1 Forklift
1 Forklift
1 Forklift
LEARNING MATERIAL
Welcome!
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.
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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.
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List of Competencies
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MODULE CONTENT
LEARNING OUTCOMES:
At the end of this module you MUST be able to:
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
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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
Contents:
1. Types and classification of Forklift
2. Components structures of forklift and their functions.
Assessment Criteria
Conditions
Assessment Method:
1. Written Exam
2. Oral Questioning
3. Task Sheets
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Learning
Experiences
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Identify forklift types/ components structure
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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
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22 Different Types of Forklifts for Indoor and Outdoor Work
Types of Forklifts
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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
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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.
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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
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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
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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.
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.
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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.
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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.
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
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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.
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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
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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
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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.
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
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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
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.
These trucks can easily operate in narrow spaces like warehouse aisles, which
means they can access ore racking space without expanding your storage area.
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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.
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.
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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.
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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?
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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
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5. This type of dump truck has a tractor and a trailer as part of
a two- part design.
a. An on-highway dump truck (rigid)
b. An off-highway dump truck (rigid)
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c. An off-highway dump truck (articulated)
d. A flat-bed trailer
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Answer Key 1.1-1
1. D
2. B
3. A
4. C
5. C
6. A
7. B
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Information Sheet 1.1-2
Components structure of forklift and their
functions
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
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.
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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.
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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
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(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.
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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.
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.
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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.
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SELF CHECK 1.1-2A
Multiple Choice:
Choose the best answer. Write the letter of your choice on your
answer sheet.
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SELF CHECK 1.1-2B
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ANSWER KEY
SELF CHECK
1. B
1.1-2A
2. C
3. C
4. A
5. B
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1. FALSE
2. FALSE
3. TRUE
4. FALSE
5. FALSE
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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
Assessment Method:
4. Written Exam
5. Oral Questioning
6. Task Sheets
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Learning Experiences
Identify forklift types/ components structure
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Information Sheet 1.2.1
Specification, Limitations and Classifications of
Forklifts based on Operations
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
Forklift Trucks
Introduction
This article takes an in depth look at forklift trucks regarding their use and
types.
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Chapter One – What is a Forklift Truck?
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.
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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.
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.
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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.
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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.
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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.
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Turret Forklift
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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.
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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.
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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.
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.
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which include order pickers, pallet jacks, stand up trucks, double deep trucks,
saddled trucks, and walkie stackers.
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
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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 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.
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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.
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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.
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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
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.
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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.
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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.
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.
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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,
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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,
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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.
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
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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 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 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
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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 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.
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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
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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.
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.
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
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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.
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.
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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.
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
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
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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.
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.
4. Tires
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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.
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- Cracked/Tread separation/Tread wear
- Bulging
- Imbedded materials
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- 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.
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.
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.
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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 .
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Answer Key
SELF CHECK
1.1-3
1. Fluids
2. Dip Stick
3. Leak
5. Replace
1.
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TASK SHEET 1.1-3
Steps/Procedure:
Assessment Method:
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PERFORMANCE CRITERIA
CHECKLIST 1.1-3
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CRITERIA Y NO
E
S
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Developed by:
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Glossary of Terms
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Heavy Equipment Date Issued by:
Operation- Forklift Developed:
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Bibliography
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Operation- Forklift Developed:
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