Lesson 1Responding to serious faults: immediate actions, isolating equipment, lockout/tagout basics, notifying supervisor and maintenance, arranging safe transfer of loads if requiredExplains the right way to handle serious faults found, including stopping work, isolating the machine, using basic lockout or tagout, telling the supervisor and maintenance team, and safely moving loads if needed.
Spot faults that need shutdownPark, lower forks and secure the machineUse basic lockout or tagout devicesTell supervisor and maintenance staffArrange safe move of hanging loadsWrite down the fault and actions doneLesson 2Complete walkaround checklist: forks, carriage, mast, chains, lift hydraulics, tilt cylindersCovers a proper walkaround of the forklift, looking at forks, carriage, mast, chains, and hydraulic parts. Learners will spot damage, wear, leaks, and wrong alignment that can affect safe lifting.
Check forks for cracks, bends and wearLook at fork locking pins and stopsExamine carriage plate and load backrestInspect mast rails, rollers and weldsCheck chains, anchors and equal tensionInspect tilt and lift cylinders for leaksLesson 3Safety labeling and data plate verification: capacity plate reading, load center understanding, warning labels legibilityTeaches how to find and read the data plate, understand rated capacity and load center, and check that all safety and warning labels are there, clear, and suitable for the attachment and place.
Find and read the machine data plateUnderstand rated capacity and load centerConfirm attachment info on plateCheck warning and hazard label placesVerify label clearness and languageSpot missing or damaged labelsLesson 4Recording and reporting defects: how to fill inspection forms, digital logs, tagging out-of-service equipmentShows how to record inspection findings properly on paper or digital forms, tag unsafe machines out of service, and report faults clearly so repairs are done before using again.
Use daily inspection checklists rightlyRecord faults with clear descriptionsAttach photos or digital proofTag and label out-of-service machinesReport critical faults right awayFollow up on repair completionLesson 5Battery and electrical system checks: battery state of charge, connector integrity, cable insulation, vent caps, electrolyte level checks (where applicable)Describes how to check the traction battery and electrical system, including charge level, connectors, cables, insulation, vent caps, electrolyte levels where needed, and signs of overheating or damage.
Check battery charge level indicatorsInspect connectors for damage or arcingCheck cable path and insulation wearVerify vent caps and covers are secureLook at electrolyte levels where allowedSpot leaks, corrosion or hot spotsLesson 6Brake system checks: parking brake, service brakes, brake fluid level indications, pedal feelCovers checks of service and parking brakes, including pedal feel, travel, holding power, and warning signs, making sure the forklift can stop and hold safely on flat and sloped areas.
Check parking brake holding on a slopeAssess service brake stopping distanceEvaluate pedal feel and free travelObserve brake warning indicatorsListen for grinding or squeal noisesSpot signs of hydraulic leaksLesson 7Steering, controls and operator aids: steering mechanism, joystick/levers, horn, lights, mirrors, seat and seatbeltDeals with checks of steering, main controls, and operator helps like mirrors, seat, and seatbelt, confirming they are there, adjusted, and working for safe, accurate machine operation.
Check steering wheel or tiller free playTest control levers or joystick responseVerify horn and light switch operationInspect mirrors and adjust for visibilityCheck seat condition and adjustmentInspect seatbelt condition and latchingLesson 8Pre-start functional tests: horn, lights, direction, lift/lower/tilt function under no-load conditionsFocuses on pre-start checks under no-load, including horn, lights, travel direction, steering, and hydraulic lift, lower, and tilt functions, confirming smooth, predictable and safe operation.
Test horn and audible warning devicesCheck headlights, brake and warning lightsVerify forward and reverse selectionConfirm steering response and free playTest lift, lower and tilt with no loadListen for abnormal noises or vibrationLesson 9Wheel and tire checks: wear, cuts, correct inflation (where applicable) and load-bearing conditionExplains checking wheels and tires for wear, cuts, chunking, flat spots, inflation where needed, and overall load-bearing condition, ensuring the machine can carry rated loads safely and steadily.
Identify tire types used on the machineInspect tread wear and remaining depthCheck for cuts, chunking and flat spotsVerify inflation on pneumatic tiresAssess rims and wheel fastenersRecognize tires unfit for service
