Manitowoc GHC 55 Operating instructions

GHC55
Translation of the original Published 01-05-2016, Control # 565-02
Operating and Maintenance Manual
ȀȀȀ !
GHC 55
Read this manual completely
before using for the first time!
Reference Only

GHC55
Grove Published 01-05-2016, Control # 565-02
Use of the
manual
Read this manual carefully all the way through before you work with
the machine.
Always keep this manual in the cab for future use.
In the event of sale, disposal or loan, the manual must accompany
the machine!
Presentation of
informative notes
Informative notes that make the work easier or contribute to better
understanding in handling the machine are presented in the following
manner:
Presentation of
handling instructions
Handling instructions are presented in tabular form as follows:
Indicates notes that draw your attention to
special features.
Indicates a cross-reference to other
documents.
1Press switch (1).
2Activate control lever (2).
3Unfasten bolt (3).
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GHC55
Published 01-05-2016, Control # 565-02
Presentation of
listings
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.
Operation and work must only be executed by trained personnel. Start-
up, maintenance, transport, and assembly/disassembly must only be
performed by trained specialists.
Detailed information on the prior knowledge and qualifications required
of the operator can be found in Chapter 1.7 REQUIREMENTS ON PERSON-
NEL of this manual.
What documents are
part of the machine?
The following documents are considered as part of the machine:
This manual
Spare parts catalog
Service booklet
Electrical system and hydraulic system diagrams
Information
The complete scope of supply is specified in the order confirmation.
How are the instructions
organized?
The manual is divided into 11 chapters:
1: Safety
Here you will find general safety instructions that must always be
complied with.
2: Overview
The main components of the machine are presented in chapter 2.
3: Technical data
Here you will find basic machine information, for example safe
working loads.
4: Start-up:
This chapter contains instructions on daily machine maintenance
and start-up.
5: SENCON 2.0:
This chapter describes the SENCON 2.0 diagnostic and control sys-
tem.
6: Operation
This chapter contains information on control elements and work
operation.
Text. Text. Listings are marked with bullet points.
– Text. Text. Sub-points in listings or procedures are
marked with dashes.
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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.
10: Troubleshooting
This chapter contains information on determining the causes of
faults and how to correct them.
11: Appendix
Here you will find an index of key words and additional information,
e.g. about the warranty and supplemental documentation, e.g. for
the driving engine.
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Grove
Table of Contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Presentation of safety information . . . . . . . . . . . . . 1-1
1.2 Danger sources . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 National and international regulations . . . . . . . . . . 1-2
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Crane categorization . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.7 Requirements on personnel . . . . . . . . . . . . . . . . . 1-6
1.8 Work operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.8.1 Boarding or exiting the crane safely . . . . . 1-14
1.8.2 Emergency exit . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.3 Regulations for applications planning . . . . 1-15
1.8.4 Ramming tasks or pulling sheet pile walls 1-16
1.8.5 Deployment on a pontoon . . . . . . . . . . . . . 1-17
1.8.6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.8.7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.8.8 Travelling . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.8.9 Decommissioning . . . . . . . . . . . . . . . . . . . 1-21
1.8.10Setup tasks . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.10 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.11 Responsibilities of the owner . . . . . . . . . . . . . . . . 1-24
1.12 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.13 Machine labelling . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.14 Warning and information signs . . . . . . . . . . . . . . 1-27
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Overall machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Uppercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Basic machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Permissible ground pressure . . . . . . . . . . . . . . . . . 3-4
3.3 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5 Permissible wind speeds . . . . . . . . . . . . . . . . . . . . 3-8
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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 . . . . . . . . . . . . 3-10
3.8 Working diagram - main boom . . . . . . . . . . . . . . . 3-12
3.9 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.10 Working loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.11 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . 3-15
4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Checks before start-up . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Switching on the battery disconnect switch . . . . . . 4-4
4.4 Machine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.1 Fastening the seat belt . . . . . . . . . . . . . . . . 4-6
4.4.2 Starting the engine . . . . . . . . . . . . . . . . . . . 4-8
4.4.3 Selecting setup status . . . . . . . . . . . . . . . . 4-11
4.4.4 Bringing the machine to operating temperature
4-12
4.4.5 Jump start . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.5 Switching off engine . . . . . . . . . . . . . . . . . . . . . . 4-14
4.6 Decommissioning the machine . . . . . . . . . . . . . . 4-15
4.7 Preservation and storage . . . . . . . . . . . . . . . . . . 4-16
4.8 Starting up the machine after long-term storage . 4-17
5 SENCON 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Overview of controls . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.1 Quick selection icons . . . . . . . . . . . . . . . . . . 5-3
5.1.2 Menu icons . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 Start screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.1 Operating status . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.2 Telescopic boom and slew uppercarriage notifi-
cation icons 5-8
5.2.3 Diesel engine notification and warning icons . . .
5-10
5.2.4 Load moment limitation notification and warning
icons 5-12
5.2.5 Overall machine notification and warning icons
5-13
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5.2.6 Working diagram . . . . . . . . . . . . . . . . . . . . 5-15
5.2.7 Winch parameters . . . . . . . . . . . . . . . . . . . 5-16
5.3 Load moment limitation . . . . . . . . . . . . . . . . . . . . 5-17
5.3.1 Entering uppercarriage inclination . . . . . . . 5-19
5.3.2 Entering undercarriage ballast . . . . . . . . . 5-20
5.3.3 Entering winch reeving . . . . . . . . . . . . . . . 5-21
5.3.4 Setting travel speed . . . . . . . . . . . . . . . . . 5-22
5.3.5 Entering track width . . . . . . . . . . . . . . . . . . 5-23
5.3.6 Entering attachments and configuring setup pro-
gram 5-24
5.3.7 Entering counterweight . . . . . . . . . . . . . . . 5-26
5.4 Setting language . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.5 Setting brightness . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.6 Setting date and time . . . . . . . . . . . . . . . . . . . . . 5-30
5.7 Configuring units . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.8 USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5.9 Request access . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5.10 Histogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5.11 Login information . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.12 General information . . . . . . . . . . . . . . . . . . . . . . . 5-37
5.13 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5.13.1Active faults engine . . . . . . . . . . . . . . . . . . 5-39
5.13.2Active faults machine . . . . . . . . . . . . . . . . 5-40
5.13.3Active faults RCL . . . . . . . . . . . . . . . . . . . . 5-44
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.1 Driver seat . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.2 Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.3 Operating elements in the cab . . . . . . . . . . . . . . 6-10
6.3.1 Emergency stop switch . . . . . . . . . . . . . . . 6-11
6.3.2 Safety lever . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3.3 Assignment of the joysticks and pedals . . 6-13
6.3.4 Storage compartment, right of the driver seat . .
6-14
6.3.5 Control panels, right . . . . . . . . . . . . . . . . . 6-16
6.3.6 Control panel, top right . . . . . . . . . . . . . . . 6-18
6.4 Slewing ring lubrication (option) . . . . . . . . . . . . . 6-19
6.5 Central lubrication system (option) . . . . . . . . . . . 6-20
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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) . . . . . . . . . . . . . . . 6-30
6.6.1 LML function . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.6.2 Audible and visual warning device statuses . . .
6-31
6.6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.6.4 Mode selection . . . . . . . . . . . . . . . . . . . . . 6-32
6.6.5 Bypassing the load moment limitation (LML) . . .
6-33
6.6.6 Operating modes table . . . . . . . . . . . . . . . 6-34
6.6.7 Safety components . . . . . . . . . . . . . . . . . . 6-36
6.7 Special equipment . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.7.1 Remote radio control (option) . . . . . . . . . . 6-40
6.7.2 Diesel filter heater (option) . . . . . . . . . . . . 6-51
6.7.3 Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
6.8 Work implementation . . . . . . . . . . . . . . . . . . . . . . 6-53
6.8.1 Crane operation . . . . . . . . . . . . . . . . . . . . . 6-54
6.8.2 Securing bottom hook block for drive mode . . .
6-55
6.8.3 Moving the machine . . . . . . . . . . . . . . . . . 6-57
6.8.4 Travel with suspended load . . . . . . . . . . . . 6-60
6.8.5 Moving on inclines and ramps . . . . . . . . . . 6-61
6.8.6 Slewing the uppercarriage . . . . . . . . . . . . . 6-62
6.8.7 Lifting and lowering loads . . . . . . . . . . . . . 6-68
6.8.8 Hook operation with both winches . . . . . . . 6-70
6.8.9 Adjusting the boom (luffing) . . . . . . . . . . . . 6-72
6.8.10Extending/retracting the boom . . . . . . . . . 6-73
6.8.11Turning on the supplemental hydraulic system
(option) 6-74
6.8.12Operating the clamping tongs (option) . . . 6-75
6.8.13Operating the soil drill (option) . . . . . . . . . . 6-77
6.8.14Refuel the machine . . . . . . . . . . . . . . . . . . 6-78
6.8.15Checking the DEF level and refilling (Tier 4f en-
gines) 6-82
7 Setup tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Walkways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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7.1.1 Mounting/Removing . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2 Setup operating mode . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 Changing the track width . . . . . . . . . . . . . . . . . . . . 7-7
7.3.1 Track width markings . . . . . . . . . . . . . . . . . 7-7
7.3.2 Extending the running gear . . . . . . . . . . . . . 7-8
7.3.3 Retracting the running gear . . . . . . . . . . . . 7-10
7.4 Access ladders . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.5 Setting up the slewing range safeguard . . . . . . . 7-13
7.6 Connections for clamping tongs and supplemental hy-
draulic system on the boom head (option) 7-15
7.7 Attaching clamping tongs (option) . . . . . . . . . . . . 7-16
7.8 Slewing the soil drill (option) into working position 7-17
7.9 Slewing the soil drill into transport position (option) . .
7-18
7.10 Attaching the fly boom (6.5 m) . . . . . . . . . . . . . . 7-19
7.11 Folding the fly boom (6.5 m) into working position 7-25
7.12 Folding the fly boom (6.5 m) into transport position . .
7-36
7.13 Folding the fly boom from 0° to 40° . . . . . . . . . . . 7-46
7.14 Folding the fly boom from 40° to 0° . . . . . . . . . . . 7-48
7.15 Attaching the fly boom extension (6.5 m) (option) 7-50
7.16 Folding the fly boom extension (6.5 m) into transport
position 7-53
7.17 Folding the fly boom extension to working position . . .
7-56
7.18 Attaching the auxiliary jib . . . . . . . . . . . . . . . . . . . 7-61
8 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Controls for unloading the machine . . . . . . . . . . . . 8-2
8.2 Switching on the battery disconnect switch . . . . . . 8-3
8.3 Unload machine . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.1 Configuring the setup program in the SENCON
8-4
8.3.2 Moving the machine off the transport vehicle . .
8-8
8.4 Lashing points . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.5 Transport dimensions and weights . . . . . . . . . . . 8-12
8.6 Locking the uppercarriage . . . . . . . . . . . . . . . . . . 8-13
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8.7 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . 8-14
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Cleaning tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.1 Disposing of lubricants and operating fluids 9-7
9.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.4 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.5 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.5.1 Cummins diesel engine QSB4.5, Tier 4f . . 9-15
9.5.2 Cummins diesel engine QSB4.5, Tier IIIa . 9-21
9.6 Combination cooler . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.7 Water separator . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.8 Belt drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.9 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.9.1 Hydraulic hose lines . . . . . . . . . . . . . . . . . 9-38
9.9.2 Depressurizing the hydraulic system . . . . . 9-39
9.9.3 Checking the oil level . . . . . . . . . . . . . . . . 9-41
9.9.4 Changing the hydraulic oil . . . . . . . . . . . . . 9-43
9.9.5 Return filter – changing filter element . . . . 9-46
9.9.6 Leak oil filter – changing the filter element 9-48
9.9.7 Replacing the aeration filter . . . . . . . . . . . . 9-49
9.9.8 Checking the pre-load of the pressure accumula-
tor 9-50
9.9.9 Replacing the HydroClean micro-filter element .
9-51
9.10 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.10.1Maintaining the brake . . . . . . . . . . . . . . . . 9-55
9.10.2Checking the winch gearbox oil level . . . . 9-55
9.10.3Changing the winch gearbox oil . . . . . . . . 9-56
9.11 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-57
9.11.1Cleaning and lubricating . . . . . . . . . . . . . . 9-57
9.11.2Checking the travel drive oil level . . . . . . . 9-58
9.11.3Changing the travel drive oil . . . . . . . . . . . 9-59
9.11.4Crawler track . . . . . . . . . . . . . . . . . . . . . . . 9-61
9.11.5Spring tensioning fixture - adjusting track tension
9-64
9.11.6Track rollers . . . . . . . . . . . . . . . . . . . . . . . . 9-66
9.11.7Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
9.11.8Base plates . . . . . . . . . . . . . . . . . . . . . . . . 9-67
9.12 Rotary connection . . . . . . . . . . . . . . . . . . . . . . . . 9-68
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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 . . . . . . . . 9-77
9.13.2Inspect the telescoping boom . . . . . . . . . . 9-78
9.13.3Rope mechanism in the telescopic boom – hol-
ding lines and haulback lines 9-79
9.14 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
9.14.1Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
9.14.2Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-84
9.15 Automatic climate control . . . . . . . . . . . . . . . . . . 9-85
9.15.1Cleaning the recirculating air filter . . . . . . . 9-85
9.15.2Cleaning the fresh air filter . . . . . . . . . . . . 9-86
9.16 Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88
9.17 Maintenance schedule . . . . . . . . . . . . . . . . . . . . 9-89
9.17.1Hydraulic oil analysis . . . . . . . . . . . . . . . . . 9-94
9.17.2Lubrication point overview . . . . . . . . . . . . . 9-99
9.17.3Fill quantities . . . . . . . . . . . . . . . . . . . . . . 9-100
9.17.4Tightening torques for screws . . . . . . . . . 9-101
10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3 Heating/air-conditioning system . . . . . . . . . . . . . 10-4
10.3.1Heat output . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10.3.2Cooling capacity . . . . . . . . . . . . . . . . . . . . 10-6
10.3.3System very noisy . . . . . . . . . . . . . . . . . . . 10-8
10.4 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.5 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.6 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1 Reeving Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 Handling, Installation, and Maintenance of Steel Wire
Ropes 11-1
11.3 Driver Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.4 Camera System . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.5 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . 11-1
11.6 Cleaning the Cooling System . . . . . . . . . . . . . . . 11-1
Reference Only

GHC55
Table of Contents
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 . . . . . . . . 11-1
11.11Operating Console . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.12Decal Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.13Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.14Personnel Basket . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.15Pole Claw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.16Reeving diagram . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Reference Only

Safety - Presentation of safety information
1 - 1
GHC55
Grove Published 01-05-2016, Control # 565-02
1 Safety
1.1 Presentation of safety information
This operating manual contains warnings to alert you to
hazardous situations.
Safety
alert symbol
This is the safety 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.
Signal word The signal word indicates the severity and the probability of
occurrence of the danger if the instruction is not complied with.
Warnings in
this operating
manual
WARNING
Warnings indicating a hazardous situation that could result
in injury are always introduced with the safety alert symbol
and the signal word.
NOTE
Warnings indicating a hazardous situation that could result
in property damage are introduced by the signal word.
DANGER indicates a hazardous
situation that, if not avoided, will result in
serious injury or death.
WARNING indicates a hazardous
situation that, if not avoided, could result
in serious injury or death.
CAUTION indicates a hazardous
situation that, if not avoided, could result
in minor to moderate injury.
NOTE indicates important information
not pertaining to a hazard.
DANGER
DANGER
WARNING
CAUTION
NOTE
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Safety - Danger sources
1 - 2
GHC55
Published 01-05-2016, Control # 565-02
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,
the machine is not operated or maintained by trained personnel,
the safety instructions are not complied with,
the machine has defects,
the attached tools do not comply with the relevant safety regulations,
the attached tools have defects.
1.3 National and international regulations
National and international regulations apply in addition to the safety
instructions in this manual.
For example, in the Federal Republic of Germany:
Winches, Lifting and Pulling Equipment (BGV D8)
Cranes (BGV D6)
Crane Inspections (BGG 905)
Information
If national regulations in the country of operation deviate from our
recommendations, the more stringent procedure must be followed.
1.4 Intended use
The machine must only be used for construction operation within the
limits specified by the classification according to Section 1.6 and in
accordance with the ambient conditions.
Assembly, disassembly, maintenance, fault diagnosis and transport
are part of the intended use if these tasks are performed by authorized
personnel in accordance with the instructions and rules in this
operating manual.
Only persons that have been trained or instructed in their task area are
permitted to be near the machine or in its working range. Particular
importance must be placed on imparting knowledge of possible
hazards when instructing or training these persons.
Reference Only

Safety - Intended use
1 - 3
GHC55
Grove Published 01-05-2016, Control # 565-02
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
responded to in accordance with regulations,
the warning, prohibition and information signs attached to the
machine are complied with,
the working range of the machine is carefully monitored,
the permissible ambient conditions are taken into consideration,
personal protective equipment is used if so required in the operating
manual or if necessary for other reasons,
the machine operator has an unobstructed view of the load and
hoisting accessories or of the working equipment and surroundings,
and/or communication between the machine operator and other
authorized persons present is assured,
the load-bearing capacity and evenness of the ground is suitable for
the work, and the permissible inclinations are taken into
consideration,
all maintenance and repair tasks are performed at the specified
intervals and by authorized persons.
Comply with the capacity specifications of the machine, as well as the
equipment in accordance with Chapter 3.
Any other use or use beyond this is considered non-intended use.
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.
Operation and work must only be carried out by trained personnel.
Start-up, maintenance, transportation and assembly/dismantling must
only be carried out by trained specialists.
Danger of injury due to falling objects!
Risk of personal injury due to heavy objects falling onto the operator
station.
If there is danger of heavy falling objects, only deploy the machine if the
driver seat is protected by a protective roof (FOPS). The protective roof is
available from Grove as an option.
WARNING
Reference Only

Safety - Intended use
1 - 4
GHC55
Published 01-05-2016, Control # 565-02
Embankments and
excavations
The crane must be set up with a sufficient safety distance to
embankments and excavations. The distance depends on the type of
ground.
Fig. 1 Determination of the distance from embankments and excavations
Personal injury and material damage due to the machine
slipping!
The machine slips off of the embankment.
Place the machine at a minimum distance of 2 m from the edge of the
embankment.
Pay attention to the condition of the ground:
– For overgrown ground (or non-rolling ground), the safety
distance (A) must be equal to the depth of the excavation (B),
embankment angle a < 45°.
– For ground fill (or hilly), the safe distance (A) must be two times
the excavation depth (B), slope angle a < 30°.
WARNING
Reference Only

Safety - Impermissible use
1 - 5
GHC55
Grove Published 01-05-2016, Control # 565-02
1.5 Impermissible use
Impermissible
operating methods
The operational safety of the machine is only ensured if used as
intended and according to this operating manual.
The capacity information specified in Chapter 3 TECHNICAL DATA must
not be exceeded.
Impermissible use in
crane operation
The types of machine use in crane operation that are impermissible are
stated below:
Exceeding permissible safe working loads (see Section
3T
ECHNICAL DATA)
Using other than original Grove parts
Use in impermissible ambient conditions
Operating error by untrained and uninstructed personnel
Inadequate equipment for the application (for example, protection of
the cab against falling objects through protective grating)
Working on an insufficiently firm ground
Failure to perform the necessary inspection and maintenance tasks
Lifting, moving, and transport of persons
Pulling loads at angles
Dragging loads on the ground
Operation in an explosive environment
Pulling jammed loads free
These situations must always be avoided. Actions to the contrary can
result in severe injury and extensive material damage. Impermissible
use excludes any liability on the part of the manufacturer. The risk is
borne solely by the user.
Unauthorized
conversion and
production
of spare parts
Conversions and modifications of the machine are not permitted. This
applies also for the installation and use of safety devices and safety
valves, as well as for welding on load-bearing parts.
Original spare parts and Grove accessories ensure the safety of
personnel. Parts and equipment from other manufacturers are not
tested by Grove and are therefore not approved. The use of other
components can alter the machine's characteristics and pose a safety
hazard.
If other components are used, Grove will not be liable for any resulting
consequences.
Reference Only

Safety - Crane categorization
1 - 6
GHC55
Published 01-05-2016, Control # 565-02
1.6 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.
Crane group A1: Crane for general lifting tasks, not used in continuous
operation.
Collective class Q1: Cranes that very rarely lift the SWL (safe working
load) and usually only lift light loads.
Operating class U2: Occasional operation, maximum number of load
cycles at 63,000.
Use of the crane outside the safe working loads, application and
ambient conditions determined by calculation and tests results in
significantly reduced service life or premature damage.
The rope winches of the crane are categorized in accordance with
ISO 4301 Part 1 and 2 as follows:
Hoisting gear Driving gear group M5 - collective class L2 - operating class T5
1.7 Requirements on personnel
Assign responsibilities for operation and maintenance.
Observe the permitted statutory minimum age.
Danger of material damage and personal injury due to untrained
personnel
Personnel who have not been trained or instructed cause
malfunctions. Such malfunctions may cause severe personal injury.
Any personnel that is undergoing training or instruction work on the
machine must be under constant supervision of a specialist when
performing work.
Work on the machine's electrical equipment must only be carried out by a
qualified electrician.
Work on travel gear, braking and steering systems must only be carried
out by appropriately trained technicians.
Work on hydraulic equipment must only be carried out by personnel with
specific knowledge and experience in hydraulic systems.
DANGER
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Safety - Requirements on personnel
1 - 7
GHC55
Grove Published 01-05-2016, Control # 565-02
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.
Excerpt from
OSHA regulations (USA)
Machine operators must have the following qualifications:
Successful completion of a practical driving test for this machine.
A minimum vision acuity (with or without corrective lenses) of 20/30
Snell in one eye and 20/50 Snell in the other eye.
The ability to distinguish colors (red, yellow, green), if required for
the work in question.
Adequate hearing (with or without hearing aid).
A disabling heart problem or epilepsy is a valid reason for rejection
as a machine operator.
Specialized personnel Specialized personnel are those persons authorized by the owner to
fulfill qualified tasks, such as installation, setup, repair, maintenance,
and troubleshooting. The following groups of people are included in the
definition of the term 'specialized personnel':
Specialist
Due to technical training and experience, the specialist can safely
operate the product in accordance with the applicable standards. A
specialist is able to recognize and avert potential dangers during the
work.
Instructed person
An instructed person has been instructed in the following points and
is capable of implementing this instruction:
– The tasks assigned to the person
– Recognizing and avoiding potential dangers associated with
improper behavior
– The necessary protective devices and measures, applicable
regulations and accident prevention guidelines
– The respective operating conditions
Expert
An expert has the following knowledge to asses if the machine is in
a state that allows safe work:
– Technical training and adequate knowledge of the machine
– Applicable occupational health and safety regulations and
accident prevention regulations
– Acknowledged guidelines and standard engineering practice
Reference Only

Safety - Work operation
1 - 8
GHC55
Published 01-05-2016, Control # 565-02
1.8 Work operation
Danger zone Persons can be exposed to significant hazards in the working range
(danger zone) of the machine. The working range corresponds to the
slewing range with load attached or with work equipment installed,
including attachments. The working range shifts with the travel
movements.
Causes of hazards include:
Work movements of the machine, such as slewing, lifting/lowering
and luffing of loads, load suspension devices or work equipment
Swinging of the load and/or the load suspension devices (for
example, bottom hook block)
Swinging of projecting components (for example, counterweight)
Travel movements of the machine
Movement of the work equipment
Falling payload, loads or other objects
Danger to life due to uncontrolled movement of loads and
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.
Secure the machine against rolling off, for example with wheel chocks.
Park the machine on level ground, do not park it too close to excavations
or embankments under any circumstances.
Lower suspended loads to the ground.
If a storm is approaching, put the machine in park position (see
section 3.2).
Always stop the engine when leaving the machine, and safeguard it
against unauthorized start-up.
DANGER
Reference Only