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Carry out an annual safety inspection on forklifts, and complete an
inspection report
Level
4
Credits
4
Purpose
This unit standard is for people in the materials handling equipment repair
industry. People credited with this unit standard are able to prepare to carry
out inspection; and to inspect: overhead guard, mast, frame, and
attachments; engine and cooling system, transmission, and liquefied
petroleum gas (LPG) requirements; electrical and battery electric forklift
requirements; braking, steering, and wheel requirements; hydraulic
requirements; and miscellaneous requirements, and complete the report.
Subfield
Motor Industry
Domain
Automotive Preventive Maintenance
Status
Registered
Status date
20 March 2008
Date version published
20 March 2008
Planned review date
31 December 2012
Entry information
Prerequisite: Driver’s licence with F endorsement.
Accreditation
Evaluation of documentation and visit by NZQA and
industry.
Standard setting body (SSB)
NZ Motor Industry Training Organisation (Incorporated)
Accreditation and Moderation Action Plan (AMAP) reference
0014
This AMAP can be accessed at http://www.nzqa.govt.nz/framework/search/index.do.
Special notes
1
Legislation and publications relevant to this unit standard may include but is not
limited to – Health and Safety in Employment Act 1992; Land Transport Rules; New
Zealand Standards NZS/ANSI/ITSDF B56.1:2005 Safety standard for low lift and
high lift trucks; NZS/AS 2359 series Powered industrial trucks; Vehicle Inspection
Requirements Manual (VIRM) – Inspection and certification of forklifts; Annual Safety
Inspection Report – forklift trucks, New Zealand Forklift Manufacturers and
Distributors Association.
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24343 version 1
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2
New Zealand Standards are available from Standards New Zealand, Private Bag
2439, Wellington; phone 04 498 5990; or website http://www.standards.co.nz.
The VIRM is published by Land Transport New Zealand and is available online at
http://www.landtransport.govt.nz/certifiers/virm-in-service/index.html.
Annual Safety Inspection Report – forklift trucks is issued by the New Zealand Forklift
Manufacturers and Distributors Association. They can be contacted through all major
New Zealand forklift companies.
3
Definitions
Company requirements refer to instructions to staff on policy and procedures which
are documented in memo or manual format and are available in the workplace.
These requirements include but are not limited to – company specifications and
procedures, work instructions, manufacturer specifications, product quality
specifications, and legislative requirements.
Suitable tools and equipment means industry approved tools and equipment that are
recognised within the industry as being the most suited to complete the task in a
professional and competent manner with due regard to safe working practices.
4
Assessment against this standard may include any motorised (including LPG fuelled)
forklift or battery electric forklift.
5
For this unit standard, it is essential that the practical assessment evidence is
obtained in the workplace under normal workplace conditions.
6
It is recommended that the Annual Safety Inspection Report – forklift trucks be used
when carrying out this safety inspection.
Elements and performance criteria
Element 1
Prepare to carry out inspection.
Performance criteria
1.1
Forklift design complies with relevant standards and all alterations have been
approved in accordance with standards requirements.
Range
1.2
NZS/ANSI/ITSDF B56.1, NZS/AS 2359.
General information is noted in accordance with annual safety inspection report
sheet.
Range
may include but is not limited to – owner, forklift name plate,
specifications, forklift capacity, load chart, maintenance
requirements, number place registration, operator qualifications,
decal legible.
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Element 2
Inspect overhead guard, mast, frame, and attachments and fill out the report.
Performance criteria
2.1
Safe working practices are observed throughout the task in accordance with
legislative requirements.
Range
personal safety, safety of others, forklift safety, workshop safety,
environmental safety, tools and equipment safety.
2.2
Suitable tools and equipment are selected and used in accordance with
company requirements.
2.3
Overhead guard and attachments are inspected and any defects noted in
accordance with manufacturer specifications and legislative and report
requirements.
Range
2.4
Mast and attachments are inspected and any defects are noted in accordance
with manufacturer specifications and legislative and report requirements.
Range
2.5
may include but is not limited to – alterations, corrosion, damage,
support legs and mountings, strength, operation.
mast – chains, drop test, tilt test, mounts for wear, cracks;
forks – clearance, rating, cracks, straightness of blades, angle,
height of tips, positioning lock, wear, capacity;
carriage – wear, cracks, roller shimming, pin retention, sideshift,
cylinder, hose, leaks;
load backrest extension – mounting, condition, requirement.
Frame and counterweight attachments are inspected and any defects are noted
in accordance with manufacturer specifications and legislative and report
requirements.
Range
cracks, distortion, counterweight mounting.
Element 3
Inspect engine and cooling system, transmission, and LPG requirements and fill out the
report.
Performance criteria
3.1
Engine, cooling system, and attachments are inspected and any defects are
noted in accordance with manufacturer specifications and legislative and report
requirements.
Range
engine – operation, oil leaks, fuel leaks, exhaust leaks, governor
operation, mountings, shutoff, abnormal noise;
cooling system – radiator cap, belts, hoses, pump, leaks.
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3.2
Transmission, differential, and attachments are inspected and any defects are
noted in accordance with manufacturer specifications and legislative and report
requirements.
Range
3.3
clutch pedal operation, inching operation, oil leaks, cooler hoses,
mountings, drive operation.
An LPG system is inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
certification, mounting of tanks, hoses, leaks.
Element 4
Inspect electrical and battery electric forklift requirements and fill out the report.
Performance criteria
4.1
Electrical system is inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
4.2
starting, battery retention, battery cleanliness, cable insulation,
wiring, warning devices, lights, indicators, charging and
disconnecting switch, gauges.
Battery electrical forklift system is inspected and any defects are noted in
accordance with manufacturer specifications and legislative and report
requirements.
Range
weight of battery to specification, controls and insulation,
connectors, battery mounting and retention, battery charging,
terminal corrosion, travel controls, electrical protection, battery
cleanliness, battery and cell covers.
Element 5
Inspect braking, steering, and wheel requirements and fill out the report.
Performance criteria
5.1
Brake system is inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
service brake – pedal operation, linkages, master cylinder, hose,
leaks, drive tests laden and unladen, stopping distance tests;
park brake – linkage, interlock, gradient test, operational test.
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5.2
Steering system is inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
5.3
straight line operation, leaks, even turning circle, hub, king pins,
ball joints.
Wheels are inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
tyres – rating, condition, wear, pressure;
rims – deformation, cracks, rings, studs, nuts.
Element 6
Inspect hydraulic requirements and fill out the report.
Performance criteria
6.1
Hydraulic system is inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
handle lever operation, hose pipes and tube, leaks, fittings.
Element 7
Inspect miscellaneous requirements and fill out the report.
Performance criteria
7.1
Floor plate is inspected for security and any defects are noted in accordance
with manufacturer specifications and legislative and report requirements.
7.2
Operator seat is inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
7.3
security, mounting, adjustment, restraint system.
Rear view mirror is inspected and any defects are noted in accordance with
manufacturer specifications and legislative and report requirements.
Range
security adjustment, damage, cleanliness.
7.4
Forklifts working in hazardous areas are inspected and hazard protection report
is attached in accordance with manufacturer specifications and legislative and
report requirements.
7.5
The inspection report is completed in accordance with company requirements.
Range
includes but is not limited to – non-compliant items noted, remarks
and recommendations noted, organisation and technician’s
information noted.
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Please note
Providers must be accredited by NZQA, or an inter-institutional body with delegated
authority for quality assurance, before they can report credits from assessment against
unit standards or deliver courses of study leading to that assessment.
Industry Training Organisations must be accredited by NZQA before they can register
credits from assessment against unit standards.
Accredited providers and Industry Training Organisations assessing against unit standards
must engage with the moderation system that applies to those standards.
Accreditation requirements and an outline of the moderation system that applies to this
standard are outlined in the Accreditation and Moderation Action Plan (AMAP). The
AMAP also includes useful information about special requirements for organisations
wishing to develop education and training programmes, such as minimum qualifications for
tutors and assessors, and special resource requirements.
Comments on this unit standard
Please contact the NZ Motor Industry Training Organisation (Incorporated)
moderation@mito.org.nz if you wish to suggest changes to the content of this unit
standard.
 New Zealand Qualifications Authority 2016