Courses - Fork lift truck Engineer Training

Held at F-TEC's Swindon training centre, the Fork Lift Truck Association offers a wide range of forklift engineer courses, designed specifically to meet the needs of the fork truck industry.

To book, find the correct course below and click its title. This will take you to the booking page.

Thorough Examination

A highly practical course for experienced engineers.  The course is only open to engineers who can show that they are already able to inspect the automotive, electrical and hydraulic components of a fork truck.   The course concentrates on the inspection of chains and forks, current legislation, documentation and the responsibilities of a competent person.  Successful candidates are recorded on a central Fork Lift Truck Association register.

Subjects covered include:

  • The engineer’s role
  • Inspection criteria for lift chains and fork arms
  • Organisation of Thorough Examinations and the examiner’s role
  • Provision and Use of Work Equipment Regulations 1998 (PUWER)
  • Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
  • Guidance on how to conduct Thorough Examinations

Duration : two days

Thorough Examination Revalidation

Engineers who have successfully completed the “Thorough Examination” course are only qualified for a five-year period. This course brings engineers up to date with current legislation and practices and reaffirms their inspection skills. Successful candidates will be registered for a further five years.

Duration: One day

Thorough Examination Manager

The FLTA Thorough Examination Manager course is essential for individuals and companies that seek accreditation to Consolidated Fork Truck Services, in order to carry out Thorough Examinations to LOLER 98 and PUWER 98. Attendees will be given a detailed analysis of the CFTS Quality Assurance Procedural Code. This course conforms to the CFTS rules for accreditation and meets the specific needs of Thorough Examination Managers and their deputies. It may also be of value to managers overseeing CFTS activities.

Duration: One day

Electrical Connection, Isolation and Charger Fault Finding

This valuable and highly practical course will cover the relevant regulations and working practices to enable engineers to safely carry out electrical connection and isolation – charger wiring – relating to lift trucks.

Subjects covered include:

  • Types of batteries
  • Safe use of batteries
  • Electrical isolation procedures
  • Basic three-phase and single-phase wiring
  • Cable sizing, overload and short circuit protection
  • Cable types and their applications
  • Common electrical terminology and symbols
  • Basic wiring and operation of chargers
  • Practical wiring and connection of chargers
  • Fault finding testing, inspection and certification of chargers
  • Assess condition of and calculate conductor requirements
  • Conventional chargers
  • High frequency chargers
  • Types of HF chargers (error codes)
  • Fault finding testing, inspection of HF chargers

Duration: One day

NB: This course does not qualify an engineer to connect charging systems to a main supply (you will require 17th edition IEE wiring regulations, 18th IEE edition as of July 2018)

Module One - LT Electronics

The aim of this course is to provide a comprehensive and practical introduction to electronic control systems.

The course will cover:

  • Health and safety
  • Individual component testing
  • Circuits
  • Electrical theory
  • DC motor types, operation and testing
  • SCR traction control theory and operation
  • Current sensors and current limit settings
  • Fault finding traction control systems:
  • SCR traction control circuits
  • Plugging and flyback circuits
  • Bypass and field weakening circuits
  • Regenerative braking
  • Fail safe and monitoring circuits

Duration: Three days

LPG Fuel Systems

Engineers will be given instruction on the safe use of LPG systems. The course will cover the following subjects:

  • Basic principles of LPG
  • LPG Safety
  • Individual components
  • Fault finding
  • Carburettors
  • Different vaporiser units
  • LPG bottles and storage
  • Basic ignition systems
  • Inspection and adjustments
  • Introduction to fuel injection
  • Breakdown of the injector system
  • Types of injectors
  • System sensors
  • Vaporiser
  • ECU
  • Fault finding and diagnostics

Duration: Three days

Safety for Service Engineers

This important course explores a variety of Health and Safety issues in the fork truck working environment. Whilst essential for service engineers, it is a valuable source of information and understanding for anyone who works near fork lift trucks. Subjects covered include:

  • What is Health and Safety?
  • Legislation
  • Enforcement
  • Accidents and ill health
  • Reporting
  • First Aid
  • Common Hazards
  • Fire & Explosion – (LPG)
  • Electricity
  • Work equipment
  • Movement of People and Vehicles
  • COSHH
  • Manual Handling
  • Noise
  • Working at height
  • Maintenance
  • Risk Assessment
  • Portable tools
  • RIDDOR

Duration: One day

Module Two - Advanced LT Electronics

This course is for the more experienced engineer and covers a variety of the latest technology currently available, including:

  • Separately Excited Motor (SEM) control system
  • AC traction control system
  • Electronic steering
  • Generic wire guidance
  • Fault finding:
    • GE and Zappi SEM traction controllers
    • Zappi AC traction control
    • Zappi and electronic steering
  • MOSFET – control theory of operation
  • Oscilloscope/multiplexing
  • On board diagnostics
  • Fault-finding SCR and MOSFET controllers
    • ​SCR: GE EV1, EV100, Sevcon MC400
    • MOSFET: Zappi – H2 GE EVT100, Sevcon MOS90, Curtis control

Duration: Three days

Hydraulics

The aim of this course is to provide a practical insight into working with hydraulics. The course will cover the following subjects:

  • Introduction to hydraulics
  • Principles of hydraulics
  • Working safely with hydraulics
  • Individual components
  • Hydraulic circuits
  • Hydraulic diagnostics and pressure testing
  • Identification of components
  • Explanation of how the torque converter operates
  • Introduction to hydrostatic machines
  • Identification of the components and safety
  • Explanation of how the hydrostatic (incl. wet brakes) operates
  • Diagnostics and fault finding (pressure testing)

Duration: Three days