What are the official safety rules for operating a lift truck?

Forklifts, or powered industrial trucks (PITs), are indispensable machines in the modern supply chain, yet they remain one of the most significant sources of workplace fatalities and serious injuries.1 The sheer size, weight, and inherent instability of a lift truck—coupled with its rear-wheel steering and dynamic load characteristics—create a constant hazard if not operated under strict control.

In the United States, the Occupational Safety and Health Administration (OSHA) Standard 29 CFR 1910.178 provides the mandatory and comprehensive framework for the safe operation, maintenance, and training related to powered industrial trucks in general industry.2 This article offers a technical deep dive into these official safety rules, categorizing them into the three critical phases of operation: Preparation, Traveling & Maneuvering, and Load Handling.3

1. Phase I: Preparation and Accountability (Before Operation)

Safety begins before the key is even turned. This phase establishes the administrative, training, and equipment integrity requirements necessary for legal operation.

1.1. Operator Certification and Training

The most critical safety rule is that only authorized, trained, and certified operators may operate a forklift.4 This training is not optional; it is a legal requirement.5

Training Mandate: Operators must be evaluated and certified as competent to operate a PIT safely (29 CFR 1910.178(l)).6

Age Restriction: Federal law prohibits anyone under 18 years of age from operating a forklift (FLSA).7

Refresher Training: An operator's performance must be evaluated at least once every three years.8 Refresher training is required immediately after an accident, near-miss, observation of unsafe operation, or if the operator is assigned to a different type of truck or environment.

Site-Specific Training: Training must cover general operating instructions and specific operating conditions in the employer's workplace (e.g., aisle widths, hazardous locations, ramp grades).9

1.2. The Daily/Shift Inspection (Pre-Operation Check)

OSHA mandates that every lift truck must be examined at least daily, or after each shift if used round-the-clock, before being placed into service.10 Any truck found to be in an unsafe operating condition must be immediately removed from service until the defect is corrected.11

Component Check (Visual, Key Off)	Operational Check (Engine/Power On)
Fluids	Oil, water, hydraulic fluid levels.
Tires	Condition, cuts, gouges, and correct pressure.
Forks & Mast	Damage to forks (heel, top clip pin); chain condition, tension, and lubrication (use a stick/device, never hands).
Safety Gear	Lights, horn, seatbelt, back-up alarm, and overhead guard/load backrest extension integrity.
Decals	Nameplate, capacity rating, and safety decals legible and in place.

2. Phase II: Traveling and Maneuvering (Dynamic Control)

Safe travel is defined by maintaining stability, visibility, and positive control of the truck at all times.12

2.1. Speed and Control

Safe Speed: The truck must be operated at a speed that permits it to be brought to a safe stop under all travel conditions (29 CFR 1910.178(n)(8)).13 This typically means observing designated facility speed limits (often 5-7 mph) and always reducing speed for turns, wet/slippery floors, or limited visibility.14

Positive Control: The operator must keep the truck under positive control at all times.15 Stunt driving, horseplay, and reckless operations are strictly prohibited (29 CFR 1910.178(n)(9)).

Stopping: Abrupt stops or rapid acceleration/deceleration must be avoided, as they can destabilize the load and cause a tip-over.16

2.2. Visibility and Right-of-Way

Direction of Travel: The driver must look in the direction of, and keep a clear view of, the path of travel (29 CFR 1910.178(n)(6)).17

Obstructed View (The Reverse Rule): If the load being carried obstructs the forward view, the driver shall be required to travel with the load trailing (in reverse) (29 CFR 1910.178(n)(4)).

Pedestrians: Forklifts must yield the right-of-way to pedestrians.18 Operators should sound the horn at all cross aisles, intersections, and blind corners (29 CFR 1910.178(n)(4)).19 Never assume a pedestrian is aware of the truck.

Rear-End Swing: Operators must be constantly aware of the wide swing of the rear of the truck when turning due to the rear-wheel steering mechanism.20

2.3. Ramps, Grades, and Inclines

Operating on slopes significantly affects the truck’s stability (the stability triangle). The rule for grades exceeding 10% is governed by the direction of the load.

Condition	Travel Rule	Rationale
Traveling Loaded (Up or Down)	The load must always face uphill (upgrade).	Prevents the load from sliding off the forks and stabilizes the truck's center of gravity against the counterweight.
Traveling Unloaded (Up or Down)	The forks must always point downhill (downgrade).	The heaviest part of the unloaded truck is the counterweight (rear); driving with the counterweight uphill maintains stability.
Turns on Grades	Never turn a forklift on a ramp or grade.	Turning on an incline drastically shifts the center of gravity laterally, leading to a high risk of lateral tip-over.

2.4. Clearance and Overhead Hazards

Overhead Clearance: Operators must ensure adequate clearance is available before raising the load or mast.21 Pay attention to overhead pipes, sprinkler systems, light fixtures, and electrical wiring.

Electrical Hazard: The truck must be kept at least 10 feet (3 meters) away from overhead electrical wires, unless the wires are de-energized or insulated (a technical regulation often referencing 29 CFR 1910.183).

Dockboards and Bridgeplates: Before driving over a dockboard or bridgeplate between a dock and a trailer/railcar, the operator must ensure the plate is securely fastened and its capacity can safely support the loaded truck.22

3. Phase III: Load Handling and Stability

The primary function of a forklift is lifting and maneuvering loads. These procedures are critical to maintaining the combined stability of the truck and the load.

3.3. Stability and Center of Gravity

Forklift stability is based on the Stability Triangle concept. Tipping occurs when the combined center of gravity of the truck and the load moves outside the stability triangle.

Rated Capacity: Never exceed the truck's rated capacity.23 This capacity is listed on the data plate and is specific to the load center (the horizontal distance from the fork face to the load's center of gravity, typically 24 inches).24 Overloading causes longitudinal tip-over.

Attachments: Any modification or attachment (e.g., drum clamps, extended forks) not installed by the manufacturer requires the manufacturer's prior written approval and a new, updated capacity plate (29 CFR 1910.178(a)(4)).25

Load Securement: Loads must be stable, safely arranged, and centered.26 Loads that are damaged or unstable must be secured (e.g., banded or wrapped) before handling (29 CFR 1910.178(o)(1)).

3.2. Picking Up the Load

Forks Placement: Level the forks, and insert them completely and squarely beneath the load.27 The forks should be at least two-thirds the length of the load.

Load Engagement: Engage the load until it rests against the vertical face of the load backrest extension or carriage.28

Lift and Tilt (Load Stabilization):

Lift the load clear of the floor or rack.

Tilt the mast backward just enough to stabilize the load.29 The backward tilt shifts the center of gravity closer to the truck's main body, increasing stability.30

3.3. Traveling with the Load

Travel Height: Travel with the load and forks carried as low as possible—typically 6 to 8 inches above the floor—to maximize stability and forward visibility.31

No Simultaneous Movement: Do not raise or lower the load while traveling.32 This must only be done when the truck is stationary with the brake set (29 CFR 1910.178(o)(7)).

3.4. Placing the Load

Positioning: Approach the rack or stack slowly.33 Stop completely.

Tilt Forward: Only tilt the mast forward when the load is correctly positioned over the stack or rack, immediately prior to depositing the load (29 CFR 1910.178(o)(6)).34 Tilting forward while elevated and traveling is a major cause of tip-over.35

Disengagement: Lower the load, tilt the forks forward until level, and withdraw them slowly. Once clear of the stack, lower the forks to the safe travel height.

4. Other Critical Operational and Personnel Rules

Several overarching rules pertain to personnel safety and truck status.

4.1. Unauthorized Riders and Lifting Personnel

Riders Prohibited: Unauthorized personnel shall not ride on powered industrial trucks.36 A safe place to ride must be provided if riding is authorized (29 CFR 1910.178(a)(5)).

Lifting People: Employees may only be elevated using a forklift if they are standing on a secured work platform (man basket) that meets strict safety requirements (e.g., guardrails, toe boards, secured to the carriage/forks).37 The operator must remain at the controls while the platform is elevated (29 CFR 1910.178(e)(6)).

4.2. Parking and Leaving the Truck Unattended

An operator must follow the proper parking procedure whenever they leave the controls.38

Unattended Definition: A truck is considered unattended if the operator is more than 39$\mathbf{25 \text{ feet}}$ away from the truck or if the truck is out of the operator's view.40

Parking Procedure (Unattended):

Fully lower the load-engaging means (forks, clamp, etc.).41

Neutralize the controls.

Set the parking brake.

Shut off the power (turn the key off).42

If on an incline, block the wheels or curb the truck (29 CFR 1910.178(m)(5)).

4.3. Working Around the Truck

Keeping Clear: Employees shall not stand, pass, or work under the elevated portion of any industrial truck (loaded or empty) unless it is effectively blocked to prevent it from falling.

Safe Distance: Never drive a truck up to anyone standing in front of a bench or fixed object where the person could be pinned or caught between the truck and the object.

Conclusion: Safety as a System

The official safety rules for operating a lift truck, anchored by OSHA Standard 1910.178, establish a non-negotiable legal and technical framework for protecting workers and assets.43 These rules are engineered to mitigate the primary hazards associated with forklifts: tip-overs, collisions, and being struck or pinned.

The foundation of compliance is a systemic approach: Certified Operators who perform mandatory Pre-Shift Inspections and adhere to Rigorous Operating Protocols for stability, visibility, and load handling.44 For any business relying on lift trucks, these official safety rules are more than bureaucratic mandates—they are the essential engineering specifications for a safe, efficient, and lawful material handling operation.