Lesson 1Hydraulics and mast functions: lift chains, rollers, cylinders, tilt and reach operation checksDescribes how hydraulics drive mast and reach actions. Learners check chains, rollers, cylinders, and ensure smooth lift, tilt, reach without leaks, jerks, or odd 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 reach trucks and their interactions. Learners link each to stability, load handling, and safe work in narrow 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 stabilityFocuses on tyres, wheels, casters and their stability effects. Learners check wear, damage, inflation or solid tyre state, and see how faults 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 care. Learners inspect connectors, cables, battery state, charge level, and safe charging, ventilation, electrolyte 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 indicatorDetails safety devices that cut incident risks. Learners verify horns, lights, belts, presence systems, overload indicators, and how interlocks stop unsafe 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 responsivenessCovers braking, steering, drive systems for movement control. Learners test parking/service brakes, steering response, free play, and spot traction/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 building structured pre-start checklists. Learners prioritise ten key checks for narrow aisles/high lifts, document findings and actions 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 pinsCovers forks and attachments for reach trucks. Learners check wear, cracks, bending, spacing, locks, and match to capacity/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 controls and instruments in use. Learners verify pedals, levers, switches, displays, test emergency stops, ensure labels/symbols readable.
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 reports, lockout/tagout basics. Learners know when to take trucks out of service and report issues safely.
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
