LOLER INSPECTION GUIDE LINES - hunwick … · Issue: - MAINT/LOLER, 03 3 Last rev: 05.08.10...

Issue: - MAINT/LOLER, 03 1 Last rev: 05.08.10

FOR THE ULTIMATE IN QUALITY AND SERVICE PLEASE CONTACT US AT

The Old Airfield, Gosfield, Halstead, Essex CO9 1SA Tel: 01787 478490 Fax: 01787 476047

www.transporter-engineering.com Email: [email protected]

LOLER INSPECTION

GUIDE LINES

LOLER EXAMINATION

GUIDE LINES


CONTENTS

PREAMBLE…………………………………………………………………………3

1. INTRODUCTION………………………………………………….…………….4 2. SAMPLE OF LOLER EXAMINATION FORM………………………………..5 3. DECKS BY NUMBERS (ALL MODELS)……………………………………...6 4. STATUTORY THOROUGH EXAMINATION GUIDE LINES……………….8 SUMMARY…………………………………………………………………………21


PREAMBLE Ever increasing attention from the Health and Safety Executive coupled with the growing number of claims against truck operators has focused the attention of the industry to ensure the interests of drivers, loaders and other persons involved with the operations of car transporters, including the corporate position is protected where possible. To assist achieving this aim, we have developed these guidelines to assist operators in satisfying the regulations which at the time of writing are relevant. It’s recognised these guidelines are generalistic in nature and form part of the overall requirement in relation to ensuring your transporter equipment is safe to operate. It’s important for all operators to understand their obligations in full and ensure all aspects are covered. These guidance notes do not cover all the requirements, but are helpful in assisting the achievement of Regulation 9 of The LOLER Regulations 1998. This guidance note covers equipment manufactured by Transporter only, although the approach set out has merits for examining other manufacturers’ types. Notwithstanding this point, certain important information will be required from other manufacturers as appropriate. Whilst certain areas have been included in the guidance notes for examination, a defect may not necessarily result in a failure. However it will be prudent to advise the operator of all related observations.


1. INTRODUCTION

Car transporters with lifting decks are covered under The Lifting Operations

and Lifting Equipment Regulations 1998 (LOLER) and Regulation 9 sets out

the requirement for the equipment to be thoroughly examined by a competent person at regular intervals.

A thorough examination is a systematic and detailed examination of the lifting equipment and all its associated parts with the aim of identifying parts which are or may become dangerous. The examination also includes a degree of testing. Considering the nature of the work carried out by car transporters, we recommend the thorough examination is carried out annually on our equipment with additional routine inspections completed as part of your normal planned maintenance program.

It's important to recognise that the thorough examination should not be confused with preventative maintenance which usually involves replacing worn or damaged parts, routine adjustments and lubrication etc. The completion of the thorough examination can also act as an audit to assess whether the level of preventative maintenance is adequate. It is also important that the competent person is sufficiently independent and impartial to allow them to make an objective assessment of the equipment. For this reason it is not advisable for the same person who performs routine maintenance to carry out the thorough examination, as they are then responsible of assessing their own work.

Transporter provides the thorough examination service both at Gosfield and on site at your premises by appointment, often out of normal working hours minimising your operational downtime. To carry out this work, our engineer requires the vehicle at a suitable site, on level hard standing, access of up to 4 vehicles of a suitable weight to use for the deck creep test , and undercover during severe weather. We will also require the assistance of an operator to load the vehicles for the creep tests; we will not accept any liability for damage caused to cars during the loading operation. When the examination is complete, you will receive a certified report setting out the outcome of the examination, with observations and comments as a result of our findings. No maintenance or defect rectification work is carried out as part of the examination, providing the peace of mind about the quality of the examination.

The cost of this service is fixed if the work is carried out at Gosfield with a varying charge when the transporter equipment is examined at your locations. Carrying out the examination on a number of vehicles during the same visit enables the work to be completed whilst minimising cost and enabling maximum uptime for your fleet. This document has been compiled to assist in the completion of our examination report when examining a Transporter product.

Section 5 covers the maintenance, measurement and replacement of lifting chains. The chains are a very important part of our lifting equipment and are often overlooked until one fails; this information should help in the prevention of chain problems and increase its service life.


2. SAMPLE OF THE LOLER EXAMINATION FORM


3. DECKS BY NUMBERS (ALL MODELS)

Decks are numbered in the order that the cars are loaded; these numbers can be used

as a cross reference when reading the guidelines.

5 Car straight deck (5a)

5 car with peak (5b)

Plus 9 duck and dive (9a)

1 2 3

4 5

1 2 3

4 5

1 2 3

4

5 6 7

8 9


Plus 9 van carrier (9b)

Plus 11

4 5 6 1 2 3

7 8 8a 9 10 11

Plus 12

4 5 6 1 2 3

7 8 8a 9 12 10 11 13

1 2 3 4

5 6 7

8 9


4. STATUTORY THOROUGH EXAMINATION IN ACCORDANCE WITH LOLER

A thorough examination needs to be supported with an appropriate report setting out the observations made during the comprehensive examination. The examining engineer is required to endorse the report with suitable notes or limits as deemed appropriate. Special tools may be required, including chain wear gauges etc and inspection covers may require removal to facilitate a satisfactory examination. A suitable load will also be required to validate the safe functioning of certain moving parts.

4.1. Decking (all decks) All Models

4.1.1. Check punched decking for security, check welds securing

punched decking to cross members and stiffening bars. 4.1.2. If the vehicle is fitted with bolt in panels, check for

security/damage. 4.1.3. Check for corrosion. 4.1.4. Check for damaged decking such as splits, holes and indents

which may prevent the secure attachment of diverters and wheel chocks. This could also be a hazard to operators on the deck.

Warning If it is deemed necessary to carry out welding the earth clamp must be secured directly to the deck or section that is been welded. Failure to do this could cause damage to the lifting mechanism.

4.2. Deck rollers, guides

Model decks 5a Top 5b Top Plus 9a 1,2, top & mid

Plus 9b 1,2, top & mid Plus 11 1,2,4,6,8,10, top rigid & trailer Plus 12 1,2,4,5,8, top rigid & trailer ,mid trailer

4.2.1. Check rollers for security, make sure they are secure and the

locating washer is attached to the shaft. 4.2.2. Clean out and check the guides for damage. 4.2.3. Check the roller for wear on both inside and outside diameters,

check for flat spots on the out side of the roller.


4.3. Deck pivots and clamps

Model decks 5a Top 5b Top Plus 9a 1,2,8, top & mid

Plus 9b 1,2,8, top & mid Plus 11 1,2,4,5,8,9,10, top rigid and trailer Plus 12 1,2,4,5,8, top rigid & trailer, mid deck trailer

4.3.1. Check clamp bolts are secure with no damage or wear. 4.3.2. Check pivots for wear in the pins and bushes. 4.3.3. Check slide blocks for wear. 4.3.4. Check slide blocks on peak ramp for damage and distortion.

4.4. Deck locks, air cylinders Model decks 5a Top 5b 1, top

Plus 9a Top Plus 9b 1, top & mid Plus 11 1,2,4,5,8,9,10, top rigid and trailer Plus 12 1,2,4,5,8, top rigid & trailer, mid trailer

4.4.1. Check for air leaks on air cylinders, air valve switches and pipes. 4.4.2. Check air cylinders to make sure that they have full movement. 4.4.3. Some cylinders are fitted with yokes and clevis pins. Check for

wear in the yokes and pins.

4.5. Body securing bolts & members Model decks 5a Rigid bodywork

5b Rigid bodywork Plus 11 Rigid bodywork Plus 12 Rigid bodywork

4.5.1. Check body bolts are secure. 4.5.2. Check chassis and superstructure brackets are secure and free

from cracks. 4.5.3. Check balata packing is sandwiched between chassis and

superstructure and has not become displaced.


4.6. Shoot bolts, securing devices

Model decks Plus 11 1 van Plus 12 1 van

4.6.1. Check shoot bolts on van deck and rear loading ramps (manual

only) for security, cracks and damage. Some vehicles are fitted with shoot bolts on the rear of deck 6.

4.6.2. Check shoot bolt securing devices lock pins etc for damage or missing.

4.7. Wheel stops

Model decks

5a 1,3 5b 1,3 Plus 9a 1,4,7 Plus 9b 1,4,7 Plus 11 1,2,3,4,6,9,10,11 hydraulic loading ramps only Plus 12 1,2,4,9,11

4.7.1. Check for security; check all welds, pins, roll pins and bolts. 4.7.2. Check for damage to the stop’s profiles and bars. 4.7.3. Check locking mechanisms where fitted for damage, wear,

springs and movement, check locks are seating correctly in the ratchet.

4.7.4. If fitted with wheel tie locators check welds.

4.8. Deck lock pawls and rack bar. All models

4.8.1. Manually check pawls for freedom of movement, full travel and wear on toothed edges.

4.8.2. Check pawls and pins for wear. 4.8.3. Make sure springs are complete and located correctly and the

pawl fully meshes with the rack bars teeth when the air lock button is released.

4.8.4. Check rack bar for wear and welds for cracks.


4.9. Rams & pivot points

All models

4.9.1. Check rams for leaks and damage, exercise full strokes check for smoothness of operation.

4.9.2. Check piston rod signs of corrosion or damage e.g. bent or pitted.

4.9.3. Check pivots for security and wear, repair or replace if necessary.

4.10. Chains and anchors

All models

4.10.1 Chains must be given a thorough examination as detailed in section 5.

4.10.2 All anchors, adjusters, clevises must be checked for wear and security.

4.10.3 DO NOT USE CHEMICAL SOLVENTS & DO NOT STEAM CLEAN. Clean with paraffin or paraffin based derivative.

4.10.4 Check the pulley wheels top deck rigid and top deck of the trailer; drop the decks on to locks this relieves the weight from the chain, check that the pulley wheel moves freely backwards and forwards. Check the pulley wheel for wear on the pins.

4.10.5 Check the drag chain pulley wheels front top deck rigid and rear top deck trailer. Take the weight of the deck on the ram; this should loosen the drag chain. Check that the pulley wheels are free and check for wear on the pins.

4.11. Instructions/safety labels

All models

4.11.1 Check labels are complete and legible as they form an important part of the safety and operation of the equipment; in some cases they are a legal requirement.

4.12. Control levers/valves

All models

4.12.1 Check levers/pivot boxes for security and wear. 4.12.2 Check levers are not seized and return to neutral position when released. 4.12.3 Check lever knobs are colour coordinated and correspond with the respective air lock switches.


4.13 Handset/controls Model Deck 5a Controls optional 5b Controls optional

4.13.1 Check for security if fitted. 4.13.2 Check all connections and pipes are secure and wiring is in a

serviceable condition. 4.14 PTO Switch

All models

4.14.1 Check security and operation. 4.14.2 Check warning indicator is operating. 4.14.3 Check park brake inter-lock is disconnecting PTO when

released.

4.15 Relief Valves All models

4.15.1 Operate levers against the stops ensure that the valves are bypassing with no un-due pressure on the equipment.

4.15.2 Check decks at maximum capacity to ensure they lift without bypassing.

4.15.3 Check all caps and lock nuts are secure and wire seals are intact.

4.16 Air Piping

All models

4.16.1 Check pipes are secure, not chaffing and are clear of moving parts.

4.16.2 Check the pipe runs and that none are kinked. 4.16.3 Check for leaks.

4.17 PTO & Pump

All models

4.17.1 Check operation of PTO and pump and make sure it is

engaging and disengaging when the switch is operated. 4.17.2 Check for oil leaks on PTO/gearbox & pump/PTO.


4.18 Hoses/Pipes & fittings All models

4.18.1 Check for oil leaks. 4.18.2 Check pipes for damage and make sure that they are not

chaffing significantly in any areas. 4.18.3 Check fittings for corrosion and leaks.

4.19 Winch

Model Deck 5a Optional fitment 5b Optional fitment

4.19.1 Check for security. 4.19.2 Check for wear on drum bearings. 4.19.3 Check for damage to body and drum. 4.19.4 Check wiring is secure.

4.20 Cable/hook

Model Deck 5a Optional fitment 5b Optional fitment

4.20.1 Check cable for damage make sure all wires are intact. 4.20.2 Check hook for damage or distortion. 4.20.3 Establish the SWL of the cable and that it is marked.

4.21 Cable guide rollers & deck rollers

Model Deck 5a Optional fitment

5b Optional fitment

4.21.1 Check for security. 4.21.2 Check guide rollers for damage. 4.21.3 Check guide rollers are free with no tight spots. 4.21.4 Check deck rollers for security. 4.21.5 Check deck rollers for damage.


4.22 Spectacle Frame Model Deck 5a Optional fitment 5b Optional fitment

4.22.1 Check frame for damage, distortion welds and cracks. 4.22.2 Check pins and bushes for wear. 4.22.3 Establish the SWL of the spectacle frame and that it is marked.

4.23 Loading Ramps

All models

4.23.1 Check ramps for security make sure the locking bolt operates correctly.

4.23.2 Check ramps for damage cracks and loose punch decking. 4.23.3 Check slide channels for wear/damage. 4.23.4 Check that ramps slide in and out freely and lock securely when

in the loading position.

4.24 Ladders

All models with option not to be fitted 4.24.1 Check for security welds/fastening devices. 4.24.2 Check for damage/corrosion.

4.25 Grab Handles

4.25.1 Check for security/damage.

4.26 Hand rail posts, bases & cables

All models

4.26.1 Check hand rail posts for security, damage and corrosion. 4.26.2 Check cables for security, damage fraying and corrosion.

Cables should be tight with only 20mm slack at a central point. 4.26.3 Check the handrail post bases for cracks or distortion.


4.27 Creep test Model Deck Plus 11 1,2,4,6,8 Plus 12 2,4,6

In all cases secure the car to the deck as per your company tie down policy. Load all decks to as near the SWL as possible. This test is only carried out on systems where the deck is supported by the rams fitted with or without check valves. All other decks which are mechanically locked will have been checked earlier in the inspection. If any creep is detected after 30 minutes, that particular deck has failed this part of the examination. If no creep has occurred then the deck has not failed for this reason. This deck numbers noted below may not apply to every type of transporter.

4.27.1 Load decks 1&2 with cars driven up to the front of the ramps. Lower the rear of the decks down to the maximum with deck at maximum angle. Mark the slider/roller. Check the marks after 30mins if no movement has occurred then no creep has taken place and the deck has passed. If creep has occurred this constitutes a failure.

4.27.2 Load the canopy deck and raise on to the hydraulics. Leave for 30mins if no movement has occurred the deck has passed the test; if there is movement, the deck has failed.

4.27.3 Drive car onto deck 6 making sure that this car is only secured to the sliding section of deck 6. Set top deck of rigid with the rear in a low position and the front high. Mark the slide deck roller and guide. Leave for 30mins if no movement has occurred the deck has passed the test. If there is movement, the deck has failed.

4.27.4 Load a vehicle onto the deck 7 and lift the van flaps. Leave for 30mins if no movement has occurred the deck has passed the test; if there is movement, the deck has failed. This is not a requirement if the vehicle is fitted with a mechanical support on the van flaps.

4.27.5 Drive car onto deck 8, position the front of the deck low and the rear high. Mark the deck inner and outer slides. Leave for 30mins if no movement is evident, the deck has passed the test; if there is movement, the deck has failed.

4.27.6 EVO 3 only. Drive car onto front of deck 9 and reverse another onto deck 10 lift both ends. Lift the centre prop to the top of its stroke and mark the telescopic section of the prop. Check after 30mins if no movement has occurred the deck has passed the test, if creep has occurred the deck has failed the test.


4.28 Lifting Chains

Lift chains by their very function are subject to considerable stress. When abused or incorrectly used, improperly maintained or exposed in hostile environments, chains can suffer from decreased service life. With this in mind Transporter supplies as original fitment Super Shield Chain; this chain is corrosion resistant and is far superior than the standard chain when used in applications where there is direct contact with water. Super Shield Chain can be supplied via our after sales department for retro fitment to existing transporters. Always fit correct chain and associated components. Observance of the guidance notes detailed below for maintenance, inspection and examination should eliminate failures in lift chains when working in normal conditions and ensure optimum chain life.

4.29 MAINTENANCE

4.29.1 Chains should be kept free of dirt and debris. 4.29.2 At intervals as recommended in the maintenance schedule and with the chains in situ in a slack condition, or removed from the transporter, chains, anchors and pins should be lubricated as recommended in the operating handbook. If a chain is removed for cleaning or inspection it must be refitted in exactly the same working position. The chain and anchor pins should be witness marked to ensure that the correct working position is maintained. Refitting and adjusting must be done as recommended in the workshop manual. 4.29.3 Only lubricants approved by Transporter should be used in the

maintenance of the lifting chains. Lift lube can be ordered from our after sales department Part No 1299-995.

4.29.4 The chain(s) should be sufficiently cleaned on their external surfaces to facilitate the examination.

4.29.5 In preparation for the examination, and if deemed necessary, clean the chains sufficiently using paraffin or a paraffin derivative. DO NOT USE CHEMICAL SOLVENTS. Do not steam clean chains as this will remove the lubricant on the internal bearing surfaces and seriously reduce the service life of the chain(s).

4.29.6 If it is possible to examine the entire chain, the procedures detailed below can be carried out in situ. Where this is not possible chains must be removed from the vehicle and examined/re-lubricated and replaced in accordance with the instructions of Transporter. The chain should be examined in a slack condition.

4.29.7 For heavy chains assistance must be sought when removing or refitting.


Examine the chain(s) and or associated components for:

4.29.8 Evidence of pitting due to rust or corrosion

4.29.9 Tight chain joints

4.29.10 Missing link plates

4.29.11 Cracked or fractured link plates

4.29.12 Loose pins with enlarged pin holes

4.29.13 Protruding or turned pins

4.29.14 Worn surfaces on the chain outer links or wornIdamaged pin heads

4.29.15 Missing or damaged anchor pin locking device e.g. split pin etc.

4.29.16 Anchor pin locking mechanism integrity 4.29.17 Wear and corrosion of the anchor pin and clevis (including

integral anchor clevises)

4.29.18 Wear on link plate edges – i.e. that caused by running over the chain pulleys (subject to 3.3 below)

4.29.19 Wear between the pin and the plate and/or associated components - i.e. chain elongation (see measurement below)


h3

4.29.20 If any of the above defects are found, the chain(s) and/or associated components must be replaced within a period specified by the competent person.

4.29.21 If the competent person judges that the chain(s) and/or associated components may not remain safe to use then the faulty items must be RENEWED IMMEDIATELY and the transporter removed from service until these parts have been replaced.

4.29.22 If the examination shows no defects, measure and record the wear of the plate depth (h3). This reduction should not be more than 5% of the original dimension. Chain(s) that have plates worn in excess of 5% must be RENEWED IMMEDIATELY and the transporter removed from service until the chain has been replaced.

4.29.23 The unworn h3 (18mm) dimension may be ascertained by measuring a portion of the chain that does not run over the pulley, e.g. near the chain anchor. If the depth of the plate is less than 17.10mm the chain should be changed immediately. If in doubt replace the chain.

h3 = 18mm Min plate depth 17.10mm

Before measuring chain extension it is essential to take up any slack that may exist in the chain. 4.29.24 For chains that are not removed the weight of the deck will be

sufficient. Should the chain(s) be removed from the transporter the chain(s) must be held taught for measurement?

4.29.25 Identify the most worn section of the chain that regularly runs over the pulley wheels. Measurement must then be made over the full length of the chain using the Transporter chain gauge.

4.29.26 The measured section should then be compared with the original pitch measurement of the chain and an assessment made on the suitability for continued service as shown in 3.3.5 below. 4.29.27 When examining chains the criteria for rejection of chains due

to excessive elongation should be made on the following basis:

4.30 MEASURING ELONGATION

4.30.1 Chain elongation should be measured as described in

paragraph 3.3.3&.3.4 4.30.2 UP to 2% elongation. On newly supplied chains, excessive

deterioration compared with service history may be an indicator of manufacturing defects or unforeseen operating conditions. Under these conditions the competent person needs to make a judgement on the rate of deterioration which could lead to failure and advice on appropriate timescales for replacement of the chain.


4.30.3 >2% but <3% elongation Between these elongation limits a

judgement needs to be made on whether or not the chain can continue to be used safely up to the next thorough examination. If not a timescale for replacement should be specified. When specifying the timescale, account should be taken of the following factors:

-Date of next thorough examination, -Elongation measured, and

-Rate of deterioration since the last thorough examination

4.30.4 The general condition of the chain and the environment in which the transporter is used should be taken into account when recommending timescales for replacement. It should be note that humid, dusty or corrosive atmospheres are likely to accelerate deterioration and extreme temperatures can increase the likelihood of chain failure.

4.30.5 If the competent person judges that the chain may not remain safe to use up to the next scheduled examination they must recommend replacement within a specified time limit.

4.30.6 >3% elongation Chains with a measured elongation of 3% or more must be RENEWED IMMEDIATELY and the transporter removed from service until the chain has been replaced.

4.30.7 When measuring chains for elongation due to chain wear, a compromise must be made in determining the length of chain to be measured. Too long a length and there will be a danger of diluting the true extent of the wear caused by measuring and combining worn and unworn sections together, and too short a length will require far greater measuring accuracy than is generally available in the field.

4.30.8 With these points in mind, Transporter has developed a chain wear gauge specifically for the pitch of chain used on the transporter; approximately 254mm (10") of chain is sampled. The gauge incorporates Vs for positive pin location at the fixed end and pointers for accurate pin centre positions at the other end. The gauge is a simple but accurate method of determining if the chain is serviceable or is un-acceptable and must be replaced. The gauge is available from the after sales department Part no. SP1886.

4.30.9 Measure the chain using the Transporter chain wear gauge. The chain must be measured over its full length especially sections that have been running over the rollers; the chain must be under load whilst carrying out the measuring procedure. The weight of the deck will be sufficient.

4.30.10 To measure the chain, place the ‘V’ on side ‘A’ over a pin. Holding the gauge securely check the position of the nearest pin at the pointer end of the gauge. If the pin does not fall into the red hatched zone it is serviceable. If the pin falls into the red hatched zone the chain is more than 2% worn and must be checked using side ‘B’.


4.30.11 To check the stretch, place the ‘V’ on side ‘B’ over a pin; holding the gauge securely check the percentage of stretch. Up to 2% the chain is serviceable. If the centre of the pin is over 2% the chain must be programmed for urgent replacement. If the centre of the pin is over 3% the chain MUST be removed from service immediately.

Side ‘A’

Side ‘B’

If the chains have to be replaced always fit in pairs.

When 3/4" pitch chains are used the criteria for rejection of chains due to excessive elongation should be made on the following basis:-

Chain Pitch Nominal length of 13 pitches of new chain

Measured length when chain is 2%

worn

Measured length when chain is 3%

worn

Inch mm Inch mm Inch mm Inch mm

0.75" 19.05 9.74" 247.65 9.94" 252.60 10.04’’ 255.08

4.30.12 Normal environments Providing the chains are regularly maintained and used within the constraints laid down by Transporter, they should remain serviceable for long periods. Lack of lubrication and overloading will reduce the life of the chain dramatically.

4.30.13 Under no circumstances are chains to be lengthened by joining together (this action would invalidate the chain certification).

4.30.14 Chains must be fitted in pairs; they must be replaced together and adjusted to have equal tension in each chain.

4.30.15 Only fit replacement chains, chain anchors, anchor pins and integral anchors as specified and supplied by Transporter.

4.30.16 In all circumstances new anchor pins/end connecting links with new split pins must be used when replacing chain(s).


SUMMARY

The competent person carrying out the examination will be required to draw on their technical knowledge, experience and adequate training, supported by these guidelines to certify the transporter equipment is safe to use and that it satisfies Regulation 9 of the LOLER Regulations 1998. Transporter reserve the right to amend these guidelines without notice and recommend that operators regularly check for updates.

LOLER INSPECTION GUIDE LINES - hunwick … · Issue: - MAINT/LOLER, 03 3 Last rev: 05.08.10...

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Transcript of LOLER INSPECTION GUIDE LINES - hunwick … · Issue: - MAINT/LOLER, 03 3 Last rev: 05.08.10...