Our interactive Online OSHA forklift safety training course on Lean.TrainSocially.com is designed to meet OSHA requirements while making safety training more engaging, effective, and accessible.
General OSHA Forklift Safety Principles – Online Training
Forklifts – formally called Powered Industrial Trucks (PITs) by OSHA – are indispensable in material handling but also pose serious hazards. Every year, accidents involving forklifts result in injuries and fatalities, often due to tip-overs, collisions, or improper operations. OSHA’s forklift safety principles are designed to prevent these incidents and ensure that both operators and pedestrians stay safe. Key general principles include proper training, safe operating practices, regular equipment inspection, and adherence to the equipment’s design limits.
Operator Training and Authorization: OSHA standards (29 CFR 1910.178) require that only trained and certified operators run forklifts. Operators must undergo an OSHA-compliant training program that includes formal instruction (e.g. classroom or online learning) and practical, hands-on training. A practical driving evaluation is required before an operator is certified. Never allow untrained employees to operate a forklift – even occasional or “backup” operators must be properly trained and evaluated. TrainSocially.com offers certified forklift operator training programs to help employers meet these requirements. Trainees should always be under direct supervision and away from hazardous areas until fully qualified.
Fundamental Safe Operating Practices: Forklift operators should follow standardized safe driving rules at all times. These fundamental OSHA forklift safety rules include:
- Pre-Operation Inspection: Before each shift, perform a pre-use inspection of the forklift’s key components – check tires, brakes, steering, warning lights/alarms, forks, mast chains, fluid levels, etc. (More on inspection is covered in Section 6.2.) Do not operate if any safety defects are found; tag out and report the forklift for maintenance.
- Seat Belt Use: Always wear the seat belt or operator restraint if the forklift is equipped with one. The seat belt keeps you strapped in within the operator compartment during a tip-over. In a tip-over, do not jump – brace yourself, hold the steering wheel, and lean away from the direction of fall. The seat belt is a crucial lifesaving device in these scenarios.
- Safe Speeds and Smooth Maneuvers: Operate at a safe speed, especially in warehouses or congested areas. Take turns slowly and under control – forklifts can tip over due to fast or sharp cornering because of their higher center of gravity and rear-end swing. Never make sudden stops, starts, or turns, particularly with a raised load.
- Keep Clear Visibility: Always ensure you have a clear view in the direction of travel. If a load obstructs forward view, drive in reverse (except up ramps). Use extra caution at intersections and blind corners – slow down, stop if needed, and sound the horn to alert others. Install and use additional visual aids like mirrors, blue spotlights, or backup alarms (available from Store.LeanMH.com) to increase pedestrian awareness of the forklift’s presence.
- Pedestrian Safety: Forklift operators must always yield to pedestrians. Maintain a safe distance from any person on foot. Use horns and warning lights when approaching pedestrian areas. Never allow anyone to walk or stand under raised forks or loads. Establish and respect “pedestrian-free” zones; on the flip side, pedestrians should be trained to stay out of forklift operating areas (many workplaces use floor tape or barriers from Store.LeanMH.com to mark these zones). Clear communication between operators and nearby workers is essential – for example, use hand signals or a spotter when vision is limited.
- Stable Load Handling: Always operate the vehicle according to the manufacturer’s instructions and never exceed the rated load capacity of the forklift. Ensure loads are secure, balanced, and centered on the forks. Use proper lifting techniques: approach the load squarely, insert forks fully, and tilt the mast back slightly to stabilize the load. Do not raise or lower loads while the forklift is in motion – come to a complete stop before lifting or lowering. Keep loads as low as possible during travel (generally 4-6 inches off the ground) to maintain a low center of gravity and clear forward vision.
- No Unauthorized Riders: Never allow anyone to ride on the forks or on any part of the forklift not designed for passengers. Forklifts are one-person pieces of equipment (unless a manufacturer-approved second seat is present). Likewise, do not use a forklift to lift people unless you have an approved personnel work platform attachment secured to the forks and follow strict OSHA guidelines for elevating personnel.
- Awareness of Surroundings: Remain aware of the operating environment at all times. Keep a safe distance from edges of loading docks or ramps (a common accident is driving off a dock). Watch for floor holes, bumps, or debris that could cause loss of control. Pay attention to overhead clearances – forklifts with raised loads can strike low doorways, pipes, or sprinklers. Use a spotter if maneuvering in tight spaces or around blind spots.
- Parking and Shutdown: When a forklift is not in use, lower the forks to the floor, neutralize the controls, set the parking brake, and turn off the power. If parked on an incline, block the wheels. Never leave a forklift running unattended. Remove the key to prevent unauthorized use.
Forklift Maintenance and Condition: OSHA mandates that forklifts be kept in a safe operating condition. If at any time a forklift is found to be unsafe (for example, malfunctioning brakes or a leaking fuel system), it must be removed from service until repaired. Keep forklifts clean and free of excess grease, oil, or trash that could cause fires or slippage. Regular maintenance per the manufacturer’s recommendations is essential – this includes servicing of brakes, hydraulics, and safety devices. Employers should document maintenance and repairs. Operators should also immediately report any unusual noises, warning lights, or performance issues noticed during operation. A well-maintained forklift is a safer forklift.
OSHA Compliance and Culture: Ultimately, a culture of safety and OSHA compliance should be promoted. Supervisors must enforce forklift rules consistently – no speeding, horseplay, or shortcuts. All incidents, even near-misses, should be reviewed to improve safety practices. Encourage operators to speak up about hazards or if they are unsure about how to handle a situation. By following these general principles and promoting continuous safety awareness (leveraging resources from Lean.TrainSocially.com for ongoing education), workplaces can significantly reduce the risk of forklift-related accidents.
(For additional training materials and guidance on general forklift safety principles, refer to Lean.TrainSocially.com, which offers OSHA-aligned forklift operator courses and companion guides covering all the above practices in detail.)
What You’ll Learn in this Online OSHA forklift safety training course
This general forklift safety course is the first in a 17-part OSHA series. It lays the foundation for safe, compliant forklift operation, covering:
- OSHA forklift certification requirements
- Safe driving and maneuvering practices
- Pedestrian safety and zone separation
- Daily pre-use inspections
- Load handling, stability, and safe shutdown
What You’ll Receive from taking this Online OSHA forklift safety training course
- OSHA-compliant certificate of completion
- Forklift operator’s license
- Printable practical evaluation checklist for trainers
Why Choose Lean.TrainSocially.com for Online OSHA forklift safety training courses?
Unlike basic video training, this course is fully interactive. Operators engage with:
- Decision-based scenarios
- Real-world simulations
- Knowledge checks to reinforce retention
It’s ideal for:
- New operators seeking certification
- Experienced drivers needing renewal
- Supervisors training warehouse staff
OSHA Forklift Safety Principles Covered in the Online Course
- Operator training and supervision
- Seat belt use and tip-over response
- Visibility, safe speeds, and smooth turns
- Pre-operation inspections and reporting
- Pedestrian right-of-way and zone planning
- Stable load handling and lifting techniques
- No unauthorized riders or elevated personnel
- Shutdown procedures and dock safety
Tools to Reinforce OSHA Safety
Each online OSHA forklift safety training course includes links to:
- Job aids and safety posters
- Visual safety tools from Store.LeanMH.com – mirrors, floor tape, warning alarms
Continue Your Training Journey – More Online OSHA forklift safety training courses
This is Lesson 1 of a 17-part training series. After completing this OSHA-compliant forklift safety course, continue with:
- Battery maintenance and charging safety
- Corrosion control and watering practices
- Forklift attachments and stability
- Site-specific operating protocols
Get Started Now – Take the Online OSHA forklift safety training course
Click here to begin your OSHA forklift safety training today – it’s fully online, interactive, and includes everything you need to become a certified operator.