Properly maintained and tested aerial devices are essential to the safe and economical
operation of a fleet. Operators and their co-workers rely on the aerial devices to perform
structurally, mechanically, functionally and dielectrically as intended.
WHY SHOULD AERIAL DEVICES BE TESTED?
Aerial devices have been designed and built with
adequate safety factors however in-service accidents, overloads, and fatigue can cause
problems to develop. Also, regular annual inspections are required by OSHA and ANSI. A
thorough, regularly scheduled inspection and test program can identify developing problems
before they cause injuries or downtime. Early identification of defects are less expensive
to repair than if they are left to develop into major failures. Many equipment managers
have experienced substantial monetary savings by using written test reports to obtain
competitive quotations for repairing, rebuilding, and remounting.
American Test Center provides annual test and inspection at your site
by a well-equipped two-man crew of nondestructive technicians who are experienced in
structural and dielectric testing. They are supported by a staff of professional
engineers, Level III technicians and equipment specialists.
American Test Center performs the following tests and inspections:
I. STRUCTURAL TESTS
A. Visual Inspection: A complete inspection of
accessible areas including:
1. Outriggers; Pads, structure, welds, bolts, hoses, cylinders, valves,
pins and retainers.
2. Chassis; Truck frame, aerial sub-frame, suspension, PTO, pintle
hook, and components of the brake, steering, electrical, air, hydraulic, exhaust, and
cooling systems.
3. Pedestal; Mounting bolts and welds, pedestal structure, diagonal
brace, attachment welds or pins, hydraulic swivel joint, hydraulic components, swing drive
gearbox mounting bolts, backlash between swing pinion or bullgear, electric collector ring
and brushes and lower control operation.
4. Rotation Bearing; Upper and lower bearing attachment weld and bolts,
vertical movement of bearing, and proper torque on accessible bearing bolts.
5. Turntable; Turntable structure, bucket leveling cables, leveling
cylinders, compensating chains or sprockets, and hydraulic system components.
6. Lower Boom; Boom structure, welds, lift cylinders and attachment,
hydraulic system, leveling cables or rods, upper or extend cylinder and attachment,
pushlinks, boom rest supports, tie-down straps, lower insulator and mounting, extension
roller assembly and wear pads.
7. Elbow; Elbow structure, hydraulic hoses and leveling cables.
8. Upper Boom (Extension); Structure, welds, leveling cables or rods,
wear pads, upper insulator and mounting, hydraulic lines and components, jib structure and
mounting, tool circuit hoses and fittings, pole claw arms and mounting brackets.
9. Platform (Bucket); Mounting bracket bolts, leveling system, exterior
condition, control operation and hydraulic lines and components.
10. Digger and Auger; Digger mounting arm and housing, gearbox, auger,
digger wind-up bracket or rope, auger stop bracket, lock mechanism and control operation.
11. Winch; Mounting brackets, bolts, pins; gearbox, hydraulic
components, load line, and controls.
12. General; Load rating chart, electrical hazard placards, MADDDC
placards and upper or lower control operation placards.
The visual inspection includes removal of inspection cover plates as
necessary to do a thorough job.
B. Acoustic Emission (AE) Test: AE is the
accepted industry method for testing fiberglass and steel structures. The AE test includes
attaching sensitive sensors to the structural fiberglass and metal components from the
bucket down to the outrigger or chassis subframe. A test load of 1-1/2 or 2 times the
rated load (specified by customer) is applied to the boom. A computer system monitors
sounds emitted by defects that are growing during the test load. The computer selects the
critical noise emissions and prints a summary report.
C. Magnetic Particle Inspection: Magnetic
particle is a nondesctructive test method used to identify surface cracks on ferrous
material. It is perfromed on all critical welds, plates and castings of items listed in
Part B during the visual inspection.
D. Dye Penetrant Inspection: Dye penetrant is a nondestructive
test method used to identify surface cracks and works on any structural surface including
all critical welds, plates, castings made of non-ferrous material and any area requiring
verification in Part C or Part E.
E. Ultrasonic Inspection: Ultrasonics is a nondestructive test
method used to detect flaws in accessible critical pins. Use of ultrasonics reduces the
number of pins that have to be removed for inspection. Pins with flat end surfaces and do
not have drilled holes are best suited for ultrasonics.
F. Torque Testing: Torque testing all critical fasteners in
accessible areas including upper and lower rotation bearing, swing gearbox, boom
connections, and platform mounting.
II. FUNCTIONAL and OPERATIONAL TEST
A functional and operational test is performed to check the operation
of controls, bearings, pins, bushings, cylinders, holding valves, bucket leveling
mechanisms, outriggers, etc. This test will also find worn swing bearings or gearboxes,
worn pins or bushings, and loose fasteners critical to the operation of the aerial.
III. DIELECTRIC TEST (AC OR DC)
A dielectric test up to 100kV as specified by ANSI standards. The
dielectri test verifies the electrical insulating strength in the FRP upper and lower
booms, bucket, liners, FRP extensions on digger derricks, tool circuits, and upper control
system.
IV. OPTIONAL TESTS
Dielectric Tests: Bucket liners; Hydraulic oil to
ASTM D1816 standards; Hotsticks.
Oil Spectroanalysis: Chemical analysis of oil in
engines, transmissions, and hydraulic systems. Determines type and amount of
contamination.
DOT Inspection: A thorough inspection of the chassis
as specified by Federal or State DOT. Includes a DOT sticker and one page report.
Stability Tests: Performed to meet the requirements of
OSHA/ANSI specifications.
Thickness Testing: Ultrasonic thickness testing is a
nondestructive test method used to determine thickness of materials where thickness is
critical and difficult to measure with mechanical test equipment.
V. REPORT and CERTIFICATION
Defects found during the inspection and tests are classified for degree
of severity and printed on a computerized report. American Test Center technicians will
review the report with the customer designated representative. A signed and dated copy of
the test report listing the defects discussed is left with the representative.
The report is reviewed by American Test Center’s staff engineers
and the final report is mailed to the designated customer representative. American Test
Center retains a copy of the test report on file. Units that need rework require
verification of repair or retest in the customer file.
VI. LOCATION and SCHEDULING
American Test Center schedules tests with each customer to best meet
their individual requirements. American Test Center has mobile crews located throughout
the United States to perform the test at your site. American Test Center encourages your
representative to have all the appropriate people available after the test to review the
test results and to ask questions. American Test Center requests that operators manuals,
manufacturer bulletins, maintenance files are available for our crew and that the aerial
device be adequately cleaned prior to testing to assure a thorough test. American
Test Center is flexible and will work with you to meet special needs. |
BUCKET TRUCK and
DIGGER DERRICK