TECHNICAL_EXHIBITS.pdf

SAFETY INSPECTION AND WEIGHT TEST CERTIFICATION

OF AERIAL MAINTENANCE PLATFORM

USN NO.

COMMAND:

MANUFACTURER:

EQUIPMENT TYPE:

AERIAL MAINTENANCE PLATFORM

SERIAL NUMBER:

BASKET #

MODEL:

MODEL YEAR:

HOUR METER:

CAPACITY:

500 Lbs. Unrestricted

CERTIFICATION:

This is to certify that inspections and tests have been conducted in accordance with procedures set forth in the current NAVFAC P-300 and applicable manufactures technical manual. It is further certified that the above Aerial Maintenance Platform is satisfactory to lift its rated capacity and is fully operational.

Certified for 500 Lbs., (500 lb. un-restricted). Percent testing 100% .

Not certified for electrical or hot work

X Annual Certification Special Certification

Certification Date:

Expiration Date:

Inspector (printed name)

Inspector (signature) Date

MHE-11-2010

REVISED 07/19/10

PERIODIC MAINTENANCE INSPECTION AND SERVICE

AERIAL WORK PLATFORMS (AWP)

TECHNICAL EXHIBIT

1. Structure:

The Contractor shall inspect the platform's structural components for obvious physical damage, such as cracking, bending and deformation of members or welds. The Contractor shall also inspect the paint for cracking or flaking.

2. Hardware:

The Contractor shall inspect the entire platform for missing or loose bolts, nuts, brackets or supports.

3. Tires:

The Contractor shall inspect the condition of the tires. The Contractor shall ensure proper inflation and verify tread is not damaged or cut.

4. Hydraulic System:

The Contractor shall inspect all hydraulic lines for any possible loose connections and/or damaged fittings or hoses.

5. Hydraulic Leaks:

The Contractor shall inspect all hydraulic lines, reservoir, fuel tank, engine and gearbox for leaks.

6. Hydraulic Tank:

The Contractor shall inspect the tank for any possible damage and verify the level of hydraulic fluid.

Level should be midway between 3/4 and full with the boom in the fully lowered and retracted position.

7. Gauges & Indicators:

The Contractor shall inspect for broken, missing, inoperable or non-calibrated gauges, indicators and warning lights.

8. Basket:

The Contractor shall rotate basket to the left and to the right, in order to verify the freedom of movement of the Basket.

9. Steering:

The Contractor shall rotate the steering wheel to the left and to the right. Move aerial platform forward and aft a few feet. Ensure movements are smooth and properly operational.

10. Start-up:

The Contractor shall at the ground control console, position selector switch to "Ground". Turn ignition switch and start engine. Test all functions and verify proper operation.

11. Unusual Noises:

The Contractor shall after starting engine, listen and note any unusual noises, check for any fluid leaks, loss of power, or poor response to controls. Verify the proper operation and correct readings of all gauges and indicators. Verify that the battery is charging.

12. Stop Circuit:

The Contractor shall after the initial warm-up (5 minutes), perform engine turn off at the ground control console.

13. Aerial Control:

The Contractor shall Reposition the Aerial/Ground selector switch to "Aerial". Place ignition switches to ON position and start engine from aerial platform. After Starting the engine the Contractor shall verify proper operation of the following controls: Boom Up/Down, Rotation CW/CCW, Platform Rotation, Boom Out/In, Drive FWD/ Reverse, Throttle High/Low and Platform Tilt.

14. Boom Operation:

The Contractor shall raise and lower boom checking for freedom of movement. Extend and retract boom, and check freedom of travel. Swing boom to left and right, and check for freedom of movement.

15. Emergency Stop Switches:

The Contractor shall shutdown the engine using each of the emergency stop switches. Verify entire system shuts down.

16. Emergency System Checkout:

The Contractor shall after shutting engine off using one of the emergency stop switches, start emergency motor driven hydraulic pump and operate at least one function to verify emergency hydraulic pump is working.

17. Off-Level Warning:

The Contractor shall manually operate the off level warning device so the audible alarm can be heard, indicating the level system is functional.

18. Perform Weight Test:

The Contractor shall place the rated load on platform, lift the platform to full extension, hold for two minutes, and verify that no drifting or leaking occurs. Contractor shall then fully extend the boom to each side to test vehicle stability.

19. Maintenance:

The Contractor shall perform period maintenance requirements identified in the applicable manufacturer Technical Manual.

20. Forms:

The Contractor shall fill out and sign the attached Aerial Work Platform (AWP) Safety Inspection and Weight Test Certification. The original signed form shall be provided to the ship's Master or his designated representative. A copy of the signed form shall be provided to the MSC Norfolk MHE Program Management office.

SERVICE PERFORMED BY CONTRACTOR

PERIODIC MAINTENANCE SERVICE - DIESEL FORKLIFT

1. PERFORM DIAGNOSTICS

Perform diagnostic service utilizing dashboard display, and – when required - Hyster approved and authorized Off-Board Laptop Diagnostic

Troubleshooting Software, hardware, and diagnostic procedures.

2. PEFORM VISUAL

INSPECTION

3. PERFORM OPERATIONAL

4. CLEAN VEHICLE AND

COMPONENTS

Continued on next page

Perform a complete inspection of the vehicle to include, but not be limited to, the following:

-Fluid Leaks

-Carriage, including Rollers and Slide Blocks

-Forks and Locks

-Mast Chains, Retainers, and Anchors

-Tire Condition

-Steering Components

-Overhead Guard

-Improper Modifications

-Seat Condition and Belts

-Attachments, including towing devices

-Safety Devices

-Neutral Starting Switch

-Instruments/Horn/Lights

-Brakes, Pedals, and Linkages

-Forward and Reverse Vehicle Operation

-Parking Brake

-Inching Control

-Shift Levers

-Steering

-Exhaust Smoke

-Mast Operation

-Tilt Cylinder Operation

-All Attachments

-Backup Alarms

-All Painted Areas

-Radiator and Engine Compartment

-Steer and Drive Axle

-Mast

-Under Floor Plate

-Control Panel Area

-Operator Area

-Battery Tray

5. INSPECT ELECTRICAL

SYSTEMS

6. INSPECT HYDRAULIC

7. LUBRICATE VEHICLE

8. INSPECT FUEL SYSTEM

(as equipped)

9. PERFORM ADDITIONAL

MAINTENANCE ACTIONS:

Continued on Next Page

-Panel Power Connections

-Check Seat Switch

-Check Wire Connections and Condition

-Check Distributor Cap and Rotor (if equipped)

-Clean Battery Cable and Connections

-Other Electrical Components, as Installed

-Perform Repairs, as required

-All Hydraulic Lines, Hoses, and Fittings

-Mast and Hose Reel

-Lift, Tilt, and Shift Cylinders

-Hydraulic Tank and Breather

-Hydraulic Pumps

-Attachment Links

-Attachment Cylinders

-Control Valve Operation and Leaks

-Other Hydraulic Systems, as installed

-Perform repairs, as required

-Clutch Pedal

-Accelerator Pedal

-Drive Line U-Joints

-Steer Axle

-Steering Mechanisms

-Mast, Chains, Rollers, Carriage Attachments

-Brakes and Parking Brake Linkages

-Accelerator Pedal

-Direction Pedal

-Lift and Tilt Control Hinges

-Other Lubrication Points, as installed

-Check for Leaks

-Check Fuel Lock-Off Regulators and Drain

-Clean Water Trap

-Perform Repairs, as Required

-Verify Stencils/Marking Per NAVSUP P-538 and Re-Stencil/Re-Mark as needed

-Check for Error Codes and Perform Non-Major

Repairs, as required, to Clear Code

-Check Mast Mounting Trunions and Re-Torque

Bolts, as Needed

-Repack Leaking Lift, Tilt and Shift Cylinders

-Adjust Load Chains and Cylinder Rods

-Complete Electrical Tune-up (plus wires, rotors, etc, as equipped)

9.ADDITIONAL ACTIONS

(CONTINUED):

End of Technical Exhibit

-Check/Adjust Belts Condition and Tension;

Replace as Required

-Check Engine Compression

-Check and Adjust Ignition Timing (as equipped)

-Check and Adjust High and Low Engine RPMs

-Adjust Engine Valves and Replace Valve Cover

Gasket (as equipped)

-Clean & Check PCV Valve (as Equipped);

Replace as Needed

-Check/Clean Induction System

-Clean Filter Canister, Pre Cleaner

-Check Radiator Hoses; Replace as Required

-Replace Air Cleaner

-Replace Final Fuel Filter (as equipped)

-Change Engine Oil and Filter

-Change Transmission Oil and Filter

-Change Hydraulic Oil and Filters

-Change All Differential, Speed Reducer, and

Final Drive Lubricants

-Drain, Flush, and Change Coolant

-Adjust Hydraulic Pressure, as required

-Inspect lights, Backup Alarm, and Associated

Wiring; Repair/Replace, as required

-Remove Steer and Drive (Load) Wheels;

Inspect and Repack Bearings

-Check Brakes, Wheel Cylinders, and

Associated Hardware; Adjust/Repair as required

-Re-Torque Drive and Steer Wheel Nuts

-Evacuate Brake System; Replace Fluid with

DOT 3 Brake Fluid, or Per Tech Manual

-Adjust Parking Brake and Linkage; Repair as required

-Adjust Steering Linkage; Repair as required

-Re-Adjust all Brakes, as Required

-Perform Basic Corrosion Control Utilizing Wire

Brush and Spot Paint Techniques.

-Submit Condition Found Report (CFR) and

Quote for Required Major Repairs

PERIODIC MAINTENANCE SERVICE - ELECTRIC FORKLIFT

1. PERFORM DIAGNOSTICS Perform diagnostic service utilizing dashboard display, and – when required - Hyster approved and authorized Off-Board Laptop Diagnostic

Troubleshooting Software, hardware, and diagnostic procedures.

2. PERFORM VISUAL

3. PERFORM OPERATIONAL

4. CLEAN VEHICLE AND

COMPONENTS

Continued on next page

Perform a complete inspection of the vehicle to include, but not be limited to, the following:

-Fluid Leaks

-Carriage, including Rollers and Slider Blocks

-Forks and Locks

-Mast Chains, Retainers, and Anchors

-Tire Condition

-Steering Components

-Overhead Guard

-Improper Modifications

-Seat Condition and Belts

-Attachments, including Towing Devices

-Safety Devices

-Neutral Starting Switch

-Instruments/Horn/Lights

-Brakes, Pedals, and Linkages

-Forward and Reverse Vehicle Operations

-Parking Brake

-Shift Levers

-Steering

-Mast Operations

-Lift, Tilt, and Shift Controls

-All Attachments

-Backup Alarms

-All Painted Areas

-Steer and Drive Axle

-Mast

-Under Floor Plate

-Control Panel Area

-Operator Area

-Battery Compartment and Tray

-Motors and Pumps

5. INSPECT ELECTRICAL

6. INSPECT HYDRAULIC

7. LUBRICATE VEHICLE

8. SERVICE BATTERIES AND

BATTERY CHARGERS:

-Panel Power Connections

-Check Contactor Tips

-Check Seat Switch

-Battery Discharge Indicator, as installed

-Current Limiter, as installed

-Other Electrical Components, as installed

-All Hydraulic Lines, Hoses, and Fittings

-Mast and Hose Reel

-Lift, Tilt, and Shift Cylinders

-Hydraulic Tank and Breather

-Hydraulic Pumps

-Attachment Links

-Attachment Cylinders

-Control Valve Operation and Leaks

-Other Hydraulic Systems, as installed

-Steer Axle

-Steering Mechanisms

-Mast, Chains, Rollers, Carriage Attachments

-Brakes and Parking Brake Linkages

-Accelerator Pedal

-Direction Pedal

-Lift and Tilt Control Hinges

-Other Lubrication Points, as installed

-Perform Battery Voltage Tests

-Check/Clean/Adjust Battery Cables

-Check/Clean/Adjust Battery Connectors

-Clean Terminals, Bus Bars and Top of Battery

-Fill Flooded Batteries with Double-Distilled Water

-Check Specific Gravity of Cells, as appropriate

-Charge Battery and Evaluate Overall Health

-Check Battery Charger Settings and Reprogram

Chargers, as required

9. PERFORM ADDITIONAL

MAINTENANCE ACTIONS:

Continued on Next Page

-Verify Stencils/Markings Per NAVSUP P-538 and

Re-Stencil/Re-Mark as needed

-Check for Error Codes and Perform Non-Major

Repairs, as required, to Clear Code.

-Replace Faulty Encoder Bearings

-Check Mast Mounting Trunions and Re-Torque

Bolts, as needed.

-Repack Leaking Lift, Tilt and Shift Cylinders

-Adjust Load Chains and Cylinder Rods

-Change Hydraulic Oil, Filters, and Breathers

-Adjust Hydraulic Pressure, as required

9.ADDITIONAL ACTIONS

(CONTINUED):

End of Tech Exhibit

-Replace Loose/Warn Hydraulic Pump Motor

Mount Bushings

-Inspect Lights, Backup Alarm, and Associated

Wiring; Repair/Replace, as required.

-Check and Adjust Current Limiter

-Remove Steer and Drive (Load) Wheels, Inspect and Repack Bearings

-Check Brakes, Wheel Cylinders, and Associated

Hardware; Adjust/Repair as required.

-Re-Torque Drive and Steer Wheel Nuts

-Evacuate Front and Rear Brake Systems; Replace

Fluid with DOT 3 Brake Fluid, or per Tech Manual.

-Check and Adjust Rear Brake Master Cylinder, Actuator Cable, Pivot Mechanism, Brake Lines, and

Associated Hardware; Repair as required.

-Adjust Parking Brake and Linkage; Repair as required.

-Check and Adjust Plugging Distances

-Adjust Steering Linkage; Repair as required

-Raise Rear of Vehicle and Manually Test Rear

Brake Operation (with brake pedal pressed).

-Re-Adjust all Brakes, as required

-Perform Basic Corrosion Control Utilizing Wire

Brush and Spot Paint Techniques.

-Submit Condition Found Report (CFR) and Quote for Required Major Repairs.

SAFETY CERTIFICATION

1. PERFORM FORK INSPECTION Inspect forks in accordance with the Fork

Maintenance Inspection Procedures listed in

NAVSUP Pub 538.

2. PERFORM PERIODIC TESTING Complete all General Periodic Tests for MHE in accordance with the requirements set forth in NAVSEA SW023-AH-WHM-010.

3. PERFORM WEIGHT TESTS Perform weight tests in accordance with the requirements specified in NAVSUP Pub 538 and NAVSEA SW023-AH-WHM-010.

4. RE-STENCIL FORKLIFT Re-stencil the certification expiration data on the forklift - or affix a label - in accordance

NAVSEA SW023-AH-WHM-010.

5. CERTIFICATION PAPERWORK Complete and sign the “Fork Maintenance

Inspection Form” provided in NAVSUP Pub

538. Complete and sign the “MHE Safety

Certification Form” provided in NAVSEA

SW023-AH-WHM-010. Provide all certification and inspection forms to the designated shipboard official/POC. Provide a copy of the certification/inspection forms to the MSC MHE Program Manager’s Office within 14 days of the certification.

6. AERIAL WORK PLATFORMS (AWP)

Complete all safety inspection and testing requirements – including markings - in accordance with NAVSUP Pub 538 and the

Manufacture’s Technical Manual.