Tilt-cab and cab-over-engine (COE) trucks are designed to provide efficient access to drivetrain components by allowing the cab to pivot forward. This design is common in delivery vehicles, refuse trucks, fire apparatus, and other vocational fleets.

The Unique Risks of Tilt-Cab Truck Maintenance

While tilt-cab designs improve serviceability, they also introduce a distinct maintenance hazard: technicians often work beneath a raised cab that is supported primarily by hydraulic systems. Understanding where this hazard exists—and how it is managed—is essential for safer maintenance operations.

How Tilt-Cab Systems Work

Tilt-cab systems typically use hydraulic cylinders to raise and position the cab. Once raised, the cab remains in place as long as hydraulic pressure is maintained and system components function correctly.

Unlike structural supports, hydraulic systems are affected by:

Pressure changes
Temperature variation
Component wear
Control interaction

These factors make hydraulics unsuitable as sole protection for personnel working beneath a raised cab. With extra assistance, a tilt cab safety lock prevents the cab from accidentally lowering during maintenance, helping protect technicians and ensure safe access to the engine area.

Why Hydraulics Are Not Protective Devices

Hydraulic systems are designed to move and position loads, not to protect people. Over time, even small losses in pressure can allow movement when the cab is under load. During maintenance, technicians are often positioned directly beneath the cab structure, placing them in the load path if movement occurs. In confined spaces, reaction time may be limited.

High-Risk Tilt-Cab Maintenance Scenarios

Maintenance tasks that commonly involve working beneath a raised cab include:

Engine diagnostics and repair
Steering and suspension work
Electrical and cooling system service
Transmission access

Emergency service environments, such as fire apparatus maintenance, can further increase risk due to frequent service cycles, pressure to complete tasks quickly, and aging equipment.

Human Factors in Tilt-Cab Maintenance

Maintenance injuries often occur during routine work. Familiarity with equipment can lead to assumptions that systems will behave as expected. Additional human-factor contributors include:

Time constraints
Fatigue
Informal practices
Inconsistent use of supports

Effective safety procedures account for these realities rather than relying solely on individual judgment.

Recognized Hazard and Compliance Considerations

Working beneath a raised tilt-cab is a recognized crush hazard. OSHA expects employers to identify such hazards and implement feasible controls to reduce exposure. Controls that physically prevent movement are generally more reliable than administrative controls alone.

Secondary Mechanical Supports for Tilt-Cab Maintenance

Secondary mechanical supports are used to physically brace the cab in the raised position, reducing reliance on hydraulic pressure. Effective supports:

Provide visible confirmation of engagement
Remain in place until intentionally removed
Are compatible with routine maintenance tasks
Support consistent use across technicians

By introducing a physical load-bearing barrier, secondary supports address the core risk created by gravity acting on a raised cab.

Incorporating Cab Safety into Standard Operating Procedures (SOPs) and Training

Fleets that manage tilt-cab maintenance risks successfully:

Define when secondary supports are required
Include verification steps in SOPs
Train technicians and supervisors consistently
Reinforce expectations through routine practice

This approach reduces variability and improves long-term safety performance.

Tilt-cab truck maintenance presents unique hazards that require deliberate, well thought out controls. Understanding how these hazards arise allows fleets to design safer maintenance systems that protect technicians and support operational reliability.

To learn how secondary mechanical supports are used during tilt-cab maintenance, contact Truck Safety USA for more information about the Cab Brace®.