p&h 50t escalera

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


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)


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 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


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.


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.


Operation Section


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.


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


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


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


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


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.

Documents

p&h 50t escalera