Grove GMK7450 Ingles
April 29, 2017 | Author: Danilo Marin | Category: N/A
Short Description
Manual del operador...
Description
ADE004631 REV00
Operation and Maintenance Manual Supplement Grove GMK 7450 All Terrain Crane
Ph: +61 7 3865 2660
www.ade.net.au
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2
3
OVERVIEW ........................................................................................................................................................................ 1 1.1
LITERATURE INFORMATION .......................................................................................................................................... 1
1.2
SAFETY......................................................................................................................................................................... 1
1.3
OPERATION .................................................................................................................................................................. 1
1.4
MAINTENANCE ............................................................................................................................................................. 2
SAFETY............................................................................................................................................................................... 1 2.1
IMPORTANT SAFETY INFORMATION .............................................................................................................................. 1
2.2
SAFETY SIGNS AND LABELS ......................................................................................................................................... 3
IDENTIFICATION INFORMATION .............................................................................................................................. 1 3.1
4
SYSTEM STAGES, USES & PREREQUISITES ............................................................................................................ 1 4.1
GENERAL DESCRIPTION................................................................................................................................................ 1
4.2
CRANE CAB ACCESS PLATFORM - SYSTEM STAGES, USES AND PREREQUISITES .......................................................... 2
4.2.1
Stage 1 Raise Start/Stage 5 Lower Finish............................................................................................................... 3
4.2.2
Stage 2 Raise Start/Stage 4 Lower Finish............................................................................................................... 5
4.2.3
Stage 3 Raise Start/Stage 3 Lower Finish............................................................................................................... 6
4.2.4
Stage 4 Raise Start/Stage 2 Lower Finish............................................................................................................... 7
4.2.5
Stage 5 Raise Finish/Stage 1 Lower Start............................................................................................................... 9
4.3
5
6
ACCESS SYSTEM ID PLATE........................................................................................................................................... 1
CARRIER DECK HANDRAILS - SYSTEM STAGES, USES AND PREREQUISITES ............................................................... 10
4.3.1
Handrails Lowered ............................................................................................................................................... 10
4.3.2
Handrails Raised .................................................................................................................................................. 11
SYSTEM CONTROLS & INDICATORS ........................................................................................................................ 1 5.1
CRANE CARRIER DECK HANDRAIL & CRANE CAB ACCESS PLATFORM CONTROLS – RIGHT SIDE ............................... 2
5.2
CRANE CARRIER DECK HANDRAIL CONTROLS – LEFT SIDE ......................................................................................... 3
5.3
ACCESS SYSTEM CRANE CAB CONTROLS ..................................................................................................................... 4
MOUNTING & DISMOUNTING PROCEDURES......................................................................................................... 1 6.1
CRANE CAB ACCESS PLATFORM – GENERAL INFORMATION ........................................................................................ 1
6.2
MOUNTING PROCEDURE – CRANE CAB ACCESS PLATFORM ......................................................................................... 2
6.3
CRANE OPERATION – ACCESS SYSTEM CONFIGURATION ............................................................................................. 3
6.4
DISMOUNTING PROCEDURE – CRANE CAB ACCESS PLATFORM .................................................................................... 4
GMK 7450 - Supplement
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6.5
CRANE CARRIER OPERATION – ACCESS SYSTEM CONFIGURATION .............................................................................. 5
6.6
DISMOUNTING PROCEDURE – EMERGENCY USE ONLY................................................................................................. 7
6.7
DISMOUNTING PROCEDURE – ACCESS SYSTEM LADDER FAILURE ............................................................................... 7
6.8
MOUNTING PROCEDURE – CRANE CARRIER DECK ....................................................................................................... 8
TRANSPORTATION INFORMATION .......................................................................................................................... 1 7.1
8
OPERATING WIDTH ...................................................................................................................................................... 1
MAINTENANCE SECTION ............................................................................................................................................. 1 8.1
GENERAL HAZARD INFORMATION ................................................................................................................................ 2
8.1.1
Fluid Penetration.................................................................................................................................................... 2
8.1.2
Crushing & Cutting Prevention .............................................................................................................................. 2
8.1.3
Burn Prevention – Oils ........................................................................................................................................... 3
8.1.4
Hydraulic Hoses ..................................................................................................................................................... 3
8.2
MAINTENANCE OVERRIDE KEY SWITCH ...................................................................................................................... 4
8.3
HYDRAULIC OIL TANKS ............................................................................................................................................... 5
8.4
MAINTENANCE INTERVAL – WHEN REQUIRED ............................................................................................................. 8
8.4.1 8.5
Additional Circuit Breaker - Reset.......................................................................................................................... 8 MAINTENANCE INTERVAL – EVERY 10 SERVICE HOURS OR DAILY ............................................................................ 10
8.5.1
Walk-Around Inspection ....................................................................................................................................... 10
MAINTENANCE INTERVAL – EVERY ................................................................................................................................ 12 8.6 8.6.1
Bolts and Mounting Hardware ............................................................................................................................. 12
8.6.2
Crane Cab Audible & Visual Indicators – Test .................................................................................................... 12
8.6.3
Hydraulic System - Inspect ................................................................................................................................... 12
8.6.4
Pivot Points – Lubricate ....................................................................................................................................... 13
8.7 8.7.1 9
1000 SERVICE HOURS OR 6 MONTHS.......................................................................................................................... 12
MAINTENANCE INTERVAL – EVERY 2000 SERVICE HOURS OR YEARLY ..................................................................... 15 Rubber Bump Stops – Inspect ............................................................................................................................... 15
LITERATURE REFERENCE MATERIALS.................................................................................................................. 1 9.1
MANITOWOC REFERENCE MATERIAL ........................................................................................................................... 1
GMK 7450 - Supplement
1 1 Overview 1.1 Literature Information The operation and maintenance manual supplement should be stored in both the carrier and the crane operator’s cabins.
The operation and maintenance manual supplement contains safety, operation and maintenance information for the crane access systems as fitted by Australian Diversified Engineering and must be used in conjunction with the cranes operation and maintenance manual.
Whenever a question arises regarding the crane access system, or the operation and maintenance manual, please consult Australian Diversified Engineering Pty Ltd for the latest available information.
1.2 Safety The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs used on the crane access system.
Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance on the crane access system.
1.3 Operation The operation section includes a description of the controls, their location and operation with respect to the access system. Photographs and illustrations are provided to guide the operator through the correct operating procedures for the access system.
Overview GMK 7450 - Supplement
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1 1.4 Maintenance The maintenance information is a guide to equipment care. The illustrated, step-by-step instructions are grouped by servicing intervals. Items without specific intervals are listed under “When Required” topics. Items in the Maintenance Interval Schedule are referenced to detailed instructions that follow.
Calendar intervals shown (daily, weekly, monthly, etc.) are to be used as they provide more convenient servicing schedules. Recommended service should always be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the Maintenance Intervals schedule may be necessary.
Overview GMK 7450 - Supplement
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2 2 Safety 2.1 Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognising potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation & maintenance of this product can be dangerous and could result in injury or death.
Do not operate or perform maintenance on this product, until you have read and understood the operation and maintenance information.
Safety precautions and warnings are provided in this manual and on the product. It these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the Safety Alert Symbol" and followed by a 'Signal Word" such as "WARNING" as shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.
Safety Section GMK 7450 - Supplement
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2 Australian Diversified Engineering cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by Australian Diversified Engineering is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product would not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact Australian Diversified Engineering for replacement manuals. Proper care is your responsibility.
Before operating any of the access systems ensure that the gear selector is in neutral and the park brake is engaged. Do not release the park brake, move the gear selector or throttle pedal if any of the access systems are not fully retracted. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job from Australian Diversified Engineering.
Safety Section GMK 7450 - Supplement
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2 2.2 Safety Signs and Labels There are several specific safety signs specific to the access system. Their exact location and description of the hazard are reviewed in this section. Make sure that you can read all safety signs. You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part. Contact Australian Diversified Engineering for replacement labels.
This sign is located at the right side of the main frame for the access system
Safety Section GMK 7450 - Supplement
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2
This sign is located in three places on the side of the access system ladder
Safety Section GMK 7450 - Supplement
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2
This sign is located on each side of the crane carrier deck between the front and rear handrails
Sign located on the right side of the crane carrier deck
Safety Section GMK 7450 - Supplement
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2
Sign located on the left side of the crane carrier deck
This sign is located on the cover for the access system frame
Safety Section GMK 7450 - Supplement
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2
This sign is located on top of the hydraulics cabinet for the crane carrier deck handrails
Safety Section GMK 7450 - Supplement
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2
This sign is located inside the crane carrier cab on the left side of the dash
This sign is located inside the crane cab adjacent to the access system controls
Safety Section GMK 7450 - Supplement
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2
This sign is located inside each ground level access system control box (left side control box shown)
Safety Section GMK 7450 - Supplement
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This sign is located inside the crane cab adjacent to the access system controls
Safety Section GMK 7450 - Supplement
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3 3 Identification Information 3.1 Access System ID Plate Data plates have been fitted to the access system which indicates the model number, safe working load, date of manufacture and the serial number.
Data plate details for the crane access system
Data plate located on the side of the crane cab platform
Identification Information GMK 7450 – Supplement
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3
Data plate located beneath each ground level control box
Identification Information GMK 7450 – Supplement
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4 4 System Stages, Uses & Prerequisites 4.1 General Description The system comprises of:
A right side platform and retractable ladder to access the crane cab when in the operating position.
Right and left crane carrier deck mounted handrails.
Crane cab access platform & ladder
Crane carrier deck handrails (right side shown) System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 The crane cab access platform is a five stage electric-over-hydraulic folding system. The access system utilises a 24V DC hydraulic power pack coupled with a manifold of hydraulic sequence valves and pilot operated check valves to drive and control the hydraulic cylinders that raise and lower the access system.
The carrier deck handrails are a single stage electric-over-hydraulic folding handrail system which utilise a 24V DC hydraulic power pack to drive and control the hydraulic cylinders that raise and lower the left and right side handrail sections.
Electrical power is only provided to the access system if the crane carrier park brake is applied and remains applied. All isolation switches must also be switched on for the access systems to function.
4.2 Crane Cab Access Platform - System Stages, Uses and Prerequisites The crane cab access platform is located on the right side of the machine (with the superstructure at 180°) with controls located inside the crane cab and at ground level at the right
side
of
the
crane
carrier.
Identification of each stage of the system will now be explained and the prerequisites for each stage will be detailed to enable correct use of the system.
Fully Lowered Crane Cab Access Platform
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 4.2.1 Stage 1 Raise Start/Stage 5 Lower Finish This configuration sees the crane cab access platform in the fully lowered position. This is either the end stage to lowering of the access system or the beginning stage of the raising sequence. There is a sign located on the right cab window of the crane cab which indicates the configuration the machine must be in to allow for complete lowering of the access system. Read the label in conjunction with the Ecos crane cab display screen.
Positional indicator label to reference when lowering the access system
Positional indicator label located inside the crane cab adjacent to the access system controls System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4
Stage 1 Raise Start/Stage 5 Lower Finish
To enable this configuration the:
Carrier park brake must be applied.
Superstructure must be facing forward (180° position) for the access system to be powered.
With the access platform in the fully lowered position the access system provides access:
To the crane operator cab from ground level.
To the superstructure fuel tank.
Onto the carrier deck from the platform forward of the cab.
With the access system in this position the:
Superstructure cannot slew.
Crane cab cannot be moved from the crane operation position.
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 4.2.2 Stage 2 Raise Start/Stage 4 Lower Finish
This is an intermediate stage only.
Stage 2 Raise Start/Stage 4 Lower Finish
The access step ladder has now rotated through 60 degrees to the horizontal position. Access from the crane operator cab to ground is no longer provided by the access system.
To enable this configuration the:
Carrier park brake must be applied.
Superstructure must be facing forward (180° position) for the access system to be powered.
With the access system in this position the:
Superstructure cannot slew.
The crane cab cannot be moved from the crane operation position.
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 4.2.3 Stage 3 Raise Start/Stage 3 Lower Finish This is an intermediate stage only.
Stage 3 Raise Start/Stage 3 Lower Finish
The step ladder has retracted under the crane cab.
Access from the crane operator cab to ground is no longer provided by the access system.
To enable this configuration the:
Carrier park brake must be applied.
Superstructure must be facing forward (180° position) for the access system to be powered.
With the access system in this position the:
Superstructure cannot slew.
The crane cab cannot be moved from the crane operation position.
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 4.2.4 Stage 4 Raise Start/Stage 2 Lower Finish
This is the position for the crane cab access platform when the crane is in use. A green light located inside the crane cab adjacent to the access system controls advises the operator when the access system is in the correct position. This is also the configuration in which the access system must be in to allow for moving of the crane cab to and from the stored and transport positions.
Stage 4 Raise Start/Stage 2 Lower Finish
Crane can be used when the green status indicator is illuminated
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 The platform handrail has folded down onto the platform.
Access from the crane operator cab to ground is no longer provided by the access system.
To enable this configuration the:
Carrier park brake must be applied.
Superstructure must be facing forward (180° position) for the access system to be powered.
With the access system in this position the:
Superstructure can slew.
The crane cab can be moved from the crane operation position to the transport position.
Crane cab stowed in transport position
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 4.2.5 Stage 5 Raise Finish/Stage 1 Lower Start The crane cab is in the transport position and the access system has been fully retracted. This is either the beginning of the lowering sequence or the end of the raising sequence and is the configuration for when the crane carrier is to be driven.
Crane cab stowed in transport position and the platform raised allowing the crane carrier to be driven
The platform has folded up against the crane superstructure.
Access from the crane operator cab to ground is no longer provided by the access system.
To enable this configuration the:
Carrier park brake must be applied.
Crane cab must be stowed in the transport position.
Superstructure must be facing forward (180° position) for the access system to be powered.
With the access system in the fully raised position:
The carrier park brake can be released.
The crane carrier can be driven.
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 4.3 Carrier Deck Handrails - System Stages, Uses and Prerequisites
NOTICE The handrails are installed solely to provide a safe work area when maintenance or inspection work is being undertaken on the crane.
Electrical power is only provided to the access system if the crane carrier park brake is applied and remains applied and all isolation switches are in the ON position. Controls for the carrier deck handrails are located at ground level on the right and left sides of the crane carrier with the access platform controls. The left and right side handrails are operated independently of each other. 4.3.1 Handrails Lowered
Lowered Carrier Deck Handrails
To enable this configuration:
The carrier park brake must be applied.
The superstructure must be facing forward (between -179.90° and +180.10°).
Machine isolation points are in the connected position.
With the access system in this position:
Access onto the carrier deck is not permitted for maintenance purposes.
The carrier park brake can be released.
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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4 4.3.2 Handrails Raised
NOTICE The crane superstructure will not slew with the carrier deck handrails are in the raised position. Handrails have rotated through 90 degrees. This position allows for access onto the carrier deck.
Raised Carrier Deck Handrails
To enable this configuration:
The carrier park brake must be applied.
The superstructure must be facing forward (between -179.90° and +180.10°).
Machine isolation points are in the connected position.
With the access system in this position:
The superstructure cannot slew.
Access onto the carrier deck is permitted for maintenance purposes from the platform forward of the cab.
System Stages, Uses & Prerequisites GMK 7450 - Supplement
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5 5 System Controls & Indicators Controls to operate the access system are located inside the crane cab and at ground level on the right and left sides of the crane carrier cab (behind the carrier doors).
The access controls utilised on this machine are of the momentary push button type. This requires the operator to press the button for the duration of the raising or lowering stages as required. If the button is released at any point in the system operation then power will be cut immediately and the access system will cease to move (commonly known as ‘dead-man’ controls). Whenever the controls are operated a motion alarm located on the hydraulics cabinet will sound to warn personnel around the machine that the access systems are being operated.
System Controls & Indicators GMK 7450 - Supplement
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5 5.1 Crane Carrier Deck Handrail & Crane Cab Access Platform Controls – Right Side The controls to operate the right side deck handrails and the access system are located behind the right side crane carrier cab door. 1 2
3 4
Right side carrier deck handrails and access system controls
Controls located on this panel include: 1) Access System Raise 2) Access System Lower 3) Deck Handrails Raise 4) Deck Handrails Lower
System Controls & Indicators GMK 7450 - Supplement
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5 5.2 Crane Carrier Deck Handrail Controls – Left Side The controls to operate the left side deck handrails are located behind the left side crane carrier cab door.
5 6
Left side carrier deck handrail controls
Controls located on this panel include: 5) Deck Handrails Raise 6) Deck Handrails Lower
System Controls & Indicators GMK 7450 - Supplement
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5 5.3 Access System Crane Cab Controls The access system controls have been fitted to the right side cab console.
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8
9
10
Crane cab controls for the access system include: 7) Access System Raise 8) Access System Lower 9) Access System Light – Momentary Toggle Switch 10) Access System Retracted for Slewing Indicator (Refer Section 6.3 Crane Operation – Access System Configuration)
System Controls & Indicators GMK 7450 - Supplement
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5 (9) Access System Light
Located at the front of the crane cab is an access light fitted to illuminate the crane cab access platform and ladder. The light is switched on automatically when the access system controls are operated. It then automatically switches off after a pre-set period of time.
If mounting the machine from ground level with the access platforms in the fully lowered position momentarily push the lower control and the light will illuminate for a pre-set period of time.
If at anytime illumination of the access system is required when dismounting from the crane cab with the access system in the fully lowered position, simply switch the access light toggle switch in the crane cab and the light will also illuminate for a pre-set period of time.
System Controls & Indicators GMK 7450 - Supplement
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6 6 Mounting & Dismounting Procedures
6.1 Crane Cab Access Platform – General Information
Mount and dismount the machine only where ladders and steps are provided.
Inspect, and when necessary, clean and have repairs made to steps and handrails before mounting and dismounting.
Face the access system ladder when mounting and dismounting.
Maintain a three-point contact (two feet and one hand or one foot and two hands contact) with the steps and handrails.
Never jump off the access system.
Never attempt to use the access system when raising or lowering.
Audible motion alarms located on the hydraulic cabinets indicate when the access systems are moving.
Ensure adequate lighting for mounting and dismounting of the machine in low light conditions.
Ensure that the systems are in the fully lowered position before mounting the platforms.
Ensure all personnel are clear of the access system before operating the controls.
Mounting & Dismounting Procedures GMK 7450 - Supplement
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6 6.2 Mounting Procedure – Crane Cab Access Platform
NOTICE With the ladder in the down position the superstructure cannot slew. Lowering of the access system from fully retracted (Stage 5 Raise Finish to Stage 1 Lower Start) with the superstructure in the forward position (between -179.90° and +180.10°) and the crane cab in the transport position:
1. Ensure that the carrier park brake is applied. 2. Ensure all machine isolation switches are in the connected position. 3. Go to the ground level controls for the crane cab access system situated at the front right of the crane carrier. 4. Ensuring that the area is free from personnel use the appropriate control to lower the access system to Stage 4 Raise Start/Stage 2 Lower Finish.
Configuration of access system for Step 4
5. Move the crane cab from the transport position to the operating position. Refer to the Manitowoc Operation and Maintenance Manual for further information on positioning of the crane cab. 6. Once the crane cab is in the operating position ensuring that the area is free from personnel use the appropriate control to completely lower the access system. 7. Mount the access system to the crane cab.
Mounting & Dismounting Procedures GMK 7450 - Supplement
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6 6.3 Crane Operation – Access System Configuration Raise the access system using the crane cab mounted access system controls to the configuration shown below to allow for crane operation. Operate the crane in accordance with manufacturer and mine site instructions.
Configuration of access system for use of the crane
Crane can be used when the green status indicator is illuminated
Mounting & Dismounting Procedures GMK 7450 - Supplement
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6 6.4 Dismounting Procedure – Crane Cab Access Platform To dismount the crane cab after use of the crane:
1. Position the superstructure in the forward position (between -179.90° and +180.10°). There are visual displays installed in the crane cab which indicate when this has been achieved. 2. Check to ensure that the area is free from personnel and that there is sufficient clearance for the ladder to lower. 3. Operate the controls in the crane cab to lower the system. Continue operating the controls until the ladder is in the fully lowered position. 4. Exit the crane cab and make a visual inspection to ensure that the access ladder has completely lowered. Do not dismount the machine if the access system has failed to lower correctly. 5. Dismount the crane cab via the access platform and ladder. 6. If the crane carrier is required to be driven continue with the following steps. 7. Using the appropriate ground level control raise the access system to Stage 4 Raise Start/Stage 2 Lower Finish as shown below.
Access system raised to Stage 4 Raise Start/Stage 2 Lower Finish
8. Move the crane cab from the operating position to the transport position. Refer to the Mounting & Dismounting Procedures GMK 7450 - Supplement
6-4
6 Manitowoc Operation and Maintenance Manual for further information on the positioning of the crane cab. 9. Using the appropriate control completely raise the access system.
6.5 Crane Carrier Operation – Access System Configuration Raise the access system using the ground level access system controls to the configuration shown below to allow for crane carrier operation. Operate the crane carrier in accordance with manufacturer and mine site instructions.
Configuration of access system for use of the crane carrier
To ensure that the crane carrier is not driven with the access systems in the down position there is an audible and visual alarm located on the front cab dash. Upon release of the park brake if the audible and visual alarms are activated reapply the park brake, dismount the machine and ensure that all access systems are in the fully raised position. Do not drive the machine if the alarms are activated as there may be personnel accessing the platforms. Further to this, damage to the access systems, the crane carrier and the superstructure may occur.
Mounting & Dismounting Procedures GMK 7450 - Supplement
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6 NOTICE If the park brake is released before the access systems are completely retracted the warning light will illuminate and the alarm will sound. Always operate the crane in accordance with manufacture and mine site instructions.
Crane carrier cab mounted audible and visual alarms
Crane carrier cab mounted indicators
Mounting & Dismounting Procedures GMK 7450 - Supplement
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6 6.6 Dismounting Procedure – Emergency Use Only To dismount the crane cab onto the carrier deck in an emergency situation (without the use of the access system ladder to ground level):
1. Position the superstructure at any position which allows for egress from the crane cab and onto the carrier deck via the crane cab access platform. 2. Exit the crane cab onto the carrier deck. 3. Dismount from the carrier deck to ground level via the standard machine ladders where possible.
6.7 Dismounting Procedure – Access System Ladder Failure If the access system ladder fails to completely lower and egress from the crane cab is not available via the ladder use the procedure for emergency use of the system as outlined above.
Mounting & Dismounting Procedures GMK 7450 - Supplement
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6 6.8 Mounting Procedure – Crane Carrier Deck
NOTICE The handrails are installed solely to provide a safe work area when the maintenance or inspection work is being undertaken on the crane.
NOTICE The superstructure will not slew with the carrier deck handrails in the raised position.
To raise the handrails of the carrier deck to provide for a safe work area for maintenance and inspection:
1. Conduct all steps as outlined in the mounting procedure for the crane cab. 2. Ensuring that the area is free from personnel use the appropriate control to raise the handrail. Continue to depress the control until the handrail is in the fully up position. Continue to the other side of the machine and ensuring that the area is clear from personnel, raise the handrail releasing the switch when the handrail is in the fully raised position. 3. Maintenance and inspection can now be carried out on the carrier deck with the handrails raised via the crane cab access platform in the lowered position. 4. When maintenance and inspection has been completed dismount the machine and lower the carrier deck handrails using the ground level controls at the front right or left side of the machine. 5. Raise the access system if required.
Mounting & Dismounting Procedures GMK 7450 - Supplement
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7 7 Transportation Information 7.1 Operating Width
NOTICE Fitment of the access system to this machine has increased the crane carrier’s travel and transport width to 3400mm. There is a sign located inside the crane carrier cab to remind the operator of the crane carrier operating width of the vehicle.
Operating width label located on the side of the centre console
Transportation Information Section GMK 5220 – Supplement
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7
Operating width label located on the carrier cab air conditioner
Transportation Information Section GMK 5220 – Supplement
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8 8 Maintenance Section
Unintended machine movement may result in personal injury or death. Before performing maintenance on this machine ensure it has been isolated in accordance with mine site and manufacturer procedures and a Do Not Start Tag has been applied in the appropriate location on the machine.
Disconnection of hydraulic hoses and removal of supporting pins and bolts of the access system may result in unintended machine movement and/or release of stored energy. Personal injury or death may result. Before disassembly of any components of the access system ensure that stored energy has been relieved and components are chocked/blocked to prevent unintended movement.
NOTICE You must read and understand the warnings and instructions contained in the Safety Section of this manual, before performing any maintenance procedures.
Maintenance Section GMK 7450 - Supplement
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8 8.1 General Hazard Information Perform all maintenance unless otherwise specified as follows:
The machine parked on level ground.
The crane carrier park brake engaged.
Crane carrier and superstructure engines stopped.
The start switch key off and the key removed. (Crane and carrier cabs)
All disconnect switches locked out and a Do Not Start Tag applied to the switch.
All other external energy sources disconnected from crane.
8.1.1 Fluid Penetration Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, a doctor preferably familiar with this type of injury must treat it immediately. 8.1.2 Crushing & Cutting Prevention
Do not disconnect any hydraulic hoses unless the access platforms are fully lowered. In any position other than fully lowered the access system hydraulics will be pressurised. Releasing this pressure WILL result in uncontrolled movement of the access platform. Do not work on the access system unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact Australian Diversified Engineering for replacement manuals. Proper care is your responsibility.
Support equipment and attachments properly when working beneath them. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified.
Maintenance Section GMK 7450 - Supplement
Stay clear of all rotating and moving parts.
8-2
8 8.1.3 Burn Prevention – Oils
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.
At operating temperature, the hydraulic tank can be hot.
Relieve all pressure in hydraulic oil system before any lines, fittings or related items are disconnected or removed.
8.1.4 Hydraulic Hoses
Damage of access system hydraulic hoses, tubes or pipes from welding on or near them can result in uncontrolled movement of the access platform or fire. Do not work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact Australian Diversified Engineering for replacement manuals. Proper care is your responsibility.
Do not weld or flame cut on or near hoses, tubes or pipes that contain flammable fluids.
Do not bend or strike high-pressure lines. Do not install damaged hoses.
Replace any damaged hydraulic oil hoses. Leaks can cause fires.
Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. See Fluid Penetration in the Safety Section for more details.
Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration, rubbing against other parts, and excessive heat during operation.
Replace if any of the following conditions are found:
End fittings damaged or leaking.
Outer covering chafed or cut and wire reinforcing exposed.
Outer covering ballooning locally.
Evidence of kinking or crushing of the flexible part of hose.
Armouring embedded in the outer cover.
End fittings displaced.
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8 8.2 Maintenance Override Key Switch
To prevent damage to the access systems, crane carrier and the superstructure ensure that the step ladder is in the raised position when slewing with the maintenance override key in the override position. Failure to do so will result in damage to the access systems, crane carrier and the superstructure. This machine has been fitted with a maintenance override switch located inside the access system controls cabinet to allow troubleshooting and diagnostics on the standard superstructure electrical systems. The switch can only be turned via the use of a key and as such the key should never be left in the switch. The access platform electrical systems will be isolated from the superstructure electrical systems when the override switch is used. With the maintenance override key ON the superstructure will slew with the access systems in any configuration including in the fully lowered position and the crane cab can be moved irrespective of the position of the access system. Therefore, before activating the maintenance override key ensure that all ladders are in the raised position if it is anticipated that slewing of the superstructure is required.
Maintenance override key switch located inside the access system hydraulics cabinet
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Maintenance override switch located inside the access system hydraulics cabinet
8.3 Hydraulic Oil Tanks There are two hydraulic oil tanks located on this machine. One tank for the access system platform and ladder located on the left side of the crane superstructure and the other tank for the crane carrier deck handrails located at the front left of the crane carrier deck.
Replace the hydraulic oil and in-tank filter (if equipped) every 24 months / 2 years in consultation with Australian Diversified Engineering. Use only Castrol Hyspin AWH-M ISO Viscosity grade 68 oil or an equivalent specification oil in the hydraulic system. Use the sight level gauges on each tank when refilling.
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Hydraulic oil tank for the access platform and ladder
Fill point for the hydraulic tank accessible from the cabinet located above
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Hydraulic oil tank for the crane carrier deck handrails
Remove the cover indicated to expose the fill point for the hydraulic tank
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Oil level within both hydraulic oil tanks to be at the black line indicated
8.4 Maintenance Interval – When Required 8.4.1 Additional Circuit Breaker - Reset This machine has been fitted with four additional 10 Amp and two additional 105 Amp circuit breakers for the handrails and the access platforms. There are two circuit breakers located inside the crane carrier cab behind the centre dash panel, two circuit breakers located within the hydraulics cabinet for the access platform and ladder and a circuit breaker located beside each standard isolator switch.
Push the button in to reset the circuit breaker. If the button does not remain depressed there may be a problem with the circuit. Have the circuit inspected.
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Additional circuit breakers located within the access system hydraulics cabinet
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Two additional circuit breakers inside the hydraulics cabinet include: (1) Access System – 10 Amp (2) Access System Light – 10 Amp
Other additional circuit breakers located on this machine include: (3) In-Cab Park Brake Warning/Lower Push Button Switches – 10 Amp (Carrier Cab) (4) Proximity Switches – 10 Amp (Carrier Cab) (5) Access Power Pack – 105 Amp (Superstructure Isolation Switch) (6) Handrails Power Pack – 105 Amp (Carrier Isolation Switch)
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8 8.5 Maintenance Interval – Every 10 Service Hours or Daily 8.5.1 Walk-Around Inspection Perform a walk-around inspection on the machine prior to operation.
Ensure all steps are clean and free from debris.
Visually inspect components for damage and wear and tear. Have any damaged or missing components repaired or replaced.
Check to ensure that the access light located at the front of the crane cab operates in conjunction with the access system controls.
Access light located at the front of the crane cab
Check to ensure that the audible alarms located adjacent to each hydraulic oil tank sounds whenever the access system controls are activated.
Hydraulics cabinet mounted alarms to operate in conjunction with use of the access system
Check to ensure all labels can be read and are visible in conjunction with the Safety Signs and Labels section of this manual. Replace label/s if they cannot be read or are missing. This includes all black and yellow tape applied to step edges.
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Black and yellow tape applied to step edges
Visually inspect all hydraulic lines, hoses, fittings and hose clamps for security, damage, deterioration and leaks.
Ensure all switches of the access system are operational.
Inspect the ladder rollers ensuring that they spin freely and are not damaged. Whilst inspecting the rollers ensure the roller track which they slide into is clean and free from debris which may damage or obstruct roller operation and ladder extension/retraction. Do not lubricate rollers or track.
Ladder rollers
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Check the level of both hydraulic oil tanks. Top-up if required referring to section Hydraulic Oil Tanks in the Maintenance Section of this manual.
8.6 Maintenance Interval – Every 1000 Service Hours or 6 Months 8.6.1 Bolts and Mounting Hardware Check the tightness of all bolts fitted to the access systems. This includes checking the handrails, access platforms and their mountings. 8.6.2 Crane Cab Audible & Visual Indicators – Test The crane cab audible & visual alarms should be tested to ensure that they are operational. With one of the access platforms in a lowered position enter the crane carrier cab and release the park brake. The alarms should be activated. If the alarms do not activate it means that there is a problem with the system and it needs to be checked.
8.6.3 Hydraulic System - Inspect
Inspect all lines, hoses fittings, hose clamps and cylinders for damage and deterioration. If there are any damaged, missing or leaking parts ensure that they are replaced. Check to ensure the mountings for both hydraulic oil tanks are secure.
Open the hydraulics cabinet lid and inspect all hoses and fittings for leaks. Replace any items as required. Hydraulic systems and components should be serviced only in consultation with Australian Diversified Engineering.
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8 8.6.4 Pivot Points – Lubricate Lubricate main pivot points of the system via the grease fittings with good quality molybdenum based grease. There are two grease fittings for the access ladder and two grease fittings for the access system main frame.
Four grease points for the crane cab access platform (top view crane)
Two grease fittings for the access system ladder
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Forward grease fitting for the access system main frame
Rearward grease fitting for the access system main frame
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8 8.7 Maintenance Interval – Every 2000 Service Hours or Yearly 8.7.1 Rubber Bump Stops – Inspect Inspect the condition of the rubber bump stop mounted to the access system. Replace as required.
Bump stop for stored access system
Bump stop
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Bump stop
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9 9 Literature Reference Materials 9.1 Manitowoc Reference Material The following literature can be obtained through Manitowoc Crane Group.
GMK 7450 – Operating Instructions Volumes 1 & 2.
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