Major inspection per AS 2550.10 - strip-down, NDT, rebuild and recertification
Estimated duration: 3 - 10 days • Required at 10 years from manufacture, then every 5 years
Equipment and Inspection Details
| # | Inspection Item | Method | P / F | Notes / Measurements |
|---|---|---|---|---|
| 1. Pre-Strip Functional Testing | ||||
| 1 | Full operational cycle test (raise, lower, drive, steer) | TEST | ||
| 2 | Emergency stop buttons (all positions) | TEST | ||
| 3 | Emergency descent / manual lowering system | TEST | ||
| 4 | Tilt sensor / inclination alarm and cutout | TEST | ||
| 5 | Overload protection / sensing system | TEST | ||
| 6 | Pothole protection bars / system | TEST | ||
| 7 | Limit switches (height, travel) | TEST | ||
| 8 | Dead-man controls (platform and ground) | TEST | ||
| 2. Structural Inspection and NDT | ||||
| 9 | Sandblast all critical structural welds to bare metal | STRIP | ||
| 10 | Chassis frame - visual and NDT inspection | NDT | ||
| 11 | Scissor arm welds - dye penetrant or MPI testing | NDT | ||
| 12 | Platform frame welds - dye penetrant or MPI testing | NDT | ||
| 13 | Turntable / slew ring (if fitted) - NDT and wear check | NDT | ||
| 14 | Scissor arm pivot pins - measure diameter at wear points | MEASURE | ||
| 15 | Scissor arm bushes - measure bore diameter | MEASURE | ||
| 16 | Assessment for fatigue cracking, corrosion, deformation | INSPECT | ||
| 3. Hydraulic System Strip and Inspection | ||||
| 17 | Lift cylinder strip-down (seals, bore, rod, glands) | REBUILD | ||
| 18 | Lift cylinder rod - inspect for scoring, pitting, chrome damage | INSPECT | ||
| 19 | Hydraulic pump and motor assessment | INSPECT | ||
| 20 | Valve block inspection and pressure testing | TEST | ||
| 21 | All hydraulic hoses - inspect and replace as required | REPLACE | ||
| 22 | Leak detection test (full system under pressure) | TEST | ||
| 4. Electrical System | ||||
| 23 | Complete wiring loom inspection (damage, chafing, rodent) | INSPECT | ||
| 24 | Platform and ground control systems - full function test | TEST | ||
| 25 | Battery condition and load testing | TEST | ||
| 26 | Charger operation test (electric models) | TEST | ||
| 27 | Connector integrity (all plugs, terminals, junction boxes) | INSPECT | ||
| 5. Mechanical and Drivetrain | ||||
| 28 | Drive motors and gearboxes - strip and inspect | REBUILD | ||
| 29 | Braking system - inspect and test holding capacity | TEST | ||
| 30 | Steering components - inspect wear, alignment | INSPECT | ||
| 31 | Tyres / wheels / castors - condition and wear | INSPECT | ||
| 32 | Outrigger / stabiliser mechanisms (if fitted) | INSPECT | ||
| 6. Platform and Access | ||||
| 33 | Guardrails (top rail, midrail) - condition and secure attachment | INSPECT | ||
| 34 | Toeboards - condition and secure attachment | INSPECT | ||
| 35 | Self-closing gate / entry gate and latches | INSPECT | ||
| 36 | Platform floor integrity | INSPECT | ||
| 37 | Extension deck (if fitted) - locking, floor, guardrails | INSPECT | ||
| 7. Load and Proof Testing | ||||
| 38 | Proof load test at 125% of SWL / rated capacity | LOAD | ||
| 39 | Creep test (load held at height, check for drift) | LOAD | ||
| 40 | Functional test at rated capacity (motors, brakes, controls) | TEST | ||
| 41 | Full operational cycle under load | TEST | ||
| 8. Reassembly, Certification and Documentation | ||||
| 42 | Reassembly to OEM specifications | REBUILD | ||
| 43 | Calibration of all safety systems to manufacturer standards | VERIFY | ||
| 44 | Repaint and apply new decals as required | REPLACE | ||
| 45 | New compliance plate affixed | VERIFY | ||
| 46 | Updated logbook entry | VERIFY | ||
| 47 | Inspection certificate issued | VERIFY | ||
NDT Methods Used
Load Test Record
Defects, Recommendations and Component Replacements
Next Major Inspection Due
Inspecting Engineer
Owner / Fleet Manager