1 Forklift

HOW TO USE THIS COMPETENCY – BASED
LEARNING MATERIAL
Welcome!
The unit of competency, "Perform Pre- and Post-Operation

Procedures for Forklift", is one of the competencies of (HEO)
On-Highway Dump Truck [Rigid] NCII, a course which comprises
the knowledge, skills and attitudes required for an On-highway
dump truck driver to possess.
The module, Performing Pre- and Post-Operation Procedures

for Forklift, contains training materials and activities related to
performing visual check of equipment, performing “BLOWAF”
check, performing operation check, and performing post-operation
procedure.
In this module, you are required to go through a series of learning

activities in order to complete each learning outcome. In each
learning outcome are Information Sheets, Self-Checks, and Task
Sheets. Follow and perform the activities on your own. If you have
questions, do not hesitate to ask for assistance from your
facilitator.
Remember
to:
1. Go through all the information sheets and complete the
tasks and self-checks in each section.
2. Check your work through the answer keys found within the
package to give yourself immediate feedback.
3. Practice with the task sheets and job sheets until your
performance output conforms to the Performance Criteria
Checklist.
4. Submit outputs of the Task Sheets and Job Sheets to your
facilitator for evaluation and recording in the
Accomplishment Chart. Outputs shall serve as your
portfolio during the Institutional Competency Evaluation.
5. When you feel confident that you have had sufficient
practice, ask your trainer to evaluate you. The results
of your assessment will be recorded in your
Progress Chart and Accomplishment Chart.
Document No.
Heavy Equipment Date Issued by:
Operation- Forklift Developed:
Developed by:
Revision No.001
1
When you are ready, you may take the Institutional Competency
Evaluation for this competency. Upon passing, you will receive a
Certificate of Achievement and you will be allowed to move on
the next competency.
Document No.
Developed by:
Revision No.001
2
List of Competencies
No Unit of Module Title Code

. Competency
PERFORM PRE-
Performing pre- CON834216
AND POST-
and post-
1. OPERATION
operation
PROCEDURES
procedures for
FOR FORKLIFT
Forklift
PERFORM BASIC
PREVENTIVE Performing basic CON834217
MAINTENANCE preventive
2.
SERVICING FOR maintenance
FORKLIFT servicing for
Forklift
PERFORM
PRODUCTIVE Performing
OPERATION FOR productive
3. CON834218
FORKLIFT operation for
forklift
Document No.
Developed by:
Revision No.001
3
MODULE CONTENT
UNIT OF COMPETENCY Perform Pre- and Post-operation

Procedures for Forklift
MODULE TITLE Performing Pre- and Post-Operation

Procedures for Forklift
MODULE DESCRIPTOR: This module deals with the

outcomes
required to perform pre- and
post- operation procedures for
Forklift
NOMINAL DURATION: 24 hours
LEARNING OUTCOMES:
At the end of this module you MUST be able to:
1. LO 1. Identify forklift types/ components
2. LO 2. Perform visual check of equipment
3. LO 3. Perform BLOWAF check
4. LO 4. Check forklift system operation
5. LO 5 Check safety devices
6. LO 6 Perform post operation procedures
ASSESSMENT CRITERIA:
1 Types of Forklift and its applications
2 Forklift component structure are identified and functions are explained
3 Forklift and its lifting capacity is selected based on job requirements.
4 Operator serviceable (OS) parts are checked in accordance with equipment
checklist and manufacturer’s procedures.
5 Walk-around check is performed with equipment checklist and with engine
stopped/not running
6 BLOWAF inspection are performed following equipment checklist and with
engine stopped
7 Observed walk-around and operation check while engine is running.
8 Systems operation are checked and conforms with manufacturer’s
specifications
Document No.
Developed by:
Revision No.001
4
9 Forklift Safety devices are checked for functionality according safety
regulation
10 Personal safety devices are checked in accordance with OHS procedure
11 Post operation check is performed based on standard procedures.
12 Daily Equipment Time Record/Report (DETR) is accomplished in line with
company rules and policies
LEARNING OUTCOME NO. 1

Identify Forklift types/ components structure
Contents:
1. Types and classification of Forklift
2. Components structures of forklift and their functions.
Assessment Criteria
1. Types of forklifts and its applications

2. Forklift component structure are identified and functions are
explained.
Conditions
The participants will have access to:
1. Unit of Equipment (Forklift)

2. Forklift operations and maintenance manual
3. Handouts/Instructional Materials
Assessment Method:
1. Written Exam
2. Oral Questioning
3. Task Sheets
Document No.
Developed by:
Revision No.001
5
Learning
Experiences
Document No.
Developed by:
Revision No.001
6
Identify forklift types/ components structure
Learning Activities Special Instructions

1. Listen To the lecture / Read and understand the
discussion of your trainer information sheet and check
on the Kinds and uses of yourself by answering the self-
hauling equipment check. You must answer all
Answer self-check 1.1- questions correctly before
1 proceeding to the next
activity.
Compare the answers of
self- check 1.1-1 to the
answer key
on the Different operator yourself by answering the self-
serviceable parts and how check. You must answer all
to identify their problems questions correctly before
proceeding to the next
activity.
3. Watch the demonstration Read and understand the

of your trainer carefully information sheet. After,
and practice Performing practice the steps of the walk
the walk around check in around check. You must be
accordance with the walk able to perform the Task Sheet
around checklist before proceeding to the next
activity.
Perform Task sheet
1.1-3
Compare your performance

to the performance criteria
checklist
Document No.
Developed by:
Revision No.001
7
Information Sheet 1.1.1
Types of Forklift and its application
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. Identify the different kinds of forklift equipment
2. Choose the right type of equipment for the job requirement
Document No.
Developed by:
Revision No.001
8
22 Different Types of Forklifts for Indoor and Outdoor Work
Every one of us has seen forklifts trucks in supermarkets or warehouses moving

heavy stuff and putting it high above where a normal’s human’s arms can’t
reach. A forklift is one of the most useful and important pieces of equipment
you need to invest in if you run a warehouse, a storage facility or work on a
construction site.
However, as with all things, forklifts come in a wide variety of types and styles.
Therefore, it can be a bit difficult to know what kind if best for a certain
environment. Whether you are looking for forklifts that can safely lift extremely
heavy objects or machines that can place items high on top of shelves, this
guide can give you a list of some of the most popular types.
Types of Forklifts
Document No.
Developed by:
Revision No.001
9
 Warehouse forklifts
 Counterbalance forklifts
 Three-wheel counterbalance forklifts
 Reach forklifts
 Rough terrain forklifts
 Side loader forklifts
 Telescopic handler forklifts
 Industrial forklift
 Pedestrian operated pallet trucks
 Walkie/Power pallet trucks
 Cherry picker/Order picker forklifts
 Warehouse Forklifts
The warehouse forklift is the most popular and well-known type of forklift. This
forklift looks like a yellow golf cart and is equipped with twin forks at the front.
The warehouse forklift, as the name indicates, is used in facilities like
Document No.
Developed by:
Revision No.001
10
warehouses, where large inventories are stored. These lifts are perfect for
loading and unloading pallets as well as off-loading and transporting items from
delivery trucks.
Most warehouse lifts have a capacity of lifting at least 5,000 lbs; however,
larger, heavy-duty models are capable of lifting up to 25,000 lbs. Some of the
most popular types of forklifts are the Toyota 3-Wheel Electric Forklift and the
Komatsu 20 BX50 Hyster.
Counterbalance Forklifts
The counterbalance forklift is a type of warehouse forklift and is one of the most
common vehicles used in indoor warehouses and superstores. Counterbalance
forklifts have forks at the front and a weight at the front to counterbalance the
load. Electrical-powered counterbalance forklifts can work with a lighter
counterweight at the back since their battery is the source of power and lends
stability to the vehicle. These lifts do not have any outrigger arms, giving the
truck the ability to move to the exact location of the racking.
Document No.
Developed by:
Revision No.001
11
Counterbalance forklifts come in diesel, gas and electric powered versions.
Many of them are equipped with sideshifts, driver cabs, and a mast tilt
mechanism.
Three-Wheel Counterbalance Forklifts
These counterbalance forklifts are similar to the regular four-wheel

counterbalance forklifts mentioned above, but they are equipped with only
three wheels. This gives them the benefit of improved navigational control,
including the ability to move in tight circles and easily accessing narrow aisles
and storage spaces.
Three-wheel counterbalance forklifts are perfect for both inside and outside use
as well as load racking. The tight maneuverability and the counterbalance
combined makes sure the vehicle operates at maximum productivity.
Reach forklifts
Document No.
Developed by:
Revision No.001
12
Reach forklifts’ main feature is that they have an extended height which can lift
cargo and rack it up high, even in excess of 10 meters. They also have
wonderful maneuverability and can work in confined environments. These
trucks come equipped with stabilizing legs in the front which take the brunt of
the weight and steadies the load. They have no need of a counterweight since
they have the stabilizing legs and electric-powered battery.
Reach forklifts are great for warehouse operations but are not often used
Document No.
Developed by:
Revision No.001
13
outdoors. Their low undercarriage ground clearance makes it difficult for them
to work on uneven surfaces and their electrical system may become out of
order if it is frequently jarred.
Some reach forklifts come with a tilting cab mechanism which makes it easier
for the operator to view the work. Others come with open overhead guard for
maximum visibility. Sometimes, reach trucks are also equipped with cameras on
the fork carriage connected to an LCD screen in the cab, which allows the
operator to navigate and rack the load easily. This system can be either wired
and wireless, though wired systems are better compared to wireless as there is
no signal interference.
There are three main types of reach forklifts:
Stand-up Trucks
Stand-up truck is the most common reach forklift. They can typically lift a single
load per bay. The twin forks in the front can easily slide beneath a palletized
load and transport it to the top.
Double-deep Trucks
Double-deep trucks are similar to stand-up trucks but have longer forks, so they
can lift more than one palletized loads per bay. The longer forks can reach right
to the back of the bay.
Saddle Trucks
Saddle trucks come with long forks as well but they also have the ability to slide
under and grip the edges of the load for more secure delivery. They are ideal for
placing multiple loads on a bay that you need to access from different sides.
Rough Terrain Forklifts
Document No.
Developed by:
Revision No.001
14
Rough terrain forklifts are the ideal type of forklifts for outdoor work on rough,
uneven, or challenging terrain. These forklifts come with oversized, pneumatic
tires, which are inflatable and have thicker threads, which can provide greater
stability and balance on uneven surfaces. They also have engines that are far
more powerful than those of indoor forklifts. This helps the forklifts reach a
higher speed, improved traction and better maneuverability for transporting
heavy loads over rough ground, mud and even snow and ice.
They also come equipped with a calibrated counterbalance at the back of the
vehicle to prevent the truck from toppling over. Most models have the capacity
to shift loads between 6,000 to 8,000 lbs.
Some popular models of rough terrain forklifts include the CASE 588H and
JCB950.
Side Loader Forklifts
Document No.
Developed by:
Revision No.001
15
Side loader forklifts have forks attached to the sides. The driver stands in a
sideways compartment as the side loader loads and unloads cargo on its side.
Since they pick up loads from the side, these vehicles are great for working in
narrow areas and can easily drive up alongside the rack and unload without
having to turn. This means they are perfect for handling long objects that other
forklifts can’t like metal pipes, sheets, and timber. However, unlike other
forklifts, they have limited ability to maneuver and handle other types of
palletized loads.
Side loader forklifts also come in three versions:
Enclosed cab
The enclosed can is mostly used for outdoor work.
Stand-up cab
The stand-up cab is typically used for indoor load transporting.
Multi-way truck
Document No.
Developed by:
Revision No.001
16
The multi-way truck comes with a mechanism that allows the wheels to rotate
90 degrees, allowing for efficient drivability and transport in all directions.
Telescopic Handler Forklifts
Document No.
Developed by:
Revision No.001
17
Also called the telehandler, this forklift comes with an extendable arm and a
boom, rather than a standard straight mast that is a characteristic of other
counterbalance or reach forklifts. They are also equipped with practical
attachments like a bucket, lift table, and a pallet fork at the end. This allows
them to reach a height of 40 to 57 ft and lift 5,500 to 10,000 lbs of weight. This
makes it seem more like a small crane than a forklift.
Telescopic handler forklifts are ideal for unloading cargo in odd angles and tight
spaces. Because of this ability, they are most often used in the construction
industry as well as the agricultural industry. And have replaced trough terrain
forklifts in both these sectors since they offer more flexibility and versatility.
Another big benefit of telescopic forklifts is that they offer the ability to access
both sides of the delivery truck with only one side; this increases the efficiency
of work. However, because of their larger size and complex design, they can
sometimes be a bit unreliable and are certainly much costlier than their
traditional counterbalance counterparts.
Some of the popular models of telehandlers are made by major brands like
Caterpillar, Bobcat, Genie and Haulotte.
Industrial Forklift
The large capacity forklift or the industrial forklift has the combined
functionalities of a warehouse forklift and a telescopic handling forklift. Although
it cannot access difficult spaces like a telehandler, it can take much heavier
loads to much higher heights than the other forklifts. The maximum weight it
can bear is 30,000 lbs, but you only need this amount of power in very
specialized jobs. Hence, industrial forklift only has a limited scope.
Some big names that manufacture industrial forklifts include the Mitsubishi and
NACCO Industries.
Pedestrian Operated Pallet Trucks
Document No.
Developed by:
Revision No.001
18
Pedestrian operated or hand pallet trucks are the most commonly used forklifts
in warehouses and stores. They operate on very simple principles with the
operator pushing the forks beneath the pallet, pumping the hydraulic jack to
raise the fork and moving the weight with the handle. The front wheels are
placed inside the forks and are separated vertically from the fork as it is lifted.
The hand pallet trucks come with limited functionality and are only able to
transport goods at ground level with limited height. They are also only capable
of holding loads of small size and weight.
Although these pallet trucks don’t have maneuverability or power, they are very
cheap. The most popular pallet jack models include the Mighty Lift 20 x 36 inch
Pallet Truck.
Walkie/Power Pallet Trucks
Document No.
Developed by:
Revision No.001
19
Walkie or power pallet trucks are very similar to hand pallet trucks, except that
they can lift and transport loads with the help of an electric motor. These
vehicles do not have cabs as they are quite small. Instead, the worker walks
behind the trucks and steer it with the handle. Although they have the same
limited maneuverability as hand pumps, they can reach greater heights and can
get off much higher off the ground.
These power pallet trucks also come with a paddle control with which you can
raise or lower the forks and make the vehicle move forward or backward. These
vehicles work the best on smooth surfaces.
Cherry Picker/Order Picker Forklifts
An order picker is a sub-category of a power pallet truck and can reach a height
of 32 ft. Its biggest advantage is that it is designed to lift the driver while they
Document No.
Developed by:
Revision No.001
20
are still operating the truck. This gives increased visibility and can help the
operator maneuver the goods in the correct position.
These order pickers are only designed to pick up one or two units rather than
entire pallets and work best in customer order warehouses.
Classification of Forklifts
Forklifts are also organized based on the classification, given by the

Occupational Safety and Health Administration (OSHA). The machines are
classified based on their usage and fuel type. A forklift operator must be
certified to use a certain type of forklift. The different forklift classifications are:
Class I: Electric Motor Rider Trucks
These trucks are usually designed for sitting operations although there are
some stand-up models, as well. These forklifts are counterbalanced by the
battery and one of their main benefits is that they produce no toxic emissions
and are very quiet. Hence, they are ideal for indoor use.
They are extremely flexible and can move right into the back of a tractor-trailer
to grab pallets. Some models also come with superior maneuverability and can
fit into tight spaces. They may also have weight-sensitive features that allow
them to work in spaces like old factories. They can typically carry a weight of
3,000 to 8,000 lbs but some manufacturers like Mariotti have models which can
carry loads that weigh up to 2,300 lbs.
Class II: Electric Motor Narrow Aisle Truck
These trucks can easily operate in narrow spaces like warehouse aisles, which
means they can access ore racking space without expanding your storage area.
Document No.
Developed by:
Revision No.001
21
Because of their compact size, many units are stand-up models, although some
sit-down versions are also available in the market.
Class II forklifts include reaching forklifts, which can reach up to load pallets or
order pickers, which come with a platform to raise or lower the operator. They
are usually used for picking up and putting away items.
Some side loaders also list under this class. They can support weights from
3,000 to 5,000 lbs.
Class III: Electric Motor Hand Truck
Electric motor hand trucks include forklifts like hand jacks and pallet trucks
which can only raise the load at a limited ground level. They come in both rider
and walk-behind versions and have excellent maneuverability due to their small
size.
Class III forklifts are hand-controlled and the operator can control them using a
steering handle or tiller which come with a paddle control. These forklifts are
great for use in small storage facilities. Walkies, both with straddle legs or
counterbalance, fall in this class.
These forklifts have a maximum weight capacity of 8,000 lbs.
Class IV: Internal Combustion Engine Trucks With Solid Cushion Tires
These forklifts come in sit-down designs and are made for indoor use. They
have solid cushion tires and their engines run on either petrol or diesel fuel.
Since they have cushioned tires, they ride low to the ground and are well suited
for low-clearance environments. They are perfect for moving pallets of items
from the loading dock to the storage area.
Weight capacity ranges from 3,000 to 15,500 lbs but some powerful specialized
models can support weight up to 80,000 lbs.
Document No.
Developed by:
Revision No.001
22
Class V: Internal Combustion Engine Trucks With Pneumatic Tires
These forklifts can be used indoors in large warehouses but are specifically
designed for outdoor work. They have a similar appearance and capabilities as
Class IV forklifts, except they have pneumatic tires. Some models which work in
lumberyard and construction sites may come with reinforced pneumatic tires to
prevent puncture.
These vehicles may either have a single-wheel or dual-back wheel configuration
and their engine is fueled by diesel, CNG, petrol or gasoline. They can support
loads with weight ranging from 3,000 to 55,000 lbs.
Class VI: Internal Combustion Engine Trucks With Pneumatic Tires
Class VI forklifts are also known as “tuggers” and they pull along rather than lift
loads. Models can be powered either by electric or internal combustion engines
and they are very versatile.
An example of this type of forklifts can be seen at airports in the form of a low-
rise tractor towing luggage carts from the terminal to the plane.
Document No.
Developed by:
Revision No.001
23
Class VII: Internal Combustion Engine Trucks With Pneumatic Tires
These forklifts are characterized by oversized tires which offer a lot of traction
for outdoor work on uneven, rough surfaces. They are almost always run by
diesel fuel and may also come with a straight or telescoping mast for increased
reach.
Class VII forklifts come in both two-wheel and four-wheel versions and are used
in construction sites and lumberyard where the load has to be lifted to highly
elevated areas. Operating them requires special training.
Class VII forklifts have a weight capacity range of 6,000 to 12,000 lbs and even
more in some cases.
How To Select a Forklift
To select a forklift, you first need to determine how it will be used. Here are
some aspects that you should check out:
Weight Capacity: How much weight do you need to lift and transport?
Terrain: Can the surface of the ground support the forklift? Is it flat and even or
rough?
Height: How high do you want to place your cargo?
Fuel: What kind of fuel do you need? Electricity, diesel, petrol or gas?
Document No.
Developed by:
Revision No.001
24
SELF CHECK 1.1-1
Multiple Choice:
Choose the best answer. Write the letter of your choice on your
answer sheet.
1. You need to haul a car from area A to area B which is 5km
away. You need:
a. An on-highway dump truck (rigid)
b. An off-highway dump truck (rigid)
c. An off-highway dump truck (articulated)
d. A flat-bed trailer
2. You need to haul 50 tons of gravel inside a quarry with flat

terrain. You need:
3. You need to haul 30 tons of sand from area A to area B

through 30km of concrete public highway. You need:
4. You need to haul rocks in the mountain through a make

shift road. You need:
Document No.
Developed by:
Revision No.001
25
5. This type of dump truck has a tractor and a trailer as part of
a two- part design.
Document No.
Developed by:
Revision No.001
26
6. This type of dump truck is designed to travel long

distances on cemented roads.
7. This type of dump truck has a large design that can carry
loads of up to 400 tons.
Document No.
Developed by:
Revision No.001
27
Answer Key 1.1-1
1. D
2. B
3. A
4. C
5. C
6. A
7. B
Document No.
Developed by:
Revision No.001
28
Information Sheet 1.1-2
Components structure of forklift and their
functions
1. Identify what are the Operator Serviceable (OS) parts
2. Identify the methods of checking if the Operator
Serviceable parts are in good working order.
Forklifts have many moving parts and pieces that allow the forklift to operate
properly. Understanding the terminology of the parts and anatomy of a forklift is
important for effective communication with others while on the job. Here are
some of the fundamental features and parts that make up the anatomy of a
forklift truck.
Document No.
Developed by:
Revision No.001
29
MAST
The forklift mast is the raised vertical support that allows loads to be raised and
lowered. For most forklifts, the mast is designed toward the front of a forklift
and directly in the forklift operator’s line of vision.
Forklift masts come with various sections that elevate or lower the forklift
carriage along with the forks. These include:
 Duplex: Two mast stages
 Triplex: Three mast stages
 Quad: Four mast sections
When selecting a forklift, it is important to familiarize yourself with the different
features and terminology of a forklift mast: the mast’s lift height, the free lift
height and the extended height and the lowered height. This will allow you to
select a forklift that is designed to fulfill the specific needs of your applications.
For more information on forklift masts, read our article Forklift Mast Types.
LIFT CYLINDER
The forklift lift cylinder powers the vertical movement of the mast, or the raising
or lowering of the forklift carriage and the forks. The lift cylinder is generally
hydraulically powered and is a single-acting hydraulic cylinder, meaning it
pushes in one direction.
TILT CYLINDER
Similar to the lift cylinder, the tilt cylinder controls movement for operation
purposes. The key difference is that the tilt cylinder controls the tilt movement
of the carriage and the angle of the forks relative to the ground.
FORKLIFT CARRIAGE ASSEMBLY

The carriage is a platform located in front of the forklift mast that is used to
mount objects to be controlled by the mast. This includes the forks of the
forklift, the load backrest and other features of a forklift truck that come in
direct contact with the loads.
Document No.
Developed by:
Revision No.001
30
FORKS
Perhaps the most obvious of reach truck parts are the forks themselves, also
known as the tynes. The forks on a forklift are used to make direct contact with
a load for transport. They are attached to the forklift carriage and are designed
to carry a load from the bottom. Forklift forks come in all shapes and sizes.
There is a wide variety of fork types available for various applications. Standard
ITA forks are the most common type of forklift forks, but they too come in
various widths, lengths and shapes.
LOAD BACKREST
The forklift backrest provides the operator another surface to rest the load
against and is attached to the carriage. This helps prevent the load from
slipping backwards toward the forklift operator during lifting and travel
conditions. The forklift backrest also helps protect the forklift mast and mast
components from being damaged by the load.
It is important to use a load backrest that is designed for the forklift. It is also
important to never remove the backrest before operating the forklift for your
own safety as well as the well-being of the forklift.
COUNTERWEIGHT
The counterweight is the weight installed onto the forklift to help offset the
weight being lifted by the forklift. This helps keep the forklift stable during lifting
and traveling operations. Forklifts are designed with maximum carrying
capacities using the counterweight for balance, so it is important to know the
carrying capacity intended for the forklift. Check the rating plate on the forklift
for this information.
Internal combustion forklift counterweights are located toward the back of the
forklift, or on the opposite side of the forks. For electric lift trucks, the battery
acts as a counterweight.
POWER SUPPLY
The power supply refers to the power source of the forklift, which can include an
engine or batteries depending on the type of forklift. Forklifts can be electric
Document No.
Developed by:
Revision No.001
31
(battery powered), diesel, gas or propane powered. For internal combustion
forklifts, the engine is typically located toward the back of the forklift, below the
seat. Propane powered forklifts often have the tank externally mounted for
easier access.
TIRES
All forklifts need tires to operate, but the types of tires and layout of tires on the
forklift can vary significantly. Forklifts that use four tires are capable of lifting
heavy loads and are versatile for many applications. Three-wheel forklifts are
ideal for indoor environments where space is limited and the ability to turn and
maneuver efficiently is important.
There are two main types of forklift tires:
Cushion Tires – Generally used for forklifts operating indoors, where surfaces
are flat, smooth and consistent. Cushion tires are generally less expensive and
easier to maintain, but lack the traction pneumatic tires offer. Cushion tire
forklifts are ideal in warehouses and other indoor environments where small
turning radiuses are necessary.
Pneumatic Tires – Pneumatic tire forklifts are generally used for operating
outdoors, where surfaces can be uneven, rough or variable. Pneumatic tires are
more similar to your car’s tires making them better at handling non-paved and
rough-terrain surfaces. Pneumatic tires can be air pneumatic tires, meaning
they are filled with air, or solid pneumatic tires, meaning they are made entirely
out of solid rubber.
WHEELS
Drive Wheels
The drive wheels provide the necessary power for the forklift to travel and are
often larger than the steering wheels as they are responsible for bearing a large
amount of mass during operation.
Steering Wheels
The steering wheels are generally located in the rear of the forklift and facilitate
the steering of the forklift. It is easier to control the movement of the forklift
using the rear wheel or wheels.
Document No.
Developed by:
Revision No.001
32
OPERATOR CAB
The forklift cab can be open or enclosed depending on what options are chosen.
It is the space of the forklift where the forklift operator controls and operates
the truck. The cab contains a variety of forklift controls and operating
components and features used to maneuver and manipulate the forklift. These
include, but are not limited to: The brake pedals, the steering wheel, mast
controls, acceleration pedals, inching pedal, parking brake, levers, and gauges.
OPERATOR SEAT
If operating a sit-down forklift, the seat will be located in the operator cab.
Some forklifts are designed to have the operator stand. Whether you’re
operating a sit-down or stand-up forklift, it is important that the forklift operator
is seated or standing in the location deemed appropriate by the Operation and
Maintenance Manual for that particular forklift.
OPERATOR STEERING WHEEL

The operator steering wheel controls movement of the rear wheels or steering
wheels of the forklift. Some steering wheels have a knob attached to the wheel
to enable faster turning.
LEVERS
There are various levers located in front of the seat that control movement of
the mast and forks. These forklift levers can include:
 Tilt Lever – controls the angle of the forks relative to the ground.
 Lift Lever – controls the height of the forks.
 Side Shift Lever –controls horizontal movement of the carriage.
RATING PLATE OR CAPACITY PLATE

The capacity plate is featured on the front of a forklift and tells operators
detailed information about the forklift. This will include model carrying capacity,
lift heights, forward and back tilt degrees, tread width, tire information and
other safety information. It is important for all forklift operators to read and
understand the information on the rating or capacity plate before operating the
forklift.
Document No.
Developed by:
Revision No.001
33
OVERHEAD GUARD
The overhead guard is a critical feature of a forklift’s safety. The overhead
guard’s purpose is to help protect the operator should something fall onto the
forklift cab.
Forklifts are designed to help minimize the potential for objects falling, from
loads, on top of the overhead guard. However, factors like accidental bumps or
misplaced loads can result in an object falling on top of the forklift cab. Always
properly secure loads and follow the operator’s manual instructions prior to
lifting any load.
Document No.
Developed by:
Revision No.001
34
SELF CHECK 1.1-2A
Multiple Choice:
Choose the best answer. Write the letter of your choice on your
answer sheet.
1. What can fail due to corroded battery terminals?

a. Wiper blades
b. Gas Tank
c. Starter
d. Intake Manifold
2. Which of the following is not a result of tire underinflation?
a. Underinflated tires can crack, bulge, or explode under load
b. Underinflated tires increase the fuel consumption of your
truck by increasing the resistance of the tires and the
road
c. Underinflation increases the treadwear on the inner
edges of the tire making the tire age faster
d. Underinflation increases the treadwear on the outer
edges of the tire making the tire age faster
3. What is likely to happen when you drive your Rigid on-
highway dump truck through a flooded area
a. You might get water in your fuel line
b. You might get water in your tires
c. You might get water in your electrical system
d. You might get water in your brakes
4. Which is not a symptom that your wiper blades need replacing?
a. Skipping
b. Skating
c. Splitting
d. Squeaking
Document No.
Developed by:
Revision No.001
35
SELF CHECK 1.1-2B
1. Over-inflated tires have no negative consequence
2. Modern engines can combust water
3. The alternator charges the battery through its terminals
4. A cracked fan belt can be fixed with grease
5. Damaged wiper blades are not dangerous
Document No.
Developed by:
Revision No.001
36
ANSWER KEY
SELF CHECK
1. B
1.1-2A
2. C
3. C
4. A
5. B
SELF CHECK 1.1-2B
Document No.
Developed by:
Revision No.001
37
1. FALSE
2. FALSE
3. TRUE
4. FALSE
5. FALSE
Document No.
Developed by:
Revision No.001
38
LEARNING OUTCOME NO. 2
Perform visual check of equipment
Contents:
1. Specification, Limitations and Classifications of Forklift based on
Operations and maintenance manual.
Assessment Criteria
1 Forklift and its lifting capacity is selected based on job requirements.
2 Operator serviceable (OS) parts are checked in accordance with equipment
checklist and manufacturer’s procedures.
3 Walk-around check is performed with equipment checklist and with engine
stopped/not running.
Conditions
The participants will have access to:
4. Unit of Equipment (Forklift)

5. Forklift operations and maintenance manual
6. Handouts/Instructional Materials
Assessment Method:
4. Written Exam
5. Oral Questioning
6. Task Sheets
Document No.
Developed by:
Revision No.001
39
Learning Experiences
Identify forklift types/ components structure
Learning Activities Special Instructions

1. Listen To the lecture / discussion Read and understand the
of your trainer on the Kinds and information sheet and check
uses of hauling equipment yourself by answering the self-
check. You must answer all
questions correctly before
proceeding to the next activity.
Answer self-check 1.2-1
Compare the answers of self-
check 1.1-1 to the answer key
on the Different operator yourself by answering the self-
serviceable parts and how check. You must answer all
to identify their problems questions correctly before
proceeding to the next
activity.
3. Watch the demonstration Read and understand the
of your trainer carefully information sheet. After,
and practice Performing practice the steps of the walk
the walk around check in around check. You must be
accordance with the walk able to perform the Task Sheet
around checklist before proceeding to the next
activity.
Perform Task sheet
1.2-1
Compare your performance
to the performance criteria
checklist
Document No.
Developed by:
Revision No.001
40
Information Sheet 1.2.1
Specification, Limitations and Classifications of
Forklifts based on Operations
1. Identify the different kinds of forklift equipment
2. Choose the right type of equipment for the job requirement
Forklift Trucks
Introduction
This article takes an in depth look at forklift trucks regarding their use and
types.
You will learn more about topics such as:
 What is a Forklift Truck?

 Types of Forklift Trucks
 Uses for Forklift Trucks
 Safety Measures for Forklift Trucks
 Regulations for Forklift Trucks
 And Much More ...
Document No.
Developed by:
Revision No.001
41
Chapter One – What is a Forklift Truck?
A forklift truck is an electrical or gas powered industrial piece of equipment with

a metal fork platform attached to its front that can be used to lift heavy loads
by inserting the fork platform under cargo, pallets, or machines for moving
them or placing them in storage. The truck frame of a forklift truck forms the
base for its lifting and includes wheels, counterweights, a carriage, and a mast.
The two types of engines for forklift trucks are electrical or gas with gas being
Liquefied Petroleum Gas (LPG), compressed natural gas (CNG), diesel, or natural
gas. Electric forklift trucks get their power from rechargeable lead acid batteries
or fuel cells.
Forklift trucks are used in warehouses, manufacturing and industrial operations,

shipping docks, and truck loading and unloading. Since they come in a wide
variety of sizes and power sources, they are found at small businesses and
large complex industrial manufacturing operations. Their applications and uses
are endless.
Document No.
Developed by:
Revision No.001
42
Chapter Two – Types of Forklift Trucks
Forklift trucks are designed to safely and efficiently lift heavy loads that are
beyond human capabilities. They are an indispensable tool that helps to
increase the productivity of a work site and process while keeping workers
protected. The description of a forklift truck is based on its classification, which
includes its workload, capacity, size, terrain, and any special features or
capabilities it may have.
Heavy loads come in as many types as there are pieces of equipment to lift
them. Forklift trucks used to make those lifts have to have the components
necessary to easily and safely lift a heavy load as well as be able to place it.
Each forklift truck is chosen to fit the needs of the industry it serves and meet
the needs of that industry’s workload.
Forklift Truck Types
Articulated Forklift
Articulated forklift trucks, also known as swing mast forklift trucks, are able to
load and unload materials in narrow aisles. The fork platform of an articulating
forklift truck can be turned right or left without having to move the truck. This
allows the truck to face in a straight line as the forks are turned or twisted to
access the load. They are ideal for small spaces, small trucks, and cold storage
units.
Document No.
Developed by:
Revision No.001
43
Counterbalance Forklift
Counterbalance forklifts are one of the most common forms of forklifts and
come in three and four wheel models. The forks of a counterbalance forklift
truck stick out from the front of the truck with legs or arms for stabilization. The
name of a counterbalance forklift truck comes from the counterweight at the
rear of the truck behind the motor. It is positioned such that it compensates for
heavy loads.
The turning radius of a counterbalanced forklift truck is very wide, which limits
its operational area. Their classification requires that they be operated on level
ground. A unique feature of counterbalance forklifts is their ability to drive right
up to a load instead of reaching for it. This ensures a safe lift and a tight
connection between the load and the forklift.
Document No.
Developed by:
Revision No.001
44
Side Loader Forklift
Side loader forklift trucks lift loads from the side and are a narrow aisle form of
forklift truck. While the truck for a side loader forklift truck runs in a straight
line, its forks hang off to the side. This design makes them ideal for narrow
aisles where other forklift trucks cannot maneuver. Side loader forklift truck
forks are mounted perpendicular to the body and the direction of the truck’s
movement and can rotate 90o with a load.
There are two possible operating positions for a side loader forklift truck, which
are a man up or man down. In the man up model, the operator is close to the
load. With the man down version, the operator manipulates the forklift truck
while standing on the ground. This particular design is one of the many features
of side load forklift trucks, which makes them a very flexible and adaptable
piece of equipment.
Document No.
Developed by:
Revision No.001
45
Reach Forklift
Reach forklift trucks are a form of narrow aisle forklift used in warehouses and
have two outer legs to distribute the load with a set of wheels in the back
located below the operator. They have a long horizontal platform behind the
mast that allows the forklift to pick up bulky and heavy items in high places.
The popularity of reach forklift trucks is due to their ability to provide portability
and stability that larger and more powerful units cannot provide. They use their
elevated platform to access tight spaces where there is limited headroom.
Document No.
Developed by:
Revision No.001
46
Turret Forklift
A turret truck forklift is a counterbalanced narrow aisle forklift and has an

articulating base that rotates the forks 180o. They are ideal for order picking in
high rack warehouses and have navigation systems that help them avoid
obstacles. Turret trucks can fully rotate their forks while their truck remains
immobile. The main mast and front mast of a turret truck forklift extends much
higher than a typical forklift, while its steering and safety features are the same
as a counterbalanced forklift truck.
Document No.
Developed by:
Revision No.001
47
Rough Terrain Forklifts
A rough terrain forklift truck is designed to be driven over uneven, rocky, and
pot hold surfaces while carrying heavy loads. They are large, heavy, and have
tires designed to withstand the demands of a rough rugged surface. Three of
the types of rough terrain forklift trucks are telehandler or telescopic, rotating
telehandler, and straight mast.
Telehandler or Telescopic – A telehandler forklift truck has a telescoping boom

that allows it to pick and place loads at various distances and heights. They are
capable of lifting full loads from 18 feet up to over 50 feet with a load capacity
of 5500 lbs. too close to 12,000 lbs. Telehandlers have all wheel steering to
easily position a load close to the work site. The boom’s movements are
controlled by a joystick for movement and placement of loads.
Document No.
Developed by:
Revision No.001
48
Rotating or Roto Telehandler – Rotating telehandlers are set on a base that
allows them to rotate a full 360o, which means that the boom and operator
rotate while the base remains immovable. As with the standard telehandler
forklift truck, rotating telehandlers have a telescopic boom that is able to reach
higher and move heavy loads. The motor and engine for a rotary telehandler
are located in the lower section with the wheels and chassis.
Document No.
Developed by:
Revision No.001
49
Straight Mast – As with telehandler forklift trucks, straight mast forklifts are
designed for loading and unloading of exceptionally heavy items. They are
easily maneuverable and accessible due to their heavy duty pneumatic tires,
which are larger than other rough terrain forklift trucks. Straight mast forklift
trucks come in three and four wheel versions and are powered by propane or
diesel fuel.
Chapter Three – Stand Up Forklifts
The traditional view of a forklift is a driver seated in a cab with a steering wheel
and levers to manipulate the boom and forks. Although this is the common
view, it does not apply to all forklift maneuvering methods. The type of forklift
where the operator sits or stands in the forklift is referred to as a sit down
forklift where the driver does not have to move to make a lift or place a load.
Another version of a forklift truck is referred to as a stand up forklift truck where

the operator frequently leaves the truck to load and unload items, stack
inventory, or scan barcodes. There is a wide assortment of stand up forklifts,
Document No.
Developed by:
Revision No.001
50
which include order pickers, pallet jacks, stand up trucks, double deep trucks,
saddled trucks, and walkie stackers.
Order Picker Trucks
Order picker trucks function like a forklift and are controlled from a carriage on
the truck where the operator is able to maneuver and position it. They have
fixed forks or a working platform that is used to load products during the picking
process. The forks on an order picker truck are set in a fixed static position and
raised and lower with the operator. They make it possible to carry a pallet for
loading or picking up items. The platform can raise the operator to pick items
from warehouse racks and can reach heights of near 40 feet or higher.
Stand Up Trucks
A stand up forklift truck makes it easy for the operator to hop on and off. They
are a three wheel type of forklift that can turn easily in tight spaces. Stand up
trucks have a counterbalance that is similar to a full sized counterbalanced
forklift but in a smaller size. They are normally battery powered and operate
Document No.
Developed by:
Revision No.001
51
very quietly. The design of stand up forklifts makes it possible for them to
operate in close quarters and narrow aisles. Their movement is powered by a
pedal on the floor for the operator platform while a handle controls the direction
or steering.
Double Deep Forklift
Double deep forklift trucks are designed to work with double deep pallet
racking. The forks on a double deep forklift truck can be extended to reach into
double deep racking and have an outrigger to counterbalance the weight of
loads. They can reach further and handle heavier loads than single reach
forklifts.
Document No.
Developed by:
Revision No.001
52
Walkie Forklifts
A walkie forklift is a walk-behind forklift that has a mast for lifting pallets. It has
a similar function as a counterbalanced forklift and operates well in narrow
aisles and tight spaces. They are commonly used to move and position pallets
much like a pallet jack and are a perfect alternative for larger forklifts and small
warehouse operations.
Power for a walkie forklift can be manual or powered. For the manual version,
the forklift has a peddle or handle that is pumped to raise the forklift’s forks.
When the load needs to be lowered, a button is pushed to release the pressure.
The powered version has buttons for raising and lowering the load as well as
moving the forklift.
Document No.
Developed by:
Revision No.001
53
Chapter Four – Components of a Forklift
Truck
Forklift trucks are heavy duty industrial vehicles that are used for moving,
positioning, loading, and unloading materials and products. They have
distinctive components made of resilient and strong metals that are capable of
withstanding stressful and demanding working conditions. Since their
introduction in 1867, in the middle of the first industrial revolution, forklift
trucks have become an essential safety device used for industrial and
manufacturing operations.
Each of the elements of a forklift truck is carefully chosen to meet the standards
of the Occupational Safety and Health Administration (OSHA), which has
classifications and regulations regarding the weight capacity and performance
of forklift trucks. Each part, from the motor to the lifting forks, is selected to fit
specific working and lifting requirements.
Forklift Truck Parts
Document No.
Developed by:
Revision No.001
54
Frame or Chassis
The frame of a forklift truck forms the foundation upon which the elements of
the forklift rests and is the basic part of all forklifts. The mast, wheels, and
counterweight are attached to the frame as well as the engine, motor, and
lifting components.
Counterweight of a Forklift
The counterweight is attached to the rear of the forklift and is designed to

counterbalance the lifted load. In battery operated forklift trucks, the weight of
the battery may be sufficient to serve as the counterweight. When a load is
lifted, the load is kept as near as possible to the front wheels to keep the load
centered. The counterweight keeps the forklift from tipping forward.
This particular aspect of forklift truck operations is for which OSHA has
established classifications to protect workers and ensure forklifts are only lifting
loads that meet their abilities.
Document No.
Developed by:
Revision No.001
55
Power Source
The power source for forklifts can be electricity or gas with electric forklift trucks
running on huge industrial size batteries and gas forklift trucks using internal
combustion engines. The main types of gas fuels are diesel, liquid petroleum
gas (LPG), compressed natural gas (CNG), and gasoline.
The electric motors for forklift trucks can be direct or alternating current
powered by batteries or fuel cells. They need to be charged for eight hours to
be able to operate at maximum efficiency. Although electric forklifts have an
initial higher expense, they rarely need upkeep or maintenance and can run for
over five years. They have superior maneuverability compared to gas operated
forklifts and have a noiseless startup.
Gas powered forklift trucks are more widely used than electric forklift trucks.
They are less expensive and have greater versatility. Their high speed
acceleration and operation assists in warehouse efficiency and effectiveness.
They do need regular maintenance and have to be checked several times a year
for gas usage, oil, worn parts, and potential mechanical failures, which is
unnecessary for electrical forklift trucks.
Document No.
Developed by:
Revision No.001
56
Forklift Carriage
The carriage is the part of the forklift onto which the forks are mounted. It is
connected to the mast such that it moves the forks up and down. The motion of
the carriage is created by a chain drive or hydraulic cylinder with rollers or
bushings to guide it. Carriages are classified by their lifting capacity and height,
which is the distance between the top edge of the carriage and the lower edge
of the fork bar. The five classifications for carriages are:
Class 1 – Carriage height of 13 inches with a lifting capacity of fewer than 1.1
tons.
Class 2 – Carriage height of 16 inches and lifting capacity between 1.1 and 2.75
tons.
Class 3 – Carriage height 20 inches and lifting Capacity: Between 2.75 and 5.5
tons
Class 4 – Carriage height of 25 inches and lifting capacity: between 5.5 and 8.8
tons
Class 5 – Carriage height of 28.7 inches and lifting capacity between 8.8 and 12
tons.
Carriage classifications are a shorthand way for determining the type of forklift
truck for a job and provide a clear understanding of its forks and capabilities.
Mast of a Forklift Truck
The mast of a forklift truck, also known as its upright, is the vertical assembly
that raises and lowers loads. It includes interlocking rails that provide lateral
stability with rollers or bushings as guides. The mast has an elevating
mechanism that involves the use of a hydraulic cylinder and chain drives with
multiple sections that work together to lift loads. There are four types of forklift
masts that are categorized by their number of stages.
Included in the description of forklift truck masts is the term free lift, which
refers to the height an operator can raise the forklift’s forks without having to
change the mast height.
Document No.
Developed by:
Revision No.001
57
Single Stage: A single stage mast or simplex mast has one channel and has a
limited lifting distance. They have a stationary outer rail and a sliding inner rail
with a chain drive for lifting. Single stage forklift trucks do not have free lift.
Two Stage: A two stage mast or duplex mast has a hydraulic cylinder in the
middle of the mast to push loads up, which allows loads to rise as the mast
remains stationary. When the carriage reaches the top of the inner rails, the
side rails complete the lifting of the load. The inner section raises the carriage
and forks while the outer section remains motionless.
Three Stage: The three stage or triplex mast is the most common type of forklift
truck mast. The mechanism has two sliding rails, a stationary rail, and a large
hydraulic cylinder at the center of the mast that does most of the lifting.
Secondary hydraulic cylinders lift the middle section and chain system, which
pulls the inner section and carriage at full extension. Three stage masts provide
for free lift.
Four Stage: Of the four types of masts, the four stage or quad mast has the
highest reach. It has four sets of moving rails and chains with restricted visibility
through the mast due to the complexity of the mechanism. The productivity of a
four stage mast is dependent on powerful secondary hydraulic cylinders, rails,
Document No.
Developed by:
Revision No.001
58
and chain drives, which give it free lift and the ability to reach the highest of the
four mast types. The intricacy of the four stage mast requires special training
and certifications to be able to operate it.
The selection of a forklift truck is contingent on the overhead clearance of the
facility where it will be used since that is the physical restriction in regard to the
type of mast a forklift will have. A forklift truck’s carriage and forks should be
able to reach the highest shelves in a facility with a six inch gap. The height of
the mast is determined by the distance from the floor of a facility to the top of
the mast, which is referred to as its fully extended height. The lowered height is
the distance from the floor to the top of the fully lowered mast.
Lift Cylinder
The lift cylinder of a forklift truck provides the power for the vertical movement
of the mast that raises and lowers the carriage and forks. Lift cylinders are
hydraulically powered and push in one direction. A control valve directs
hydraulic fluid flow to the cylinder when completing a lift.
When the control valve is moved to the lower position, the weight on the mast
forces the fluid to flow back to the storage tank. The back flow is carefully
regulated by the control valve to ensure a smooth and even lowering motion.
Tilt Cylinder
The tilt cylinder is a double acting cylinder that can push or pull a load. Most
forklift trucks have two tilt cylinders connected to the stationary rails of the
mast. The placement of the tilt cylinders provides for uniform movement control
and prevents the mast from shifting from side to side.
Forks or Tines
The forks or tines make contact with the load and are attached to the carriage.
They make the connection with the bottom of the load and come in varying
shapes, lengths, and sizes. Forklift forks are long extensions, much like arms,
Document No.
Developed by:
Revision No.001
59
capable of supporting the load. The types of forks for a forklift truck match
carriage classifications for carriage height and capacity.
The dimensions and conditions of the forks guarantee the safe operation of a
forklift and prevent possible damage. They need to be inspected regularly for
cracks, straightness, and angle. Hooks should be checked for cracks, exterior
damage, and wear.
Tires and Tire Layouts
There are a wide variety of forklift tires and tire layouts. Four wheel forklift
trucks are capable of lifting huge loads and function successfully in many varied
applications.
Three wheeled forklifts are ideal for narrow aisles and where space is limited.
They turn efficiently and easily. The two common types of tires are:
Cushion Tires: Cushion tires are made of solid rubber and are less expensive to
make and easy to maintain. They are designed for indoor forklift use on smooth
Document No.
Developed by:
Revision No.001
60
even surfaces. Cushion tires are easier to maneuver in cramped small spaces
due to their smaller turning radius and are capable of lifting up to 8 tons.
Pneumatic Tires: Pneumatic tires are like car and truck tires and can be used on
uneven surfaces and rough and rugged terrain. They come in a solid form made
of solid durable rubber, which makes them puncture resistant. Air pneumatic
tires are air filled.
Chapter Five – Forklift Truck Classifications
Forklift trucks are grouped according to their size, weight limit, operational
terrain, and power supply. The Occupational Safety and Health Administration
(OSHA) has developed seven classifications or categories for forklift trucks
based on those factors. Each classification requires operators to be certified for
the class they operate.
Class I Forklifts
Class 1 forklifts are electrically powered by industrial batteries and electric

motors. They can have pneumatic or cushion tires with three or four wheel
designs. The lifting capacity for class 1 forklift trucks is between 1.5 tons to 4
tons.
Class II Forklifts
Class 2 forklifts also run on electric motors and are made for narrow spaces.
They have a lifting capacity of 1.5 tons to 2.5 tons.
Class III Forklift
Class 3 forklifts are designed to lift loads a small distance off the surface and
are stand up forklifts where the operator stands next to the truck and uses hand
controls. They are used for loading and unloading trucks and have a capacity of
4 tons.
Class IV Forklifts
Document No.
Developed by:
Revision No.001
61
Class 4 forklifts have cushion tires for warehouse use and where there are
smooth and dry surfaces. They are gas powered forklifts with propane or diesel
motors. Class 4 forklifts have a sit down design with a lifting capacity of 1.5 tons
to 7.75 tons.
Class V Forklifts
Class 5 forklifts have pneumatic tires and can lift very heavy loads between 1.5
tons to over 25 tons. They are powered by natural gas, liquid propane, or
gasoline and can be used indoors or outdoors. Class 5 forklift trucks are the
most common type of forklift in use and are sit down types.
Class VI Tractors
Class 6 tractors are known as tuggers or tow tractors and are used for towing.
They do not have forks and are a tractor type heavy duty vehicle that can be
found at airports. Class 6 tractors can be electrically or internal combustion
powered with a towing capacity of 1.5 tons to 3 tons.
Class VII Forklifts
Class 7 forklifts have large tractor type tires and are designed for heavy,
rugged, and rough terrain use. They have diesel fueled engines and require
special training for licensing and certification. Class 7 forklift trucks have a
capacity of 3 tons to 6 tons or more. Many models of class 7 forklifts are
equipped with telescoping booms to enhance their reach.
Document No.
Developed by:
Revision No.001
62
Chapter Six – Things to Consider When
Purchasing a Forklift
Forklift trucks are a ubiquitous piece of heavy duty equipment found in a wide
range of industries. They are a rugged and durable method for moving goods,
products, supplies, parts, and components from one location to another without
damaging facilities or harming staff. Introduced in the middle of the first
industrial revolution, forklifts have become necessary in the rapidly growing
industrial world.
Regardless of their many values, it is important to select the right forklift to fit
an application since ones that are too small can be damaged by over capacity
lifting and ones that are too large can be wasted on light loads. There are three
important factors to consider when choosing a forklift truck.
Capacity of Load
The type of load is the first consideration in the selection process since it will be
the main factor in regard to how safely the forklift will be able to handle the
Document No.
Developed by:
Revision No.001
63
workload. Multistage masts, articulated movement, and heavy duty forks may
not be necessary for a narrow aisle warehouse. Side loader forklifts or turret
forklifts may be more suited for such conditions and have the right capacity.
Forklift Truck Versatility
Versatility is one of the reasons that forklift trucks have been used by industry
for close to 200 years. There is a forklift to fit any lifting and loading conditions.
Free lift multistage masts allow the flexibility for reaching extreme shelf heights
in narrow aisles. Triplex swinging mast forklift trucks offer a great deal of
freedom of movement and adjustment.
Cost of Forklifts
In many cases, the cost is the first factor that buyers use as the determining
factor for the purchase of equipment. Although this is a necessary
consideration, it cannot be the sole deciding factor. A key component of forklift
use is safety since it is the means for lifting heavy loads without the need for
manual labor. The two factors that need to be considered in the purchase of a
forklift are the initial cost compared to the increased benefits over time.
Amortized over years of use, a highly versatile and highly functional forklift
truck will pay for itself in efficiency, improved product movement, and labor
savings.
Chapter Seven – Forklift Truck Benefits
Forklift trucks are one of the most dynamic and useful tools for any operation.
They smoothly, effortlessly, and safely minimize time on task and remove
repetitive actions. Today’s forklifts make it possible to reach the highest shelf in
a storage facility without endangering equipment or personnel.
Lifting Capacity
Forklifts are compact machines that can work indoors or outdoors, in cramped
and narrow spaces, and on rough and rugged terrain. They can lift the heaviest
Document No.
Developed by:
Revision No.001
64
of loads and safely place them with precision and ease. The capacities of
forklifts range from a little over a ton to more than 12 tons, making it possible
to select the perfect forklift for the conditions and loads.
Forklift Maintenance
Proper and regular maintenance is an essential part of the care for any type of
heavy duty machinery. In the case of a forklift, maintenance and upkeep are
easily completed and ensure a forklift’s years of usefulness.
Safety of a Forklift Truck
During the first industrial revolution, unsafe conditions were the main cause of
worker deaths since there was little protection from the dangers of equipment
and lifting was handled manually. The inception of the forklift was a major step
in the efforts to protect workers and save their lives. This foundational principle
is still the hallmark for the use of forklifts. In some companies, attempting to lift
a heavy load without a forklift can lead to a reprimand or disciplinary action.
Every company has a set of standards for forklift operations and requires all
forklift operators to be certified. Although there are standards established by
OSHA, manufacturers have developed their own requirements that exceed
those from OSHA and specifically fit their manufacturing processes.
Conclusion
 A forklift truck is an electrical or gas powered industrial piece of equipment with

a metal fork platform attached to its front that can be used to lift heavy loads
by inserting the fork platform under cargo, pallets, or machines for moving
them or placing them in storage. The truck frame of a forklift forms the base for
its lifting and includes wheels, counterweights, and a mast.
 Forklift trucks are an essential safety tool that protects workers from injury
associated with picking and lifting heavy materials.
 Forklift trucks are designed to safely and efficiently lift heavy loads that are
beyond the capabilities of humans. They are an indispensable tool that helps to
Document No.
Developed by:
Revision No.001
65
increase the productivity of a work site and process while keeping workers
protected.
 Forklift trucks are grouped according to their size, weight limit, operational
terrain, and power supply. The Occupational Safety and Health Administration
(OSHA) has developed seven classifications or categories for forklift trucks
based on those factors.
 Forklift trucks are one of the most dynamic and useful tools for any operation.
They smoothly, effortlessly, and safely minimize time on task and remove
repetitive actions. Today’s forklifts make it possible to reach the highest shelf in
a storage facility without endangering equipment or personnel.
Information Sheet 1.2-3

BLOWAF (Battery, Lights,
Oil, Water, Air, Fuel)
1. Perform the pre-operation walk around check
2. Identify all the parts to be checked during the pre-
operation walk around check
Even before stepping into the cab of the Rigid on-highway dump
truck, you can already spot plenty of possible problems from the
way your unit looks. Here you will learn to spot the telltale signs
of problems of your dump truck during the pre-operation walk
around check.
With the term “walk around” you will have to walk around the
outside of the dump truck while looking closely at certain parts to
ensure that there are no problems with them and that your dump
truck is ready before you proceed to the more thorough “BLOWAF”
check.
1. Leaks
First check your unit for leaks. Looking underneath your dump truck
Document No.
Developed by:
Revision No.001
66
will show any leaks or puddles forming underneath it. If you find a
leak or a puddle underneath, check immediately to see if it is
water, oil, coolant or any other liquid your dump truck may use. If it
is water, check to see if it is coming from the radiator or from air
condition condensation. If it’s the latter, then there’s nothing to
worry about. If it’s the radiator, or if you find any other liquid
dripping or pooling under the dump truck, inform your mechanic
immediately.
2. Worn out/damaged/missing parts
Next check you dump truck for any worn-out parts that’s visible to
the naked eye. It’s important to replace worn out parts immediately
to keep your dump truck in good working condition.
3. Fluid levels
Fluids are the life blood of any truck. Your dump truck needs the
right amount of fluids to continue to operate properly, running out
of even one type of fluid may damage parts of the dump truck to
beyond repair.
Aside from fuel, there are 5 different fluids that run through your truck.
- Brake Fluid
- Engine Oil
- Gear Oil
- Hydraulic Oil
- Coolant
From these 5, the ones that you should check during the walk
around check are the brake fluid, engine oil, and coolant.
Checking these fluids is easy. For the brake fluid and coolant, you
have to check their respective tanks to see the fluid levels. Always
maintain fluids between min. and max. level.
As for the engine oil, engines commonly have what’s called a

dipstick located at the center of the engine. Pull the dipstick out
and clean the tip before putting it back in again. Pull it out a second
time to see the level of engine oil in your engine. Again, the oil
level always has to be between min. and max. Note that it is best
to do this before you first start the engine in the morning while all
the oil is in the oil pan.
4. Tires
Document No.
Developed by:
Revision No.001
67
Your tires play an integral role in the performance of your truck and
keeping you safe. Well performing tires ensure the dump truck’s
traction to the road to prevent slipping. We also learned in
information sheet 1.1-2 the dangers of over or under inflated tires.
To check the inflation of your tires, you need to use a tire pressure
gauge. Simply remove the rubber cap on the wheel and connect
the tire pressure gauge. Note that the tire pressure requirements of
big trucks such as this go up to 120psi. So, make sure your gauge
is capable of measuring it.
Aside from its inflation, you also need to check the physical state of
your tires. Here are the following signs you need to look out for. If
you see any of the following, request for repair or replacement
immediately.
Document No.
Developed by:
Revision No.001
68
- Cracked/Tread separation/Tread wear
- Bulging
- Imbedded materials
Document No.
Developed by:
Revision No.001
69
- Damaged rim
5. Side Mirrors
Side mirrors are an important part of your visibility once you start
operating your dump truck. Check your side mirrors for any cracks,
dirt or grime that have accumulated on the glass. If it’s dirty then
clean it immediately, if it’s cracked, then replace.
6. Cab Condition and Windshield
Next, check the condition of the cab and its windshields for dirt,
grime or damage. Keeping your cab clean will help keep the cab
from rusting and at the same time help you see better out of
your windshield. If there is any damage, arrange for it to be
repaired at the soonest possible time.
7. Wipers and Wiper fluid
Lastly, the wipers have to be in good working order, while the wiper
fluid should be refilled if it gets too low. You learned in the
Information sheet 1.1-2 regarding the proper maintenance of
wipers.
Now that you know the things you need to check for your pre-
operation check, follow each step while going around the dump
truck, checking each part carefully. You should be able to check all
the parts of this checklist in one or two walk arounds of the truck to
save time.
Document No.
Developed by:
Revision No.001
70
SELF CHECK 1.1-3
Identification:
Identify the subject pertained by the question
1. This is the life blood of your dump truck. Without it, your
dump truck will not operate properly.
2. Engines commonly have a that is used to check
engine oil levels.
3. If you find puddles underneath your dump truck, you probably have
a
.
4. To check the tire pressure, you need a .
5. If you find missing parts, you should it immediately.
Document No.
Developed by:
Revision No.001
71
Answer Key
SELF CHECK
1.1-3
1. Fluids
2. Dip Stick
3. Leak
4. Tire Pressure Gauge
5. Replace
1.
Document No.
Developed by:
Revision No.001
72
TASK SHEET 1.1-3
Title: Perform Pre-operation Walk Around Check
Performance Objective: Provided with the proper

equipment, you should be able to perform a
walk around check efficiently and effectively
Supplies/Materials: Pre-operation walk around checklist
Equipment: On-highway Dump Truck (rigid)
Steps/Procedure:
1. Approach On-highway dump truck (rigid)
2. Check underneath the dump truck for leaks
3. Check for worn out, damaged or missing parts on the

outside of the dump truck
4. Check brake fluid levels
5. Check engine oil level
6. Check tire pressure and look for signs of damage
7. Check side mirrors
8. Check cabin condition and windshield
9. Check wipers and wiper fluid
Assessment Method:
Performance assessment using performance criteria checklist
Document No.
Developed by:
Revision No.001
73
PERFORMANCE CRITERIA
CHECKLIST 1.1-3
Document No.
Developed by:
Revision No.001
74
CRITERIA Y NO
E
S
Did you check under the dump truck properly?
Did you do a thorough check on all the external

parts of the dump truck?
Did you check the brake fluid level properly?
Did you dip the dipstick twice to check on the oil

level?
Did you thoroughly check all the tires?
Did you check all the glass panels of the dump

truck?
Did you check the rubber squeegee of the wiper

and the level of wiper fluid?
Document No.
Developed by:
Revision No.001
75
Glossary of Terms
1. abnormal load : oversize

2. airlock : an air bubble in fuel system etc.
3. articulated vehicle : any vehicle towing a trailer, usually refers to a
semi- trailer truck
4. backdoor : a slower truck that maintains the rear of a convoy/train.
Keeps an eye out for bears from behind.
5. blow-out : burst tire
6. bulk cargo/bulk : loose cargo (not packaged)
7. crawler gear : the lowest gear in a gearbox (below 1st gear)
8. exhaust brake - A moveable flap in the exhaust system that
creates backpressure to retard the engine and create more
engine braking to assist when driving downhill.
9. forwarding : shipping
10. freight : goods / charge for goods carried
11.hammer : accelerate (mashing on the pedal real hard); accelerator
12.injection pump : the pump that injects fuel into the cylinders
13.kilometer : 0.6 miles approx. (100 km =62 miles) literally one
thousand meters
14.lorry (some regions of GB) : truck (A lorry was originally a
horse-drawn vehicle. Diesel-engined vehicles were called motor
lorries but the word motor was later dropped)
15. logistics : movement and supply of goods
16. metric ton / tonne : 2205 lb
17. odometer : mile or kilometer counter
18.pallet : wooden board for carrying goods
19.RORO : roll-on-roll-off
20.retarder / Telma / telma : electro-magnetic device for slowing a
vehicle down without using the wheel brakes
21.shunter : (GB) Vehicle used in yard specifically for maneuvering trailers
22.semi-trailer : a trailer without a front axle (the front is
supported by a tractor unit or a dolly : semi-trailers have legs
to support them when uncoupled)
23. tanker : a semi-trailer designed for the transport of liquid,
usually gasoline or milk
24. tailgating : driving too closely to the preceding vehicle
25. tractor (unit) / tractive unit : prime mover for pulling semi-trailers
Document No.
Developed by:
Revision No.001
76
Bibliography
1. Home Front Heroes: A Biographical Dictionary of Americans

During Wartime. Edited by Benjamin F. Shearer, November
30, 2006, Volume 1, pp 319, Greenwood Publishing Group,
Inc., Westport, Connecticut
2. Wood, Donald (2001). Dump Trucks. 729 Prospect Ave.
Osceola, WI 54020: MBI Publishing Company. pp. 11–30.
3. Wanger, James (1994). Ford Trucks Since 1905. Motorbooks Intl.
4. Mario Theriault, Great Maritime Inventions 1833-1950,
Goose Lane Editions, 2001, p. 71
5. Hulcher Services Inc., 2018, USA, June 20, 2018
http://hulcher.com/contractor-equipment/engineering-
maintenance- of-way/dump-truck.asp
6. J.J.Keller & Associates Inc. 1953, USA, June 23, 2018
https://www.jjkeller.com/learn/preventive-maintenance-program
7. Equipment World, 2018, June 20, 2018,
https://www.equipmentworld.com/owning-and-operating-
costs-8/
8. United States. United States Department of Labor,
Hazards of Unintended Movement of Dump Truck Body
Beds. September 9, 2006. June 21, 2018.
https://www.osha.gov/dts/shib/shib091806.html
9. Galion -Godwin Truck and Body Co. LLC.,
http://galiongodwin.com/docs/DumpTruckOperatorManual.
pdf
Document No.
Developed by:
Revision No.001
77

1 Forklift

Uploaded by

Copyright:

Available Formats

1 Forklift

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1 Forklift

Uploaded by

Copyright:

Available Formats

HOW TO USE THIS COMPETENCY – BASED

The unit of competency, "Perform Pre- and Post-Operation

The module, Performing Pre- and Post-Operation Procedures

In this module, you are required to go through a series of learning

No Unit of Module Title Code

UNIT OF COMPETENCY Perform Pre- and Post-operation

MODULE TITLE Performing Pre- and Post-Operation

MODULE DESCRIPTOR: This module deals with the

NOMINAL DURATION: 24 hours

1. LO 1. Identify forklift types/ components

2. LO 2. Perform visual check of equipment

3. LO 3. Perform BLOWAF check

4. LO 4. Check forklift system operation

5. LO 5 Check safety devices

6. LO 6 Perform post operation procedures

LEARNING OUTCOME NO. 1

1. Types of forklifts and its applications

The participants will have access to:

1. Unit of Equipment (Forklift)

Learning Activities Special Instructions

3. Watch the demonstration Read and understand the

Compare your performance

Every one of us has seen forklifts trucks in supermarkets or warehouses moving

These counterbalance forklifts are similar to the regular four-wheel

There are three main types of reach forklifts:

Rough Terrain Forklifts

Side Loader Forklifts

Side loader forklifts also come in three versions:

Telescopic Handler Forklifts

Cherry Picker/Order Picker Forklifts

Forklifts are also organized based on the classification, given by the

Class I: Electric Motor Rider Trucks

Class II: Electric Motor Narrow Aisle Truck

Class III: Electric Motor Hand Truck

2. You need to haul 50 tons of gravel inside a quarry with flat

3. You need to haul 30 tons of sand from area A to area B

4. You need to haul rocks in the mountain through a make

6. This type of dump truck is designed to travel long

FORKLIFT CARRIAGE ASSEMBLY

OPERATOR STEERING WHEEL

RATING PLATE OR CAPACITY PLATE

1. What can fail due to corroded battery terminals?

1. Over-inflated tires have no negative consequence

2. Modern engines can combust water

3. The alternator charges the battery through its terminals

4. A cracked fan belt can be fixed with grease

5. Damaged wiper blades are not dangerous

SELF CHECK 1.1-2B

The participants will have access to:

4. Unit of Equipment (Forklift)

Learning Activities Special Instructions

1. Identify the different kinds of forklift equipment

2. Choose the right type of equipment for the job requirement

You will learn more about topics such as:

 What is a Forklift Truck?

A forklift truck is an electrical or gas powered industrial piece of equipment with

Forklift trucks are used in warehouses, manufacturing and industrial operations,

Forklift Truck Types

A turret truck forklift is a counterbalanced narrow aisle forklift and has an