Forklift and Powered Industrial Truck Operator Safety: Complete Course

Forklift tipovers, falls from dock edges and pedestrian strikes kill dozens of workers every year and injure tens of thousands more. This in-depth course explains OSHA's Powered Industrial Truck standard (29 CFR 1910.178 for general industry and 1926.602 for construction), the seven classes of trucks, how a forklift stays stable and why it tips, the pre-shift inspection, safe driving practices on flat ground, ramps and in tight places, picking up, carrying and stacking loads, working at loading docks and in trailers, fueling LP gas, diesel and charging batteries, pedestrian and traffic management, narrow-aisle and rough-terrain trucks, and how employers must train, evaluate and refresh operators. It ends with case studies and a final exam. This course supplies the classroom knowledge part of operator training. OSHA requires the employer to also provide practical, hands-on training and an evaluation of each operator on the actual truck in the actual workplace, and this course cannot do that for you. It is not an OSHA-issued certification.

What you’ll learn

• Explain the OSHA requirements for powered industrial truck operators and employers
• Identify the classes and types of trucks and read a capacity data plate
• Describe the stability triangle and the causes of tipovers, and know what to do if a truck tips
• Perform a complete pre-shift inspection and decide when a truck must be removed from service
• Drive safely on the level, on ramps and around pedestrians and obstructions
• Pick up, carry, stack and place loads, including unstable and oversize loads, without tipping or dropping them
• Work safely at loading docks and in trailers and avoid dock and trailer accidents
• Refuel LP gas and diesel trucks and charge or change batteries safely
• Understand narrow-aisle, reach, order picker, rough terrain and telehandler hazards
• Describe how operators must be trained, evaluated and refreshed, and how supervisors keep a safe operation

Who it’s for

Forklift and pallet jack operators, warehouse and manufacturing workers, construction and landscape equipment operators, supervisors, safety coordinators, trainers, and anyone who works around powered industrial trucks. No experience is needed.

Course outline

Module 1: Forklift Basics and the OSHA Rule 4 lessons · quiz

Why forklifts are dangerous, what the OSHA standard requires, and the classes of powered industrial trucks.

• Why forklift safety matters 12 min Free preview
• OSHA's powered industrial truck standard 14 min
• Classes and types of trucks 14 min
• Parts of a forklift and the data plate 14 min

Module 2: Stability and Tipovers 4 lessons · quiz

The stability triangle, center of gravity, the factors that cause tipovers, and what to do if a truck starts to tip.

• The stability triangle and center of gravity 15 min Free preview
• Causes of tipovers 14 min
• If the truck tips: the seat belt rule 14 min
• Load capacity, load center and attachments 14 min

Module 3: Inspections, Fueling and Charging 4 lessons · quiz

The daily pre-shift inspection, defects that take a truck out of service, battery charging and changing, and LP gas, gasoline and diesel fueling.

• The pre-shift inspection 15 min Free preview
• Maintenance, repairs and modifications 12 min
• Battery charging and changing (electric trucks) 14 min
• Fueling LP gas, gasoline and diesel trucks 14 min

Module 4: Driving Safely 4 lessons · quiz

Starting and stopping, speed, turning, visibility, ramps and slopes, pedestrians, and the rules of the road for forklifts.

• Mounting, starting and basic operation 14 min Free preview
• Speed, turning and visibility 15 min
• Ramps, slopes and rough surfaces 14 min
• Pedestrians and traffic rules 14 min

Module 5: Handling Loads 3 lessons · quiz

Picking up, carrying, placing and stacking loads, pallets, racks, unstable and oversize loads, and the rule against lifting people.

• Picking up and carrying a load 15 min Free preview
• Stacking and racking 14 min
• Special loads and attachments 14 min

Module 6: Docks, Trailers and Special Environments 4 lessons · quiz

Loading docks, trailers and dock plates, vehicle restraints, working in trailers, cold storage, outdoors, hazardous locations and construction sites.

• Loading dock hazards 15 min Free preview
• Working inside trailers and containers 14 min
• Cold, wet, outdoor and hazardous locations 14 min
• Emergencies and incident response 12 min

Module 7: Other Powered Trucks 3 lessons · quiz

Pallet jacks, reach trucks, order pickers, stand-up riders, tow tractors and telehandlers, and the special hazards of each.

• Pallet jacks and low-lift trucks 12 min Free preview
• Reach trucks, order pickers and narrow-aisle trucks 15 min
• Rough terrain forklifts and telehandlers 15 min

Module 8: Training, Programs and Case Studies 4 lessons · quiz

How OSHA requires operators to be trained, evaluated and refreshed, how to run a safe forklift program, and lessons from real kinds of incidents.

• Operator training requirements 15 min Free preview
• Refresher training and evaluation 12 min
• Running a safe forklift program 15 min
• Case studies and lessons learned 14 min

What’s included

• 30 lessons you can read at your own pace, on a phone or a computer
• A short quiz after every module, with the correct answer shown for any you miss
• A final exam of 30 questions (pass at 80% or higher)
• A numbered certificate of completion with a QR code anyone can scan to verify it
• Your progress saved to your account, with access that doesn’t expire

Questions

Can an employer check my certificate? Yes. Each certificate has a number and a QR code that opens a public verification page on this site.

Can I get a refund? Yes, within 7 days of purchase if you have completed less than 25% of the course and haven’t earned its certificate. Email support@toddallynmedia.com. Details are in section 13 of the Terms of Use. Payment is handled by PayPal; we never see your card details.

What do I need? A free account and any phone, tablet or computer. Questions or problems? Email support@toddallynmedia.com.