Forklift Safety Course

Lesson 1 • Forklift Types and Applications

Covers counterbalance, reach, order picker, and pallet jack variants and their intended uses. Builds vocabulary needed for all subsequent technical chapters.

Lesson 2 • Regulatory Framework and Operator Duties

Introduces workplace safety authority requirements, employer obligations, and operator certification standards. Establishes the compliance mindset carried throughout the course.

Lesson 3 • Forklift Components and Terminology

Identifies mast, forks, carriage, tilt cylinders, overhead guard, and controls by name and function. Shared terminology prevents miscommunication during practical exercises.

Lesson 1 • Fluid and Battery Checks

Covers engine oil, hydraulic fluid, coolant, and fuel levels for IC forklifts, plus battery water and charge for electric models. Proper fluid levels prevent mechanical failure mid-operation.

Lesson 2 • Purpose and Frequency of Inspections

Explains why daily and shift-start inspections are mandatory and how they reduce incident rates. Connects inspection discipline to the regulatory obligations introduced in Chapter 1.

Lesson 3 • Exterior and Structural Checks

Guides operators through inspecting tyres, forks, mast, chains, and frame for visible damage. Structural integrity directly affects load stability and tip-over risk.

Lesson 4 • Operational Function Testing

Tests horn, lights, brakes, steering, hydraulics, and safety devices before each shift. Functional testing confirms that controls respond correctly under no-load conditions.

Lesson 1 • Mounting, Dismounting, and Seating

Covers three-point contact mounting, seat adjustment, seatbelt use, and safe dismounting technique. Correct seating posture reduces fatigue and keeps the operator within the protective envelope.

Lesson 2 • Hydraulic Control Operation

Practices lift, lower, tilt, and side-shift lever inputs with precision and smooth motion. Hydraulic control skill directly determines load stability during travel and placement.

Lesson 3 • Basic Manoeuvring Exercises

Executes straight travel, turns, reversing, and parking in a marked practice area. Repetitive drills build the spatial awareness required for warehouse aisle navigation.

Lesson 4 • Steering and Directional Controls

Explains rear-wheel steering dynamics, turning radius, and directional lever operation. Understanding counterintuitive rear-wheel steering prevents overcorrection and tip-over.

Lesson 1 • Rated Capacity and Load Charts

Teaches how to read the data plate, interpret load centre distances, and calculate allowable loads with attachments. Overloading is a leading cause of tip-overs and structural failure.

Lesson 2 • Load Placement and Stacking

Guides operators through approach, positioning, lifting to height, and depositing loads safely. Precise placement prevents rack damage, load collapse, and pedestrian injury.

Lesson 3 • Travelling with a Load

Establishes travel height, mast tilt, speed limits, and visibility practices when carrying loads. Loaded travel is the highest-risk phase of forklift operation.

Lesson 4 • Stability Triangle and Centre of Gravity

Explains the three-point stability triangle, combined centre of gravity, and how load position shifts it. This physics foundation is prerequisite to every load handling decision.

Lesson 1 • Forklift and Pedestrian Separation

Covers designated lanes, barriers, signage, and exclusion zones that physically separate forklifts from foot traffic. Physical separation is the most effective struck-by prevention measure.

Lesson 2 • Right-of-Way and Traffic Rules

Establishes intersection protocols, right-of-way hierarchy, and speed limits in shared areas. Consistent rules reduce unpredictability that leads to collisions.

Lesson 3 • Visibility and Communication Techniques

Teaches horn use, eye contact, hand signals, and spotter coordination in low-visibility areas. Active communication compensates for blind spots and noisy environments.

Lesson 4 • Blind Spot and Obstruction Management

Addresses mirrors, cameras, and slow-speed travel through blind corners and doorways. Operators learn to treat every blind area as occupied until confirmed clear.

Lesson 1 • Ramp and Incline Operations

Covers grade limits, load orientation on slopes, and braking technique for ascending and descending. Incorrect ramp technique is a primary cause of tip-overs and runaway loads.

Lesson 2 • Narrow Aisle and High-Rack Operations

Teaches reach truck and order picker techniques for very narrow aisles and elevated picking. Height and confined space amplify every stability and visibility risk.

Lesson 3 • Cold Storage and Hazardous Environments

Addresses condensation on controls, battery performance in cold, and operating near flammable materials. Environmental extremes require equipment selection and behavioural adjustments.

Lesson 4 • Loading Dock and Trailer Operations

Addresses dock plate use, trailer chocking, landing gear checks, and floor integrity before entry. Trailer movement during loading is a leading cause of fatal forklift incidents.

Lesson 1 • Post-Incident Investigation Basics

Introduces root cause analysis, witness statements, and corrective action documentation. Operators understand their role in the investigation process and the value of honest reporting.

Lesson 2 • Collision and Struck-By Response

Covers immediate shutdown, scene securing, injury assessment, and incident reporting after a collision. Correct first response preserves evidence and prevents secondary incidents.

Lesson 3 • Tip-Over Survival Technique

Teaches the stay-in-seat, brace, and lean-away response that saves lives during lateral tip-overs. Operators must override the instinct to jump, which is the leading cause of crush fatalities.

Lesson 4 • Fire and Fuel Emergency Procedures

Addresses LPG leak response, battery fire characteristics, and fire extinguisher selection for forklift fires. Fuel type determines the correct suppression method and evacuation urgency.

Lesson 1 • Safety Culture and Reporting Habits

Builds the mindset of proactive hazard reporting, near-miss disclosure, and peer accountability. A strong safety culture sustains compliance between formal evaluations.

Lesson 2 • Continuous Improvement in Forklift Safety

Connects incident data, audit findings, and industry best practices to ongoing programme improvement. Operators see how their feedback drives systemic safety enhancements.

Lesson 3 • Operator Performance Monitoring

Introduces supervisor observation, telematics data review, and behavioural safety indicators used to track performance. Monitoring data identifies skill decay before it causes incidents.

Lesson 4 • Certification Evaluation Criteria

Details the written knowledge test, practical skills evaluation, and observation checklist used to certify operators. Clear criteria allow operators to self-assess readiness before formal evaluation.