Certificate Course in Forklift Technician
forklift-technician
Syllabus
Faculty: SUDEEP KUMAR SINGH
Nowadays warehouses are using more and more material handling equipment.
Getting the proper knowledge about the material handling equipment and its operation is a vital aspect for effective utilization of it. Although the forklift are versatile and robust machines, but it's operation as per the standard operating procedure is very important. The preventive maintenance and breakdown maintenance knowledge can reduce the laydown period to a considerable extent.
Module-1
Introduction to Material Handling Equipment
Introduction to Material Handling Equipment, Different types of Material Handling Equipment, Cranes and hoists, Conveyors, Introduction to Godrej Material Handling, Product offerings, Know your FORKLIFT, Features of Diesel, Electric& LPG Forklifts,Forklift Main parts
Module -2
Engine
Four stroke engines, working principles, applications, types of engines as per power & efficiency. Classification of heat engines. Based on fuel used, Based ignition of fuel, Based on working cycle, Construction of an IC engine, Working principle of IC engine. Four stroke cycle engine and two stroke cycle engine. Four stroke cycle engine(Diesel/ Petrol Engine) Four stroke cycle engine, Working principle of Diesel engine, Engine components, terminology connected with engine power. The Different types of engines in used diesel forklifts, General engine features
Module - 3
Typical Engine Parts maintenance
Adjusting Intake and Exhaust Valve Clearance, Changing Engine Oil and Oil Filter, Checking and Adjusting Fan Belt, Checking cooling System, Hoses and Connections, 8 Cleaning or Replacing Air Cleaning Filter, engine maintenance work
Module-4
TRANSMISSION SYSTEM
INTRODUCTION, Working principles, Godrej Diesel / LPG forklifts are equipped with an Automatic Transmission, Hydrodynamic transmission gear-box power transmit, TORQUE CONVERTER, Torque Converter Testing, Oil Feed Pump, Valve Control Operation, Hydrodynamic transmission gear-box power transmission, Hydraulic transmission, Hydrodynamic clutch, Differential, Brake System Mechanism
Maintain Health & safety – 5
Will know the importance of safety first, Will be able to know the standard precautions for maintaining personal and tool safety, Will be aware of different PPE equipment’s used in the Warehouse, Handle emergency situations
Introduction to Material Handling Equipment, Different types of Material Handling Equipment
Video link: https://www.youtube.com/watch?v=WXmIdbVDJqE
Practice: Identify the different types of Material Handling Equipment and its body parts components name
Cranes and hoists & Conveyors
Video link: https://www.youtube.com/watch?v=nTI5C5jxWDA
Video link: https://www.youtube.com/watch?v=LOxcZcS0Cxk
Practice: Develop a preventive maintenance check sheet for Cranes and hoists & Conveyors
Introduction to Godrej Material Handling, Product offerings (Different counterbalance products and warehousing equipment offered by Godrej Material Handling)
Video link: https://www.youtube.com/watch?v=tNOiPaj0FQY
Practice: Disassembly & assemble a manual Pallet Jack
Know your FORKLIFT, Features of Diesel, Electric& LPG Forklifts
Video link: https://www.youtube.com/watch?v=MOc1_uB9yQU
Video link: https://www.youtube.com/watch?v=trtwXt_cxUw
Video link: https://www.youtube.com/watch?v=VTVcszX66lg
Practice: Identify the exterior & interior body parts of forklift
FOUR STROKE ENGINES, WORKING PRINCIPLES
Video link: https://www.youtube.com/watch?v=Pu7g3uIG6Zo&t=34s
Practice: Take an observation of a forklift engine & identify the different components
APPLICATIONS - Types, power and efficiency, Classification of heat engines. Based on fuel used, Based ignition of fuel, Based on working cycle,
Video link: https://www.youtube.com/watch?v=NSbtvrveLTo
Practice: Disassemble & assemble the Forks.
Construction of an IC engine, working principle of IC engine. Four stroke cycle engine/ Two stroke cycle engine. Four stroke cycle engine/Two stroke cycle engine. Four stroke cycle engine(Diesel/ Petrol engine)
Video link: https://www.youtube.com/watch?v=kU5G20s4ILA&t=8s
Practice: Replace the Tires of a forklift
Four stroke cycle engine, working principal of diesel engine.
Video link: https://www.youtube.com/watch?v=DZt5xU44IfQ&t=222s
Practice: Develop a preventive maintenance check list for a diesel operated forklift
Engine specification., major exterior components or parts of the forklift (instrument on a dash board of a vehicle- Speedometer, Tachometer, Odometer and Fuel gauge, and Indicators such as gearshift position, Seat belt warning light, Parking-brake-engagement warning light and an)
Video link: https://www.youtube.com/watch?v=KLll6gnLGr0
Practice: Measure the cylinder bore worn out by bore dial gauge
Description and Constructional feature of Cylinder head, Importance of Cylinder head design
Video link: https://www.youtube.com/watch?v=26SVb0DCfpE&t=274s
Practice- Demonstration and Practice of Perform measuring practice to check the flatness of the cylinder head is warped or twisted with straightedge is used with a feeler gauge.
Valves & Valve Actuating Mechanism (Description and Function of Engine Valves, different types, materials, - Type of valve operating mechanism, Importance of Valve seats, Valve seats inserts in cylinder heads
Video link: https://www.youtube.com/watch?v=UjlHm9Gp-98
Video link: https://www.youtube.com/watch?v=CC4doq880Hc
Video link: https://www.youtube.com/watch?v=8jTM5rPKI6M
Video link: https://www.youtube.com/watch?v=_N6yQyCXnVA
Practice: Disassembling and assembling of differential
Video link: https://www.youtube.com/watch?v=mvDkWnownI8
Video link: https://www.youtube.com/watch?v=Dv-mBXueRtY
Practice: Demonstration of Perform measuring practice on cylinder bore, Connecting rod bore, inside diameter (ID) of a camshaft bearing with Telescope gauges.
Importance of Turbulence Description & functions of different types of pistons, piston rings and piston pins and materials. Used recommended clearances for the rings and its necessity precautions while fitting rings, common troubles and remedy. Compression ratio.
Video link: https://www.youtube.com/watch?v=WhvDBg1wj9c
Practice- Demonstration and Practice of Checking connecting rod for bend and twist. Assemble the piston and connecting rod assembly.
Description function of connecting rod importance of big- end split obliquely Materials used for connecting rods big end & main bearings. Shells piston pins and locking methods of piston pins
Video link: https://www.youtube.com/watch?v=yyY82nLzHjk&t=19s
Practice: Remove the fly wheel & take observation and mount it.
TERMINOLOGY CONNECTED WITH ENGINE POWER,
Video link: https://www.youtube.com/watch?v=Zv0iXhctqSM
The Different types of engines in used diesel forklifts, General engine features
Video link: https://www.youtube.com/watch?v=CYnp_KC2Bx8
Video link: https://www.youtube.com/watch?v=g48Ycj7jBcM
Practice: Changing Engine Oil and Oil Filter
Adjusting Intake and Exhaust Valve Clearance, Changing Engine Oil and Oil Filter
Video link: https://www.youtube.com/watch?v=PSmWOgPxatY
Practice: Adjusting Intake and Exhaust Valve Clearance
Checking and Adjusting Fan Belt, Checking cooling System,
Video link: https://www.youtube.com/watch?v=_FD4BT5goig
Video link: https://www.youtube.com/watch?v=a-ZZELjxF0g
Practice: Replace the engine oil & engine coolant
Hoses and Connections, cleaning or Replacing Air Cleaning Filter, engine maintenance work
Video link: https://www.youtube.com/watch?v=wLBHXIAarjA
Video link: https://www.youtube.com/watch?v=XDGLn04fFS4
Practice: Replacing Air Cleaning Filter
INTRODUCTION, Working principles, Godrej Diesel / LPG forklifts are equipped with an Automatic Transmission
Video link: https://www.youtube.com/watch?v=Qb8EqQOQc6g
Video link: https://www.youtube.com/watch?v=B-eEFvRdKJE
Practice: identify the different symbols present in a forklift dash board and prepare a document by writing its function.
Hydrodynamic transmission gear-box power transmit,
Video link: https://www.youtube.com/watch?v=N0gFKZizPWM
Practice: Assembly the forklift engine with maintain the proper SOP.
Video link: https://www.youtube.com/watch?v=9YW3NRhF_KY
Practice: Disassembly & assembly the any forklift gear box.
TORQUE CONVERTER, Torque Converter Testing,
Video link: https://www.youtube.com/watch?v=z5G2zQ_3xTc
Practice: Disassembly & assembly the any forklift gear box
Oil Feed Pump, Valve Control Operation, and Hydrodynamic transmission gear-box power transmission
Video link: https://www.youtube.com/watch?v=u_y1S8C0Hmc
Practice: Disassembly & assembly the torque converter
Hydraulic transmission, Hydrodynamic clutch,
Video link: https://www.youtube.com/watch?v=Q_divwaifQE
Practice: A fully Dismantle the forklift engine and write the different components name in your observation copy.
Differential, Air Brake System Mechanism
Video link: https://www.youtube.com/watch?v=DerS-EXKWLM
Practice: Take an observation of air brake system
Forklift Operator’s Handbook
(E-Book - https://www.rta.ae/wpsv5/eservices/PDF_Catalog/Forklift_Handbook_EN.pdf)
J Series Counterbalanced Battery Forklift Truck OPERATION AND MAINTENANCE MANUAL
(E-Book - https://courseware.cutm.ac.in/files/spec_5342_472.pdf)
Description:
Nowadays warehouses are using more and more material handling equipment.
Getting the proper knowledge about the material handling equipment and its operation is a vital aspect for effective utilization of it. Although the forklift are versatile and robust machines, but it's operation as per the standard operating procedure is very important. The preventive maintenance and breakdown maintenance knowledge can reduce the laydown period to a considerable extent.
Course Objectives
- This course was designed to be the ultimate boot-camp for anyone who wants to master in forklift maintenance skill.
- Ensure that forklift is fit for use
- Ensure safe and healthy working practices
- Load and Unload Materials safety
- Meet the customer demand as per the requirement
- Carry out the work effectively at the work place
- Driving skills can include strong knowledge of maintenance knowledge and problem-solving skills.
Learning Outcomes
- It is applicable in both your personal and professional lives.
- Can be self employed
- Carry out the general servicing of forklift
- Provide best service to customers
Course Syllabus
Module-1
Introduction to Material Handling Equipment
Introduction to Material Handling Equipment, Different types of Material Handling Equipment, Cranes and hoists, Conveyors, Introduction to Godrej Material Handling, Product offerings, Know your FORKLIFT, Features of Diesel, Electric& LPG Forklifts,Forklift Main parts
Module -2
Engine
Four stroke engines, working principles, applications, types of engines as per power & efficiency. Classification of heat engines. Based on fuel used, Based ignition of fuel, Based on working cycle, Construction of an IC engine, Working principle of IC engine. Four stroke cycle engine and two stroke cycle engine. Four stroke cycle engine(Diesel/ Petrol Engine) Four stroke cycle engine, Working principle of Diesel engine, Engine components, terminology connected with engine power. The Different types of engines in used diesel forklifts, General engine features
Module - 3
Typical Engine Parts maintenance
Adjusting Intake and Exhaust Valve Clearance, Changing Engine Oil and Oil Filter, Checking and Adjusting Fan Belt, Checking cooling System, Hoses and Connections, 8 Cleaning or Replacing Air Cleaning Filter, engine maintenance work
Module-4
TRANSMISSION SYSTEM
INTRODUCTION, Working principles, Godrej Diesel / LPG forklifts are equipped with an Automatic Transmission, Hydrodynamic transmission gear-box power transmit, TORQUE CONVERTER, Torque Converter Testing, Oil Feed Pump, Valve Control Operation, Hydrodynamic transmission gear-box power transmission, Hydraulic transmission, Hydrodynamic clutch, Differential, Brake System Mechanism
Maintain Health & safety – 5
Will know the importance of safety first, Will be able to know the standard precautions for maintaining personal and tool safety, Will be aware of different PPE equipment’s used in the Warehouse, Handle emergency situations
Session Plan
Session 1
Introduction to Material Handling Equipment, Different types of Material Handling Equipment
Video link: https://www.youtube.com/watch?v=WXmIdbVDJqE
Practice: Identify the different types of Material Handling Equipment and its body parts components name
Session 2
Cranes and hoists & Conveyors
Video link: https://www.youtube.com/watch?v=nTI5C5jxWDA
Video link: https://www.youtube.com/watch?v=LOxcZcS0Cxk
Practice: Develop a preventive maintenance check sheet for Cranes and hoists & Conveyors
Session 3
Introduction to Godrej Material Handling, Product offerings (Different counterbalance products and warehousing equipment offered by Godrej Material Handling)
Video link: https://www.youtube.com/watch?v=tNOiPaj0FQY
Practice: Disassembly & assemble a manual Pallet Jack
Session 4
Know your FORKLIFT, Features of Diesel, Electric& LPG Forklifts
Video link: https://www.youtube.com/watch?v=MOc1_uB9yQU
Session 5
Forklift Main parts
Video link: https://www.youtube.com/watch?v=trtwXt_cxUw
Video link: https://www.youtube.com/watch?v=VTVcszX66lg
Practice: Identify the exterior & interior body parts of forklift
Session 6
FOUR STROKE ENGINES, WORKING PRINCIPLES
Video link: https://www.youtube.com/watch?v=Pu7g3uIG6Zo&t=34s
Practice: Take an observation of a forklift engine & identify the different components
Session 7
APPLICATIONS - Types, power and efficiency, Classification of heat engines. Based on fuel used, Based ignition of fuel, Based on working cycle,
Video link: https://www.youtube.com/watch?v=NSbtvrveLTo
Practice: Disassemble & assemble the Forks.
Session 8
Construction of an IC engine, working principle of IC engine. Four stroke cycle engine/ Two stroke cycle engine. Four stroke cycle engine/Two stroke cycle engine. Four stroke cycle engine(Diesel/ Petrol engine)
Video link: https://www.youtube.com/watch?v=kU5G20s4ILA&t=8s
Practice: Replace the Tires of a forklift
Session 9
Four stroke cycle engine, working principal of diesel engine.
Video link: https://www.youtube.com/watch?v=DZt5xU44IfQ&t=222s
Practice: Develop a preventive maintenance check list for a diesel operated forklift
Session 10
Engine specification., major exterior components or parts of the forklift (instrument on a dash board of a vehicle- Speedometer, Tachometer, Odometer and Fuel gauge, and Indicators such as gearshift position, Seat belt warning light, Parking-brake-engagement warning light and an)
Video link: https://www.youtube.com/watch?v=KLll6gnLGr0
Practice: Measure the cylinder bore worn out by bore dial gauge
Session 11
Description and Constructional feature of Cylinder head, Importance of Cylinder head design
Video link: https://www.youtube.com/watch?v=26SVb0DCfpE&t=274s
Practice- Demonstration and Practice of Perform measuring practice to check the flatness of the cylinder head is warped or twisted with straightedge is used with a feeler gauge.
Session 12
Valves & Valve Actuating Mechanism (Description and Function of Engine Valves, different types, materials, - Type of valve operating mechanism, Importance of Valve seats, Valve seats inserts in cylinder heads
Video link: https://www.youtube.com/watch?v=UjlHm9Gp-98
Video link: https://www.youtube.com/watch?v=CC4doq880Hc
Video link: https://www.youtube.com/watch?v=8jTM5rPKI6M
Video link: https://www.youtube.com/watch?v=_N6yQyCXnVA
Practice: Disassembling and assembling of differential
Session 13
Type of Diesel combustion chambers, - Effect on size of Intake & exhaust passages, Head gaskets
Video link: https://www.youtube.com/watch?v=mvDkWnownI8
Video link: https://www.youtube.com/watch?v=Dv-mBXueRtY
Practice: Demonstration of Perform measuring practice on cylinder bore, Connecting rod bore, inside diameter (ID) of a camshaft bearing with Telescope gauges.
Session 14
Importance of Turbulence Description & functions of different types of pistons, piston rings and piston pins and materials. Used recommended clearances for the rings and its necessity precautions while fitting rings, common troubles and remedy. Compression ratio.
Video link: https://www.youtube.com/watch?v=WhvDBg1wj9c
Practice- Demonstration and Practice of Checking connecting rod for bend and twist. Assemble the piston and connecting rod assembly.
Session 15
Description function of connecting rod importance of big- end split obliquely Materials used for connecting rods big end & main bearings. Shells piston pins and locking methods of piston pins
Video link: https://www.youtube.com/watch?v=yyY82nLzHjk&t=19s
Practice: Remove the fly wheel & take observation and mount it.
Session 16
TERMINOLOGY CONNECTED WITH ENGINE POWER,
Video link: https://www.youtube.com/watch?v=Zv0iXhctqSM
Session 17
The Different types of engines in used diesel forklifts, General engine features
Video link: https://www.youtube.com/watch?v=CYnp_KC2Bx8
Video link: https://www.youtube.com/watch?v=g48Ycj7jBcM
Practice: Changing Engine Oil and Oil Filter
Session 18
Adjusting Intake and Exhaust Valve Clearance, Changing Engine Oil and Oil Filter
Video link: https://www.youtube.com/watch?v=PSmWOgPxatY
Practice: Adjusting Intake and Exhaust Valve Clearance
Session 19
Checking and Adjusting Fan Belt, Checking cooling System,
Video link: https://www.youtube.com/watch?v=_FD4BT5goig
Video link: https://www.youtube.com/watch?v=a-ZZELjxF0g
Practice: Replace the engine oil & engine coolant
Session 20
Hoses and Connections, cleaning or Replacing Air Cleaning Filter, engine maintenance work
Video link: https://www.youtube.com/watch?v=wLBHXIAarjA
Video link: https://www.youtube.com/watch?v=XDGLn04fFS4
Practice: Replacing Air Cleaning Filter
Session 21
INTRODUCTION, Working principles, Godrej Diesel / LPG forklifts are equipped with an Automatic Transmission
Video link: https://www.youtube.com/watch?v=Qb8EqQOQc6g
Video link: https://www.youtube.com/watch?v=B-eEFvRdKJE
Practice: identify the different symbols present in a forklift dash board and prepare a document by writing its function.
Session 22
Hydrodynamic transmission gear-box power transmit,
Video link: https://www.youtube.com/watch?v=N0gFKZizPWM
Practice: Assembly the forklift engine with maintain the proper SOP.
Video link: https://www.youtube.com/watch?v=9YW3NRhF_KY
Practice: Disassembly & assembly the any forklift gear box.
Session 23
TORQUE CONVERTER, Torque Converter Testing,
Video link: https://www.youtube.com/watch?v=z5G2zQ_3xTc
Practice: Disassembly & assembly the any forklift gear box
Session 24
Oil Feed Pump, Valve Control Operation, and Hydrodynamic transmission gear-box power transmission
Video link: https://www.youtube.com/watch?v=u_y1S8C0Hmc
Practice: Disassembly & assembly the torque converter
Session 25
Hydraulic transmission, Hydrodynamic clutch,
Video link: https://www.youtube.com/watch?v=Q_divwaifQE
Practice: A fully Dismantle the forklift engine and write the different components name in your observation copy.
Session 26
Differential, Air Brake System Mechanism
Video link: https://www.youtube.com/watch?v=DerS-EXKWLM
Practice: Take an observation of air brake system
Project
Prepare Manual Walkie-Stacker
Prepare Manual Pallet Jack
References:
Forklift Operator’s Handbook
(E-Book - https://www.rta.ae/wpsv5/eservices/PDF_Catalog/Forklift_Handbook_EN.pdf)
J Series Counterbalanced Battery Forklift Truck OPERATION AND MAINTENANCE MANUAL
(E-Book - https://courseware.cutm.ac.in/files/spec_5342_472.pdf)
Session plan & materials
No materials published yet.