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://www.forklift.ee/wp-content/uploads/spec_5342_472.pdf)