HSE ACOP L117 – Rider-operated Lift Trucks: Operator Training and Safe Use (Approved Code of Practice)
PUWER 1998, Regulation 9 – Provision and Use of Work Equipment Regulations: Training requirement
LOLER 1998 – Lifting Operations and Lifting Equipment Regulations: Safe lifting at height
Level 2 FLT Operations NOS – National Occupational Standards for Forklift Truck Operations
When Is a Refresher Required?
Routine refresher every 3–5 years (as recommended by HSE L117)
Following an accident or near miss involving a reach truck
Unsafe habits observed by management or colleagues (particularly at height)
Workplace change (new warehouse, racking layout, truck model, or aisle configuration)
Returning after a prolonged absence from reach truck operations
Transition between different reach truck models or mast configurations
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Target Learners & Entry Requirements
Who Is This Course For?
Existing reach truck operators with evidence of previous training (certificate, operator card, or employer records)
Operators due for refresher within the 3–5 year cycle
Operators referred following an incident, near miss, or observed unsafe behaviour
Operators returning after workplace changes affecting reach truck operations (e.g., new racking systems, aisle widths, or truck models)
Operators requiring familiarisation with a different reach truck type or mast configuration
Entry Requirements
Previous training evidence – Certificate, operator log, or employer confirmation of prior reach truck competence
Medical fitness – Employer confirms fitness to operate (FS19-style medical declaration or occupational health clearance). Reach truck operators must have adequate vision for high-level work and no conditions affecting spatial awareness or balance.
Minimum age 18 – Reach trucks operate in warehouse environments; standard minimum age 18 for this truck category
Adequate English to understand theory content and safety instructions
Important
If a candidate cannot demonstrate evidence of previous reach truck training or competence, they must complete a full novice operator course (typically 3–5 days) rather than this refresher. Counterbalance experience alone does not qualify for a reach truck refresher – the operating characteristics are fundamentally different.
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Duration & Ratios
Individual Candidate
~4.5 Hours (Half Day+)
Small Group (Max 3)
1 Full Day (Up to 6.5 Hours)
Trainer-to-Candidate Ratios
Component
Max Ratio
Notes
Theory delivery
1 trainer : 6–8 candidates
Classroom or meeting room setting
Practical assessment
1 trainer : 1 candidate : 1 truck
One-to-one on the truck at all times during aisle work
Practical rotation
Max 3 candidates per truck
Rotate through practical whilst others do theory/quiz
Scheduling Tip
For groups of 3, run theory to the full group first, then rotate candidates through practical assessment whilst others complete the written test. Reach truck practicals take slightly longer per candidate than counterbalance due to high-level stacking requirements – allow 45–60 minutes per candidate on the truck.
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Learning Outcomes
Knowledge Outcomes
On successful completion, the candidate will be able to:
Legal duties – Explain operator responsibilities under HSWA 1974, PUWER 1998, LOLER 1998, and HSE ACOP L117
Reach truck components & safety systems – Identify and describe the function of key reach truck components including the pantograph/scissors mechanism, tilting mast, and battery compartment
Stability principles – Explain the stability triangle specific to reach trucks, the effects of high-level lifting on centre of gravity, and the importance of level floor surfaces
High-level operations – Describe correct procedures for picking and placing loads at height, including mast staging, tilt control, and residual capacity at full lift height
Narrow aisle navigation – Demonstrate understanding of safe navigation in narrow aisles, including clearances, pedestrian exclusion, and speed management
Battery management – Explain safe battery charging, handling, and maintenance procedures including hydrogen gas risks and PPE requirements
Pedestrian safety – Identify pedestrian hazards in warehouse environments and describe safe systems of work for mixed traffic areas
Registration and candidate verification. Introductions and course overview. Quick initial knowledge check (informal). Overview of HSWA 1974, PUWER 1998, LOLER 1998, and L117 ACOP. Employer and operator duties. Consequences of non-compliance. Specific legal requirements for working at height with powered equipment.
Session 2 60–75 min
Theory Review – Reach Truck Specifics
Reach truck design and operating principles (stand-on vs sit-in, pantograph reach, tilting mast). Stability triangle specific to reach trucks. Centre of gravity changes at height. Residual capacity and de-rating at extended reach/height. Narrow aisle operations and clearances. Battery care, charging procedures, and hydrogen gas risks. Discussion of real warehouse incidents involving reach trucks.
Session 3 30–45 min
Practical Demonstration
Trainer demonstration of full pre-use inspection (RT-01). Demonstration of correct aisle entry, navigation, and exit. Demonstration of high-level pick and place operations with running commentary. Demonstration of safe parking and battery connection procedures. Candidates observe and ask questions.
Session 4 60–90 min
Supervised Practice & Practical Assessment
Each candidate performs pre-use inspection (RT-01). Manoeuvring: forward, reverse, aisle entry, tight turns (RT-02). Load handling: approach, pick, travel, high-level stack, de-stack from racking (RT-03). Parking and shutdown procedure including battery connection (RT-04). One-to-one coaching and correction. Formal practical assessment using Section 7 assessment sheet.
Session 5 30–45 min
Theory Assessment
25-question closed-book written test covering all knowledge outcomes. Pass mark: 80% (20/25). Candidates who fail may have one resit opportunity at the trainer's discretion.
Session 6 20–30 min
Debrief & Certification
One-to-one feedback session. Review of theory and practical results. Identification of bad habits and development areas. Individual action plan agreed. Certificate issued (if competent). Discussion of site-specific procedures and ongoing CPD.
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Theory Quiz – 25 Questions
Closed-book assessment. Pass mark: 80% (20 out of 25).
A. Legislation & Legal Duties (Questions 1–5)
Question 1
Which regulation specifically requires that forklift operators receive adequate training before operating a reach truck?
COSHH 2002
PUWER 1998
RIDDOR 2013
Environmental Protection Act 1990
Answer: (b) Provision and Use of Work Equipment Regulations 1998 (PUWER), specifically Regulation 9 – Training. This requires that all persons who use, supervise, or manage the use of work equipment have received adequate training for health and safety purposes.
Question 2
What is the main legal duty of a reach truck operator under the Health and Safety at Work Act 1974?
Write risk assessments for the warehouse
Carry out mechanical repairs on the reach truck
Take reasonable care for their own safety and that of others who may be affected by their actions
Train other operators
Answer: (c) Under Section 7 of HSWA 1974, every employee must take reasonable care for their own health and safety and that of others who may be affected by their acts or omissions at work.
Question 3
What does LOLER 1998 stand for and why is it relevant to reach truck operations?
Lifting Operations and Lifting Equipment Regulations – it covers all lifting operations including raising loads to height
Loading Obligations and Legal Employment Regulations – it covers employee contracts
Logistics Operations and Logistics Equipment Regulations – it covers warehouse management
Lift Operator and Lift Equipment Regulations – it only covers passenger lifts
Answer: (a) Lifting Operations and Lifting Equipment Regulations 1998. LOLER requires that lifting operations are properly planned, supervised, and carried out safely. Reach trucks routinely lift loads to significant heights, making LOLER directly applicable to their operation.
Question 4
According to HSE ACOP L117, what are the three stages of forklift operator training?
Online learning, written test, practical test
Basic training, specific job training, familiarisation training
Answer: (b) L117 identifies three stages: (1) Basic training – off-the-job, covering core skills; (2) Specific job training – on-site, covering workplace-specific operations; (3) Familiarisation training – on the specific truck(s) and in the actual working environment. All three must be completed.
Question 5
Name four circumstances in which a reach truck refresher or re-test would be recommended.
Answer: (1) Routine refresher every 3–5 years as recommended by HSE L117; (2) After an accident or near miss; (3) When unsafe habits are observed by management or colleagues; (4) When changing workplace, truck type, racking layout, or operating conditions. Also accepted: returning after prolonged absence from reach truck operations.
B. Pre-Use Checks & Battery Care (Questions 6–10)
Question 6
What specific items must be checked on the reach truck mast during a pre-use inspection?
Answer: Check for: damaged or bent mast sections; worn or cracked lift chains (equal tension, no stretching); hydraulic hoses and cylinders (leaks, damage); carriage and fork condition (cracks, wear at heel); mast rollers (wear, smooth operation); reach mechanism (pantograph arms or scissors for damage, smooth operation); tilt cylinder condition. Any defects must be reported immediately and the truck taken out of service.
Question 7
Why is checking the battery particularly important on a reach truck before starting work?
Battery weight affects stability and the truck may not operate correctly with a low charge
It only affects the horn volume
Low battery just means the lights are dimmer
Battery condition has no effect on reach truck performance
Answer: (a) The battery is a major component of the truck's counterweight. A missing or incorrect battery significantly affects stability. Low charge also reduces hydraulic performance, which is critical when operating at height. Check battery charge level, electrolyte levels (if applicable), terminal connections, and that the correct battery type is fitted.
Question 8
What are the main hazards associated with battery charging areas?
Noise pollution only
Hydrogen gas (explosive), acid burns from electrolyte, electrical shock, heavy lifting injuries
There are no specific hazards
Only the risk of tripping over cables
Answer: (b) Battery charging produces hydrogen gas which is highly explosive – charging areas must be well ventilated with no naked flames or ignition sources. Sulphuric acid electrolyte can cause severe burns to skin and eyes. Electrical short circuits can cause burns or fire. Batteries are extremely heavy (typically 1,000–2,500 kg) and require proper handling equipment for changes. PPE (goggles, acid-resistant gloves, apron) must be worn.
Question 9
During pre-use checks you discover a hydraulic oil leak beneath the reach mechanism. What is your first action?
Top up the hydraulic oil and continue working
Ignore it if the leak is small
Report it immediately, take the truck out of service, and clean up the spillage
Ask a colleague whether they think it is serious
Answer: (c) Report the fault immediately to your supervisor and take the truck out of service. A hydraulic leak can cause sudden loss of lift capability – extremely dangerous when loads are at height. The spillage must be cleaned up to prevent slip hazards. Tag or isolate the truck to prevent others from using it.
Question 10
List five items you would check during a daily pre-use walk-around inspection of a reach truck.
Answer: Any five from: battery charge level and connections; forks (cracks, heel wear, alignment); mast and carriage (damage, chain tension); reach mechanism (smooth operation, damage); hydraulic system (leaks, hose condition); wheels and tyres (wear, damage, debris); brakes (footbrake, parking brake); steering (play, smooth response); warning devices (horn, beacon, lights); operator compartment (seatbelt/dead man's switch, controls, cleanliness); load backrest (secure, undamaged).
C. Load Handling at Height (Questions 11–15)
Question 11
What happens to the rated capacity of a reach truck as the mast is raised to full height?
Capacity increases because the mast provides more leverage
Capacity stays exactly the same at all heights
Capacity decreases as the centre of gravity rises, reducing stability
Capacity doubles when the reach is extended
Answer: (c) As the load is raised, the combined centre of gravity moves upward, reducing the truck's stability. The rated capacity at full height and full reach is significantly less than at ground level. Always check the capacity plate for the specific lift height and reach distance before attempting to lift.
Question 12
When stacking a load at high level in racking, at what point should you tilt the mast forward?
Before raising the load
Only once the load is at the correct height and positioned over the racking beam, using minimal forward tilt
Immediately after picking up the load
Tilting forward is never required
Answer: (b) Forward tilt at height is extremely dangerous and must be minimised. Raise the load to height with the mast vertical or very slightly tilted back. Only apply minimal forward tilt when the forks are positioned directly over the racking location to place the load. Excessive forward tilt at height is one of the most common causes of reach truck tip-overs.
Question 13
What is “residual capacity” and why must the operator understand it?
Answer: Residual capacity is the actual lifting capacity available at a given mast height and reach extension. It is always less than the ground-level rated capacity. As the mast extends upward and the reach mechanism extends forward, the effective counterweight moment decreases. The operator must check the capacity plate to confirm that the load weight does not exceed the residual capacity at the intended height and reach distance. Exceeding residual capacity will cause a tip-over.
Question 14
Why should loads never be raised or lowered whilst the reach truck is travelling?
It uses too much battery power
It creates an unstable, moving centre of gravity and reduces the operator's ability to control the truck safely
It is only a problem on slopes
It slows down the truck
Answer: (b) Raising or lowering a load whilst travelling creates a constantly shifting centre of gravity. Combined with the forward/backward forces of travel, this significantly reduces stability and control. The operator must also focus fully on the travel route and cannot safely monitor load positioning at the same time. Always stop completely before operating hydraulics.
Question 15
What precautions must be taken before placing or retrieving a load from racking?
Answer: (1) Check the racking is in good condition (no damage to uprights or beams); (2) Confirm the racking is rated for the load weight; (3) Position the truck square to the racking face; (4) Apply the parking brake before raising the mast; (5) Check above and around for obstructions and other workers; (6) Ensure the aisle is clear of pedestrians; (7) Verify the load weight against the residual capacity at the required height; (8) Raise smoothly and place carefully, using minimal tilt.
D. Narrow Aisle Operations & Pedestrian Safety (Questions 16–20)
Question 16
What is the minimum recommended clearance between the reach truck (including load) and the racking on either side in a narrow aisle?
No clearance is needed
At least 50mm clearance on each side for safe passage
At least 200mm clearance on each side
The truck should touch the racking as a guide
Answer: (c) A minimum of 200mm clearance on each side is the general recommended guideline, though specific clearances should be based on the site risk assessment and truck manufacturer's guidance. Tight clearances require slower speeds and heightened awareness. Guide rails or wire guidance systems may be fitted in very narrow aisles.
Question 17
Why should pedestrians be excluded from aisles where reach trucks are operating?
Pedestrians slow the truck down
The narrow space leaves no escape route, and falling loads from height can cause fatal injuries
It is only a recommendation, not a requirement
Pedestrians are only at risk from counterbalance trucks
Answer: (b) Narrow aisles give pedestrians no escape route if a truck approaches. The primary risk is from loads falling from height – a pallet falling from 8 metres is almost certainly fatal. Reach trucks also have limited rear visibility. Pedestrians must be excluded from operating aisles using physical barriers, signage, and traffic management systems.
Question 18
When entering a narrow aisle, what checks must the operator carry out?
Answer: (1) Sound the horn before entering; (2) Check that the aisle is clear of other trucks, pedestrians, and obstructions; (3) Ensure the load (if carried) is within the aisle width with adequate clearance; (4) Confirm forks are at the correct travel height (approximately 150–200mm); (5) Check overhead clearance including sprinklers and lighting; (6) Enter slowly and maintain observation. Some sites use traffic light or one-way systems – always follow site-specific rules.
Question 19
What should you do if you notice damage to a racking upright or beam whilst operating in an aisle?
Continue working and mention it at the end of the shift
Immediately stop work, leave the aisle, report the damage, and ensure the area is cordoned off
Try to straighten the damaged section
Only report it if a load falls
Answer: (b) Damaged racking can collapse without warning, potentially causing a domino effect across multiple bays. Stop work immediately, leave the aisle safely, report the damage to your supervisor, and ensure the area is cordoned off until a competent racking inspector can assess it. Never attempt to repair racking yourself. SEMA guidelines require immediate reporting of any racking damage.
Question 20
What systems may be used to manage pedestrian and truck traffic in a warehouse?
Answer: (1) Designated pedestrian walkways separated by barriers or floor markings; (2) One-way aisle systems; (3) Traffic light systems at aisle ends; (4) Physical barriers (bollards, guardrails) at pedestrian crossings; (5) High-visibility clothing for all pedestrians; (6) Speed limits enforced by signage or electronic limiters; (7) Mirrors at blind corners; (8) Blue spot or red zone lights on trucks; (9) Pedestrian exclusion zones in operating aisles; (10) Audible and visual warnings on trucks (horn, beacon, reversing alarm).
E. Emergency Procedures, Parking & Post-Use (Questions 21–25)
Question 21
If the reach truck loses power whilst a load is raised at height, what should you do?
Jump off the truck immediately
Stay on the truck, apply the parking brake, warn others to stay clear, and call for assistance
Try to lower the load by rocking the truck
Leave the area and deal with it later
Answer: (b) Stay on the truck and remain calm. Apply the parking brake. Do not attempt to leave if the load could fall on or near you. Use the horn or radio to warn others to stay clear of the area beneath the raised load. Call for a supervisor or engineer. Most reach trucks have an emergency lowering valve that a trained person can operate manually to lower the load safely.
Question 22
What is the correct procedure if a reach truck begins to tip over?
Jump clear of the truck
Stay in the operator compartment, brace yourself, hold on firmly, and lean away from the direction of the fall
Try to steer out of the tip
Release all controls and close your eyes
Answer: (b) Never attempt to jump from a tipping truck – operators who jump are frequently crushed by the overhead guard or mast. Stay in the compartment, brace yourself with feet firmly on the floor, hold onto the steering wheel or grab handles, and lean away from the point of impact. The operator compartment and overhead guard are designed to protect you.
Question 23
In the event of a fire alarm, what should a reach truck operator do?
Answer: (1) Stop the truck immediately in a safe position (not blocking emergency routes); (2) Lower any raised load to the ground if it can be done quickly and safely; (3) Apply the parking brake; (4) Switch off the truck and remove the key; (5) Evacuate the building via the nearest emergency exit on foot; (6) Report to the designated assembly point; (7) Never return to the truck until authorised by the fire marshal or emergency services.
Question 24
Describe the correct parking and shutdown sequence for a reach truck.
Answer: (1) Park in the designated safe area, away from traffic routes, fire exits, and racking; (2) Lower forks fully to the ground; (3) Retract the reach mechanism fully; (4) Ensure the mast is vertical (no tilt); (5) Apply the parking brake; (6) Select neutral; (7) Switch off the truck; (8) Remove the key and store securely; (9) If required, connect the truck to the battery charger following the correct sequence (charger off → connect → charger on).
Question 25
What is the correct sequence for connecting a reach truck battery to a charger?
Plug in whilst the charger is running to save time
Ensure the charger is switched off, connect the battery plug to the charger, then switch the charger on
It does not matter what order you connect it
Switch the charger on first, then connect the battery
Answer: (b) Always ensure the charger is switched off before connecting or disconnecting the battery. Connecting under load can cause arcing and sparks, which is an ignition risk near hydrogen gas produced during charging. Sequence: charger OFF → connect battery plug → charger ON. To disconnect: charger OFF → disconnect battery plug. Ensure adequate ventilation in the charging area at all times.
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Practical Assessment Sheet
Candidate Details
Candidate Name
Company
Date
Truck Type / ID
Score each item: C = Competent | ND = Needs Development | NYC = Not Yet Competent
RT-01: Pre-Use Inspection (10 Items)
Assessment Item
C
ND
NYC
1. Approaches truck safely, checks for hazards around vehicle
□
□
□
2. Checks battery charge level, connections, and condition
□
□
□
3. Checks wheels/tyres (wear, damage, debris embedded in treads)
Date of Assessment________________________________
Assessor________________________________
Refresher Due________________________________
Units Achieved
RT-01: Prepare Reach Truck for Use (Pre-Use Checks & Battery)
RT-02: Operate and Manoeuvre Safely (Including Narrow Aisle Navigation)
RT-03: Handle Loads at Height (Stacking, De-stacking & Racking Operations)
RT-04: Secure and Shut Down (Post-Operational Checks & Battery Charging)
Aligned to Level 2 Forklift Truck Operations National Occupational Standards, PUWER 1998, and LOLER 1998.
Assessor Name & Signature
Employer Authorisation
This is not a CPCS, NPORS, or RTITB accredited card. This certificate confirms unit achievement assessed by PHW Services in accordance with HSE ACOP L117 recommendations. Employer authorisation confirms the operator is permitted to operate within their workplace.
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Trainer Notes
Structuring the Day
Recommended Flow
Start with theory – deliver Sessions 1 & 2 to the full group. This refreshes knowledge before they touch the truck, and covers the reach-specific stability and battery content.
Trainer demonstration – run Session 3 (practical demo) with all candidates observing. Talk through every action so candidates understand the standard expected.
Rotate practical – send Candidate 1 to the truck (Session 4) while Candidates 2 & 3 complete the written quiz (Session 5). Rotate through.
Finish with feedback – once all candidates have completed practical and theory, do individual debrief sessions (Session 6).
For individuals – run straight through Sessions 1–6 sequentially. Allow natural breaks between theory and practical.
Key Points to Emphasise
Residual capacity at height – this is the single most important concept for reach truck operators. Many experienced operators assume the ground-level capacity applies at all heights. Use the capacity plate on the actual truck to demonstrate how dramatically capacity drops at full height and full reach extension. Make them calculate real examples.
Tilt at height is lethal – excessive forward tilt with a load at 8+ metres is one of the most common causes of reach truck tip-overs. Only tilt at ground level; level the mast before raising. Demonstrate what happens to the centre of gravity using a simple model (water bottle on a ruler on a fulcrum).
Battery safety is not optional – hydrogen gas explosions in charging areas do happen. Acid burns are serious. Walk through the charging area if possible and physically point out ventilation, PPE, eye wash, and spill kits.
Racking damage kills – show images of racking collapses (SEMA has excellent case studies). A single damaged upright can cause a progressive collapse across multiple bays. The operator must report ANY contact with racking immediately, no matter how minor it appears.
Pedestrian exclusion – reach trucks operate in narrow aisles where pedestrians have no escape route. A pallet falling from 10 metres is fatal. Ensure operators understand their responsibility to check aisles are clear before entering and to use all available warning systems.
Floor surface matters – reach trucks operate on small polyurethane wheels. Any debris, moisture, or uneven surface significantly affects steering and stability, far more than a counterbalance on pneumatic tyres. Operators must report floor defects.
Common Bad Habits to Watch For
Bad Habit
Why It Matters
Correction
Skipping battery checks
Wrong/low battery affects stability and hydraulic performance at height
Walk through full battery check; explain weight and performance link
Not checking residual capacity
Overloading at height causes tip-over
Make them read the capacity plate for specific height/reach combinations
Tilting forward at height
Load slides off forks; catastrophic instability
Only tilt at ground level; demonstrate centre of gravity shift
Raising/lowering whilst travelling
Shifting centre of gravity; loss of control
Full stop before any hydraulic operation; make it automatic
Entering aisles without checking
Collision with other trucks or pedestrians
Horn, visual check, and slow entry every single time
Excessive speed in aisles
No escape room; racking strikes; pedestrian danger
Walking pace in aisles; demonstrate stopping distances
Not reporting racking strikes
Progressive collapse risk; delayed failure
Show collapse case studies; explain legal consequences
Incorrect charging procedure
Arcing risk near hydrogen gas; acid exposure
Walk through correct sequence; demonstrate PPE requirements
Standing outside operator compartment
Exposure to falling loads and moving parts
Feet inside the compartment at all times when operating
Reach Truck vs Counterbalance – Key Differences to Highlight
Many refresher candidates also hold counterbalance certificates. Emphasise these critical differences:
Feature
Counterbalance
Reach Truck
Operating environment
Indoor/outdoor, open areas
Indoor warehouse only, narrow aisles
Primary lifting height
Typically 3–5 metres
Typically 6–12 metres
Stability method
Heavy rear counterweight
Battery as counterweight + wide straddle legs
Reach mechanism
None (fixed mast)
Pantograph or scissors extends load forward
Tyres
Pneumatic or cushion (large)
Small polyurethane (sensitive to debris/moisture)
Steering
Rear-wheel steer
Rear-wheel steer (tighter turning)
Capacity at height
Moderate reduction
Significant reduction (check plate carefully)
Battery management
May be diesel/LPG
Always electric; battery is critical counterweight
Handling Failed Candidates
Process for “Not Yet Competent” Results
Theory fail (below 80%) – offer one resit opportunity on the same day. If they fail again, recommend further study and a re-test on another date. Do not pass them.
Practical fail – identify specific areas of weakness and provide targeted coaching. If minor issues (e.g., hesitancy at height), allow a second attempt after coaching. If fundamental competence concerns (e.g., cannot judge clearances, poor mast control at height), recommend additional training hours or a full novice conversion course.
Document everything – complete the assessment sheet fully, noting specific areas of concern. This protects the training provider and gives the employer clear information.
Communicate with the employer – explain the result professionally. Focus on the candidate's development needs, not personal criticism. Recommend a clear pathway to competence.
Never pass a candidate who isn’t competent – your signature on that certificate carries legal weight. Reach truck incidents at height are frequently fatal. If there is a serious incident, your assessment records will be examined by the HSE.
Documentation Checklist
Complete all of the following for every candidate:
Document
When
Retain For
Candidate registration form (name, company, previous training evidence)
Before course starts
3 years minimum
Medical fitness declaration (FS19-style, signed by employer)