p&h 50t escalera
DESCRIPTION
P&H 50t CraneTRANSCRIPT
ADE006413
REV00
Operation & Maintenance
Manual Supplement
Access System
P&H 50t Rough Terrain Crane
Ph: +61 7 3865 2660 www.ade.net.au
Access System – P&H 50t RT Crane
1 OVERVIEW..........................................................1
1.1 LITERATURE INFORMATION .............................1 1.2 SAFETY .........................................................1 1.3 OPERATION ...................................................1 1.4 MAINTENANCE ...............................................1
2 SAFETY ...............................................................2
2.1 IMPORTANT SAFETY INFORMATION..................2 2.2 SAFETY SIGNS & LABELS ...............................3
3 PRODUCT IDENTIFICATION INFORMATION...5
3.1 ACCESS SYSTEM – ID PLATE .........................5
4 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 ALTERNATE EGRESS....................................11 4.6.1 Dismounting Procedures.......................11
4.7 CRANE USE INCLUDING SLEW BRAKE ...........11
5 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 Circuit Breaker - Reset..........................14 5.4 MAINTENANCE INTERVAL - BEFORE USE .......14
5.4.1 Walk-Around Inspection........................14 5.5 MAINTENANCE INTERVAL - EVERY 250 SERVICE
HOURS OR MONTHLY ................................................15 5.5.1 Access System Sliding Beams –
Lubricate ............................................................15 5.6 MAINTENANCE INTERVAL - EVERY 1000
SERVICE HOURS OR 6 MONTHS.................................15 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 EVERY 4000 SERVICE HOURS OR 2 YEARS...16 5.7.1 Hydraulic Oil Compartment...................16
6 LITERATURE REFERENCE MATERIALS.......17
6.1 REFERENCE MATERIAL ................................17
Overview
Access System – P&H 50t RT Crane 1
1 Overview 1.1 Literature Information
The operation and maintenance manual supplement
should be permanently stored in the operator’s cabin.
The operation and maintenance manual supplement
contains safety, operation and maintenance
information for the access system as fitted by
Australian Diversified Engineering and must be used in
conjunction with the machine specific P&H 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 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.
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.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
in the Maintenance Intervals schedule may be
necessary.
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.
Safety Section Access System – P&H 50t RT Crane 2
Improper operation & maintenance of this product
can be dangerous and could result in injury or
death.
Do not operate or perform maintenance on this
product, until you have read and understood the
operation and maintenance information.
Safety precautions and warnings are provided in this
manual and on the product. It these hazard warnings
are not heeded, bodily injury or death could occur to
you or other persons.
The hazards are identified by the Safety Alert Symbol"
and followed by a 'Signal Word" such as "WARNING"
as shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is involved.
Australian Diversified Engineering cannot anticipate
every possible circumstance that might involve a
potential hazard. The warnings in this publication and
on the product are therefore not all inclusive. If a tool,
procedure, work method or operating technique not
specifically recommended by Australian Diversified
Engineering is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that
the product would not be damaged or made unsafe by
the operation, lubrication, maintenance or repair
procedures you choose.
Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact Australian Diversified Engineering for replacement manuals. Proper care is your responsibility.
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
Australian Diversified Engineering.
2.2 Safety Signs & Labels
Safety Section Access System – P&H 50t RT Crane 3
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 on the ground level access system
control box
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 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 Identification Information
3.1 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
Operation Section
4 Operation Section 4.1 General Information
The access system is a three 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.
Access System – P&H 50t RT Crane 6
Access system in the lowered position
Access system in the raised position for crane
operation
4.2 Controls & Indicators
The access system is operated via controls located
inside the cab and at ground level.
Access system control panel located in the cab
3
41 2
In-cab control panel features raise and lower controls,
access lights switch and visual ladder status indicator
Operation Section
Access System – P&H 50t RT Crane 7
Cab audible alarm
Ground level access system controls located near the
front left stabiliser
5
1
2
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 audible alarm mounted on the hydraulics
cabinet (5)
Operation Section
(1) & (2) Raise and Lower Controls
Depress the required button to either raise or lower the
access system.
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 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 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.
(4) Access System Light
Located on top of the crane cab is an access light fitted
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.
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.
Access system light for mounting and dismounting
access system in low light conditions
(5) Cab and Ground Level Audible Alarms
When the access system is being raised or lowered the
hydraulics cabinet mounted alarm will sound.
When the park brake is released and the access
system is not stowed the cab mounted audible alarm
will also sound.
Access System – P&H 50t RT Crane 8
Operation Section
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
hand or one foot and two hands contact) with the
steps and handholds.
Never jump off the access system.
Ensure adequate lighting for mounting and
dismounting of the machine in low light conditions.
Ensure that the access system is fully lowered
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
handrails.
Configuration for use of the access system
4.5 System Stages
The access system must cycle through all three stages
correctly to allow use. Do not use if one or more of the
following cycles fails.
Stored access system
The stages which the access system will cycle through
from the stored position to the lowered position are:
1. Both the deck handrails raise.
Access System – P&H 50t RT Crane 9
Operation Section
Access System – P&H 50t RT Crane 10
First stage of lowering – both deck handrails raise.
2. Access system ladder slides out from underneath
the deck.
Second stage of lowering – ladder slides out from
underneath deck.
3. Ladder lowers and handrails raise.
Access system in the lowered position ready for use.
The retraction stages of the access system are the
opposite to lowering.
Third stage of lowering – ladder lowers and handrails
raise.
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.
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
contact.
5. Enter the cab and make a visual inspection of the
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
Operation Section
the stairs are moving.
7. Once stowed correctly the red LED status indicator
will cease to illuminate and machine can be driven
and operated in accordance with mine site and
manufacturer instructions.
Access System – P&H 50t RT Crane 11
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.
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.
4.6 Alternate Egress
4.6.1 Dismounting Procedures
To dismount the machine (without the use of the
access system) in the event of partial or complete
access system failure or to promptly egress the
machine in an emergency situation:
1. Stop the machine in accordance with procedures
outlined in the Operation and Maintenance Manual
as well as applicable mine site instructions.
2. Ensuring the park brake is applied; dismount the
machine via the right side standard ladder to
ground level.
3. Ensure the ladder failure is investigated and fault/s
repaired.
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
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
platforms. Further to this, damage to the access
system may occur.
Releasing the park brake with the access system in the
lowered position will also apply the slew brake to the
superstructure. The access system must be in the
stored position to allow the crane superstructure to
slew.
NOTICE Always operate the crane in accordance with manufacture and mine site instructions.
5 Maintenance Section
Maintenance Section Access System – P&H 50t RT Crane 12
5.1 General Hazard Information
Perform all maintenance unless otherwise specified as
follows:
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
Not Start Tag applied to the switch.
All other external energy sources disconnected
from the crane.
5.1.1 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.
5.1.2 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.
5.1.3 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.
NOTICE You must read and understand the warnings and instructions contained in the Safety Section of this manual, before performing any maintenance procedures.
Unintended machine movement may result in personal injury or death. Before performing maintenance on this machine ensure it has been isolated in accordance with mine site and manufacturer procedures and a Do Not Start Tag has been applied in the appropriate location on the machine.
Disconnection of 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.
5.1.4 Hydraulic Hoses
Maintenance Section Access System – P&H 50t RT Crane 13
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.
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.
5.2 Maintenance Override Key Switch
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
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 the ladder is in the raised position if it
is anticipated that slewing of the superstructure is
required.
Maintenance override key switch located inside the cab
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.
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.
5.3 Maintenance Interval – When Required
Maintenance Section Access System – P&H 50t RT Crane 14
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.
Circuit breaker located inside the hydraulics cabinet at
the left side of the machine and inside the cab
32
(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
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.
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.
1
Check to ensure that the audible alarm is
operational.
5.5 Maintenance Interval - Every 250 Service Hours or Monthly
5.5.1 Access System Sliding Beams –
Lubricate
Maintenance Section Access System – P&H 50t RT Crane 15
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.
Two grease points on the left side of the rear main
beam
Two grease points on the left side of the forward main
beam
Grease point located on the right side of the forward
main sliding 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.
5.7 Every 4000 Service Hours or 2 Years 5.6.2 Hydraulic System – Inspect
Maintenance Section Access System – P&H 50t RT Crane 16
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
Reference Information Access System – P&H 50t RT Crane 17
6 Literature Reference Materials
6.1 Reference Material
Machine specific P&H Operation and Maintenance
Manual.