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 way to handle major faults, such as halting operations, isolating the machine, using simple lockout or tagout methods, informing key personnel, 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 external inspection of the forklift, emphasising forks, carriage, mast, chains, and hydraulic parts. Trainees learn to detect damage, wear, leaks, and poor alignment that could affect safe lifting operations.
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 legibilityTeaches how to find and interpret the data plate, understand rated capacity and load centre, and ensure all safety and warning labels are visible, readable, and suitable for the attachments and work setting.
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 accurate logging of inspection results on forms or digital systems, marking unsafe equipment as out of service, and clearly reporting issues to ensure fixes are done before reuse in operations.
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)Explains inspecting the drive battery and electrical setup, covering charge level, connectors, cables, insulation, vent covers, electrolyte where relevant, and indicators of overheating or harm.
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 feelReviews checks for service and parking brakes, including pedal response, travel, holding power, and warning lights, to confirm the forklift stops and holds reliably on flat and sloped areas.
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 seatbeltCovers inspections of steering, main controls, and aids like mirrors, seat, and belt, verifying they are in place, adjusted, and working for safe, accurate machine handling.
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 conditionsConcentrates on no-load startup tests for horn, lights, direction, steering, and hydraulic functions for lifting, lowering, and tilting, ensuring smooth, reliable, and safe performance.
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 conditionDescribes checking wheels and tyres for wear, cuts, chunks, flat areas, inflation where needed, and load support, to guarantee the machine handles rated loads safely and steadily.
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
