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Contents

What this Learners 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

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Australian National Training Authority 2003 Page 1Customised and Developed by Armstrongs Driver Education P/L April 2008 ADELG1016

What this Learners Guide is about

ThisLearnersGuideisabouttheskillsandknowledgerequiredtotestequipmentandisolatefaultsinaccordancewithworkplacerequirements,includingidentifyingscopeoftheoperationaltest,planningoperationaltests,checkingtheequipmentthroughitsfulloperatingrange,andisolatingfaultsand/orworkplaceproceduresandrelevantregulatoryrequirements.

Theactivitiesaredesignedtogiveanopportunitytopractiseusingprocedures,formsandworkinstructionsalongwithmanufacturersspecificationsandguidancenotesfromtherelevantWorkcoverauthority.Yourcompanysstandardsthatapplyshouldalsobetaken

intoconsideration.

TheElementsofCompetencyfromtheunitTLIB207CTestequipmentandisolatefaultscoveredinthisLearnersGuidearelistedbelow.

Identifyscopeofoperationalcheck

Planoperationalchecks

Checkunitthroughfulloperatingrange

Isolatefaultand/orformulaterecommendations

ThisunitofcompetencyisfromtheTransportandLogisticsTrainingPackage(TLI07).

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Planning your learning

ItisimportanttoplanyourlearningbeforeyoustartbecauseyoumayalreadyhavesomeoftheknowledgeandskillsthatarecoveredinthisLearnersGuide.Thismightbebecause:

youhavebeenworkingintheindustryforsometime,and/or

youhavealreadycompletedtraininginthisarea.

Togetherwithyoursupervisorortrainerusethechecklistsonthefollowingpagestohelpyouplanyourstudyprogram.Youranswerstothequestionsinthechecklistwillhelpyouworkoutwhichsectionsof

thisLearnersGuideyouneedtocomplete.

ThisLearnersGuideiswrittenwiththeideathatlearningismademorerelevantwhenyou,thelearner,areactuallyworkingintheindustry.Thismeansthatyouwillhavepeoplewithintheenterprisewhocanshowyouthings,discusshowthingsaredoneandansweranyquestionsyouhave.Alsoyoucanpractisewhatyoulearnandseehowwhatyoulearnisappliedintheenterprise.

IfyouareworkingthroughthisLearnersGuideandhavenotyetfoundajobintheindustry,youwillneedtotalktoyourtraineraboutdoingworkexperienceorworkingandlearninginsomesortofsimulatedworkplace.

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Section 1: Identify scope of operational check

Areyouableto: Yes No

1. detailwhichforms,proceduresand/orworkinstructionsareusedinthewarehouseforthecheckingandmaintenanceofallmaterialshandlingequipmentsoastoensuretheirsafeworkingorder?

2. demonstratewhereapplicablehowthesedocumentscomplywithanyrequirementsbyWorkcover,therelevantmanufacturers

specificationsandtheelementsofanaccreditedqualitysystem?

3. identifytheproceduresandparametersusedforcheckingandmaintainingmaterialshandlingequipmentinthewarehouseandstatehowtheobservationsandfindingsarerecordedandwhereitfitsintheoverallsysteminyourworkplace?

Section 2: Plan operational checks

Areyouableto: Yes No

1. explainthesystemusedfortheplanningofoperationalchecksonmaterialshandlingequipment?

2. specifywhowillberesponsiblefor: nominatingasafeareafortesting carryingouttheinitialcheck

authorisingthecheck thereportingofobservationsandfindings determiningiftheequipmentisunsafe decidingonreplacementequipment/staff.

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Section 3: Check unit through full operatingrange

Areyouableto: Yes No

1. explainhowthetestingofthematerialshandlingequipmentisconducted?

2. demonstratetheformatusedforrecordingthefindingsofthesetests?

3. detailhowirregularitiesarereportedtotherepairer?

4. statewhatobligationisontheproprietor

ofanymaterialshandlingequipmentwhenitrequiresorisunderrepair?

5. specifywhatcalibrationrecordsarekeptonequipment,whatparametersareusedandhowoftenequipmentiscalibrated?

6. listwhatcheckstheoperatormustmakeatthestartofdutytoensurethematerialshandlingequipmentissafetooperate?

7. detailwhatprecautionsshouldbetaken

whenaleakinthefuelsystemissuspectedordetected?

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Section 4: Isolate fault and/or formulaterecommendations

Areyouableto: Yes No

1. explainhowyouisolatematerialshandlingequipmentthatisconsideredunsafesoastopreventaccidentalusage,andhowstaffarenotifiedofthis?

2. explaintheproceduresusedwhenmaterialshandlingequipmentisbeingrepairedinregardsto: whodecidesontheurgencyofthe

repair whoauthorisestherepair whocostsouttherepair whoauthorisesthecost doyouuseanapprovedsupplier whoordersthepartsanddotheyusea purchaseorder whoauthorisestherepair whodecidesonwhatneedstobe

done toremedytheworkschedule.

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How you will be assessed

AssessmentofthisUnitofCompetencywillincludeobservationofrealorsimulatedworkprocessesusingworkplaceproceduresandquestioningonunderpinningknowledgeandskills.Itmustbedemonstratedinanactualorsimulatedworksituationundersupervision.

Youwillberequiredto:

demonstratethecorrectprocedurefortestingmaterialshandlingequipmentandthecorrectprocedureforisolatingfaultsfoundduringtestingordailyoperation

researchtheuseofmaterialshandlingequipmentinthewarehousingindustryandpresentanoralorwrittenreportonthetestingandreportingofmaterialshandlingequipmentandtheisolationprocedureofequipmentfoundtonotcomplywiththesafetystandard

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Section 1

Identify scope of operationalcheck

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Section outline

Areascoveredinthissection

Inspectionandtestingprocedures

Qualityassuranceexample

Controlofequipment

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Inspection and testing procedures

Youmustestablishproceduresto:

ensureyourequipmentisasaccurateasrequired

calibrateyourequipment,soitalwaysmeasurescorrectly

lookafteryourequipmentsoitremainsreliable

keeprecordstoshowwhenitwaslastcheckedandwhenitshouldbecheckedagain.

TheISOstandardrequiresthatyou:

determinetheaccuracyrequirementsofyourequipment

determinethecalibrationfrequencyofyourequipment

lookafteryourequipmentsoitremainsaccuratetoyourrequirements

keeprecordsofinspectionandcalibrationofyourequipment.

Clauses from a quality assurance standard oninspection and testing

General

Thesuppliershallestablishandmaintaindocumentedproceduresforinspectionandtestingactivitiesinordertoverifythatthespecifiedrequirementsfortheproduct/servicearemet.Therequiredinspectionandtesting,andtherecordstobeestablished,shallbedetailedinthequalityplanordocumentedprocedures.

In-processinspectionandtesting

Thesuppliershall:

inspectandtesttheproduct/serviceasrequiredbythequalityplanand/ordocumentedprocedures

holdproductorserviceuntiltherequiredinspectionandtestshavebeencompletedornecessaryreportshavebeenreceivedandverified,exceptwhenproductorserviceisclearedforuseunderpositive-recallprocedures.

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Finalinspectionandtesting

Thesuppliershallcarryoutallfinalinspectionandtestinginaccordancewiththequalityplanand/ordocumentedproceduresto

completetheevidenceofconformanceofthefinishedproductorservicetothespecifiedrequirements.

Thequalityplanand/ordocumentedproceduresforfinalinspectionandtestingshallrequirethatallspecifiedinspectionandtests,includingthosespecifiedeitheronreceiptofproduct/serviceorin-process,havebeencarriedoutandthattheresultsmeetspecifiedrequirements.

Inspectionandtestrecords

Thesuppliershallestablishandmaintainrecordsthatprovideevidencethattheproduct/servicehasbeeninspectedand/ortested.Theserecordsshallshowclearlywhethertheproduct/servicehaspassedorfailedtheinspectionsand/ortestsaccordingtodefinedacceptancecriteria.Wheretheproductfailstopassanyinspectionand/ortest,theproceduresforcontrolofnonconformingproduct/serviceshallapply.

Recordsshallidentifytheinspectionauthorityresponsibleforthereleaseofproduct/service.

Controlofinspection,measuringandtestequipment

Wheretheavailabilityoftechnicaldatapertainingtotheinspection,measuringandtestequipmentisaspecifiedrequirement,suchdatashallbemadeavailable,whenrequiredbythecustomerorcustomersrepresentative,forverificationthattheinspection,measuringandtestequipmentisfunctionallyadequate.

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Section 2

Plan operational checks

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Section outline

Areascoveredinthissection

Inspectionandtesting

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Inspection and testing

Allspecificationsandnotesfromanypreliminaryobservationsshould

becheckedandareasclarifiedandclearlyidentifiedinordertoachievethecorrectresult.

Athoroughsequenceoftestsshouldbeplannedforallmaterialshandlingequipmentanditshouldbeclearlynotedwheretheresultsofthesetestsandgeneralobservationswillberecorded.Anapprovedsystemofforms,proceduresandworkinstructionsshouldbeestablishedwithasuitableauditregistersetuptodisplaythetraceabilityofthetestingofallmaterialshandlingequipmentthatwillclearlydetailallrequirements.

Youmustplan:

wheninspectionandtestingistobecarriedout

whatistobecheckedandhow

howthechecksaretoberecorded

arrangementsforanyadditionalstaffingorequipmentrequirements.

Daily check

Irrespectiveofanyotherinspectionormaintenancecarriedout,operatorsshouldcarryoutthefollowingchecksbeforeusingmaterialshandlingequipment.Rememberitispeoplesafetythatisatstake.Asimplecheckproceduremaypreventanaccident.

Before starting

Onallelectricmaterialshandlingequipmentcheck: thatthebatteryisfullycharged

tomakesurethechargeristurnedoff

thatthechargingleadisdisconnectedandthebatteryleadisreconnectedtothemachine

thatthelevelofelectrolyteinthebatteriesiswithinlimits

tyresforwearordamageincludingembeddedobjects

conditionofapronandfootguards

hydraulichosesandhoistchains

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foranylooseordamageditems

anyattachmentsforsecurity.

After starting

Check:

theoperationofbrake/controlhandle

theoperationofthemastandallhydrauliccontrols

theoperationofthesteeringmechanism

theoperationofthehorn

foroilleaksbymovingtheequipmentandinspectingthefloorforsignsofoilleaksfromthehydraulicsystem.

Safe working area

Asafeareashouldbedesignatedforthetestingofallmaterialshandlingequipment.

Thisareashouldnotconflictwithloading/unloadingbays,pickingareas,stagingareas,crossdockingbays,otherbusytrafficareasorcommonlyusedpedestrianwalkways.Careshouldalsobetakennot

toobstructanyfireexits.

Sampleguidetoplanningasafematerialshandlingtestingarea

Walkaroundandassesstheworkplacetoidentifyhazards,suchas:

overheadpipesandfittings,powerlines,blindcorners,lowdoorways,othertraffic,unevenoperatingsurfaces,noisymachines,lightingconditions.

Identifylocation/proximityof:

otherpeople equipment

loading/unloadingarea.

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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 andcorrect operation of selected functions

8. Correct start up procedure

9. Equipment is checked for damage

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Section 3

Check unit through full operatingrange

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Section outline

Areascoveredinthissection

Basictroubleshooting

Safetychecksandoperatingpractice

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A note about safety

Allsafetyandoperationalrequirementsneedtobeadheredtowhentestinganymaterialshandlingequipment.Thefollowingissuesshould

beconsidered.

WorkCoverrequirements(OccupationalHealthandSafety)

workplacequalityproceduresandworkinstructions

workplacesafetyprocedures

manufacturersspecifications.

Onlyapprovedformsshouldbeusedfordocumentingthetestingandresultsofallchecksconductedonmaterialshandlingequipment.Anyreporteditemsshouldalwaysbedoublecheckedpriortotakingany

actiontowardscorrectingtheproblem.

A basic troubleshooting procedure

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Ten most commonly asked questions whenconfirming reported problems by users of materialshandling equipment

1. Whatistheproblemexactly?

2. Inwhatwaydoesitshowup?

3. Isitpermanent?

4. Ifnotpermanent,underwhatconditionsdoesitappear?

5. Hastherebeenanyabuse?

6. Didtheproblemcomeongraduallyorstartsuddenly?

7. Didithappenwhensomeonewasusingtheequipment?

8. Isthisproblemconfinedtoonefunction?

9. Canyouofferanyotherinformation?

10. Didanyonetrytorepairit?

Sample work instruction

Dailymaterialshandlingequipmentpre-operationalcheck

Beforecommencingoperationsatthestartofashifteachoperatorshallperformthefollowingcheckstoensurethattheirequipmentcanoperatesafelyandeffectively:

1. tyres(forpressure,damage,etc.)

2. tyresfordistortion,cracksordamage

3. checkforoilleaks

4. checkengineoillevel,radiatorwaterlevelandcharge;batteryelectricmodelsshallbefullychargedbeforestartingwork

5. hydraulicoillevel

6. fuellevel

7. gascylindersforcorrectpositioning

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8. allhydraulicmotions

9. warningdevices(i.e.horn,flashinglights,brakelights,turninglights)

10. rearvisionmirrors

11 steering

12. brakes(checkinbothforwardandreversedirections).

Reportanyproblemsidentifiedintheabovechecksorduringoperation,immediatelytotheWarehouseManager.

Sample safety checks and operating practice

Forsafetyandefficientoperation,alloperatorsshouldmakecertainchecksoftheirequipmentbeforeeachuse.Practicegoodsafetyrulesandbeconsciousofprotectingyourself,yourfellowworkers,andthepropertyinyourworkingarea.Followingisachecklistofitemsthatshouldbeinspectedonaregularbasis,andsomebasicsafetyrules.

Reportanymalfunctionsandremoveequipmentfromserviceuntilitcanberepaired.

Visualchecks

1. Battery(s)ischarged;waterlevelisOK;ventcapsareinplace;connectorissecure.

2. Liftingchainsareinplace.

3. Tyresandloadwheelsareingoodcondition.

4. Safetyshieldisclean.(ifprovided)

5. Forksareinplaceandproperlysecured.

Operationalchecks

1. Operateandre-engageemergencypowerdisconnectorbatteryconnector.

2. Checkhornisworking(tootit).

3. Raiseandlowerforks.

5. Travelslowly.

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6. Applybrakes.

7. Checksteering.

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

9. Extendandretractreachmechanism(ifprovided).

10. tiltmastforwardandreverseorforktipsdownwardorupward(iftiltisprovided)

11. Payattentiontoalllabelsandmarkings.

12. Ensurethatyou,thedriver,areandalert.

SampleDoadailysafetycheckalifecoulddependonit

Youremployerisresponsibleformakingsurethatallmaterialshandlingequipmentusedinyourworkplacecomplieswithcurrentregulations.TheregulationsrefertoAustralianStandardsandrequirethatequipmenthasthefeaturesnecessarytodothejobrequiredsafely.

Asanoperator,itisinyourinteresttocheckthattheForkliftisingoodworkingconditionbeforestartingeachshift.

Establishasimpleroutineandcheckthefollowingitemsdaily:

Okay Fix

Tyres

arethetyrescutordamaged?

arethetyrespumpeduptotherecommendedpressure?

Mast

isthemaststillstraight?

arealltherollersonthemaststillinplaceandturning?

areallthechainsingoodorderandcorrectlyadjusted?

isthecarriagedamaged?

isthebackreststillinplace?

arethehydrauliccylinders,liftandtilt,

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leaking?

arethetines(forks)worn,crackedorbent?

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Okay Fix

arethetyresproperlyattachedtothecarriage?

arelimitswitchesworking?(iffitted)

Seating

istheseat(orseats)brokenorwornout?

istheseat(orseats)firmlyattached?

Controls

arethecontrolsclearlymarked?

dothecontrolsworkproperly?

Warningdevices

isthehornworking?

istheflashinglightworking?

arethebrakeandturninglights(iffitted)working?

Liquidlevels

battery

hydraulicoil

engineoil

transmission

brakefluid

coolingwater

fuel

Capacity

istheloadplatetothemanufacturersspecificationsfitted?(donotusetheForkliftuntilthisloadplateisfitted).

Brakes

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arebothhandandfootbrakesworkingproperly?

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Steering

isthesteeringwheelmovingproperly?

Thereshouldbenoslackorplayinthesteeringwheel(thatis,thereshouldbenofreemovementinthesteeringwheelbeforethewheelsstarttoturn).

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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 manufacturers 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 importantto 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 theForklift truck and equipment you are testing?

____________________________________________________

____________________________________________________

____________________________________________________

For what reason is the fuel isolating valve turned off after parkingand 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 goodwelder would you fix it yourself?

____________________________________________________

____________________________________________________

____________________________________________________

There is feedback on this activity at the back of this LearnersGuide.

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Section 4

Isolate fault and/or formulaterecommendations

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Section outline

Areascoveredinthissection

Inspectingforfaults

Calibratingequipment

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Inspecting for faults

Faultsinmaterialshandlingequipmentcaneffecttheperformanceof

themachineandtheemployee.Thiseffectwillhaveanimpactonyourproposedworkschedule.Itisthereforeimportanttoregularlyinspectequipmentthoroughlyandproperlyinordertoensureasafeworkingorderandeffectiveutilisationoftheequipment.Anyrepairsandmaintenanceshouldbecarriedoutassoonaspossiblewiththeaimofzerodowntime.

Somewarehouse/transportoperationsmayhavetheirownon-siteworkshoptocarryoutrepairsandmaintenancewhileothersmayutiliseathirdparty.Athirdscenarioiswherethematerialshandling

equipmentishiredwiththerepairsandmaintenancecarriedoutbythehireraspartofthecontract.

Allreputablewarehousesandrepairersuseasimpleformtorecordanyfaultsfoundduringatestordailyoperation.Oncefilledoutandtherepairerismadeawareofanyitemsrequiringattention,itisafairlysimpletasktooutlinetheoptionsavailableandtorecommendanestimatedcostforpartsandlaboursothattheauthorisedworkplacerepresentativecanapprovethecommencementandtimingofrepairs.

Partsareusuallyobtainedthroughanapprovedsupplieroftherepairerinaccordancewithallcompanyprocedures.Therepairermustauthorisetheequipmentasbeinginasafeworkingorderorroadworthyconditionpriortoitsuseinthewarehouse.

Calibration

1. Themeasuringdevicesandreferencestandardsarelistedandhavebeenallocatedanidentificationnumber.

2. Eachitemhasanallocatedcalibrationinterval,aprocedureforcalibrationandarecordoftheresultsofthecalibration.

3 Calibrationisperformedundersuitableenvironmentalconditionsasspecifiedintherelevantprocedure.

4 Recordsofresultsincludedetailsofthecalibrationinterval,deviationsfromstandardorpreviousresults,referencestandardidentificationandtheidentityofthepersonperformingthecalibration.

5 Transitandstorageproceduresareavailable.

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6 Employeeownedandcustomersupplieddevicesareincludedinthesystem.

7 Proceduresareavailableforcheckingallnewmeasuringequipmentandreferencestandardsbeforeuse.

8 Physicalreferencestandardsaretraceabletonationalorinternationalstandardsarestoredinanenvironmentsuitabletothemaintenanceoftheiraccuracy.

9 Calibrationstatuslabelsareinuse.Exceptionsaretraceablyidentifiedtoanequipmentcalibrationschedule.

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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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Page 32 Australian National Training Authority 2003ADELG1016 Customised and Developed by Armstrongs Driver Education P/L April 2008

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Australian National Training Authority 2003 Page 33Customised and Developed by Armstrongs Driver Education P/L April 2008 ADELG1016

Feedback onactivities

The responses provided in this section are suggested responses.Because every workplace is different, your responses may varyaccording to your specific workplace procedures, the equipmentavailable 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 toan 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 Forklifttruck?

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 conditionimportant 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 beforeoperating 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 themanufacturer.

For what reason is the fuel isolating valve turned off afterparking 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 inoil or hydraulic systems, vehicle/equipment is ready for nextoperation, etc.

During a post operational check of the Forklift Truck younotice a small crack in the heel of one of the fork arms. If youare a good welder would you fix it yourself?

No, defect must be reported to an authorised person.