Grove GMK7450 Ingles

8/10/2019 Grove GMK7450 Ingles

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ADE004631

REV00

Ph: +61 7 3865 2660 www.ade.net.au

Operation andMaintenance

ManualSupplement

Grove GMK 7450

All Terrain Crane


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GMK 7450 - Supplement

1 OVERVIEW........................................................................................................................................................................ 1

1.1 LITERATURE INFORMATION.......................................................................................................................................... 1

1.2 SAFETY......................................................................................................................................................................... 11.3 OPERATION .................................................................................................................................................................. 1

1.4 MAINTENANCE............................................................................................................................................................. 2

2 SAFETY............................................................................................................................................................................... 1

2.1 IMPORTANT SAFETY INFORMATION.............................................................................................................................. 1

2.2 SAFETY SIGNS AND LABELS ......................................................................................................................................... 3

3 IDENTIFICATION INFORMATION.............................................................................................................................. 1

3.1 ACCESS SYSTEM IDPLATE........................................................................................................................................... 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




4.2.5 Stage 5 Raise Finish/Stage 1 Lower Start............................................................................................................... 94.3 CARRIER DECK HANDRAILS -SYSTEM STAGES,USES AND PREREQUISITES............................................................... 10

4.3.1 Handrails Lowered .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... ........... .......... ....... 10

4.3.2 Handrails Raised .................... .......... ........... ........... .......... ........... ........... .......... ........... .......... .......... ........... .......... 11

5 SYSTEM CONTROLS & INDICATORS ........................................................................................................................ 1

5.1 CRANE CARRIER DECK HANDRAIL &CRANE CAB ACCESS PLATFORM CONTROLSRIGHT SIDE ............................... 2

5.2 CRANE CARRIER DECK HANDRAIL CONTROLSLEFT SIDE......................................................................................... 3

5.3 ACCESS SYSTEM CRANE CAB CONTROLS..................................................................................................................... 4

6 MOUNTING & DISMOUNTING PROCEDURES......................................................................................................... 1

6.1 CRANE CAB ACCESS PLATFORMGENERAL INFORMATION ........................................................................................ 1

6.2 MOUNTING PROCEDURECRANE CAB ACCESS PLATFORM......................................................................................... 2

6.3 CRANE OPERATIONACCESS SYSTEM CONFIGURATION............................................................................................. 3

6.4 DISMOUNTING PROCEDURECRANE CAB ACCESS PLATFORM.................................................................................... 4


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6.5 CRANE CARRIER OPERATIONACCESS SYSTEM CONFIGURATION.............................................................................. 5

6.6 DISMOUNTING PROCEDUREEMERGENCY USE ONLY................................................................................................. 7

6.7 DISMOUNTING PROCEDUREACCESS SYSTEM LADDER FAILURE ............................................................................... 7

6.8 MOUNTING PROCEDURECRANE CARRIER DECK....................................................................................................... 8

7 TRANSPORTATION INFORMATION .......................................................................................................................... 1

7.1 OPERATING WIDTH ...................................................................................................................................................... 1

8 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 INTERVALWHEN REQUIRED............................................................................................................. 8

8.4.1 Additional Circuit Breaker - Reset................... ........... ........... .......... ........... ........... ........... .......... ........... .......... ....... 8

8.5 MAINTENANCE INTERVALEVERY 10SERVICE HOURS OR DAILY............................................................................ 10

8.5.1 Walk-Around Inspection ....................................................................................................................................... 10

MAINTENANCE INTERVALEVERY ................................................................................................................................ 12

8.6 1000SERVICE HOURS OR 6MONTHS.......................................................................................................................... 12

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 MAINTENANCE INTERVALEVERY 2000SERVICE HOURS OR YEARLY..................................................................... 15

8.7.1 Rubber Bump Stops Inspect .......... .......... ........... ........... ........... ........... .......... ........... ........... .......... ........... .......... 15

9 LITERATURE REFERENCE MATERIALS.................................................................................................................. 1

9.1 MANITOWOC REFERENCE MATERIAL........................................................................................................................... 1


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1

Overview 1-1


1 Overview

1.1 Literature Information

The operation and maintenance manual supplement should be stored in both the carrier and the

crane operators 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.


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1

Overview 1-2


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 WhenRequired 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.


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2

Safety Section 2-1


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:

At tention! Become Aler t! 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.


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Safety Section 2-2


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 andothers. You should also ensure that the product would not be damaged or made unsafe by the

operation, lubrication, maintenance or repair procedures you choose.

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.

Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation andMaintenance Manual. Failure to follow theinstructions or heed the warnings could result

in injury or death. Contact AustralianDiversified Engineering for replacementmanuals. Proper care is your responsibili ty.

Before operating any of the access systemsensure that the gear selector is in neutral andthe park brake is engaged. Do not release thepark brake, move the gear selector or throttlepedal if any of the access systems are not ful lyretracted.


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2

Safety Section 2-3


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


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2

Safety Section 2-4


This sign is located in three places on the side of the

access system ladder


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Safety Section 2-5


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


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Safety Section 2-6


Sign located on the left side of the crane carrier deck

This sign is located on the cover for the access system frame


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2

Safety Section 2-7


This sign is located on top of the hydraulics cabinet for the crane

carrier deck handrails


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Safety Section 2-8


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


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Safety Section 2-9


This sign is located inside each ground

level access system control box

(left side control box shown)


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Safety Section 2-10


This sign is located inside the crane cab adjacent to the access

system controls


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3

Identification Information 3-1

GMK 7450 Supplement

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


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Identification Information 3-2

GMK 7450 Supplement

Data plate located beneath each ground level

control box


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4

System Stages, Uses & Prerequisites 4-1


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)


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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


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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 Ecoscrane 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


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Stage 1 Raise Start/Stage 5 Lower Fini sh

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.


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This is an intermediate stage only.


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.




powered.


Superstructure cannot slew.

The crane cab cannot be moved from the crane operation position.


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This is the position for the crane cab access platform when the crane is in use. A green lightlocated 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.


Crane can be used when the green status indicator

is illuminated


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The platform handrail has folded down onto the platform.


To enable this configuration the: Carrier park brake must be applied.


powered.


Superstructure can slew.

The crane cab can be moved from the crane operation position to the transport position.

Crane cab stowed in transport position


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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.




Crane cab must be stowed in the transport position.


powered.

With the access system in the fully raised position:

The carrier park brake can be released.

The crane carrier can be driven.


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4.3 Carrier Deck Handrails - System Stages, Uses and Prerequisites

NOTICE

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.

The handrails are installed solely to provide asafe work area when maintenance orinspection work is being undertaken on thecrane.


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4.3.2 Handrails Raised

NOTICE

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.

The crane superstructure will not slew with thecarrier deck handrails are in the raised position.


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5

System Controls & Indicators 5-1


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.


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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.

Left side carrier deck handrail controls

Controls located on this panel include:

5) Deck Handrails Raise

6) Deck Handrails Lower

5

6


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5.3 Access System Crane Cab Controls

The access system controls have been fitted to the right side cab console.

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 Conf iguration )

7 89 10


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(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 areoperated. 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.


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6

Mounting & Dismounting Procedures 6-1


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.


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6.2 Mounting Procedure Crane Cab Access Platform

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 ofthe 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 theManitowoc 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.

NOTICEWith the ladder in the down position thesuperstructure cannot slew.


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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 andmine site instructions.

Configuration of access system for use of the crane

Crane can be used when the green status indicator

is illuminated


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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


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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.


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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.


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6.8 Mounting Procedure Crane Carrier Deck

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.

NOTICEThe superstructure will not slew with thecarrier deck handrails in the raised posit ion.

NOTICEThe handrails are installed solely to provide asafe work area when the maintenance orinspection work is being undertaken on thecrane.


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7

Transportation Information Section 7-1

GMK 5220 Supplement

7 Transportation Information

7.1 Operating Width

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

NOTICEFitment of the access system to this machinehas increased the crane carriers travel andtransport w idth to 3400mm.


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Transportation Information Section 7-2

GMK 5220 Supplement

Operating width label located on the carrier cab air conditioner


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8

Maintenance Section 8-1


8 Maintenance Section

NOTICEYou must read and understand the warningsand instructions contained in the SafetySection o f this manual, before performing anymaintenance procedures.

Unintended machine movement may result inpersonal injury or death. Before performingmaintenance on this machine ensure it hasbeen isolated in accordance with mine siteand manufacturer procedures and a Do NotStart Tag has been applied in the appropriatelocation on the machine.

Disconnection of hydraulic hoses andremoval of supporting pins and bolts of theaccess system may result in unintendedmachine movement and/or release of storedenergy. Personal injury or death may result.Before disassembly of any components of theaccess system ensure that stored energy hasbeen relieved and components arechocked/blocked to prevent unintendedmovement.


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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

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.

Stay clear of all rotating and moving parts.

Do not disconnect any hydraulic hoses unlessthe access platforms are fully lowered. In anyposition other than fully lowered the access

system hydraulics will be pressurised.Releasing this pressure WILL result inuncont rolled movement of the access platform.Do not work on the access system unless youhave read and understand the instructions andwarnings in the Operation and MaintenanceManual. Failure to follow the instructions orheed the warnings could result in injury ordeath. Contact Australian DiversifiedEngineering for replacement manuals. Propercare is your responsibility.


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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

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.

Damage of access system hydraulic hoses,tubes or pipes from welding on or near them

can result in uncontrolled movement of theaccess platform or fire. Do not work on thismachine unless you have read and understandthe instructions and warnings in the Operationand Maintenance Manual. Failure to follow theinstructions or heed the warnings could resultin injury or death. Contact AustralianDiversified Engineering for replacementmanuals. Proper care is your responsibili ty.


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8.2 Maintenance Override Key Switch

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

To prevent damage to the access systems,crane carrier and the superstructure ensurethat the step ladder is in the raised positionwhen slewing with the maintenance overridekey in the override position. Failure to do sowill result in damage to the access systems,crane carrier and the superstruc ture.


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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

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)

1 2


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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 Tanksin 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. Withone 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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8.6.4 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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8.7 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 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.

Date post:	02-Jun-2018
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