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!
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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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