Lesson 1Hydraulics and mast functions: lift chains, rollers, cylinders, tilt and reach operation checksDetails how the hydraulic system drives mast and reach moves. Learners check chains, rollers, cylinders, and confirm smooth lift, tilt, reach without leaks, jerks, or odd 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, stabilizers, forks)Explains main structure and working parts of a reach truck and how they work together. Learners link each part to steadiness, load handling, and safe work in narrow aisles and high lifts.
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, casters and their effect on steadiness and handling. Learners check wear, damage, inflation or solid tyre state, and see how faults 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 and battery care. Learners check connectors, cables, battery state, charge level, and safe charging, airing, electrolyte handling.
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 stop or lessen incident harm. Learners check horns, lights, belts, presence systems, overload signs, and how interlocks block unsafe moves.
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, drive systems for movement control. Learners test parking and service brakes, check steering response and play, spot 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, prioritizing, and documenting at least 10 critical checks with reasoning for narrow aisles/high liftsGuides building and using a pre-start checklist. Learners prioritise ten key checks for narrow aisles and high lifts, document findings and actions clearly.
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 for reach trucks. Learners check wear, cracks, bending, spacing, locks, confirm match to capacity and 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 controls and instruments in use. Learners check pedals, levers, switches, displays, test emergency stops, confirm readable labels.
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 maintenance times, fault reporting, lockout/tagout basics. Learners know when to take truck out of service and report issues safely.
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
