Lesson 1Hydraulics and mast functions: lift chains, rollers, cylinders, tilt and reach operation checksShows how fluids power mast and arm moves. Check chains, rollers, cylinders for smooth lift, tilt, reach without leaks, jumps, or odd sounds.
Hydraulic circuit basics and componentsLift chains, anchors, and tension checksMast rollers, guides, and lubricationHydraulic cylinders, seals, and leaksTilt and reach function test procedureLesson 2Reach truck main components and functions (mast, reach mechanism, stabilizers, forks)Explains key build and work parts of reach truck and how they fit. Link each to balance, load lift, safe work in tight aisles and high lifts.
Mast structure and stages overviewReach mechanism travel and stabilityStabilizers and outrigger functionFork carriage, backrest, and forksChassis, counterweight, and overhead guardLesson 3Tyres, wheels, and casters: wear patterns, inflation/solid tyre checks, impact on stabilityLooks at tyres, wheels, rollers and how they affect hold and steer. Check wear, damage, air or solid tyre state, see how faults hit brakes and turns.
Tyre types used on reach trucksTread wear patterns and damage signsInflation and solid tyre condition checksDrive, load wheel, and caster inspectionEffect of tyre defects on stabilityLesson 4Electrical systems and battery inspection: connectors, state of charge, electrolyte and charger safetyCovers power electrics and battery care. Check plugs, wires, battery state, charge level, safe charging, air flow, fluid handling.
Battery types and capacity ratingsConnector, cable, and plug inspectionsState of charge and indicator checksSafe charging area and ventilation rulesElectrolyte handling and PPE useLesson 5Safety devices and interlocks: horn, lights, seatbelt, presence sensor, deadman switch, overload indicatorCovers safety tools that stop or lessen trouble. Test horn, lights, belts, sensors, overload signs, see how locks block bad moves.
Horn, warning lights, and alarmsSeatbelt and operator restraint checksPresence sensor and deadman pedal testsTravel and lift interlock functionsOverload indicator and capacity alarmsLesson 6Brakes, steering, and drive systems: parking brake, service brake checks, steering responsivenessDeals with brakes, steer, drive for control. Test park and work brakes, steer feel and slack, spot grip or drive problems.
Parking brake holding power testService brake response and fade checksSteering free play and smoothnessDrive motor noises and performanceTraction control and creep speed testsLesson 7Pre-start checklist: writing, prioritizing, and documenting at least 10 critical checks with reasoning for narrow aisles/high liftsGuides making and using start checklist. Pick top ten checks for tight aisles high lifts, note findings and fixes clear for records.
Designing a daily pre-start checklistTen critical safety checks with reasonsVisual walk-around and leak detectionFunctional tests before entering aislesRecording, signing, and storing checklistsLesson 8Forks and attachments: wear, deformation, correct spacing, locking pinsLooks at forks and add-ons for reach trucks. Check wear, cracks, bends, spacing, locks, match to load weight and type.
Fork heel, blade, and tip wear checksDetecting fork bending and deformationCorrect fork spacing and levelingAttachment mounting and locking pinsCapacity plates for forks and attachmentsLesson 9Operator controls and instrumentation: pedals, levers, gauges, emergency stop testsFocuses on driver controls and gauges in use. Check pedals, sticks, switches, screens, test stop button, read all marks.
Pedal layout and correct operationHydraulic control levers and functionsDisplay panels, gauges, and warning iconsEmergency stop and cut-off testsControl labeling and symbol clarityLesson 10Routine maintenance scheduling, defect reporting, and lockout/tagout basicsExplains check times, fault reports, lockout basics. Know when to take truck out, tell maintenance safe and clear.
Planned maintenance and service intervalsDaily operator care and housekeepingDefect reporting channels and formsWhen to tag out and remove from serviceBasic lockout/tagout roles and limits
