1596K-001

REV-00

Operation and
Maintenance
Manual
Supplement
Grove GMK 5220
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

2.3

GENERAL HAZARD INFORMATION ................................................................................................................................ 9

2.4

FLUID PENETRATION .................................................................................................................................................. 10

2.5

CRUSHING OR CUTTING PREVENTION......................................................................................................................... 10

2.6

BURN PREVENTION OILS ......................................................................................................................................... 11

2.7

FIRE OR EXPLOSION PREVENTION .............................................................................................................................. 12

2.7.1
2.8
3

Fire Extinguisher Location ................................................................................................................................... 13

LINES, TUBES AND HOSES .......................................................................................................................................... 15

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

3.1

CARRIER HANDRAILS ................................................................................................................................................... 1

3.2

CRANE CAB ACCESS PLATFORM .................................................................................................................................. 2

3.3

ENGINE MODULE ACCESS PLATFORM .......................................................................................................................... 4

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

4.1

GENERAL DESCRIPTION................................................................................................................................................ 1

4.2

CRANE CAB ACCESS PLATFORM - SYSTEM STAGES, USES AND PREREQUISITES .......................................................... 3

4.2.1

Stage 1 Raise Start/Stage 4 Lower Finish............................................................................................................... 5

4.2.2

Stage 2 Raise Start/Stage 3 Lower Finish............................................................................................................... 7

4.2.3

Stage 3 Raise Start/Stage 2 Lower Finish............................................................................................................... 8

4.2.4

Stage 4 Raise Start/Stage 1 Lower Finish............................................................................................................... 9

4.2.5

Stage 4 Raise Start/Stage 1 Lower Start ............................................................................................................... 10

4.3

ENGINE MODULE ACCESS PLATFORM - SYSTEM STAGES, USES AND PREREQUISITES ................................................ 11

4.3.1

Stage 1 Raise Start/Stage 4 Lower Finish............................................................................................................. 12

4.3.2

Stage 2 Raise Start/Stage 3 Lower Finish............................................................................................................. 14

4.3.3

Stage 3 Raise Start/Stage 2 Lower Finish............................................................................................................. 15

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Stage 4 Raise Start/Stage 1 Lower Finish............................................................................................................. 16

4.3.5

Stage 4 Raise Finish/Stage 1 Lower Start............................................................................................................. 17

4.4

4.4.1

Handrails Lowered ............................................................................................................................................... 18

4.4.2

Handrails Raised .................................................................................................................................................. 19

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

5.1

HANDRAILS, CRANE CAB & ENGINE MODULE ACCESS PLATFORMS ............................................................................ 1

5.2

ACCESS SYSTEM LIGHTING .......................................................................................................................................... 6

5.3

ANCILLARY COMPARTMENT ........................................................................................................................................ 7

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

6.1

CRANE CAB & ENGINE MODULE ACCESS PLATFORMS GENERAL INFORMATION ...................................................... 1

6.2

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

6.3

DISMOUNTING PROCEDURE CRANE CAB ACCESS PLATFORM .................................................................................... 3

6.4

DISMOUNTING PROCEDURE EMERGENCY USE ONLY................................................................................................. 3

6.5

DISMOUNTING PROCEDURE STEP LADDER FAILURE .................................................................................................. 4

6.6

MOUNTING PROCEDURE ENGINE MODULE ACCESS PLATFORM ................................................................................ 4

6.7

DISMOUNTING PROCEDURE ENGINE MODULE ACCESS PLATFORM ........................................................................... 5

6.8

MOUNTING PROCEDURE CRANE CARRIER DECK ....................................................................................................... 5

6.9

CRANE SLEWING AND USE ........................................................................................................................................... 6

6.9.1
6.10
7

CARRIER DECK HANDRAILS - SYSTEM STAGES, USES AND PREREQUISITES ............................................................... 18

Access System Configuration Indicators................................................................................................................. 7

CRANE CARRIER OPERATION ..................................................................................................................................... 11

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

7.1

FLAG HOLDERS ............................................................................................................................................................ 1

7.2

OPERATING WIDTH ...................................................................................................................................................... 3

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

8.1

MAINTENANCE OVERRIDE KEY .................................................................................................................................... 2

8.2

HYDRAULIC OIL TANKS ............................................................................................................................................... 4

8.3

WHEN REQUIRED ......................................................................................................................................................... 5

8.3.1

Circuit Breaker - Reset ........................................................................................................................................... 5

8.3.2

Drain/Fill Point Crane Engine Oil ...................................................................................................................... 7

8.4

EVERY 10 SERVICE HOURS OR DAILY .......................................................................................................................... 9

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8.5

EVERY 1000 SERVICE HOURS OR 6 MONTHS ................................................................................................................ 9

8.5.1

Bolts and Mounting Hardware ............................................................................................................................... 9

8.5.2

Crane Cab Audible & Visual Indicators Test .................................................................................................... 10

8.5.3

Engine Oil Drain/Refill Point Inspect................................................................................................................ 10

8.5.4

Fire Extinguisher .................................................................................................................................................. 11

8.5.5

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

8.5.6

Pivot Points Lubricate ....................................................................................................................................... 14

8.5.7

Step Edge Nosing Inspect................................................................................................................................... 17

8.6
8.6.1
8.7
8.7.1
9

Walk-Around Inspection ......................................................................................................................................... 9

EVERY 2000 SERVICE HOURS OR YEARLY ................................................................................................................. 17

Rubber Bump Stops Inspect ............................................................................................................................... 17
EVERY 6 YEARS ......................................................................................................................................................... 17
Fire Extinguisher Pressure Test ........................................................................................................................ 17

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

9.1

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

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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, lubrication and
maintenance information for the crane access systems and must be used in conjunction with the
cranes operation and maintenance manual Publication No.: 3 112 310 en GMK 5220 Operating
Instructions Volumes 1 & 2 15-09-2006

Read, study and keep the operation and maintenance manual with the machine.

Whenever a question arises regarding the crane access systems, 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 systems.

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

1.3

Operation
The operation information is a reference for the new operator and a refresher for the experienced
one. This information includes a description of the controls, their location and operation with respect
to the crane access systems. Photographs and illustrations are provided to guide the operator
through the correct operating procedures for the access systems.

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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.

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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, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair 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.

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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.

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2.2

Safety Signs and Labels

There are several specific safety signs on your machine. Their exact location and description of the
hazard are reviewed in this section. Please take the time to familiarise yourself with these safety
signs. Make sure that you can read all safety signs. Clean or replace these if you cannot read the
words or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use
solvent, diesel etc.

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 and left side of the machine on the main frame for the access
platforms

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This sign is located inside the cab adjacent to the right joystick control

This sign is located on the outside of the cab door adjacent to the door handle

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This sign is located on the side of the crane cab access ladder

This sign is located on the side of the engine module access ladder

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This sign is located in two places on top of the hydraulics cabinet for the access platforms

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This sign is located inside the crane carrier cab

This sign is located inside the crane cab adjacent to the right joystick control

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This sign is located inside each ground level access system control box

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

2.3

General Hazard Information

Attach a Do Not Operate warning tag (as shown) to start
switch or controls before servicing or repairing the machine.

Know the width of the vehicle so proper clearance can be

maintained when operating near fences, boundary obstacles,
etc.

Wear a hard hat, protective glasses and other protective

equipment as required by job conditions.

Do not wear loose clothing or jewellery that can catch on

controls or other parts of the machine.

Make certain all-protective guards and covers are secured in

place on the machine.

Keep the machine, especially the deck, walkways and steps, free of foreign material, such as
debris, oil, tools and other items that are not part of the machine.

Secure all loose items such as personal protection equipment, lunch boxes, tools and other items
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that are not part of the machine in their appropriate locations.

Never put maintenance fluids into glass containers.

Report all needed repairs and do not allow unauthorised personnel on the machine.

Perform all maintenance unless otherwise specified as follows:

The machine parked on level ground.
The transmission control in NEUTRAL.
The parking brake engaged.
The engine stopped.
The start switch key off and the key removed.
All disconnect switch keys are off and the keys locked-out or removed.

2.4

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.

2.5

Crushing or 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 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.
Support equipment and attachments properly when working beneath them. Never attempt
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adjustments while the machine is moving or the engine is running unless otherwise specified.

Stay clear of all rotating and moving parts.

Retainer pins, when struck with force, can fly out and injure nearby persons. Make sure the area is
clear of people when driving retainer pins.

Wear protective glasses when striking a retainer pin to avoid injury to your eyes.

Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying
debris before striking any object.

2.6

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 systems before any lines, fittings or related items are
disconnected or removed.

Fill point cap for the hydraulic oil tank which services the handrails

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Fill point cap for the hydraulic oil tank which services the access platforms

2.7

Fire or Explosion Prevention

Damage of access platform 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.

Keep all fuels and lubricants stored in properly marked containers and away from all unauthorised
persons.

Store all oily rags or other combustible material in a protective container.

Do not weld or flame cut on or near hoses, tubes or pipes that contain flammable fluids.

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Remove all flammable materials such as diesel, oil and other debris before they accumulate on the
machine.

Do not expose the machine to flames, burning brush, etc., if at all possible.
2.7.1

Fire Extinguisher Location

This machine has been fitted with one 4.5kg dry chemical powder fire extinguisher. It is to assist the
operator to clear the machine in the event of a fire only and should not be used for major fire
fighting operations.

Fire extinguisher located on the front of the hydraulics cabinet

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1

1) Safety Pin
2) Latch

To remove and operate the fire extinguisher:

1) Safely access the fire extinguisher.
2) Remove the safety pin (1).
3) Rotate the latch (2) outwards to release the hold on the fire
extinguisher.
4) Remove the fire extinguisher from the mounting and egress the
machine using the extinguisher in accordance with instructions outlined
on the extinguisher label and mine site instructions.

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2.8

Lines, Tubes and Hoses

Damage of access platform 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 bend or strike high-pressure lines. Do not install bent or damaged lines, tubes or hoses.

Replace any damaged hydraulic oil lines, tubes and hoses. Leaks can cause fires.

Check lines, tubes and hoses carefully. 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.

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3

Identification Information
Data plates have been fitted to the access platforms and handrails which indicate the model
number, safe working load (where applicable), date of manufacture and the serial number.

3.1

Carrier Handrails

Data plate details for the handrails

Data plate for the left side handrail

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Data plate for the right side handrail

3.2

Crane Cab Access Platform

Data plate details for the crane cab access platform

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Data plate located on the side of the crane cab platform

Data plate located on the main support for the crane cab access system

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3.3

Engine Module Access Platform

Data plate details for the engine module access platform

Data plate located on the side of the engine module platform

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Data plate located on the main support for the engine module access platform

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4

System Stages, Uses & Prerequisites

4.1

General Description
The engine module and crane cab access platforms are a four stage electric-over-hydraulic folding
system. The access systems utilise 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 systems.

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 handrails.

Electrical power is only provided to the access systems if:

The crane carrier park brake is applied and remains applied. Refer to section Crane
Carrier Operation in the Transportation Information section of this manual.

Both machine isolation points are in the connected position. Refer below for locations on
the locations of isolation points. Refer to third party instructions on the use of the isolators.

Isolator for the upper engine is located at the left rear of the crane on the ancillary compartment

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Isolator upper engine

Isolator for the lower engine is located at the front right of the crane carrier

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Isolator lower engine

The system comprises of:

1) Left side access platform to the crane cab
2) Right side access platform to the crane engine module
3) Left and Right crane carrier deck mounted handrails

4.2

Crane Cab Access Platform - System Stages, Uses and

Prerequisites
The crane cab access platform is located on the left side of the machine (with the crane
superstructure position at 180) with controls located inside the crane cab and at ground level at the
right and left sides 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.

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Fully Lowered Crane Cab Access Platform

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4.2.1

Stage 1 Raise Start/Stage 4 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 completely lowering the access system

Positional indicator label located inside the crane cab adjacent to the access system controls

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Stage 1 Raise Start/Stage 4 Lower Finish

To enable this configuration:

The carrier park brake must be applied.

The superstructure must be facing forward (between -179.90 and +180.10) or rearward
(between -000.10 and +000.10) for the step ladder to lower.

Both machine isolation points are in the connected position.

With the access platform in the fully lowered position the system now provides:

Access to the crane operator cab from ground level.

Access to the electrical and battery boxes.

Access onto the carrier deck from the platform forward of the cab.

With the access system in this position the:

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Superstructure cannot slew.

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4.2.2

Stage 2 Raise Start/Stage 3 Lower Finish

If the crane counterweights are positioned on

the carrier deck then the crane cab access
platform must be fully retracted before slewing.
Failure to do so will result in damage of the
crane cab platform.
This is the recommended position for the operator cab access platform when the crane is in use as
the superstructure can slew in this configuration. This is NOT the configuration for slewing when
there are counterweights on the carrier deck.

Stage 2 Raise Start/Stage 3 Lower Finish

The access step ladder has now rotated through 150 degrees to enclose the platform and provides:

Access from the crane operator cab onto the carrier deck (Stage 1 Raise Start/Stage 4
Lower Finish).

To enable this configuration the:

Carrier park brake must be applied.

Both machine isolation points are in the connected position.

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With the access system in this position the:

Superstructure can slew. If the Engine Module is in the fully raised position the green visual
indicators (located at the rear of each side of the superstructure and inside the crane cab)
will illuminate. Refer to section Access System Configuration Indicators in the Mounting
and Dismounting section of this manual for additional information.

Last stage of lowering will only occur if the crane superstructure is facing forward (between
-179.90 and +180.10) or rearward (between -000.10 and +000.10).

4.2.3

Stage 3 Raise Start/Stage 2 Lower Finish

If the crane counterweights are positioned on

the carrier deck then the crane cab access
platform must be fully retracted before slewing.
Failure to do so will result in damage of the
crane cab platform.
This is an intermediate stage and is not a recommended position of the platform when the crane is
in use. However it does allow the crane operator to step off the platform onto the carrier deck in an
emergency from a slew position other than 0 and 180. This is NOT the configuration for slewing
when there are counterweights on the carrier deck.

Stage 3 Raise Start/Stage 2 Lower Finish

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The platform handrail has folded down through 90 degrees onto the platform and the system now
provides:

Emergency egress from the crane cab.

To enable this configuration:

The carrier park brake must be applied.

Both machine isolation points are in the connected position.

With the access system in this position the:

4.2.4

Superstructure can slew.

Stage 4 Raise Start/Stage 1 Lower Finish

If the crane counterweights are positioned on

the carrier deck then the crane cab access
platform must be fully retracted before slewing.
Failure to do so will result in damage of the
crane cab platform.
The step ladder has now folded down onto the platform. This is NOT a recommended position of
the platform including when the crane is in use and when there are counterweights on the carrier
deck.

Stage 4 Raise Start/Stage 1 Lower Finish

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To enable this configuration:

The carrier park brake must be applied.

Both machine isolation points are in the connected position.

With the access system in this position the:

4.2.5

Superstructure can slew.

Stage 4 Raise Start/Stage 1 Lower Start

The crane cab door must be closed before

completing the final stage of raising the crane
cab platform. Failure to do so will result in
damage of the crane cab door.

If the crane counterweights are positioned on

the carrier deck then the crane cab access
platform must be fully retracted before slewing.
Failure to do so will result in damage of the
crane cab platform.
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. The crane cab door must be closed for the platform to complete its last stage of raising.
Failure to do so will result in damage to the crane cab door. This is also the position the crane cab
access platform must be in if the cranes counterweights are to be removed, or are on the carrier
deck prior to slewing. Failure to do so will result in damage of the crane cab platform.

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Stage 4 Raise Finish/Stage 1 Lower Start

To enable this configuration:

The carrier park brake must be applied.

Both machine isolation points are in the connected position.

Crane cab door must be closed.

With the access system in the fully raised position the:

4.3

Superstructure can slew.

Carrier park brake can be released.

Crane carrier can be driven.

Engine Module Access Platform - System Stages, Uses and

Prerequisites
The engine module access platform is located on the right side of the machine (with the crane
superstructure position at 180) with controls located at ground level at the right and left sides 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.

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Fully Lowered Engine Module Access Platform

4.3.1

Stage 1 Raise Start/Stage 4 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 system or the beginning stage of the raising sequence of the
system. 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.

Positional indicator label to reference when completely lowering the access system

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Positional indicator label located inside the crane cab adjacent to the access system controls

Stage 1 Raise Start/Stage 4 Lower Finish

To enable this configuration:

The carrier park brake must be applied.

The superstructure must be facing forward (between -179.90 and +180.10) or rearward
(between -000.10 and +000.10) for the step ladder to lower.

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Both machine isolation points are in the connected position.

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With the access platform in the fully lowered position the system provides:

Access to the engine module and the access system hydraulic module from ground level.

With the access system in this position the:

4.3.2

Superstructure cannot slew.

Stage 2 Raise Start/Stage 3 Lower Finish

The access step ladder has now rotated through 150 degrees to enclose the platform. Personnel
are not permitted on the access platform at this intermediate stage.

Stage 2 Raise Start/Stage 3 Lower Finish

To enable this configuration:

The carrier park brake must be applied.

The superstructure must be facing forward (between -179.90 and +180.10) or rearward
(between -000.10 and +000.10).

Both machine isolation points are in the connected position.

Hydraulic cabinet and engine bay doors must be closed.

With the access system in this position the:

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4.3.3

Stage 3 Raise Start/Stage 2 Lower Finish

The platform handrail has folded down through 90 degrees onto the platform. Personnel are not
permitted on the access platform at this intermediate stage.

Stage 3 Raise Start/Stage 2 Lower Finish

To enable this configuration:

The carrier park brake must be applied.

The superstructure must be facing forward (between -179.90 and +180.10) or rearward
(between -000.10 and +000.10).

Both machine isolation points are in the connected position.

Hydraulic cabinet and engine bay doors must be closed.

With the access system in this position the:

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Superstructure cannot slew.

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4.3.4

Stage 4 Raise Start/Stage 1 Lower Finish

The step ladder has folded down onto the platform. Personnel are not allowed on the access
platform at this intermediate stage.

Stage 4 Raise Start / Stage 1 Lower Finish

To enable this configuration:

The carrier park brake must be applied.

The superstructure must be facing forward (between -179.90 and +180.10) or rearward
(between -000.10 and +000.10).

Both machine isolation points are in the connected position.

Hydraulic cabinet and engine bay doors must be closed.

With the access system in this position the:

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Superstructure cannot slew.

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4.3.5

Stage 4 Raise Finish/Stage 1 Lower Start

NOTICE
The superstructure will only slew if the engine
module access platform is in the fully raised
position (Stage 4 Raise Finish/Stage 1 Lower
Start).

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 is to be driven or the
superstructure is to be used.

Stage 4 Raise Finish/Stage 1 Lower Start

With the access system in the fully raised position the:

Superstructure can slew.

Carrier park brake can be released.

Hydraulic cabinet and engine bay doors must be closed.

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4.4

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 when the crane superstructure is facing forward (+180). 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. 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.
4.4.1

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).

Both machine isolation points are in the connected position.

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With the access system in this position:

4.4.2

Access onto the carrier deck is not permitted for maintenance purposes.

The carrier park brake can be released.

Handrails Raised

NOTICE
The crane superstructure will not slew if the
carrier deck handrails are in the raised position.
Therefore to slew, the carrier deck handrails
must be lowered.
Handrails have rotated through 90 degrees. The position allows for safe 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).

Both 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 is from the platform
forward of the cab.

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5

System Controls & Indicators

5.1

Handrails, Crane Cab & Engine Module Access Platforms

Controls to operate the access systems 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). Due to the arrangement of
the machine however, only the controls closest to the access platform will operate the hydraulics.
For example: If the crane superstructure is facing forward (180 position) with respect to the crane
carrier (ie. The crane cab platform is on the left hand side of the carrier) then only the left hand side
controls will operate the crane cab access platform hydraulics. Conversely, if the crane
superstructure is facing rearward (0 position) with respect to the crane carrier (ie. The crane cab
platform is on the right hand side of the carrier) then only the right hand side controls will operate
the crane cab access platform hydraulics. The crane cab controls for the access system will only
ever operate the crane cab access platform regardless of the orientation of the superstructure.

The ground level controls will only work at 0 and 180 positions, whereas the controls in the crane
cab can operate the crane cab access platform in any angular position with respect to the crane
carrier (ie. from 0 to 180).

However, stage 1 of raising (same as stage 4 of lowering) will only function if the crane
superstructure is positioned forward (between -179.90 and +180.10) or rearward (between 000.10 and +000.10). The crane superstructure will not slew if the crane cab access platform is

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fully lowered, ie. the rear ladder is lowered.

The access controls utilised on this machine are of the momentary push button type. This
necessitates 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 siren located inside the hydraulics cabinet will sound to warn
personnel around the machine that the access systems are being operated.

Crane cab controls for the access system

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1

Crane cab access platform controls include:

1) Access System Raise
2) Access System Lower
3) Access System Light
4) Access System Configured To Slew Indicator

There is a sign located inside the cab to indicate the functions for the crane cab controls
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GMK 5220 - Supplement

5-3

Labelling of the access system crane cab controls

Ground level controls for the access system located at the front right and left side of the crane
carrier

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Ground level controls for the access system (door closed)

Ground level controls for the access system (door open)

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1

Controls located within the compartment include:

1) Access Platform Raise
2) Access Platform Lower
3) Carrier Handrail Raise
4) Carrier Handrail Lower

5.2

Access System Lighting

NOTICE
No lighting provided for the engine bay access
platform.
Maintenance
and
inspection
procedures in low light conditions must include
sufficient lighting to illuminate required areas.

Located at the left rear of the superstructure is an access light fitted to illuminate the crane cab
access platform and ladder. The light is automatically operated in conjunction with the access
system controls on a timed period. After a pre-set time period the access light will switch off. If
mounting the machine from ground level with the access platforms in the fully lowered position
momentarily push any access system control and the light will illuminate for a pre-set period of time.

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Access system lighting

control located inside the
crane cab

Access system light located at the left rear of the superstructure

If at anytime illumination of the crane carrier access system is required when dismounting from the
crane cab, simply depress the button mounted in the crane cab and the light will illuminate for a
pre-set period of time and then switch off.

5.3

Ancillary Compartment
Dealer fitted electrical components to the left rear of the crane cab have been relocated to an
ancillary panel to left rear of the superstructure accessible from ground level (depending on the
angular position of the crane).

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Ancillary compartment located at the left rear of the crane

Ancillary compartment

Located on the ancillary compartment is a circuit breaker for the access platforms.

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6

Mounting & Dismounting Procedures

6.1

Crane Cab & Engine Module Access Platforms General

Information

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

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

Face the machine 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 handholds.

Never get on or off a moving machine.

Never jump off the machine.

Do not try to climb on or off the machine when carrying tools or supplies. Use a hand line to pull
equipment up onto the platform.

Do not use any controls as handholds.

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.

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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 Stage 4 Raise Finish to Stage 1 Lower Start with the
superstructure in the forward position (between -179.90 and +180.10) or rearward position
(between -000.10 and +000.10):

1. Ensure that the carrier park brake is applied.

2. Ensure both machine isolation switches (crane carrier mounted switch and the crane
switch) are in the connected position.
3. Go to the ground level controls for the crane cab access system situated at the front of the
crane carrier. If the superstructure is in the forward position (between -179.90 and
+180.10) then the left side controls must be used. If the superstructure is in the rearward
facing position (between -000.10 and +000.10) then the right side controls must be used.
4. Ensuring that the area is free from personnel use the appropriate control to lower the
access system. Continue to depress the control until the system has cycled through all
stages and the step ladder is in the down position. If at any stage during lowering an
intermediate stage is required simply release the control and the system will stop.

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6.3

Dismounting Procedure Crane Cab Access Platform

To dismount the crane cab after use of the crane:

1. Slew the machine to the forward position (between -179.90 and +180.10) or rearward
position (between -000.10 and +000.10). There are visual displays installed in the crane
cab which indicate when this has been achieved. Note: if the crane carrier is required to be
driven, the cab access platform must be returned to the left side of the machine ie. the
forward position (between -179.90 and +180.10).
2. Check to ensure that the area is free from personnel and that there is sufficient clearance
for the step ladder to lower.
3. With the crane in the forward position (between -179.90 and +180.10) or rearward
position (between -000.10 and +000.10) operate the controls in the crane cab to lower the
system. Continue operating the controls until the step ladder is in the fully down position.
4. Dismount the crane cab via the access platform and step ladder.
5. If the crane carrier is required to be driven locate the controls on the right side of the
machine and completely raise the access system until Stage 4 Raise has been achieved.

6.4

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 step ladder to ground level):

1. Slew the machine to any position which allows for egress from the crane cab and onto the
carrier deck via the side access platform.
2. Ensure that the access system is in the operational position ie. The platform is down and
the handrails are up.
3. Dismount the crane cab onto the carrier deck.
4. Exit the cab onto the carrier deck and locate the fire extinguisher (if accessible) mounted on
the front of the hydraulics cabinet.
5. Dismount from the carrier deck to ground level via the standard machine ladders where
possible.

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6.5

Dismounting Procedure Step Ladder Failure

If the step ladder fails to completely open and egress from the crane cab is not available via the
step ladder use the procedure for emergency use of the system as outlined above.

6.6

Mounting Procedure Engine Module Access Platform

NOTICE
The superstructure will only slew if the engine
module access platform is in the fully raised
position (Stage 4 Raise Finish/Stage 1 Lower
Start).

To mount the engine module access platform from Stage 4 Raise Finish/Stage 1 Lower Start:

1. Ensure that the carrier park brake is applied.

2. Ensure both machine isolation switches (crane carrier mounted switch and the crane
switch) are in the connected position.
3. Ensure that the crane engine access doors and the hydraulic cabinet doors are closed.
4. Ensure that the superstructure is positioned in either the forward position (between 179.90 and +180.10) or rearward position (between -000.10 and +000.10).
5. Go to the required ground level controls for the access system situated at the front of the
crane carrier. If the superstructure is in the forward position (between -179.90 and
+180.10) then the right side controls must be used. If the superstructure is in the rearward
position (between -000.10 and +000.10) then the left side controls must be used.
6. Ensuring that the area is free from personnel use the appropriate control to lower the
access system. Continue to depress the control until the system has cycled through all
stages and the step ladder is in the down position. If at any stage during lowering an
intermediate stage is required simply release the control and the system will stop.

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6.7

Dismounting Procedure Engine Module Access Platform

To dismount the engine module access system after use:
1. Orientate the machine into the forward position (between -179.90 and +180.10) or
rearward position (between -000.10 and +000.10) and use the cab controls to lower the
system only after checking that it is free from personnel.
2. Dismount the machine via the access platform and rear ladder.
3. With the crane in the forward position (between -179.90 and +180.10) or rearward
position (between -000.10 and +000.10) operate the ground level controls to raise the
system. Continue operating the controls until the step ladder is in the fully raised position.

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. Ensure that the carrier park brake is applied.

2. Ensure both machine isolation switches (crane carrier mounted switch and the crane
switch) are in the connected position.
3. Check to ensure that the superstructure is in the forward position (between -179.90 and
+180.10). If the superstructure is in any other position other than the forward position
follow procedures for mounting the crane cab via the access system and orientate the
superstructure so that it is in the forward position (between -179.90 and +180.10). If the
superstructure is already in the forward position follow procedures for mounting of the
crane cab access system.
4. Once the crane cab access system is in the fully down position, go to the required ground
level controls for the handrails situated at the front of the crane carrier. The left side

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controls operate the left side handrail and the right side controls operate the right handrail.
5. 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.
6. 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.
7. 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.

6.9

Crane Slewing and Use

If the crane counterweights are positioned on
the carrier deck then the crane cab access
platform must be fully retracted before slewing.
Failure to do so will result in damage of the
crane cab platform.

NOTICE
DO NOT LOWER CAB ACCESS PLATFORM
LADDER WHEN COUNTERWEIGHT WINGS ARE
FITTED. DAMAGE TO THE ACCESS SYTEM
MAY RESULT IF LADDER IS LOWERED WITH
COUNTERWEIGHT WINGS FITTED.

To allow use of the crane superstructure:

1. Follow steps outlined in the mounting procedure for the crane cab access platform.
2. Ensure that the engine module access platform is in the fully raised position.

NOTICE
The superstructure will only slew with the
engine module access platform in the fully
raised position (Stage 4 Raise Finish/Stage 1
Lower Start).

3. Access the crane cab and perform all manufacturer instructions to commence use of the

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crane.
4. Check to ensure that there are no counterweights on the carrier deck. If there are no
counterweights present on the carrier deck, raise the access system until Stage 2 Raise
Start/Stage 3 Lower Finish arrangement has been achieved. If there are counterweights on
the carrier deck then the crane cab access platform must be fully raised. When raising the
crane cab access system to the fully retracted position ensure that the crane carrier door is
closed.
5. Operate the crane in accordance with manufacturer and mine site instructions.
6.9.1

Access System Configuration Indicators

There are green visual indicators at the right and left sides of the crane superstructure as well as an
indicator located inside the crane cab which illuminates when the access systems are in the correct
configuration to allow for crane slewing and use.

When illuminated the:

Crane cab access platform is at Stage 2 Raise Start/Stage 3 Lower Finish or higher.

Engine module access platform is at Stage 4 Raise Finish/Stage 1 Lower Start

Crane cab access platform at Stage 2 Raise Start/Stage 3 Lower Finish

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Engine module access platform at Stage 4 Raise Finish/Stage 1 Lower Start

Green visual indicator on the crane cab side of the machine

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Green visual indicator on the engine module side of the machine

External Visual indicator

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Crane Cab Mounted Indicator

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6.10

Crane Carrier Operation

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.

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

Crane cab mounted audible and visual alarms

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Crane cab mounted indicators

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7

Transportation Information

7.1

Flag Holders
Brackets to allow for temporary fitting of wide load flags have been fitted to the front right and left
sides of the machine as well as both sides of the rear. Use the flag holders in accordance with
applicable mine site and government road rules and regulations.

Flag holders located at the front right and left side of the machine

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GMK 5220 Supplement

7-1

Front left flag holder

Flag holders located at the rear right and left side of the machine

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GMK 5220 Supplement

7-2

Rear left flag holder

7.2

Operating Width

NOTICE
Fitment of access platforms to this machine
has increased the crane carriers travel and
transport width to 3900mm.
There is a sign located inside the crane carrier cab to remind the operator of the crane carrier
operating width of the vehicle.

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Operating width label located on the centre console

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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 systems 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
No lighting is provided for the engine bay
access platform. Maintenance and inspection
procedures in low light conditions must
include sufficient lighting to illuminate
required areas.

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

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8.1

Maintenance Override Key

To prevent damage to the access systems,

crane carrier and the superstructure ensure
that all step ladders are 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 adjacent to the engine module
platform 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 all ladders are in
the raised position if it is anticipated that slewing of the superstructure is required.

Maintenance override switch located on the side of the hydraulics cabinet

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Maintenance override switch (lid closed)

Maintenance override switch (lid open)

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8.2

Hydraulic Oil Tanks

Replace the hydraulic oil and in-tank filter 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. Refill capacity of each tank is approximately 20
litres.

Fill point cap for the hydraulic oil tank which services the handrails

Fill point cap for the hydraulic oil tank which services the platforms

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Hydraulic oil tank level for both tanks should be at the black line indicated

8.3

When Required

8.3.1

Circuit Breaker - Reset

This machine has been fitted with two additional 105 Amp circuit breakers for the handrails and the
access platforms. The handrail circuit breaker is located at the front right of the crane carrier and
the circuit breaker for the access platforms is located on the ancillary compartment at the left rear of
the crane. Reset the circuit breakers when required. If a circuit breaker continually trips have the
circuit checked.

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8-5

Access platforms circuit breaker located at the left rear of the crane on the ancillary compartment

Access platforms circuit breaker

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GMK 5220 - Supplement

8-6

Handrails circuit breaker located at the front right of the crane carrier

Handrails circuit breaker

8.3.2

Drain/Fill Point Crane Engine Oil

The crane engine oil sump has been fitted with a drain/refill point that is now located on the right
side of the crane superstructure and is accessible from ground level. Use the drain/fill point in
accordance with procedures outlined by the manufacture for oil replacement intervals, refill
capacities as well as the type of oil and the viscosity required.

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Crane engine oil drain/refill point located at the right rear of the crane superstructure

Crane engine oil drain/refill point

To use the drain/refill point on this machine:

1. Remove the cap (1).
2. Connect hose to the quick release coupling (2).
3. Turn the lever (3) to open the valve.
4. Drain/fill the tank as required remembering that the oil maybe hot if the machine has just
been running. Refer to the Manitowoc manual for the refill capacity of the crane engine

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sump.
5. When finished draining/refilling close the valve by turning the lever (3).
6. Remove the drain/fill hose from the quick coupling.
7. Replace the cap (1).

8.4
8.4.1

Every 10 Service Hours or Daily

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.

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 left rear of the crane superstructure
operates in conjunction with the access system controls.

Check to ensure that the audible alarms located adjacent to each hydraulic oil tank sound
whenever the access system controls are activated.

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.

Visually inspect all hydraulic lines, hoses, fittings and hose clamps for security, damage,
deterioration and leaks. Check for pools of oil under the machine which may indicate a
possible problem or damaged item.

Visually inspect all switches of the system. Ensure components mounted on the ancillary
compartment are secure and tight. Have any damaged items repaired or replaced.

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.

8.5

Every 1000 Service Hours or 6 Months

8.5.1

Bolts and Mounting Hardware

Check the tightness of all bolts fitted to the access systems. This includes checking the standard
deck bolts as well as the handrails, access platforms and their mountings as well as the stair
treads.

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8.5.2

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.

Crane carrier cab mounted audible and visual alarms

8.5.3

Engine Oil Drain/Refill Point Inspect

Inspect the crane engine oil drain/refill point for damage and security. Ensure that the fittings are
not leaking and the mounting bolts are secure. Inspect the hose which runs to the engine sump for
damage and security. Have the hose replaced if damaged or leaking.

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Crane engine oil drain/refill point hose

8.5.4

Fire Extinguisher
Perform the following maintenance on the fire extinguisher:

Remove the extinguisher from the mounting and turn the fire extinguisher upside down for
10 minutes to ensure that the powder is free flowing. After 10 minutes return the
extinguisher back to the mounting checking to ensure that the mounting bracket is secure
and the strap holding the extinguisher is tight.

Check to ensure that the pressure is in the green zone. Have the extinguisher serviced by a
registered fire extinguisher service organisation or replace the extinguisher.

Check to ensure that there are no blockages to the nozzle or outlet.

If an extinguisher is discharged, even partially, it needs to be refilled by a registered fire

extinguisher service organisation.

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8.5.5

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.

Operating Instructions
GMK 5220 - Supplement

8-12

Hydraulics cabinet (lid closed)

Components within the hydraulic cabinet

Operating Instructions
GMK 5220 - Supplement

8-13

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8.5.6

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 each side platform. Grease both the engine module
and crane cab access platforms.

Two grease points for the crane cab access platform

The points where the ladder rotates on the pivoting arms are also required to be greased at this
interval. This includes two points on the crane cab side and two points on the engine module side.

Operating Instructions
GMK 5220 - Supplement

8-14

Outer end cap for the crane cab ladder

Outer end cap for the engine module access ladder

Operating Instructions
GMK 5220 - Supplement

8-15

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1

End cap (1) and mating surface required to be greased

To grease the end cap matting surface of the access ladders:

1. Remove the bolt holding the end cap.
2. Remove the end cap (1) and apply grease to the mating surface. Note: the entire surface is
not required to be grease only the outer of the mating surface.
3. Replace the end cap (1).
4. Apply Loctite to the bolt and reinstall. Tighten the bolt to the torque value indicated in table
1.
5. Repeat this procedure three more times for the remaining end caps.

TORQUE SETTING
Bolt Specification: M16 grade 8.8

Operating Instructions
GMK 5220 - Supplement

Torque: 210 N/m

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8.5.7

Step Edge Nosing Inspect

Check to ensure all step-edge nosing is secure and not missing. Replace nosing as required. Also
check the condition of anti-slip and black and yellow tape fitted around the machine. Replace as
required.

Stair edge nosing, anti-slip and black and yellow tape located on the engine module access
platform

8.6
8.6.1

Every 2000 Service Hours or Yearly

Rubber Bump Stops Inspect
Inspect the condition of rubber bump stops mounted to the access system. Replace as required.

8.7

Every 6 Years

8.7.1

Fire Extinguisher Pressure Test

Ensure the fire extinguisher is pressure tested by a registered fire extinguisher service organisation.

Operating Instructions
GMK 5220 - Supplement

8-17

Typical bump stops located on the crane cab access ladder

Operating Instructions
GMK 5220 - Supplement

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9

Literature Reference Materials

9.1

Manitowoc Reference Material

The following literature can be obtained through Manitowoc Crane Group.

3 112 310 en

Operating Instructions
GMK 5220 - Supplement

GMK 5220 Operating Instructions Volumes 1 & 2 15-09-2006

9-1