P&h 50t Ingles.pdf

ADE006413 REV00

Operation & Maintenance Manual Supplement Access System P&H 50t Rough Terrain Crane

Ph: +61 7 3865 2660

www.ade.net.au

1

HOURS OR MONTHLY ................................................15

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

5.5.1

2

1.1

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

1.2

SAFETY .........................................................1

1.3

OPERATION ...................................................1

1.4

MAINTENANCE ...............................................1

Lubricate ............................................................15 5.6

IMPORTANT SAFETY INFORMATION..................2

2.2

SAFETY SIGNS & LABELS ...............................3

5.6.1

Bolts and Mounting Hardware...............15

5.6.2

Hydraulic System – Inspect ..................16

5.6.3

Ladder Pivot Points – Lubricate ............16

5.7 5.7.1

3

6

Hydraulic Oil Compartment...................16

LITERATURE REFERENCE MATERIALS .......17

ACCESS SYSTEM – ID PLATE .........................5 6.1

OPERATION SECTION.......................................6 4.1

GENERAL INFORMATION .................................6

4.2

CONTROLS & INDICATORS ..............................6

4.3

MOUNTING & DISMOUNTING ...........................9

4.3.1

General Information ................................9

4.4

SYSTEM PREREQUISITES................................9

4.5

SYSTEM STAGES ...........................................9

4.5.1

Mounting Procedure..............................10

4.5.2

Dismounting Procedure ........................11

4.6 4.6.1 4.7 5

EVERY 4000 SERVICE HOURS OR 2 YEARS...16

PRODUCT IDENTIFICATION INFORMATION ...5 3.1

4

MAINTENANCE INTERVAL - EVERY 1000

SERVICE HOURS OR 6 MONTHS .................................15

SAFETY ...............................................................2 2.1

Access System Sliding Beams –

ALTERNATE EGRESS ....................................11 Dismounting Procedures.......................11 CRANE USE INCLUDING SLEW BRAKE ...........11

MAINTENANCE SECTION................................12 5.1

GENERAL HAZARD INFORMATION ..................12

5.1.1

Fluid Penetration ...................................12

5.1.2

Crushing & Cutting Prevention..............12

5.1.3

Burn Prevention – Oils ..........................12

5.1.4

Hydraulic Hoses ....................................13

5.2

MAINTENANCE OVERRIDE KEY SWITCH .........13

5.3

MAINTENANCE INTERVAL – WHEN REQUIRED 14

5.3.1 5.4 5.4.1 5.5

Circuit Breaker - Reset..........................14 MAINTENANCE INTERVAL - BEFORE USE .......14 Walk-Around Inspection........................14 MAINTENANCE INTERVAL - EVERY 250 SERVICE

Access System – P&H 50t RT Crane

REFERENCE MATERIAL ................................17

1.4

1 Overview 1.1

Literature Information

Maintenance

The maintenance information is a guide to equipment care. The illustrated, step-by-step instructions are

The operation and maintenance manual supplement

grouped by servicing intervals. Items without specific

should be permanently stored in the operator’s cabin.

intervals are listed under “When Required” topics. Items in the Maintenance Interval Schedule are

The operation and maintenance manual supplement contains

safety,

operation

and

referenced to detailed instructions that follow.

maintenance

information for the access system as fitted by

Under extremely severe, dusty or wet operating

Australian Diversified Engineering and must be used in

conditions, more frequent lubrication than is specified

conjunction with the machine specific P&H Operation

in the Maintenance Intervals schedule may be

and Maintenance Manual.

necessary.

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 front access system.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance on the crane access system. 1.3

Operation

The operation section includes a description of the controls, their location and operation with respect to the access system. Photographs and illustrations are provided to guide the operator through the correct operating procedures for the access system.

Overview Access System – P&H 50t RT Crane

1

on the product are therefore not all inclusive. If a tool,

2 Safety 2.1

procedure, work method or operating technique not

Important Safety Information

specifically recommended by Australian Diversified Engineering is used, you must satisfy yourself that it is

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

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.

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.

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact Australian Diversified Engineering for replacement manuals. Proper care is your responsibility. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. Obtain the complete and most current information before starting any job from

Safety precautions and warnings are provided in this

Australian Diversified Engineering.

manual and on the product. It these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the Safety Alert Symbol" and followed by a 'Signal Word" such as "WARNING" as shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is involved.

Australian Diversified Engineering cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and Safety Section Access System – P&H 50t RT Crane

2

2.2

Safety Signs & 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 also located inside the cab adjacent to the access system control panel

This sign is located inside the cab adjacent to the access system control panel This sign is located on the ground level access system control box

Safety Section Access System – P&H 50t RT Crane

3

This sign is located in three places along the side of the access system This sign is located on the side of the access system ladder (access system retracted)

Safety Section Access System – P&H 50t RT Crane

4

3 Product Information 3.1

Identification

Access System – ID Plate

An ID plate has been fitted to the access system which indicates information such as the model number, date of manufacture and the serial number. Refer to the plate fitted for specific details.

ID plate for the access system located on the edge of the access system deck

ID plate for the access system

Product Identification Information Access System – P&H 50t RT Crane

5

4 Operation Section 4.1

General Information

4.2

Controls & Indicators

The access system is operated via controls located inside the cab and at ground level.

The access system is a three stage electric-overhydraulic 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.

Access system control panel located in the cab

3

1

4

2

Access system in the lowered position In-cab control panel features raise and lower controls, access lights switch and visual ladder status indicator

Access system in the raised position for crane operation Operation Section Access System – P&H 50t RT Crane

6

5 1

2

Cab audible alarm

Ground level access system controls

The controls on the in-cab control panel include: (1) Raise Control (2) Lower Control (3) “Access System Status” – Red Visual Indicator (4) Access Lights Switch (5) Audible Alarms – Cab and Ground Level

5

Ground level access system controls located near the front left stabiliser

Ground level audible alarm mounted on the hydraulics cabinet (5)

Operation Section Access System – P&H 50t RT Crane

7

(1) & (2) Raise and Lower Controls

If at anytime illumination of the access system is required when dismounting from the crane cab with the

Depress the required button to either raise or lower the access system.

access system in the fully lowered position, simply switch the access light toggle switch in the crane cab

The access controls utilised on this machine are of the momentary push button type. This requires the

and the light will also illuminate for a pre-set period of time.

operator to press the button for the duration of raising or lowering. 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).

(3) Access System Status - Red Visual Indicator

Red visual indicator illuminates depending on the following situation:

a) Constant illumination when the system is any position other than the stowed position.

b) Constant

illumination

in

Access system light for mounting and dismounting access system in low light conditions

conjunction

with

sounding of the in-cab audible alarm if the park brake is released and the access system is not in the stowed position.

(5) Cab and Ground Level Audible Alarms

When the access system is being raised or lowered the hydraulics cabinet mounted alarm will sound.

(4) Access System Light

When the park brake is released and the access system is not stowed the cab mounted audible alarm

Located on top of the crane cab is an access light fitted

will also sound.

to illuminate the access platform and ladder. The light is switched on automatically when the access system controls are operated. It then automatically switches off after a pre-set period of time.

If mounting the machine from ground level with the access

platforms

in

the

fully

lowered

position

momentarily push the lower control and the light will illuminate for a pre-set period of time.

Operation Section Access System – P&H 50t RT Crane

8

4.3

Mounting & Dismounting

4.3.1 General Information 

Mount and dismount the machine only where steps, ladders and/or handholds are provided.



Do not operate access when personnel are mounting dismounting or using system.



Inspect, and when necessary, clean and have repairs made to steps and handholds before mounting and dismounting.



Face the ladder when mounting and dismounting the access system ladder.



Maintain a three-point contact (two feet and one

Configuration for use of the access system

hand or one foot and two hands contact) with the steps and handholds.

4.5



Never jump off the access system.



Ensure



adequate

lighting

for

mounting

and

System Stages

The access system must cycle through all three stages

dismounting of the machine in low light conditions.

correctly to allow use. Do not use if one or more of the

Ensure that the access system is fully lowered

following cycles fails.

before boarding. 4.4

System Prerequisites

To allow use of the access system: 1. The battery disconnect switch is connected. 2. The park brake is applied. 3. The crane superstructure and car body are in-line. 4. The access system is free from personnel before operating the controls. 5. The ladder is fully lowered with the handrails raised. 6. All handrails have raised including the ladder

Stored access system

handrails. The stages which the access system will cycle through from the stored position to the lowered position are:

1. Both the deck handrails raise.

Operation Section Access System – P&H 50t RT Crane

9

First stage of lowering – both deck handrails raise.

Third stage of lowering – ladder lowers and handrails raise.

2. Access system ladder slides out from underneath the deck. 4.5.1 Mounting Procedure Do not attempt to access the machine whilst the crane or car body are moving or whilst another operator is in the machine and the engine running. Refer to applicable mine site regulations for approaching machines.

To mount the machine using the access system: 1. Ensure that the battery disconnect switch is in the connected position. Refer to the machine specific Operation and Maintenance Manual for location and operation of the battery disconnect switch. 2. Ensure the access system is illuminated when mounting in low light conditions. Second stage of lowering – ladder slides out from underneath deck.

3. Ensure the access system is completely lowered. 4. With the access system in the lowered position mount the ladder whilst maintaining a three point

3. Ladder lowers and handrails raise.

contact. 5. Enter the cab and make a visual inspection of the

Access system in the lowered position ready for use. The retraction stages of the access system are the opposite to lowering. Operation Section Access System – P&H 50t RT Crane

access system to ensure it is free from personnel. 6. Raise the stairs using the stair raise button. During stair raising an audible alarm will sound to indicate

10

the stairs are moving.

machine via the right side standard ladder to

7. Once stowed correctly the red LED status indicator will cease to illuminate and machine can be driven

ground level. 3. Ensure the ladder failure is investigated and fault/s

and operated in accordance with mine site and

repaired.

manufacturer instructions. 4.5.2 Dismounting Procedure To dismount the machine via the access system: 1. Stop the machine or orientate the superstructure so that it is in-line with the car body in accordance with procedures outlined in the machine specific Operation and Maintenance Manual as well as applicable mine site instructions. 2. Engage the park brake and make a visual inspection of the access system to ensure the access

system

lowering

area

is

free

from

personnel. 3. Lower the stairs using the stair lower button.

Alternate egress from the cab deck via the ladder on the right side of the machine if the access system fails to operate or too slow in an emergency situation 4.7

Crane Use Including Slew Brake

During stair lowering an audible alarm will sound to indicate the stairs are moving. 4. Ensure the access system is illuminated when dismounting in low light conditions. 5. Exit the cab and make a visual inspection to ensure the access system has lowered. 6. Dismount the machine maintaining three point contact at all times.

To ensure that the crane is not driven with the access system in the down position there are audible and visual alarms. Upon release of the park brake if the audible and visual alarms are activated reapply the park brake and ensure that the access system is in the fully raised position. Do not drive the crane or operate the superstructure if the alarms are activated as there may be personnel accessing the

4.6

Alternate Egress

platforms. Further to this, damage to the access system may occur.

4.6.1 Dismounting Procedures Releasing the park brake with the access system in the To dismount the machine (without the use of the

lowered position will also apply the slew brake to the

access system) in the event of partial or complete

superstructure. The access system must be in the

access system failure or to promptly egress the

stored position to allow the crane superstructure to

machine in an emergency situation:

slew.

1. Stop the machine in accordance with procedures outlined in the Operation and Maintenance Manual as well as applicable mine site instructions.

NOTICE Always operate the crane in accordance with manufacture and mine site instructions.

2. Ensuring the park brake is applied; dismount the Operation Section Access System – P&H 50t RT Crane

11

5 Maintenance Section

5.1.1 Fluid Penetration

Always use a board or cardboard when checking for a Unintended machine movement may result in personal injury or death. Before performing maintenance on this machine ensure it has been isolated in accordance with mine site and manufacturer procedures and a Do Not Start Tag has been applied in the appropriate location on the machine.

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. 5.1.2 Crushing & Cutting Prevention

Disconnection of hoses and removal of supporting pins and bolts of the access system may result in unintended machine movement and/or release of stored energy. Personal injury or death may result. Before disassembly of any components of the access system ensure that stored energy has been relieved and components are chocked/blocked to prevent unintended movement.

Do not disconnect any hydraulic hoses unless the access platforms are fully lowered. In any position other than fully lowered the access system hydraulics will be pressurised. Releasing this pressure WILL result in uncontrolled movement of the access platform. Do not work on the access system unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact Australian Diversified Engineering for replacement manuals. Proper care is your responsibility.

NOTICE You must read and understand the warnings and instructions contained in the Safety Section of this manual, before performing any maintenance procedures.

5.1

General Hazard Information



Support equipment and attachments properly when working beneath them. Never attempt adjustments

Perform all maintenance unless otherwise specified as

while the machine is moving or the engine is

follows:

running unless otherwise specified.



The machine parked on level ground.



The park brake engaged.



The engine stopped.



The start switch key off and the key removed.



Battery disconnect switch locked out and a Do



5.1.3 Burn Prevention – Oils 

All other external energy sources disconnected from the crane.

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the

Not Start Tag applied to the switch. 

Stay clear of all rotating and moving parts.

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.

Maintenance Section Access System – P&H 50t RT Crane

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5.1.4 Hydraulic Hoses

Damage of access system hydraulic hoses, tubes or pipes from welding on or near them can result in uncontrolled movement of the access platform or fire. Do not work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact Australian Diversified Engineering for replacement manuals. Proper care is your responsibility.

5.2

Maintenance Override Key Switch

To prevent damage to the access systems, crane ensure that the ladder is in the raised position when slewing with the maintenance override key in the override position. Failure to do so will result in damage to the access systems, crane superstructure. This machine has been fitted with a maintenance override switch located inside the cab 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

Do not weld or flame cut on or near hoses, tubes or

should never be left in the switch. The access platform

pipes that contain flammable fluids.

electrical

systems

will

be

isolated

from

the

superstructure electrical systems when the override Do not bend or strike high-pressure lines. Do not install

switch is used. With the maintenance override key ON

damaged hoses.

the superstructure will slew with the access systems in any configuration including in the fully lowered position.

Replace any damaged hydraulic oil hoses. Leaks can

Therefore, before activating the maintenance override

cause fires.

key ensure that the ladder is in the raised position if it

Do not use your bare hand to check for leaks. Use a

is anticipated that slewing of the superstructure is

board or cardboard to check for leaks. See Fluid

required.

Penetration in the Safety 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

Maintenance override key switch located inside the cab

installed correctly to prevent vibration, rubbing against other parts, and excessive heat during operation.

Maintenance Section Access System – P&H 50t RT Crane

13

5.3

Maintenance Interval – When Required 3

2

5.3.1 Circuit Breaker - Reset The electrical system for the access system has one circuit breaker located inside the hydraulics cabinet and two circuit breakers located inside the cab.

Reset the circuit breakers when required. If a circuit breaker continually trips have the circuit checked.

(1) Main Circuit Breaker – 120 Amp (2) Battery Positive – 10 Amp (3) Ignition – 10 Amp 5.4

Maintenance Interval - Before Use

5.4.1 Walk-Around Inspection Perform a walk-around inspection on the machine prior Circuit breaker located inside the hydraulics cabinet at the left side of the machine and inside the cab

to operation. 

Clean the access steps from any rubbish build-up or debris (once lowered).



Visually inspect components for damage and wear and

tear.

Have

any

damaged

or

missing

components repaired or replaced. 

Visually inspect all hydraulic lines, hoses, fittings and

hose

clamps

for

security,

damage,

deterioration and leaks. 

Check to ensure that the access system light is in working condition.



Visually inspect all switches of the system. Ensure all visual indicators are operational.

 1

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.



Check to ensure that the audible alarm is operational.

Maintenance Section Access System – P&H 50t RT Crane

14

5.5

Maintenance Interval - Every 250 Service Hours or Monthly

5.5.1 Access

System

Sliding

Beams

–

Lubricate Lubricate the main sliding beams of the access system via the grease fittings with good quality molybdenum based grease. There are six grease fittings for the main sliding beams.

Grease point located on the right side of the forward main sliding beam

Two grease points on the left side of the rear main beam

Grease point located on the right side of the rearward main sliding beam 5.6

Maintenance Interval - Every 1000 Service Hours or 6 Months

5.6.1 Bolts and Mounting Hardware Check the tightness of all bolts fitted to the access system. This includes checking the handrails, access platforms and their mountings.

Two grease points on the left side of the forward main beam Maintenance Section Access System – P&H 50t RT Crane

15

5.7

5.6.2 Hydraulic System – Inspect

Every 4000 Service Hours or 2 Years

5.7.1 Hydraulic Oil Compartment Replace the hydraulic oil 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.

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 the hydraulic cabinet 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. 5.6.3 Ladder Pivot Points – Lubricate Lubricate the access system pivot points via the grease fittings with good quality molybdenum based grease. There are six grease fittings for the access system. Fill point cap for the hydraulic oil compartment

Two grease points for the ladder Maintenance Section Access System – P&H 50t RT Crane

16

6 Literature Materials 6.1

Reference

Reference Material

Machine specific P&H Operation and Maintenance Manual.

Reference Information Access System – P&H 50t RT Crane

17