Lesson 1Hydraulics and mast functions: lift chains, rollers, cylinders, tilt and reach operation checksDetails how the hydraulic system powers mast and reach movements. Learners check chains, rollers, and cylinders, and verify smooth, controlled lift, tilt, and reach functions without leaks, jerks, or abnormal 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, stabilisers, forks)Explains the main structural and functional parts of a reach truck and how they interact. Learners relate each component to stability, load handling, and safe operation in narrow aisles and high-lift applications.
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 effect on stability and handling. Learners inspect wear, damage, and inflation or condition of solid tyres, and understand 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 power systems and battery care. Learners inspect connectors, cables, and battery condition, check state of charge, 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 reduce incident severity. Learners verify horns, lights, restraints, presence systems, and overload indicators, and understand how interlocks disable unsafe 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 that control movement. Learners test parking and service brakes, assess steering response and free play, and recognise signs of traction or drive faults.
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, prioritising, and documenting at least 10 critical checks with reasoning for narrow aisles/high liftsGuides operators in building and using a structured pre-start checklist. Learners prioritise at least ten critical checks for narrow aisles and high lifts and document findings and actions clearly and traceably.
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 pinsExplores forks and attachments used on reach trucks. Learners inspect wear, cracks, and bending, verify spacing and locking devices, and confirm attachments match rated capacity and intended 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 used during operation. Learners verify pedals, levers, switches, and displays, test emergency stop devices, and confirm all labels and symbols are 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 routine maintenance intervals, reporting defects, and basic lockout/tagout. Learners know when to remove a truck from service and how to communicate issues to maintenance safely and clearly.
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
