19. Appx 6 MHE.docx

APPENDIX 6 – MATERIAL HANDLING EQUIPMENT WEIGHT TEST PROCEDURES

1. Purpose: The following are guidelines for accomplishing weight testing on Material Handling Equipment (MHE). These guidelines are to be used as a means of safely exercising MHE hydraulic systems and pumps under a normal expected load as specified in Section C-1-1, para 11.1.5 of the contract PWS.

2. Applicability: These guidelines specifically address weight testing of 10K forklifts, 25K loaders, 40K loaders and 60K loaders. However, the basic guidelines can be applied to other types of MHE (i.e. wide body elevator loaders, 25K High Reach Mod) as well.

3. Safety: The most important aspect of weight testing the respective MHE is safety. At no time or under any circumstances should safety be compromised in the accomplishment of the weight testing procedure.

a. Never exceed maximum rated load for the vehicle/equipment being tested. Maximum load capacity is annotated on vehicle data plates and in T.O.'s. It must be noted that some vehicles cannot lift their full rated load throughout their entire range of motion. For instance, a 10K forklift may lift 10K pounds with the mast perpendicular to the ground, but it may not safely lift 10K with the mast tilted forward.

b. Personnel assisting in weight testing must remain out from under the test load at all times. Under no circumstances should anyone place themselves in a position where they would be endangered by a falling load.

c. Particular attention must be paid to vehicle safety devices and limit switch operation during lifting operations. Any discrepancies noted should be reported to maintenance immediately.

4. Test Loads: For purposes of conducting weight testing on K-loaders, standard loads will be comprised of concrete barriers placed on and strapped to, 463L pallets. No pallet is required for forklift tests. Note that barriers weigh approximately 7,600 pounds, and 463L pallets weigh 290 pounds each. The utmost care must be used in handling barriers and pallets. Normal test loads are identified below:

a. 10K forklift: one barrier.

b. 25K aircraft cargo loader: 2 pallets with one barrier per pallet.

c. 40K and 60K aircraft cargo loaders: 3 pallets with one barrier per pallet.

5. Specific Procedures for 10K Forklift:

a. Perform preoperational checks as described in applicable T.O.

b. Place a barrier on fully lowered forks. NOTE: Before proceeding, check vehicle data plate and or T.O. to ensure the forklift is capable of performing these tasks with the test load.

c. Fully extend and retract the loaded carriage and mast assembly five times. Sideshift the carriage assembly five times. Tilt the mast five times, making sure the mast tilt cylinders operate and stop evenly. Ensure there is no binding in the mast and that inner and outer weldments and carriage assembly move freely. Lower the carriage assembly to the ground.

d. Raise forklift carriage 3 feet. Place the lift/lower control in neutral. Allow the load to remain suspended for 10 minutes. Check main lift cylinder and tilt cylinders for drift. Hydraulic cylinder drift of more than 1 inch indicates problems in the hydraulic system. Lower the forklift carriage to the ground

e. Down load and store barrier.

f. If any discrepancies were noted, turn the vehicle in to maintenance for repair.

6. Specific Procedures for 25K and 40K Loaders:

a. Perform preoperational checks as described in applicable T.O.

b. Place one loaded 463L pallet on the loader deck. Ensure the emergency pallet stops are raised. Use the pallet conveyors (if equipped) to move the pallet the length of the loader deck. Ensure proper operation of all conveyors.

c. If weight testing a 25K, place one additional loaded pallet on the loader deck, if testing a 40K, place 2 additional loaded pallets on the deck. Engage the pallet locks.

d. Raise and lower the loader deck fully 5 times. Ensure free movement of the deck throughout its range of motion.

e. Raise the loader deck at least 5 feet, and exercise the deck roll and side shift functions.

Ensure free movement of the deck throughout its range of motion. Return deck to center and level position. Leave the deck raised for 20 minutes, and check for hydraulic cylinder drift. Lower the deck all the way.

f. Down load and store all pallets.

g. If any discrepancies were noted, turn the vehicle in to maintenance for repair.

7. Specific Procedures for 60K Loaders.

a. Perform Operator Inspection IAW Operator T.O. 36M2-35-11. Check critically for any evidence of leaks under the loader.

b. Start loader, allow to warm up and check carefully for leaks or abnormalities.

c. Fully extend and lower the suspension system five times, bypassing the load and travel positions. Return the suspension to the load position.

d. Place one loaded 463L pallet on the 60K. Using the pallet conveyors, shift the pallet from the rear of the 60K to the front of the 60K then back to the rear of the 60K. Repeat this process 5 times.

e. Place two more loaded pallets on the 60K loader (total of 3) and lock them down using the pallet locks.

f. Raise and lower the suspension system five times, from the load position to the travel position, ending in the load position.

g. Raise the loader deck to its highest point and lower it to its lowest point. Accomplish this five times. After the fifth ascent, leave the deck fully extended for approximately ten minutes, then check for hydraulic cylinder ram leak down and fluid leakage.

h. Lower the deck completely. Raise the deck approximately three feet above the chassis.

i. Perform the following functions. Each function should be repeated five times.

(1) Roll the deck left, then right. Return the deck to level position.

(2) Fully side shift to the right then to the left. Return the deck to center position.

j. Lower the deck to its lowest point.

k. Perform after operation inspection IAW T.O. 36M2-35-11, section 2-6.

l. Download and store all pallets.

m. If any discrepancies were noted during the exercise procedures, the 60K must be turned in to maintenance for repair.

APPENDIX 6 – MATERIAL HANDLING EQUIPMENT WEIGHT TEST PROCEDURES