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AS Ladder Maintenance Manual V15 March 15

1. E S A JA mi LA 4 Tela lie jl Figure 27 Figure 28 Page 20 4 7 Cable AS Ladders where fitted Special attention should be given to the cable condition to ensure there are no kinks and or loose wire strands The condi tion of the straining screw is important and attention should be given to the security of the locking nut Correct assembly of this device is essential for safe and smooth operation of the ladder 4 7 1 Correct Cable adjustment AS Ladders where fitted 1 lf the cable is deemed mechanically and visually safe the next phase is to correctly set up the tension of the cable when housed on the ladder Firstly ensure that the feed direction is as shown through the cable return pulley as sembly Figure 29 Once the cable pulley and cable are set up onto the ladder extend the sections from the Heal of the ladder up to the second rungs so that the pawls are sitting in contact with the rung in each Case respectively see Figure 30 Adjust the cable tensioned attachment bolt see Figure 30 and adjust If the cable is set up correctly the contact ed pawls onto the second rungs will move away circa 5mm gap due to the correct tension of the cable WGablatowarts at of ladder Foot of ladder Cable towards it of kacde Figure 29 Figure 30 4 7 2 Cable Pulley Assembly Current Old AS Ladders There are currently 4 Four options either in service OEM by request see figure 28 29 30 31
2. If in any doubt return the ladder to Supply or contact your local agent for repair Page 53 6 7 5 Ladder Twist After riveting has taken place the ladder must be checked prior to reassembly to ensure that no twisting of the structure is evident This is carried out according to the following procedure e The ladder section is mounted on the repair table on two blocks of timber approximately 1m 3ft long placed 150mm 6 in from the end of the ladder section e Feel the weight of the ladder section by lifting each corner in rotation to see if the section is equally balanced e In the event of detecting an imbalance the heavier side should have a loose fitting clamp at the opposite end of the ladder and using a length of timber as a lever the ladder is twisted against the clamp to restore the balance Care must be taken when carrying out this procedure to ensure that no damage occurs to the stiles of the ladder Figure 123 e Figure 123 Twisting of ladder e Note It is not possible to see the twist that may reside in a ladder section as this can be masked by the weight of the ladder which will assume the profile of the surface on which it lies e The above has been found over many years to give the most accurate way of checking for ladder twist 6 8 Removal of Rungs AS Ladders In the event of rungs becoming damaged the ladder should be carefully inspected for damage to the stiles channels before replacement i
3. to the floor H3 e The second deflection D2 is calculated by subtracting the second load height H3 from the initial height H1 e The second deflection D2 must not xceed 1 5 times the first deflection D1 D2 lt 1 5xD1 e Remove the loads and again measure from the underside of the ladder S to the floor H4 The initial height H1 must be more than the final height H4 A measuring tolerance or 3mm 1 8 applies Test loads Extension ladders to JCDD deflection Pre load 3 x 10kg 1x 5kg 1x 2kg 1x 1kg Total 38kg First load 7 x 10kg tx 5kg 1 x 1kg Total 76kg Second load 11 x 10kg 1 x 2kg 2 x 1kg Total 114kg Roof ladder hook test With the ladder resting horizontally on a test rig with the bearing point of the hook against a stop the load is to be applied away from the centre line of the ladder Test load 16 x 10kg Total 160kg No permanent deformation to occur Note the weight of the test weight cradle may reduce the number of weights required Page 34 5 2 Roof Ladder Annual Test for JCDD Ladder The test to be carried out with the ladder laid flat on a bench and held in position by the roof hook bearer engaging on one end of the bench A load of 160kg 352lbs is to be gradually applied to the middle of the bottom rung and in a separate test to at least one other rung by means of a rope attached to a metal hook having a bearing surface of 50mm wide and suitably lined to preve
4. 1 2 4 Cable pulley assembly shown in Figure 31 is currently housed on ladders pre 2011 Cable pulley shown in Figure 32 is currently housed on OEM ladders post 2011 This pulley assembly part number S098 WN can be bought as an retrofit kit to replace old cable assembly shown in Figure 31 The full replacement components consist of 1 x S098 WN Cable Assembly 2 x S012 and Middle section rein forced Rung assembly 32 x S202 solid rivets 8 4 x S243M MG x 40 csk slot screw Cable pulley assembly shown in Figure 33 is an option where the Brigade Technician can keep the original fold ed clip plate but can replace the Steel pulley sheave with the revised improved Nylatron Pulley sheave S1060 It is also important to be aware that the Through Pivot pin S082 clip plate has been recently updated to Stainless steel We recommend that the replacement components should be 1 x 1060 1 x Revised S082 amp 1 x S1062 Cable pulley guard wide Cable pulley assembly shown in Figure 34 is currently housed on ladders pre 2011 Important Irrespective of the Clip plate Supply strongly recommend that the Steel pulley Sheave should be replaced with the Nylatron Pulley Sheave inclusive of the above relevant components added for fitment Figure 31 Folded body Steel Figure 32 Extruded Figure 33 Folded Figure 34 Extruded Pulley Sheave body Nylatron Pulley Sheave body Nylatron Pulley Sheave body Steel Pulley Sheave Page 21 4 8 Stabiliser
5. a visual inspection Once inspection is complete place ladder up against structure and house ladder within normal procedures Part No S394 AAD DE ACTIVATOR PIN 8 T TAIL Stabiliser Bar Check that all the fixings are secure and that there is no denting or damage has occurred Pay particular attention to the spindles These should be easily windable Check that onceyyou have stopped winding they don t free the wheel further Wall Wheel Assembly where fitted Check for denting that can oftenoccur from being drive under low tree branches The wheel should be free to run and run Roof Hook where fitted Check the roof ladder hooks for any structural damage Ensure it opens closes and AS Fire Page 11 3 10 3 11 3 12 3 13 Slide Wheels Check the slide wheels for cracks or damage Hinge Assemblies where fitted Inspect for any kind of damage Check that they open close lock and release correctly On the Old style AS Hinges figure 2 check the hinge spigot hasn t overly dented or elongated the hole that it rests in when j opened Check that the spring is still connected to its anchor Female Assemblies where fitted Ensure that the assembly fits together and come apart easily and that the anchor pin fits freely through BS EN 1147 2010 Test Labels Check that the correct labels are in tactiand readable e Supply e Papworth Everard UK 44 0 1480 832200 O www
6. apply it for a minimum of 60 seconds Measure the distance C from the point on the ladder mid span between the two mobile trestles to the horizontal datum Figure 59 Remove the load and measure the distance A from a point on the ladder mid span between the two mobile trestles to a horizontal datum on the ground vertically below Figure 57 e Figure 60 Test Return Not more than 60 seconds after removal ofthe loadin the first deflection test measure the distance D from a point on the ladder mid span between the two mobile trestles to the horizontal datum Figure 60 The ladder shall not touch the ground during any point of the test The preceding test outlines the test procedures for BS EN 1147 2010 However it is highly recommended that each workshop holds its Own copy of BS EN 1147 2010 available from the British Standards Institute The contents of this manual do not set out togive a comprehensive guide to the requirements It is the responsibility of the testing centre to ensure that they comply fully with the requirements of the standard Recommended roof ladder hook test not a requirement within the specification With the ladder resting horizontally on a test rig with the bearing point of the hook against a stop the load is to be applied away from the hook along the centre line of the ladder Test load 6 x 25kg Total 150kg for 60 seconds No permanent deformation to occur Page 31 5 1 4 BS EN 1147 Test Loads All la
7. bolt The wire cable where fitted together with i the pulley assembly is removed as detailed in section 6 4 To detach the cable from the pulley assembly remove the split pin from the pivot and remove the pivot and pulley The cablescan then be pulled through the housing Ensuring that the straining screw is in the open position to allow for maximum adjustment fitting the new cable is the reverse of the procedure above Page 55 6 14 Wall Wheel Assembly AS Ladders The wall wheel assembly can be removed by unscrewing the four screws holding the two bearing blocks orangle spigots The bearing blocks axle or axle spigots should be replaced if worn and new wheels fitted if the tyre is worn or damaged 6 15 Wear on Stiles Channel and Rung Sections AS Ladders Wear to ladder components are normally caused when the ladder is housed on the gantry of a moving vehicle An element of wear on both stile sand rungs is acceptable only under the following conditions It is presumed that ladders are regularly maintained and will be re inspected on a quarterly basis 1 The centre of the ladder is to be regarded as high stress and it is only permissible for the beading on the edge of the stile to be allowed to be worn away by the rung Wear on rungs should be no deeper than 1mm 0 040 2 Inthe area of the slide wheels wear up to 50 of the material thickness of the stile is acceptable If wear is beyond the above limits the compon
8. components whilst hinge assembly is housed onto the ladder Check the outer Anchor hinge body plate for damage or wear or oxidisation It is not possible to replace this component due to the position and joining to the inner tensioned spring see Figure 68 item 4 which is not accessible whilst being housed on the ladder Check latch strike pin anchor plate retaining pivot pin for damage or wear it is possible to replace these components whilst hinge assembly is housed onto the ladder Check the tension spring is working correctly and observe within the inspection hole that the spring ends are housed within the washer tabs and the spring retaining pin which is housed through the Anchor plate Figure 68 item 5 It is not possible to replace this spring mechanism whilst being housed onto the roof sections The Anchor hinge body 316 L R hand holding rivets will need to be removed see figure 69 As such due to the anchor body side see figure 68 item 1 amp the retaining body being see figure 68 item 2 housed onto different sections we strongly recommend the complete replacement of both housings Once channel rivets S255 are removed the hinge bodies can be removed and parts replaced if required Only replace the hinge assembly if you have attended the ladder maintenance course in the past three years if so follow instructions in section 6 6 2 for pop rivet removal Check hinge location hole for elongation wear replace as per section 4 if requi
9. for any Bayley ladders Under no circumstances that welding or repairing rungs or sections shall be undertaken Page 38 6 4 Ladders Dismantling and reassembly AS Rivet Truss Construction including Roof ladders When dismantling the ladder for repair or inspection the following procedure should be followed Lay the ladder in the partially extended position across two trestles When a rope clip is fitted disconnect the rope from the stabiliser bar remove the eight securing bolts and detach the stabiliser bar Where fitted withdraw the stanchion pole hinge bolts and remove the props Where fitted disconnect the wire cable at both ends by removing the remaining bolts Figures 61 62 Unscrew the four screws retaining the cable pulley see section 3 7 reference 31 34 and remove complete with cable Remove the extending line retaining bolt Figure 63 and withdraw the line from its pulleys Figure 61 Figure 62 Figure 63 Figure 65 Remove fixings from return pulley and pulley assembly Figure 64 Remove the screws from each stop block Figure 65 and remove the blocks Pull out the top and middle sections where fitted from the bottom section To reassemble the ladder reverse the above procedure It is importantafter the ladder is reassembled that the cable is correctly adjusted The ladder must be extended onto the second rung by adjustment of the bottle screw the feet of the pawls must be almost touching the rung so that when put under te
10. not recommend that you leave ladders outside for long periods of time If this is the case then the life and condition of the parts will shorten Storing in a dry environment is recommended Important Before procuring any cleaning solution ensure the Brigade Workshops is authorised to use the Solvents and is privy to the COSHH regulations Data Sheets can be obtained if required by the solvent manufacturer Lubrication Sub components and Fasteners Remove existing grease before applying specified new grease Good quality high melting point grease ref Rocal Sapphire Aqua Sil should be used on the axle stanchion assembly pawls nylon slide wheels wire and return pulley Excess lubrication only attracts dirt and should be avoided Clean off surplus lubricant with a rag soaked in cleaning agent Amberklene FE10 or LO30 Lubrication points are illustrated in Figures 42 to 49 for AS Ladders AS TX Ladder s which house the Nylatron pulley sheave within the Cable Assembly do not need lubricating Bayley Ladders Due to the construction of the Bayley it is not required to Lubricate the components ref Rocal Sapphire Aqua Sil with the exception of the Wall Wheel see AS Figure 46 which are housed on Bayley DX ladders Figure 42 Lubrication 1 Figure 43 Lubrication 2 Figure 44 Lubrication 3 Lubricate Centre of Pin for Lubricate Runner Wheel Lobe Points Lubricate Runner Wheel Lobe Points old Style Pulley only Page 25 Figure 45 Lubricatio
11. supplyplus com e yon of manufacture 20 Papworth Everard UK E 44 0 1490 837200 vwa supply Mus com a k Part io Ep5 PANT MO Giada CART Wo Gow 1 Mas PART NO S636 a Mar Norecany dowricerneup marking Page 12 3 14 3 15 3 16 Rubber Feet Stanchion Poles AS Ladders where fitted Examine for signs of damage and sight along each pole to ensure they are not bent or distorted Small dents no greater than 20mm across in either direction can be tolerated but poles with more severe damage should be replaced ai X ii a j Ensure Red Flash markings are visible on Compulsory Pole ladders Pawls Inspect bodies for any sign of cracks deformation Pay particular attention to the pawl feet and ensure they touch the rung atthe same mmn time i a e oo Also check that the pawl fingers have some play when resting on the rung below Check the rubber feet and their attachments for signs of excessive wear and or damage Check the fixings are secure Page 13 4 ANNUAL INSPECTION AS Ladders amp Bayley To be carried out by personnel trained by Supply Plus and certified competent within the last three years The annual inspection should be a more detailed and intensive version of the quarterly inspection detailed in section 3 In general the procedures are the same but after the preliminary inspection in its extended state the ladder should be dism
12. the Pen ladder and then checked using a 3mm gauge The gauge should not fit in the gap Shown in Figure 2 This check should be carried out on all slide wheels at the top and bottom of the ladder e f the gap exceeds 3mm the washers holding the slide wheel should be swapped around so he thicker washers are placed between the rung bracket amp slide wheel and the thin washer by the nut e The ladder should be then moved to the opposite side and the checks carried out again to all slide wheels top and bottom e Check stiles for deformation These checks should be carried out with the ladder in the closed mid open and fully open positions to ensure that there are no issues with excessive float e If swapping the washers does not reduce the gap sufficiently this would indicate either i Wear of the slide wheel shoulder requiring replacement of the slide wheel ii Excessive strain has been exerted on the ladder causing the ladder to distort In either of these cases the ladder should be returned to workshops for investigation and analysis Alternatively the ladder can be returned to Supply for the investigation and analysis to be carried out Lhe wheels should also be examined to ensure there is no additional tapering effect of the wheels If additional tapering has taken place on the slide wheels they should be replaced Please note that during this process any dirt or oil and grease residue should be removed Figure 22 4 5 2 A
13. to the Bayley construction rung stile replacement cannot be carried out for any Bayley ladders Under no circumstances that welding or repairing rungs or sections shall be undertaken House stowaway see figure 111 112 113 onto clean level floor in folded state and inspect the whole ladder particularly the hinge assembly ladder retaining straps and also the shape of the stowaway in the folded state if it is shown that there is twist in the closed state then it would either indicate stile damage or hinge damage Due to the fitment of the Hinge assembly it is not possible to replace this component at the Technicians brigade workshop The whole ladder will need to be sent back to Supply for assessment and where necessary hinge replacement undertaken if it has shown that the stiles are deformed or damaged in any way the whole section will need to be replaced Replacement of the rubber feet and strap retention replacement is the same as in the bayley roof see figure 108 110 Unfold stowaway see figure 114 and place on trestles and inspect further pay extra attention to the hinge assembly and surrounding components for any closure housed looseness or damage Also check the stile sections and the condition of the rungs for damage or looseness see section 3 4 Next fold the centre hinge mechanism and place the stowaway where applicable into the A frame configuration see figure 115 instability could indicate worn feet damaged stiles an
14. 1 always replace both sides at the same time e Check and inspect operation Roof hook assembly standard Ashford fixed see Figure 71 Check and inspect folding open close operation of roof hook Check and inspect roof spring locking latch mechanism and retraction detraction operation Ensure the operation is smooth Inspect the retaining latch holes Check for general were or oxidisation of the roof hook assembly Importantsinspect all the weld points within the whole assembly for cracking pitting oxidisation Check and inspect the rubber support pad were wear perishing this part is heat shrunk training is required when replacing this part Inspect wall wheels and the fasteners for damage wear rolling performance Check roof assembly joining plate and fasteners rivets and bolts for damage to remove the whole hook assembly just remove 4 off bolts shown in Figure 72 Page 41 Additional Roof 3 Rung extension for Fixed section only An additional option by brigade request is to carry an additional 3 rung roof ladder extension section which offers the increased overall ladder length The joining mechanism which allows this process to take place is a male and female coupling which is secured using a sword pin through the joining coupling or a ball pin If it is shown that the joining components are loose then a new male female coupling can be supplied and repairs carried out as per section 6 6 amp 6 8 respectively Check Channel co
15. 17 4 5 1 Detailed Instructions for Ladder Slide Wheel Inspection AS Ladders 18 4 5 2 Annual Removal Replacement of Ladder Guide Wheels AS Ladders 18 4 5 3 Bayley Roller Wheel where fitted Slide Inspection 18 4 6 Extending Line where fitted 19 4 6 1 AAD Automatic Arrest Device AS Ladders amp Bayley where fitted 19 4 6 2 AAD Inspection Workshop AS Ladders amp Bayley 19 20 4 7 Cable AS Ladders where fitted 21 4 7 1 Correct Cable Adjustment AS Ladders where fitted 21 4 7 2 Cable Pulley Assembly current old AS Ladders 21 4 8 Stabiliser Bar AS Ladders where fitted 22 4 9 Wall Wheel Assembly AS Ladders amp Bayley 23 4 10 Pawls and Stanchion Pole Assemblies AS Ladders amp Bayley 24 4 11 Detailed Inspection AS Ladders amp Bayley 24 4 12 Repairs AS Ladders amp Bayley 24 25 4 13 Lubrication amp Cleaning AS Ladders amp Bayley 25 26 5 ANNUAL TESTS AS Ladders 8 Bayley 27 5 1 Annual Tests AS Ladders amp Bayley 2 5 1 1 BS EN 1147 2010 Testing AS Ladders 8 Bayley 2 5 1 2 Deflection test for all ladders not covered by section 5 1 3 28 29 5 1 3 Deflection test for compulsory pole ladders including Roof Ladder Hook Test 30 31 9 1 4 BS EN 1147 Test Loads AS Ladders amp Bayley including Roof Ladder Hook Test 32 5 1 5 BS EN 1147 Test Loads above 11 Meters 33 5 1 6 JCDD Test Loads included as a guide for operators still using JCDD specification ladders 34
16. 2 Page 15 4 2 Stanchion Poles AS Ladders where fitted Examine for signs of damage and sight along each pole to ensure they are not bent or distorted Small dents no greater than 20mm across in either direction can be tolerated but poles with more severe damage should be replaced The latest stanchion pole incorporates aluminium castings for the top hinge assembly Figure 13 and for the ground spike on the other end Earlier versions of this were remanufactured from fabricated assemblies which would allow with force for the pole to be incorrectly stowed 180 out of phase and thereby cause damage to the pole and ladder strings Ensure markings are visible on Compulsory Pole ladders Figure 13 4 3 Rivets AS Ladders only It is important that only rivets purchased from Supply are used throughout the ladder When an aluminium rivet is squeezed up in a gun it will work harden It is essential that the correct grade of rivet is used so that when installed it is of comparable hardness to the aluminium extrusions of the ladder All solid rivets supplied by our organisation carry the letter S on the head all rivets used to manufacture new ladders carry the letter A Any loose rivets should be re tightened only once or replaced using the procedure in section 6 7 If a ladder is dropped this can impose a shearing action on the ladder rivets Special care should be taken when visually inspecting a ladder to ensure rivet integr
17. 9 Remove the loads after 60 seconds again measure from the underside of the ladder to the floor H4 The initial height H1 and the final height H4 must be thessame A measuring tolerance or 3mm applies Test loads 3 Person rescue rated deflection Pre load 3 x 25kg 1 x 20kg 1x 10kg total 105kg First load 2 x 25kg 1 x 20kg total 70kg Second load 3 x 25kg 1 x 20kg 1 x10kg total 105kg Roof ladder 1 person access rated deflection Pre load 3 x 25kg 1 x10kg 1 x 5kg total 90kg First load 2 x 25kg 1 x 10kg total 60kg Second load 3 x 25kg 1 x 10kg 5kg total 90kg Recommended roof ladder hook test not a requirement within the specification With the ladderresting horizontally on a test rig with the bearing point of the hook against a stop the load to be applied away from the hook along the centre line of the ladder Test load 6 x 25kg Total 150kg for 60 seconds No Permanent deformation to occur Page 32 5 1 5 BS EN 1147 Test Loads All ladders above 11 meters Annex B Weights required Soff 25kg 3 extra if roof hook testing 10ff 20kg 10ff 10kg Weight tolerance or 1 Equipment required 1 x fixed 2 x wheeled trestle horizontal even surface Deflection test procedure Measuring tolerance or 3mm 1 Support the ladder horizontally at its maximum working length on the trestles Place 200mm in from each end with a third trestle at the joining point of the poles t
18. ADDERS ALL DOUBLE F EXTENSION LADDERS The following end cap assemblies are located using 255 pop rivets e Foot of main ladder section stabiliser attachment e Head of top ladder section wall wheel axle bearing blocks All other end caps and some rope clip stirrups etc are located using pop rivets ref no S 270 6 6 1 Solid Rivets There are two ways of removing a rivet from your ladder 1 Firstly if you are just replacing a rung or a single rivet you need to take more care so you do not damage the stiles or channels involved This is done by carefully filing or grinding a flat surface onto the rivet s then using a centre punch to give you a place to start drilling Using a 3 5mm drill bit drill in just further than the rivet heads thickness then using a cold chisel and hammer lightly tap and remove the weakened rivet head You will now be able to see the rivet s hole in the stile or channel letting you punch orfinish drilling out the back of the rivet 2 The second way of removing rivets is done when you are removing a complete stile or channel This is done by using the cold chisel and hammer to forcibly remove the rivet heads on the whole stile or channel involved Figure 120 121 Next get a good set of mole grips or pliers and start at one end of the stile channel and lift the stile channel away from the rungs After going down once repeat the process but this time you will pop off the other side of the stile chann
19. Bar AS Ladders where fitted All Stabilisers are subject to the same inspection and maintenance criteria For your notice there are several types of stabilisers currently in service the simple classification is 1 Steel Stabiliser Fixed Currently supplied with older ladders or OEM preference only Housed on older TX ladders see Figure 35 2 Steel Stabiliser Removable supplied as optional housed on TX ladders currently in service see Figure 36 3 Alloy Stabiliser Fixed currently supplied as standard OEM on all TX ladders amp DX if specified see Figure 37 4 Alloy stabiliser LW identical to 3 with the exception one fixed hand wheel and spigot and one adjustable as per normal stabiliser see Figure 38 Figure 38 Check that the hand wheels see Figure 37 all types can be freely rotated over the full travel of the screw threads and that the foot pads are free to rotate and swivel The rubber foot pads should be replaced if worn If the screw thread is damaged a new assembly must be fitted Friction pads where fitted should be adjustedsto apply light friction to the spindles A check should be made to examine the hand wheel for cracking around the spoke rim join and to the handles to ensure that no cracks exist Figure 39 The condition of the stand off rings and their liners should be examined for damage and corrosion and replaced if necessary see Figure 37 1 Also it is required to ensure that the clamp pad inside th
20. Gun n Figure 15 Figure 16 Figure 17 Page 16 4 4 Rungs all AS Ladders amp Bayley AS Rivet Truss Check all rungs for looseness or excessive wear looseness is where the rung can be turned without applying force excessive wear can be judged by the wear on the non slip elements It is recommended that only those rung assemblies which are not in high stress areas should be replaced by brigades using the procedure detailed in section 6 8 Bayley Ladders Inspect the swage form see Figure 18 for any discrepancies The shape of the swage should be concentric and held tight against the stile no gaps Check inside the rung for any cracks Also hold the rung and twist back and forth whilst doing this check to see if there is any sideways rotation at the swaged side of the rung 1 See Figure 19 If excessive movement is found the section ladder should be removed from service operation and Supply Plus are to be contacted for further inspection and if deemed necessary a replacement section ladder is to be obtained Important Due to the Bayley construction rung replacement cannot be carried out for any Bayley ladders Under no circumstances that welding or repairing rungs or sections shall be undertaken T GyWand ad check Figure 18 Figure 19 Note Supply Recommend Rung replacement should only be carried out by your engineers after they have attended a 2 or 4 day training course within the last three years Please contac
21. Ladders amp Bayley When testing ladders it is important that they are tested to the specification standard to which they were built Our ladders are all now built to BS EN 1147 2010 and this is the standard to which they should be tested Older ladders which conform to the requirements and standards of the Home Office JCDD mark should be tested using the tests laid down for that standard Ladders may be damaged and could be a potential hazard if they are tested to the wrong standard If you have any doubts please contact us for clarification 5 1 1 BS EN 1147 2010 Testing AS Ladders amp Bayley Unless specified to the contrary all AS Bayley extension ladders that have the new EN1147 1 2 3 person rescue serial number plate shall also have the 1 2 3 person max self adhesive label shown in Figure 50 This is to be positioned AS Ladders on the climbing side of the bottom section right hand stile 5th rung up from the foot For bayley ladders the Labels shall be positioned on the outside of the bottom section right hand stile between the 5th 8 6th rung up from the foot Where is it stated for a 1 person access ladder AS ladder serial plate the Non carry down carry up label 1max label must be placed on the climbing side of therbottom section right hand stile 5th rung up from the foot Finally for Bayley 1 person access the relevant labels shall be positioned on the outside of the bottom section right hand stile between the Sth amp 6th rung u
22. Page 3 Contents 5 2 Roof Ladder Annual Test for JCDD Ladder 5 3 Failure of Annual Test AS Ladders 8 Bayley All AS Ladders amp Bayley Repair amp Replacement Section 6 REPAIR AND REPLACEMENT AS Ladders amp Bayley including Roof Ladders 6 1 AS Tools required All Ladders 6 1 1 Bayley Tools Required All Ladders 6 2 Repair Table AS Rivet Truss Construction 6 2 1 Bayley Repair Conditions All Ladders 6 3 Other Repairs AS Rivet Truss Construction including Roof Ladders 6 3 1 Other Repairs Bayley Ladders excluding Roof Ladders 35 35 36 37 3 38 38 38 38 38 6 4 AS Ladders Dismantling and Reassembly of the Ladder AS Rivet Truss Construction 39 41 6 4 1 AS Roof Ladder Sub Component amp Inspection including Roof Ladders 41 42 6 4 2 Bayley Construction Ladders Dismantling and Reassembly including Roof Ladders 42 6 4 3 Bayley Ladders DX 7 3m 9m 10 5m EN 1147 6 4 4 Bayley Auto Pawl RemovalReplacement only for EN 1147 DX Ladders Handed Pairs 6 4 5 Bayley Roof Ladders Repair amp Replacement all types amp Stowaway all types 6 5 Position of Ladder Sections on Repair Table all ladders 6 6 Removal of Rivets AS Ladders 6 6 1 Solid Rivets AS Ladders 6 6 2 Pop Rivets AS Ladders 6 7 Solid Rivets AS Ladders 6 7 1 Tightening Loose Rivets AS Ladders 6 7 2 New Rivets AS Ladders 6 7 3 Pop Rivets AS Ladders 6 7 4 Re Bowing of Lad
23. Su by Engineering AS amp Bayley Ladders Maintenance amp Repair Manual Issue 15 March 2015 Contents Cover Page 1 Index 2 3 4 5 INSPECTION SECTION 6 1 INTRODUCTION 7 2 GENERAL CARE 7 2 1 Vehicle Ladder Gantries AS Ladders amp Bayley 7 2 2 Adjustment of Ladder Gantry 7 2 3 Handling AS Ladders amp Bayley 8 2 4 Periodic Inspection and Tests AS Ladders amp Bayley 8 2 5 Repairs AS Ladders amp Bayley 8 3 QUARTERLY INSPECTION 9 3 1 Rivets amp Bolts 9 3 2 Rungs amp Rung Brackets 9 3 3 Stiles Channels 10 3 4 Extending Line where fitted 10 3 5 Cable where fitted 10 3 6 AAD Automatic Arrest Device where fitted 11 3 7 Stabiliser Bar where fitted 11 3 8 Wall Wheel Assembly where fitted 11 3 9 Roof Hook where fitted 11 3 10 Slide Wheels 12 3 11 Hinge Assemblies where fitted 12 3 12 Female Assemblies where fitted 12 3 13 BS EN 1147 2010 Test Labels 12 3 14 Stanchion Poles AS Ladders where fitted 13 3 15 Pawls 13 3 16 Rubber Feet 13 Page 2 Contents 4 ANNUAL INSPECTION AS Ladders amp Bayley 14 4 1 Pawls all AS Ladders excluding Roof Ladders 14 4 1 1 Pawls Bayley Ladders 15 4 2 Stanchion Poles All Ladders where fitted 16 4 3 Rivets AS Ladders only 16 4 3 1 Rivet Gun set up amp Air Pressure Solid Rivets only 16 4 4 Rungs all AS Ladders amp Bayley 17 4 5 Stiles amp Channels all ladders and Slide Wheels where fitted
24. airs Only spare parts supplied by Supply should be used and the repair procedures given here should be followed exactly If in any doubt regarding maintenance training or repair please contact our office or local agent With all enquiries please quote the ladder serial number All enquiries to Supply Plus Limited 1 Papworth Business Park Papworth Everard Cambridge CB23 3WA Tel 01480 832200 email info supplyplus com wwwirsupplyplus com 2 GENERAL CARE 2 1 Vehicle Ladder Gantries AS Ladders amp Bayley Ladders spend most of their life on vehicle gantries and it is important that they do not damage the ladders We manufacture an extensive range of gantry packages to cover mostrequirements details of which are available on request It is most important that the gantries are installed and correctly adjusted in accordance with the appropriate installation guidelines A wrongly adjusted or third party gantry could cause substantial damage and generate the need for expensive repairs 2 2 Adjustment of Ladder Gantry Please note There are two types of Beam Gantry currently in service 1 Slide amp Tilt Gantry Movable Beam Profile Pivot Base Rollers 2 Traditional Gantry Inclined Trough Fixed Rollers amp Gantry Lock It is our experience that damage is caused by the incorrect adjustment of the centre and rear rollers of the traditional ladder gantry system 1 The following procedure should be adopted when these che
25. antled into its separate sections dependant on section type to allow more detailed examination of each section to be made Important It is also important to note that high use ladders in service will have a greater exposure to environmental conditions Therefore components fasteners on all areas of the ladder which are plated will need to be inspected for oxidisation If deemed to show excessive oxidisation then replace components straight away If you are unsure as to which components are mild steel stainless then use a magnet Please be aware that some stainless steels are slightly magnetic ferritic martensitic If you are unsure contact our Office 4 1 Pawls AS Ladders excluding Roof Ladders The pawl finger fitted to the earlier ladder has been replaced with a thicker version which in operation has the effect of giving greater clearance of the pawl foot over ladder rungs Figure 6 It is important that this clearance is checked and if necessary pawl fingers together with their springs be replaced as a pair A clearance of 2 5mm should be seen between the pawl foot and the adjacent rung When the finger is resting on a rung thereby lifting the pawl foot the pawl finger should not be at the extent of its travel The effectiveness of pawl finger springs should also be noted and replaced if necessary The pawls must have a full and free action When the ladder is in the inclined position both pawl feet must be adjusted to sit equally o
26. as well as some others A similar device is fitted to BAYLEY rope operated EN1147 ladders and the following applies With the ladder housed and the bottom wide section up INSPECTION 1 The AAD should be visually inspected 2 The rope on both sides of the pulley wheel should be pulled at the same time towards the base of the ladder shown in Fig1 The pulley should move towards the base of the ladder and return freely under the action of its spring when the rope is released kai Figure 1 AAD Inspection Figure 2 AAD inspection 3 With the pulley pulled away Shown in Fig 2 the toothed cam should be checked for ease of movement shown Fig 3 and it should spring back to the rest position when released Figure 3 AAD Inspection 4 Check there is no significant sideways play in the wheel or the cam ensuring they are aligned TESTING CAUTION The AAD should be tested by releasing the rope whilst lowering the ladder sections If unable to stand up the ladder follow the process using trestles The method set out below should be used 5 Pull the rope from the bottom of the ladder moving the ladder up to just past the 2 rung so the pawls aren t footed This will momentarily free the cam with each pull Figure 4 Ladder pulled out past the 2 rung Page 58 6 Push the upper section back from the top end down towards the stowed position shown Fig 5 Note that the ladder will start to show signs of resis
27. at the rivet guns position will allow the rivet to form spread correctly when housed between the desired ladder substrates Do not fire gun with drill in Place check with drill post firing Step 5 Test the Rivet Gun and rivets onto a small sample ladder section stile channel tie plate Do not attempt to test the rivets performance and joining test onto a new repair AS Rivet Truss ladder use a sample piece Step 6 Check to see if the Solid rivet has pulled the required Substrates Materials together visually inspect as per instruc tions in laid out section 4 3 f it is shown that the rivet has not fully pulled tightened against the adjoining tie plates stiles within the test sample adjust the pressure in small amounts above bar psi from Step 3 It is only permitted to re sequence one more time to an already formed rivet Step 7 If the rivet has formed pulled correctly then you will see no obvious gaps between the head of the rivet 1 and the substrate andsthe formed neck 2 of the underside of the rivetis squashed uniformly see figure 16 Step 8 Once all of the above has been met and the workshop Technician Engineer is confident that he can achieve the required criteria thenshe she can move on to the actual in service Ladder and repair where if required Note The operation and use of the Rivet Gun will be demonstrated on the Ladder Maintenance Training course If in doubt post training refer to your course notes or contact Supply Rivet
28. ble to have an element of minor fluffing and line wear Cuts and serious fraying of the line require replacement Also particular attention should be observed at each end of the Rope extending line and check for algae build up from leaving outside for long periods or grease build up from over lubrication of parts Cable Check the full length of the cable for signs of wear fraying and most Importantly kinks If frays or kinks are found the ladder must be removed from service and returned to the workshop for the cable to be replaced To check the tension of the cable extend the ladder by one rung pull the pawls on to the rung and the top section should have a spring Page 10 3 6 3 7 3 8 3 9 AAD Automatic Arrest Device The AAD should be visually inspected All components and fasteners must be checked for wear or damage This should also include the joining fasteners to the ladder rungs a r Note If an automatic arrest device is fitted a pin can be Visualh inspec inserted through the hole in the casing to render the unit inoperative to enable the ladder to be re housed This feature a must only be used for servicing purposes The locking pin must be removed immediately after the ladder has undergone a deflection test If personnel do not have access to trestles and AAD pins erect the ladder up against a structure inline with the usual operational procedures then lay ladder down on the ground for
29. cks are made On replacing the ladder on the vehicle check that 1 The centre gantry rollers are clear of the ladder and that you can see daylight between the rollers and the ladders The more clearance the better and aminimum of 6mm is recommended Figure 1 2 Ladders fitted with a stabiliser should have the rear rollers just touching the ladder in such a way that you can easily turn the rollers When sighting along the ladder there should be no twist visible Incorrect set up of the Slide amp Tilt Gantry 2 will also result in Damage to the Gantry system and the Equipment being housed Figure 1 Page 7 2 3 Handling all AS Ladders 8 Bayley The ladder is designed to withstand normal handling and use but because of its lightweight aluminium consStruction it can be damaged if subject to shock loads which apply high stress in localised areas At all times the ladder should be handled with reasonable care and should not be allowed to fall heavily when being pitched against a wall or replaced on the ladder gantry Please refer to Fire Service Manual Volume 4 Fire Service Training ISBN 9780113412860 2 4 Periodic Inspection and Tests all AS Ladders amp Bayley The deflection tests are designed to show that the ladder is in good condition and that repairs have been Carried out to a satisfactory standard Testing a damaged ladder may result in further damage occurring and thereforeinspection and any obvious repairs shoul
30. d always be carried out before subjecting the ladder to test loads 2 5 Repairs all AS Ladders amp Bayley Repairs should only be carried out by competent personnel who have attended our 2 or 4 day course within the last three years The passing of this course affirms that the Workshop Technician Engineer is certified in his her ability to competently carry out the test and inspection Maintenance regime by themselves at a desired workshop designation outside of Supply Attending the recent courses within this period also affirms thatthe Technician Engineer is currently up to date with all of the aspects of the ladders construction and test Only AS Fire amp Rescue equipment shall be permitted to be used within the Inspection Repair Maintenance and Test phases Also all known Test equipment used for the BS EN 1147 JCDD TEST shall be obtained from Supply Plus Other repair procedures should not be used and on no account should welding of any type be carried out on the ladder without authority from the manufacturer Only high tensile alloy rivets supplied by ourselves may be used Page 8 3 QUARTERLY INSPECTION Note 3 1 3 2 To prepare for inspection the ladder should be initially viewed in the housed position to ascertain the shape of and the clearance between the ladder sections it should then be extended one rung to ensure thatrboth pawls on the extending sections sit squarely This is a check for impact damage which may ha
31. d damaged hinge assemblies It is still required that the BS EN 1147 Deflection test is carried out post replacement of relevant parts Heat Sensors are to be replaced iffound to be damaged see section 7 ref qty and appendix ref for positioning Page 49 Check Hinge assembly housing retaining holes lead ins Ramp and plunger bousina for oxi dresatian Place stowaway on leart level floor and inspect 5 OO de la Figure 112 Check ladder shape for any twits in each line direction Figure 113 Q Ff Figure 114 Figure 115 Page 50 6 5 Position of Ladder Sections on Repair Table AS Ladders In describing the correct positioning of ladder sections on the repair table it should be understood that with the ladder pitched the front of each section will face away from the building and the back will face towards it Some ladder sections have a set or contour shown diagrammatically in Figure 116 which must be maintained whenrrivets are being tightened or replaced This is done by firmly clamping each section in a specific way to the curved repair table using 150mm 6 G clamps positioned on both sides of the section in the middle and at the ends as shown in Figure 117 118 Fig 117 i FA pi g Fig 118 p Clamping Ladder sections on repair table straight sections bowed top amp bottom sections a A an Am 14 SWG Alloy amm 14 SiG Alloy or hardboard packer or hardboard packer 10mm 3 8 additional pack
32. dders below 11 meters Annex A including Roof ladder Hook test Weights required Soff 25kg 3 extra if roof hook testing 10ff 20kg 10ff 10kg 1off 5kg Weight tolerance or 1 Equipment required 1 x fixed 1 x wheeled trestle horizontal even surface Deflection test procedure Measuring tolerance or 3mm 1 Secure the trestles to the ladder 200mm in from each end Extension ladders to be fully extended and secured in the pawled position to prevent further extension 2 Atthe loading point mid way between the trestles apply the pre load to the ladder for 60 seconds The permitted load spread is no more than two rung spaces 3 Remove the pre load and measure the span between the trestles S 4 Atmid span S measure from underside of the ladder to the floor Hb 5 Apply the first load to the load point and after 60 seconds again measure from the underside of the ladder to the floor H2 6 The first deflection D1 is calculated by subtracting the first load height H2 from the initial height H1 The first deflection D1 must not exceed 2 5 of the span S D1 lt 0 025xS 7 Apply the second load at the load point and after 60 seconds again measure from the underside of the ladder to the floor H3 8 The second deflection D2 is calculated by subtracting the second load height H3 from the initial height H1 The second deflection D2 must not exceed 1 5 times the first deflection D1 D2 lt 1 5xD1
33. dders amp Bayley see Section 6 Repair amp Replacement Dismantle the ladder into its separate sections if possible using the procedure given in AS section 6 4 amp Bayley Section Each section should be examined separately by placing horizontally onto two trestles positioned approximately 300mm from each end The trestles should be set up with perfectly horizontal bearing surfaces by checking with a spirit level Inspection should then be carried out as detailed in AS section 4 and Bayley Section 4 covering the following details e Rivets e Rungs and Rung Brackets e Stiles Channels e Extending Line where fitted e Heat Labels where fitted e Cable where fitted e AAD automatic arrest device where fitted e Stabiliser Bar where fitted e Wall Wheel Assembly where fitted e Roof Hook where fitted e Slide Wheels e Hinge Assemblies where fitted e Female Assemblies where fitted e BS EN 1147 2010 Test Labels 4 12 Repairs AS Ladder amp Bayley AS Rivet Truss We recommend that any AS rungs found to have cracks in the ends should be replaced Any replacement or tightening of the rivets or replacement of AS rung assemblies should be carried out at this stage before continuing with the next stage of inspection It is recommended that onlythose rung assemblies which are not in high stress areas are replaced by workshops using the procedure dealt with in section 6 8 Page 24 Bayley Ladders inspection Due to the Ba
34. der Sections AS Ladders 6 7 5 Ladder Twist AS Ladders 43 44 45 46 47 50 51 52 52 52 53 53 53 53 53 53 54 Page 4 6 8 Removal of Rungs AS Ladders 54 6 9 Stanchion Poles AS Ladders where fitted 54 55 6 10 Steel Stabiliser Bar AS Ladders where fitted 55 6 11 Aluminium Stabiliser Bar AS Ladders where fitted 595 6 12 Pawl Assembly AS Ladders where fitted 55 6 13 Extending Line and Cable AS Ladders where fitted 55 6 14 Wall Wheel Assembly AS Ladders 56 6 15 Wear on Stiles Channel and Rung Sections 56 6 16 Auto Arrest Device AAD Retrofit Installation Guide 56 7 HEAT REACTIVE LABELS where fitted 56 8 SETTING OF THE RIVET GUN 56 57 Appendix A Automatic Arrest Device 58 59 Appendix B Roof Ladder Hinge Upgrade 60 62 Page 5 Inspection Section Inspection Section This manual is written expressively for the Inspection and Maintenance of ladders manufactured by AS Fire amp Safety inclusive within this are the Angus Sacol Rivet Truss Ladders and the Bayley Swaged ladders Additionally this Technical manual also covers the test regime for Angus Sacol Rivet truss ladders by the British Standard BS EN1147 and where applicable the testing of Bayley Ladders to this standard It is important to note that due to Fire authorities obtaining older versions of the Bayley Access Roof ladders in the field ladders within this period need to be Tested to the Home office JCDD The
35. e fixing ends and the retaining pins shall be inspected for wear or damage and also the retaining fasteners needito be checked fitted correctly Finally the stirrup housing Figure 25 3 also needs to be checked for stress cracksyand wear and the condition of the rung and the joining rivets 4 6 1 AAD Automatic Arrest Device AS Ladders amp Bayley where fitted The Automatic Arrest Device AAD see Figure 26 which eliminates the possibility of a ladder free falling in the event of the extending line being released after the pawls have been tripped Please see Appendix A for the operational functionaltest of the AAD Important Do not attempt to replace any of the components if it has shown that parts or the prior to this the mechanical operation has been impaired The AAD must be returned to the Manufacturer Supply Plus for further inspection and test Presently there should not be any BS EN 1147 Ladder s in service that does not have the AAD fitted as standard 4 6 2 AAD Inspection Workshop AS Ladders 8 Bayley lt must be stated that only inspection of the AAD see Figure 26 for wear or damage shall be carried out by competent certified Technicians FUNCTIONAL INSPECTION on ladder 1 The AAD should be visually inspected see Figure 26 All components and fasteners must be checked for wear or damage Also the Joining fasteners to the ladder rungs need to be inspected 2 The rope on both sides of the pulley wheel should be
36. e stabiliser tube see Figure 40 is correctly set so that there is some degree of turning resistance when cranking the hand wheel Common sense should prevail here if you over tighten the clamp pad then turning will become harder and vice versa Figure 35 Figure 36 Figure 37 To tighten the spindle travel use the available allen key access hole as shown in figure 35 Use an 8mm metric allen key Cramp plate Figure 39 Figure 40 Page 22 4 9 Wall Wheel Assembly AS Ladders amp Bayley If the covering of the wheel is worn or damaged new wheels should be fitted see Figure 41 Special attention should be paid to the bonding of the tyre to the wheel hub see Figure 41 Also pre 2011 the Wall wheel axle was manufacture in steel and zinc plated However post 2011 we have replaced the steel axle with an improved stainless steelaxle We recommend that older ladders with the steel plated axle should be replaced with the stainless version Where fitted the wall wheel heat sensor label should also be inspected see section 2 6 for details Check for wear damage Check for oxidisation or damage Bearing block LIR Figure 41 Page 23 4 10 Pawls and Stanchion Pole Assemblies AS Ladders 8 Bayley These should be checked for damage and signs of wear in the Stanchion pole hinges before dismantling the ladder as in sections 4 1 and 4 2 For Bayley Ladders refer to sections 4 5 3 4 4 3 41 1 4 11 Detailed Inspection AS La
37. eemchecked join the sections together and check the operation of the auto pawls laid out in section 4 1 1 Heat Sensors are to be replaced if found to be damaged see section 7 for instructions Page 45 Figure 100 Figure 101 Spring must sit an shoulder Figure 102 Page 46 6 4 5 Bayley Roof ladders Repair 8 Replacement all types and Stowaway all types As with all ladders specified ensure that all of the relevant labels have been used and are currently housed onthe ladders see section 7 for heat sensor qty by ladder designation Important Due to the Bayley construction rung stile replacement cannot be carried out for any Bayley ladders Under no circumstances that welding or repairing rungs or sections shall be undertaken At present there are 4 Four Generic Roof ladder configurations out in service Bayley Roof Ladders configurations 2 section Folding Roof ladder with fixed 2 Section Folding Roof ladder with folding hook Ashford fold hook or standard Single section Roof ladder with folding hook Ashford fold hook or standard Single section Roof ladder with fixed hook All of the above are available in various lengths and folding points dependant on brigade specification Replacement of the Roof Hook can be carried out at workshop level it is not a mandatory requirement but Supply recommend that the hook shall re tested BS EN 1147 as laid out in section if workshop has the roof hook test equipment and test sheet
38. el Once the stile channel is totally removed you can use the rivet back removal tool to finish clearing the rungs ready for the new stile channel to be fitted Great care should be taken not to elongate the holes in both methods e Figure 120 rivet removal a Figure 121 rivet removal Page 52 6 6 2 Pop Rivets Removal of pop rivets should be carried out by carefully drilling out the head of the rivet and tapping out with the pin punch Use a 4 9mm dia Twist Drill for the removal of S255 rivets Use a 4mm dia Twist Drill for the removal of S270 rivets 6 7 Solid Rivets AS Ladders 6 7 1 Tightening Loose Rivets AS Ladders When several rivets require tightening the section should be set up on the trestle table as indicated in Figures 120 121 slight pressure being applied in order to hold the Rivet in position The riveter should be held horizontally and square to the ladder section to ensure correct location of the rivet see Figure 122 The riveter should be operated for a couple of seconds to ensure that the rivet is fully tightened Care must be taken to set the jaw gap correctly in accordance with the tool manufacturers recommendations See notes in section 7 regarding the setting procedure for different rivets Figure 122 tighten loose 6 7 2 New Rivets lf rivets have previously been re tightened they should be removed as described in section 6 6 New rivets should be placed with the domed head
39. ents must be replaced 6 16 Auto Arrest Device AAD Retrofit Installation Guide Converting from JCDD to BS EN 1147 The same AAD Figure 127 is used on both double and triple extension ladders but e Figure 127 Auto Arrest Device should only be fitted to ladders that have pawl dampers AAD 1 With the ladder wide section up remove the existing rope pulley from the wide section 2 Offer up the AAD as shown above using the original left hand fixing holes and drilling new holes for the right hand It will be necessary to file the AAD body to fit tightly between the rungs 3 Fill the original pulley right hand fixing holes with bolts 4 Having fitted the AAD pull the sheave away fromthe cam and insert a pin or screwdriver through the maintenance holes in the AAD body angles The rope can now be fitted 5 Remove the pin or screwdriver and the AAD and the ladder is now operational Note It is important that both the cable and rope are in good condition with the cable adjuster fitted being the closed eye type and that the cable and not spliced ends 7 HEAT REACTIVE LABELS AS Ladders amp Bayley where fitted Where heat reactive labels have changed colour the central section goes from grey to black they should be removed and replaced with new labels To remove the labels simply peel off it will then be necessary to clean the glue residue off using a spirit based cleaner This will ensure that the area is also grease free
40. er Figure 119 Page 51 A 25mm x 40mm 1 x 1 x 1 wooden block should be placed inside the stile under each clamp to prevent damage when the clamps are tightened There is a strengthening bead along each stile and to prevent distortion when clamping 100mm x 50mm 4 x 2 packer preferably 2mm 14SWG light alloy or alternatively hardboard should be placed at each clamping point between the stiles and the table Alternatively the repair rig may be closed together so as to allow the beads to sit over the edge of the rig and the packing placed under the beams Figure 119 The correct positioning for each section is as follows e Bowed bottom sections must be clamped with uppermost e g the section should be clamped with the two stile sections down and the two U channels uppermost The beams should be approximately 450mm 18 apart e Straight sections can be clamped either way up but in addition to the normal alloy or hardboard backing under each clamp alloy or 5mm 3 16 packing must be placed between the rig and the trestles at the points where the four clamps are positioned No extra packing should be placed under the two middle clamps e Bowed top sections are clamped directly onto the table with the front uppermost and the back resting on the table The beams should be placed approximately 200mm 8 apart 6 6 Removal of Rivets all ladders Figure 119 Ladder bowing 15 METRE ai SERES L
41. et up correctly both beams should be straightand in the same horizontal plane Check this by sighting along each beam for straightness and use a spirit level placed square across the two beams at several points along their length to ensure they are horizontal Pack the trestles if necessary to obtain the correct position It is then necessary to set a convex contour in the table This is done by placing metal packing strips 5mm thick between the beams and the middle trestle andisuspending 25kg 56lbs weights approximately 305mm 1ft from the end of each beam The weights bow the beams to the correct contour and ensure they rest firmly across the three trestles 6 2 1 Bayley Repair conditions all ladders The only requirement for the repair bed is a workshop which has the space and working height for the correct removal of the sections if required And trestles which have protective lining to prevent stile damage 6 3 Other Repairs AS Rivet Truss Construction including Roof ladders Repairs to or replacement of pawls cables stabiliser bar stanchion poles and wall wheel assemblies may also be carried out without fully dismantling the ladder 6 3 1 Other Repairs Bayley Ladders excluding Roof ladders For Bayley repairs to sub components Rollers it is required to remove DX TX sections and placed individually per section on a suitable repair bed Important Due to the Bayley construction rung stile replacement cannot be carried out
42. for application of the new label The new label is applied and smoothed using any flat object Please contact Supply Plus for the label position instructions and the quantity used 8 SETTING OF THE RIVET GUN AS Ladders The correct setting of the rivet gumis of vital importance as if set too wide the assembled structure will not have the correct tension The correct setting is achieved as follows Page 56 For 4mm diameter rivets used on all rungs and tie plates the gap between the snaps should be 3 16 This is best set using the shank of a 3 16 diameter drill 5mm rivets used for stanchion attachment brackets should be set using theyshank of a diameter drill After any adjustments ensure that the locking ring is tightened to prevent movementof the yoke of the gun Rivets may only be tightened once To achieve this the yoke can be tightened by not more than 4 This must never be exceeded or damage to the rung brackets may result Note DO NOT shoot the rivet gun snap onto the drill diameter you require as this will damage the snaps cups Instead shoot the rivet gun and then try to insert the drill diameter between the gun and the front resting on the table Page 57 APPENDIX A Automatic Arrest Device Inspection amp Testing The procedures below are intended as a guide to the inspection and testing of the AS Fire amp Rescue AAD This device is fitted as standard on all AS rope operated EN1147 ladders
43. ill increase the damping of the spindle To remove the spindle undo but do not remove the nuts until the spindle is free moving 6 12 Pawl Assembly AS Ladders where fitted In normal use the only parts of the pawl assembly which should be replaced are the pawl finger hook and finger springs Should other parts become damaged or worn a complete new assembly should be fitted To replace either hook or finger spring firstly remove the assembly by unscrewing the four retaining screws Remove the split pin from the appropriate pivot pin and withdraw the pin The hook or finger can then be removed together with the spring A new spring should then be fitted the hook or finger repositioned and the pivot pinrreplaced Before replacing the split pin always use a new pin check that the spring is correctly located under the spring retainer Adjust the finger spring if necessary by bending it carefully with a pair of snub nosed pliers and refit thevassembly Check that both pawl and finger clear the rungs 6 13 Extending Line and Cable AS Ladders where fitted The extending line and wire cable should be checked for damage and replaced if necessary To replace the extending line disconnect it from the rope clip remove e Figure 126 Extending line retaining the retaining bolt Figure 126 and withdraw it through the pulley assemblies Feed the new extending line through the pulley assemblies in the reverse baj manner and secure the retaining
44. ion to those in high stress areas which have additional reinforcing between the rounds Check the tightness of all rivets and bolts Rung brackets should be visually checked around the rivet holes to ensure that no splits or hole elongations are present Rungs amp AS Ladder Rung Brackets all AS Ladders amp Bayley i AS Rivet Truss Check all rungs for looseness or excessive wear looseness is where the rung can be turned without applying force excessive wear can be judged by the wear on the non slip elements ii Bayley Ladders Inspect the swage form for any discrepancies The shape of the swage should be concentric and held tight against the stile no gaps Check inside the rung for any cracks Also hold the rung and twist back and forth whilst doing this check to see if there is any sideways rotation at the swaged side of the rung 1 If excessive movement is found the section ladder should be removed from service operation and Supply Plus are to be contacted for further inspection and if deemed necessary a replacement section ladder is to be obtained Page 9 3 3 3 4 3 9 Stiles 8 Channels all ladders and Slide Wheels where fitted Examine stiles channels for signs of cracking splintering breaks gouges distortion or other damage whilst checking for slide wheel damage lf 50 Yo or more wear is found it is highly recommended that a new stile is fitted Extending Line where fitted It is accepta
45. ity This should be done by feel on the blind side as well as a visual inspection on the face surfaces paying particular attention to those in high stress areas which have additional reinforcing between the rounds Figure 14 Solid rivets must not be replaced with pop rivets Rung brackets should be visually checked around the rivet holes to ensure that no splits or hole elongations are present The effect of over tightening rivets through an incorrectly adjusted gun can split the rung bracket from the hole to the outer edge or enlarge the stile channel rung bracket hole If this occurs it will dramatically reduce the overall strength of the ladder Figure 14 4 3 1 Rivet Gun Set up amp Air Pressure Solid rivets only This guide example is for the Solid Rivet s S202 S20 For rivet S257 replace rivet snap tool as shown in Figure 17 with larger head profile Do not attempt to carry out repair or maintenance without official Training Certification from Supply Plus Step 1 Ensure Workshop PPE and Training has been implemented for the use of Air tools Step 2 Inspect Air line connectors ensure that there isn t any air leakages around the couplings Step 3 Ensure Air Line Pressure to Rivet Gun atthe localised point is set to circa 5 5 bar 80 psi amp 5 9 bar 86 psi Step 4 Ensure that the Rivet gun yoke head distance is correctly set see figure 15 a 4 9mm DIA metric drill is placed between the gap this gap is critical in ensuring th
46. l n 340 to 450 gram Hammer o Goff 150 mm G Clamps for use in conjunction with item b p Wick Loc lock pins pliers q mm Spanner r 8mm Spanne Ss 10mm Spanner t 2 of43mm Spanners u lt 2 of 17mm Spanners v 10mm Socket w Air Twist Drill x Set of Flat Blade Screwdrivers y Phillips Screwdriver Page 37 6 1 1 Bayley Tools Required all ladders Spanners 4mm 19mm Allen Keys hex 2mm 8mm Screw DriversSmall flat to Large flat Steel Hammer Mole grips Small to Large Drill Pneumatic Rivet Gun see 3 3 1 step 3 for pressure settings Hacksaw 6 2 Repair Table AS Rivet Truss construction Certain ladder sections are built with a contour or set and this must be maintained when repairs involving tightening or new rivets are undertaken Before starting repairs the ladder must be clamped to a specially contoured ladder rig The table is set up using three steele trestles 750mm 30in to 900mm 3G6in4 high with bearing surfaces at least 750mm 30in long They are positioned at 240mm 8 feet intervals on a perfectiy level floor with the bearing surfaces checked with a spirit level to ensure they are horizontal Two 6100mm 20ft lengths of 127mm x 63 5mm x 8mm Sin X 2 5ins X5 16in channel section steel beam are laid flat side uppermost across the tops of the trestles and square to them The two beams must be adjusted to suit the particular ladder sections under repair lf the trestles have been s
47. l contact between the pin and the ramp you should see a polishing effect on the surface This is normal If you see very deep scratches then this would indicate that the hinge assembly has been incorrectly housed stile section damage or the ladder has been misused imoperation It is not possible to replace these components individually as this hinge body s L R function as a pair Our recommendation is to replace both bodies if damage has occurred on either side This wilhensure that the wear rate is distributed equally between both sides ref item 2 amp 4 figure 66 Hinge main bodies are to be checked for any excessive wear or damage as Stated in item 1 2 3 figure 66 Also check that the rivets that house the bodies onto the channels have formed correctly A small amount of twist between the roof sections should occur however excessive twist would indicate channel damage orwithin the hinge body joining rivets some indication of mechanical failure rivets have sheared rivets not formed due to incorrect gun pressure wrong rivets used pre drilled rivet holes within the hinge bodies are too big If you are unsure then remove the roof ladder from inspection tag quarantine ladder laid out in you workshop procedure and replace the damaged hinge assembly Also if you have damage to the hinge then there may also be damage to the ladder channels inspect and replace if required Only attempt to replace hinge assembly if you have attended the ladder main
48. mole grips to hold blind nuts and then remove screws and replace clamp if required Remove rubber feet by drilling out 1x pop rivet replace Rubber feet and replace rivet Pull casting remove bolt shown in e 1 and drill out rivet shown in e 2 replace pawl and replace rivet and if required the bolt if shown to be damaged Replacing identification plates all ladder types if needed requires the technician to drill out the existing rivets and replacement with new rivets see Figure 74 For all other labels see section 5 1 1 for correct label based on the type of ladder Page 42 Figure 74 6 4 3 Bayley Ladders DX 7 3m 9m 10 5m BS EN 1147 As with all ladders specified ensure that all of the relevant labels have been used and are currently housed on the ladders see section 7 for heat sensor qty by ladder designation The general pictorial s shown below are for the removal and replacement of the 7 3m DX with Auto pawls the design is the same as the 9m amp 10 5DX with the only difference being the length Therefore for dismantling instruction for the 9m 8 10 5m DX use the method below as shown for the 7 3mDX As for the 9m DX we do offer an alternative A pawl configuration which will be shown within this document Before the removal of Auto pawls the ladder must removed in to it syindividuahsections Dismantling and Removal of ladder sections DX Lay down ladder on trestles as shown in Figure 75 Remove ladder retaining stra
49. n 4 Figure 48 Lubrication 7 Figure 46 Lubrication 5 Lubricate middle of pin Figure 49 Lubrication 8 Lubricate narrowed ends of axle Figure 47 Lubrication 6 Ensure threaded spigot bar is fully wound in out before applying specified grease Apply lubricant onto threaded spigot and wind the handle until the threaded spigot h leted the t to it s natural st int Lubricate middle point s of the pawl finger pin amp the pawl arm pin a Moar ee ee ik Page 26 5 ANNUAL TESTS AS Ladders amp Bayley The following tests are to be carried out annually or when considered necessary see criteria for necessary but only after the ladder has undergone the annual procedure and any necessary repairs have been made A measuring tolerance of 3mm applies to all the test measurements given in this section Criteria examples for Ladder testing outside Annual test When the ladder s have been damaged within operation and repairs have been carried out When the ladder s have been exposed to excessive heat Fire Damage and repairs have been Carried out When any Ladder components or parts have been replaced within the quarterly period s When the ladder has been damaged when stowed on the fire appliance and repairs have been carried out Rescue and access Rescue and access Access Access Rescue and access One piece Roof Access Rescue and access Sectional Rescue and access Access 5 1 Annual Tests AS
50. n the adjacent ladder rung The folded pawl casing Figure 7 and the wire cable clip plate should be checked for splits or cracks around the area of the screwixing This does not effect the later extruded profile pawl body and wire cable clip plate The finger damper spring helps to ensure that the finger does not impact a rung when the ladder is housed or extended at high speed The finger damper spring helps to ensure that the finger does not impact a rung when the ladder is housed or extended at high speed This will hold the finger at an angle when at rest Figure 8 Figure6 Figure 7 Figure 8 Page 14 4 1 1 Pawls Bayley Ladders The Construction of the Bayley Auto pawl is different to the AS Pawl in respect to it s positioning and construction see Figure 9 However the operation travel of the pawl over the adjoining sections is identical see figure 9 Due to the Auto pawl being housed in the side of the stile and the adjoining section uses a plastic guide see figure 10 for the correct height the clearance is always set at the correct distance Inspect all of the parts for wear and deformation cracks within the Auto pawl assembly see Figure 11 pay particular attention to the pawl casting and pawl finger casting for any signs of fracture Replace all parts in pairs handed Ensure you re test the pawls operation if parts have been replaced Check the mechanical operation of the Auto pawls L R Handed see Figure 9 ensu
51. ndition Figure 71 Figure 72 6 4 2 Ladders Dismantling and reassembly Bayley Construction including Roof ladders As with all ladders specified ensure that all of the relevantJabels have been used and are currently housed on the ladders see section 7 for heat sensor instructions Important Due to the Bayley construction rung stile replacement cannot be carried out for any Bayley ladders Under no circumstances that welding or repairing rungs or sections shall be undertaken DX TX Short These ladder s are particularly low maintenance however if the ladder is subjects to high use then parts will wear and it is then necessary to replace relevantcomponents Due to the simplicity of the DX amp TX Bayley short ladders the removal of the ladder into it s individual section is fairly straightforward see Figure 73 Removal of the top Hi Figure 73 Removal of Bayley DX TX Short components if required Due to the extensive variation parts and fasteners please contact Technical sales for the correct replacement Rivets fasteners and components Laddenslide block held using pop rivets replace slide by drilling out rivets and replacing with new rivets Roller wheelguide held using cross head machine screw replace by removing screw Ladder clamp housed within an cut out in the stile and held using 2 x blind nuts Remove roller wheel and remove 2 x countersunk screws which are locked into 2 x Aluminium blind nuts To remove clamps use relevant
52. new hinge with a dia 4 9mm drill bit Rivet new hinge into place using 4 9mm tank rivets When all existing rivet holes have been riveted drill 2 further dia 4 9mm holes in position as shown on the now shortened channel ta ensure this channel has 3 rivets rivet the 2 new positions using a 4 9mm tank rivet Please note hat fre Rivet the large rubbers back on using oigna bofis cannot be 5 1mm stainless steel pop rivets used dir fo access Fresiicions Page 61 Measure and mark a position 60mm in fram the hook end ofthe ladder on the opposite side to the large rubber Mark through the rubber toot and drill using a 6 35 mm 1 4 drill bit Fitthe new rubber foot with ME x 35mm Pan Head Bolt S2713 M6 Stainless Steel Washer R2125h M Myloc Mutts 2103 and M form B washerlta252 hh Page 62
53. ng the pressure plates is achieved by removing the outer 4 x retaining screws and therretaining inside blind nuts When replacing with new pressure plate make sure the fasteners are secured with Loctite 243 Inspect retaining strap figure 108 for degradation or fraying and observe rivets for damage Drill out 2x rivets and replace strap with new rivets if required Carry out folding hinge open close operation to identify any operational mechanical difficulties with the hinge assembly Folding hinge assembly Shown in folded state see figure 109 check plunger pin housing 1 for damage amp oxidisation check hinge bodies 2 3 for damage pay particular attention to the latch pin lead in 4 and the retaining latch pin hole 5 for elongation and damage Due to the fitment of the Hinge assembly hinge replacement must be undertaken back at the manufacturing facility at Supply Plus Inspect rubber feet see figure 110 if shown to worn then replace by roving the holding rivet which is housed on the side of the stile Heat Sensors are to be replaced if found to be damaged see section 7 for instructions Page 47 Figure 106 Figure 107 Figure 108 Figure 109 Page 48 Figure 110 Stowaway replacement components parts and inspection As with all ladders specified ensure that all of the relevant labels have been used and are currently housed on the ladders see section 7 for heat sensor qty by ladder designation Important Due
54. nnual Removal Replacement of Ladder Guide wheels and Fasteners AS Ladders We have reviewed the need for annual replacement and are satisfied that these wheels should be inspected and replacements made only when they cannot be adjusted into tolerance or are showing other signs of excessive wear of any kind The adjustments should be made as detailed in section 4 5 1 4 5 3 Bayley Roller wheel slide Inspection where fitted The Bayley roller guide wheels and slides see Figure 23 24 are also exposed to the same wear exposure as the AS ladder guide wheels Please follow the procedure from 4 5 2 Figure 24 Page 18 4 6 Extending Line where fitted The choice of material and size of extending line is a product of the grip factor and the comfort of operator and is not determined by line strength The extending line used has a breaking strain of two tonnes and when in use the normal loading it is subjected to is pull load between 25kg 50kg dependent on the exact angle of deploymentand type of ladder As a result it is acceptable to have an element of minor fluffing and line wear see Figure 25 Cuts and serious fraying of the line require replacement Also particular attention should be observed at each end of the Rope extending line Due to variations in the AS Fire 8 Bayley Ladders the fixed end 1 as shown in Figure 25 and the stirrup retaining pins 2 are different depending on the types of ladders However the principle is the same th
55. nsion the feet can be made to contact the rung Check slide wheel clearance in both stowed and extended conditions This should not exceed 3mm with the ladder pushed to one side If greater adjust the spacing washers to close the gap toless than 3mm in both open and closed positions See section 3 5 1 for fully detailed instructions Note If an automatic arrest device is fitted a pin must be inserted through the hole in the casing to render the unit inoperative to enable the ladder to be re housed This feature must only be used for servicing purposes The locking pin must beyremoved immediately after the ladder has undergone a deflection test see section 3 6 Information AS Fire roof ladders are based on the same construction as the AS Rivet truss extension ladders with the exception that all AS roof ladders are not extended using the manual push operation or rope pulley system The open close operation from folding roof ladders is achieved by two variation design hinge mechanisms see Figure 66 67 Figure 66 Figure 67 Page 39 In principle the mechanical operation closure of the above hinges are similar in operation and both if maintained inspected correctly will work AS Old Hinge Design see Figure 67 Areas to check ladder hinge link ensure block is in good condition also check the pivot pins and the nylatron washers check mechanical operation of the pivot to identify any excess slack or tightness it is possible to replace these
56. nt bruising of the rung The rope for applying the load isto be fed centrally between the stiles and over a pulley at the opposite end of the bench from the ridge hook to the testing weights There must be no sign of failure or permanent distortion of any part of the ladder or roof hook assembly 5 3 Failure of Annual Test AS Ladders amp Bayley If it is found that the ladder does not comply with the specifications laid downn any of these tests the ladder should be returned to Supply for overhaul and assessment or contact Supply No ladder which has failed any of these tests should be in service Page 35 AS amp Bayley Repair amp Replacement Section all ladders where required This manual is written expressly for Inspection and Maintenance of ladders manufactured by AS Fire amp Safety The use of this manual to carry out procedures on ladders manufactured by other companies could resultin damage to them or in some circumstances cause the ladder to fail in service For instructions on other manufacturer s ladders please consult their manual Page 36 6 REPAIR AND REPLACEMENT AS Ladders 8 Bayley including roof ladders Information for Bayley construction Bayley ladders are very low maintenance due to construction of the main stile 8 rungs The section outlined for Bayley is predominantly replacement of sub components Auto pawls Rollers pawls rollers rubber foot pads All ladders that have been inspected and c
57. nt of the rubbers on the stand off bracket if fitted and friction pads and replacement of the spindle should the threads become damaged The original style rubber strips on the stand off brackets have been phased out and replaced by polyurethane pads These are now replaceable and are secured by bolts to the stand off brackets Should the spindle thread become damaged a new assembly should be fitted To remove the spindle firstly unscrew the retaining socket screw and drift off the hard wheel Remove the friction pads and adjusters if fitted The spindle should then be unscrewed from the assembly If the spindle is severely bent it may be necessary to cut the spindle to facilitate removal Since the ball joint is a press fit in the end of the spindle the complete assembly must be replaced The new spindle assembly should be fitted and the hand wheel replaced by reversing the above procedure If assembly has been damaged in anyother way it should be returned to Supply for overhaul and repair 6 11 Aluminium Stabiliser Bar AS Ladders where fitted On aluminium stabiliser bars it is possible to replace the stand off rings if required It is not considered practicable to replace the tube as special tools and jigs are required A replacement tube assembly is available from our factory or agents To remove or adjust the spindle damper first remove the plastic end cap from the tube This will reveal an aluminium plate held by 2 nuts Tightening these w
58. o the ladder Ensure the trestle at the bottom end of the ladder is fixed and the other two are mobile Secure the trestles to the ladder 2 Apply the pre load for a minimum of 60 seconds at the mid span point between the twomobile trestles 3 Remove the pre load and measure the distance from the underside of the ladder to the floor at the mid span point between the two mobile trestles H1 4 Apply the first load for a minimum of 60 seconds at the mid span point between the mobile trestles After 60 seconds measure the distance from the underside of the ladder to the floor atthe mid span point between the two mobile trestles H2 5 The first deflection is done by subtracting the first load height H2 from the initial height H1 This is D1 6 Increase the load to the second load and after 60 seconds measure the distance to the floor at the mid span point between the two mobile trestles H3 7 The second deflection is done by subtracting the second load height H3 from the initial height H1 This is D2 8 Remove all of the weights After 60 seconds measure the distance to the ground at the mid span point between the two mobile trestles H4 9 The final deflection is done by multiplying D1 by 1 5 This is D3 10 The deflection is that D2 must be less than D3 with a3mm tolerance 11 The distance of H4 must be within 3mm or of the initial height of H1 12 The ladder should never touch the ground during this test Test load
59. omponents that have been replaced must post this repair shall undertake the BSEN1147 JCDD ladder specific tests Re certification and acceptance can only be carried out by an certified ladder Technician who has attended the Ladder maintenance course at Supply within the last Three years Due to the huge variances of components and fasteners we are not able to name part numbers for components fasteners within this document with the exception of common AS Rivets However we understand that parts fasteners will need to be replaced if so then please send photos of parts fasteners with a clear description Our Technical sales will then be able to send replacement parts fasteners if required We will also be able to send a parts list to assist the technician 6 1 AS Tools required all ladders The following tools and equipment are required to carry out all the repairs described in this manual a Pneumatic riveting gun the riveter should only be used with an air supply of 5 5 to 5 9 bar 80 85 psi The tool complete with the special yoke and riveting snaps is available from Supply Part No TS034 b Repair table this is fully explained in section 6 2 c Lazy Tongs blind riveting tool 4mm nose piece and 5mm nose piece d Locating Pins e Cold Chisel f 3mm Pin Punch g 3 5mm Twist Drill h 4mm Twist Drill l omm Twist Drill j 5 16mm Twist Drill k 6 35mm Twist Drill l 8mm Twist Drill m 10 3mm Twist Dril
60. p see Figure 76 Remove extending line from stirrup housing see Figure 77 Lift Auto pawls up as shown in photo and push top section forwards towards the head of the bottom section see Figure 78 Continue to push the top section towards the head of theladder until it reaches the Rung stop push the stop inside the rung see Figure 79 Once it has cleared the rung clamp plate see Figure 80 then continue to remove the section until it reaches the end see Figure 81 Place the top section on trestles next to the bottom section see Figure 82 Carry out visual inspectiomof all the sub components The AAD will need to be tested see appendix A if found to be damaged or not functioning correctly then remove the 4 x fasteners see Figure 83 and return to Supply Bottom section Inspection Inspect the stiles and rungs for excessive damage or wear remove from service and contact Supply for new section Check AAD All fasteners Hold down clamp stops see Figure 84 Rubber feet Rollers guide See Figure 84 and the extension line and the karabiner housing Replace relevant parts if required with the excluding the AAD Top Section inspection Check all fasteners ladder slide guide see figure 85 stops see figure 86 Stirrup see figure 87 Wall wheel assembly see figure 88 Rubber feet amp Auto Pawls see Figure 81 89 for removal replacementiof Auto pawl see section 6 4 5 Figure 75 Figure 76 Figure 77 Page 43 Fig
61. p from the foot Figure 50 Test Labels PART NO S695 PART H Biga PART HO Sag 1 Max PART HO S636 W Y 2 Max kod 3 Max Non carry dowrcarry up marking Page 27 Table 5 1 Deflection Test Loads Ladder Type Material Pre Load First Load Second Load 3 Person Wooden 735N 75kg 490N 50kg 735N 75kg Ladder All Other 1029N 105kg 686N 70kg 1029N 105kg 2 Person 588N 60kg 392N 40kg 588N 60kg Ladder nn All Other 822N 90kg 588N 60kg 822N 90kg 1 Person All 735N 75kg 490N 50kg 735N 75kg Ladder Roof Ladder 822N 90kg 588N 60kg 822N 90kg 5 1 2 Deflection test for all ladders not covered by section gt 5 1 3 e Figure 51 Deflection Test Layout 200 Q e Figure 52 Test Datum Point xX Page 28 e Figure 53 First Deflection A an Apply the first load as specified in Table 5 1 for a minimum of 60 seconds at a point on the laddermid span between the trestles Measure the distance B from the point on the ladder mid span between the trestles to thephorizontal datum Figure 53 Remove the load and measure the distance A from a point on the ladder mid span between the trestles to a horizontal datum on the ground vertically below Figure 52 e Figure 54 Second Deflection Increase the load to the second load specified in Table 5 1 and apply it for a minimum of 60 seconds at a point on the ladder mid span between the t
62. ponents amp fasteners this includes wear factors and any stress cracks on the castings replace if required see figure 96 97 Remove pawl finger casting and Pawl arm casting the relevantitorsion spring s must be replaced at this point remove spring arms from their respective holding points see figure 97 Remove pawl finger pawl casting pivot pin s using mole grips held on to pivot pin and socket wrench located onto the blind nuts see figure 98 99 Once all parts have been removed check the condition of the relevant retaining holes see figure 100 on the stile for elongation or damage If elongation has been identified then remove section and all parts and contact Supply Plus Technical sales for a complete section replacement If at this stage that as shown in section 9 that the pawl retaining holes are acceptable then replace worn damaged components and follow the process above but in reverse Important for the Auto pawl to function operate correctly it is required that the Pawl arm torsion spring post re housing the assembly see figure 101 that the spring sits on the pivot pin Sits on the shoulder portion of the pivot pin see figure 102 Otherwise the Auto pawl will not work Use a small flat head screw driver to lift the spring onto the shoulder in position whilst tightening the Pawl arm nut When all the components have beenstightened and the pawl housing cover is secured figure 91 and all the top section components have b
63. pulled at the same time towards the base of the ladder see Appendix A The pulley should move towards the base of the ladder and return freely under the action of its spring when the rope is released Ji With the pulley pulled away the toothed camshould be checked for ease of movement and it should spring back to the rest position when released 4 Even though it has shown from this preliminary inspection that the AAD is working as it should it still doesn t mean that the individual parts are not Therefore if you identify wear oxidisation damage of the AAD Parts Then remove AAD from the ladder see figure 27 as shown using the retaining pin which holds the AAD main spring in tension and pull the Extension line through and pulley and remove the AAD completely by loosening the 4 off bolts Page 19 MECHANICAL INSPECTION removal from ladder Only required when it is deemed necessary from Functional inspection findings AAD on ladder 1 2 Si 4 Identify anomalous part by labelling of highlighting component see examplerfrom Figure28 Remove component into quarantine and fill out the relevant documents and send back to Supply Plus Contact technical sales for full replacement AAD Assembly to be sent to the workshop Adopt the reverse process when installing the AAD Carry out functional inspection and operation test laid out in Appendix A Figure 25 Figure 26 _ ta po ANTE k a JA e eS Li
64. re that the pawl finger is positioned at rest as shown in figure 9 Ensure that the Main pawl casting has encapsulated the round rung Also ensure that the Auto pawl mechanism and encapsulation occurs simultaneously for the Handed auto pawls If this does not happen remove the section from service and investigate further In some instances it is required to adjust the grub screw within the pawl casting see Figure 12 to allow the pawl casting to sit concentrically onto the rung This will be set correctly at the manufactured level but if it is required that the component is replaced by a spare then adjust accordingly until both handed pawls are sitting concentrically Please also note that the short bayley triple extension ladders do not use Auto pawls but they still use Rung holding pawl s that are also Aluminium casted Also within the UK 8 Europe the traditional A shaped pawls are sometimes used These casting components will also need to checked for stress cracks and the mechanical operation of the A pawls will need to be carried out Because the A pawls mechanism is synchronised with a the operation of the rope both the rope and the return pulley of this system will need to checked for wear and mechanically operationally tested Conducting any these teats and servicing may require further discussions with Supply Plus Please ask for assistance Pal at Rest Paw at Travel Figure 9 Figure 10 Figure 11 Figure 1
65. red This elongation will only occur if the hinge bodies section do not align together when being operated opening closing REMOVE RIVETS 5255 BOTH SIDES Figure 68 Figure 69 In principle the mechanical operation closure of the old new hinges are similar in operation and both if maintained inspected correctly will work AS New Hinge Design see Figure 66 Areas to check ladder hinge plunger assembly and pin ensure hinge bodies are in good condition Check mechanical operation of the pivot to identify any excess slack or tightness Hinge plunger assembly check wear or damage and plunger operation due to mechanism being held by compression spring the spring action should be smooth Check the plunger pin location hole for elongation or damage This hole should be concentric if there is any indication of hole elongation or damage then it would suggest that the hinge assembly has been incorrectly housed stile section damage or the ladder has been misused in operation The hinge mechanism is tested in build for such issues before being released to workshops Page 40 It is not possible to replace these components individually as this hinge body s L R function as a pair Our recommendation is to replace both bodies if damage has occurred on either side This will ensure that the wear rate is distributed equally between both sides ref item 284 figure 66 Check guide plunger pin half moon cut out lead in for damage or wear For norma
66. restles Measureithe distance C from the point on the ladder mid span between the trestles to the horizontal datum Figure 52 e Figure 55 Deflection Test Return X a Not more than 60 seconds after removal of the load in the first deflection measure the distance D from the point on the ladder mid span between the trestles to the horizontal datum Figure 52 The ladder shall not touch the ground during any point of the test Page 29 5 1 3 Deflection test for compulsory pole ladders e Figure 56 Test Layout Support the ladder horizontally at its maximum working length on trestles placed 200mm in from each end of the stile with third trestle at the joining point of the poles to the ladder Ensure the trestle at the bottom end of the ladder is fixed and the other two are mobile Secure the trestles to the ladder Figure 56 e Figure 57 Test Datum Figure 58 First Deflection Apply the first load from Table 5 1 for a minimum of 60 seconds at a point on the ladder mid span between the two trestles Measure the distance B from the point on the ladder mid span between the two mobile trestles to the horizontal datum Figure 58 Remove the load and measure the distance A from a point on the ladder mid span between the two mobile trestles to a horizontal datum on the ground vertically below Figure 57 Page 30 e Figure 59 Second Deflection Increase the load to the second load in Table 5 1 and
67. s 3 Person rescue rated deflection Pre load 3 x 25kg 1 x20kg 1 x 10kg total 105kg First load 2 x 25kg 1 x 20kg total 70kg Second load 3 x 25kg 1 x 20kg 1 x 10kg total 105kg Page 33 5 1 6 JCDD Test Loads included as a guide for operators still using JCDD specification ladders Please note that we no longer manufacture JCDD ladders unless specifically requested Therefore all ladders manufactured currently conform to the requirements of BS EN 1147 2010 Weights required 11 of 10kg 5 extra for roof hook testing 1 of 5kg 1 of 2kg 2 of 1kg Equipment required 2 trestles without wheels horizontal even surface Deflection Test Procedure Measuring tolerance or 3mm 1 8 e Place the trestles under the ladder 610mm 24 in from each end Extensionsladders to be fully extended and pawled At the loading point midway between the trestles apply the pre load to the ladder for 60 seconds Remove the pre load e At mid span between the trestles S measure from the underside floor H1 e Apply the first load at the load point and again measure from the underside of the ladder H1 e The first deflection D1 is calculated by subtracting the first load height H2 from the initial height H1 The first deflection D1 must not exceed the value of the ladder stated in our Maintenance amp Repair Manual e Apply the second load at the load point and again measure from the underside of the ladder S
68. s on the outside of the section and tightened as indicated above 6 7 3 Pop Rivets If rungs are replaced close to the foot of the bottom section of the ladder it may be convenient to remove the stabiliser attachment end cap assemblies in order to remove the rungs and fit new ones The stabiliser bar should be bolted on before re riveting the end cap assemblies The normal pop riveting procedure is used with rivets ref no S 255 Pop rivets ref no S 270 are used elsewhere onthe ladder and normal pop riveting procedures should be followed 6 7 4 Re Bowing of Ladder Sections If a ladder section needs to be re bowed to give the necessary clearances between sections the following procedure should be adopted 1 After inspection of the ladder section it should be placed on the repair table on two blocks of timber placed under the extreme ends of the ladder section with the direction of desired bow down against the table 2 Clamp the ladder at the centre of the point at which adjustment is required 3 With a sacrificial timber block approximately 50mm sq x 300mm long 2 sq x 12 long and of suitable thickness gently dress the area over the rungs 4 Repeat the above until the desired shape is achieved 5 When this procedure is complete check that no damage has occurred to the rivets or ladder structure generally Note The procedure must only be carried out by trained personnel and should only be used as a matter of last resort
69. s undertaken If it is found that the stiles channels are cracked or badly deformed the ladder should be returned to Supply for overhaul unless your engineers have attended the 2 or 4 day training course Rungs are removed using one of two methods 1 Firstly if you need to replace any of the end three rungs in the ladder you should remove all the rivets using rivet method 1 from all the rungs up to and including the damaged one Whensthe r ngS are removed tap the rung s out of the end then replace with new rung s 2 Secondly if you need to replace a middle rung start by removing all of the damaged rung s rivets using rivet method 1 then the top rivets from the 2 rungs either side of the damaged rung When all these rivets are removed use the rung removal tool to twist the damaged rung so it sits at a 45 angle This will allow e Figure 124 Rung R room to insert the new rung When the new rung is set at an angle of 45 angle you can twist the damaged rung completely out Finally you can twistthe new rung into position and use the locating pins before riveting can begin Figure 124 6 9 Stanchion Poles AS Ladders where fitted The stanchion poles cannot be repaired if they become bent or damaged and should therefore be replaced To replace a stanchion pole remove the pivot bolt and detach The new stanchion pole should be bolted on care being taken to ensure that it is correctly positioned with regard to
70. see section 5 1 4 Removal and replacement of Roof ladder sub components roofiladder shown with Ashford hook e Lay Roof ladder onto trestles and where required unfold see figure 102 103 Carry out general inspection to identify any other issues damage wear Start at the roof hook end and work along towards the foot of the ladder and inspect the Stiles and the rungs see section Bayley 3 4 Check the open close operation figure 102 of the roof hook and check the folding hook pin 2 figure 104 for damage and operation Replace L R hand see figure 104 if shown to be damaged to remove hook pin 2 or spring 3 use long nose pliers to remove split pin 4 and washer s 5 Before replacement of components check the roof hook retaining holes for elongation or excessive oxidisation L R hand see Figure 104 6 Both the folded portion hook and the assembly can be totally removed if required from the ladder see figure 105 1 amp 2 e Also the fixed roof hook arm with walhwheel can also be totally removed if found to be damaged see figure 106 3 Within the folded portion of the rook hook see figure 105 the Head bar 4 and the ties 5 also can be replaced by removing the screws either end Replace wall wheels See figure 106 1 if found to have excessive wear or cracking remove screw and blind nut to replace wall wheel housing Next move along and inspect and replace where required the pressure plate assembly 1 see figure 107 replaci
71. t our factory or your local agent for further details 4 5 Stiles amp Channels all ladders and Slide Wheels where fitted Examine stiles channels for signs of cracking distortion or other damage Minor dents can be tolerated but with other damage especially cracking Also please observe the hammering effect the ladder guide wheels are creating see figure 20 onto the channels If there is excessive hammering which deems to be detrimental to the structures strength then remove the section in question and get a second opinion If then it is required to remove the section please contact Supply and we will further advise whether it is essential to replace the channel Note If the hammering effect is very slight mild weycan offer Anti wear plate s S1074 8 S1075 see Figure 21 for the various ladder sections We offer as an retrofit kit supplied with rivets S204 Please contact Supply Plus for further information The ladder should be returned to our factory for repair unless your engineers have attended our 2 or 4 day training course Ladders with damaged stiles should not bekept in service Shape is put into a ladder to give acceptable clearances to minimise wear while the ladder is on the gantry Different ladders require different shapes Anti wear plate Figure 21 Page 17 4 5 1 Detailed Instructions for Ladder Slide Wheel Inspection AS ladders e The ladder should be moved against the slide wheels on the opposite side of
72. tance vi l Figure 5 Pushing top section back 7 Once the ladder cannot be pushed back without any resistance check the AAD has locked This will indicate that the AAD is working sufficiently w ji ju WAS Figure 6 AAD working correctly Figure 7 AAD Cam engaging with rope MAINTENANCE Because of the important nature of the function carried out by this item maintenance should not be attempted and the AAD returned to our factory for repair If we can be of further assistance please contact us Page 59 APPENDIX B Roof Ladder Hinge Upgrade KEY POINTS OPERATION DESCRIPTION QUALITY CRITERIA VISUALISATION SKETCHES Remove all the rivets on the fitted hinge by drilling them outwith a 4 9mm Dia Drill bit Remove the rivets ghighied on the photo Remove the latch and the large rubbers near the hinge Fullthe two sections apart and disqard the old hinge Lising a steel rule measure 105mm on the longest channel and mark from the centre af the last rivet to the end Page 60 Carefully cut the longer channel to the Both channels to be the length marked at op40 same length Remove burrs from the cut channel with a file Ensure that the widened part of the Hinge ends flush with the end of the Slide the new hinge into the channel channels Hinge Plunger to go into the section with the hook attached Using the holes in the channels as a template drill through them into the
73. tenance course within the last 3 years AS Roof ladder Upgrade It is now possible to replace the traditional hinge with the new hinge see appendix B for procedure to achieve this Only attempt to upgrade hinge assembly if you have attended the ladder maintenance course within the last 3 years 6 4 1 AS Roof Sub components and inspection As with all ladders specified ensure that all of the relevant labels have been used and are currently housed on the ladders see section 7 for heat sensor qty by Ladder designation Generic inspection whole ladder Check overall condition of the ladder particularly in respect to the hinge mechanism unfold where applicable the roof ladder onto trestles and look down the length of the ladder from the base of the ladder and check for the ladders flatness in the horizontal plane y axis and then check the flatness in the x axis If it is found that there is excessive twist in both axis orone side of the channel is higher than the other then further inspection is required to determine the cause of the Change in plane reference height This would indicate damage in operation incorrect rung assembly replacement incorrect hinge set up loose rivets Replace components if required to do so Sub components including all fasteners Replace components if required to do so post inspection Check stand off pads and rubber block for fire damage or excessive wear perishing replace if required to do so see Figure 7
74. the offset Figure 125 e Figure 125 Stanchion pole Page 54 if the plastic Netlon hand grips are damaged they can be replaced by cutting off the old grip and fitting new ones after first having removed the stanchion pole from the ladder Swarfega or a similar type of hand cleanser smeared onto the pole will facilitate the fitting of Netlon mesh type plastic hand grips and can be washed off with water when fitting is complete To replace grip tape use a pointed edge to lift the end and then pull off Clean the area and apply a new length Heat shrink grips can be replaced wholly or in part using a soft flame propane torch or similar heat source To replace the ground spike drill out the retaining pop rivet and then drift out the unit which is a tight push fit in the tube When re fitting the ground spike tap into the prop tube using a copper mallet It is essential that when refitting the unit it is pushed squarely into the tube and that the rivet holes are aligned Secure the unit by means ofrthree pop rivets ref no S270 Should the stanchion pole retaining clip become damaged on the old type of metal clips the rivets should be removed and a new clip bolted into position Note that the latest clip supplied is manufactured from polyurethane and will not damage the stanchion pole 6 10 Steel Stabiliser Bar AS Ladders where fitted It is recommended that the only repairs that should be carried out to the jacks are the replaceme
75. ure 83 Figure 85 Figure 86 Figure 87 Figure 88 Figure 89 6 4 4 Bayley Auto pawl removal replacement only for BS EN 1147 DX ladders Handed pairs Due to the huge variances of components and fasteners we are not able to name part numbers for components fasteners within this document However we understand that parts fasteners will need to be replaced if so then please send photos of parts fasteners with a clear description Our Technical sales will then be able to send replacement parts fasteners if required We will also be able to send a parts list to assist the technician Important Only remove this assembly if it is absolutely required only if you have discovered any Auto pawl mechanical operational difficulties or any obvious component failure Which requires the pawl housing to be removed Note Replacement shown for RH Auto pawl assembly Acquire tools as shown in figure 90 Remove Button Head Socket screws 2x as shown in figure 91 use socket wrench to hold the blind nuts see figure 92 whilst removing bolts in figure 91 Next remove the nuts see figure 93 holding the pawl finger pivot pin 1 andthe pawl arm pivot pin 2 Remove all retaining fasteners store in a safe place then remove pawl cover plate housing figure 94 Store the cover plate and ensure that the spring retaining rivet is positioned as shown when required for refit see figure 95 Check the condition of the Pawl arm and the pawl finger all com
76. use of this manual to carry out procedures on ladders manufactured by other companies could result in damage to them or in some circumstances cause the ladder to fail in service For instructions on other manufacturer s ladders please consult their manual Page 6 1 INTRODUCTION Ladders manufactured by Supply Plus combine light weight with strength and rigidity and with the correct maintenance will give many years of useful service This manual has been prepared to set out the standards of inspection repair and testing to ensure that ladders are maintained in good working order For normal use it is recommended that a thorough visual inspection in accordance with the BS EN 1147 Standard is carried out at least quarterly and a more detailed inspectionsand testing is required Annually In cases where the ladder has failed a visual inspection or there is reason to suspect that the ladder may have been damaged either by accident or misuse the ladder should be subjected to the annual inspection procedure repaired if necessary and tested before being returned to service Instructions are given on those repairs and replacements which maybe undertaken in workshops with the appropriate equipment Where extensive damage has occurred or where critical components such as Side members are involved the ladder should be returned to Supply Plus for complete overhaul and repair unless the workshop has the facilities and qualified personnel to undertake major rep
77. ve lozenged the ladder The ladder should then be extended in the horizontal position on two supports positioned near the top and bottom ends of the main section lf personnel do not have access to trestles and AAD pins erect the ladder up against a structure inline with the usual operational procedures then lay ladder down on the ground for a visual inspection Once inspection is complete place ladder up against structure and house ladder within normal procedures Ladders must only be extended using the rope and never by pulling the extending sections which could result in damage to the wire cable on triple extension ladders Visual Inspections are to include the following items 3 1 Rivets amp Bolts 3 2 Rungs amp Rung Brackets 3 3 Stiles Channels 3 4 Extending Line where fitted 3 5 Cable where fitted 3 6 AAD automatic arrest device where fitted 3 7 Stabiliser Bar where fitted 3 8 Wall Wheel Assembly where fitted 3 9 Roof Hook where fitted 3 10 Slide Wheels 3 11 Hinge Assemblies where fitted 3 12 Female Assemblies where fitted 3 13 BS EN 1147 2010 Test Labels 3 14 Stanchion Poles AS Ladders where fitted 3 15 Pawls Rescue ladders only 3 16 Rubber Feet Rivets and Bolts AS Ladders only Special care should be taken when visually inspecting a ladder to ensure rivet integrity This shouldybe done by feel on the blind side as well as a visual inspection on the face surfaces paying particular attent
78. yley construction the rungs are not replaceable individually If the rungs are damaged or cracked then the whole section will need to be replaced However due to the manufacturing swaging process of the rung and the stile It is extremely rare that any cracking or damage will happen at the manufacture level The most common occurrences of damage or cracking is the misuse of the ladders capabilities and operation If it has shown that the rung and the joining stiles are in acceptable conditions then dismantling sub assemblies shall be adhered to in Bayley section 6 4 3 6 4 6 4 13 Lubrication amp Cleaning AS ladders amp Bayley Only clean on stiles and channels only A non abrasive and dust free cloth should be used to remove excess oil grease deposits from the stiles and channels Then a cleaning agent such as Amberklene FE10 or LO30 is to be used along the stiles and channels Wipe any excess deposits with a dust free cloth Do not use abrasive cleaning pads As the particulates in the pads will impregnate into the aluminium and will contaminate the alloy You will commonly see some white marks on the aluminium stiles and channels if the ladders are continuously left outside this is known as water staining If you are unsure and believe this is something other than water excess then contact Supply for further investigation It is our recommendation that correct sensible storage of spare ladders or ladders in for repair are carried out We do

AS Ladder Maintenance Manual V15 March 15

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