TLIB207C Test

equipment and
isolate faults
Learner Guide
Contents
What this Learner’s Guide is about ........................................ 1
Planning your learning ........................................................... 2
How you will be assessed ...................................................... 1

Section 1............................................................................................. 3
Identify scope of operational check........................................ 3

Section 2............................................................................................. 7
Plan operational checks ......................................................... 7

Section 3........................................................................................... 13
Check unit through full operating range ............................... 13

Section 4........................................................................................... 27
Isolate fault and/or formulate recommendations .................. 27

Feedback on activities .................................................................... 33

 TLIB207C Test equipment and isolate faults

What this Learner’s Guide is about

This  Learner’s  Guide  is  about  the  skills  and  knowledge  required  to  test  
equipment  and  isolate  faults  in  accordance  with  workplace  
requirements,  including  identifying  scope  of  the  operational  test,  
planning  operational  tests,  checking  the  equipment  through  its  full  
operating  range,  and  isolating  faults  and/or  workplace  procedures  and  
relevant  regulatory  requirements.  

The  activities  are  designed  to  give  an  opportunity  to  practise  using  
procedures,  forms  and  work  instructions  along  with  manufacturers  
specifications  and  guidance  notes  from  the  relevant  Workcover  
authority.    Your  company’s  standards  that  apply  should  also  be  taken  
into  consideration.      

The  Elements  of  Competency  from  the  unit  TLIB207C  Test  equipment  
and  isolate  faults  covered  in  this  Learner’s  Guide  are  listed  below.  

Identify  scope  of  operational  check  

Plan  operational  checks  

Check  unit  through  full  operating  range  

Isolate  fault  and/or  formulate  recommendations  

This  unit  of  competency  is  from  the  Transport  and  Logistics  Training  
Package  (TLI07).  

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TLIB207C Test equipment and isolate faults

Planning your learning

It  is  important  to  plan  your  learning  before  you  start  because  you  may  
already  have  some  of  the  knowledge  and  skills  that  are  covered  in  this  
Learner’s  Guide.  This  might  be  because:  
• you  have  been  working  in  the  industry  for  some  time,  
and/or  
• you  have  already  completed  training  in  this  area.  

Together  with  your  supervisor  or  trainer  use  the  checklists  on  the  
following  pages  to  help  you  plan  your  study  program.  Your  answers  to  
the  questions  in  the  checklist  will  help  you  work  out  which  sections  of  
this  Learner’s  Guide  you  need  to  complete.  

This  Learner’s  Guide  is  written  with  the  idea  that  learning  is  made  more  
relevant  when  you,  the  learner,  are  actually  working  in  the  industry.  
This  means  that  you  will  have  people  within  the  enterprise  who  can  
show  you  things,  discuss  how  things  are  done  and  answer  any  
questions  you  have.  Also  you  can  practise  what  you  learn  and  see  how  
what  you  learn  is  applied  in  the  enterprise.  

If  you  are  working  through  this  Learner’s  Guide  and  have  not  yet  found  
a  job  in  the  industry,  you  will  need  to  talk  to  your  trainer  about  doing  
work  experience  or  working  and  learning  in  some  sort  of  simulated  
workplace.    

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 TLIB207C Test equipment and isolate faults

Section 1: Identify scope of operational check

Are  you  able  to:   Yes   No  

1. detail  which  forms,  procedures  and/or  
work  instructions  are  used  in  the  
warehouse  for  the  checking  and  
maintenance  of  all  materials  handling  
equipment  so  as  to  ensure  their  safe  
working  order?        
2. demonstrate  where  applicable  how  these  
documents  comply  with  any  requirements  
by  Workcover,  the  relevant  manufacturers  
specifications  and  the  elements  of  an  
accredited  quality  system?        
3. identify  the  procedures  and  parameters  
used  for  checking  and  maintaining  
materials  handling  equipment  in  the  
warehouse  and  state  how  the  observations  
and  findings  are  recorded  and  where  it  fits  
in  the  overall  system  in  your  workplace?        

Section 2: Plan operational checks

Are  you  able  to:   Yes   No  

1. explain  the  system  used  for  the  planning  
of  operational  checks  on  materials  
handling  equipment?        
2. specify  who  will  be  responsible  for:  
–   nominating  a  safe  area  for  testing  
–   carrying  out  the  initial  check  
–   authorising  the  check  
–   the  reporting  of  observations  and  findings  
–   determining  if  the  equipment  is  unsafe  
–   deciding  on  replacement  equipment/staff.      

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Section 3: Check unit through full operating
range

Are  you  able  to:   Yes   No  

1. explain  how  the  testing  of  the  materials  
handling  equipment  is  conducted?        
2. demonstrate  the  format  used  for  recording  
the  findings  of  these  tests?        
3. detail  how  irregularities  are  reported  to  the  
repairer?        
4. state  what  obligation  is  on  the  proprietor  
of  any  materials  handling  equipment  when  
it  requires  or  is  under  repair?        
5. specify  what  calibration  records  are  kept  
on  equipment,  what  parameters  are  used  
and  how  often  equipment  is  calibrated?          
6. list  what  checks  the  operator  must  make  at  
the  start  of  duty  to  ensure  the  materials  
handling  equipment  is  safe  to  operate?          
7. detail  what  precautions  should  be  taken  
when  a  leak  in  the  fuel  system  is  suspected  
or  detected?          
Section 4: Isolate fault and/or formulate
recommendations

Are  you  able  to:   Yes   No  

1. explain  how  you  isolate  materials  
handling  equipment  that  is  considered  
unsafe  so  as  to  prevent  accidental  usage,  
and  how  staff  are  notified  of  this?          
2. explain  the  procedures  used  when  
materials  handling  equipment  is  being  
repaired  in  regards  to:  
–   who  decides  on  the  urgency  of  the  
repair  
–   who  authorises  the  repair  
–   who  costs  out  the  repair  
–   who  authorises  the  cost  
–   do  you  use  an  approved  supplier  
–   who  orders  the  parts  and  do  they  use  
a    
  purchase  order  
–   who  authorises  the  repair  
–   who  decides  on  what  needs  to  be  
done      
  to  remedy  the  work  schedule.        
 TLIB207C Test equipment and isolate faults

How you will be assessed

Assessment  of  this  Unit  of  Competency  will  include  observation  of  real  
or  simulated  work  processes  using  workplace  procedures  and  
questioning  on  underpinning  knowledge  and  skills.  It  must  be  
demonstrated  in  an  actual  or  simulated  work  situation  under  
supervision.  

You  will  be  required  to:  

• demonstrate  the  correct  procedure  for  testing  materials  
handling  equipment  and  the  correct  procedure  for  
isolating  faults  found  during  testing  or  daily  operation  
• research  the  use  of  materials  handling  equipment  in  the  
warehousing  industry  and  present  an  oral  or  written  report  
on  the  testing  and  reporting  of  materials  handling  
equipment  and  the  isolation  procedure  of  equipment  
found  to  not  comply  with  the  safety  standard  

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TLIB207C Test equipment and isolate faults

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 TLIB207C Test equipment and isolate faults

Section 1

Identify scope of operational

check

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TLIB207C Test equipment and isolate faults

Section outline

Areas  covered  in  this  section  

Inspection  and  testing  procedures  

Quality  assurance  example  

Control  of  equipment  

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Inspection and testing procedures

You  must  establish  procedures  to:  

• ensure  your  equipment  is  as  accurate  as  required  
• calibrate  your  equipment,  so  it  always  measures  correctly  
• look  after  your  equipment  so  it  remains  reliable  
• keep  records  to  show  when  it  was  last  checked  and  when  
it  should  be  checked  again.  

The  ISO  standard  requires  that  you:  

• determine  the  accuracy  requirements  of  your  equipment  
• determine  the  calibration  frequency  of  your  equipment  
• look  after  your  equipment  so  it  remains  accurate  to  your  
requirements  
• keep  records  of  inspection  and  calibration  of  your  
equipment.  

Clauses from a quality assurance standard on

inspection and testing

General  

The  supplier  shall  establish  and  maintain  documented  procedures  for  

inspection  and  testing  activities  in  order  to  verify  that  the  specified  
requirements  for  the  product/service  are  met.    The  required  inspection  
and  testing,  and  the  records  to  be  established,  shall  be  detailed  in  the  
quality  plan  or  documented  procedures.  

In-­‐process  inspection  and  testing    

The  supplier  shall:  

• inspect  and  test  the  product/service  as  required  by  the  
quality  plan  and  /  or  documented  procedures  
• hold  product  or  service  until  the  required  inspection  and  
tests  have  been  completed  or  necessary  reports  have  been  
received  and  verified,  except  when  product  or  service  is  
cleared  for  use  under  positive-­‐recall  procedures.      

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TLIB207C Test equipment and isolate faults

Final  inspection  and  testing    

The  supplier  shall  carry  out  all  final  inspection  and  testing  in  
accordance  with  the  quality  plan  and/or  documented  procedures  to  
complete  the  evidence  of  conformance  of  the  finished  product  or  
service  to  the  specified  requirements.  

The  quality  plan  and/or  documented  procedures  for  final  inspection  

and  testing  shall  require  that  all  specified  inspection  and  tests,  
including  those  specified  either  on  receipt  of  product/service  or  in-­‐
process,  have  been  carried  out  and  that  the  results  meet  specified  
requirements.  

Inspection  and  test  records    

The  supplier  shall  establish  and  maintain  records  that  provide  evidence  
that  the  product/service  has  been  inspected  and/or  tested.    These  
records  shall  show  clearly  whether  the  product/service  has  passed  or  
failed  the  inspections  and/or  tests  according  to  defined  acceptance  
criteria.    Where  the  product  fails  to  pass  any  inspection  and/or  test,  the  
procedures  for  control  of  nonconforming  product/service  shall  apply.  

Records  shall  identify  the  inspection  authority  responsible  for  the  

release  of  product/service.  

Control  of  inspection,  measuring  and  test  equipment  

Where  the  availability  of  technical  data  pertaining  to  the  inspection,  
measuring  and  test  equipment  is  a  specified  requirement,  such  data  
shall  be  made  available,  when  required  by  the  customer  or  customer’s  
representative,  for  verification  that  the  inspection,  measuring  and  test  
equipment  is  functionally  adequate.      

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Section 2

Plan operational checks

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TLIB207C Test equipment and isolate faults

Section outline

Areas  covered  in  this  section  

Inspection  and  testing  

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 TLIB207C Test equipment and isolate faults

Inspection and testing

All  specifications  and  notes  from  any  preliminary  observations  should  

be  checked  and  areas  clarified  and  clearly  identified  in  order  to  achieve  
the  correct  result.  

A  thorough  sequence  of  tests  should  be  planned  for  all  materials  
handling  equipment  and  it  should  be  clearly  noted  where  the  results  of  
these  tests  and  general  observations  will  be  recorded.    An  approved  
system  of  forms,  procedures  and  work  instructions  should  be  
established  with  a  suitable  audit  register  set  up  to  display  the  
traceability  of  the  testing  of  all  materials  handling  equipment  that  will  
clearly  detail  all  requirements.  

You  must  plan:  

• when  inspection  and  testing  is  to  be  carried  out  
• what  is  to  be  checked  and  how  
• how  the  checks  are  to  be  recorded  
• arrangements  for  any  additional  staffing  or  equipment  
requirements.  

Daily check

Irrespective  of  any  other  inspection  or  maintenance  carried  out,  

operators  should  carry  out  the  following  checks  before  using  materials  
handling  equipment.    Remember  it  is  people  safety  that  is  at  stake.    A  
simple  check  procedure  may  prevent  an  accident.  

Before starting

On  all  electric  materials  handling  equipment  check:  

• that  the  battery  is  fully  charged    
• to  make  sure  the  charger  is  turned  off  
• that  the  charging  lead  is  disconnected  and  the  battery  lead  
is  reconnected  to  the  machine  
• that  the  level  of  electrolyte  in  the  batteries  is  within  limits  
• tyres  for  wear  or  damage  including  embedded  objects  
• condition  of  apron  and  foot  guards  
• hydraulic  hoses  and  hoist  chains  

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• for  any  loose  or  damaged  items  

• any  attachments  for  security.  

After starting

Check:  
• the  operation  of  brake/control  handle  
• the  operation  of  the  mast  and  all  hydraulic  controls  
• the  operation  of  the  steering  mechanism  
• the  operation  of  the  horn  
• for  oil  leaks  by  moving  the  equipment  and  inspecting  the  
floor  for  signs  of  oil  leaks  from  the  hydraulic  system.  

Safe working area

A  safe  area  should  be  designated  for  the  testing  of  all  materials  
handling  equipment.  

This  area  should  not  conflict  with  loading/unloading  bays,  picking  

areas,  staging  areas,  cross  docking  bays,  other  busy  traffic  areas  or  
commonly  used  pedestrian  walkways.    Care  should  also  be  taken  not  
to  obstruct  any  fire  exits.  

Sample  guide  to  planning  a  safe  materials  handling  testing  area  

Walk  around  and  assess  the  workplace  to  identify  hazards,  such  as:  
• overhead  pipes  and  fittings,  power  lines,  blind  corners,  low  
doorways,  other  traffic,  uneven  operating  surfaces,  noisy  
machines,  lighting  conditions.  

Identify  location/proximity  of:  

• other  people  
• equipment  
• loading/unloading  area.  

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 TLIB207C Test equipment and isolate faults

Activity 1: Materials handling equipment

Plan operational checks carried out in accordance with

manufacturers specifications/operating manual covering:

1. Brake systems – service and park

2. Steering sys

3. Attachments and their security

4. Lights, horn, gauges

5. Hydraulic leaks

6. Battery charged and retainer locked

7. Operation of controls for smooth and

correct operation of selected functions

8. Correct start up procedure

9. Equipment is checked for damage

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 TLIB207C Test equipment and isolate faults

Section 3

Check unit through full operating

range

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TLIB207C Test equipment and isolate faults

Section outline

Areas  covered  in  this  section  

Basic  troubleshooting  
Safety  checks  and  operating  practice    

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A note about safety

All  safety  and  operational  requirements  need  to  be  adhered  to  when  
testing  any  materials  handling  equipment.    The  following  issues  should  
be  considered.  
• WorkCover  requirements  (Occupational  Health  and  Safety)    
• workplace  quality  procedures  and  work  instructions  
• workplace  safety  procedures  
• manufacturers  specifications.  

Only  approved  forms  should  be  used  for  documenting  the  testing  and  
results  of  all  checks  conducted  on  materials  handling  equipment.    Any  
reported  items  should  always  be  double  checked  prior  to  taking  any  
action  towards  correcting  the  problem.  

A basic troubleshooting procedure

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Ten most commonly asked questions when

confirming reported problems by users of materials
handling equipment

1.   What  is  the  problem  exactly?  

2.   In  what  way  does  it  show  up?  

3.   Is  it  permanent?  

4.   If  not  permanent,  under  what  conditions  does  it  appear?  

5.   Has  there  been  any  abuse?  

6.   Did  the  problem  come  on  gradually  or  start  suddenly?  

7.   Did  it  happen  when  someone  was  using  the  equipment?  

8.   Is  this  problem  confined  to  one  function?  

9.   Can  you  offer  any  other  information?  

10.   Did  anyone  try  to  repair  it?  

Sample work instruction

Daily  materials  handling  equipment  pre-­‐operational  check  

Before  commencing  operations  at  the  start  of  a  shift  each  operator  
shall  perform  the  following  checks  to  ensure  that  their  equipment  can  
operate  safely  and  effectively:  

1.   tyres  (for  pressure,  damage,  etc.)  

2.   tyres  for  distortion,  cracks  or  damage  

3.   check  for  oil  leaks  

4.   check  engine  oil  level,  radiator  water  level  and  charge;  battery  
electric  models  shall  be  fully  charged  before  starting  work  

5.   hydraulic  oil  level  

6.   fuel  level  

7.   gas  cylinders  for  correct  positioning  

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8.   all  hydraulic  motions  

9.   warning  devices  (i.e.  horn,  flashing  lights,  brake  lights,  turning  

lights)  

10.   rear  vision  mirrors  

11   steering  

12.   brakes  (check  in  both  forward  and  reverse  directions).  

Report  any  problems  identified  in  the  above  checks  or  during  
operation,  immediately  to  the  Warehouse  Manager.      

Sample safety checks and operating practice

For  safety  and  efficient  operation,  all  operators  should  make  certain  
checks  of  their  equipment  before  each  use.    Practice  good  safety  rules  
and  be  conscious  of  protecting  yourself,  your  fellow  workers,  and  the  
property  in  your  working  area.    Following  is  a  checklist  of  items  that  
should  be  inspected  on  a  regular  basis,  and  some  basic  safety  rules.  

Report  any  malfunctions  and  remove  equipment  from  service  until  it  
can  be  repaired.  

Visual  checks  

1.   Battery(s)  is  charged;  water  level  is  OK;  vent  caps  are  in  place;  
connector  is  secure.  

2.   Lifting  chains  are  in  place.  

3.   Tyres  and  load  wheels  are  in  good  condition.  

4.   Safety  shield  is  clean.  (if  provided)  

5.   Forks  are  in  place  and  properly  secured.  

Operational  checks  

1.   Operate  and  re-­‐engage  emergency  power  disconnect  or  battery  

connector.  

2.   Check  horn  is  working  (toot  it).  

3.   Raise  and  lower  forks.  

5.   Travel  slowly.  

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6.   Apply  brakes.  

7.   Check  steering.  

8. Test travel through full speed range both forward and reverse.

9.   Extend  and  retract  reach  mechanism  (if  provided).  

10.   tilt  mast  forward  and  reverse  or  fork  tips  downward  or  upward    
(if  tilt  is  provided)  

11.   Pay  attention  to  all  labels  and  markings.  

12.   Ensure  that  you,  the  driver,  are  and  alert.  

Sample  –  Do  a  daily  safety  check  –  a  life  could  depend  on  it  

Your  employer  is  responsible  for  making  sure  that  all  materials  
handling  equipment  used  in  your  workplace  complies  with  current  
regulations.    The  regulations  refer  to  Australian  Standards  and  require  
that  equipment  has  the  features  necessary  to  do  the  job  required  
safely.  

As  an  operator,  it  is  in  your  interest  to  check  that  the  Forklift  is  in  good  
working  condition  before  starting  each  shift.  

Establish  a  simple  routine  and  check  the  following  items  daily:  

  Okay   Fix  

Tyres      
• are  the  tyres  cut  or  damaged?      
• are  the  tyres  pumped  up  to  the      
recommended  pressure?  

Mast      
• is  the  mast  still  straight?      
• are  all  the  rollers  on  the  mast  still  in  place  and      
turning?  
• are  all  the  chains  in  good  order  and  correctly      
adjusted?  
• is  the  carriage  damaged?      
• is  the  backrest  still  in  place?      
• are  the  hydraulic  cylinders,  lift  and  tilt,      

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leaking?  
• are  the  tines  (forks)  worn,  cracked  or  bent?      

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  Okay   Fix  
• are  the  tyres  properly  attached  to  the      
carriage?  
• are  limit  switches  working?  (if  fitted)      
Seating      
• is  the  seat  (or  seats)  broken  or  worn  out?      
• is  the  seat  (or  seats)  firmly  attached?      
Controls      
• are  the  controls  clearly  marked?      
• do  the  controls  work  properly?      
Warning  devices      
• is  the  horn  working?      
• is  the  flashing  light  working?      
• are  the  brake  and  turning  lights  (if  fitted)      
working?  

Liquid  levels      
• battery      
• hydraulic  oil      
• engine  oil      
• transmission      
• brake  fluid      
• cooling  water      
• fuel      
Capacity      
• is  the  load  plate  to  the  manufacturer’s      
specifications  fitted?  (do  not  use  the  Forklift  
until  this  load  plate  is  fitted).  

Brakes      

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• are  both  hand  and  foot  brakes  working      

properly?  

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Steering      
• is  the  steering  wheel  moving      
properly?  

There  should  be  no  ‘slack’  or  ‘play’  in  the  steering  wheel  (that  is,  there  
should  be  no  free  movement  in  the  steering  wheel  before  the  wheels  
start  to  turn).  

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Activity 2: For materials handling equipment

The applicant is asked to carry out a complete routine check on a

Forklift truck in accordance with the manufacturer’s instructions.
1. Lift and tilt system

2. Mast assembly

3. Tyre condition and inflation where appropriate

4. Liquid levels are correct:

• battery

• hydraulic oil

• engine oil

• transmission oil

• brake fluid

• cooling water

• fuel

5. Seating position

• seat adjusted secure

• controls clearly marked, if fitted

• mirrors adjusted and clean

• windscreen clean

• seat belt (condition and security)

6. Guards (condition and security)

• load guard

• overhead guard

7. LPG or battery powered Forklift truck

• check security of gas cylinder/battery and

condition of system

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Activity 3: Sample safety checks and operating practice

What precautions should be taken when a leak in the fuel system is

suspected or detected?

____________________________________________________

____________________________________________________

____________________________________________________

Why must batteries be charged in a well ventilated area?

____________________________________________________

____________________________________________________

____________________________________________________

What checks must be made on a jib attachment on a Forklift truck?

____________________________________________________

____________________________________________________

____________________________________________________

Why is tyre pressure (for pneumatic type) and condition important

to the stability of a Forklift truck?

____________________________________________________

____________________________________________________

____________________________________________________

Give three reasons why a pre-check is necessary before operating

a Forklift truck.

1.___________________________________________________

2.___________________________________________________

3.___________________________________________________

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How would you establish the capabilities and limitations of the

Forklift truck and equipment you are testing?

____________________________________________________

____________________________________________________

____________________________________________________

For what reason is the fuel isolating valve turned off after parking
and leaving an LPG powered Forklift truck?

____________________________________________________

____________________________________________________

____________________________________________________

Give three reasons for doing post-operational checks.

1.___________________________________________________

2.___________________________________________________

3.___________________________________________________

During a post operational check of the Forklift Truck you notice a

small crack in the heel of one of the fork arms. If you are a good
welder would you fix it yourself?

____________________________________________________

____________________________________________________

____________________________________________________

There is feedback on this activity at the back of this Learner’s

Guide.

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Section 4

Isolate fault and/or formulate

recommendations

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Section outline

Areas  covered  in  this  section  

Inspecting  for  faults  

Calibrating  equipment  

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Inspecting for faults

Faults  in  materials  handling  equipment  can  effect  the  performance  of  
the  machine  and  the  employee.    This  effect  will  have  an  impact  on  your  
proposed  work  schedule.    It  is  therefore  important  to  regularly  inspect  
equipment  thoroughly  and  properly  in  order  to  ensure  a  safe  working  
order  and  effective  utilisation  of  the  equipment.    Any  repairs  and  
maintenance  should  be  carried  out  as  soon  as  possible  with  the  aim  of  
zero  down  time.  

Some  warehouse/transport  operations  may  have  their  own  on-­‐site  

workshop  to  carry  out  repairs  and  maintenance  while  others  may  
utilise  a  third  party.    A  third  scenario  is  where  the  materials  handling  
equipment  is  hired  with  the  repairs  and  maintenance  carried  out  by  the  
hirer  as  part  of  the  contract.      

All  reputable  warehouses  and  repairers  use  a  simple  form  to  record  
any  faults  found  during  a  test  or  daily  operation.    Once  filled  out  and  
the  repairer  is  made  aware  of  any  items  requiring  attention,  it  is  a  fairly  
simple  task  to  outline  the  options  available  and  to  recommend  an  
estimated  cost  for  parts  and  labour  so  that  the  authorised  workplace  
representative  can  approve  the  commencement  and  timing  of  repairs.      

Parts  are  usually  obtained  through  an  approved  supplier  of  the  
repairer  in  accordance  with  all  company  procedures.    The  repairer  
must  authorise  the  equipment  as  being  in  a  safe  working  order  or  
roadworthy  condition  prior  to  its  use  in  the  warehouse.  

Calibration

1.   The  measuring  devices  and  reference  standards  are  listed  and  

have  been  allocated  an  identification  number.  

2.   Each  item  has  an  allocated  calibration  interval,  a  procedure  for  

calibration  and  a  record  of  the  results  of  the  calibration.  

3   Calibration  is  performed  under  suitable  environmental  conditions  

as  specified  in  the  relevant  procedure.  

4   Records  of  results  include  details  of  the  calibration  interval,  

deviations  from  standard  or  previous  results,  reference  standard  
identification  and  the  identity  of  the  person  performing  the  
calibration.  

5   Transit  and  storage  procedures  are  available.  

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6   Employee  owned  and  customer  supplied  devices  are  included  in  

the  system.  

7   Procedures  are  available  for  checking  all  new  measuring  

equipment  and  reference  standards  before  use.  

8   Physical  reference  standards  are  traceable  to  national  or  

international  standards  are  stored  in  an  environment  suitable  to  
the  maintenance  of  their  accuracy.  

9   Calibration  status  labels  are  in  use.    Exceptions  are  traceably  

identified  to  an  equipment  calibration  schedule.  

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Activity 4: Identifying damage

What would you do if you identified damage or defects affecting

safe operation when checking any materials handling equipment?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

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Feedback on
activities
The responses provided in this section are suggested responses.
Because every workplace is different, your responses may vary
according to your specific workplace procedures, the equipment
available and the nature of the business.

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Activity 3: Sample safety checks and operating practice

What precautions should be taken when a leak in the fuel

system is suspected or detected?
The machine should be immediately stopped, the leak reported to
an authorised person and an appropriate sign displayed on the unit.

Why must batteries be charged in a well ventilated area?

To reduce risk of explosive gas mixture.

What checks must be made on a jib attachment on a Forklift

truck?
Jib attachment of an appropriate type, suitable for the Forklift truck,
correct load capacity, properly fitted with locking bolt housed, etc.

Why is tyre pressure (for pneumatic type) and condition

important to the stability of a Forklift truck?
A flat or under inflated tyre can cause the Forklift truck to tip over.

Give three reasons why a pre-check is necessary before

operating a Forklift truck.
It prevents damage, accidents, ensures safe operation or other.

How would you establish the capabilities and limitations of the

Forklift truck and equipment you are testing?
By information provided by the employer and documented by the
manufacturer.

For what reason is the fuel isolating valve turned off after
parking and leaving an LPG powered Forklift truck?
To eliminate the risk of explosive gas mixture prior to start up.

Give three reasons for doing post-operational checks.

Check for damage, systems are closed off, metal fatigue, leaks in
oil or hydraulic systems, vehicle/equipment is ready for next
operation, etc.

During a post operational check of the Forklift Truck you

notice a small crack in the heel of one of the fork arms. If you
are a good welder would you fix it yourself?
No, defect must be reported to an authorised person.

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