter design and conditions, the manufacturer the filter element recommends changing the filter element after 1 year of operating time at the latest. If the element is exposed to greater dynamic strain, it can be necessary to keep shorter change intervals, as well as for startup, repairs, oil changes, etc.
Page 325 Maintenance - Belt drives GHC55 9.8 Belt drives Safety instructions  Before beginning maintenance, turn off the machine and secure it against being restarted without authorization.  Only execute maintenance tasks with drive engine shut down and at a standstill. ...
Page 326 Maintenance - Hydraulic system GHC55 9.9 Hydraulic system Risk of injury from loose hydraulic connections and hot WARNING hydraulic oil system. Persons in the danger zone can be injured by leaking hydraulic oil.  Seek immediate medical attention for injuries caused by hydraulic oil. ...
Page 327 Maintenance - Hydraulic system GHC55 Cylinder Pressure cylinders are subject to slight leakage. Remove excess leak oil with a cloth. Dispose of the oil-soaked cloth as hazardous waste. The sliding surfaces of the piston rods are chrome-plated. Heavier leakage indicates damaged sliding surfaces or defective seals. Clean hydraulic cylinders: ...
Page 328 Maintenance - Hydraulic system GHC55 9.9.1 Hydraulic hose lines Storage and Even with proper storage and use at permissible loads, hoses and hose service life lines are subject to natural aging. This means that their service life is limited. The owner is responsible for ensuring that hose lines are replaced at suitable intervals, even if safety defects cannot be detected on the hose line.
Page 329 Maintenance - Hydraulic system GHC55 9.9.2 Depressurizing the hydraulic system The hydraulic system must be depressurized before beginning any work. Lower attached loads and the boom to the ground. Turn off the diesel engine and turn the ignition key back to the 1 position.
Page 330 Maintenance - Hydraulic system GHC55 Fig. 207 M1 measurement connection Connect the pressure gauge (up to 600 bar) to the M1 measurement connection (2) in Fig. 207. Move both joysticks in the cab several times in all directions. Operate all pedals and switches with a hydraulic function several times.
Page 331 Maintenance - Hydraulic system GHC55 9.9.3 Checking the oil level Risk of injury from hot or pressurized hydraulic oil. WARNING Hot or pressurized hydraulic oil can cause serious scalding and injury.  Work on the hydraulic system may only be carried out by trained personnel with special knowledge and experience in hydraulics.
Page 332 Maintenance - Hydraulic system GHC55 Ȁ Fig. 208 Hydraulic tank Check the oil level on the oil level indicator (1) in Fig. 208: – The oil level must reach the upper marking on the sight glass. Add hydraulic oil as needed. Top up hydraulic oil Unscrew the cap to the oil filler neck (2) in Fig.
Page 333 Maintenance - Hydraulic system GHC55 9.9.4 Changing the hydraulic oil Risk of injury from hot or pressurized hydraulic oil, or loose WARNING hydraulic connections. Hot or pressurized hydraulic oil, or loose hydraulic connections can cause serious scalding and injury.  Work on the hydraulic system may only be carried out by trained personnel with special knowledge and experience in hydraulics.
Page 334 Maintenance - Hydraulic system GHC55 Replace the filter element of return filter as specified in Section 9.9.5. Ȁ Fig. 209 Oil drain plug and filler neck Fig. 210 Counterpart with hose on oil drain 9 - 44 Published 01-05-2016, Control # 565-02...
Page 335 Maintenance - Hydraulic system GHC55 Place a large enough container under the drain hole of the tank (see Section 9.17.3 for quantity). Unscrew the oil drain plug (1) in Fig. 209 on the bottom of the tank and screw on the counterpart with hose (3) in Fig. 210. Collect the used oil in the container.
Page 336 Maintenance - Hydraulic system GHC55 9.9.5 Return filter – changing filter element The manufacturer recommends changing the filter element after 1 year of operating time at the latest. If the element is exposed to greater dynamic strain, it can be necessary to keep shorter change intervals, as well as for startup, repairs, oil changes, etc.
Page 337 Maintenance - Hydraulic system GHC55 Clean the housing and cover. Check the filter, especially the sealing surfaces, for mechanical damage. Check the O-rings and replace as needed. Coat the sealing surfaces and the O-rings with a clean medium. Carefully insert the new filter element. Replace the cover and tighten the screws by hand (alternating between screws).
Page 338 Maintenance - Hydraulic system GHC55 9.9.6 Leak oil filter – changing the filter element The manufacturer recommends changing the filter element after 1 year of operating time at the latest. Ȁ Fig. 212 Leakage oil filter Loosen the four nuts on the square tube. Remove the return pipe (1) in Fig.
Page 339 Maintenance - Hydraulic system GHC55 9.9.7 Replacing the aeration filter Temperature changes and the use of cylinders or pressure accumulators cause the oil level in hydraulic system containers to vary constantly. Exchanging air with the surrounding atmosphere is necessary to avoid unsafe pressure build-up in the container.
Page 340 Maintenance - Hydraulic system GHC55 9.9.8 Checking the pre-load of the pressure accumulator Fig. 214 Pressure accumulator measurement connection Place attached loads and the boom on the ground. Connect the pressure gauge to connection M25 (1) in Fig. 214. Turn off the engine. Immediately turn the ignition key back to position 1.
Page 341 Maintenance - Hydraulic system GHC55 9.9.9 Replacing the HydroClean micro-filter element Risk of injury from hot engine parts. WARNING Persons can be injured by the hot parts on a running engine.  Only perform maintenance when the drive motor is off and the cooling system has cooled down.
Page 342 Maintenance - Hydraulic system GHC55 Clean the components, check the seal and replace it as needed. Insert the new filter element. Screw the cover back on. Start the drive motor. Loosen the hex screw (2) in Fig. 215 until the breather hole is open.
Page 343 Maintenance - Winch GHC55 9.10 Winch Risk of injury from high spring tension. WARNING The winch brakes are under extreme spring tension and if opened can cause injury.  Do not disassemble the winch brakes.  Only work on the winch and its attachments when the machine is off and not under load.
Page 344 Maintenance - Winch GHC55 remaining service life, or every 10 years at the latest. Fig. 216 Winch Oil filler neck – gearbox Oil level indicator Oil drain – gearbox 9 - 54 Published 01-05-2016, Control # 565-02...
Page 345 Maintenance - Winch GHC55 Information Mixing different types of oils, lubricants and operating fluids is prohibited. Only mix the same type of or identical (same specification) oils, lubricants and operating fluids from the same manufacturer. 9.10.1 Maintaining the brake Safety instructions ...
Page 346 Maintenance - Winch GHC55 9.10.3 Changing the winch gearbox oil Information Mixing different types of oils, lubricants and operating fluids is prohibited. Only mix the same type of or identical (same specification) oils, lubricants and operating fluids from the same manufacturer. Park the machine on a level surface.
Page 347 Maintenance - Undercarriage GHC55 9.11 Undercarriage Risk of injury from rotating and hot parts. WARNING Persons can be injured and scalded by rotating and hot parts. Only perform maintenance when the drive motor is off and the distributor  gearbox is cool. Risk of environmental damage due to improper disposal of oil.
Page 348 Maintenance - Undercarriage GHC55 9.11.2 Checking the travel drive oil level Risk of scalding from hot oil. WARNING Persons can be injured when draining hot oil.  Only drain the oil when the gearbox is warm. Information Mixing different types of oils, lubricants and operating fluids is prohibited.
Page 349 Maintenance - Undercarriage GHC55 9.11.3 Changing the travel drive oil Risk of injury due to oil coming into contact with skin. WARNING Contact with oil can cause severe skin disorders and other severe injuries.  Wear gloves and safety glasses with side protection. ...
Page 350 Maintenance - Undercarriage GHC55 Park the machine on an even and hard surface so the lubricating points (1) and (2) are as shown in Fig. 218. Switch off the diesel engine. Place a collecting vessel under the closure for lubricating point (1) and lubricating point (2).
Page 351 Maintenance - Undercarriage GHC55 9.11.4 Crawler track Information Properly adjusted track tension will reduce the wear of running gear parts. Grease and a grease gun are needed for adjusting track tension. More detailed information can be found in the attached list of operating materials.
Page 352 Maintenance - Undercarriage GHC55 ȀȀ ! Fig. 219 Driving the crawler undercarriage onto wooden planks Measure the distance (3) between the frame of the track wheel carrier and the track shoe on the 4th track roller in Fig. 220. The distance has to be approx. 27 cm (11 in) to 30 cm (12 in). Ȁ...
Page 353 Maintenance - Undercarriage GHC55 To adjust the track tension, unscrew the service panel (4) in Fig. 221 on the back of the track wheel carrier and add grease through the lubricating nipple (5) with a grease gun. ȀȀ ! Fig. 221 Adjusting track tension Check the track tension again.
Page 354 Maintenance - Undercarriage GHC55 9.11.5 Spring tensioning fixture - adjusting track tension Risk of death from ejecting grease. WARNING Without lubricating nipples or valve, the grease sprays out at high pressure and the valve is ejected from the machine. This can cause serious injury or death.
Page 355 Maintenance - Undercarriage GHC55 Part the machine on even, hard ground. Prepare the grease gun (1) in Fig. 222. Remove the screws and cover (2) in Fig. 222. Insert the connection hose (3) in Fig. 222 into the lubricating valve. Inject the grease.
Page 356 Maintenance - Undercarriage GHC55 9.11.6 Track rollers Re-tighten screws Fig. 223 Track rollers Information Retighten the screws (1) in Fig. 223 with a torque wrench. Observe the tightening torque specified in Section 9.17.4. 9.11.7 Sprocket Re-tighten screws Fig. 224 Sprocket mounting screws Information Retighten the sprocket mounting screws with a torque wrench.
Page 357 Maintenance - Undercarriage GHC55 9.11.8 Base plates Re-tighten screws Fig. 225 Base plate mounting screw Information Retighten base plate mounting screws with a torque wrench. Tighten M18x1.5 hex screws to a tightening torque of 530 Nm. Grove 9 - 67 Published 01-05-2016, Control # 565-02...
Page 358 Maintenance - Rotary connection GHC55 9.12 Rotary connection Make sure the rotary connection is well lubricated.  Bearing race (1) in Fig. 226 – via lubrication nipple  Gearing (2) in Fig. 226 – via lubricating nipples or – With gear spray ...
Page 359 Maintenance - Rotary connection GHC55 9.12.1 Lubricating the slewing ring bearing race Information Mixing different types of oils, lubricants and operating fluids is prohibited. Only mix the same type of or identical (same specification) oils, lubricants and operating fluids from the same manufacturer. Information The specified lubricating intervals can be shortened in the following situations:...
Page 360 Maintenance - Rotary connection GHC55 Fig. 228 Rotary connection sealing lips Turn off the diesel engine. Open the right service door. Lubricate the top 8 lubricating nipples (1) in Fig. 227 (outlet no. 5–12) until grease comes out of the sealing lips (3) in Fig.
Page 361 Maintenance - Rotary connection GHC55 9.12.2 Lubricating the slewing ring gearing Lubricate the slewing ring every 10 operating hours or daily, depending on operating conditions. Information Mixing different types of oils, lubricants and operating fluids is prohibited. Only mix the same type of or identical (same specification) oils, lubricants and operating fluids from the same manufacturer.
Page 362 Maintenance - Rotary connection GHC55 Pinion gearing lubrication (option) Ȁ Fig. 230 Gear tooth lubrication Slewing ring, outer teeth Slew-ring pinion shaft Pinion lubrication push-button Information Clean the lubrication point thoroughly down to the bare metal before the first application of lubricant to ensure that the lubricant creates a continuous film across the surface.
Page 363 Maintenance - Rotary connection GHC55 Lubrication process: – Press and hold the push-button (3) in Fig. 230 on the control panel. – Slew the uppercarriage with the left control lever 360° to the left and to the right to distribute the lubricant evenly over the gearing.
Page 364 Maintenance - Rotary connection GHC55 Safety instructions Proceed as follows before checking the plastic skid (2) in Fig. 231:  Lower attached loads and the boom to the ground.  Pull the left safety lever back.  Before beginning maintenance, turn off the machine and secure it against being restarted without authorization.
Page 365 Maintenance - Rotary connection GHC55 9.12.3 Tightening the slewing ring bolts Risk of death due to uppercarriage tipping over. DANGER Defective slewing ring bolts can cause the uppercarriage to tip over, resulting in serious injury or death.  Check the slewing ring bolts every 5,000 operating hours or every 5 years and replace as needed.
Page 366 Maintenance - Rotary connection GHC55 A - A Fig. 233 Slewing ring bolts Turn off the drive motor. Retighten the slewing ring bolts (2, 3 – M22) in Fig. 233 with a torque wrench in a criss-cross pattern. Tighten M22 slewing ring bolts to a tightening torque of 750 Nm.
Page 367 Maintenance - Telescopic boom GHC55 9.13 Telescopic boom 9.13.1 Lubricating the telescopic boom Sufficient and regular lubricating is required for reliable boom operation. The specified lubricating intervals can be shortened in the following situations:  High humidity  High levels of dust ...
Page 368 Maintenance - Telescopic boom GHC55 Thoroughly clean the telescopic boom before lubricating. Let the surfaces being lubricated dry completely. Fully retract the telescopic boom and lower it as far as it will go. Bring the telescopic boom in line with the vehicle. The end of the shaft has 6 inspection openings.
Page 369 Maintenance - Telescopic boom GHC55 9.13.3 Rope mechanism in the telescopic boom – holding lines and haulback lines Fig. 235 Rope mechanism in the telescopic boom Basic body Telescope 1 Telescope 2 Telescope 3 Telescope 2 (C) in Fig. 235 is pushed out of the telescoping cylinder at the same time when telescope 1 (B) in Fig.
Page 370 Maintenance - Telescopic boom GHC55 Re-tensioning holding lines (4) Tensioning the holding lines (4) using the nuts and disc spring assemblies Detail X Holding rope Fig. 236 Tension stopping cables Tighten the nuts (14) in Fig. 236 until telescope 1 and telescope 2 move outward.
Page 371 Maintenance - Telescopic boom GHC55 Information Make sure the telescopes are pushed in simultaneously each time you re-tension the lines. Checking synchronization Carefully retract the telescopes as far as they will go. IF this is not the case, proceed as follows: –...
Page 372 Maintenance - Electrical system GHC55 9.14 Electrical system Safety instructions  Only qualified electricians may work on the electrical system.  Observe the appropriate regulations for installing electrical equipment and preventing accidents. 9.14.1 Batteries Risk of death from exploding battery. DANGER An exploding battery can cause serious injury or death.
Page 373 Maintenance - Electrical system GHC55 Ȁ Fig. 238 Battery and battery disconnect switch Checking battery terminals and cables Press the battery disconnect switch (2) in Fig. 238. Clean the terminals and cables of the battery (1) in Fig. 238, make sure they are seated properly and apply terminal grease. Press the battery disconnect switch back to its initial position.
Page 374 Maintenance - Electrical system GHC55 9.14.2 Fuses Risk of injury and burns from incorrect fuses. WARNING Using incorrect fuses poses a risk of fire that can cause serious injury. Do not repair fuses.  Always use new fuses with the same amperage. ...
Page 375 Maintenance - Automatic climate control GHC55 9.15 Automatic climate control Safety instructions Maintenance and repairs may only be performed by trained and authorized professionals. Information Check the following components monthly:  wiring  Condition of the heating and cooling lines ...
Page 376 Maintenance - Automatic climate control GHC55 Replace the filter element if it has been damaged or it is too dirty. Insert the cleaned filter element or a new filter element into the filter cartridge. Information The arrows on the filter element must point toward the back of the cab. 9.15.2 Cleaning the fresh air filter Ȁ...
Page 377 Maintenance - Automatic climate control GHC55 Insert the cleaned filter element or a new filter element. – The colored side of the filter element must point toward the interior of the cab. Close the cover. Close the cover closures with a screwdriver. Grove 9 - 87 Published 01-05-2016, Control # 565-02...
Page 378 Maintenance - Ropes GHC55 9.16 Ropes Steel wire ropes are lubricated during manufacture. This lubrication suffices for storage and for initial operation. The lubrication intervals for ropes depend on the operating conditions (type of rope, weather conditions, uses) so they cannot be specified precisely by Grove.
Page 379 Maintenance - Maintenance schedule GHC55 9.17Maintenance schedule The maintenance schedule lists activities that must be performed on individual assemblies. The maintenance intervals are specified in operating hours (OH). Safety instructions  The maintenance work stated must only be performed by trained and instructed specialists.
Page 380 Maintenance - Maintenance schedule GHC55 Activity Every Every Once after Every Every Every 10 operating 50 operating 250 operating 500 operating 1,000 operating 2,000 operating hours/day hours/week hours/6 weeks hours/ hours/year hours/2 years 3 months – Check engine oil level. Comply with intervals as specified in the manual provided by the engine...
Page 381 Maintenance - Maintenance schedule GHC55 Activity Every Every Once after Every Every Every 10 operating 50 operating 250 operating 500 operating 1,000 operating 2,000 operating hours/day hours/week hours/6 weeks hours/ hours/year hours/2 years 3 months – Batteries: Check cables and fuses. –...
Page 382 Maintenance - Maintenance schedule GHC55 Activity Every Every Once after Every Every Every 10 operating 50 operating 250 operating 500 operating 1,000 operating 2,000 operating hours/day hours/week hours/6 weeks hours/ hours/year hours/2 years 3 months – Preload pressure: Have hydraulic accumulator checked by a qualified hydraulics company.
Page 383 Maintenance - Maintenance schedule GHC55 Activity Every Every Once after Every Every Every 10 operating 50 operating 250 operating 500 operating 1,000 operating 2,000 operating hours/day hours/week hours/6 weeks hours/ hours/year hours/2 years 3 months Every 4,500 operating hours. Long life coolant as specified by Cummins > 2,000 operating hours. Certain hydraulic oils do not have to be changed as often depending on the results of regularly performed hydraulic oil analyses.
Page 384 Maintenance - Maintenance schedule GHC55 9.17.1 Hydraulic oil analysis Every Grove machine is filled with Shell hydraulic oil at the factory. Performing regular hydraulic oil analyses allows this hydraulic oil to be used for extended periods. These hydraulic oil analyses can detect critical states in the hydraulic system early and prevent damage.
Page 385 Maintenance - Maintenance schedule GHC55 Sampling point The sampling point is designated by the sticker in Fig. 242. ȀȀ ! " Fig. 242 Sampling point sticker Take the sample from the measurement connection (1) in Fig. 243 on the HydroClean filter. ȀȀ...
Page 386 Maintenance - Maintenance schedule GHC55 Sampling Risk of machine damage due to incorrect hydraulic oil NOTICE analysis. The hydraulic system could be damaged if the results of the analysis are distorted due to an unclean hydraulic oil sample. Ensure absolute cleanliness when sampling. ...
Page 387 Maintenance - Maintenance schedule GHC55 Risk of severe burns from hot parts and hydraulic oil. WARNING Contact with hot hydraulic system parts or hot hydraulic oil can cause severe burns. Avoid contact with hot parts.   Wear protective clothing and protective gloves. Risk of serious injury from pressurized hydraulic oil.
Page 388 Maintenance - Maintenance schedule GHC55 Ȁ " ȀȀ Ȁ! Fig. 246 Taking hydraulic oil sample Open a new, clean sample container (3) in Fig. 246 and fill it to the MAX mark with hydraulic oil. Make sure the sample con- tainer or closure do not become contaminated.
Page 389 Maintenance - Maintenance schedule GHC55 9.17.2 Lubrication point overview Ȁ " Fig. 247 Lubrication points on the machine Telescopic boom, sliding surfaces Central lubricating strip Undercarriage Cross member Grove 9 - 99 Published 01-05-2016, Control # 565-02...
Page 390 Maintenance - Maintenance schedule GHC55 9.17.3 Fill quantities Information Mixing different types of oils, lubricants and operating fluids is prohibited. Only mix the same type of or identical (same specification) oils, lubricants and operating fluids from the same manufacturer. The following values are guide values. The fill level shown on the respective part is authoritative.
Page 391 Maintenance - Maintenance schedule GHC55 9.17.4 Tightening torques for screws Information Values other than those in this table may apply for some mounting screws on the undercarriage. Observe the information in the appropriate sections. Strength class 8.8 Coarse-pitch thread Fine-pitch thread (black, lightly oiled, µ...
Page 392 Maintenance - Maintenance schedule GHC55 Strength class 10.9 Coarse-pitch thread Fine-pitch thread (black, lightly oiled, µ = 0.14) Screw Tightening torque Screw Tightening torque [Nm] [Nm] M8x1 M10x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 1050 M27x2 1500 1400 M30x2 2100...
Page 393 Maintenance - Maintenance schedule GHC55 Strength class 12.9 Coarse-pitch thread Fine-pitch thread (black, lightly oiled, µ = 0.14) Screw Tightening torque Screw Tightening torque [Nm] [Nm] M8x1 M10x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 1200 1100 M27x2 1750 1650 M30x2...
Page 394 Maintenance - Maintenance schedule GHC55 This Page Blank 9 - 104 Published 01-05-2016, Control # 565-02...
Page 395 Troubleshooting - Drive engine GHC55 10 Troubleshooting Safety when correcting Comply with Chapter 1 S  AFETY faults Personnel for maintenance, inspection and fault correction must  have the appropriate qualifications for these tasks. For activities not described in more detail, contact the GROVE ...
Page 396 Troubleshooting - Hydraulic system GHC55 10.2Hydraulic system Oil leaks on the hydraulic system Cause Remedy Hose clampings loose – Contact your Grove Service Partner. Hoses or seals – Contact your Grove Service Partner. damaged Hydraulic pump does not work Cause Remedy Fault in pump circuit –...
Page 397 Troubleshooting - Hydraulic system GHC55 No power or low power of the Cause Remedy hydraulic system Hose clampings loose – Contact your Grove Service Partner. Hoses or seals – Contact your Grove Service Partner. damaged Pressure relief valve – Contact your Grove Service Partner. opens too soon Hydraulic pump worn –...
Page 398 Troubleshooting - Heating/air-conditioning system GHC55 10.3 Heating/air-conditioning system 10.3.1 Heat output Fan does not work Cause Remedy Fuse defective or loose – Make sure the fuse is properly seated and insert it correctly if necessary. Replace defective fuse. – If the defect recurs within a short period of time, this indicates a short- circuit or a blockage.
Page 399 Troubleshooting - Heating/air-conditioning system GHC55 No or insufficient heat output Cause Remedy Water intake temperature – Wait until the diesel engine has too low warmed up. Vehicle thermostat – Contact your Grove Service defective Partner. Heat exchanger lamellas – Check the heat exchanger and are contaminated clean if necessary.
Page 400 Troubleshooting - Heating/air-conditioning system GHC55 Cause Remedy Control system defective – Contact your Grove Service Partner. 10.3.2 Cooling capacity Compressor does not work Cause Remedy Interruption in the solenoid – Check the power to the clutch. coil of the compressor V-belt loose or torn –...
Page 401 Troubleshooting - Heating/air-conditioning system GHC55 Loss of refrigerant Cause Remedy Break in refrigerant line – Check all lines for break due to external effects or abrasion. Leakage in the system – Contact your Grove Service Partner. Cooling capacity insufficient Cause Remedy Air filter clogged –...
Page 402 Troubleshooting - Slewing gear GHC55 10.3.3 System very noisy System very noisy Cause Remedy V-belt loose or excessively – If loose, adjust the tension of the V- worn belt. If worn, replace the V-belt. Clutch noisy – Repair the clutch. The compressor bracket is –...
Page 403 Troubleshooting - Undercarriage GHC55 10.5Undercarriage Oil leaks on the travel gear Cause Remedy Plug is loose – Fasten plug. Seals – Contact your Grove Service Partner. damaged 10.6Cab Increased shaking or vibration of the cab Cause Remedy Cab suspension or cab –...
Page 404 Troubleshooting - Cab GHC55 This Page Blank 10 - 10 Published 01-05-2016, Control # 565-02...
Page 405 Appendix - Reeving Diagram GHC55 11 Appendix 11.1 Reeving Diagram 11.2 Handling, Installation, and Maintenance of Steel Wire Ropes 11.3 Driver Seat 11.4 Camera System 11.5 Radio Remote Control 11.6 Cleaning the Cooling System 11.7 Residual Useful Life of Winches 11.8 Installing Large Roller Bearings, Slewing Gears and Flange Connections 11.9 PFEIFER Pouch Lock System...
Page 406 Appendix - Reeving diagram GHC55 11.16Reeving diagram 11 - 2 Published 01-05-2016, Control # 565-02...
Page 407 Appendix - Reeving diagram GHC55 Grove 11 - 3 Published 01-05-2016, Control # 565-02...
Page 408 Appendix - Reeving diagram GHC55 11 - 4 Published 01-05-2016, Control # 565-02...
Page 409 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes 10 Appendix 10.1 Handling, Installation, and Maintenance of Steel Wire Ropes 10.1.1 Rope selection Grove cranes and excavators are already fitted with high-quality wire ropes on delivery. When ropes are ready for discarding they should be replaced by new wire ropes of the same type, with the same nominal diameter, identical wire strength and the same type and direction of lay.
Page 410 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes 10.1.3 How should wire ropes be stored? Wire ropes should be stored under cover in clean, cool and dry conditions. Contact with the ground should be avoided, e.g. by storing on pallets. If storage outdoors is unavoidable, the ropes must be covered in such a way that they do not come into contact with water.
Page 411 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes 10.1.4.2 Unwinding from the reel A wire rope wound on a reel is likewise preferably unwound by a turntable or a payoff stand. Unreeling on the ground, which is repeatedly recommended in the pertinent literature, is not very satisfactory in practice because the reel unwinds an increasingly smaller amount of rope than the distance it covers, i.e.
Page 412 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes A wire rope pulled sideways off the coil or reel resists the twisting and forms loops. If a rope of this type is loaded, the loops contract and produce a kink, an irreparable deformation.
Page 413 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes leader rope cannot twist. Twist-free wire rope types or three-strand fiber ropes, for example, are recommendable as leader ropes. When conventional wire ropes are used it should be ensured that they at least have the same lay direction as the wire rope to be drawn in.
Page 414 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes Whereas it is often adequate to mount the wire rope normally and then unwind it and rewind it with the aid of an external load, this is not possible in other cases, e.g.
Page 415 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes First mark the cutting point with chalk or insulating tape. Then lay one end of the tying wire over a length of about 4 times the rope diameter on the rope and start to wrap the wire rope and this piece of wire away from the cutting point.
Page 416 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes greased + regreased greased degreased Tensile stress [N / mm According to DIN 15020: ‘Wire ropes must be relubricated at regular intervals which depend on the operating conditions, in particular in the bending zone”. It also states: ”If relubrication of the rope must be discontinued for operating reasons, a shorter life should be anticipated and the monitoring suitably adapted.”...
Page 417 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes thing is that it takes place regularly from the outset and is not started only when the first damage has already been detected. 10.1.5.2 Cleaning of wire ropes According to DIN 15020: “Extremely dirty wire ropes should be cleaned externally from time to time.
Page 418 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes However, the success of such measures is disputed. In any case the expenditure is only worthwhile where the rope value is a multiple of the assembly costs. 10.1.6 Inspection of wire ropes 10.1.6.1 Why must a wire rope be inspected? A wire rope is an article of daily use with a limited life.
Page 419 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes must be discarded if its diameter has been reduced by 10% compared to the nominal dimension, even if no wire breaks are detected. Wear. A wire rope must be discarded if it’s static breaking force or operat- ing strength has been unduly reduced by metallic wear.
Page 420 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes d. Wire loosening. In the event of wire loosening caused by rust or wear, a wire rope must be discarded. In the event of other causes the consequen- tial damage is determinative for discard of the rope. Knot formations.
Page 421 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes ing of two rope drums. Moisture may also deposit between rope and pul- ley and cause locally increased corrosion. Rope zones on rope drums. Load pick-up points and crossover points on rope drums are exposed to heavier wear and should therefore be inspected in particular for wear, wire breaks and structural changes.
Page 422 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes  a tape measure  a piece of white chalk, a piece of black wax chalk  an endless roll of paper tape  a screwdriver  a magnifier (possibly measuring magnifier, thread counter) ...
Page 423 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes measurements should ensure that the rope is discarded when the maximum diameter reduction specified in the standards is achieved. With reduction of the rope diameter to 90% of its nominal value a wire rope must be discarded according to DIN 15020.
Page 424 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes impression of the outer wires of the rope is thus obtained via the top sides of the strands. The paper strip is labeled for subsequent evaluation. By laying impressions of the dead drum turns and the investigated zone over each other and viewing them against the light it can be roughly ascertained in situ whether changes have occurred.
Page 425 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes additional stresses resulting from the greater rope deformation (ovalization of the rope) likewise lead to reduction of the rope life. The grooves are checked by groove gauges. Although these gauges are commercially available, circular templates made on a lathe are the best method.
Page 426 Appendix - Handling, Installation, and Maintenance of Steel Wire Ropes The flanks of the rope pulleys should also be checked regularly. Abrasion marks pointing radially to the groove base show that the rope first contacts the flank when running over the pulley and then slides down into the groove only on further rotation of the pulley.
Page 427 Appendix - Driver Seat 10.2 Driver Seat GRAMMER AG: Seating comfort for high demands! You have acquired a GRAMMER seat. Congratulations! Take your seat please, and enjoy the ultimate in seating comfort and safety. You will be enjoying a driver's seat characterized by user-friendliness and a high degree of adaptability.
Page 428 Appendix - Driver Seat Item Description Item Description Weight adjustment Headrest* *** Height adjustment Storage box * Absorber* Seat heater* Fore/aft adjustment Lumbar support* *** Seat pan angle adjustment* Lumbar support* *** Seat depth adjustment* Backrest adjustment Armrest adjustment* Lateral isolator* Armrests* *** Fore/aft isolator* * if fitted...
Page 429 Appendix - Driver Seat 10.2.1 General Instructions  The operating instructions must be read in full before use.  The operating instructions must be kept in the vehicle and always be at hand.  The driver's seat may only be fitted, serviced and repaired by specialist personnel.
Page 430 Appendix - Driver Seat  Seatbelts are fitted or can be retrofitted to the driver’s seat. Seatbelts may only be fitted on the approval of the vehicle manufacturer, as they increase the load in the seat mounting area.  Seatbelts must be fitted in accordance with specific national regulations and guidelines, and must be approved by GRAMMER AG.
Page 431 Appendix - Driver Seat Seat heater Compressor Seat heater compressor For building an electric connection, select an electric circuit by means of which the electric consumers of the driver’s seat are separated from the live network when the ignition is switched off. 10.2.4 Guarantee and liability ...
Page 432 Appendix - Driver Seat 10.2.5.4 Fore/aft adjustment The fore/aft adjustment is released by lifting the locking lever. WARNING Risk of accident! Do not operate the locking lever while driving.  After the adjustment, the locking lever must latch into the desired position with an audible click.
Page 433 Appendix - Driver Seat 10.2.5.9 Headrest * *** The headrest can be individually adjusted for height by pulling it upward over the various increments up the end stop. By pushing foreward or rearward the angle of the headrest can be adjusted individually.
Page 434 Appendix - Driver Seat 10.2.5.14 Backrest adjustment Pull up the locking lever to release the backrest catch. When releasing the backrest catch, do not apply load to the backrest by pressing against it. By exerting pressure on or off the front or rear part of the seat pan it can be moved to the desired position.
Page 435 Appendix - Camera system 10.3 Camera system MD3072B Art.-no. 401 0040 000 MD3072B-Quad Art.-no. 401 0041 000 10.3.1 Product description The TFT Monitor MD3072B/MD3072B-Quad shall be used to display up to 4 video images at vehicles and / or mobile machines. Using the connected camera, the driver/operator is able to monitor areas outside his direct visibility.
Page 436 Appendix - Camera system 10.3.1.4 Optional accessories Match Code Part Number Description MD-KG 406 0089 007 Progressively adjustable joint mount (406 0089 022 is required) KG24-V50 406 0089 008 Extension 50mm for MDKG- ball joint MD-V 406 0089 023 Anti-vibrations unit for display mount 10.3.2 Safety Instructions WARNING The electrical connection and commissioning of this system may only be...
Page 437 Appendix - Camera system vehicle. Additional dangers may arise when connecting this product to other products:  Do not install cables in the vicinity of engines or other sources of heat.  Protect the cables against damage by means of cable ducts or protective hoses.
Page 438 Appendix - Camera system 10.3.3 Operating and Display Elements Display on / off Menus are activated and toggled in the order: Brightness .....Brightness - 0(MIN) ... 60 (MAX) Contrast ....Contrast - 0(MIN) ... 60 (MAX) Color ......Color saturation - 0 (MIN) ... 60 (MAX) Standard ....Reset to factory settings Volume ....Volume - 0 (MIN) ...
Page 439 Appendix - Camera system 10.3.4 Commissioning Fasten the display mount inside the driver cabin such that the driver can easily see the TFT display. Make sure that no display instruments are hidden and that the driver’s front view is not obstructed. Connect the supply cable MD3072B-AK according to the following table.
Page 440 Appendix - Camera system 10.3.5.3 Three Camera Operation Three cameras are connected in this operating mode. Camera 1 has the highest priority, i.e. images of camera 1 will be displayed on the screen if other cameras have been selected simultaneously. Camera 2 has a higher priority than camera 3. 10.3.5.4 Four Camera Operation Two or more cameras are connected in this operating mode.
Page 441 Appendix - Camera system 10.3.7 Maintenance The TFT monitor is maintenance-free. Clean the monitor cover using only a soft, slightly moistened cloth. The ventilation slots of the color display should occasionally be freed from dust using a cloth or a brush. Motec products have been designed to operate error-free and with minimum maintenance for a long time.
Page 442 Appendix - Radio Remote Control 10.4 Radio Remote Control 10.4.1 Introduction 10.4.1.1 The operating manual Read the manual of all system components carefully and completely before operating the system. The content will make yourself familiar with the safety instructions and the controls during standard operation and maintenance. Keep the manual in a place where the operator can access it at any time.
Page 443 Appendix - Radio Remote Control 10.4.1.4 Copyright All rights are reserved. Copying, reshaping, recording on electronic media and translating into other languages is only allowed with the written permission of HETRONIC Germany GmbH. Subject to technical change without prior notice. HETRONIC Germany GmbH reserves the right to change, improve or phase out the products anytime without public notice or obligation.
Page 444 Appendix - Radio Remote Control 10.4.2.6 Protection devices All industrial HETRONIC radio remote control systems are equipped with an emergency stop button, located on the control panel of the transmitter. The radio remote control system is provided with protection devices, which are activated automatically in the following cases: ...
Page 445 Appendix - Radio Remote Control Battery monitoring: The transmitter´s electronics permanently monitors the battery state. If the battery voltage is low, an optical or accoustical signal will alert the operator for about 30 seconds. Afterwards the transmitter automatically sends out a stop signal and brings the machine into a safe state.
Page 446 Appendix - Radio Remote Control ATTENTION!  The installation of the receiver unit on the electric system of the machine may only be performed by a qualified person, familiar with the electrical circuitry of the machine and the technical features of the radio remote control. ...
Page 447 Appendix - Radio Remote Control 10.4.5.2 Visual checkup ATTENTION! Always check the transmitter for damages each time before use!  Are all protection devices present and fully functional?  Are there any broken parts?  Are the rubber sleeves and the pushbutton caps in good order? (transmitter) ...
Page 448 Appendix - Radio Remote Control  If the stop button works properly – you may start the system.  If the stop button does not work properly, the system has to be checked by a qualified person.  Now your radio remote control is ready for operation. Activate any of the functions using the transmitter and check if the machine operation immediately stops if the function is released.
Page 449 Appendix - Radio Remote Control Red stop button Green start button and key switch 10.4.6.3 Receiver status display Compact version with vision panel The LED Display is on the right side of the housing. Compact version without vision panel The LEDs are only visible when receiver lid opened. Modular Version There are 3 LEDs on both the decoder and the emergency stop decoder LED Explanation...
Page 450 Appendix - Radio Remote Control 10.4.7.1 MFS transmission technology (Multi Frequency Sharing) Pocket, Hand Held and Ergo are also available as MFSHL versions. MFS technology allows the operation of several systems with the same frequency in the immediate vicinity. Transmitter: ERGO-MFS-HL Pocket-MFS-HL HandHeld-MFS-HL Receiver: RX/AC 8 and 16 MFS-HL...
Page 451 Appendix - Radio Remote Control H-Link programming interface RX types H-Link ERGO F POCKET PC with H-Link card Serial programming interface 10.4.8 Battery charger and rechargeable batteries 10.4.8.1 Replacing and charging rechargeable batteries The batteries have to be fully charged before startup! Place the charger in a clean and dry location.
Page 452 Appendix - Radio Remote Control 10.4.8.2 Display and error messages of the battery charger (Picture 2 and Picture 3) LED-Display of the battery charger  Charging process is running: yellow LED[1] flashing  Fast charging: yellow [1] and red [2] LED flashing, after activation of the fast charge button [2] ...
Page 453 Appendix - Radio Remote Control Battery charger types: Picture 1 Picture 2 Picture 3 Versa Pak charger HETRONIC charger HETRONIC charger with battery 3,6V with battery 9,6V 10.4.9 Battery handling 10.4.9.1 Replacing alkaline batteries (Size AA – round cell)  The battery voltage is constantly monitored by the transmitter. If the voltage is low, the red LED on the transmitter starts flashing and according to the type you will also hear an acoustic signal.
Page 454 Appendix - Radio Remote Control 10.4.9.3 Battery replacement for type Hand Held (Pict. 3 – 6)  Push the lever at the end of the battery compartment, until the battery tube or the rechargeable battery releases (pict. 3 – 5). ...
Page 455 Appendix - Radio Remote Control 10.4.10 Diagnostics Problem Possible Cause Solution The transmitter does not respond The battery is empty. Charge the batteries or replace the when it is switched on. alkaline batteries. The fuse is blown. The fuse has to be replaced by an authorized expert.
Page 456 Appendix - Radio Remote Control 10.4.11 Special Technical Data 10.4.11.1 System Frequency range: .... 400 – 470 MHz, Europe 433/434 MHz and 869 MHz RF synthesizer: ....Microprocessor-controlled PLL synthesizer with 32 selectable frequencies RF-output: ....... <10mW standard, increased transmitting power available on demand, certified for frequency ranges subject to approval and freely assignable frequency ranges in over 40 states.
Page 457 Appendix - Radio Remote Control Antenna: ......external antenna, with moisture repellent connection, partly internal Digital outputs: ....Fail-safe and self-monitoring emergency stop circuit, all relay outputs 275VAC/8A Prop. resolution: ....8 Bit (256 steps per function), built-in ramp function selectable Prop. outputs: ....PWM signal with selectable dither frequency and current range, linear output voltage, setting of proportional functions via the transmitter (Quick set) or via potentiometer, multiple speed ranges selectable, all...
Page 458 Appendix - Radio Remote Control Possible repairs may only be performed in service stations that are authorized or recommended by HETRONIC or directly in HETRONIC’s service and spare parts department. The use of non original spare parts or the assignment of unauthorized personnel will immediately void your guarantee.
Page 459 Appendix - Radio Remote Control 10.4.13 Complaint form Grove 10 - 393 Published 11-18-2015, Control # 602-00...
Page 460 Appendix - Radio Remote Control 10.4.14 Abbreviations and definitions 10.4.14.1 Abbreviations AK ....Analog channel DK ....Digital channel EPROM ..Electrical programmable read-only memory FM ....Frequency modulation GND ....Ground HF....High frequency KHz....Kilohertz LED ....Light emitting diode mAH ....
Page 461 Appendix - Radio Remote Control Machine data Data of the radio remote control ____________________________ _______________________________ Manufacturer Manufacturer ____________________________ _______________________________ Type number Model ____________________________ _______________________________ Serial number Type HETRONIC Germany GmbH ____________________________ _______________________________ Production year System number I/We have carried out the installation, startup and safety checks for the radio remote control system on the above mentioned machine.
Page 462 Appendix - Radio Remote Control 10.4.16 EC Declaration of Conformity We hereby declare that the components of the equipment, specified below, are suitable for the installation on machinery or other devices, designed for machinery or not, according to the following EU Directives with revisions and subsequent amendments: Machinery Directive 2006/42/EC...
Page 463 Appendix - Radio Remote Control 10.4.17 HF-Part Conformity Europe Declaration of Conformity in accordance with the Radio and Telecommunications Terminal Equipment Act (FTEG) and Directive 1999/5/FC (R&TTE Directive) HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 Manufacturer / responsible person 84085 Langquaid Deutschland Declares that the product RF-Modul CS 434 TXN/RXN Type (if applicable, configuration including the...
Page 464 Appendix - Radio Remote Control Address HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 84085 Langquaid Deutschland Phone, fax, email: Tel. +49 (0) 9452 189 610 Fax: +49 (0) 9452 189 201 Langquaid, 01.08.2010 Place, date of issue Signature 10 - 398 Published 11-18-2015, Control # 602-00...
Page 465 Appendix - Radio Remote Control Declaration of Conformity in accordance with the Radio and Telecommunications Terminal Equipment Act (FTEG) and Directive 1999/5/FC (R&TTE Directive) Manufacturer / responsible person HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 84085 Langquaid Deutschland Declares that the product RF-Modul Type (if applicable, configuration including the CS 434 TRT/TRR modules)
Page 466 Appendix - Radio Remote Control Address HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 84085 Langquaid Deutschland Phone, fax, email: Tel. +49 (0) 9452 189 610 Fax: +49 (0) 9452 189 201 Langquaid, 01.08.2010 Place, date of issue Signature 10 - 400 Published 11-18-2015, Control # 602-00...
Page 467 Appendix - Radio Remote Control Declaration of Conformity in accordance with the Radio and Telecommunications Terminal Equipment Act (FTEG) and Directive 1999/5/FC (R&TTE Directive) Manufacturer / responsible person HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 84085 Langquaid Deutschland Declares that the product RF-Modul Type (if applicable, configuration including the CS 869 TRT/TRR modules)
Page 468 Appendix - Radio Remote Control Address HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 84085 Langquaid Deutschland Phone, fax, email: Tel. +49 (0) 9452 189 610 Fax: +49 (0) 9452 189 201 Langquaid, 01.08.2010 Place, date of issue Signature 10 - 402 Published 11-18-2015, Control # 602-00...
Page 469 Appendix - Radio Remote Control Declaration of Conformity in accordance with the Radio and Telecommunications Terminal Equipment Act (FTEG) and Directive 1999/5/FC (R&TTE Directive) Manufacturer / responsible person HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 84085 Langquaid Deutschland Declares that the product RF-Modul Type (if applicable, configuration including the FBTX/FBRX modules)
Page 470 Appendix - Radio Remote Control Address HETRONIC-Germany GmbH Adalbert-Stifter-Str. 2 84085 Langquaid Deutschland Phone, fax, email: Tel. +49 (0) 9452 189 610 Fax: +49 (0) 9452 189 201 Langquaid, 01.08.2010 Place, date of issue Signature 10 - 404 Published 11-18-2015, Control # 602-00...
Page 471 Appendix - Radio Remote Control 10.4.18 Mounting Antennas for Feedback-Systems Important! To guarantee a trouble free operation, follow the instructions given below to mount the antennas.  Keep a minimum in distance of 3 to 6 ft between the receiver-antenna and the transmitter-antenna.
Page 472 Appendix - Radio Remote Control 10.4.19 Mounting instruction for directional antenna on top slewing cranes The mounting of the directional antenna has to be done on the counter-boom of the crane. The mounting position should be easily accessible from all sides and not be hidden by any components.
Page 473 Appendix - Radio Remote Control the point of time at which the defect was noticeable to the buyer without any closer inspection, considering normal usage. Along with the fault notice, the buyer has to deliver any proofs (photographs, drawings, fault descriptions etc.). In case of a guarantee condition HETRONIC has the right to re-improve the same item three times because of the same fault.
Page 474 Appendix - Cleaning the cooling system 10.5 Cleaning the cooling system The cooling system of a machine comprises a coolant cooler, an oil cooler and a charge-air cooler and additional coolers, depending on the design. The cooling system ensures that the machine runs at a constant operating temperature.
Page 475 Appendix - Cleaning the cooling system 10.5.2 Coolant cooler 10.5.2.1 External cleaning Dirt and cleaning Dust, insects, foliage or leaves - Compressed air (max. 3,5 bar) procedure Oily and greasy deposits - Steam jet Caution Ensure that the cooling fins are not damaged. Fig.
Page 476 Appendix - Cleaning the cooling system Start the engine and allow it to run for approx. 1.5 hours. Drain the mixture into suitable containers and dispose of it in accordance with regulations. Flush the cooling system thoroughly with clean water; repeat this process several times.
Page 477 Appendix - Residual Useful Life of Winches 10.5.5 Charge-air cooler 10.5.5.1 External cleaning Dirt and cleaning Dust, insects, foliage or leaves - Compressed air (max. 3,5 bar) procedure Oily and greasy deposits - Steam jet Caution Ensure that the cooling fins are not damaged. 10.5.6 Oil cooler 10.5.6.1 External cleaning Dirt and cleaning...
Page 478 Appendix - Residual Useful Life of Winches 10.6.3.1 Theoretical length of useful life When calculating and dimensioning the winches of your crane, the design engineers have assumed particular operating conditions and a theoretical total running time, from which results a theoretical length of useful life. In accordance with DIN-Fachbericht 1, ISO 4301/1, or FEM 9.511, respectively, the winches of your crane have been classified as follows: Driving gear group:...
Page 479 Appendix - Residual Useful Life of Winches Duty Definition Breakdown of Factor of Graphical Representation Cycle Running Time duty cycle Class light km=0,125 Driving gears or parts 10% of running time with Load % thereof which are subject maximum load (dead to maximum stress in load+1/1 working load) exceptional cases only,...
Page 480 Appendix - Residual Useful Life of Winches Establishing the effective service hours T The effective service hours established as outlined below must be entered in the crane inspection and test log book for the inspection interval concerned. There are the following four distinct cases: Service hour meter available on each winch When your crane has been equipped with a service hour meter on each winch, the number of effective service hours T...
Page 481 Appendix - Residual Useful Life of Winches When the theoretical length of useful life D has been attained (see " HEORETICAL " on page 10-412), continued operation of the winch is LENGTH OF USEFUL LIFE not allowed until after a general overhaul. A general overhaul must be carried out not later than 10 years after commissioning of the crane at any rate.
Page 482 Appendix - Residual Useful Life of Winches x 480- h = 1920 h 0,125 Residual theoretical length of useful life: D2 = 3040 h – 1920 h = 1120 h Inspection No. 3 (third year) The crane has been used for erection work and occasionally for unloading work in the harbour: Duty cycle: L , that is, km =0,25...
Page 483 Appendix - Residual Useful Life of Winches Grove 10 - 417 Published 11-18-2015, Control # 602-00...
Page 484 Appendix - Residual Useful Life of Winches 10 - 418 Published 11-18-2015, Control # 602-00...
Page 485 Appendix - Installing Large Roller Bearings, Slewing Gears, and Flange Connections 10.7 Installing Large Roller Bearings, Slewing Gears, and Flange Connections Current when going to Ongoing development ensures the advanced technology and the high level of quality in our machines. This may result in deviations between these Instructions press and your machine.
Page 486 Appendix - Installing Large Roller Bearings, Slewing Gears, and Flange Connections 1) Upper structure 2) Slewing ring 3) Pylon or lower assembly 4) Pylon Flange connection with Loctite 10 - 420 Published 11-18-2015, Control # 602-00...
Page 487 Appendix - Installing Large Roller Bearings, Slewing Gears, and Flange Connections 10.7.4 Tightening torques for bolts Note For certain fixing bolts on the undercarriage, values differing from those listed in this table may apply. Please observe notes in the respective sections. Strength class 8.8 Coarse thread Fine thread...
Page 488 Appendix - Installing Large Roller Bearings, Slewing Gears, and Flange Connections Strength class 10.9 Coarse thread Fine thread Bolt Tightening torque Bolt Tightening torque (Nm) (Nm) M8x1 M10x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 1050 M27x2 1500 1400 M30x2 2100...
Page 489 Appendix - PFEIFER Pouch Socket System 10.8 PFEIFER Pouch Socket System 10.8.1 Preamble The instruction manual has to be read and understood carefully before using the PFEIFER Pouch Socket System. The instruction manual must be adhered to while using the PFEIFER Pouch Socket System. The safety of the PFEIFER Pouch Socket System is only guaranteed if the pouch socket will be used, installed and maintained as described in this instruction manual.
Page 490 Appendix - PFEIFER Pouch Socket System Any other use of the PFEIFER Pouch Socket System than those described hereunder is prohibited! CAUTION 10.8.4 General information The pouch sockets type 22 A of the PFEIFER Pouch Socket System consist of following parts (see Fig. 1): Pouch socket, bolt with safety clip pin A and safety pin with arresting cable and safety clip pin B.
Page 491 Appendix - PFEIFER Pouch Socket System PFEIFER swaged sleeve Type 11A (Fig2) PFEIFER resin socket Type 13 A Tested according to EN13411 Field of application: High performance rotation resistant ropes Characteristic: Without rotary locking device at the tail Reeving eye for mounting of a reeving-rope on the end termination.
Page 492 Appendix - PFEIFER Pouch Socket System 10.8.5 Installation and Assembling Before assembling, the pouch socket, the bolts and the end terminations has to be proofed for visible damages e.g. cracks, corrosion, deformations etc. Parts with shown cracks, deformations or other damages must not be installed or used.
Page 493 Appendix - PFEIFER Pouch Socket System Fig. 7 Fig. 8 Fig. 9 Fig. 10 Grove 10 - 427 Published 11-18-2015, Control # 602-00...
Page 494 Appendix - PFEIFER Pouch Socket System 10.8.6 Important security informations Accidental releasing of the load or releasing the load as a result of failure of the PFEIFER Pouch Socket System poses direct or indirect danger to the health and safety of persons within the danger zone.
Page 495 Appendix - PFEIFER Pouch Socket System During the operation pay attention to the correct fit of the bolt the safety pin the safety clip pins and the end terminations (swaged sleeve and resin socket) in the pouch socket. During the operation avoid side-loading of the pouch socket and oblique pull.
Page 496 Appendix - PFEIFER Pouch Socket System Bolt Safety Clip Pin A Safety Pin Safety Clip Pin B 214275 112121 228505 212842 214556 112112 228514 212842 214561 112112 228551 212842 214204 112123 228556 212842 213240 112123 228589 212842 212770 112123 558590 212842 214042 230723...
Page 497 Appendix - PFEIFER Pouch Socket System Repairs of components of the whole PFEIFER Pouch Socket System may only be carried out by trained and approved technicians and by the company PFEIFER Seil- und Hebetechnik GmbH authorized service personnel. PFEIFER SEIL- UND HEBETECHNIK GMBH PRÜFSERVICE DR.-KARL-LENZ-STRASSE 66 D-87700 MEMMINGEN...
Page 498 Appendix - Operating Fluids and Lubricants 10.9 Operating Fluids and Lubricants Foreword This List of Operating Fluids and Lubricants contains the operating fluids and lubricants used and recommended. The fluid or lubricant filled at the factory is specified on a sticker located at the corresponding filling point.
Page 499 Appendix - Operating Fluids and Lubricants 10.9.1 Hydraulic system 10.9.1.1 Hydraulic oil Fig. 3 Temperature ranges Recommendation ID no. Specification Alternative Shell Tellus S4 VX 32 SE: 157284 DIN 51524-3 HVLP-D Avia Syntofluid PEB 30 Shell: 001D7769 (ISO VG 32) PAO 9999300308 9999300309 9999300310 Mobil DTE 10 Excel 32...
Page 500 Appendix - Operating Fluids and Lubricants 10.9.2 Diesel engine 10.9.2.1 Diesel engine oil Cummins Diesel Engine Emissions levels Tier 2 and Tier 3 Fig. 4 Temperature ranges Recommendation ID no. Specification Alternative OMV Super Truck SAE SE: 124846 API CI-4; 9999300326 9999300327 5W-30 Cummins CES 20078...
Page 501 Appendix - Operating Fluids and Lubricants Recommendation ID no. Specification Alternative Valvoline Premium Blue SE: 157283 API CJ-4; Cummins Shell Rotella T6 5W-40; Extreme 5W-40 CES20081 Motorex Nexus FE 5W-30 Shell Rotella T5 10W-30 SE: 179999 API CJ-4; Cummins Eni i-Sigma top MS 10W- Shell: 001D5436 CES20081 30;...
Page 502 Appendix - Operating Fluids and Lubricants 10.9.2.5 Diesel exhaust fluid for Tier 4 Final diesel engines Recommendation ID no. Specification SE: 149060 ISO 22241; DIN 70070; AUS 32 10.9.3 Gearbox 10.9.3.1 Slewing gear GHC75 Gear oil Fig. 6 Temperature ranges Recommendation ID no.
Page 503 Appendix - Operating Fluids and Lubricants 10.9.3.3 Grease lubricating points Gear oil Fig. 8 Temperature ranges Recommendation ID no. Specification Alternative Fuchs Stabyl LT 50 SE: 157280 DIN 51502 -KPHC2N-50; Avia Grease PE Polar NLGI 2 9999300306 Mobil Mobilith SHC 220 NLGI 2 Shell Gadus S2 V220 2 SE: 179226 DIN 51825 LI;...
Page 504 Appendix - Operating Fluids and Lubricants 10.9.4 Lubrication 10.9.4.1 Grease - slewing ring roller bearings Fig. 10 Temperature ranges Recommendation ID no. Specification Alternative Fuchs Stabyl LT 50 SE: 157280 DIN 51502 -KPHC2N-50; Avia Grease PE Polar NLGI 2 9999300306 Mobil Mobilith SHC 220 NLGI 2 Shell Gadus S2 V220 2 SE: 179226...
Page 505 Appendix - Operating Fluids and Lubricants 10.9.4.3 Grease - manual lubricating points Fig. 12 Temperature ranges Recommendation ID no. Specification Alternative Fuchs Stabyl LT 50 SE: 157280 Specification Avia Grease PE Polar DIN 51502 -KPHC2N-50; 9999300306 Mobil NLGI 2 Mobilith SHC 220 NLGI 2 Shell Gadus S2 V220 2 SE: 179226 DIN 51502 - KP2K-20;...
Page 506 Appendix - Operating Fluids and Lubricants Recommendation ID no. Specification Alternative Fuchs Stabyl LT 50 SE: 157280 Specification Avia Grease PE Polar DIN 51502 -KPHC2N-50; 9999300306 Mobil NLGI 2 Mobilith SHC 220 NLGI 2 Shell Gadus S2 V220 2 SE: 179226 DIN 51502 - KP2K-20;...
Page 507 Appendix - Operating Fluids and Lubricants Recommendation ID no. Specification Alternative Pfeifer RL-S SE: 185735 Rope spray Rope grease F 315 L (adhesive grease in the spray can) 90022608 90022609 Crosby Vitalife 400 Wire Rope Lubricant Pfeifer RL-B SE: 185736 Rope oil Rope grease F 315 L (adhesive grease in the...
Page 508 Appendix - Operating Fluids and Lubricants 10.9.6 Windshield washer system 10.9.6.1 Antifreeze Fig. 18 Temperature ranges Recommendation ID no. Specification Alternative Off-the-shelf window SE: 185734 Fresh water with a 90037773 Splash cleaners with antifreeze proportion of at last Windshield Washer Fluid - 50%antifreeze 30°...
Page 509 vSCALE Operating console Working Area Limiter Contents Sennebogen Telescopic Crane Safety instructions Product description Installation / Wiring Commissioning Operation Maintenance / Repair Technical data User manual Issue A - 03/2015 This document has the order no. 50-700-19-6003_ en...
Page 510: Table Of Contents
CONTENTS Safety instructions ................... 5 EC conformity declaration ................5 Product description ..................6 Product identification ..................6 Overview of functional elements ..............7 Installation and wiring..................8 Installation .....................
Page 511 Introduction INTRODUCTION This manual is a component of the equipment or system supplied by Hirschmann Automation and About this manual Control GmbH. Keep this manual in a safe place and ensure that it is available to all users. The contents of this manual are subject to change. Hirschmann Automation and Control GmbH Liability disclaimer does not provide any guarantee for this material, including the associated guarantee regarding marketability and suitability for certain intended purposes.
Page 512 Introduction Marking of notices Dangers and other important notices are marked as follows in this user manual: WARNING Warning of direct threat of personal injury and damage to property. Instructions on precautions to avert the danger. CAUTION Warning of dangerous situations. Also warns of damage to property. Instructions for averting the danger.
Page 513: Safety Instructions
Safety instructions 1 Safety instructions WARNING Imminent threat of personal injury and damage to property due to incorrect system settings! The settings can only be carried out by operators who are completely familiar with the operation and functions of the crane and the SLI. The correctness of these settings must be guaranteed before starting the crane operations! IMPORTANT Connection to the wrong power supply will cause damage to the device.
Page 514: Product Description
Product description 2 Product description The vSCALE D3 console is the operable component of the working area limiter of the programmable safe load indicator and contains following functions: Luffing angle limiting  Height limiting  Radius limiting  Slewing angle limiting ...
Page 515: Overview Of Functional Elements
Product description 2.2 Overview of functional elements TFT colour display Function keys F1 - F12 Light sensor and status displays (LED) Rotary control (encoder) with pushbutton function Function key (SYSTEM) for system settings (not used here) Function key (Home) for return to SLI main menu Function key (Esc) for return or abort (not used here) Front- USB 2.0 interface (use for service purposes) ©...
Page 516: Installation And Wiring
Installation and wiring 3 Installation and wiring This chapter contains instructions for mounting and installation of the console. For the electrical wiring of the system and the console, please refer to the relevant connection and wiring diagram, which is not part of this manual. 3.1 Installation The console is intended for vertical surface mounting or recessed mounting.
Page 517: Recessed Mounting
Installation and wiring 3.1.2 Recessed mounting An installation frame, which is available as an accessory, is provided for recessed mounting in operating panels or instrument panels. Installation frame: Art. no. 608465  NOTE Please note that the material thickness of the operating panel may not exceed 10 mm! Installation frame 4 off M5 x (see table for length)
Page 518 Installation and wiring The dimensions for the cut-out in the operating panel can be taken from the following sketch: Cut-out dimensions On request you can also print out the templates (last page in this manual). Template © 2015 Hirschmann Automation and Control GmbH · Mobile Machine Control Solutions · www.hirschmann-mcs.com 50-700-19-6003_xxxxxx_en.doc / 2015-03-20 / Issue A / cb.
Page 519 Installation and wiring 4 x M5 screws, DIN EN ISO 4762 (DIN 912) and matching spacers are used for mounting of the Installation Installation frame installation frame. IMPORTANT Console could be damaged by use of screws of the wrong length and excessive torque! Note the screw length information in the following overview.
Page 520: Electrical Connection
Installation and wiring 3.2 Electrical connection The electrical wiring for the system and the console can be found in the current connection and wiring diagram for your crane. It is not included in this manual. CAUTION Danger of electrical short-circuits. Switch off all systems before commencing with the installation work! IMPORTANT Connection to the wrong power supply will cause damage to the device.
Page 521: Central Connector -X1
Installation and wiring 3.2.1 Central connector –X1 The central connector –X1 contains terminals for the power supply, ignition, grounds, CAN-Bus (1 and 2), USB, RS232 and further signals. Connector kit: 1x connector, 26x crimp contacts, 26x dummy plug Art. no. 536276 Matching counter- connector parts Crimping tool: special tool...
Page 522: Ethernet Connection
Installation and wiring 3.2.2 Ethernet connection There is an Ethernet interface available for programming purposes. Ethernet Patch-Kabel, 1m, M12, 4-pin, <-> RJ45 Art. no. 326603 Matching counter- connector parts Ethernet Patch-Kabel, 5m, M12, 4-pin, <-> RJ45 Art. no. 325900 Connector overview Pin assignation 3.2.3 Camera connection (not used) Three video interfaces are available for integrating video signals.
Page 523: Commissioning
Commissioning 4 Commissioning This chapter contains information, advice and instructions for commissioning the device. 4.1 Switching device on and off The working area limiting device has no on/off switch. The console automatically switches on after connecting the power supply and control voltage (ignition, terminal 15) Upon completion of the boot process and the internal system tests the main menu appears on the screen.
Page 524: Operation
Operation 5 Operation This chapter contains information, advice and instructions for using the console. You will also find the description of function elements and menus. 5.1 Functional elements Function keys F1 to F12: for calling operating functions Light sensor: measures the ambient brightness for controlling the background lighting Operating display: shines green when the supply voltage is connected USB data display: shines yellow when data is exchanged via the front USB interface Status display: (no function here)
Page 525: Function Keys (Soft Keys)
Operation 5.2 Function keys (soft keys) The F1…F12 key functions are displayed with assigned symbols: Example The function key symbols normally have grey sidebars. Colour bars Certain statuses are indicated by the change in colour or flashing of these sidebars: Examples Grey Relevance here: no geometrical limit is programmed...
Page 526: Working Area Limiter
Operation 5.3 Working area limiter The SLI system has programmable functions to limit geometrical values of the working area: Height limitation > See chapter 5.3.1  Radius limitation > See chapter 5.3.2  Luffing angle limitation > See chapter 5.3.3 ...
Page 527: Height Limitation
Operation 5.3.1 Height limitation Programmable function to limit the maximum boom tip height. Calling up the height limitation function from the main menu: Height limit symbol: Limit not programmed or inactive Limit active Limit value reached Current height or exceeded Saved limit value Switch on/off height monitoring...
Page 528: Radius Limitation
Operation 5.3.2 Radius limitation Programmable function to limit the minimum/maximum boom radius. Calling up the radius limitation function from the main menu: Radius limit symbol Limit not programmed or inactive Limit active Limit value reached Current radius or exceeded Saved limit value of maximum radius Saved limit value of minimum radius...
Page 529: Luffing Angle Limitation
Operation 5.3.3 Luffing angle limitation Programmable function for monitoring the upper/lower luffing angle. Calling up the luffing angle limitation function from the main menu: Luffing angle limit symbol: Limit not programmed or inactive Limit active Current luffing angle Limit value reached or exceeded Saved limit value of lower luffing angle...
Page 530: Slewing Angle Limitation
Operation 5.3.4 Slewing angle limitation Programmable function to limit the left / right slewing angle. Calling up the slewing angle limitation function from the main menu: Slewing angle limit symbol: Limit not programmed or inactive Limit active Current slewing angle Limit value reached or exceeded Display of current slewing...
Page 531: Error Messages
Operation Error messages In case of disconnection of the CANopen communication with the LMB following screen appears: If the error can not be reset by shutting down and restarting the system, there is probably a wiring fault. © 2015 Hirschmann Automation and Control GmbH · Mobile Machine Control Solutions · www.hirschmann-mcs.com 50-700-19-6003_xxxxxx_en.doc / 2015-03-20 / Issue A / cb.
Page 532: Maintenance And Repair
Maintenance and Repair 6 Maintenance and Repair The vSCALE D3 operating console contains no wearing parts and therefore cannot be opened. If Maintenance you notice malfunctions or differences between actual and displayed measured values, you should switch the device off and have it checked and, if necessary, repaired immediately by an authorised Hirschmann service partner.
Page 533: Technical Data
Technical Data 7 Technical Data Part no. 608415 Console vSCALE D3-C1 (w/o Touch) 608416 Console vSCALE D3-C2 (with Touch) Operating voltage 9…36 V DC, suitable for 12 and/or 24 V on-board power supply Overvoltage protection overvoltage up to max. 48V DC / 2 minutes Reverse polarity protection up to -48V DC Display...
Page 534 Feedback Feedback What do you think about this manual? In our manuals we always endeavour to describe the product concerned as fully as possible and to convey important background knowledge, so that this product can be used without problems. We take the task of constant improvement and the reduction of errors very seriously. Your comments and suggestions assist us in increasing the quality and the level of information of this documentation still further.
Page 535 Feedback Suggestions for improvements and amendments: General comments: Sender: Company / Department Name / Telephone no. Street Town / Post code Date Dear user, please complete both sides of this feedback form and return it: by fax to: +49 (0)7243 709 3222 ...
Page 536 Feedback Notes © 2015 Hirschmann Automation and Control GmbH · Mobile Machine Control Solutions · www.hirschmann-mcs.com 50-700-19-6003_xxxxxx_en.doc / 2015-03-20 / Issue A / cb. / rk.
Page 537 ANSI signage for GHC55 GHC55 DANGER WARNING CAUTION NOTICE SE 186583 SAFETY INSTRUCTIONS SE 187222 SE 186737 WSS-rec-0135 Release date: 05.11.2015 Current revision status: 2 Printed copies are not subject to change...
Page 539 Foreword Foreword Information on this decal scheme This decal scheme contains an overview of safety-relevant signage and is part of the operating manual. It refers to the state of the machine upon delivery. It must be reviewed and modified as needed if changes are made to the machine's equipment.
Page 540 Foreword GHC55 13.11.2015...
Page 541 Table of contents Table of contents ANSI signage for the Maxcab cab........7 1.1 Overview graphics of Maxcab cab........ 7 1.2 ANSI warning and safety signage for Maxcab cab..8 ANSI signage for GHC55 undercarriage......21 2.1 Overview graphics of GHC55 undercarriage....21 2.2 Warning and safety signs on GHC55 undercarriage.
Page 542 Table of contents GHC55 13.11.2015...
Page 543: Ansi Signage For The Maxcab Cab
ANSI signage for the Maxcab cab Overview graphics of Maxcab cab ANSI signage for the Maxcab cab 1.1 Overview graphics of Maxcab cab Exterior cab Fig. 1: Exterior cab signage Interior cab Fig. 2: Interior cab signage 13.11.2015 GHC55...
Page 544: Ansi Warning And Safety Signage For Maxcab Cab
ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Cab platform and safety guard 210 220 Fig. 3: Cab platform and FOPS signage 1.2 ANSI warning and safety signage for Maxcab cab Fire extinguisher label General Fire extinguisher storage locations application area...
Page 545 Do not operate this crane unless Option Grove You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personell. You read, understand, and follow the safety and operating recommendations contained in the crane manufacturerer‘s manuals and load lift charts, your employer‘s work rules, and applicable...
Page 546 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Crane Star General Exterior cab application area Option Grove / SE 187881 187881 Warning. Rotating machine can cause death or serious injury. Stay clear of the danger zone. General Exterior cab, exterior uppercarriage application area...
Page 547 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Warning. Falling loads can result in death or serious injury. Never stand under suspended loads. General Exterior cab, uppercarriage access ladder application area WARNING Suspended loads can cause serious injury or death Option ANSI...
Page 548 If you do not understand the language in which the operating manual is written, you are not permitted to place the machine in service. If necessary contact Manitowoc cranes Si no entiende el idioma del manual de instrucciones, usted no está autorizado a poner en funcionamiento la máquina.
Page 549 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Danger. Electric current from overhead lines can result in death or serious injury. Maintain a safe distance. General Interior cab application area Exterior cab DANGER Electrocution hazard. Keep all parts of this machine, the rigging and materials being lifted at least 20 feet away from all electrical power lines and Option 1...
Page 550 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Emergency exit label Material handling Rear interior cab machine applica- SAFETY tion area INSTRUCTIONS Emergency exit Other application Right interior cab area SE 187970 Option ANSI 187970 Danger.
Page 551 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Failure to observe load lift charts and operating instructions can result in death or serious injury. General Interior cab application area SAFETY INSTRUCTIONS Ignoring laod lift charts and operating instructions can Option 1 cause injury due to maloperation.
Page 552 Do not operate this crane unless Option Grove You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personell. You read, understand, and follow the safety and operating recommendations contained in the crane manufacturerer‘s manuals and load lift charts, your employer‘s work rules, and applicable...
Page 553 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Warning. Failure to read the operating manual and safety information can result in death or serious injury. Manual must be kept in the machine at all times. General Interior cab, interior uppercarriage, undercarriage hitch, other application area...
Page 554 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Emergency drop label General On emergency drop levers application area SAFETY INSTRUCTIONS Emergency Option 1 ANSI lowering feature Option 2 Cab adjustment SE 194111 194111 Warning sign hatching General Outer edges of platform (machine boundaries), on shearing application area...
Page 555 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab Other decals Warning sign hatching General On shearing points application area Option 1 Cab adjustment Option 2 Mobile undercarriage with claw support 186734 13.11.2015 GHC55...
Page 556 ANSI signage for the Maxcab cab ANSI warning and safety signage for Maxcab cab GHC55 13.11.2015...
Page 557: Ansi Signage For Ghc55 Undercarriage
ANSI signage for GHC55 undercarriage Warning and safety signs on GHC55 undercarriage ANSI signage for GHC55 undercarriage 2.1 Overview graphics of GHC55 undercarriage Crawler undercarriage Fig. 4: Crawler undercarriage signage, front/rear view 2.2 Warning and safety signs on GHC55 undercarriage 13.11.2015 GHC55...
Page 558 ANSI signage for GHC55 undercarriage Warning and safety signs on GHC55 undercarriage Lashing point label General On lashing points application area Option SE 186793 186793 Insertion track label General Stabilizer insertion tracks application area Option Telescopic crawler undercarriage: MS40, MS30, MS16, T119, SE 187964 T73, T41/410HD SE 187964...
Page 559 ANSI signage for GHC55 undercarriage Warning and safety signs on GHC55 undercarriage Warning. Pressurized sealing cover can cause serious injury. Maintain a safe distance. General Undercarriage application area WARNING Ejected objects can Option 1 ANSI cause severe injury. Work at necessary safety distance.
Page 560 ANSI signage for GHC55 undercarriage Warning and safety signs on GHC55 undercarriage Grease General Manual grease points application area Option SE 000000 See List of Operating Fluids and Lubricants Slewing ring grease General Grease cylinder application area Option SE 000000 See List of Operating Fluids and Lubricants GHC55 13.11.2015...
Page 561: Ansi Signage For Ghc55 Uppercarriage
ANSI signage for GHC55 uppercarriage Overview graphics of GHC55 uppercarriage ANSI signage for GHC55 uppercarriage 3.1 Overview graphics of GHC55 uppercarriage Exterior uppercarriage Fig. 5: Left/right exterior uppercarriage signage 13.11.2015 GHC55...
Page 562 ANSI signage for GHC55 uppercarriage Overview graphics of GHC55 uppercarriage Top uppercarriage Fig. 6: Top left/right uppercarriage signage GHC55 13.11.2015...
Page 563: Warning And Safety Signs On Ghc55 Uppercarriage
ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Interior uppercarriage Fig. 7: Left/right interior uppercarriage signage 3.2 Warning and safety signs on GHC55 uppercarriage 13.11.2015 GHC55...
Page 564 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning sign hatching General On shearing points application area Option 1 Cab adjustment Option 2 Mobile undercarriage with claw support 186734 No smoking General Diesel filler neck application area DANGER Option 1 ANSI...
Page 565 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Lifting point label General On lifting points application area Option SE 186792 186792 Warning. Rotating machine can cause death or serious injury. Stay clear of the danger zone. General Exterior cab, exterior uppercarriage application area...
Page 566 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Risk of collapse/falling when exceeding maximum platform load per section as per DIN EN ISO 2867 and ISO 11660-2. Do not exceed maximum platform load. General Exterior cab, exterior uppercarriage application area WARNING Fall hazard.
Page 567 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Lowering cab can result in crushing. Stay clear of the danger zone. General applica- On shearing points between cab and uppercarriage tion area WARNING Option 1 ANSI Crush hazard.
Page 568 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Improper fastening of the rope can cause serious injury. Read the manual. General Top uppercarriage application area WARNING Improperly attached winch rope can Option 1 ANSI cause serious injury. Use recommended cable wedge to attach winch rope to the cable drum.
Page 569 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Failure to read the operating manual and safety information can result in death or serious injury. Manual must be kept in the machine at all times. General Interior cab, interior uppercarriage, undercarriage hitch, other application area WARNING...
Page 570 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Unauthorized use of the ladder can cause injury from falling. Authorized personnel only. General Uppercarriage access ladder application area WARNING Unauthorized use of Option ANSI the access ladder can cause serious injury.
Page 571 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage No smoking General Diesel filler neck application area DANGER Option 1 ANSI smoking Option 2 Diesel engine SE 187984 187984 Sulfur-free diesel fuel or diesel fuel with less than 15 mg/kg sulfur content only. General Top uppercarriage: diesel filler neck application area...
Page 572 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Failure to read the operating manual and safety information can result in death or serious injury. Manual must be kept in the machine at all times. General Interior cab, interior uppercarriage, undercarriage hitch, other application area WARNING...
Page 573 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Overflow or boil-over can cause serious injury or scalding. Maintain a safe distance. General Interior uppercarriage, top uppercarriage application area WARNING Overﬂow or boilover Option ANSI can cause serious injury or scalding.
Page 574 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Voltage can cause electric shock or burns. Turn off machine before performing mainte- nance. General Interior uppercarriage, top uppercarriage application area WARNING Hazardous voltage. Option 1 ANSI Contact may cause electrical shock or burn.
Page 575 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Hydraulic oil sampling point label General Hydraulic oil sampling point application area Option SE 186594 186594 Warning. Failure to read the operating manual and safety information can result in death or serious injury.
Page 576 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage AdBlue ® Diesel exhaust fluid for US EPA Tier 4 final/EU Level IV diesel engines General At filling point application area AdBlue ® Option 1 AdBlue ® Option 2 Tier IIIb/Tier IVi/Tier IVf (ISO22241 / DIN70700 / AUS32) SE 187996...
Page 577 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Do not clean with high-pressure cleaner. General Interior uppercarriage: central hydraulic system application area Interior uppercarriage: switch cabinet NOTICE Do not clean Top uppercarriage: optional generator with steam cleaner.
Page 578 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Failure to read the operating manual and safety information can result in death or serious injury. Manual must be kept in the machine at all times. General Interior cab, interior uppercarriage, undercarriage hitch, other application area WARNING...
Page 579 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Only use engine oils as per specification ACEA E9-08 or API CJ-4. General Interior uppercarriage: diesel engine application area Engine Oil API CJ-4 only Option 1 Diesel engine Caterpillar ECF-3 Cummins CES 20081 Deutz DQC IV-10 LA...
Page 580 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Warning. Failure to read the operating manual and safety information can result in death or serious injury. Manual must be kept in the machine at all times. General Interior cab, interior uppercarriage, undercarriage hitch, other application area WARNING...
Page 581 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage 24 V socket label General On every 24 V socket application area 24 V Option 24 V socket SE 186587 186587 40 A ignition fuse label General Interior uppercarriage: battery application area NOTICE Option 1...
Page 582 ANSI signage for GHC55 uppercarriage Warning and safety signs on GHC55 uppercarriage Leave battery disconnect switch on for at least 2 minutes after turning off diesel engine. Read man- uals for more information. General Interior uppercarriage: battery disconnect switch NOTICE application area Leave battery disconnecting...
Page 583: Index
Index Index SE 187236 ......9, 13 SE 187877 ......15 Coolant .
Page 584 Index Transmission oil ....22, 31, 40 GHC55 13.11.2015...
Page 585 DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel.
Page 586 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Page 587 AUGER OPERATOR MANUAL TABLE OF CONTENTS TABLE OF CONTENTS Safety..............1-1 Safety Tips - Auger Equipped Cranes .
Page 588 TABLE OF CONTENTS OPERATOR MANUAL AUGER This Page Blank TOC-2...
Page 589: Safety
OPTIONS AUGER OPTIONS AUGER The following safety rules apply specifically to the auger • Stow only in the proper direction as indicated on the operation and are to be used in conjunction with and controls. supplemental to the safety information in the Safety and •...
Page 590: Auger System
AUGER OPTIONS return to the tank. The orifice creates a pressure drop across A stow bracket and lock mechanism with wind-up the cylinder, which retracts the cylinder. Once the button is rope for storing auger on the boom. pressed again both sides are pressurized by the oil to create An auger mount assembly and boom transfer equal pressure on both sides of the cylinder.
Page 591 OPTIONS AUGER Auger Latch Switch Press the auger latch switch (4, Figure 1) to open the stow DANGER bracket latch, press the switch again to close the latch. Free Swinging Auger Hazard Auger Stow Control • Never stow or unstow the auger until all persons are The auger stow control joystick (1, Figure 1) rotates the clear of the auger area.
Page 592: Auger Operation
AUGER OPTIONS Figure 2 Item Numbers 12. Remove latch pin from transport latch assembly. 13. Raise the bottom hook block. Leave a distance of 0.5 m Item Description between bottom hook block and lifting limit switch. Flighting 14. Lower the boom to approximately 45° so the auger can Rope swing into working position.
Page 593: Operating Auger
OPTIONS AUGER screw itself into the ground (corkscrew) and cause a machine overload. WARNING NOTE: When the flighting (1, Figure 3) is filled with dirt, pull the auger from the hole and deposit the dirt in a Severe Personal Injury Hazard desirable location.
Page 594 AUGER OPTIONS To stow the auger with the flighting attached, connect the Item Description wind-up rope to the attachment hole in the flighting using the Overwind Valve hook (7) and stow as shown. Spacer To stow the auger without the flighting attached; remove flighting (1) and attach windup tube and spacer to driveshaft Tube Assembly and connect the wind-up rope to the to the tube using the...
Page 595: Machine Usage With Auger Stowed
(over wind) valve for signs of leaks. Travel with Auger Tightness of all mounting and securing bolts. See torque Manitowoc recommends stowing the auger when chart in operator and service manuals. traveling. Damage may occur to auger and surrounding components if auger is allowed to swing during travel.
Page 596: Changing The Gear Oil
AUGER OPTIONS the ends of the threads on the plug, oil should start to Drain lube oil immediately after oil has reached come out. This is an indication the oil level is adequate, operating temperature. This will ensure that any loose but in order to correctly measure the amount of oil, the particles will be flushed out when oil is drained.
Page 597 OPTIONS AUGER TROUBLESHOOTING Make sure there is contact between the auger flighting tube and the selector (over wind) valve spool. Adjust selector (over wind) valve location as required. Auger wind-up torque not limited during stowing or unstowing Check selector (over wind) valve for proper function. Repair or replace as required.
Page 598 AUGER OPTIONS This Page Blank 1-10 Published 11-13-2015, Control # 570-01...
Page 599 AUGER OPERATOR MANUAL Alphabetical Index Auger Operation ............O-4 Auger system description .
Page 600 OPERATOR MANUAL AUGER This Page Blank...
Page 601 • Avoid unsafe operation and maintenance. • This basket must be operated and maintained by trained and experienced personnel. Manitowoc is not responsible for qualifying these personnel. • Do not operate or work on this basket without first reading and understanding this Operator Manual the crane Operator Manual and Rating Plate supplied with crane.
Page 602 This Page Blank...
Page 603 PERSONNEL BASKET TABLE OF CONTENTS TABLE OF CONTENTS ..........Personnel Basket Safety.
Page 604 TABLE OF CONTENTS PERSONNEL BASKET This Page Blank TOC-2...
Page 605: Personnel Basket
OPTION PERSONNEL BASKET PERSONNEL BASKET SAFETY 12. Do not use the load line to lift or handle loads while personnel are in the basket. Load block must be The following safety rules apply specifically to basket removed from load line. operation and are to be used in conjunction with and 13.
Page 606: Equipment Operator
PERSONNEL BASKET OPTION 22. Precautions such as but not limited to the following shall b. The operator has been working for more than ten be taken: hours prior to the start of the lift or the lift will not be completed before the operator has been working for When welding is to be accomplished from the twelve hours.
Page 607: Ground Crew
OPTION PERSONNEL BASKET 13. Verify that the hoisting equipment is set up and 27. Not operate a platform with motion controls without the maintained within one percent of grade level (± 0.30°). platform operation manual available in the platform. 14. For hoisting equipment with a boom attached platform, 28.
Page 608: Communications
PERSONNEL BASKET OPTION 16. Keep entrance gate closed and pinned in the horizontal Not interfere with the platform operator or the designated signal person in the platform except to give position, except when entering or exiting the platform. an emergency stop signal. Communications Keep their personnel fall protection device lanyard fastened to the provided anchorage points at all times,...
Page 609: Lifting Personnel Near Power Lines
OPTION PERSONNEL BASKET Lifting Personnel Near Power Lines Power lines are de-energized and grounded to ground and between phases. (This is the preferred condition.) b. Power lines are energized with the hoisting equipment outside the prohibited zone but there is a potential for the hoisting equipment or platform being energized.
Page 610: Inspection And Testing
PERSONNEL BASKET OPTION Condition B and the devices testing requirements prescribed by the device manufacturer. The following steps shall be taken when lifting personnel in a Condition B situation: Condition C A meeting, on the job site, between the job site Lifting personnel under this condition is prohibited.
Page 611 OPTION PERSONNEL BASKET PERSONNEL LIFT PLATFORM PRE-LIFT INSPECTING Inspector Date Platform ID Satisfactory Unsatisfactory 1. Markings Platform decals and placecards (all information legible) Suspension system decals and placards 2. Structure Load supporting welds/bolts Load supporting members Barrier from toe board to intermediate rail Hand Rail Fall protection device anchor points Gate locking mechanisms...
Page 612 PERSONNEL BASKET OPTION PERSONNEL PLATFORM LIFT PLANNING AND AUTHORIZATION FORM 1. Location Date 2. Purpose of Lift ___________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 3. Hoisting Equipment Mfg. Model# Serial # 4. Expected radius (max) (at work location) 5. (A) Rated load at radius (B) Maximum lift load (50% of 5A) 6.
Page 613: Lift Testing
OPTION PERSONNEL BASKET Lift Testing • Never use a basket that fails the Proof Lift. Trial Lift All equipment used in lifting of personnel should be tested and inspected to protect against failure during lifting Perform a trial lift prior to lifting personnel on each shift the operations.
Page 614: Basket Type And Test Weights
PERSONNEL BASKET OPTION Basket Type and Test Weights Jib Trial Lift Jib Proof Lift Boom Trial Lift Boom Proof Lift (125%) (Item (125%) Basket Type (Item No. (lb.) ** (Item No. (lb.) ** No. (lb.) ** Item No. (lb.) ** Yoke (2 person) 4 (500 lb.) 4,5 (625 lb.)
Page 615 OPTION PERSONNEL BASKET BSAY-2 YOKE BASKET TEST WEIGHT ASSEMBLIES - TWO PERSON Typical Main Boom Nose 8470-2 8501-1 Typical Test Weights FIGURE 1-2 Grove Published 8-01-2015, Control # 557-00...
Page 616 PERSONNEL BASKET OPTION Use with Main Boom Nose Only Typical Main Boom Nose GHC55 8470-5 Use with Typical GHC55 Jib GHC55 Jib Only Only 8470-4 FIGURE 1-3 1-12 Published 8-01-2015, Control # 557-00...
Page 617 OPTION PERSONNEL BASKET Use with Main Boom Nose Only Typical Main Boom Nose Use with GHC75/ 8497-1 Typical Jib GHC75/ GHC130 8497-2 FIGURE 1-4 Grove Published 8-01-2015, Control # 557-00...
Page 618: Yoke Basket
PERSONNEL BASKET OPTION Yoke Basket The basket can be attached to either the tip of the boom or DANGER the tip of the jib for the purpose of lifting personnel and their work equipment to elevated working heights. Falling hazard! Working at elevated heights without using proper fall protection can result in severe injury or death.
Page 619: Basket Yoke To Main Boom Installation
OPTION PERSONNEL BASKET Basket Yoke to Jib Boom Installation Remove adapter (8) from the boom nose to allow for jib A2B Switch Link deployment. Stow away adapter for future use. Properly deploy the jib to the main boom nose (Refer to Lanyard Crane Operator Manual).
Page 620: Before Making The Lift
PERSONNEL BASKET OPTION Before Making the Lift If your crane has the hoist mounted to the turret (as shown in Figure 1-7) - DO NOT connect the hoist cable to any place • Set the tracks at the full extended position and with the on the boom.
Page 621 OPTION PERSONNEL BASKET FIGURE 1-9 7126-2 After the basket platform is raised to the working position; rotate the brake selector (2) to the CCW (counterclockwise) position to lock the brake. This locks the yoke assembly into position and prevents free-swing when the basket platform is attached to the FIGURE 1-8 7126-1 boom nose.
Page 622 PERSONNEL BASKET OPTION This Page Blank 1-18 Published 8-01-2015, Control # 557-00...
Page 623 OPTION PERSONNAL BASKET Alphabetical Index Basket Installation ........... . . 1-14 Inspection and Testing.
Page 624 PERSONNAL BASKET OPTION This Page Blank...
Page 625 You are sure that all safety signs, guards, and other safety features are in place and in proper condition. • The Operator Manual and Load Chart are in the holder provided on crane. © 2015 Manitowoc Published 09-25-2015, Control # 564-00...
Page 626 This Page Blank...
Page 627 POLE CLAW OPERATOR MANUAL TABLE OF CONTENTS TABLE OF CONTENTS Safety..............1-1 Description.
Page 628 TABLE OF CONTENTS OPERATOR MANUAL POLE CLAW This Page Blank TOC-2...
Page 629: Safety
OPTIONS POLE CLAW OPTIONS POLE CLAW The following safety rules apply specifically to the pole claw operation and are to be used in conjunction with and supplemental to the safety information in the Safety and DANGER Operation sections in the front of the crane Operator Manual. Two blocking the loadline will result in The contents of this section are provided as follows: Death or Serious Injury.
Page 630: Description
POLE CLAW OPTIONS DESCRIPTION • Never operate pole claw until all persons are clear of the area. Pole Claw System • Stow only in the closed position. A supplemental hydraulic system is used to operate the • Stand clear of pole claw during operation, cleaning and tilting pole claw system.
Page 631: Switching On The Supplemental Hydraulic System
OPTIONS POLE CLAW Switching on the Supplemental Hydraulic System • Push the Changeover Clamping Tong/Supplemental CAUTION Hydraulics Switch (2 Figure 1) to the Rearward position Pushing the Changeover Clamping Tong/Supplemental (R) to activate the supplemental hydraulic system. Hydraulics Switch Rearward position (R) on switch NOTE: Pushing Changeover...
Page 632 POLE CLAW OPTIONS This Page Blank Published 09-25-2015, Control # 564-00...
Page 633 POLE CLAW OPERATOR MANUAL Alphabetical Index Attaching the Pole Claw........... 2 Description.
Page 634 OPERATOR MANUAL POLE CLAW This Page Blank...

Manitowoc GHC 55 Operating And Maintenance Manual

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