Grove GMK7450 Ingles

ADE004631
REV00
Operation and
Maintenance
Manual
Supplement
Grove GMK 7450
All Terrain Crane
Ph: +61 7 3865 2660
www.ade.net.au
OVERVIEW ........................................................................................................................................................................ 1
1.1
LITERATURE INFORMATION .......................................................................................................................................... 1
1.2
SAFETY......................................................................................................................................................................... 1
1.3
OPERATION .................................................................................................................................................................. 1
1.4
MAINTENANCE ............................................................................................................................................................. 2
SAFETY............................................................................................................................................................................... 1
2.1
IMPORTANT SAFETY INFORMATION .............................................................................................................................. 1
2.2
SAFETY SIGNS AND LABELS ......................................................................................................................................... 3
IDENTIFICATION INFORMATION .............................................................................................................................. 1

3.1
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
4.2.2
4.2.3
4.2.4
4.2.5
Stage 5 Raise Finish/Stage 1 Lower Start............................................................................................................... 9
4.3
ACCESS SYSTEM ID PLATE........................................................................................................................................... 1
CARRIER DECK HANDRAILS - SYSTEM STAGES, USES AND PREREQUISITES ............................................................... 10
4.3.1
Handrails Lowered ............................................................................................................................................... 10
4.3.2
Handrails Raised .................................................................................................................................................. 11
SYSTEM CONTROLS & INDICATORS ........................................................................................................................ 1

5.1
CRANE CARRIER DECK HANDRAIL & CRANE CAB ACCESS PLATFORM CONTROLS RIGHT SIDE ............................... 2
5.2
CRANE CARRIER DECK HANDRAIL CONTROLS LEFT SIDE ......................................................................................... 3
5.3
ACCESS SYSTEM CRANE CAB CONTROLS ..................................................................................................................... 4
MOUNTING & DISMOUNTING PROCEDURES......................................................................................................... 1

6.1
CRANE CAB ACCESS PLATFORM GENERAL INFORMATION ........................................................................................ 1
6.2
MOUNTING PROCEDURE CRANE CAB ACCESS PLATFORM ......................................................................................... 2
6.3
CRANE OPERATION ACCESS SYSTEM CONFIGURATION ............................................................................................. 3
6.4
DISMOUNTING PROCEDURE CRANE CAB ACCESS PLATFORM .................................................................................... 4
GMK 7450 - Supplement
6.5
CRANE CARRIER OPERATION ACCESS SYSTEM CONFIGURATION .............................................................................. 5
6.6
DISMOUNTING PROCEDURE EMERGENCY USE ONLY................................................................................................. 7
6.7
DISMOUNTING PROCEDURE ACCESS SYSTEM LADDER FAILURE ............................................................................... 7
6.8
MOUNTING PROCEDURE CRANE CARRIER DECK ....................................................................................................... 8
TRANSPORTATION INFORMATION .......................................................................................................................... 1

7.1
OPERATING WIDTH ...................................................................................................................................................... 1
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 INTERVAL WHEN REQUIRED ............................................................................................................. 8
8.4.1
8.5
Additional Circuit Breaker - Reset.......................................................................................................................... 8

MAINTENANCE INTERVAL EVERY 10 SERVICE HOURS OR DAILY ............................................................................ 10
8.5.1
Walk-Around Inspection ....................................................................................................................................... 10
MAINTENANCE INTERVAL EVERY ................................................................................................................................ 12

8.6
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
8.7.1
9
1000 SERVICE HOURS OR 6 MONTHS.......................................................................................................................... 12
MAINTENANCE INTERVAL EVERY 2000 SERVICE HOURS OR YEARLY ..................................................................... 15

Rubber Bump Stops Inspect ............................................................................................................................... 15
LITERATURE REFERENCE MATERIALS.................................................................................................................. 1

9.1
MANITOWOC REFERENCE MATERIAL ........................................................................................................................... 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.
Overview
1-1
1
1.4 Maintenance
The maintenance information is a guide to equipment care. The illustrated, step-by-step instructions
are grouped by servicing intervals. Items without specific intervals are listed under When
Required topics. Items in the Maintenance Interval Schedule are referenced to detailed instructions
that follow.
Calendar intervals shown (daily, weekly, monthly, etc.) are to be used as they provide more
convenient servicing schedules. Recommended service should always be performed at the interval
that occurs first.
Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is
specified in the Maintenance Intervals schedule may be necessary.
Overview
1-2
2
2 Safety
2.1 Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognising
potentially hazardous situations before an accident occurs. A person must be alert to potential
hazards. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation & 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.
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.
Safety Section
2-1
2
Australian Diversified Engineering cannot anticipate every possible circumstance that might involve
a potential hazard. The warnings in this publication and on the product are therefore not all
inclusive. If a tool, procedure, work method or operating technique not specifically recommended by
Australian Diversified Engineering is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product would not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
Do not operate or work on this machine unless

you have read and understand the instructions
and
warnings
in
the
Operation
and
Maintenance Manual. Failure to follow the
instructions or heed the warnings could result
in injury or death. Contact Australian
Diversified
Engineering
for
replacement
manuals. Proper care is your responsibility.
Before operating any of the access systems

ensure that the gear selector is in neutral and
the park brake is engaged. Do not release the
park brake, move the gear selector or throttle
pedal if any of the access systems are not fully
retracted.
The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the
service given to the product. Obtain the complete and most current information before starting any
job from Australian Diversified Engineering.
Safety Section
2-2
2
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
Safety Section
2-3
This sign is located in three places on the side of the

access system ladder
Safety Section
2-4
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
Safety Section
2-5
Sign located on the left side of the crane carrier deck
This sign is located on the cover for the access system frame
Safety Section
2-6
This sign is located on top of the hydraulics cabinet for the crane
carrier deck handrails
Safety Section
2-7
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
Safety Section
2-8
This sign is located inside each ground

level access system control box
(left side control box shown)
Safety Section
2-9
This sign is located inside the crane cab adjacent to the access
system controls
Safety Section
2-10
3
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
Identification Information
GMK 7450 Supplement
3-1
Data plate located beneath each ground level

control box
Identification Information
GMK 7450 Supplement
3-2
4
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)

System Stages, Uses & Prerequisites
4-1
4
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

4-2
4
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 Ecos crane 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
4-3
Stage 1 Raise Start/Stage 5 Lower Finish
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.

4-4
4
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.
The crane cab cannot be moved from the crane operation position.

4-5
4
This is an intermediate stage only.
The step ladder has retracted under the crane cab.
powered.
The crane cab cannot be moved from the crane operation position.

4-6
4
This is the position for the crane cab access platform when the crane is in use. A green light
located 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

4-7
4
The platform handrail has folded down onto the platform.
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

4-8
4
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.

4-9
4
4.3 Carrier Deck Handrails - System Stages, Uses and Prerequisites
NOTICE
The handrails are installed solely to provide a
safe work area when maintenance or
inspection work is being undertaken on the
crane.
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.

4-10
4
4.3.2 Handrails Raised
NOTICE
The crane superstructure will not slew with the
carrier deck handrails are in the raised position.
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.

4-11
5
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.
System Controls & Indicators

5-1
5
5.1 Crane Carrier Deck Handrail & Crane Cab Access Platform Controls
Right Side
The controls to operate the right side deck handrails and the access system are located behind the
right side crane carrier cab door.
1
2
3
4
Right side carrier deck handrails and access system controls
Controls located on this panel include:

1) Access System Raise
2) Access System Lower
3) Deck Handrails Raise
4) Deck Handrails Lower

5-2
5
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.
5
6
Left side carrier deck handrail controls
Controls located on this panel include:

5) Deck Handrails Raise
6) Deck Handrails Lower

5-3
5
5.3 Access System Crane Cab Controls
The access system controls have been fitted to the right side cab console.
10
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 Configuration)

5-4
5
(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 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.

5-5
6
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.
Mounting & Dismounting Procedures

6-1
6
6.2 Mounting Procedure Crane Cab Access Platform
NOTICE
With the ladder in the down position the
superstructure cannot slew.
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 of
the 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 the
Manitowoc 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.

6-2
6
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 and
mine site instructions.
Configuration of access system for use of the crane
Crane can be used when the green status indicator

is illuminated

6-3
6
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
6-4
6
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.

6-5
6
NOTICE
If the park brake is released before the access
systems are completely retracted the warning
light will illuminate and the alarm will sound.
Always operate the crane in accordance with
manufacture and mine site instructions.
Crane carrier cab mounted audible and visual alarms
Crane carrier cab mounted indicators

6-6
6
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.

6-7
6
6.8 Mounting Procedure Crane Carrier Deck
NOTICE
The handrails are installed solely to provide a
safe work area when the maintenance or
inspection work is being undertaken on the
crane.
NOTICE
The superstructure will not slew with the
carrier deck handrails in the raised position.
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.

6-8
7
7 Transportation Information
7.1 Operating Width
NOTICE
Fitment of the access system to this machine
has increased the crane carriers travel and
transport width to 3400mm.
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
Transportation Information Section

GMK 5220 Supplement
7-1
Operating width label located on the carrier cab air conditioner
Transportation Information Section

GMK 5220 Supplement
7-2
8
8 Maintenance Section
Unintended machine movement may result in

personal injury or death. Before performing
maintenance on this machine ensure it has
been isolated in accordance with mine site
and manufacturer procedures and a Do Not
Start Tag has been applied in the appropriate
location on the machine.
Disconnection of hydraulic 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.
NOTICE
You must read and understand the warnings
and instructions contained in the Safety
Section of this manual, before performing any
maintenance procedures.
Maintenance Section
8-1
8
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
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.
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.
Maintenance Section
Stay clear of all rotating and moving parts.
8-2
8
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
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.
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.
Maintenance Section
8-3
8
8.2 Maintenance Override Key Switch
To prevent damage to the access systems,

crane carrier and the superstructure ensure
that the step 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 carrier and the superstructure.
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
Maintenance Section
8-4
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.
Maintenance Section
8-5
Hydraulic oil tank for the access platform and ladder
Fill point for the hydraulic tank accessible from the cabinet
located above
Maintenance Section
8-6
Hydraulic oil tank for the crane carrier deck handrails
Remove the cover indicated to expose the fill point for the
hydraulic tank
Maintenance Section
8-7
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.
Maintenance Section
8-8
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)
Maintenance Section
8-9
8
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.
Maintenance Section
8-10
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
Maintenance Section
8-11
Check the level of both hydraulic oil tanks. Top-up if required referring to section Hydraulic
Oil Tanks in 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. With
one of the access platforms in a lowered position enter the crane carrier cab and release the park
brake. The alarms should be activated. If the alarms do not activate it means that there is a
problem with the system and it needs to be checked.
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.
Maintenance Section
8-12
8
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
Maintenance Section
8-13
Forward grease fitting for the access system main frame
Rearward grease fitting for the access system main frame
Maintenance Section
8-14
8
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
Maintenance Section
8-15
Bump stop
Maintenance Section
8-16
9
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.
Literature Reference Material

9-1

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

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

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

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

SYSTEM STAGES, USES & PREREQUISITES ............................................................................................................ 1

Stage 1 Raise Start/Stage 5 Lower Finish............................................................................................................... 3

Stage 2 Raise Start/Stage 4 Lower Finish............................................................................................................... 5

Stage 3 Raise Start/Stage 3 Lower Finish............................................................................................................... 6

Stage 4 Raise Start/Stage 2 Lower Finish............................................................................................................... 7

Stage 5 Raise Finish/Stage 1 Lower Start............................................................................................................... 9

ACCESS SYSTEM ID PLATE........................................................................................................................................... 1

CARRIER DECK HANDRAILS - SYSTEM STAGES, USES AND PREREQUISITES ............................................................... 10

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

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

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

CRANE CARRIER DECK HANDRAIL CONTROLS LEFT SIDE ......................................................................................... 3

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

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

CRANE CAB ACCESS PLATFORM GENERAL INFORMATION ........................................................................................ 1

MOUNTING PROCEDURE CRANE CAB ACCESS PLATFORM ......................................................................................... 2

CRANE OPERATION ACCESS SYSTEM CONFIGURATION ............................................................................................. 3

DISMOUNTING PROCEDURE CRANE CAB ACCESS PLATFORM .................................................................................... 4

GMK 7450 - Supplement

CRANE CARRIER OPERATION ACCESS SYSTEM CONFIGURATION .............................................................................. 5

DISMOUNTING PROCEDURE EMERGENCY USE ONLY................................................................................................. 7

DISMOUNTING PROCEDURE ACCESS SYSTEM LADDER FAILURE ............................................................................... 7

MOUNTING PROCEDURE CRANE CARRIER DECK ....................................................................................................... 8

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

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

MAINTENANCE SECTION ............................................................................................................................................. 1

GENERAL HAZARD INFORMATION ................................................................................................................................ 2

Crushing & Cutting Prevention .............................................................................................................................. 2

Burn Prevention Oils ........................................................................................................................................... 3

Hydraulic Hoses ..................................................................................................................................................... 3

MAINTENANCE OVERRIDE KEY SWITCH ...................................................................................................................... 4

HYDRAULIC OIL TANKS ............................................................................................................................................... 5

MAINTENANCE INTERVAL WHEN REQUIRED ............................................................................................................. 8

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

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

MAINTENANCE INTERVAL EVERY ................................................................................................................................ 12

Bolts and Mounting Hardware ............................................................................................................................. 12

Crane Cab Audible & Visual Indicators Test .................................................................................................... 12

Hydraulic System - Inspect ................................................................................................................................... 12

Pivot Points Lubricate ....................................................................................................................................... 13

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

MAINTENANCE INTERVAL EVERY 2000 SERVICE HOURS OR YEARLY ..................................................................... 15

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

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

GMK 7450 - Supplement

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is involved.

Do not operate or work on this machine unless

Before operating any of the access systems

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

Sign located on the right side of the crane carrier deck

Sign located on the left side of the crane carrier deck

This sign is located inside each ground

Data plate details for the crane access system

Data plate located on the side of the crane cab platform

Data plate located beneath each ground level

Right and left crane carrier deck mounted handrails.

Crane cab access platform & ladder