§1910.178 Powered industrial trucks

[Code of Federal Regulations]
[Title 29, Volume 5]
[Revised as of January 1, 2007]
From the U.S. Government Printing Office via GPO Access
[CITE: 29CFR1910.178]

[Page 537-551]

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 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 units, are provided with

additional safeguards to the electrical system to

[[Page 538]]

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.

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 gases will normally be confined within closed

containers or closed systems

[[Page 539]]

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 540]]

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 541]]

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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 542]]

(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 543]]

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 544]]

(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;

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;

(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 545]]

(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;

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 546]]

(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)-(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

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

[[Page 547]]

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]

(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.''

[[Page 548]]

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.

[[Page 549]]

[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 550]]

[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

[[Page 551]]

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; 68 FR 32638, June 2, 2003; 71 FR 16672, Apr. 3,

2006]