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, informing the boss and repair 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 through a full walkaround check of the forklift, looking at forks, carriage, mast, chains, and hydraulic parts. You'll learn to spot damage, wear, leaks, and misalignment that could affect safe lifting in busy Zambian warehouses.
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 clear, readable, and suitable for the attachments and work environment in Zambia.
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 equipmentDemonstrates how to record check findings accurately on paper or digital forms, tag unsafe equipment out of service, and report faults clearly so that repairs are done before the machine is used again in the workplace.
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 common in Zambian conditions.
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 make sure the forklift can stop and hold safely on flat and sloped surfaces in warehouses.
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 operator aids like mirrors, seat, and seatbelt, ensuring they are there, adjusted properly, and working for safe and 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, and tilt, to confirm smooth 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 tire checks: wear, cuts, correct inflation (where applicable) and load-bearing conditionExplains checking wheels and tyres for wear, cuts, chunking, flat spots, inflation if applicable, and load-bearing state, ensuring the truck can handle rated loads safely in Zambian sites.
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
