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Forklift Maintenance Course

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Forklift Maintenance Course

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Forklift Maintenance Course

Name: Forklift Maintenance Course
Price: 204 GBP
Rating: 5 (3 reviews)

Master every system on a forklift — from hydraulics and electrical controls to brakes, mast assemblies, and powertrains. This course gives working technicians the hands-on knowledge to perform professional-grade maintenance, pass compliance audits, and keep equipment running safely. If you turn wrenches for a living, this is the training that moves your career forward.

Dedika for businesses

What you will learn:

You will learn how to safely inspect, service, and repair all major forklift systems, including LP gas, diesel, and electric powertrains. The course covers hydraulic pump and cylinder rebuilds, electrical fault diagnosis using wiring diagrams and scan tools, and complete mast and fork overhaul procedures. You will also develop skills in preventive maintenance scheduling, fluid analysis, brake and steering service, and regulatory compliance documentation. Supplementary topics include telematics and fleet management, environmental waste handling, parts inventory control, and technical report writing. By the end, you will have the knowledge to certify equipment as fit for service and advance towards industry credentials.

How you study in practice Forklift Maintenance Course

How you practise Forklift Maintenance Course

For businesses looking to train their team

With Dedika for businesses, the course includes exercises and examples tailored to your own business and the way your company needs.

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Course content

8 Chapters • 40 LessonsDuration between 4 and 360 hours (you decide)

Chapter 1See details

Workplace Safety and Regulatory Compliance

Lesson 1 • Fire Prevention and Chemical Safety
Addresses fuel, battery acid, and hydraulic fluid fire risks in service areas. Connects safe chemical handling to spill response and waste disposal requirements.
Lesson 2 • Regulatory Standards and Documentation
Introduces industry safety standards, inspection recordkeeping, and incident reporting obligations. Builds the compliance mindset required for professional maintenance practice.
Lesson 3 • Lockout/Tagout Procedures
Covers energy isolation steps for hydraulic, electrical, and pneumatic systems. Directly prevents accidental energisation during maintenance tasks covered throughout the course.
Lesson 4 • Hazard Identification in Maintenance Areas
Teaches recognition of chemical, electrical, mechanical, and ergonomic hazards. Prepares technicians to assess risk before starting any service task.
Lesson 5 • Personal Protective Equipment Selection
Matches PPE types to specific forklift maintenance tasks and hazard levels. Ensures technicians choose appropriate protection before each job.

Chapter 2See details

Forklift Systems and Components Overview

Lesson 1 • Forklift Types and Configurations
Covers counterbalance, reach, order picker, and rough-terrain forklifts. Establishes context for why maintenance procedures differ across machine types.
Lesson 2 • Mast, Forks, and Attachments
Details mast stages, fork geometry, and common attachments such as side-shifters. Grounds technicians in load-handling hardware before inspection tasks begin.
Lesson 3 • Hydraulic System Components
Identifies pumps, cylinders, control valves, and hoses that drive lifting functions. Provides the component vocabulary needed for all hydraulic maintenance tasks.
Lesson 4 • Electrical and Control Systems
Surveys wiring harnesses, fuses, relays, and electronic control modules. Establishes baseline electrical knowledge required for diagnostic work in later chapters.
Lesson 5 • Powertrain and Engine Fundamentals
Explains internal combustion and electric powertrain architectures. Connects power source selection to maintenance schedules and service intervals.

Chapter 3See details

Preventive Maintenance Schedules and Inspections

Lesson 1 • Filter and Fluid Replacement
Covers engine oil, hydraulic, transmission, and air filter replacement procedures. Reinforces correct torque values and disposal practices for used fluids and filters.
Lesson 2 • Fluid Analysis and Sampling
Teaches oil, coolant, and hydraulic fluid sampling techniques and result interpretation. Links fluid condition data to early detection of internal component wear.
Lesson 3 • Periodic Maintenance Intervals
Defines 250-hour, 500-hour, and 1,000-hour service tasks and their rationale. Connects interval-based maintenance to manufacturer specifications and warranty compliance.
Lesson 4 • Maintenance Documentation and Tracking
Explains how to record PM tasks, parts used, and technician sign-offs in service logs. Builds the documentation discipline required for regulatory audits and warranty claims.
Lesson 5 • Pre-Shift Inspection Procedures
Walks through the standardised daily walkaround check covering fluid levels, tyres, and controls. Establishes the habit of catching defects before operation begins.

Chapter 4See details

Engine and Powertrain Maintenance

Lesson 1 • Diesel Engine Maintenance
Details fuel filter replacement, injector cleaning, and cooling system service for diesel engines. Builds on engine fundamentals introduced in Chapter 1.
Lesson 2 • LP Gas System Service
Covers regulator inspection, fuel filter replacement, and leak testing on LP gas systems. Directly applies safety knowledge from Chapter 2 to live fuel system work.
Lesson 3 • Transmission and Drive Axle Service
Covers fluid changes, seal inspection, and drive axle lubrication for both manual and automatic transmissions. Prepares technicians for drivetrain diagnostics in Chapter 7.
Lesson 4 • Battery Maintenance and Charging
Teaches watering, equalisation charging, and capacity testing for lead-acid and lithium batteries. Connects battery health directly to electric forklift runtime and safety.
Lesson 5 • Electric Motor and Controller Service
Covers brush inspection, motor cleaning, and controller parameter verification for electric forklifts. Requires the electrical system knowledge established in Chapter 1.

Chapter 5See details

Hydraulic System Maintenance and Repair

Lesson 1 • Hydraulic Fluid Management
Covers fluid selection, contamination control, and reservoir maintenance procedures. Establishes clean fluid practices that prevent the majority of hydraulic failures.
Lesson 2 • Hose and Fitting Replacement
Teaches hose condition assessment, fitting selection, and correct installation torque for hydraulic lines. Prevents high-pressure leaks that create safety and environmental hazards.
Lesson 3 • Control Valve Service
Covers spool valve cleaning, relief valve adjustment, and flow control valve replacement. Ensures precise hydraulic function for lift, tilt, and attachment circuits.
Lesson 4 • Pump Inspection and Replacement
Teaches gear and piston pump wear assessment, removal, and installation procedures. Builds on hydraulic component knowledge from Chapter 1.
Lesson 5 • Cylinder Rebuild and Seal Replacement
Details lift and tilt cylinder disassembly, seal replacement, and reassembly to specification. Directly restores mast lifting capacity and eliminates drift caused by internal leaks.

Chapter 6See details

Steering, Brakes, and Tyres

Lesson 1 • Service Brake Maintenance
Details drum and disc brake inspection, adjustment, and lining replacement procedures. Builds on hydraulic knowledge from Chapter 5 for brake cylinder service.
Lesson 2 • Parking Brake Service
Covers cable tension adjustment, actuator inspection, and holding force verification for parking brakes. Ensures the forklift remains stationary on gradients during loading operations.
Lesson 3 • Steering System Inspection and Adjustment
Covers power steering pump, orbitrol valve, and tie-rod inspection and adjustment procedures. Connects steering precision to safe load handling in narrow aisles.
Lesson 4 • Tyre Types and Replacement
Explains cushion, pneumatic, and solid tyre selection, mounting, and inflation procedures. Connects tyre condition to load stability and floor surface compatibility.
Lesson 5 • Wheel Hub and Bearing Service
Covers bearing inspection, repacking, and hub seal replacement for drive and steer axles. Prevents wheel separation failures that pose serious safety risks.

Chapter 7See details

Electrical Diagnostics and Repair

Lesson 1 • Reading Wiring Diagrams
Covers schematic symbols, circuit numbering, and connector location conventions in forklift wiring diagrams. Enables technicians to trace any circuit before touching a wire.
Lesson 2 • Using Electrical Test Equipment
Teaches multimeter, clamp meter, and oscilloscope use for forklift electrical circuits. Establishes measurement skills required for every diagnostic task in this chapter.
Lesson 3 • Sensor and Switch Diagnostics
Covers testing of speed sensors, pressure switches, temperature sensors, and proximity switches. Connects sensor faults to the control module error codes introduced next.
Lesson 4 • Control Module Fault Code Diagnosis
Teaches scan tool connection, fault code retrieval, and freeze-frame data interpretation for electronic control modules. Enables technicians to resolve software-driven faults efficiently.
Lesson 5 • Diagnosing Open and Short Circuits
Applies voltage drop and resistance testing to locate open circuits, shorts to ground, and shorts to power. Builds on wiring diagram skills to speed fault isolation.

Chapter 8See details

Mast, Fork, and Attachment Overhaul

Lesson 1 • Attachment Hydraulic and Mechanical Service
Covers side-shifter, clamp, and rotator attachment hydraulic hose routing, cylinder service, and mechanical wear inspection. Applies hydraulic repair skills from Chapter 5 to attachment circuits.
Lesson 2 • Mast Roller and Bearing Replacement
Details load roller, side roller, and thrust bearing removal and replacement in mast channels. Restores smooth mast travel and eliminates binding that reduces lift capacity.
Lesson 3 • Mast Rail and Chain Inspection
Covers rail wear measurement, chain elongation testing, and anchor pin inspection procedures. Identifies the most common causes of mast failure before they become critical.
Lesson 4 • Carriage and Backrest Service
Covers carriage bar wear, fork pin retention, and load backrest extension inspection and repair. Connects carriage integrity to safe load containment during travel.
Lesson 5 • Fork Inspection and Replacement Criteria
Applies industry fork inspection standards to measure blade wear, heel cracks, and angle deviation. Ensures forks are removed from service before structural failure occurs.

Certification

Your valid completion certificate

This course is for you:

Forklift technician: wants to close skill gaps and work more independently.
Warehouse maintenance worker: handles equipment repairs without formal technical training.
Diesel mechanic: looking to branch into material handling equipment service.
Fleet supervisor: needs deeper technical knowledge to manage maintenance teams effectively.
Career changer: transitioning from general labour into a skilled trades maintenance role.
Apprentice technician: building foundational competency before pursuing industry certification.

What our students say

Your lessons are perfect. I purchased the one-year package and finally have the opportunity to follow various topics of interest without needing to change platforms... I'm grateful for everything you do, I've already recommended you to other people...