HOW TO USE THIS COMPETENCY – BASED

LEARNING MATERIAL
Welcome!

The unit of competency, "Perform Basic Preventive

maintenance 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, Perform Basic Preventive maintenance 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.
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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.

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

No Unit of Module Title Code

. Competency
PERFORM PRE-
Performing pre- CON834216
AND POST-
and post-
1. OPERATION
operation
PROCEDURES FOR
procedures for
FORKLIFT
Forklift
PERFORM BASIC
PREVENTIVE Performing CON834217
MAINTENANCE basic
2.
SERVICING FOR preventive
FORKLIFT maintenance
servicing for
Forklift
PERFORM
PRODUCTIVE Performing
OPERATION FOR productive
3. CON834218
FORKLIFT operation for
forklift

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MODULE CONTENT

UNIT OF COMPETENCY Perform Basic Preventive

Maintenance for Forklift

MODULE TITLE Perform Basic Preventive

Maintenance for Forklift

MODULE DESCRIPTOR: This module covers the knowledge , skills

and attitudes required to perform routine basic preventive maintenance and
servicing of Forklift

NOMINAL DURATION: 24 hours

LEARNING OUTCOMES:

At the end of this module you MUST be able to:

1. LO 1. Perform safety practices and housekeeping

2. LO 2. Perform basic preventive maintenance and servicing

ASSESSMENT CRITERIA:

1. Forklift is parked in safe and level ground

2. Parking brake is applied gear shift lever in neutral position.
3. Fork is rested on the ground
4. Master disconnect is set in off position
5. Work place is freed of hazardous materials
6. OS (Operator’s Serviceable) parts/standard are serviced according to the
manufacturer’s condition.
7. Fluids and lubricants are used based on manufacturer’s manual
8. Appropriate basic hand tools and equipment are used as per job
requirements.
9. Basic preventive maintenance servicing is carried out in accordance
with manufacturers and or as per job requirement
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LEARNING OUTCOME NO. 1
Perform Safety practices and housekeeping

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Contents:
1. Recommended safe parking procedures

Assessment Criteria

1. Forklift is parked in safe and level ground

2. Parking brake is applied gear shift lever in neutral position.
3. Fork is rested on the ground
4. Master disconnect is set in off position
5. Work place is freed of hazardous materials

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

Learning Experiences

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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 2.1- questions correctly before
1 proceeding to the next
activity.
Compare the answers of
self- check 2.1-1 to the
answer key
2. Listen To the lecture / Read and understand the
discussion of your trainer information sheet and check
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
2.1-1

Compare your performance

to the performance criteria
checklist

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Information Sheet 2.1.1
Recommended safe parking procedures

How to Park a Forklift Safely

May 2021 by Paul Hinz
Filed under: Safety

At the end of every shift it is important that all operators shutdown their forklifts
correctly and park them in a safe place overnight.
In this blog we briefly look at the criteria that needs to be considered when
choosing the safest place to park a forklift and the correct procedure for parking
a unit.

Criteria for Selecting a Safe Forklift Parking Area

It is important to select a safe and appropriate area to reduce the likelihood of
causing damage or injury.
It can be very easy to create a safety problem by parking a forklift in the wrong
area.

Below is a list of inappropriate parking areas for forklifts:

1. Blocking any exit including emergency exists or in a place that prevents the
exit from being fully opened
For health and safety it is imperative that the forklift isn’t parked blocking any
exits particularly emergency exists.
In the event of an emergency such as fire staff need to exist a premises swiftly
and don’t need the additional hindrance of having to find keys, start up and
move a forklift out of the way of the exit.

2. Blocking any passageway even if it is only partially

Parking a forklift even partially across a passageway can cause disruption to
employees walking whilst carrying heavy goods.

3. On a ramp or incline
If a forklift is parked on a ramp or incline there is a small chance the handbrake

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failing and the unit rolling away with momentum potentially causing damage to
the surrounding area or unexpected injury to those working around the forklift.
If the only available safe parking space for the forklift is on a ramp or incline it is
imperative that the wheels are chocked to reduce the likelihood of the unit
rolling away.

4. Where other vehicles need to drive around the forklift

Forklifts are safest when parked away from areas where other vehicles operate.
If a forklift is parked in an area where other vehicles there is a heightened
chance for collisions that cause damage to the forklift and/or the other vehicle
from occurring.

5. Where other vehicles may come into contact with the forklift
Another common mistake made is parking a forklift next to industrial bins,
dumpsters or skips, if a truck arrives to empty or pick-up the forklift parked near
can obstruct access.

Collection can be delayed whilst the forklift is moved or even skipped if no one
is on-site to move the forklift at the time of collection.

6. Near or obstructing a first aid station

Similar to obstructing an emergency exit, in the event of a medical incident

quick access is required to a first aid station to treat injuries or potentially save
an employee’s life.
A forklift obstructing access to the first aid station and vital medical supplies
may have major detrimental effects to the injured employee receiving vital
lifesaving treatment in the worst case scenario.

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7. Next to a source of heat

Leaving a forklift next to a constant source of heat overnight can have a

detrimental effect on the unit’s components as they may be burned or melted.
Burnt or melted parts of a forklift can easily lead to larger problems including
full blown fire incidents if they aren’t immediately extinguished.
Forklift Parking Procedure
Once a safe parking area for the forklift has been located, operators must never
leave a forklift in a condition or position where there is the potential for it to
cause damage or injury.

When parking a forklift it is recommended the following procedure is followed:

1. Stop the forklift and apply the handbrake

Operators must apply the handbrake when vacating the forklift to prevent it
from inadvertently moving uncontrolled potentially causing damage or injury.

2. Fully lower the carriage and tynes

3. Tilt the mast forward so the tyne tips are touching the ground
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Due to their length a forklift tynes are a large potential trip hazard when raised.
Completely lowering the unit’s carriage and tynes to the floor as mentioned in
the above steps two and three minimises the risk of those walking near the
forklift from tripping over the tynes.

4. Turn the key or keyless switch to the ‘off’ position

By turning off the key or keyless switch stops power running to the forklift.
This reduces the risk of the unit moving unexpectedly if the operator accidently
presses the accelerator pedal whilst exiting the cabin.

5. Release the units seatbelt and safely dismount from the operator cabin

6. If the forklift is battery electric connect the charger cables for overnight
charging

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If the forklift is a battery electric model to ensure it is ready to begin the next
day’s shift it can be left connected to charge overnight.

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Self-Check 2.1-1
Enumeration: what are the proper techniques when parking a
forklift

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Answer key 2.1-1

1. Stop the forklift and apply the handbrake

2. Fully lower the carriage and tynes

3. Tilt the mast forward so the tyne tips are touching the ground

4. Turn the key or keyless switch to the ‘off’ position

5. Release the units seatbelt and safely dismount from the operator
cabin

6. If the forklift is battery electric connect the charger cables for

overnight charging

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LEARNING OUTCOME NO. 2
Perform basic preventive maintenance servicing

Contents:
1. Performing basic preventive maintenance

Assessment Criteria

1. Forklift is parked in safe and level ground

2. Parking brake is applied gear shift lever in neutral position.
3. Fork is rested on the ground
4. Master disconnect is set in off position
5. Work place is freed of hazardous materials

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

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Learning Experiences

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 2.2- questions correctly before
1 proceeding to the next
activity.
Compare the answers of
self- check 2.2-1 to the
answer key
2. Listen To the lecture / Read and understand the
discussion of your trainer information sheet and check
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
2.1-1

Compare your performance

to the performance criteria
checklist

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Information Sheet 2.1.1
Perform Basic Preventive Maintenance Servicing

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
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
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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

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
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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.

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.

Tips for Basic Preventive Maintenance for

Forklifts

Posted on February 14, 2019 by Trekker Group

Forklifts are one of the most widely used pieces of heavy equipment, found
everywhere from the largest-scale construction sites to small warehouses.
They handle a lot of the grunt work of moving all sorts of loads around.
Preventive maintenance for forklifts is crucial to keeping them operating
productively and safely for as long as possible.

Basic preventive maintenance for machines involves regularly checking them

out, keeping components clean, and promptly addressing any concerns. This
helps keep them working at full power and efficiency, confirms that safety
mechanisms and features are functioning, minimizes downtime, and heads
off more costly repairs and part replacements. Ultimately, it extends the life
of forklifts and other machines, reducing equipment costs.
So it’s well worth the effort of staying on top of preventive maintenance for
forklifts. Properly cared for, a high-quality forklift will serve you well for many
years.

Tackling Preventive Maintenance for Forklifts

 Stick closely to the cleaning and maintenance steps and schedules
recommended by the OEM in the owner’s manual
 Don’t exceed the forklift’s official lift capacity, as this causes undue wear and
damage, and it can also cause tips, spills, and other forklift safety concerns
 Conduct a thorough pre- and post-operation inspection whenever the forklift
is used, looking for visible damage and checking things like hoses, cylinders,
belts, tires, brakes, fluid levels, forks, overhead guards, safety features,
cabin controls, hood latch security, etc.
 Confirm that the forks are straight to preserve load stability, and inspect top
clip retaining pins and heels
 Pay close attention to your forklift tires’ pressure and condition, especially
with machines that regularly run the same path, as these are highly
susceptible to uneven wear; tire issues can easily cause poor turning, load
shifts, reduced fuel efficiency, and other concerns
 Clean forklifts weekly, including washing the exterior down with water,
blowing out the radiator, and replacing dirty filters to prevent flammable
buildup, a blocked radiator, and other problems
 Have a proactive fluid management process in place for all forklifts
 Make sure moving forklift parts are greased to avoid unnecessary friction,
wear, and diminished performance
 Replace worn-out ball bearings as needed to keep the lift operating smoothly
and efficiently
 Charge and clean the forklift battery as instructed in the owner’s manual