Manual Grove GMK5220 Ingles
October 7, 2022 | Author: Anonymous | Category: N/A
Short Description
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Description
1596K-001 REV-00
Operation and Maintenance Manual Supplement Grove GMK 5220 All Terrain Crane
Ph: +61 7 3865 3865 2660
www.ade.net.au ww w.ade.net.au
1
OVERVIEW.................................... OVERVIEW...................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 1 1.1
LITERATURE I NFORMATION............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 1
1.2
SAFETY.............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................ 1
1.3 1.4
O ............................ .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ...................... ........ 1 MAINTENANCE .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ................. .... 2
PERATION
2
SAFETY.................................. SAFETY.................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................ 1 2.1
IMPORTANT SAFETY I NFORMATION............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................ 1
2.2
SAFETY SIGNS AND LABELS ............ .......................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 3
2.3
GENERAL HAZARD I NFORMATION............. ........................... ............................ ............................ ............................ ............................ ............................ ........................... ........................... .................. .... 9
2.4
FLUID PENETRATION .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 10
2.5
CRUSHING OR CUTTING PREVENTION............ .......................... ............................ ............................ ............................ ............................ ............................ ............................ ......................... ........... 10
2.6
BURN PREVENTION – OILS .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ......................... ........... 11
2.7
FIRE OR EXPLOSION PREVENTION ............. ........................... ............................ ............................ ............................ ............................ ............................ ........................... ........................... ................ .. 12
2.7.1 2.8 3
4
Fire Exting Extinguishe uisherr Locati Location on ........................... ......................................... ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 13 LINES, TUBES AND HOSES ............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 15
IDENTIFICATION IDENTIFICA TION INFORMATION.................................. INFORMATION................................................ ............................ ............................ ............................ ............................ ............................ ...................... ........ 1 3.1
CARRIER HANDRAILS ............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ...................... ........ 1
3.2
CRANE CAB ACCESS PLATFORM ............ .......................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 2
3.3
E NGINE MODULE ACCESS PLATFORM .............. ............................ ............................ ............................ ............................ ............................ ........................... ........................... ......................... ........... 4
SYSTEM STAGES, USES & PREREQUISITES PREREQUISITES ............................ .......................................... ........................... ........................... ............................ ............................ ......................... ........... 1 4.1
GENERAL DESCRIPTION............ .......................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 1
4.2
CRANE CAB ACCESS PLATFORM - SYSTEM STAGES, USES AND PREREQUISITES ............ .......................... ............................ ............................ .................. .... 3
4.2.1
Stage 1 Raise Start/S Start/Stage tage 4 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ .................. .... 5
4.2.2
Stage 2 Raise Start/S Start/Stage tage 3 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ .................. .... 7
4.2.3
Stage 3 Raise Start/S Start/Stage tage 2 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ .................. .... 8
4.2.4
Stage 4 Raise Start/S Start/Stage tage 1 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ .................. .... 9
4.2.5
Stage 4 Raise Start/Stage 1 Lower Start .............. ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 10
4.3
E NGINE MODULE ACCESS PLATFORM - SYSTEM STAGES, USES AND PREREQUISITES .............. ............................ ............................ .................... ...... 11
4.3.1
Stage 1 Raise Start/S Start/Stage tage 4 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ ................ .. 12
4.3.2
Stage 2 Raise Start/S Start/Stage tage 3 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ ................ .. 14
4.3.3
Stage 3 Raise Start/S Start/Stage tage 2 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ ................ .. 15
Operating Instructions GMK 5220 - Supplement
4.3.4
Stage 4 Raise Start/S Start/Stage tage 1 Lower Finish......... Finish....................... ............................ ............................ ............................ ............................ ............................ ............................ ................ .. 16
4.3.5
Stage 4 Raise Finish/ Finish/Stage Stage 1 Lower Start............ Start.......................... ............................ ............................ ............................ ............................ ............................ ........................... ............. 17
4.4
5
6
4.4.1
Handrails Lowered .......... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ................. ....... 18
4.4.2
Handrails Raised .......... .................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... .......... 19
SYSTEM CONTROL CONTROLS S & INDICATO INDICATORS RS .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ...................... ........ 1 5.1
HANDRAILS , CRANE CAB & E NGINE MODULE ACCESS PLATFORMS.............. ............................ ............................ ............................ ............................ .................... ...... 1
5.2
ACCESS SYSTEM LIGHTING ............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 6
5.3
A NCILLARY COMPARTMENT .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ........................ ........... 7
MOUNTING & DISMOUNTIN DISMOUNTING G PROCEDURE PROCEDURES S ............. ........................... ............................ ............................ ............................ ............................ ............................ ...................... ........ 1 6.1
CRANE CAB & E NGINE MODULE ACCESS PLATFORMS – GENERAL I NFORMATION ............. ........................... ............................ ........................... ............. 1
6.2
MOUNTING PROCEDURE – CRANE CAB ACCESS PLATFORM............. ........................... ............................ ............................ ............................ ............................ .................... ...... 2
6.3
DISMOUNTING PROCEDURE – CRANE CAB ACCESS PLATFORM............. ........................... ............................ ............................ ............................ ............................ ................ 3
6.4
DISMOUNTING PROCEDURE – EMERGENCY USE O NLY.............. ............................ ............................ ............................ ............................ ............................ ........................... ............. 3
6.5
DISMOUNTING PROCEDURE – STEP LADDER FAILURE ............. ........................... ............................ ............................ ............................ ............................ ............................ ................ 4
6.6
MOUNTING PROCEDURE – E NGINE MODULE ACCESS PLATFORM .............. ............................ ........................... ........................... ............................ ......................... ........... 4
6.7
DISMOUNTING PROCEDURE – E NGINE MODULE ACCESS PLATFORM ............. ........................... ............................ ............................ ............................ .................... ...... 5
6.8
MOUNTING PROCEDURE – CRANE CARRIER DECK ............. ........................... ............................ ............................ ............................ ............................ ............................ .................... ...... 5
6.9
CRANE SLEWING AND USE .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 6
6.9.1 6.10 7
8
CARRIER DECK HANDRAILS - SYSTEM STAGES, USES AND PREREQUISITES ............. .......................... ........................... ............................ ....................... ......... 18
Access System Configuration Indicators.................. Indicators........ ..................... ..................... ..................... ..................... ..................... ..................... ..................... ...................... ..................... .......... 7 CRANE CARRIER OPERATION ............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ........................... ...................... ......... 11
TRANSPORTATION TRANSPORTA TION INFORMATION INFORMATION .............. ............................ ............................ ............................ ........................... ........................... ............................ ............................ ......................... ........... 1 7.1
FLAG HOLDERS ............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ................. .... 1
7.2
OPERATING WIDTH .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ........................ ........... 3
MAINTENANCE MAINTENAN CE SECTION .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................ 1 8.1
MAINTENANCE OVERRIDE K E EY Y .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 2
8.2
HYDRAULIC OIL TANKS .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ........................... .................. .... 4
8.3
WHEN R EQUIRED EQUIRED .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 5
8.3.1
Circuit Break Breaker er - Reset ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 5
8.3.2
Drain/Fill Point – Crane Engine Oil .................... ......... ..................... ..................... ...................... ..................... ..................... ..................... ..................... ..................... ..................... .............. ... 7
8.4
EVERY 10 SERVICE HOURS OR DAILY .............. ............................ ............................ ............................ ............................ ............................ ........................... ........................... ......................... ........... 9
Operating Instructions GMK 5220 - Supplement
8.4.1 8.5
EVERY 1000 SERVICE HOURS OR 6 MONTHS............. ........................... ............................ ............................ ............................ ............................ ............................ ............................ ................ 9
8.5.1
Bolts and Mounting Hardware ........................ ............. ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ................... ......... 9
8.5.2
Crane Cab Audib Audible le & Visual Indicator Indicatorss – Test ............ .......................... ............................ ............................ ............................ ............................ ............................ .................. .... 10
8.5.3
Engine Oil Drain/Refill Point Poi nt – Inspect..... Inspect................ ..................... ..................... ...................... ..................... ..................... ..................... ..................... ..................... ..................... ............. 10
8.5.4
Fire Exting Extinguisher....................... uisher..................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ......................... ........... 11
8.5.5
Hydraulic System – Inspect................ Inspect..... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ..................... .......... 12
8.5.6
Pivot Points – Lubric Lubricate ate .......................... ........................................ ............................ ............................ ............................ ............................ ............................ ............................ ......................... ........... 14
8.5.7
Step Edge Nosing – Inspe Inspect........... ct......................... ............................ ............................ ............................ ............................ ............................ ........................... ........................... ....................... ......... 17
8.6
8.6.1 8.7
8.7.1 9
Walk-Around Walk-A round Inspection Inspection ............ .......................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 9
EVERY 2000 SERVICE HOURS OR YEARLY .............. ............................ ............................ ............................ ............................ ............................ ........................... ........................... ................ .. 17
Rubber Bump Stops – Inspect .................... .......... ..................... ..................... ..................... ..................... ..................... ..................... ..................... ...................... ..................... ..................... ............. 17 EVERY 6 YEARS .............. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 17
Fire Extingu Extinguisher isher – Pres Pressure sure Test ............................ ......................................... ........................... ............................ ............................ ............................ ............................ ....................... ......... 17
LITERATURE LITERATU RE REFERENC REFERENCE E MATERIAL MATERIALS........................ S...................................... ............................ ............................ ............................ ............................ ............................ .................... ...... 1 9.1
MANITOWOC R EFERENCE EFERENCE MATERIAL ............ .......................... ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 1
Operating Instructions GMK 5220 - 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, lubrication and maintenance information for the crane access systems and must must be be used in conjunction with the cranes operation and maintenance manual – Publication No.: 3 112 310 en GMK 5220 – Operating Instructions Volumes 1 & 2 – 15-09-2006
Read, study and keep the operation and maintenance manual with the machine.
Whenever a question arises regarding the crane access systems, 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 systems.
Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on the crane access systems.
1.3
Operation The operation information is a reference for the new operator and a refresher for the experienced one. This information includes a description of the controls, their location and operation with respect to the crane access systems. Photographs and illustrations are provided to guide the operator through the correct operating procedures for the access systems.
Operating Instructions GMK 5220 - 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.
Operating Instructions GMK 5220 - Supplement
1-2
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, lubrication, maintenance maintenance or repair of this produc t can be dangerous and could result in in jury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read read and u nderstood the operation, lubrication, maintenance and repair 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: At ten tenti ti on ! B Beco eco me Aler A ler t! Your You r Safety Saf ety is in volv vo lved. ed.
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.
Operating Instructions GMK 5220 - Supplement
2-1
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 Proper care is your responsibili ty.
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 ful ly 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.
Operating Instructions GMK 5220 - Supplement
2-2
2 2.2
Safety Signs and Labels There are several specific safety signs on your machine. Their exact location and description of the hazard are reviewed in this section. Please take the time to familiarise yourself with these safety signs. Make sure that you can read all safety signs. Clean or replace these if you cannot read the words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvent, diesel etc.
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 and left side of the machine on the main frame for the access platforms
Operating Instructions GMK 5220 - Supplement
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2
This sign is located inside the cab adjacent to the right joystick control
This sign is located on the outside of the cab door adjacent to the door handle
Operating Instructions GMK 5220 - Supplement
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2
This sign is located on the side of the crane cab access ladder
This sign is located on the side of the engine module access ladder
Operating Instructions GMK 5220 - Supplement
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2
This sign is located in two places on top of the hydraulics cabinet for the access platforms
Operating Instructions GMK 5220 - Supplement
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2
This sign is located inside the crane carrier cab
This sign is located inside the crane cab adjacent to the right joystick control
Operating Instructions GMK 5220 - Supplement
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2
This sign is located inside each ground level access system control box
Operating Instructions GMK 5220 - Supplement
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2
This sign is located inside the crane cab adjacent to the access system controls
2.3
General Hazard Information Attach a “Do Not Operate” warning tag (as shown) to start switch or controls before servicing or repairing the machine.
Know the width of the vehicle so proper clearance can be maintained when operating near fences, boundary obstacles, etc.
Wear a hard hat, protective glasses and other protective equipment as required by job conditions.
Do not wear loose clothing or jewellery that can catch on controls or other parts of the machine.
Make certain all-protective guards and covers are secured in place on the machine.
Keep the machine, especially the deck, walkways and steps, free of foreign material, such as debris, oil, tools and other items i tems that are not part of the machine.
Secure all loose items such as personal protection equipment, lunch boxes, tools and other items Operating Instructions GMK 5220 - Supplement
2-9
2 that are not part of the machine in their appropriate locations.
Never put maintenance fluids into glass containers.
Report all needed repairs and do not allow unauthorised personnel on the machine.
Perform all maintenance unless otherwise specified as follows: The machine parked on level ground.
•
The transmission control in NEUTRAL.
•
The parking brake engaged.
•
The engine stopped.
•
The start switch key off and the key removed.
•
All disconnect switch keys are off and the keys locked-out or removed.
•
2.4
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 iinjury njury must treat it immediately.
2.5
Crushing or Cutting Prevention
Do not disconnect any hydraulic hoses unless the access access platforms are fully lowered. In a any ny position other than fully lowered the access system hydraulics will be pressurised. Releasing this pressure WILL result in uncontr olled movement of the access access platform. 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. Support equipment and attachments properly when working beneath them. Never attempt Operating Instructions GMK 5220 - Supplement
2-10
2 adjustments while the machine is moving or the engine is running unless otherwise specified.
Stay clear of all rotating and moving parts.
Retainer pins, when struck with force, can fly out and injure nearby persons. Make sure the area is clear of people when driving retainer pins.
Wear protective glasses when striking a retainer pin to avoid injury to your eyes.
Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying debris before striking any object.
2.6
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 systems before any lines, fittings or related items are disconnected or removed.
Fill point cap for the hydraulic oil tank which services the handrails Operating Instructions GMK 5220 - Supplement
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2
Fill point cap for the hydraulic oil tank which services the access platforms
2.7
Fire or Explosion Prevention
Damage of access platform 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 rea read d and und erstand 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 Proper care is your responsibili ty.
Keep all fuels and lubricants stored in properly marked containers and away from all unauthorised persons.
Store all oily rags or other combustible material in a protective container.
Do not weld or flame cut on or near hoses, tubes or pipes that contain flammable fluids.
Operating Instructions GMK 5220 - Supplement
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2 Remove all flammable materials such as diesel, oil and other debris before they accumulate on the machine.
Do not expose the machine to flames, burning brush, etc., if at all p possible. ossible.
2.7.1 2.7.1
Fire Extinguisher Location This machine has been fitted with one 4.5kg dry chemical powder fire extinguisher. It is to assist the operator to clear the machine in the event of a fire only and should not be used for major fire fighting operations.
Fire extinguisher located on the front of the hydraulics cabinet
Operating Instructions GMK 5220 - Supplement
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2 1
2
1) Safety Pin 2) Latch
To remove and operate the fire extinguisher: 1) Safely access the fire extinguisher. 2) Remove the safety pin (1). 3) Rotate the latch (2) outwards to release the hold on the fire extinguisher. 4) Remove the fire extinguisher from the mounting and egress the machine using the extinguisher in accordance with instructions outlined on the extinguisher label and mine site instructions.
Operating Instructions GMK 5220 - Supplement
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2 2.8
Lines, Tubes and Hoses
Damage of access platform 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 rea read d and und erstand 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 Proper care is your responsibili ty.
Do not bend or strike high-pressure lines. Do not install bent or damaged lines, tubes or hoses.
Replace any damaged hydraulic oil lines, tubes and hoses. hoses. Leaks can cause fires.
Check lines, tubes and hoses carefully. 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 S afety Section for more details.
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.
•
•
•
•
•
•
Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration, rubbing against other parts, and excessive heat during operation.
Operating Instructions GMK 5220 - Supplement
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3 3
Identification Information Data plates have been fitted to the access platforms and handrails which indicate the model number, safe working load (where applicable), date of manufacture and the serial number.
3.1
Carrier Handrails
Data plate details for the handrails
Data plate for the left side handrail
Operating Instructions GMK 5220 – Supplement
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3
Data plate for the right side handrail
3.2
Crane Cab Access Platform
Data plate details for the crane cab access platform
Operating Instructions GMK 5220 – Supplement
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3
Data plate located on the side of the crane cab platform
Data plate located on the main support for the crane cab access system
Operating Instructions GMK 5220 – Supplement
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3 3.3
Engine Module Access Platform
Data plate details for the engine engi ne module access platform
Data plate located on the side of the engine module platform
Operating Instructions GMK 5220 – Supplement
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3
Data plate located on the main support for the engine module access platform
Operating Instructions GMK 5220 – Supplement
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4 4
System Stages, Uses
4.1
General Description
Prerequisites
The engine module and crane cab access platforms are a four stage electric-over-hydraulic folding system. The access systems utilise 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 lowe r the access systems.
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 handrails.
Electrical power is only provided to the access systems if: The crane carrier par park k brake is applied and remains remains applied. Refer to section ‘Crane •
Carrier Operation’ in the Transportation Information section of this manual.
•
Both machine isolation points are in the connec connected ted position. Refer below below for locations on the locations of isolation points. poi nts. Refer to third party instructions on the use of the isolators.
Isolator for the upper engine is located at the left rear of the crane on the ancillary compartment
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4
Isolator – upper engine
Isolator for the lower engine is located at the front right of the crane carrier
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4
Isolator – lower engine
The system comprises of: 1) Left side access platform platform to to the crane cab 2) Right side access platform to the crane engine module 3) Left and Right crane carrier deck mounted mounted handrails
4.2
Crane Cab Access Platform - System Stages, Uses and Prerequisites The crane cab access platform is located on the left side of the machine (with the crane superstructure position at 180°) with controls located inside the crane cab and at ground level at the right and left sides 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.
Operating Instructions GMK 5220 - Supplement
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4
Fully Lowered Crane Cab Access Platform
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4 4.2.1 4.2.1
Stage 1 Raise Start/Stage 4 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 completely lowering the access system
Positional indicator label located inside the crane cab adjacent to the access system controls
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4
Stage 1 Raise Raise Start/Stage 4 Lower Fini sh
To enable this configuration: The carrier park brake must be applied. •
•
The superstr superstructure ucture must must be facing forward forward (between -179.90° and +180.10°) or rearward rearward (between -000.10° and +000.10°) for the step ladder to lower.
•
Both machine isolation points are in the connected position.
With the access platform in the fully lowered position the system now p provides: rovides:
Access to the crane operator cab from ground level.
Access to the electrical and battery boxes.
Access onto the the carrier carrier deck from the platform forward of the cab.
•
•
•
With the access system in this position the:
•
Operating Instructions GMK 5220 - Supplement
Superstructure cannot slew.
4-6
4 4.2.2 4.2.2
Stage 2 Raise Start/Stage 3 Lower Finish
If the crane counterweights are positioned on the carrier deck then the crane cab access platform must be fully retracted before sle slewing. wing. Failure to do so will result in damage of the crane cab latform.
This is the recommended position for the operator cab access platform when the crane is in use as the superstructure can slew in this configuration. This is NOT NOT the configuration for slewing when there are counterweights on the carrier deck.
Stage 2 Raise Raise Start/Stage 3 Lower Fini sh sh
The access step ladder has now rotated through 150 degrees to enclose the platform and provides:
•
Access from the crane operator cab onto the carrier deck (Stage 1 Raise Start/Stage 4 Lower Finish).
To enable this configuration the:
Carrier park brake must be applied.
Both machine isolation points are in the connected position.
•
•
Operating Instructions GMK 5220 - Supplement
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4 With the access system in this position the:
•
Superstructure can slew. If the Engine Module is in the fully raised position the green visual indicators (located at the rear of each side of the superstructure and inside the crane cab) will illuminate. Refer to section section Ac Ac cess ces s System Sys tem Con Confi fi gu rat io n Ind Indic ic ato rs in rs in the Mounting
•
and Dismounting section of this manual for additional information. Last st stage age of lowering will only occur if the crane superstructure superstructure is facing facing forward (between -179.90° and +180.10°) or rearward (between -000.10° and +000.10°).
4.2.3 4.2.3
Stage 3 Raise Start/Stage 2 Lower Finish
If the crane counterweights are positioned on the carrier deck then the crane cab access platform must be fully retracted before sle slewing. wing. Failure to do so will result in damage of the crane cab latform.
This is an intermediate stage and is not a recommended position of the platform when the crane is in use. However it does allow the crane operator to step off the platform onto the carrier deck in an emergency from a slew position other than 0° and 180°. This is NOT NOT the the configuration for slewing when there are counterweights on the carrier deck.
Stage 3 Raise Raise Start/Stage 2 Lower Fini sh sh
Operating Instructions GMK 5220 - Supplement
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4 The platform handrail has folded down through 90 degrees onto the platform and the system now provides:
•
Emergency egress from the crane cab.
To enable this configuration: The carrier park brake must be applied. •
•
Both machine isolation points are in the connected position.
With the access system in this position the:
•
4.2.4 4.2.4
Superstructure can slew.
Stage 4 Raise Start/Stage 1 Lower Finish
If the crane counterweights are positioned on the carrier deck then the crane cab access platform must be fully retracted before sle slewing. wing. Failure to do so will result in damage of the crane cab latform.
The step ladder has now folded down onto the platform. This is NOT NOT a a recommended position of the platform including when the crane is in use and when there are counterweights on the carrier deck.
Stage 4 Raise Raise Start/Stage 1 Lower Fini sh sh
Operating Instructions GMK 5220 - Supplement
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4 To enable this configuration:
The carrier park brake must be applied.
Both machine isolation points are in the connected position.
•
•
With the access system in this position the: Superstructure can slew. •
4.2.5 4.2.5
Stage 4 Raise Start/Stage 1 Lower Start
The crane cab door must be closed before completing the final stage of raising the crane cab platform. Failure to do so will result in damage of the crane cab door.
If the crane counterweights are positioned on the carrier deck then the crane cab access platform must be fully retracted before sle slewing. wing. Failure to do so will result in damage of the crane cab latform. 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. The crane cab door must be closed for the platform to complete its last stage of raising. Failure to do so will result in damage to the crane cab door. This is also the position the crane cab access platform must be in if the crane’s counterweights are to be removed, or are on the carrier deck prior to slewing. Failure to do so will result in damage of the crane cab platform.
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4
Stage 4 Raise Raise Finis h/Stage 1 Lower Start Start
To enable this configuration:
The carrier park brake must be applied.
Both machine isolation points are in the connected position.
Crane cab door must be closed.
•
•
•
With the access system in the fully raised position the:
Superstructure can slew.
Carrier park brake can be released.
Crane carrier can be driven.
•
•
•
4.3
Engine Module Access Platform - System Stages, Uses and Prerequisites The engine module access platform is located on the right side of the machine (with the crane superstructure position at 180°) with controls located at ground level at the right and left sides 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.
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4
Fully Lowered Engine Module Access Platform 4.3.1 4.3.1
Stage 1 Raise Start/Stage 4 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 system or the beginning stage of the raising sequence of the system. 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.
Positional indicator label to reference when completely lowering the access system
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4
Positional indicator label located inside the crane cab adjacent to the access system controls
Stage 1 Raise Raise Start/Stage 4 Lower Fini sh sh
To enable this configuration:
The carrier park brake must be applied.
The superstr superstructure ucture must must be facing forward forward (between -179.90° and +180.10°) or rearward rearward
•
•
(between -000.10° and +000.10°) for the step ladder to lower.
•
Operating Instructions GMK 5220 - Supplement
Both machine isolation points are in the connected position. 4-13
4 With the access platform in the fully lowered position the system provides:
•
Access to the engine module and the ac access cess syst system em hydraulic module from ground level.
With the access system in this position the:
•
4.3.2 4.3.2
Superstructure cannot slew.
Stage 2 Raise Start/Stage 3 Lower Finish The access step ladder has now rotated tthrough hrough 150 degrees to enclose the platform. Personnel are not permitted on the access platform at this intermediate stage.
Stage 2 Raise Raise Start/Stage 3 Lower Fini sh sh
To enable this configuration:
The carrier park brake must be applied.
The superstr superstructure ucture must must be facing forward forward (between -179.90° and +180.10°) or rearward rearward
•
•
(between -000.10° and +000.10°).
Both machine isolation points are in the connected position.
Hydraulic cabinet and engine bay doors must be closed.
•
•
With the access system in this position the:
•
Operating Instructions GMK 5220 - Supplement
Superstructure cannot slew.
4-14
4 4.3.3 4.3.3
Stage 3 Raise Start/Stage 2 Lower Finish The platform handrail has folded down through 90 degrees onto the platform. Personnel are not permitted on the access platform at this intermediate stage.
Stage 3 Raise Raise Start/Stage 2 Lower Fini sh sh
To enable this configuration:
The carrier park brake must be applied.
The superstr superstructure ucture must must be facing forward forward (between -179.90° and +180.10°) or rearward rearward
•
•
(between -000.10° and +000.10°). •
•
Both machine isolation points are in the connected position. Hydraulic cabinet and engine bay doors must be closed.
With the access system in this position the:
•
Operating Instructions GMK 5220 - Supplement
Superstructure cannot slew.
4-15
4 4.3.4 4.3.4
Stage 4 Raise Start/Stage 1 Lower Finish The step ladder has folded down onto the platfo platform. rm. Personnel are not allowed on th the e access platform at this intermediate stage.
Stage 4 Raise Raise Start / Stage 1 Low er Finish
To enable this configuration:
The carrier park brake must be applied.
The superstr superstructure ucture must must be facing forward forward (between -179.90° and +180.10°) or rearward rearward
•
•
(between -000.10° and +000.10°).
Both machine isolation points are in the connected position.
Hydraulic cabinet and engine bay doors must be closed.
•
•
With the access system in this position the:
•
Operating Instructions GMK 5220 - Supplement
Superstructure cannot slew.
4-16
4 4.3.5 4.3.5
Stage 4 Raise Finish/Stage 1 Lower Start
NOTICE The superstructure will only s lew if the engine module access platform is in the fully raised position (Stage 4 Raise Finish/Stage 1 Lower Start).
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 is to be driven or the superstructure is to be used.
Stage 4 Raise Raise Finis h/Stage 1 Lower Start Start With the access system in the fully raised position the:
Superstructure can slew.
Carrier park brake can be released.
Hydraulic cabinet and engine bay doors must be closed.
•
•
•
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4 4.4
Carrier Deck Handrails - System Stages, Uses and Prerequisites
NOTICE The handrails are installed solely to provide a safe workwork area when undertaken maintenance or inspection is being on the crane.
Electrical power is only provided to the access system if the crane carrier park brake is applied (and remains applied) and when the crane superstructure is facing forward (+180°). 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. 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. 4.4.1 4.4.1
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°).
Both machine isolation points are in the connected position.
•
•
•
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4 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.
•
•
4.4.2 4.4.2
Handrails Raised
NOTICE The crane superstructure will not slew if the carrier deck handrails are in the raised position. Therefore to slew, the carrier deck handrails must be lowered. Handrails have rotated through 90 degrees. The position allows for safe 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°).
Both 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 is from the platform
•
•
forward of the cab. Operating Instructions GMK 5220 - Supplement
4-19
5 5
System Controls
5.1
Handrails, Crane Cab
Indicators
Engine Module Access Platforms
Controls to operate the access systems are located inside the crane cab and at ground level on the right and left sides of the the crane carrier cab (behind the carrier doors). doors). Due to the arrangement of the machine however, only the controls closest to the access platform will operate the hydraulics. For example: If the crane superstructure is facing forward (180° position) with respect to the crane carrier (ie. The crane cab platform is on the left hand side of the carrier) then only the left hand side controls will operate the crane cab access platform hydraulics. Conversely, if the crane superstructure is facing rearward (0° position) with respect to the crane carrier (ie. The crane cab platform is on the right hand side of the carrier) then only the right hand side controls will operate the crane cab access platform platform hydraulics. The crane cab controls for the access system will only ever operate the crane cab access platform regardless of the orientation of the superstructure.
The ground level controls will only work at 0° and 180° positions, whereas the controls in the crane cab can operate the crane cab access platform in any angular position with respect to the crane carrier (ie. from ±0° to ±180°).
However, stage 1 of raising (same as stage 4 of lowering) will only function if the crane superstructure is positioned forward (between -179.90° and +180.10°) or rearward (between 000.10° and +000.10°). The crane superstructure will not slew if the crane cab access platform is
Operating Instructions GMK 5220 - Supplement
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5 fully lowered, ie. the rear ladder is lowered.
The access controls utilised on this machine are of the momentary push button type. This necessitates 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 siren located inside the hydraulics cabinet will sound to warn personnel around the machine that the access systems are being operated.
Crane cab controls for the access system
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5 1
3
2
4
Crane cab access platform controls include: 1) Access System Raise 2) Access System Lower 3) Access System Light 4) Access System Configured To Slew Indicator
There is a sign located inside the cab to indicate the functions for the crane cab controls Operating Instructions GMK 5220 - Supplement
5-3
5
Labelling of the access system crane cab controls
Ground level controls for the access system located at the front right and left side of the crane carrier
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5
Ground level controls for the access system (door closed)
Ground level controls for the access system (door open)
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5 1
2
3
4
Controls located within the compartment include: 1) Access Platform Raise 2) Access Platform Lower 3) Carrier Handrail Raise 4) Carrier Handrail Lower
5.2
Access System Lighting
NOTICE No lighting provided for the engine bay access platform. Maintenance and inspection procedures procedure s in low light conditions must include sufficient lig hting to illuminate required are areas. as.
Located at the left rear of the superstructure is an access light fitted to illuminate the crane cab access platform and ladder. The light is automatically operated in conjunction with the access system controls on a timed period. After a pre-set time period the access light will switch off. If mounting the machine from ground level with the access platforms in the fully lowered position momentarily push any access system control and the light will illuminate for a pre-set period of time.
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5
Access system lighting control located inside the crane cab
Access system light located at the left rear of the superstructure superstructure
If at anytime illumination of the crane carrier access system is required when dismounting from the crane cab, simply depress the button mounted in the crane cab and the light will illuminate for a pre-set period of time and then switch off.
5.3
Ancillary Compartment Dealer fitted electrical components to the left rear of the crane cab have been relocated to an ancillary panel to left rear of the superstructure accessible from ground level (depending on the angular position of the crane).
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5
Ancillary compartment located at the left rear of the crane crane
Ancillary compartment
Located on the ancillary compartment is a circuit breaker for the access platforms.
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6 6
Mounting
6.1
Crane Cab
Dismounting Procedures
Engine Module Access Platforms – General
Information
Mount and dismount dismount the machine only where steps, ladders and/or and/or handholds are provided.
Inspect, an and d when necessary, clean and have repairs mad made e to steps and handholds before
•
•
mounting and dismounting.
Face the machine when mounting and dismounting.
Maintain a three-point contact (two (two feet and one hand or one foot and two hands contact) contact) with
•
•
the steps and handholds.
Never get on or off a moving machine.
Never jump off the machine.
Do not try to climb on or off the machine when carrying tools or supplies. Use a hand line to pull
•
•
•
equipment up onto the platform.
Do not use any controls as handholds.
Ensure ad adequate equate lighting for mounting and and dismounting of the machine in low light conditions.
Ensure that the the system systems s are in the fully lowered position before mounting the the platforms. platforms.
•
•
•
Operating Instructions GMK 5220 - Supplement
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6 6.2
Mounting Procedure – Crane Cab Access Platform
NOTICE With the ladder in the down position the superstructu re cannot slew. Lowering of the access system from Stage 4 Raise Finish to Stage 1 Lower Start with the superstructure in the forward position (between -179.90° and +180.10°) or rearward position (between -000.10° and +000.10°):
1.
Ensure that the carrier park brake is applied.
2.
Ensure both machine isolation switches (crane carrier mounted switch and and the crane switch) are in the connected position.
3.
Go to the ground level controls for the crane cab access system situated at the fr front ont of the crane carrier. If the superstructure is in the forward position (between -179.90° and +180.10°) then the left side controls must be used. If the superstructure is in the rearward facing position (between -000.10° and +000.10°) then the right side controls must be used.
4.
Ensuring that the ar area ea is free from personnel use the appropriate control to lower the access system. Continue to depress the control until the system has cycled through all stages and the step ladder is in the down position. If at any stage during lowering an intermediate stage is required simply release the control and the system will stop.
Operating Instructions GMK 5220 - Supplement
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6 6.3
Dismounting Procedure – Crane Cab Access Platform To dismount the crane cab after use of the crane:
1.
Slew the machine to the forward forward position (between (between -179.90° and +180.10°) or rearward position (between -000.10° and +000.10°). There are visual displays installed in the crane cab which indicate when this has been achieved. Note: if the crane carrier is required to be driven, the cab access platform must be returned to the left side of the machine ie. the forward position (between -179.90° and +180.10°).
2.
Check to ensure that the area is free free from personnel and that there is sufficient clearance for the step ladder to lower.
3.
With the crane in the forward position (between -179.90° and +180.10°) or rearward position (between -000.10° and +000.10°) operate the controls in the crane cab to lower the system. Continue operating the controls until the step ladder is in the fully down position.
4. 5.
Dismount the crane cab via the access platform platform and step ladder. If the crane carr carrier ier is required to be driven locate the controls on the right side of the machine and completely raise the access system until Stage 4 Raise has been achieved.
6.4
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 step ladder to ground level):
1.
Slew the machine to any position which allows for eg egress ress from the crane cab and onto the carrier deck via the side access platform.
2.
Ensure that the access system is in the operational position ie. The platform is down and the handrails are up.
3.
Dismount the crane cab onto the carrier carrier deck.
4.
Exit the cab onto the carrier deck and locate the fire extinguisher (if accessible) mounted on the front of the hydraulics cabinet.
5.
Dismount from tthe he carrier deck to ground level via the standard machine ladders where possible.
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6 6.5
Dismounting Procedure – Step Ladder Failure If the step ladder fails to completely open and egress from the crane cab is not available via the step ladder use the procedure for emergency use of the system as outlined above.
6.6
Mounting Procedure – Engine Module Access Platform
NOTICE The superstructure will only s lew if the engine module access platform is in the fully raised position (Stage 4 Raise Finish/Stage 1 Lower Start).
To mount the engine module access platform from Stage 4 Raise Finish/Stage 1 Lower Start:
1.
Ensure that the carrier park brake is applied.
2.
Ensure both machine isolation switches (crane carrier mounted switch and and the crane switch) are in the connected position.
3.
Ensure that the crane engine access doors and the hydraulic cabinet doors are closed.
4.
Ensure that the superst superstructure ructure is positioned in eit either her the forward position (between 179.90° and +180.10°) or rearward position (between -000.10° and +000.10°).
5.
Go to the rrequired equired ground level controls for the access system situated at the front of the crane carrier. If the superstructure is in the forward position (between -179.90° and +180.10°) then the right side controls must be used. If the superstructure is in the rearward position (between -000.10° and +000.10°) then the left side controls must be used.
6.
Ensuring that the area is free from personnel use the appropriate control to lower the access system. Continue to depress the control until the system has cycled through all stages and the step ladder is in the down position. If at any stage during lowering an intermediate stage is required simply release the control and the system will stop.
Operating Instructions GMK 5220 - Supplement
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6 6.7
Dismounting Procedure – Engine Module Access Platform To dismount the engine module access system after use: 1.
Orientate the machine int into o the forward position ((between between -179.90° and +180.10°) or rearward position (between -000.10° and +000.10°) and use the cab controls to lower the system only after checking that it is free from personnel.
2.
Dismount the machine via the access platform and rear ladder.
3.
With the crane in the forward position (between -179.90° and +180.10°) or rearward position (between -000.10° and +000.10°) operate the ground level controls to raise the system. Continue operating the controls until the step ladder is in the fully raised position.
6.8
Mounting Procedure – Crane Carrier Deck
NOTICE The handrails handrails are installed solely to p rovide 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 posit ion. To raise the handrails of the carrier deck to provide for a safe work area for maintenance and inspection:
1. 2.
Ensure that the carrier park brake is applied. Ensure both machine isolation switches (crane carrier mounted switch and and the crane switch) are in the connected position.
3.
Check to ensure th that at the superstruct superstructure ure is in the fo forward rward position (between -179.90° and +180.10°). If the superstructure is in any other position other than the forward position follow procedures for mounting the crane cab via the access system and orientate the superstructure so that it is in the forward position (between -179.90° and +180.10°). If the superstructure is already in the forward position follow procedures for mounting of the crane cab access system.
4.
Once the cra crane ne cab access system is in the fully down position, go to the rrequired equired ground level controls for the handrails situated at the front of the crane carrier. The left side
Operating Instructions GMK 5220 - Supplement
6-5
6 controls operate the left side handrail and the right side controls operate the right handrail. 5.
Ensuring that the ar area ea is free from personnel use the appr appropriate opriate 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.
6.
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.
7.
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.
6.9
Crane Slewing and Use If the crane counterweights are positioned on the carrier deck then the crane cab access platform must be fully retracted before sle slewing. wing. Failure to do so will result in damage of the crane cab latform.
NOTICE DO NOT LOWER CAB ACCESS PLATFORM LA DDER WHEN COUNTER COUNTERWEIGHT WEIGHT WINGS ARE FITTED. DAMAGE TO THE ACCESS SYTEM MAY RESULT IF LADDER IS LOWERED WITH COUNTERWEIGHT WINGS FITTED.
To allow use of the crane superstructure:
1.
Follow steps outlined in the m mounting ounting procedure for the crane cab access platform.
2.
Ensure that the engine module access platform is in the ffully ully raised position.
NOTICE The superstructure will only slew with the engine module access platform in the fully raised position (Stage 4 Raise Finish/Stage 1 Low er Start).
3.
Operating Instructions GMK 5220 - Supplement
Access the crane cab and perfor perform m all manufactur manufacturer er instructions to to commence use use of the
6-6
6 crane. 4.
Check to ensure that there are no counterweights on tthe he carrier deck. If there are no counterweights present on the carrier deck, raise the access system until Stage 2 Raise Start/Stage 3 Lower Finish arrangement has been achieved. If there are counterweights on the carrier deck then the crane cab access platform must be fully raised. When raising the crane cab access system to the fully retracted position ensure that the crane carrier door is closed.
5. 6.9.1 6.9.1
Operate the crane in accordance with manufacturer and mine site instructions. instructions.
Access System Configuration Indicators There are green visual indicators at the right and left sides of the crane superstructure as well as an indicator located inside the crane cab which illuminates when the access systems are in the correct configuration to allow for crane slewing and use.
When illuminated the:
Crane cab access plat platform form is at Stage 2 Raise Start/Stage 3 Lower Finish or higher.
Engine mo module dule acce access ss plat platform form is at Stage 4 Raise Finish/Stage 1 Lower St Start art
•
•
Crane cab access platform at Stage 2 Raise Start/Stage 3 Lower Finish
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6
Engine module access platform at Stage 4 Raise Finish/Stage 1 Lower Start
Green visual indicator on the crane cab side of the machine
Operating Instructions
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GMK 5220 Supplement
6
Green visual indicator on the engine module side of the machine
External Visual indicator
Operating Instructions
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GMK 5220 Supplement
6
Crane Cab Mounted Indicator
Operating Instructions
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GMK 5220 - Supplement
6 6.10
Crane Carrier Operation 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.
NOTICE Alw ays op erat e the th e cr ane in acc or dan dance ce wi th manufacture and and mine site instru ctions.
Crane cab mounted audible and visual alarms
Operating Instructions
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Crane cab mounted indicators
Operating Instructions
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Transportation Information
7.1
Flag Holders Brackets to allow for temporary fitting of wide load flags have been fitted to the front right and left sides of the machine as well as both sides of the rear. Use the flag holders in accordance with applicable mine site and government road rules and regulations.
Flag holders located at the front right and left side of the machine
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Front left flag holder
Flag holders located at the rear right and left side of the machine
Operating Instructions
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Rear left flag holder
7.2
Operating Width
NOTICE Fitment of access platforms to this machine has increased the crane carrier’s travel and transport w idth t o 3900mm. 3900mm. There is a sign located inside the crane carrier cab to remind the operator of the crane carrier operating width of the vehicle.
Operating Instructions
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Operating width label located on the centre console
Operating Instructions
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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 th e machine. machine.
Disconnection of hydraulic hoses and removal of supporting pins and bolts of the access systems may result in unintended machine movement and/or release of stored energy. Personal injury or death may result. Before disassembly of any any compo nents of the access system ensure that stored energy has been relieved and components are chocked/blocked to prevent unintended movement.
NOTICE No lighting is provided for the engine bay access platform. Maintenance and inspection procedures in low light conditions must include sufficient lighting to illuminate required areas.
NOTICE You must read and understand the warnings and instructions contained in the Safety Section Se ction o f this m anual, before performing any maintenance proc edures.
Operating Instructions
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GMK 5220 - Supplement
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Maintenance Override Key
To prevent damage to the access systems, crane carrier and the superstructure ensure that all step ladders are in the raised position when slewing with the maintenance override key in the override override position. Fa Failure ilure to do so will result in damage to the access systems, crane carrier and the superstruc ture. This machine has been fitted with a maintenance override switch adjacent to the engine module platform 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. 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 switch located on the side of the hydraulics cabinet
Operating Instructions
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Maintenance override switch (lid closed)
Maintenance override switch (lid open)
Operating Instructions
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GMK 5220 - Supplement
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Hydraulic Oil Tanks Replace the hydraulic oil and in-tank filter 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. Refill capacity of each tank is approximately 20 litres.
Fill point cap for the hydraulic oil tank which services the handrails
Fill point cap for the hydraulic oil tank which services the platforms
Operating Instructions
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Hydraulic oil tank level for both tanks should be at the black line indicated
8.3
When Required
8.3.1 8.3.1
Circuit Breaker - Reset This machine has been fitted with two additional 105 Amp circuit breakers for the handrails and the access platforms. The handrail circuit breaker is located at the front right of the crane carrier and the circuit breaker for the access platforms is located on the ancillary compartment at the left rear of the crane. Reset the circuit breakers when required. If a circuit breaker continually trips have the circuit checked.
Operating Instructions
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Access platforms circuit breaker located at the left rear of the crane on the ancillary compartment
Access platforms circuit breaker
Operating Instructions
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Handrails circuit breaker located at the front right of the crane carrier
Handrails circuit breaker
8.3.2 8.3.2
Drain/Fill Point – Crane Engine Oil The crane engine oil sump has been fitted with a drain/refill point that is now located on the right side of the crane superstructure and is accessible from ground level. Use the drain/fill point in accordance with procedures outlined by the manufacture for oil replacement intervals, refill capacities as well as the type of oil and the viscosity required.
Operating Instructions
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Crane engine oil drain/refill point located at the right rear of the crane superstructure
2
1
3
Crane engine oil drain/refill point
To use the drain/refill point on this machine: 1.
Remove the cap (1).
2.
Connect hose tto o the quick release coupling (2). (2).
3.
Turn tthe he lever (3) to open the valve.
4.
Drain/fill the tank as required remembering remembering that the oil maybe hot if the machine has just been running. Refer to the Manitowoc manual for the refill capacity of the crane engine
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When finished draining/refilling close the valve by turning the lever (3).
6.
Remove tthe he drain/fill hose from the quick coupling.
7.
Replace the cap (1).
8.4
Every 10 Service Hours or Daily
8.4.1 8.4.1
Walk-Around Inspection Perform a walk-around inspection on the machine prior to operation.
Clean the access steps from any rubbish build-up or debris.
Visually inspect components for damage damage and wear and tear. Have any damaged or missing missing
•
•
components repaired or replaced.
•
Check to ensure that the access light located at the left rear of the crane superst superstructure ructure operates in conjunction with the access system controls.
Check to ensure that the audible alarms located adjacent to each hydraulic oil tank sound whenever the access system controls are activated.
Check to ensure all labels can be read and are visible in conjunction with the Safety Signs
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•
and Labels section of this manual. Replace label/s if they cannot be read or are missing.
•
Visually inspect all hydraulic lines, hoses, fittings and hose clamps for security, security, damage, deterioration and leaks. Check for pools of oil under the machine which may indicate a possible problem or damaged item.
•
Visually inspect all switches of the system. Ensure comp components onents mounted mounted on the an ancillary cillary compartment are secure and tight. Have any damaged items repaired or replaced.
•
Check the level of both hydraulic oil tanks. Top-up if required referring referring to section Hydraulic Oil Tanks in Tanks in the Maintenance Section of this manual.
8.5
Every 1000 Service Hours or 6 Months
8.5.1 8.5.1
Bolts and Mounting Hardware Check the tightness of all bolts fitted to the access systems. This includes checking the standard deck bolts as well as the handrails, access platforms and their mountings as well as the stair treads.
Operating Instructions
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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.
Crane carrier cab mounted audible and visual alarms 8.5.3 8.5.3
Engine Oil Drain/Refill Point – Inspect Inspect the crane engine oil drain/refill point for damage and security. Ensure that the fittings are not leaking and the mounting bolts are secure. Inspect the hose which runs to the engine sump for damage and security. Have the hose replaced if damaged or leaking.
Operating Instructions
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Crane engine oil drain/refill point hose
8.5.4 8.5.4
Fire Extinguisher Perform the following maintenance on the fire extinguisher:
•
Remove the extinguisher fr from om the mounting and turn the fire extinguisher upside down for 10 minutes to ensure that the powder is free flowing. After 10 minutes return the extinguisher back to the mounting checking to ensure that the mounting bracket is secure and the strap holding the extinguisher is tight.
•
Check to ensure that the pressur pressure e is in the green zone. Have the extinguisher serviced by a registered fire extinguisher service organisation or replace the extinguisher.
Check to ensure that there are no blockages to to the nozzle or outlet.
If an extinguisher is discharged, even partially, it needs to be refilled by a registered fire
•
•
extinguisher service organisation.
Operating Instructions
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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.
Operating Instructions
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Hydraulics cabinet (lid closed)
Components within the hydraulic cabinet
Operating Instructions
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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 each side platform. Grease both the engine module and crane cab access platforms.
Two grease points for the crane cab access platform
The points where the ladder rotates on the pivoting arms are also required to be greased at this interval. This includes two points on the crane cab side and two points on the engine module side.
Operating Instructions
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Outer end cap for the crane cab ladder
Outer end cap for the engine module access ladder
Operating Instructions
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End cap (1) and mating surface required to be greased
To grease the end cap matting surface of the access ladders: 1.
Remove the bolt holding the end cap.
2.
Remove the end ca cap p (1) and a apply pply grease to the mating surface. Note: the entire sur surface face is not required to be grease only the outer ¼ of the mating surface.
3.
Replace the end cap (1).
4.
Apply Loctite to the bolt and reinstall. reinstall. Tighten the bolt to the torque value indicated in table 1.
5.
Repeat this procedure tthree hree more times ffor or the remaining end caps.
TORQUE SETTING Bolt Specification: Specificatio n: M16 grade 8.8
Operating Instructions
Torque: 210 Torque: 210 N/m
8-16
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8 8.5.7 8.5.7
Step Edge Nosing – Inspect Check to ensure all step-edge nosing is secure and not missing. Replace nosing as required. Also check the condition of anti-slip and black and yellow tape fitted around the machine. Replace as required.
Stair edge nosing, anti-slip and black and yellow tape located on the engine module access platform
8.6
Every 2000 Service Hours or Yearly
8.6.1 8.6.1
Rubber Bump Stops – Inspect Inspect the condition of rubber bump stops mounted to the access system. Replace as required.
8.7
Every 6 Years
8.7.1 8.7.1
Fire Extinguisher – Pressure Test Ensure the fire extinguisher is pressure tested by a registered fire extinguisher service organisation.
Operating Instructions
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Typical bump stops located on the crane cab access ladder
Operating Instructions
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Literature Reference Materials
9.1
Manitowoc Reference Material The following literature can be obtained through Manitowoc Crane Group.
3 112 310 en
GMK 5220 – Operat Operating ing Instructions Instructions Volumes 1 & 2 – 15-09-2006
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