The following text is excerpted from the OSHA regulations for Powered Industrial Trucks. You can access the original text here. (Current as of February 2025.)

These rules can also be found in the Code of Federal Regulations, §1910.178.

1910.178(l) Operator training.

(1) Safe operation.

(i) The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l).

(ii) Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph (l), except as permitted by paragraph (l)(5).

(2) Training program implementation.

(i) Trainees may operate a powered industrial truck only:

1. Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence; and
2. Where such operation does not endanger the trainee or other employees.

(ii) Training shall consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace.

(iii) All operator training and evaluation shall be conducted by persons who have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.

(3) Training program content. Powered industrial truck operators shall receive initial training in the following topics, except in topics which the employer can demonstrate are not applicable to safe operation of the truck in the employer's workplace.

(i) Truck-related topics:

1. Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate;
2. Differences between the truck and the automobile;
3. Truck controls and instrumentation: where they are located, what they do, and how they work;
4. Engine or motor operation;
5. Steering and maneuvering;
6. Visibility (including restrictions due to loading);
7. Fork and attachment adaptation, operation, and use limitations;
8. Vehicle capacity;
9. Vehicle stability;
10. Any vehicle inspection and maintenance that the operator will be required to perform;
11. Refueling and/or charging and recharging of batteries;
12. Operating limitations;
13. Any other operating instructions, warnings, or precautions listed in the operator's manual for the types of vehicle that the employee is being trained to operate.

(ii) Workplace-related topics:

1. Surface conditions where the vehicle will be operated;
2. Composition of loads to be carried and load stability;
3. Load manipulation, stacking, and unstacking;
4. Pedestrian traffic in areas where the vehicle will be operated;
5. Narrow aisles and other restricted places where the vehicle will be operated;
6. Hazardous (classified) locations where the vehicle will be operated;
7. Ramps and other sloped surfaces that could affect the vehicle's stability;
8. Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust;
9. Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

(iii) The requirements of this section.

(4) Refresher training and evaluation.

(i) Refresher training, including an evaluation of the effectiveness of that training, shall be conducted as required by paragraph (l)(4)(ii) to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.

(ii) Refresher training in relevant topics shall be provided to the operator when:

1. The operator has been observed to operate the vehicle in an unsafe manner;
2. The operator has been involved in an accident or near-miss incident;
3. The operator has received an evaluation that reveals that the operator is not operating the truck safely;
4. The operator is assigned to drive a different type of truck; or
5. A condition in the workplace changes in a manner that could affect safe operation of the truck.

(iii) An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years.

(5) Avoidance of duplicative training. If an operator has previously received training in a topic specified in paragraph (l)(3) of this section, and such training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely.

(6) Certification. The employer shall certify that each operator has been trained and evaluated as required by this paragraph (l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.

If your team members operate a forklift or other type of Powered Industrial Truck (PIT), you've probably thought about getting them officially trained. Maybe you do some basic orientation, but unless your organization or business already has a custom training program in place, figuring out how to train them according to OSHA standards might be intimidating.

Training your forklift operators per OSHA standards could be simpler than you think.

According to federal regulations, there are five key things that operators need in order to become officially "certified." (Even if your state has its own Health and Safety department, the OSHA standards for forklift operation are still the highest as far safety in this arena.)

Step 1: Provide your operators with good knowledge training.

OSHA standards require a "formal instruction" component, such as "lecture, discussion, interactive computer learning, video tape, [or] written material." A self-directed online course is one easy way to fulfill this requirement. You may alternatively choose to deliver the material in a more traditional classroom-based format, with a slide deck, textbooks, and exams.

Step 2: Conduct a safety audit of your facility to assess forklift hazards.

Check for any areas that would be dangerous for operators, pedestrians, objects, or equipment, and think about the types of activities that will be carried out using the forklift. OSHA standards list the following:

• Surface conditions where the vehicle will be operated
• Composition of loads to be carried
• Types of load manipulation, stacking, and unstacking
• Pedestrian traffic in areas where the vehicle will be operated
• Narrow aisles and other restricted places where the vehicle will be operated
• Hazardous locations where the vehicle will be operated (such as areas with flammable materials)
• Ramps and other sloped surfaces that could affect the vehicle's stability
• Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust
• Any other potentially hazardous environmental conditions that could affect safe operation

Step 3: Make sure you are familiar with the forklift or other Powered Industrial Truck  that you will be training on.

Each operator will need to be trained and certified on the forklift (or other Powered Industrial Truck, such as a pallet jack or lift) that they will be using on the job. PITs may operate on similar principles, but each one has its own unique features. This means that prior to training, you should familiarize yourself with the specifics of the machines you'll be teaching your operators to use. This includes the operating instructions, warnings, and precautions that are included in the manual, the truck controls and instrumentation, and other features such as fueling and fork attachment.

If you have multiple types of PITs at your facility, you will need to know the ins and outs of each one, and make sure your operators receive training on them separately.

Step 4: Understand how to conduct effective practical training for your team.

Good learning happens under good trainers, and becoming a good trainer takes practice. Develop a training plan and follow it each time so that you stay consistent. OSHA requires that you evaluate your operators, so it is good to have a written evaluation sheet where you can track each operator's performance. When showing them how to operate each PIT, first demonstrate each skill, then allow each operator to practice carefully while you coach them. Depending on their experience level, they may not need any help at all, or they may need additional practice before they are cleared to operate on their own.

Step 5: Keep a record of certification for each operator, and retrain as needed.

OSHA standards require that you keep a log of training and certification for each operator. We recommend keeping this in a spreadsheet, but you can also use a written or typed log, as long as it is somewhere safe and accessible. Operators are required to be reevaluated every 3 years, but they should also receive refresher training if they are observed operating in an unsafe manner, have been involved in an accident or near-miss incident, need to drive a different type of PIT that they have not been previously trained on, or workplace conditions change in a manner that could affect safe operation of the truck.

But am I qualified?

If you have knowledge of and experience with operating a PIT, and you are willing to complete the 5 steps above, then yes, you are qualified to be a trainer at your workplace!

Good training means long-run savings.

Organizations and businesses need their teams operating safely and efficiently, and it all starts with the right training.

Not sure you're comfortable becoming a trainer on your own? If you're in the Pacific Northwest region, our master trainers are skilled coaches who can come help get you up to speed, usually in just one day. They'll come to your facility to conduct a hazard analysis, and guide you through the process of practical training for your employees so that you can confidently do it yourself.

If you are looking for a little bit more guidance, but you don't need one-on-one coaching, our PDF instructor kit contains everything we discussed in this article, including a workplace hazard evaluation sheet, practical operator evaluation sheet, and certification record spreadsheet, as well as detailed instructions on how to conduct your training — plus 5 free seats in our online knowledge course.

Don’t bring me down

There’s a scene in the 2006 Pixar movie Cars in which Lightning McQueen and his towtruck friend Mater spend a reckless evening tractor tipping. It’s played for laughs, but we can laugh at it because it’s a cartoon about talking cars. You don’t actually want to find yourself in a tipover situation when you’re operating heavy machinery.

https://youtu.be/HF0s-pXOHck

Tipovers are dangerous and preventable. But thanks to gravity—the force that pulls objects toward each other—they’re all too common.

Gravity is kind of sneaky. It pretends to be your biggest supporter, but it really just wants to bring you down. It’s the reason we’re able to stand on the ground without floating off into space … but it’s also the reason we hit the ground instead of floating up into the air when we trip and fall.

The center of everything

Every object has a center of gravity, which is the point at which its combined mass is concentrated. For a large, complex object like a forklift, the center of gravity is the point at which all of its parts balance one another.

Forklift suspension systems are built around three points: the two front drive wheels, and the turning center (pivot pin) of the back wheels. The forklift’s own center of gravity sits within this triangle—also known as the stability triangle. The points of the stability triangle also extend upwards to one point at the top of the mast, creating a pyramid shape.

When a load is lifted onto the forks, their centers of gravity are combined, and the overall center of gravity changes. The higher the load is lifted, the less stable the forklift becomes. The combined center of gravity (load + forklift) must stay within the pyramid, or the forklift will tip over. This is why it’s important to be aware of your forklift’s weight limit.

Uneven ground surfaces and ramps can also affect your vehicle’s stability, and in turn its center of gravity.

Remembering these key points while operating your forklift can help mitigate the risk of a tipover:

• Remember that an unloaded forklift is less stable than a properly loaded one.
• Always read and understand the load chart.
• Wear your seatbelt and keep all limbs inside.
• Have a good idea of your load’s center of gravity.
• Always make sure the load is sitting all the way against the backrest.
• Do not raise, lower, or carry a load with the forks tilted forward.
• Do not tilt the mast too far back when raised.
• Never make turns with the load elevated.
• When traveling, always keep the load low to the ground.
• Never make a turn on an inclined surface.
• Do not start, stop, or change speeds too quickly.
• Never travel at a speed greater than normal walk­ing speed.
• Always use caution when turning.

CAUTION

If you find yourself needing to grip the steering wheel tightly on a turn, you are going too fast and are at risk of tipping.

If your truck does start to tip, DO NOT TRY TO JUMP OUT. Grip the steering wheel, brace your feet on the floor, and ride out the tipover inside the operator compartment.

Remember, tipovers are relatively uncommon compared to other workplace injuries. However, due to the size and weight of the equipment and loads, they can be catastrophic, responsible for damage to equipment and goods, worker injuries, and even death. Taking the steps to prevent tipovers can help prevent such accidents.

Taking the First Step:

If you are interested in taking our online forklift operator training course, or need a refresher course before recertifying, you can learn more about it below. It provides the same quality training as our classroom course, but is conveniently available online! It’s affordable, easy-to-use, mobile-friendly, and satisfies the OSHA “classroom” training requirement.

Learn More

“Your Certification in One Hour!”
“Get a forklift License Today!!”
“Get forklift certified for free … today!”

Maybe you’ve seen offers like this and thought, "Well, that sounds to good to be true." That's because in this case, it is. The most blatant red flag is that forklift operators do not need a license, but a certification, to be OSHA-Compliant.

Furthermore, while it’s true that many providers, including Evergreen Safety Council, offer online forklift training courses, completion of an OSHA-compliant training course is only the first step to becoming forklift-certified.

OSHA, which sets and enforces workplace safety standards, requires prospective forklift operators to complete a three-step process before they are allowed to use one in the workplace.

Step by step breakdown:​

• Step 1: Completion of an OSHA-certified forklift training course, such as Evergreen Safety Council’s online Forklift Training course
• Step 2: Practical, or “hands-on,” training at your place of employment. Some in-person forklift training classes include a hands-on session with a forklift to familiarize you with forklift operation, but this step must also be completed at your worksite on each piece of equipment you’ll be operating. Your workplace training will include a tour of your workplace or job site, where you’ll be made aware of safety protocol and potential hazards. You will also receive hands-on training on the specific vehicle you will be operating. This gives you the opportunity to practice necessary hands-on skills prior to your evaluation.
• Step 3: Practical evaluation on the forklift you’ll be operating. Your trainer will evaluate your performance and certify you have the ability to operate the PIT properly and safely in your workplace.

You must complete all three of these steps to be considered “forklift certified.” Companies that allow uncertified users to operate forklifts are in violation of OSHA regulations, and risk being fined.

So, when an advertisement for “free” or “easy” forklift certification seems too good to be true, be sure to read the fine print. Online training courses can be affordable and informative, but they are only the first step toward becoming forklift certified.

One step at a time

Our online forklift operator training course satisfies the first step to becoming forklift certified. Our course provides quality forklift safety training, conveniently online! It is affordable, easy-to-use, mobile-friendly, and satisfies the OSHA “classroom” training requirement.

For practical training, Evergreen Safety Council has designed an instructor training kit that includes everything an employer needs to effectively train, evaluate, and certify their Forklift operators on the forklift they'll be operating at work. Not confident you can teach your staff? If you're in the Pacific Northwest, we can come to you and provide train-the-trainer mentorship.

*Note: Your PIT operator certification is good for a three-year period, unless there is a change in workplace conditions (including a change in job sites) or the vehicle to be operated. In these cases, you must be retrained and re-evaluated to ensure you can safely operate under these new conditions.

Ask any elite athlete about their training regimen, and the word diet is sure to come up. Perhaps more than anybody, athletes understand how the foods they choose to fuel their body affects their performance.

This is not a story about diets, but it is a story about fuel. Powered industrial trucks (like forklifts) are invaluable tools in the workplace, but like humans they need fuel to perform. And like elite athletes, they need the correct fuel to perform their best.

The care and feeding of your forklift​

Different forklift classes require different types of fuel, which includes liquid fuels, batteries, and liquefied petroleum gas (LPG). When it’s time to refuel your PIT, you should know which type of fuel it requires, and the risks associated with each. This information should be clearly stated in your vehicle’s operator’s manual.

Consult your operator’s manual for instructions on how to safely change and dispose of used fuel.

CAUTION

No smoking around fuel, regardless of the type of fuel you are using.

Fuel it up​

Liquid Fuels

When refueling with liquid fuel, such as gasoline or diesel:

• Always stop and turn off the engine before refueling.
• Do not overfill the tank.
• Make sure there is adequate ventilation.
• Wear the proper personal protective equipment (PPE) to protect yourself from ingesting it or inhaling the fumes.

Battery service

As an operator, it is unlikely that you will need to refill a battery. However, if you do, observe the following precautions:

• Wear acid-resistant PPE, gloves, long sleeves, and pant legs to protect yourself from battery acid.
• Use only the type of battery charger recommended by the manufacturer.
• If low on electrolyte, add only distilled water. Bring the level up to approximately ¼ inch above the battery plates. This will leave room for expansion, as the electrolyte is heated during the charging process.
• Make sure you have adequate ventilation when charging. Charging emits hydrogen gas which is extremely flammable.
• An emergency washing station is required if you regularly replace or refill and charge batteries.

Liquefied Petroleum Gas (LPG)

Many forklifts are powered by LPGs such as propane or butane.

To change the LPG tank:

• Purge the fuel supply hose:
  • start the engine, shut off the fuel supply valve on the tank, allow the engine to run until out of fuel
• Remove the empty tank
• Get help to lift a full bottle onto the cradle
• Make sure the bottle is properly oriented in the cradle, with the locating pin aligned

CAUTION

Because of their chemical properties, LPGs are extremely cold. If gas escaping from the tank touches your skin, it can freeze your skin immediately and cause frostbite. When handling or refilling propane tanks, wea goggles and thermal protection for your hands and skin.