Lesson 1Hydraulics and mast functions: lift chains, rollers, cylinders, tilt and reach operation checksDetails how the hydraulic system drives mast and reach movements. Learners inspect chains, rollers, and cylinders, and verify smooth lift, tilt, and reach functions without leaks, jerks, or unusual noises.
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 main structural and functional parts of a reach truck and their interactions. Learners link each component to stability, load handling, and safe operation in narrow aisles and high-lift tasks.
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 stabilityFocuses on tyres, wheels, and casters and their role in stability and handling. Learners check wear, damage, and tyre condition, understanding how defects affect braking and steering.
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 electrical systems and battery maintenance. Learners inspect connectors, cables, battery condition, check charge levels, and follow safe charging, ventilation, and electrolyte handling practices.
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 devices that prevent or mitigate incidents. Learners verify horns, lights, restraints, presence systems, and overload indicators, understanding interlock functions for safe movements.
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 responsivenessAddresses braking, steering, and drive systems for movement control. Learners test parking and service brakes, check steering response, and spot traction or drive issues.
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 operators in creating and using a structured pre-start checklist. Learners prioritise ten key checks for narrow aisles and high lifts, documenting findings clearly for traceability.
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 pinsExamines forks and attachments for reach trucks. Learners inspect wear, cracks, bending, verify spacing and locks, ensuring they match rated capacity and load types.
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 operator controls and instruments. Learners verify pedals, levers, switches, displays, test emergency stops, and ensure labels and symbols are legible.
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 maintenance schedules, defect reporting, and lockout/tagout basics. Learners know when to take trucks out of service and communicate issues safely to maintenance.
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
