Lesson 1Responding to serious faults: immediate actions, isolating equipment, lockout/tagout basics, notifying supervisor and maintenance, arranging safe transfer of loads if requiredOutlines the proper response to serious faults, including halting operations, isolating the forklift, applying basic lockout or tagout measures, informing supervisors and maintenance, and safely transferring loads if needed.
Recognize defects that require shutdownPark, lower forks and secure the forkliftApply 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 cylindersGuides through a systematic walkaround inspection of the forklift, emphasising forks, carriage, mast, chains, and hydraulic parts. Participants will identify damage, wear, leaks, and misalignment that could affect 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 legibilityCovers locating and reading the data plate, understanding rated capacity and load centre, and ensuring all safety and warning labels are visible, readable, and suitable for the attachments and work setting.
Locate and read the forklift 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 equipmentDemonstrates accurate recording of inspection results on forms or digital systems, tagging unsafe equipment out of service, and clear communication of defects to ensure repairs are done before reuse.
Use daily inspection checklists correctlyRecord defects with clear descriptionsAttach photos or digital evidenceTag and label out-of-service forkliftsEscalate 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)Explains inspecting the traction battery and electrical system, covering state of charge, connectors, cables, insulation, vent caps, electrolyte levels if relevant, 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 feelDetails checks for service and parking brakes, including pedal feel, travel, holding power, and warning lights, to confirm the forklift can stop and hold safely on flat and sloped 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 seatbeltFocuses on inspecting steering, main controls, and aids like mirrors, seat, and seatbelt, ensuring they are in place, adjusted, and working for safe and accurate forklift 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 conditionsEmphasises pre-start checks without load, testing horn, lights, travel direction, steering, and hydraulic functions for lift, lower, and tilt, ensuring smooth and reliable 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 conditionCovers inspecting wheels and tyres for wear, cuts, chunking, flat spots, inflation if needed, and load-bearing state, to ensure the forklift can handle rated loads safely.
Identify tyre types used on the forkliftInspect tread wear and remaining depthCheck for cuts, chunking and flat spotsVerify inflation on pneumatic tyresAssess rims and wheel fastenersRecognize tyres unfit for service
