MAJOR INSPECTION SPECIFIC RECOMMENDATIONS

Transcription

1 MAJOR INSPECTION SPECIFIC RECOMMENDATIONS MODELS: TT16, TT19 1 GENERAL This document outlines specific recommendations relating to GMJ EWP Models TT16-300, TT and TT19-350S. It is to be read in conjunction with the general requirements for major inspections. 2 AS (INT) 2004 The above models were designed to the requirements of AS and the following is noted: 1. These units are not fitted with High Voltage Chassis Insulation as required by AS The Low Voltage Insulation does not meet the requirements of the Ring Test specified in AS The insulation rating of these models, in the clean and dry condition is 66kV/LV DRY Only. Hazards addressed by these requirements are outlined in AS Appendix L. It is the responsibility of the owner to determine the continued suitability of the EWP relative to the type of work being performed. 3 SAFETY DEVICES The National Regulators Group for High Risk Plant has published guidelines with respect to safety devices on new EWP s. AS requires investigation of the practicability of upgrading to the requirements of AS1418 and it is possible that the requirements could become retrospective. Applicable requirements for safety devices on these models include a) Installation of an emergency stop system, b) Modification of the Boom interlock system to achieve Category 3 safety security. c) Modification of the outrigger interlocks to achieve Category 1. d) Provision of the travel interlock, to prevent the vehicle being driven with the boom raised. Page 1

2 4 SPECIFIC RECCOMMENDATIONS 4.1 Emergency Stop Install an Emergency Stop System which can be by Fibre-Optic control from the basket, emergency stop switches at the turret and tray interfaced with a Pico-Guard safety controller. Radio control, is also available. Consult GMJ for details. 4.2 Upper Controls Mechanical Lock in Neutral Controls These are provided at the basket and consist of joysticks that lock in the neutral or off position when released. This control arrangement must be fitted with an emergency stop system at the basket, turret and tray. The joysticks can be replaced with a power on switch that can is activated when the joystick handle is lifted from the neutral position which can be interfaced with the hydraulic system so that hydraulic pressure is made available to the main control valve when the handle is lifted. Maintenance of the Joystick assembly: Check the following: (i) The boot for damage and wear. Replace as necessary. (ii) The cap located on top of the joystick handle seal the cap to prevent ingress of moisture. (iii) Free movement of the joystick and in particular the sliding motion of the joystick handle. Lubricate with silicon grease and replace the boot Hydraulic Pilot Joysticks with separate Deadman Lever. Check the following: (i) The boot for damage and wear. Replace as necessary. (ii) The cap located on top of the joystick handle seal the cap to prevent ingress of moisture. (iii) Free movement of the joystick. Lubricate with silicon grease and replace the boot. (iv) The deadman lever and valve. Check in particular free movement of the valve and that it returns to the closed position when the lever is released. 4.3 Power Tool Outlets Power tool Outlets should be arranged to point away from the basket 4.4 Hydraulic Hoses and basket leveling Ensure that all hydraulic hoses are secured and do not lie loosely beneath the basket. Check the hoses connected to the leveling cylinder, the holding valve and valve fittings. On units with the leveling cylinder beneath the basket, check the mechanical security of the externally mounted holding valve. Page 2

3 4.5 Lower Controls Mechanical Lock in Neutral Controls These units are fitted with a control selector and basket tilt control. Check the operation of all control levers in all positions. Ensure free movement of all levers. Check the operation of the Emergency Stop System, and ensure that with the Emergency Stop depressed at the upper controls the lower controls can override the upper stop and still function to effect retrieval Hydraulic Pilot Joysticks with separate Deadman Lever. Check the following: That the deadman operates and all controls return to neutral when released. 4.6 Outrigger Interlocks Installation of striker bars and limit switches on the rear outriggers. 4.7 Boom Reach Interlocks This system consists of limits switches located on the outer boom to limit the degree of extension depending on the boom angle. Switches are located on the turret near the rear of the boom (Angle detection) and on each side of the outer boom 9Length detection). (Refer to the manual) Check the operation of each switch separately to ensure: (a) That the boom does not telescope when one single switch on the turret is depressed. (Check each in turn) (b) The boom cannot lower when one switch on the boom is activated (check each in turn). Check each switch for free movement and proper operation. 4.8 Leveling System (i) Replace the threaded clevis on the lower end of the leveling rod located in the fly boom. (ii) Check pivot pin grease galleries are clear and free of debris (iii) Seal the upper end of the leveling rod against ingress of moisture and contaminants (iv) Replace bushes. (v) Check the relief valves and checks located in the turret. 4.9 Telescopic System Chains Replace chains and chain end anchor bolts. Note the chains are permitted to freely rotate and nuts and lock nuts are placed on the one side of the anchor points Telescopic Cylinder Check the cylinder rod for damage and scoring. Strip and reseal and NDT (MPI Inspection) barrel welds, the rod end weld and threaded end. Page 3

4 Note: The bolts supporting the cylinder at the rod end are not intended to be torqued and should provide a clearance between the head of the bolt and the cylinder of 3-4mm on assembly. Check on assembly that bolts do not interfere with boom support rollers Booms Visually Inspect all booms and NDT critical weldments such as: (i) Cylinder connections and associated structure. (ii) Check the leveling cylinder connection at the lower boom for cracking and deformation of the angle cross member. (iii) Chain Anchor Points (iv) Chain sprocket mounts (v) The rails located under the middle boom. (Also for damage and distortion) (vi) The support roller fabrications at the end of the outer and middle boom (vii) Check the rear of the middle boom for damage to the chain sprocket pin mounting. (viii) All pivot bosses Visually Inspect: (i) The interior of the middle and outer booms for corrosion (especially at the turret end of the outer boom) and for scoring as a result of worn wear pads. (ii) The ends of the fly boom for corrosion and separation of the glass insert. (iii) Check the LV FRP wrap for laminations this can be checked by tapping the glass. Any areas of separation between the glass and the steel must be repaired by removing the glass, preparing the surface and covering with 4mm FRP Basket Visually Check: (i) Harness anchorage points (replace if worn) (ii) Drain Holes (<15mm diameter) (iii) Floor and steps (cracks and wear) (iv) Structure for cracks/ damage Check the basket tie down strap and anchorages. GMJ recommends the installation of a tie down strap interlock to prevent raising the boom with the tie down secured. Drain holes should be fitted with shields to prevent breaching the insulation through the hole. NOTE: Fully enclosed baskets must be provided with a cover Turret NDT the turret in the following areas: The side plate/base Plate Welds Levelling cylinder anchorage Lower Boom Cylinder Anchorage All pivot bosses Strip and Inspect the slew brake. Page 4

5 4.13 Outriggers Outriggers should be inspected for wear and signs of cracking. Inspect and replace wear pads as necessary. NDT outrigger subframe connections and at the ends of the outer housing assembly at both ends. Check security of limit switches and check for internal corrosion Chassis/Subframe Replace all subframe mounting bolts and correctly torque. NOTE: Bolts should have shanks in contact with the shear plates and chassis. 5 TESTING 5.1 Functional Test 1 From the lower controls: Operate the unit through all motions and confirm: No sign of interference, Correct smooth operation Proper functional of the boom reach interlock. Check basket leveling and tilt control. Check operation of manual release screws, emergency pump and pressure settings and speeds. (Consult manual for these settings). 5.2 Stability Test Procedure 1 Remove all equipment and tools from the vehicle. Set up the unit on a 5.5 degree side slope Outriggers engaged Extend the boom to maximum reach over the rear of the vehicle Apply 475kg to a sling suspended from the basket mounting bracket. Gradually slew the unit towards the front on the downhill side. Outriggers must remain in contact with the support surface. Repeat the test over the opposite side. 5.3 Stability Test 2. (non interlocked rear outriggers) Remove all equipment and tools from the vehicle. Set up the unit on a 5.5 degree side slope Front outriggers engaged only Deflate the outside rear tyre on the downhill side Extend the boom to maximum reach over the rear of the vehicle Apply 475kg to a sling suspended from the basket mounting bracket. Gradually slew the unit towards the front on the downhill side. Outriggers must remain in contact with the support surface. Rear tyres must remain in contact with eth support surface Repeat the test over the opposite side. 5.4 Dynamic Test Apply kg distributed in the basket. Operate boom through all motions one at a time through the entire operating envelope bringing each motion to a halt at maximum height, and maximum reach. Page 5

6 5.5 Functional Test 2 Operate the unit from the upper controls and check operation of all controls and check for binding and interference. 5.6 Electrical Insulation Test The insulation system on the unit must be acceptance tested according to the requirements of AS for an insulation rating of 66kV/LV/LV DRY. NOTE: An insulating liner should not be fitted to these units. Page 6