Magirus Testreport TTL CS-Version according to DIN 14701

Magirus-manufacturer‘s test specification

Customer address: Inspected Vehicle:

TTL-Type:
VIN:
Order No.:
Mileage / Op.-Hours:
First registration:
License plate:
Location address

See document no.:

Inspecting Technician:

Assembly group Test inspected Results

I. Chassis

Inspection and repair of defects is carried out by authorized dealer on behalf of the customer
Additional rear axle steering (HZL)
Power take-off:
Add. for automatic transmission:
Add. in case of low design chassis:
Remarks:
Function, locking, condition, tightness, oil level
Mechanical function, Seals, PTO switch, Pneumatic switch,
power take-off „on-off“, indicator light in the driver‘s cab, mechanical
interlock
Driving mode, flashing light - elevation frame after „PTO-on
Checking the pump for hydraulic pump direct attachment
Toggle switch power take-off „ON-OFF“ , Travel interlock
Relay switch power take-off in driver‘s cab
Check screw connection of ladder rest frame & attachments
Fan drive: check tension of rear V-belt
With HZL: Visual inspection of position claw coupling hydraulic pump &
fastening

2. Electrics, Drivers Cabin

Special signaling equipment: Function, switch, relay

Auxiliary charging equipment: Function, cut-off relay
Hour meter: Function
Auxiliary lighting: Mirror, HZL, environment, circuit and function
Indicator and warning lights: Function
Fuses: Visual inspection, damage, fastening and corrosion
Camera systems: Function control, switches and screens
Remarks:
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification

Assembly group Test inspected Results

3. Substructure

sub frame Mechanical connection to chassis frame (cracks, corrosion)

Ladder rest: Visual inspection, fastening, wear of plastic support
Jacking system Functions, mech. connections
Guide elements: lubrication bolts / guide beams , noises
Outer and inner beams: detailed corrosion inspection
Support plates: mobility, corrosion, lubrication, flashing lamps/ lights on
supports and rear end
Axle Spring lock: Function, condition, fastenings, ropes, pulleys, return springs
Mobility of rope thimble, wear marks from driving operation
Hydraulic cylinder: Fastening, bearings, tightness, connections, lines, chrome plating
Hydraulic tank: Fastening, oil level, filter, fan, tightness
Pump drive: Visual inspection, tightness, suction and pressure lines, suspension and
drive train
Hydraulic system: Control block fastening, tightness, function
Pipe fittings, pipelines and hoses
Check valves for fastening, condition and tightness
Oil feed-through: Fastening, tightness
Slip ring Function
Control panel Jacking system Jacking function (engine speed, swivel of the basket , support selection, .)
Safety function: Parking brake, four-wheel parking brake, emergency stop function
Ladder suspension switch: attachment and function
Locking of jacking system when ladder is not in support position
Locking of ladder operation in „not supported“ condition
Control panel Jacking system with warning tone in case of outrigger
movement
Air suspension (chassis): no control after extending the first outrigger out
of driving-position
Signal switch: Jacking system retracted, length detection support, ground contact switch
Function pressure sensors, emergency stop impact switch
Joysticks
Level turntable: Slewing ring, fastening, function, lubrication, state of gearing
Slewing gear, brake, fastening, function, tightness, oil level
Fuses: Condition: corrosion, contacts, main fuses for conductor operation, emer-
gency operation,
undercarriage, turntable, rescue cage
Electrical system in general: Control box, wires and cables, plug contacts
Relay control Main relay Power supply via PTO „On/Off“ , self-retaining after stabiliza-
tion
General visual inspection for fastening and condition
Emergency operation manual / 24V / Function of all axles and directions at maximum load, emergency opera-
230V / 400 V: tion pumps, pressure relief valve, tightness
Remarks:
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification

Assembly group Test inspected Results

4. Superstructure

Bodywork: Brackets, frame, sheeting - condition, fastening

Equipment rooms Framework, sheet metal - condition, fastening, ventilation
Roller shutters Condition - Check functions, switches, spring shafts, locks, brush seals
Bearings Condition - fastening, locking
Lighting: Equipment compartment - perimeter - access - clearance lights - condi-
tion, function, state
Edge lighting (SW)
Steps Condition, sheeting, steps, handholds
Valves Condition, fastening, locking
Battery Fastening, locking and corrosion, charging condition, voltage, cable con-
nections
Battery charger 12V / 24V / 230V / Function, starting lock, display in drivers cabin
400V :
Remarks:
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification

Assembly group Test inspected Results

5. Turntable

Visual inspection: Welded construction, fastening elements, elevation cylinder

Bearings on the turntable
Bolt connection: check with torque wrench:
Elevation cylinder
Ladder set to the elevation frame
Axle shaft screw connections
Hydraulic system: Control block, fastening, tightness, function
Hydraulic lines, hoses and valves
Check roller valves for fastening, condition, function and tightness
Lateral adjustment - function, tightness
Check all movement axles for function and tightness
Winch: Condition of winch bearings, visual inspection of screw connections
Rope end attachments on drum
Oil level, tightness
Winch overhauled-date:
Rotary gear: Oil level, tightness, clearance to turntable
Controls/ Ladder function with and without basket operation, operating speed
Functional tests: Control lever, function keys and dead man‘s switch
Displays on the control unit: ladder length, angle of elevation
Push-button on joystick, intercom system
Oil pressure only when control lever is in neutral position, automatic
return to ladder support
ladder support, switching between basket limits 5-4-3-2-1-0 man
- SE version: Retraction stop with articulated arm angled downwards
- SE version: Active control of articulated arm Raising during retraction GL angle up to
2°.
Safety functions: Limit switch-off: Comparison of target/actual discharge values
Acoustic warning tone Emergency stop function at Main control panel
Deceleration when approaching the limit
Right-angle encoder: mounting, function
Overload, bridge, end positions
Turning range circuit, cab safety device
End position stops maximum at elevation angle ≤ 77°.
- AA version: Rescue function
Signal switch / sensors: Position detection of all axles
Detection of cross and lenght inclination-angle, “ladder retracted” sensor
Operating elements and displays on the control unit
Level turntable: Sensors slewing ring control, function, cleanliness
Indicators: Display, degree arc, spirit level, condition, function
Lighting: Check lights for fastening, function and tightness
Emergency actuation: Function of all axes and directions
Function of speed increase in emergency operation
Function of lowering brake valves
Function warning tone
Speed limitation by adjusting rings (emergency operation)
- AA-telescopic version: Function mech. change-over valves for telescope extend/retract - elevate/
depression
Electr. system general: Control box, lines, connectors, slip ring
General visual inspection for fastening and condition
Remarks:
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification

Assembly group Test inspected Results

6. Ladder Set

Ladder section: Visual inspection of the entire welded structure:

Damage, deformation, cracking, paint damage.
Especially in the area of the screw connections to the elevation frame
Greasing and wear of ropes and pulleys
Rung alignment, extension symmetry
- SE version: Splitter (according to adjustment instruction 5 0319 2656)
Transfer unit (according to document 5 0385 6484)
6 Sliding guides in ylinder area in LT I
Cage suspension bearing: Condition, deformation, cracking, locking lever, function
Sensor cage latch / cage detection
Climbing hanger: Condition of guides and locking on cage
Roller guides: Condition, movement, adjustment
Rocker bearings on ladder head, rollers, adjustment, mobility, contact
pattern, deformations
Sliding guides: Sliders at ladder foot: wear, contact pattern, fastening, adjustment, lubrica-
tion
Running surfaces: Bottom side of wear pad, outer surface of wear pad
Stainless Steel - rails: Slideways, cleanliness, damage, cleaning, paint
condition
Rope guides: Ropes: Condition, attachment, tension, adjustment, wear
Ground cable on rope thimble
Deflection pulleys - bearing, pulleys, condition, wear
Cable guides: Conductor replacement cable: condition, looping, sheath damage, abra-
sion,
Tension and ease of movement
Idler pulleys and guide carriage: condition, tension
Condition of sockets and junction boxes
Function of loudspeakers
Rungs and coverings:: Condition, wear, rusting, damage
Clamping rail, fastening
Articulated ladder: Hydraulic hoses in LS, condition, deflection units, fastening, tightness
Articulated arm cylinders, telescopic cylinders, locking valves, switching
valves:
Fastening, tightness
Swivel joint: angle sensor, water feed-through, fastening, condition,
function,
fastening, tightness
Water Pipe: Water pipe, ladder section 1: fastening, leakage, tightness
Telescopic water pipe: fastening, wear, leakage,tightness
230/400V system: Yearly check according to DGUV-V-V A3 carried out by a electrical spe-
cialist.
Remarks:
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification
Assembly group
7. Rescue Cage
Mechanics and structure:
RC 400 / RC 500 C:
Hydraulic system:
Signal switches / sensors:
Operating functions:
Remarks:
8. Accessories
Anchor points for personal safety on
turntable and ladder tip (EN 795):
Generator:
Remote control generator:
Rescue Loader - RL500:
Safety circuit in the ladder set:
Test inspected Results
Typ
Visual inspection of the entire welded construction: damage, deformation,
cracking (especially basket suspension), paint damage
Access ladder and doors at the front and rear wall, doors
Handrails: movement of all pivot bolts and automatic locks
Release of rear wall, flange connection, swivel drives
Suspension ladder hook-in bearing
Suspension pivot drives, function, fastening
MultiFunctionalColumn: locking, locking bolts on MFC
Climb-over bar, function and locking device
Function of friction disc, handrail front left / right
Rescue cage securing points: damage, marking, signs
Cage acting into driving position - uniformly touch to the upper chord
Multi-joint gear
Function Unlocking the rear walls - tension adjustment
Lubrication condition locking bolts of the rear walls
Wear release block (brass)
Mobility carriage
Hydraulic power unit, emergency pump, control block, condition oil and
filter, slewing drives,
Load holding function both cylinders, tightness, fastening
Hydraulic lines, hoses, fastening, tightness, hydraulic cylinder
Checking impact monitoring left/right + right/left, sensors multifunctional
column
Operating elements and displays on the control unit
Intercom system, microphone
Check ultrasonic sensors (SW)
Check camera and video system (SW)
Basket vertical position -15° - +75
Limit position switch +/- 12° via change-over lever using emergency
pump
Emergency stop, „rescue“ from main control station, hydr. emergency
operation
Basket limit switch, main control position priority
Oil pressure only with control lever in neutral position
Control lever, function keys and dead man‘s switch
Annual inspection carried out and documented by a qualified person.
Visual inspection for:
- mechanical damage
- deformations
- Welds for rust, rough spots, fine cracks, etc.
Visual inspection of type plate:
- present
- readable
General visual inspection of the generator environment for damage (e.g.
due to exhaust gas routing, shocks, vibration).
Inspection of generator fastening, exhaust hose if present
Generator start/stop function
Inspection according to own test report RL500
with Document-No.
Function test TTL with RL 500
Condition of operating and display elements
Check function of operating and display elements individually
Check prevention of engine start when safety circuit is activated
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification
Assembly group
Fall protection in the ladder set:
Breathing air system:
High voltage warning device:
Safety Five:
Crane winch on the lower ladder:
Flexi Foam adapter:
Remarks:
9. Cage Accessories
Climb-over aid:
Flexible self-securing:
Safety Peak:
Test inspected Results
Safety rope drop guard: condition, fastenings, damage, wear and tear
Safety lugs in ladder set/articulated part: Annual inspection carried out
and documented by expert:
Visual inspection for:
- mechanical damage
- deformations
- Welds for rust, rough spots, fine cracks, etc.
Visual inspection of type plate:
- present
- readable
Fall arrest harnesses and lanyards Fall arrest: Annual inspection by PPE
expert carried out and documented (inspection form in manual of the Fall
arrest)
see inspection instruction 5 0319 8974 NE
Inspection according to the specifications in the manual for the high-volt-
age warning device
Inspection according to own test report Safety5 with
Document-No.:
Function test TTL with Safety5
Inspection according to own test report crane winch with
Document-No.:
Hanging and safe locking at the top of the ladder
Welded parts and mechanics in general: damage, missing parts, corrosion
Function fold-out, pull-out, tilt adjustment, turn adjustment; each with
locking device
Connecting hose: damage in general, cracking, age, securing Coupling
Visual inspection of the entire welded structure: damage, deformation,
cracking, paint damage.
Lubrication and wear condition of the guide elements
Screw connections, especially rail fastening on the base body
Function of sensor - transfer aid retracted
Annual inspection carried out by a PPEgA-expert:
Safety insection of flexible personal fall arrester in the rescue cage.
Inspection of retractable type fall arrester (EN360:2000) according to
manufactuere´s test book:
Height safety device 1, S-Nr.:
Break adjustment value, Nm:
Height safety device 2, S-Nr.:
Break adjustment value, Nm:
Height safety device 3, S-Nr.:
Break adjustment value, Nm:
Height safety device 4, S-Nr.:
Break adjustment value, Nm:
The determined values were entered into the test book.
Annual inspection of the retractable type fall arrester by a person
authorised by the manufacturer of the retractable type fall arrester and
documented.
2 Safety Peak attachment bolts in the basket basins and multifunctional
attachments: Damage, cracking, corrosion, locking, secure seating of the
Safety Peak. S-Nr.:
Annual inspection carried out by expert and documented
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification

Assembly group Test inspected Results

Access ladder:
Storage boxes:
Headlights and additional lighting:
Stretcher holder:
Cage stretcher holder:
RC400/RC500 heavy-duty basket
stretcher adapter:
Heavy duty basket stretcher adapter:
Water guidance / self-protection:
Monitors
other installed options
Remarks:
Visual inspection of the entire welded construction: damage, deformation,
cracking
Visual inspection, closure
Function
Depending on design
mechanical folding mechanism
Fastening to rescue cage / pick-up element
Welded body: damage, cracks, deformation, corrosion
Attachment parts: Completeness, fastening/screwing, damage, corrosion
Backlash-free fit of MFA bolts, holes/ recesses of twist locks
Ease of movement and, if necessary, automatic engagement Rotating latch
Ease of movement & locking if necessary Stretcher locks at head and foot
end
Safety belts: condition, damage, completeness
Belt retractors: retraction, release of retraction lock,
Tensioning, retraction Belt, secure locking Belt buckle
Type plate, operating instructions, maximum load information
Compatibility information on label or reference to manual
Cage support guide and other attachments:
Damage, fastening, corrosion, secure locking
for lateral support arms also function standing up and turning,
gas spring and damper, pinning and bearing shaft
Welding base:
Damage, cracks, deformation, corrosion, backlash-free fit Bolt MFA
Function Locking MFA on heavy-duty adapter
Heavy-duty adapter can be securely attached to the basket on both sides
Adapter rails: Damage, riveting, cracks, deformation, corrosion.
Attachment parts: Completeness, fastening/screwing, damage, corrosion
Function Attachment of adapter rails to stretcher holder
in case of additional attachment straps also attachment points straps and
straps:
Condition, damage, completeness
Function of suspension straps and buckles
Function, tightness
see operating instructions Alco (5 0318 8285 NE)
General condition, visible damage, recognisable hazards, safe storage/fas-
tening (if necessary for inspection, ask for further information).
Magirus Testreport TTL CS-Version according to DIN 14701
Magirus-manufacturer‘s test specification
Assembly group
10. Stability
Static overload test:
(3 Man Cage Limit Upper Corner)
Monitoring equipment stability 2 MCL Support maximum: increase load until warning signal sounds, enter limit
limit:
Only in case of recalibration DMS.
(above point not fulfilled).
Dynamic test:
Monitoring equipment stability
TTL operation with RL 500:
Remarks:
Turntable ladder
operationally safe
Turntable ladder conditionally
safe to operate
Turntable ladder not operationally
safe
Signature of technician:
Test inspected Results
Preload the LS in the longitudinal axis of the vehicle for 1 minute, then let
it stand under load for 10 minutes and measure the cage height before/
after Perm. height diff. up to -100 mm- Test load 435 kg (1.5 x Pn + Pz)
m Rescue height before
m projection
m Rescue height after
m projection
mm Difference
kg Nominal load of rescue cage
load (permissible values from 190 kg - 265 kg), kg:
Support width Small, 2 MCL at AW 0°, kg:
Support width Small, 2 MCL in UC, kg:
Support width Large, 2 MCL at AW 0°, kg:
Support width Large, 2 MCL in UC, kg:
Set the TTL at an angle (possibly with the help of the drive-up ramps).
Load the basket with 90 kg. Fully extend the DLK and depress to the
geometric stop of 2 MCL UC. Switch to 1 man basket operation. Turn the
TTL at maximum speed 3x 360° with 90° interruptions. Then elevate the
TTL to the maximum elevation angle.
After the dynamic test check the ladder set for deformations, cracks and
changes in the weld seams.
Support TTL XL, approach UC, load at the two suspension eyes for the
chain hoist (black) with compensation anchorage (up to max. 510 kg),
check load cut-off and bell, compare with factory setting, kg:
Support TTL S, approach UC, load at the two suspension eyes for the
chain hoist (black) with compensation anchorage (up to max. 510 kg),
check load cut-off and bell, compare with factory setting.
kg:
The operational safety of the turntable ladder is guaranteed if no defects are found or the
defects found have been rectified.
The vehicle owner is responsible for rectifying the defects. The test report must be kept by the
vehicle owner.