OSHA Forklift Safety Online Training

OSHA Forklift Certification & Safety Training – 18-Course Series

Compliant with OSHA Standard 29 CFR 1910.178
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Forklifts—officially known as Powered Industrial Trucks (PITs)—are essential in warehouses and industrial environments, but they come with serious risks. Each year, thousands of workers are injured in forklift-related incidents. OSHA mandates formal training, evaluation, and certification for all forklift operators.

This 18-course online training series is designed to meet—and exceed—OSHA’s requirements. Whether you’re onboarding new operators or recertifying seasoned drivers, our practical, interactive courses ensure compliance, reinforce safety culture, and reduce liability.

Course List

1. General OSHA Forklift Safety Principles
   Covers inspection routines, driving best practices, load handling, pedestrian safety, and OSHA certification guidelines.  You will need this course plus a lift truck (ITA Class) specific course to complete the theory portion and receive the appropriate certificates.  Add #18 "Forklift Safety Practicum – Operator Evaluation" to receive a drivers license.

   Course Syllabus: 

   • Lesson 1: OSHA Compliance & Operator Certification

   • Lesson 2: Equipment Familiarity & Controls

   • Lesson 3: Pre-Operational Inspection (Daily Checklist)

   • Lesson 4: Safe Load Handling

   • Lesson 5: Stability Principles

   • Lesson 6: Safe Driving Practices

   • Lesson 7: Pedestrian Awareness

   • Lesson 8: Environmental & Workplace Hazards

   • Lesson 9: Battery & Fuel Safety (Electric, LPG, Diesel)

   • Lesson 10: Proper Shutdown & Parking

2. OSHA Forklift Safety for Class 1, 4, & 5
   For sit-down counterbalanced trucks (electric and internal combustion). Covers fulcrum effect, visibility, tip-over risk, and confined space hazards. Course prerequisite: #1 General OSHA Forklift Safety Principles.  Add #5 OSHA-Compliant Forklift Battery Safety to complete the theory training for Class 2 lift trucks.

   Course Syllabus: 

   • Lesson 1: Understanding Class 1, 4 & 5 Forklift Types

   • Lesson 2: Mounting, Dismounting & Operator Safety

   • Lesson 3: The Stability Triangle in Real-World Driving

   • Lesson 4: Rear-End Swing & Visibility Hazards

   • Lesson 5: Safe Use of Attachments

   • Lesson 6: Class-Specific Load Handling Techniques

   • Lesson 7: Indoor vs. Outdoor Environments

   • Lesson 8: Fueling & Battery Protocols

   • Lesson 9: Ergonomics and Fatigue Prevention

   • Lesson 10: Emergency Procedures for Sit-Down Forklifts

3. OSHA Forklift Safety for Class 2
   Training for narrow aisle and reach trucks. Includes extended center of gravity, high stacking precautions, and guidance system awareness.  Course prerequisite: #1 General OSHA Forklift Safety Principles.  Add #5 OSHA-Compliant Forklift Battery Safety to complete the theory training for Class 2 lift trucks.

   Course Syllabus:

   • Lesson 1: Introduction to Class 2 Forklifts

   • Lesson 2: Understanding Reach Truck Stability

   • Lesson 3: Safe Lifting and Load Handling

   • Lesson 4: Operating in Tight Spaces

   • Lesson 5: Operator Positioning and Exit Safety

   • Lesson 6: Order Picker Fall Protection

   • Lesson 7: Elevated Work Hazards

   • Lesson 8: Housekeeping and Aisle Conditions

   • Lesson 9: Wire Guidance

   • Lesson 10: Specialized Training and Employer Authorization

4. OSHA Forklift Safety for Class 3
   For walk-behind pallet trucks and stackers. Emphasizes pinch points, jack stability, pedestrian zones, and slow-speed maneuvering.  Course prerequisite: #1 General OSHA Forklift Safety Principles.  Add #5 OSHA-Compliant Forklift Battery Safety to complete the theory training for Class 2 lift trucks.
5. OSHA-Compliant Forklift Battery Safety
   Covers charging area setup, PPE, hydrogen gas risks, acid spill neutralization, and LOTO procedures for battery maintenance. Required for operating a battery-powered lift truck.
6. Engineering Principles: Load Center, Center of Gravity & Stability Triangle
   Explains the physics behind forklift stability with practical visuals and calculations.
7. Daily Inspection & Documentation Requirements
   Checklists and pre-use inspection procedures aligned with OSHA guidelines.
8. Operator Qualification and Evaluation Process
   Details formal instruction, practical evaluation, and ongoing authorization protocols.
9. Workplace Hazards and Safe Practices
   Identifies facility-based risks including ramps, docks, blind intersections, and low lighting.
10. Safe Handling of Wood Pallets
    Proper techniques for lifting, stacking, inspecting, and disposing of wood pallets safely.
11. Supervisor Responsibilities Under OSHA Forklift Standards
    Covers safety enforcement, documentation, refresher training, and incident response.
12. Site-Specific Forklift Training Protocols
    Guidance for tailoring training to facility layout, equipment types, and operational hazards.
13. Forklift Safety in Agricultural Environments
    Addresses off-road use, livestock zones, dusty environments, and rural terrain handling.
14. OSHA Regulations for Forklift Drivers
    Explains age restrictions, retraining triggers, and documentation requirements.
15. Handling Hazardous Materials & Mechanical Maintenance Near Forklifts
    Best practices for operating near flammable substances, chemicals, and during maintenance.
16. Pedestrian Safety in Forklift Work Zones
    Covers communication, visibility, and shared workspace protocols to avoid collisions.
17. Instructor Requirements & Training Delivery Best Practices
    Designed for in-house trainers or safety managers delivering OSHA-compliant forklift instruction.
18. Forklift Safety Practicum – Operator Evaluation
    Video-based performance evaluation, reviewed by certified trainers. Required by OSHA as part of operator certification for each model needed for OSHA certification.

Why Choose This Series?

✅ Fully OSHA-Compliant (29 CFR 1910.178)
✅ Self-paced, mobile-friendly online format
✅ Video modules, diagrams, and real-world examples
✅ Certificate provided upon successful completion
✅ Ideal for operators, supervisors, trainers, and safety managers

What is the Minimum Number of OSHA Forklift Safety Courses I need to Drive a Forklift?

You need to take the following courses to become licensed to drive a lift truck:

1. General OSHA Forklift Safety Principles - All models of lift trucks
Covers inspection routines, driving best practices, load handling, pedestrian safety, and OSHA certification guidelines.  Everyone needs this course.

2. OSHA Forklift Safety for Class 1, 4, & 5 - if you have a sit-down forklift
For sit-down counterbalanced trucks (electric and internal combustion). Covers fulcrum effect, visibility, tip-over risk, and confined space hazards. You need this course (in addition to the General OSHA safety principles course) if you operate a sit down or stand-up counterbalanced lift truck.

3. OSHA Forklift Safety for Class 2 - if you have a stand-up reach or orderpicker
Training for narrow aisle and reach trucks. Includes extended center of gravity, high stacking precautions, and guidance system awareness.

4. OSHA Forklift Safety for Class 3 - if you have a pallet jack
For walk-behind pallet trucks and stackers. Emphasizes pinch points, jack stability, pedestrian zones, and slow-speed maneuvering.

5. OSHA-Compliant Forklift Battery Safety - if you use electric, battery powered lift trucks
Covers charging area setup, PPE, hydrogen gas risks, acid spill neutralization, and LOTO procedures for battery maintenance.

6.⭐ Forklift Safety Practicum – Operator Evaluation⭐ 
Video-based performance evaluation, reviewed by certified trainers. Required by OSHA as part of operator certification for each model needed for OSHA certification.

I want a job driving a forklift

If you would like to take the certificate course in order to be able to apply for a forklift operators job and put the certification on your resume, send us an email or use the chat feature to receive a 100% off coupon.

Train Your Team Today

Buy individual courses or full bundles for your team. For group pricing, custom onboarding, or site-specific adaptations, visit Lean.TrainSocially.com or contact us at info@LeanMH.com.

🏭 Need Onsite Group Training?

Looking to train your entire maintenance or facility team at once? We can bring the classroom to you.

Lean Inc. offers in-person, onsite group classes for Battery Maintenance and Safety. Our certified instructors will travel to your facility to provide comprehensive, hands-on training tailored specifically to your equipment, charging stations, and operational layout.

Why choose onsite group training?

• Hands-On Practice: Your team learns using your actual batteries, chargers, and watering systems.

• Site-Specific Safety: We address the unique layout and potential hazards of your specific charging and maintenance areas.

• Team Alignment: Train your entire staff simultaneously to ensure consistent standards and Lean accountability.

Contact us for an Onsite Training Quote or call us at 1-888-310-0008 to discuss group pricing and availability.