[Code of Federal Regulations]
[Title 29, Volume 5]
[Revised as of July 1, 2002]
From the U.S. Government Printing Office via GPO Access
[CITE: 29CFR1910.178]
[Page 542-556]
TITLE 29--LABOR
CHAPTER XVII--OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT
OF LABOR
PART 1910--OCCUPATIONAL SAFETY AND HEALTH STANDARDS--Table of Contents
Subpart N--Materials Handling and Storage
Sec. 1910.178 Powered industrial trucks.
(a) General requirements. (1) This section contains safety
requirements relating to fire protection, design, maintenance, and use
of fork trucks, tractors, platform lift trucks, motorized hand trucks,
and other specialized industrial trucks powered by electric motors or
internal combustion engines. This section does not apply to compressed
air or nonflammable compressed gas-operated industrial trucks, nor to
farm vehicles, nor to vehicles intended primarily for earth moving or
over-the-road hauling.
(2) All new powered industrial trucks acquired and used by an
employer after the effective date specified in paragraph (b) of
Sec. 1910.182 shall meet the design and construction requirements for
powered industrial trucks established in the ``American National
Standard for Powered Industrial Trucks, Part II, ANSI B56.1-1969'',
which is incorporated by reference as specified in Sec. 1910.6, except
for vehicles intended primarily for earth moving or over-the-road
hauling.
(3) Approved trucks shall bear a label or some other identifying
mark indicating approval by the testing laboratory. See paragraph (a)(7)
of this section and paragraph 405 of ``American National Standard for
Powered Industrial Trucks, Part II, ANSI B56.1-1969'', which is
incorporated by reference in paragraph (a)(2) of this section and which
provides that if the powered industrial truck is accepted by a
nationally recognized testing laboratory it should be so marked.
(4) Modifications and additions which affect capacity and safe
operation shall not be performed by the customer or user without
manufacturers prior written approval. Capacity, operation, and
maintenance instruction plates, tags, or decals shall be changed
accordingly.
(5) If the truck is equipped with front-end attachments other than
factory installed attachments, the user shall request that the truck be
marked to identify the attachments and show the approximate weight of
the truck and attachment combination at maximum elevation with load
laterally centered.
(6) The user shall see that all nameplates and markings are in place
and are maintained in a legible condition.
(7) As used in this section, the term, approved truck or approved
industrial truck means a truck that is listed or approved for fire
safety purposes for the intended use by a nationally recognized testing
laboratory, using nationally recognized testing standards. Refer to
Sec. 1910.155(c)(3)(iv)(A) for definition of listed, and to Sec. 1910.7
for definition of nationally recognized testing laboratory.
(b) Designations. For the purpose of this standard there are eleven
different designations of industrial trucks or tractors as follows: D,
DS, DY, E, ES, EE, EX, G, GS, LP, and LPS.
(1) The D designated units are units similar to the G units except
that they are diesel engine powered instead of gasoline engine powered.
(2) The DS designated units are diesel powered units that are
provided with additional safeguards to the exhaust, fuel and electrical
systems. They may be used in some locations where a D unit may not be
considered suitable.
(3) The DY designated units are diesel powered units that have all
the safeguards of the DS units and in addition do not have any
electrical equipment including the ignition and are equipped with
temperature limitation features.
(4) The E designated units are electrically powered units that have
minimum acceptable safeguards against inherent fire hazards.
(5) The ES designated units are electrically powered units that, in
addition to all of the requirements for the E
[[Page 543]]
units, are provided with additional safeguards to the electrical system
to prevent emission of hazardous sparks and to limit surface
temperatures. They may be used in some locations where the use of an E
unit may not be considered suitable.
(6) The EE designated units are electrically powered units that
have, in addition to all of the requirements for the E and ES units, the
electric motors and all other electrical equipment completely enclosed.
In certain locations the EE unit may be used where the use of an E and
ES unit may not be considered suitable.
(7) The EX designated units are electrically powered units that
differ from the E, ES, or EE units in that the electrical fittings and
equipment are so designed, constructed and assembled that the units may
be used in certain atmospheres containing flammable vapors or dusts.
(8) The G designated units are gasoline powered units having minimum
acceptable safeguards against inherent fire hazards.
(9) The GS designated units are gasoline powered units that are
provided with additional safeguards to the exhaust, fuel, and electrical
systems. They may be used in some locations where the use of a G unit
may not be considered suitable.
(10) The LP designated unit is similar to the G unit except that
liquefied petroleum gas is used for fuel instead of gasoline.
(11) The LPS designated units are liquefied petroleum gas powered
units that are provided with additional safeguards to the exhaust, fuel,
and electrical systems. They may be used in some locations where the use
of an LP unit may not be considered suitable.
(12) The atmosphere or location shall have been classified as to
whether it is hazardous or nonhazardous prior to the consideration of
industrial trucks being used therein and the type of industrial truck
required shall be as provided in paragraph (d) of this section for such
location.
(c) Designated locations. (1) The industrial trucks specified under
subparagraph (2) of this paragraph are the minimum types required but
industrial trucks having greater safeguards may be used if desired.
(2) For specific areas of use, see Table N-1 which tabulates the
information contained in this section. References are to the
corresponding classification as used in subpart S of this part.
(i) Power-operated industrial trucks shall not be used in
atmospheres containing hazardous concentration of acetylene, butadiene,
ethylene oxide, hydrogen (or gases or vapors equivalent in hazard to
hydrogen, such as manufactured gas), propylene oxide, acetaldehyde,
cyclopropane, diethyl ether, ethylene, isoprene, or unsymmetrical
dimethyl hydrazine (UDMH).
(ii)(a) Power-operated industrial trucks shall not be used in
atmospheres containing hazardous concentrations of metal dust, including
aluminum, magnesium, and their commercial alloys, other metals of
similarly hazardous characteristics, or in atmospheres containing carbon
black, coal or coke dust except approved power-operated industrial
trucks designated as EX may be used in such atmospheres.
(b) In atmospheres where dust of magnesium, aluminum or aluminum
bronze may be present, fuses, switches, motor controllers, and circuit
breakers of trucks shall have enclosures specifically approved for such
locations.
(iii) Only approved power-operated industrial trucks designated as
EX may be used in atmospheres containing acetone, acrylonitrile,
alcohol, ammonia, benzine, benzol, butane, ethylene dichloride,
gasoline, hexane, lacquer solvent vapors, naphtha, natural gas, propane,
propylene, styrene, vinyl acetate, vinyl chloride, or xylenes in
quantities sufficient to produce explosive or ignitable mixtures and
where such concentrations of these gases or vapors exist continuously,
intermittently or periodically under normal operating conditions or may
exist frequently because of repair, maintenance operations, leakage,
breakdown or faulty operation of equipment.
(iv) Power-operated industrial trucks designated as DY, EE, or EX
may be used in locations where volatile flammable liquids or flammable
gases are handled, processed or used, but in which the hazardous
liquids, vapors or
[[Page 544]]
gases will normally be confined within closed containers or closed
systems from which they can escape only in case of accidental rupture or
breakdown of such containers or systems, or in the case of abnormal
operation of equipment; also in locations in which hazardous
concentrations of gases or vapors are normally prevented by positive
mechanical ventilation but which might become hazardous through failure
or abnormal operation of the ventilating equipment; or in locations
which are adjacent to Class I, Division 1 locations, and to which
hazardous concentrations of gases or vapors might occasionally be
communicated unless such communication is prevented by adequate
positive-pressure ventilation from a source of clear air, and effective
safeguards against ventilation failure are provided.
[[Page 545]]
Table N-1--Summary Table on Use of Industrial Trucks in Various Locations
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Classes Unclassified Class I locations Class II locations Class III locations
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Description of classes...... Locations not possessing Locations in which flammable gases or vapors are, Locations which are hazardous because of the Locations where easily
atmospheres as described in or may be, present in the air in quantities presence of combustible dust. ignitible fibers or
other columns. sufficient to produce explosive or ignitible flyings are present
mixtures. but not likely to be
in suspension in
quantities sufficient
to produce ignitible
mixtures.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Groups in classes None A B C D E F G None
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Examples of locations Piers and wharves inside Acetylene Hydrogen Ethyl ether Gasoline Metal dust Carbon black Grain dust, flour dust, Baled waste,
or atmospheres in and outside general Naphtha coal dust, starch dust, organic cocoa fiber,
classes and groups. storage, general Alcohols coke dust dust cotton,
industrial or commercial Acetone excelsior, hemp,
properties. Lacquer istle, jute,
solvent kapok, oakum,
Benzene sisal, Spanish
moss, synthetic
fibers, tow.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Table N-1--Summary Table on Use of Industrial Trucks in Various Locations--Continued
--------------------------------------------------------------------------------------------------------------------------------------------------------
1 2 1 2 1 2
--------------------------------------------------------------------------------------------------------------------------------------------------------
Divisions (nature None Above condition Above condition Explosive mixture Explosive mixture Locations in Locations in
of hazardous exists may occur may be present not normally which easily which easily
conditions) continuously, accidentally as under normal present, but ignitible fibers ignitible fibers
intermittently, due to a puncture operating where deposits of or materials are stored or
or periodically of a storage drum. conditions, or dust may cause producing handled (except
under normal where failure of heat rise in combustible in the process
operating equipment may electrical flyings are of manufacture).
conditions. cause the equipment, or handled,
condition to where such manufactured, or
exist deposits may be used.
simultaneously ignited by arcs
with arcing or or sparks from
sparking of electrical
electrical equipment.
equipment, or
where dusts of an
electrically
conducting nature
may be present.
[[Page 546]]
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Authorized uses of trucks by types in groups of classes and divisions
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Groups in classes None A B C D A B C D E F G E F G None None
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Type of truck authorized:
Diesel:
Type D.................... D**.............. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................
Type DS................... ................. ................. ................. ................. ................. ................. ................. ................. DS............... ................. ................. ................. ................. ................. DS............... ................. DS
Type DY................... ................. ................. ................. ................. ................. ................. ................. ................. DY............... ................. ................. ................. ................. ................. DY............... DY............... DY
Electric:
Type E.................... E**.............. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. E
Type ES................... ................. ................. ................. ................. ................. ................. ................. ................. ES............... ................. ................. ................. ................. ................. ES............... ................. ES
Type EE................... ................. ................. ................. ................. ................. ................. ................. ................. EE............... ................. ................. ................. ................. ................. EE............... EE............... EE
Type EX................... ................. ................. ................. ................. EX............... ................. ................. ................. EX............... ................. EX............... EX............... ................. ................. EX............... EX............... EX
Gasoline:
Type G.................... G**.............. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................
Type GS................... ................. ................. ................. ................. ................. ................. ................. ................. GS............... ................. ................. ................. ................. ................. GS............... ................. GS
LP-Gas:
Type LP................... LP**............. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................
Type LPS.................. ................. ................. ................. ................. ................. ................. ................. ................. LPS.............. ................. ................. ................. ................. ................. LPS.............. ................. LPS
Paragraph Ref. in No. 505..... 210.211 201 203 209 204 202 205 209 206 207(a) 208 (a)
(a)................(a),.............................................................................................................................................................................................................................................................................
(b)..............................................................................................................................................................................................................................................................................
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
**Trucks conforming to these types may also be used--see subdivision (c)(2)(x) and (c)(2)(xii) of this section.
[[Page 547]]
(v) In locations used for the storage of hazardous liquids in sealed
containers or liquefied or compressed gases in containers, approved
power-operated industrial trucks designated as DS, ES, GS, or LPS may be
used. This classification includes locations where volatile flammable
liquids or flammable gases or vapors are used, but which, would become
hazardous only in case of an accident or of some unusual operating
condition. The quantity of hazardous material that might escape in case
of accident, the adequacy of ventilating equipment, the total area
involved, and the record of the industry or business with respect to
explosions or fires are all factors that should receive consideration in
determining whether or not the DS or DY, ES, EE, GS, LPS designated
truck possesses sufficient safeguards for the location. Piping without
valves, checks, meters and similar devices would not ordinarily be
deemed to introduce a hazardous condition even though used for hazardous
liquids or gases. Locations used for the storage of hazardous liquids or
of liquified or compressed gases in sealed containers would not normally
be considered hazardous unless subject to other hazardous conditions
also.
(vi)(a) Only approved power operated industrial trucks designated as
EX shall be used in atmospheres in which combustible dust is or may be
in suspension continuously, intermittently, or periodically under normal
operating conditions, in quantities sufficient to produce explosive or
ignitable mixtures, or where mechanical failure or abnormal operation of
machinery or equipment might cause such mixtures to be produced.
(b) The EX classification usually includes the working areas of
grain handling and storage plants, room containing grinders or
pulverizers, cleaners, graders, scalpers, open conveyors or spouts, open
bins or hoppers, mixers, or blenders, automatic or hopper scales,
packing machinery, elevator heads and boots, stock distributors, dust
and stock collectors (except all-metal collectors vented to the
outside), and all similar dust producing machinery and equipment in
grain processing plants, starch plants, sugar pulverizing plants,
malting plants, hay grinding plants, and other occupancies of similar
nature; coal pulverizing plants (except where the pulverizing equipment
is essentially dust tight); all working areas where metal dusts and
powders are produced, processed, handled, packed, or stored (except in
tight containers); and other similar locations where combustible dust
may, under normal operating conditions, be present in the air in
quantities sufficient to produce explosive or ignitable mixtures.
(vii) Only approved power-operated industrial trucks designated as
DY, EE, or EX shall be used in atmospheres in which combustible dust
will not normally be in suspension in the air or will not be likely to
be thrown into suspension by the normal operation of equipment or
apparatus in quantities sufficient to produce explosive or ignitable
mixtures but where deposits or accumulations of such dust may be ignited
by arcs or sparks originating in the truck.
(viii) Only approved power-operated industrial trucks designated as
DY, EE, or EX shall be used in locations which are hazardous because of
the presence of easily ignitable fibers or flyings but in which such
fibers or flyings are not likely to be in suspension in the air in
quantities sufficient to produce ignitable mixtures.
(ix) Only approved power-operated industrial trucks designated as
DS, DY, ES, EE, EX, GS, or LPS shall be used in locations where easily
ignitable fibers are stored or handled, including outside storage, but
are not being processed or manufactured. Industrial trucks designated as
E, which have been previously used in these locations may be continued
in use.
(x) On piers and wharves handling general cargo, any approved power-
operated industrial truck designated as Type D, E, G, or LP may be used,
or trucks which conform to the requirements for these types may be used.
(xi) If storage warehouses and outside storage locations are
hazardous only the approved power-operated industrial truck specified
for such locations in this paragraph (c)(2) shall be used. If not
classified as hazardous, any approved power-operated industrial truck
[[Page 548]]
designated as Type D, E, G, or LP may be used, or trucks which conform
to the requirements for these types may be used.
(xii) If general industrial or commercial properties are hazardous,
only approved power-operated industrial trucks specified for such
locations in this paragraph (c)(2) shall be used. If not classified as
hazardous, any approved power-operated industrial truck designated as
Type D, E, G, or LP may be used, or trucks which conform to the
requirements of these types may be used.
(d) Converted industrial trucks. Power-operated industrial trucks
that have been originally approved for the use of gasoline for fuel,
when converted to the use of liquefied petroleum gas fuel in accordance
with paragraph (q) of this section, may be used in those locations where
G, GS or LP, and LPS designated trucks have been specified in the
preceding paragraphs.
(e) Safety guards. (1) High Lift Rider trucks shall be fitted with
an overhead guard manufactured in accordance with paragraph (a)(2) of
this section, unless operating conditions do not permit.
(2) If the type of load presents a hazard, the user shall equip fork
trucks with a vertical load backrest extension manufactured in
accordance with paragraph (a)(2) of this section.
(f) Fuel handling and storage. (1) The storage and handling of
liquid fuels such as gasoline and diesel fuel shall be in accordance
with NFPA Flammable and Combustible Liquids Code (NFPA No. 30-1969),
which is incorporated by reference as specified in Sec. 1910.6.
(2) The storage and handling of liquefied petroleum gas fuel shall
be in accordance with NFPA Storage and Handling of Liquefied Petroleum
Gases (NFPA No. 58-1969), which is incorporated by reference as
specified in Sec. 1910.6.
(g) Changing and charging storage batteries. (1) Battery charging
installations shall be located in areas designated for that purpose.
(2) Facilities shall be provided for flushing and neutralizing
spilled electrolyte, for fire protection, for protecting charging
apparatus from damage by trucks, and for adequate ventilation for
dispersal of fumes from gassing batteries.
(3) [Reserved]
(4) A conveyor, overhead hoist, or equivalent material handling
equipment shall be provided for handling batteries.
(5) Reinstalled batteries shall be properly positioned and secured
in the truck.
(6) A carboy tilter or siphon shall be provided for handling
electrolyte.
(7) When charging batteries, acid shall be poured into water; water
shall not be poured into acid.
(8) Trucks shall be properly positioned and brake applied before
attempting to change or charge batteries.
(9) Care shall be taken to assure that vent caps are functioning.
The battery (or compartment) cover(s) shall be open to dissipate heat.
(10) Smoking shall be prohibited in the charging area.
(11) Precautions shall be taken to prevent open flames, sparks, or
electric arcs in battery charging areas.
(12) Tools and other metallic objects shall be kept away from the
top of uncovered batteries.
(h) Lighting for operating areas.
(1) [Reserved]
(2) Where general lighting is less than 2 lumens per square foot,
auxiliary directional lighting shall be provided on the truck.
(i) Control of noxious gases and fumes. (1) Concentration levels of
carbon monoxide gas created by powered industrial truck operations shall
not exceed the levels specified in Sec. 1910.1000.
(j) Dockboards (bridge plates). See Sec. 1910.30(a).
(k) Trucks and railroad cars. (1) The brakes of highway trucks shall
be set and wheel chocks placed under the rear wheels to prevent the
trucks from rolling while they are boarded with powered industrial
trucks.
(2) Wheel stops or other recognized positive protection shall be
provided to prevent railroad cars from moving during loading or
unloading operations.
(3) Fixed jacks may be necessary to support a semitrailer and
prevent upending during the loading or unloading when the trailer is not
coupled to a tractor.
[[Page 549]]
(4) Positive protection shall be provided to prevent railroad cars
from being moved while dockboards or bridge plates are in position.
(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:
(A) Under the direct supervision of persons who have the knowledge,
training, and experience to train operators and evaluate their
competence; and
(B) 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:
(A) Operating instructions, warnings, and precautions for the types
of truck the operator will be authorized to operate;
(B) Differences between the truck and the automobile;
(C) Truck controls and instrumentation: where they are located, what
they do, and how they work;
(D) Engine or motor operation;
(E) Steering and maneuvering;
(F) Visibility (including restrictions due to loading);
(G) Fork and attachment adaptation, operation, and use limitations;
(H) Vehicle capacity;
(I) Vehicle stability;
(J) Any vehicle inspection and maintenance that the operator will be
required to perform;
(K) Refueling and/or charging and recharging of batteries;
(L) Operating limitations;
(M) 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:
(A) Surface conditions where the vehicle will be operated;
(B) Composition of loads to be carried and load stability;
(C) Load manipulation, stacking, and unstacking;
(D) Pedestrian traffic in areas where the vehicle will be operated;
(E) Narrow aisles and other restricted places where the vehicle will
be operated;
(F) Hazardous (classified) locations where the vehicle will be
operated;
(G) Ramps and other sloped surfaces that could affect the vehicle's
stability;
(H) Closed environments and other areas where insufficient
ventilation or poor vehicle maintenance could cause a buildup of carbon
monoxide or diesel exhaust;
(I) 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.
[[Page 550]]
(ii) Refresher training in relevant topics shall be provided to the
operator when:
(A) The operator has been observed to operate the vehicle in an
unsafe manner;
(B) The operator has been involved in an accident or near-miss
incident;
(C) The operator has received an evaluation that reveals that the
operator is not operating the truck safely;
(D) The operator is assigned to drive a different type of truck; or
(E) 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.
(7) Dates. The employer shall ensure that operators of powered
industrial trucks are trained, as appropriate, by the dates shown in the
following table.
------------------------------------------------------------------------
The initial training and
If the employee was hired: evaluation of that employee
must be completed:
------------------------------------------------------------------------
Before December 1, 1999................ By December 1, 1999.
After December 1, 1999................. Before the employee is assigned
to operate a powered
industrial truck.
------------------------------------------------------------------------
(8) Appendix A to this section provides non-mandatory guidance to
assist employers in implementing this paragraph (l). This appendix does
not add to, alter, or reduce the requirements of this section.
(m) Truck operations. (1) Trucks shall not be driven up to anyone
standing in front of a bench or other fixed object.
(2) No person shall be allowed to stand or pass under the elevated
portion of any truck, whether loaded or empty.
(3) Unauthorized personnel shall not be permitted to ride on powered
industrial trucks. A safe place to ride shall be provided where riding
of trucks is authorized.
(4) The employer shall prohibit arms or legs from being placed
between the uprights of the mast or outside the running lines of the
truck.
(5)(i) When a powered industrial truck is left unattended, load
engaging means shall be fully lowered, controls shall be neutralized,
power shall be shut off, and brakes set. Wheels shall be blocked if the
truck is parked on an incline.
(ii) A powered industrial truck is unattended when the operator is
25 ft. or more away from the vehicle which remains in his view, or
whenever the operator leaves the vehicle and it is not in his view.
(iii) When the operator of an industrial truck is dismounted and
within 25 ft. of the truck still in his view, the load engaging means
shall be fully lowered, controls neutralized, and the brakes set to
prevent movement.
(6) A safe distance shall be maintained from the edge of ramps or
platforms while on any elevated dock, or platform or freight car. Trucks
shall not be used for opening or closing freight doors.
(7) Brakes shall be set and wheel blocks shall be in place to
prevent movement of trucks, trailers, or railroad cars while loading or
unloading. Fixed jacks may be necessary to support a semitrailer during
loading or unloading when the trailer is not coupled to a tractor. The
flooring of trucks, trailers, and railroad cars shall be checked for
breaks and weakness before they are driven onto.
(8) There shall be sufficient headroom under overhead installations,
lights, pipes, sprinkler system, etc.
[[Page 551]]
(9) An overhead guard shall be used as protection against falling
objects. It should be noted that an overhead guard is intended to offer
protection from the impact of small packages, boxes, bagged material,
etc., representative of the job application, but not to withstand the
impact of a falling capacity load.
(10) A load backrest extension shall be used whenever necessary to
minimize the possibility of the load or part of it from falling
rearward.
(11) Only approved industrial trucks shall be used in hazardous
locations.
(12) Whenever a truck is equipped with vertical only, or vertical
and horizontal controls elevatable with the lifting carriage or forks
for lifting personnel, the following additional precautions shall be
taken for the protection of personnel being elevated.
(i) Use of a safety platform firmly secured to the lifting carriage
and/or forks.
(ii) Means shall be provided whereby personnel on the platform can
shut off power to the truck.
(iii) Such protection from falling objects as indicated necessary by
the operating conditions shall be provided.
(13) [Reserved]
(14) Fire aisles, access to stairways, and fire equipment shall be
kept clear.
(n) Traveling. (1) All traffic regulations shall be observed,
including authorized plant speed limits. A safe distance shall be
maintained approximately three truck lengths from the truck ahead, and
the truck shall be kept under control at all times.
(2) The right of way shall be yielded to ambulances, fire trucks, or
other vehicles in emergency situations.
(3) Other trucks traveling in the same direction at intersections,
blind spots, or other dangerous locations shall not be passed.
(4) The driver shall be required to slow down and sound the horn at
cross aisles and other locations where vision is obstructed. If the load
being carried obstructs forward view, the driver shall be required to
travel with the load trailing.
(5) Railroad tracks shall be crossed diagonally wherever possible.
Parking closer than 8 feet from the center of railroad tracks is
prohibited.
(6) The driver shall be required to look in the direction of, and
keep a clear view of the path of travel.
(7) Grades shall be ascended or descended slowly.
(i) When ascending or descending grades in excess of 10 percent,
loaded trucks shall be driven with the load upgrade.
(ii) [Reserved]
(iii) On all grades the load and load engaging means shall be tilted
back if applicable, and raised only as far as necessary to clear the
road surface.
(8) Under all travel conditions the truck shall be operated at a
speed that will permit it to be brought to a stop in a safe manner.
(9) Stunt driving and horseplay shall not be permitted.
(10) The driver shall be required to slow down for wet and slippery
floors.
(11) Dockboard or bridgeplates, shall be properly secured before
they are driven over. Dockboard or bridgeplates shall be driven over
carefully and slowly and their rated capacity never exceeded.
(12) Elevators shall be approached slowly, and then entered squarely
after the elevator car is properly leveled. Once on the elevator, the
controls shall be neutralized, power shut off, and the brakes set.
(13) Motorized hand trucks must enter elevator or other confined
areas with load end forward.
(14) Running over loose objects on the roadway surface shall be
avoided.
(15) While negotiating turns, speed shall be reduced to a safe level
by means of turning the hand steering wheel in a smooth, sweeping
motion. Except when maneuvering at a very low speed, the hand steering
wheel shall be turned at a moderate, even rate.
(o) Loading. (1) Only stable or safely arranged loads shall be
handled. Caution shall be exercised when handling off-center loads which
cannot be centered.
(2) Only loads within the rated capacity of the truck shall be
handled.
(3) The long or high (including multiple-tiered) loads which may
affect capacity shall be adjusted.
(4) Trucks equipped with attachments shall be operated as partially
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loaded trucks when not handling a load.
(5) A load engaging means shall be placed under the load as far as
possible; the mast shall be carefully tilted backward to stabilize the
load.
(6) Extreme care shall be used when tilting the load forward or
backward, particularly when high tiering. Tilting forward with load
engaging means elevated shall be prohibited except to pick up a load. An
elevated load shall not be tilted forward except when the load is in a
deposit position over a rack or stack. When stacking or tiering, only
enough backward tilt to stabilize the load shall be used.
(p) Operation of the truck. (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.
(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.
(5) Open flames shall not be used for checking electrolyte level in
storage batteries or gasoline level in fuel tanks.
(q) Maintenance of industrial trucks. (1) Any power-operated
industrial truck not in safe operating condition shall be removed from
service. All repairs shall be made by authorized personnel.
(2) No repairs shall be made in Class I, II, and III locations.
(3) Those repairs to the fuel and ignition systems of industrial
trucks which involve fire hazards shall be conducted only in locations
designated for such repairs.
(4) Trucks in need of repairs to the electrical system shall have
the battery disconnected prior to such repairs.
(5) All parts of any such industrial truck requiring replacement
shall be replaced only by parts equivalent as to safety with those used
in the original design.
(6) Industrial trucks shall not be altered so that the relative
positions of the various parts are different from what they were when
originally received from the manufacturer, nor shall they be altered
either by the addition of extra parts not provided by the manufacturer
or by the elimination of any parts, except as provided in paragraph
(q)(12) of this section. Additional counterweighting of fork trucks
shall not be done unless approved by the truck manufacturer.
(7) Industrial trucks shall be examined before being placed in
service, and shall not be placed in service if the examination shows any
condition adversely affecting the safety of the vehicle. Such
examination shall be made at least daily.
Where industrial trucks are used on a round-the-clock basis, they shall
be examined after each shift. Defects when found shall be immediately
reported and corrected.
(8) Water mufflers shall be filled daily or as frequently as is
necessary to prevent depletion of the supply of water below 75 percent
of the filled capacity. Vehicles with mufflers having screens or other
parts that may become clogged shall not be operated while such screens
or parts are clogged. Any vehicle that emits hazardous sparks or flames
from the exhaust system shall immediately be removed from service, and
not returned to service until the cause for the emission of such sparks
and flames has been eliminated.
(9) When the temperature of any part of any truck is found to be in
excess of its normal operating temperature, thus creating a hazardous
condition, the vehicle shall be removed from service and not returned to
service until the cause for such overheating has been eliminated.
(10) Industrial trucks shall be kept in a clean condition, free of
lint, excess oil, and grease. Noncombustible agents should be used for
cleaning trucks. Low flash point (below 100 deg.F.) solvents shall not
be used. High flash point (at or above 100 deg.F.) solvents may be
used. Precautions regarding toxicity, ventilation, and fire hazard shall
be consonant with the agent or solvent used.
(11) [Reserved]
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(12) Industrial trucks originally approved for the use of gasoline
for fuel may be converted to liquefied petroleum gas fuel provided the
complete conversion results in a truck which embodies the features
specified for LP or LPS designated trucks. Such conversion equipment
shall be approved. The description of the component parts of this
conversion system and the recommended method of installation on specific
trucks are contained in the ``Listed by Report.''
Appendix A to Sec. 1910.178--Stability of Powered Industrial Trucks
(Non-mandatory Appendix to Paragraph (l) of This Section)
A-1. Definitions.
The following definitions help to explain the principle of
stability:
Center of gravity is the point on an object at which all of the
object's weight is concentrated. For symmetrical loads, the center of
gravity is at the middle of the load.
Counterweight is the weight that is built into the truck's basic
structure and is used to offset the load's weight and to maximize the
vehicle's resistance to tipping over.
Fulcrum is the truck's axis of rotation when it tips over.
Grade is the slope of a surface, which is usually measured as the
number of feet of rise or fall over a hundred foot horizontal distance
(the slope is expressed as a percent).
Lateral stability is a truck's resistance to overturning sideways.
Line of action is an imaginary vertical line through an object's
center of gravity.
Load center is the horizontal distance from the load's edge (or the
fork's or other attachment's vertical face) to the line of action
through the load's center of gravity.
Longitudinal stability is the truck's resistance to overturning
forward or rearward.
Moment is the product of the object's weight times the distance from
a fixed point (usually the fulcrum). In the case of a powered industrial
truck, the distance is measured from the point at which the truck will
tip over to the object's line of action. The distance is always measured
perpendicular to the line of action.
Track is the distance between the wheels on the same axle of the
truck.
Wheelbase is the distance between the centerline of the vehicle's
front and rear wheels.
A-2. General.
A-2.1. Determining the stability of a powered industrial truck is
simple once a few basic principles are understood. There are many
factors that contribute to a vehicle's stability: the vehicle's
wheelbase, track, and height; the load's weight distribution; and the
vehicle's counterweight location (if the vehicle is so equipped).
A-2.2. The ``stability triangle,'' used in most stability
discussions, demonstrates stability simply.
A-3. Basic Principles.
A-3.1. Whether an object is stable depends on the object's moment at
one end of a system being greater than, equal to, or smaller than the
object's moment at the system's other end. This principle can be seen in
the way a see-saw or teeter-totter works: that is, if the product of the
load and distance from the fulcrum (moment) is equal to the moment at
the device's other end, the device is balanced and it will not move.
However, if there is a greater moment at one end of the device, the
device will try to move downward at the end with the greater moment.
A-3.2. The longitudinal stability of a counterbalanced powered
industrial truck depends on the vehicle's moment and the load's moment.
In other words, if the mathematic product of the load moment (the
distance from the front wheels, the approximate point at which the
vehicle would tip forward) to the load's center of gravity times the
load's weight is less than the vehicle's moment, the system is balanced
and will not tip forward. However, if the load's moment is greater than
the vehicle's moment, the greater load-moment will force the truck to
tip forward.
A-4. The Stability Triangle.
A-4.1. Almost all counterbalanced powered industrial trucks have a
three-point suspension system, that is, the vehicle is supported at
three points. This is true even if the vehicle has four wheels. The
truck's steer axle is attached to the truck by a pivot pin in the axle's
center. When the points are connected with imaginary lines, this three-
point support forms a triangle called the stability triangle. Figure 1
depicts the stability triangle.
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[GRAPHIC] [TIFF OMITTED] TR01DE98.002
A-4.2. When the vehicle's line of action, or load center, falls
within the stability triangle, the vehicle is stable and will not tip
over. However, when the vehicle's line of action or the vehicle/load
combination falls outside the stability triangle, the vehicle is
unstable and may tip over. (See Figure 2.)
[[Page 555]]
[GRAPHIC] [TIFF OMITTED] TR01DE98.003
A-5. Longitudinal Stability.
A-5.1. The axis of rotation when a truck tips forward is the front
wheels' points of contact with the pavement. When a powered industrial
truck tips forward, the truck will rotate about this line. When a truck
is stable, the vehicle-moment must exceed the load-moment. As long as
the vehicle-moment is equal to or exceeds the load-moment, the vehicle
will not tip over. On the other hand, if the load moment slightly
exceeds the vehicle-moment, the truck will begin to tip forward, thereby
causing the rear to lose contact with the floor or ground and resulting
in loss of steering control. If the load-moment greatly exceeds the
vehicle moment, the truck will tip forward.
A-5.2. To determine the maximum safe load-moment, the truck
manufacturer normally rates the truck at a maximum load at a given
distance from the front face of the forks. The specified distance from
the front face of the forks to the line of action of the load is
commonly called the load center. Because larger trucks normally handle
loads that are physically larger, these vehicles have greater load
centers. Trucks with a capacity of 30,000 pounds or less are normally
rated at a given load weight at a 24-inch load center. Trucks with a
capacity greater than 30,000 pounds are normally rated at a given load
weight at a 36- or 48-inch load center. To safely operate the vehicle,
the operator should always check the data plate to determine the maximum
allowable weight at the rated load center.
A-5.3. Although the true load-moment distance is measured from the
front wheels, this
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distance is greater than the distance from the front face of the forks.
Calculating the maximum allowable load-moment using the load-center
distance always provides a lower load-moment than the truck was designed
to handle. When handling unusual loads, such as those that are larger
than 48 inches long (the center of gravity is greater than 24 inches) or
that have an offset center of gravity, etc., a maximum allowable load-
moment should be calculated and used to determine whether a load can be
safely handled. For example, if an operator is operating a 3000 pound
capacity truck (with a 24-inch load center), the maximum allowable load-
moment is 72,000 inch-pounds (3,000 times 24). If a load is 60 inches
long (30-inch load center), then the maximum that this load can weigh is
2,400 pounds (72,000 divided by 30).
A-6. Lateral Stability.
A-6.1. The vehicle's lateral stability is determined by the line of
action's position (a vertical line that passes through the combined
vehicle's and load's center of gravity) relative to the stability
triangle. When the vehicle is not loaded, the truck's center of gravity
location is the only factor to be considered in determining the truck's
stability. As long as the line of action of the combined vehicle's and
load's center of gravity falls within the stability triangle, the truck
is stable and will not tip over. However, if the line of action falls
outside the stability triangle, the truck is not stable and may tip
over. Refer to Figure 2.
A-6.2. Factors that affect the vehicle's lateral stability include
the load's placement on the truck, the height of the load above the
surface on which the vehicle is operating, and the vehicle's degree of
lean.
A-7. Dynamic Stability.
A-7.1. Up to this point, the stability of a powered industrial truck
has been discussed without considering the dynamic forces that result
when the vehicle and load are put into motion. The weight's transfer and
the resultant shift in the center of gravity due to the dynamic forces
created when the machine is moving, braking, cornering, lifting,
tilting, and lowering loads, etc., are important stability
considerations.
A-7.2. When determining whether a load can be safely handled, the
operator should exercise extra caution when handling loads that cause
the vehicle to approach its maximum design characteristics. For example,
if an operator must handle a maximum load, the load should be carried at
the lowest position possible, the truck should be accelerated slowly and
evenly, and the forks should be tilted forward cautiously. However, no
precise rules can be formulated to cover all of these eventualities.
[39 FR 23502, June 27, 1974, as amended at 40 FR 23073, May 28, 1975; 43
FR 49749, Oct. 24, 1978; 49 FR 5322, Feb. 10, 1984; 53 FR 12122, Apr.
12, 1988; 55 FR 32015, Aug 6, 1990; 61 FR 9239, Mar. 7, 1996; 63 FR
66270, Dec. 1, 1998]