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 truck, basic lockout or tagout measures, alerting supervisors and maintenance, and safely transferring loads if needed.
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 systematic walkaround of the forklift, emphasising forks, carriage, mast, chains, and hydraulic parts. Learners 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 legibilityExplains locating and reading the data plate, interpreting rated capacity and load centre, and ensuring all safety and warning labels are visible, readable, and suitable for attachments and the 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 equipmentDemonstrates accurate recording of inspection findings on paper or digital forms, tagging unsafe equipment out of service, and clear communication of defects to ensure repairs before reuse.
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 inspecting the traction battery and electrical system, covering state of charge, 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 checks of service and parking brakes, including pedal feel, travel, holding power, and warning indicators, ensuring 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 seatbeltAddresses checks of steering, main controls, and operator aids like mirrors, seat, and seatbelt, confirming they are present, adjusted, and working for safe, accurate 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 checks under no-load, including horn, lights, travel direction, steering, and hydraulic lift, lower, and tilt functions, ensuring 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 tyre 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, ensuring the truck supports rated loads safely and reliably.
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
