Lesson 1Responding to serious faults: immediate actions, isolating equipment, lockout/tagout basics, notifying supervisor and maintenance, arranging safe transfer of loads if requiredDetails the correct response when serious faults are found, including stopping operation, isolating the truck, applying basic lockout or tagout controls, notifying responsible persons, and arranging safe load transfer.
Recognise defects that require shutdownPark, lower forks and secure the truckApply basic lockout or tagout devicesNotify supervisor and maintenance staffArrange safe transfer of suspended loadsDocument the fault and actions takenLesson 2Complete walkaround checklist: forks, carriage, mast, chains, lift hydraulics, tilt cylindersCovers a structured walkaround of the forklift, focusing on forks, carriage, mast, chains, and hydraulic components. Learners will recognise damage, wear, leaks, and misalignment that can compromise safe lifting.
Inspect forks for cracks, bends and wearCheck 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 labelling and data plate verification: capacity plate reading, load centre understanding, warning labels legibilityExplains how to locate and read the data plate, interpret rated capacity and load centre, and verify that all safety and warning labels are present, legible, and appropriate for the attachment and environment.
Locate and read the truck data plateInterpret rated capacity and load centreConfirm attachment information on plateCheck warning and hazard label locationsVerify label legibility and languageIdentify missing or damaged labelsLesson 4Recording and reporting defects: how to fill inspection forms, digital logs, tagging out-of-service equipmentShows how to accurately record inspection findings on paper or digital forms, tag unsafe equipment out of service, and communicate defects clearly so repairs are completed before further use.
Use daily inspection checklists correctlyRecord defects with clear descriptionsAttach photos or digital evidenceTag and label out-of-service trucksEscalate critical defects immediatelyFollow up on repair completion statusLesson 5Battery and electrical system checks: battery state of charge, connector integrity, cable insulation, vent caps, electrolyte level checks (where applicable)Describes how to inspect the traction battery and electrical system, including state of charge, connectors, cables, insulation, vent caps, electrolyte levels where applicable, and signs of overheating or damage.
Check battery state of charge indicatorsInspect connectors for damage or arcingCheck cable routing and insulation wearVerify vent caps and covers are secureObserve electrolyte levels where allowedIdentify leaks, corrosion or hot spotsLesson 6Brake system checks: parking brake, service brakes, brake fluid level indications, pedal feelCovers checks of the service and parking brakes, including pedal feel, travel, holding ability, and any warning indicators, ensuring the forklift can stop and hold safely on level and graded surfaces.
Check parking brake holding on a slopeAssess service brake stopping distanceEvaluate pedal feel and free travelObserve brake warning indicatorsListen for grinding or squeal noisesIdentify signs of hydraulic leaksLesson 7Steering, controls and operator aids: steering mechanism, joystick/levers, horn, lights, mirrors, seat and seatbeltAddresses checks of steering, primary controls, and operator aids such as mirrors, seat, and seatbelt, confirming they are present, adjusted, and functioning to support safe, precise truck 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 functional checks under no-load conditions, 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 tyre checks: wear, cuts, correct inflation (where applicable) and load-bearing conditionExplains inspection of wheels and tyres for wear, cuts, chunking, flat spots, inflation where applicable, and overall load-bearing condition, ensuring the truck can support rated loads safely and predictably.
Identify tyre types used on the truckInspect tread wear and remaining depthCheck for cuts, chunking and flat spotsVerify inflation on pneumatic tyresAssess rims and wheel fastenersRecognise tyres unfit for service
