Forklift Operator Training Course

Lesson 1 • Regulatory Framework for Forklift Safety

Introduces the federal agency standards governing powered industrial trucks and employer obligations. Operators understand which rules apply and why compliance is mandatory.

Lesson 2 • Types of Forklifts and Their Uses

Covers counterbalance, reach, order picker, and rough-terrain forklifts. Matching equipment type to task is the first step towards safe operation decisions.

Lesson 3 • Forklift Accident Statistics and Causes

Presents industry injury and fatality data to contextualise why training matters. Understanding root causes motivates operators to internalise safe practices.

Lesson 1 • Mast, Forks, and Carriage Assembly

Explains the structure and movement of the mast, fork arms, and carriage. Operators learn how load-handling components interact during lifting and tilting.

Lesson 2 • Operator Controls and Instrumentation

Maps every control lever, pedal, switch, and gauge in the operator compartment. Familiarity with controls is prerequisite to safe pre-shift and operational procedures.

Lesson 3 • Steering, Braking, and Drive Systems

Details rear-wheel steering mechanics, service brakes, parking brakes, and drive axles. Operators understand how these systems affect control and stopping distance.

Lesson 4 • Power Sources: Electric, LP Gas, and Diesel

Compares battery-electric, liquid propane, and diesel powertrains across performance and hazard profiles. Operators select and handle the correct power source safely.

Lesson 1 • OSHA Pre-Shift Inspection Requirements

States the regulatory requirement to inspect forklifts before each shift and after any incident. Operators understand the legal basis and documentation expectations.

Lesson 2 • Removing Equipment from Service

Establishes criteria for tagging out a defective forklift and notifying maintenance. Operators learn that operating unsafe equipment is a regulatory violation, not a judgment call.

Lesson 3 • Fluid and Leak Inspection

Covers engine oil, hydraulic fluid, coolant, and battery electrolyte checks. Fluid deficiencies and leaks are leading indicators of imminent mechanical failure.

Lesson 4 • Exterior and Structural Inspection

Guides operators through checking the frame, mast, forks, tyres, and overhead guard. Structural defects identified here prevent catastrophic failures during operation.

Lesson 1 • Nameplate Capacity and Load Centres

Explains how to read the data plate, interpret rated capacity, and apply load centre distances. Operators calculate actual capacity for non-standard loads before lifting.

Lesson 2 • Load Weight Estimation and Verification

Teaches methods for estimating unknown load weights using volume, density, and shipping documents. Operators never lift a load whose weight exceeds verified capacity.

Lesson 3 • Attachments and Capacity Modifications

Covers side shifters, clamps, rotators, and their effect on rated capacity. Operators understand that every attachment requires a revised data plate before use.

Lesson 1 • Ramps, Grades, and Dock Plates

Details ascending and descending ramp procedures, grade limits, and dock plate weight ratings. Operators navigate elevation changes without losing load control or stability.

Lesson 2 • Travelling with Loads

Covers fork height, mast tilt, and travel direction rules for loaded forklifts. Proper load position during travel is the single greatest factor in preventing tip-overs.

Lesson 3 • Safe Travel Speeds and Distances

Defines speed limits, following distances, and stopping distance calculations for loaded and unloaded forklifts. Operators adjust speed proactively based on load, surface, and visibility.

Lesson 4 • Pedestrian Interaction and Right of Way

Establishes rules for yielding to pedestrians, using horns at intersections, and maintaining safe separation. Operators treat pedestrian protection as a non-negotiable priority.

Lesson 1 • Handling Unusual and Unstable Loads

Addresses round, liquid, fragile, and unevenly distributed loads that require modified techniques. Operators apply additional securing and speed restrictions for non-standard loads.

Lesson 2 • High-Rack Stacking Techniques

Teaches approach, elevation, and placement procedures for stacking loads at height. Precision at elevation reduces rack damage and prevents falling load incidents.

Lesson 3 • Fork Insertion and Load Pickup

Details fork insertion depth, lift height, and tilt sequence for safe load pickup. Operators confirm load balance before travelling to prevent mid-travel shifts.

Lesson 4 • Retrieving Loads from Elevated Storage

Covers approach, fork alignment, and controlled lowering when pulling loads from racking. Operators verify rack integrity and load condition before every retrieval.

Lesson 1 • Carbon Monoxide and Fuel Hazards

Addresses CO buildup from internal combustion forklifts in enclosed spaces and LP gas leak risks. Operators recognise symptoms, ventilation requirements, and emergency shutdown steps.

Lesson 2 • Workplace Environmental Hazards

Identifies floor conditions, lighting, overhead clearances, and congestion as primary environmental risks. Operators scan and adapt to changing conditions throughout every shift.

Lesson 3 • Near-Miss Reporting and Hazard Communication

Establishes the value of near-miss reporting and how hazard communication prevents repeat incidents. Operators understand that reporting is a professional duty, not an admission of fault.

Lesson 4 • Struck-By and Caught-Between Hazards

Covers risks of loads falling, forklifts striking workers, and pinch points during operation. Operators use spotters, barriers, and travel rules to eliminate these hazards.

Lesson 1 • Staying Current with Safety Standards

Encourages operators to monitor regulatory updates, attend refresher training, and engage with safety committees. Continuous learning is the foundation of a zero-incident safety culture.

Lesson 2 • Employer Audit and Recordkeeping

Explains what records employers must maintain and how inspectors verify compliance during audits. Operators understand their role in supporting accurate documentation.

Lesson 3 • Certification Training Requirements

Details the three-part training requirement: formal instruction, practical training, and performance evaluation. Operators understand what each component must include to satisfy regulatory standards.

Lesson 4 • Recertification Triggers and Intervals

Identifies the events and time intervals that require operators to be re-evaluated. Operators know that certification is not permanent and must be renewed under specific conditions.