You're tackling two really important issues here-thanks for laying them out so clearly.

On training and evaluation:
Unfortunately, OEMs and dealers rarely provide structured training materials beyond the operator's manual. Your approach of combining a generic forklift video/quiz with a tailored, task-specific hands-on evaluation is exactly what OSHA expects-training customized to the actual equipment and work environment. Many companies in heavy manufacturing build their own checklists, breaking down the real-world lifts and transports (as you described) into critical steps. That not only satisfies compliance but also ensures practical skill-building. Documenting those scenarios with photos and step-by-step instructions will strengthen your training program.

On travel with elevated loads:
You're right to stick with OSHA and the operator's manual-loads should be carried as low as safely possible (typically 4-6 inches off the ground). Even without overhead hazards, elevated travel greatly increases the risk of tip-over, equipment strain, and uncontrolled load drop. Operator habit and "we've always done it this way" are common challenges, but they don't override safety fundamentals.

Your policy-requiring reverse travel when forward view is obstructed-is consistent with OSHA guidance. Yes, it comes with ergonomic challenges (neck rotation, obstructed exhaust view), but those are lower-risk compared to catastrophic instability. Some employers address this by:

Adding rear-view cameras or mirrors to improve reverse visibility.

Using rotating seats (if available) to reduce operator strain.

Providing refresher training specifically on reversing with large loads.

Bottom line: your plan to formalize task-specific training and enforce reverse travel when visibility is blocked is solid. You might get more buy-in by presenting a risk matrix that compares the likelihood/severity of elevated travel accidents vs. reverse travel challenges, showing why the safer compromise is necessary.

Would you like me to draft a sample task-based evaluation checklist for your heavy lift truck operators that you could adapt to your environment?