1910.178(p): Safe Operation of Powered Industrial Trucks
Employers must take any forklift or powered industrial truck that needs repair, is defective or is unsafe out of service until it is fixed. Fuel tanks must not be filled with the engine running, spills must be cleaned up before restarting, trucks with fuel leaks must not be operated, and open flames must not be used to check battery electrolyte or fuel levels.
Key takeaways
- 1910.178(p) is part of OSHA's general industry standards (29 CFR Part 1910, Subpart N).
- OSHA cited it 595 times in the last 3 years, in 594 inspections, with $1,873,746 in current penalties.
- 8 deaths are linked to inspections that cited this rule.
- Most citations: TX (48), FL (47), IL (31).
- Related part: 1910.178(p)(1) (594 citations).
- Free 5-minute toolbox talk for your crew below.
In this article
What this rule covers
29 CFR 1910.178(p) ("Operation of the truck") is one requirement inside 1910.178 Powered industrial trucks, an OSHA general industry standard (Part 1910, Subpart N). It includes 5 sub-paragraphs. The official text below is copied word for word from the Electronic Code of Federal Regulations (eCFR). The numbers, injury cases and training on this page show how OSHA enforces it on real job sites.
Official text
(p) Operation of the truck. 595 citations
(1) If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition. Open (p)(1) 594 citations
(2) Fuel tanks shall not be filled while the engine is running. Spillage shall be avoided.
(3) Spillage of oil or fuel shall be carefully washed away or completely evaporated and the fuel tank cap replaced before restarting engine.
(4) No truck shall be operated with a leak in the fuel system until the leak has been corrected. 1 citations
(5) Open flames shall not be used for checking electrolyte level in storage batteries or gasoline level in fuel tanks.
Source: eCFR, text current as of 2026-10-15. Read all of 1910.178.
Injuries linked to this rule
8 deaths are linked to inspections where OSHA cited 1910.178(p).
At 8:34 a.m. on February 20, 2025, Employee #1 and coworkers were closing a steel door mounted on a railing system with track wheels. While manually adjusting the door, one of the track wheels came off the rail, causing the door to jackknife. Three employees…
Full case list with employer, penalty, filters and download is part of OSHA Data (Purple Belt).
Unlock with Purple BeltWhere and how often it was cited
| Year | Citations |
|---|---|
| 2023 | 38 |
| 2024 | 239 |
| 2025 | 200 |
| 2026 | 118 |
Top states: TX (48), FL (47), IL (31), GA (30), TN (29)
Largest penalties
| Employer | Location | Penalty for this rule |
|---|---|---|
| NOVAE | LOUISIANA, MO | $68,098 |
| ROSS EXPRESS LLC | BOSCAWEN, NH | $57,620 |
| THE HOME DEPOT #8938 | KENAI, AK | $29,842 |
| HUTCHENS INDUSTRIES INC. | SEYMOUR, MO | $28,371 |
| ACCELERATED USA | HOUSTON, TX | $16,550 |
Free toolbox talk
A 5-minute crew talk on 1910.178(p), plus alerts when this rule changes. Free.
OSHA interpretation letters
- Powered Industrial Truck Servicer Labeling Responsibilities for a Customer's Unsafe Powered Industrial Trucks (2013-04-04)
- Powered industrial trucks must not be placed into service, or must be removed from service, when any condition exists that adversely affects the safety of the vehicle (2004-09-13)
- Requirements for the sound level of a warning device (horn) located on a forklift (2004-08-13)
- Clarification of the Powered Industrial Truck (1910.178) standard's use of the terms "in need of repair," "defective," and "unsafe." (2004-06-17)
Related parts of this rule
- 1910.178(p)(1) 594 citations
Get your crew competent
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Frequently asked questions
What do we do with an unsafe forklift?
Take it out of service until it is restored to safe operating condition.
Can I refuel with the engine running?
No. Fuel tanks shall not be filled while the engine is running, and spillage should be avoided.
Can I use a lighter to check the fuel or battery level?
No. Open flames shall not be used for checking battery electrolyte level or fuel level.
About this page
Sources
- 29 CFR 1910.178 (eCFR), text current as of 2026-10-15
- U.S. Department of Labor enforcement data: OSHA inspections, citations and accident records, copied nightly; data as of 2026-10-20
3-year window. Federal OSHA only; state-plan rules are not counted. Plain-language text is a summary, not legal advice; the official text controls. Black Belt Safety is not part of OSHA or the Department of Labor.