Forklift Training Checklist: Complete OSHA Operator Training Guide [2025]

Forklift training is mandatory under OSHA 1910.178, with specific requirements for classroom instruction, practical training, and operator evaluation. This comprehensive forklift training checklist ensures your training program meets all federal requirements while effectively preparing operators for safe, productive work. Organizations with thorough training programs report 70% fewer accidents and dramatically lower workers compensation costs.

OSHA Forklift Training Requirements Overview

OSHA 29 CFR 1910.178(l) establishes comprehensive forklift training requirements. Training must be conducted by persons with knowledge, training, and experience to train operators. The training program must cover three main components:

• Formal Instruction: Classroom lectures, videos, written materials, or computer-based training
• Practical Training: Hands-on demonstrations and exercises on actual equipment
• Operator Evaluation: Performance assessment by qualified evaluator in actual workplace

Forklift Training Checklist: Classroom Topics

OSHA requires training to cover both truck-related and workplace-related topics. Use this checklist to ensure your classroom training addresses all required elements:

Truck-Related Topics

• Operating instructions, warnings, and precautions for the type of truck used
• Differences between truck and automobile (steering, braking, visibility)
• Truck controls and instrumentation (location, function, proper use)
• Engine or motor operation and limitations
• Steering and maneuvering characteristics
• Visibility restrictions and compensating techniques
• Fork and attachment adaptation, operation, and limitations
• Vehicle capacity and stability factors
• Vehicle inspection and maintenance requirements
• Refueling and charging procedures
• Operating limitations and restrictions

Workplace-Related Topics

• Surface conditions where vehicle will operate (slopes, uneven surfaces, debris)
• Composition of loads (stability, fragility, hazardous materials)
• Load manipulation, stacking, and unstacking procedures
• Pedestrian traffic in work areas
• Narrow aisles and restricted areas
• Hazardous locations and classified atmospheres
• Ramps and sloped surfaces navigation
• Closed environments and ventilation requirements
• Other unique or potentially hazardous conditions in workplace

Forklift Training Checklist: Practical Training

Practical training builds hands-on competence through supervised exercises on actual equipment. Training must occur in an area separate from other workers until trainee demonstrates competence.

Pre-Operation Skills

• Proper mounting and dismounting procedures
• Seat belt and operator restraint usage
• Pre-operational inspection procedures (see our daily forklift inspection checklist)
• Equipment familiarization (controls, gauges, warning devices)
• Startup and shutdown procedures
• Recognition of unsafe equipment conditions

Basic Operating Skills

• Forward and reverse travel at appropriate speeds
• Steering and maneuvering in confined spaces
• Proper braking techniques (gradual stops, emergency stops)
• Turning and cornering safely
• Traveling on grades and ramps
• Operating on uneven or sloped surfaces

Load Handling Skills

• Approaching loads properly (centered, level, low)
• Picking up loads safely
• Traveling with loads (forks low, tilted back)
• Stacking and unstacking at various heights
• Placing loads accurately and safely
• Handling different load types (pallets, drums, irregular shapes)

Safety Awareness Skills

• Maintaining safe distances from pedestrians
• Using horn at intersections and blind corners
• Yielding to pedestrians
• Proper parking procedures
• Understanding and obeying workplace traffic rules
• Recognition and avoidance of hazards

Forklift Training Checklist: Operator Evaluation

OSHA requires operators to be evaluated after training to verify they can operate safely. Evaluation must occur in the actual workplace and cover all skills needed for assigned tasks.

Evaluation Requirements

• Conducted by qualified evaluator with knowledge, training, and experience
• Performed in actual workplace conditions
• Covers all tasks operator will perform
• Tests both skills and safety awareness
• Results documented and maintained
• Failed evaluations require additional training before re-evaluation

Skills to Evaluate

• Pre-operational inspection completion
• Safe startup and shutdown
• Smooth, controlled travel
• Safe load handling throughout cycle
• Proper stacking and placement
• Pedestrian awareness and yielding
• Following workplace traffic rules
• Proper parking procedure
• Safe refueling or battery charging

Refresher Training Requirements

OSHA requires refresher training and re-evaluation when any of these situations occur:

• Operator observed operating unsafely
• Operator involved in accident or near-miss
• Operator receives evaluation revealing unsafe operation
• Operator assigned to different type of truck
• Conditions in workplace change affecting safe operation
• Minimum of every 3 years regardless of above

Training Documentation Checklist

Maintain complete records demonstrating compliance with training requirements:

• Operator name and signature
• Date of training completion
• Date of evaluation
• Identity of trainer(s) and evaluator(s)
• Type(s) of forklift operator is certified to operate
• Topics covered in training
• Evaluation results and any remedial training
• Certification expiration date (3-year maximum)

Frequently Asked Questions

How long does forklift training take?

OSHA does not specify minimum training hours. Training duration should be based on trainee prior experience, complexity of equipment, and workplace conditions. Typical programs range from 4-8 hours for classroom plus 2-4 hours practical training.

Who can conduct forklift training?

Training must be conducted by persons with knowledge, training, and experience to train operators and evaluate their competence. This can be in-house supervisors with proper qualifications or third-party training providers.

Is forklift certification transferable between employers?

There is no universal forklift license. Each employer must verify operator training and evaluate competence in their specific workplace conditions. Previous training can reduce training time but does not eliminate employer evaluation requirements.

Conclusion

A comprehensive forklift training checklist ensures your program meets OSHA requirements while effectively preparing operators for safe work. Combine thorough classroom training covering all required topics, supervised practical exercises building hands-on skills, and rigorous evaluation demonstrating competence. After training, operators should use a standardized forklift inspection checklist for daily pre-shift inspections. Maintain complete documentation to demonstrate compliance during audits and protect your organization from liability.