Forklift Types, Components, and Pre-Operation Inspection
This domain tests recognition of common truck families and the pre-shift inspection that decides whether a truck may be used. The exam expects component names, failure signs, and the correct response: tag out and report, not 'monitor it'.
Truck families and key components
- Counterbalanced trucks (electric or IC) carry the load ahead of the drive axle; the counterweight offsets it. Cushion tyres suit smooth indoor floors; pneumatic tyres suit rough or outdoor surfaces.
- Reach trucks and order pickers are narrow-aisle warehouse trucks; their stability and operator position differ from counterbalanced trucks.
- Common components: mast, carriage, forks, load backrest, overhead guard, lift chains, hydraulic cylinders and hoses, counterweight, data plate, tyres, brakes, steering, horn, lights, seat belt, and hour meter.
Pre-operation inspection
- Visual: fork cracks, bends, and heel wear; chain tension, wear, and lubrication; hydraulic leaks; tyre damage; loose or missing guards; data plate legibility; battery connector or LP cylinder security.
- Operational: horn, lights, brakes (service and parking), steering, mast lift/lower/tilt, and unusual noise or drift.
- If a defect affects safe operation, do not use the truck. Tag it, remove the key or isolate power as required, and report it.
Worked example
An operator finds one lift chain with a broken link and fresh metal shavings on the mast. The truck is unsafe: a chain failure can drop the carriage. The correct action is to park it in a safe area, lower the forks, apply the parking brake, tag 'Do not operate', and notify maintenance. Cleaning the shavings and continuing because 'it still lifts' is a fail.
Traps
Calling a walk-around a full inspection without operational checks; ignoring fork heel wear or chain stretch; using a truck with an illegible data plate; treating a leak as minor.