Lesson 1Responding to serious faults: immediate actions, isolating equipment, lockout/tagout basics, notifying supervisor and maintenance, arranging safe transfer of loads if requiredExplains the right way to handle serious faults, like stopping work right away, isolating the machine, using basic lockout or tagout, telling the supervisor and maintenance team, and safely moving loads if needed.
Recognize 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 cylindersGuides you through a full walkaround check of the forklift, looking at forks, carriage, mast, chains, and hydraulic parts to spot damage, wear, leaks, or 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 labeling and data plate verification: capacity plate reading, load center understanding, warning labels legibilityShows how to find and read the data plate, understand rated capacity and load centre, and check that all safety and warning labels are there, clear, and suitable for the attachments and work area.
Locate and read the truck data plateInterpret rated capacity and load centerConfirm 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 equipmentTeaches how to record inspection findings accurately on paper or digital forms, tag unsafe equipment out of service, and report defects clearly so repairs happen before using it again.
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 checking the traction battery and electrical system, including charge level, connectors, cables, insulation, vent caps, electrolyte levels if 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 checking service and parking brakes, including pedal feel, travel, holding power, and warning lights, to ensure the forklift stops and holds 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 seatbeltDeals with checks for steering, main controls, and aids like mirrors, seat, and seatbelt, making sure they are there, adjusted, and working for safe, accurate 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 functional checks before starting under no load, including horn, lights, travel direction, steering, and hydraulic lift, lower, tilt, to confirm smooth, predictable 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 tire checks: wear, cuts, correct inflation (where applicable) and load-bearing conditionExplains inspecting wheels and tyres for wear, cuts, chunking, flat spots, inflation if applicable, and load-bearing condition, to ensure the truck supports rated loads safely.
Identify tire types used on the truckInspect tread wear and remaining depthCheck for cuts, chunking and flat spotsVerify inflation on pneumatic tiresAssess rims and wheel fastenersRecognize tires unfit for service
