The telehandler is a kind of multi-functional engineering machinery and equipment with the functions of forklift, crane and loader. It is equipped with a variety of tools such as forks, buckets, booms, operation platforms and so on through telescopic arms that can be extended forward and upwards. However, this powerful equipment also comes with significant safety risks. Accidents such as overturning, collisions, and load falls can occur at any time under improper operation. According to OSHA statistics, a considerable proportion of equipment accidents every year involve improper operation or operator mistakes.
This guide systematically sorts out the safety points of the whole process of telescopic boom forklifts from pre-operation inspection, start-up driving, load handling, equipment replacement, restricted space operation to legal certification, and helps operators, safety managers and fleet leaders to establish a complete safety operation system. Whether you are a newcomer to equipment or a manager who wants to regulate team operations, this article will provide you with implementable and executable operating standards.
The stability of the telescopic forklift is determined by the “stability triangle”, and the two front wheels and the center points of the rear axle form the supporting bottom surface. When the load is lifted and extended forward, the center of gravity of the whole machine moves forward. Once the center of gravity exceeds the front edge of the support bottom, the device will tilt forward. Therefore, the rated load of the equipment is not a fixed number, but a dynamic value that changes in random height, forward extension distance, weight and ground conditions.
Before starting the equipment, the operator must have a clear understanding of the key parts of the machine and its functions.
The cab; the operator’s command center, including the steering wheel, joystick, pedal, dashboard and various safety indicator lights.
Telescopic arm; multi-stage extendable arm frame, providing vertical lifting and horizontal forward extension ability, is the core and most dangerous part of the equipment.
The tool connection frame; located at the end of the arm frame, it is used to quickly connect and lock all kinds of tools.
Stabilizer/leg; some models are equipped to increase the support area and improve stability during heavy load or high-extreture operation.
Hydraulic system; the state of the drive boom is directly related to whether the load can be safely controlled.
Steering system; Most telescopic forklifts support three modes: four-wheel steering, two-wheel steering and crab steering to meet the needs of different sites.
Before the start of each shift, the operator must conduct a complete winding inspection of the equipment. OSHA clearly requires that power industrial vehicles should be inspected before each shift of use in 29 CFR 1910.178 in order to detect them before they evolve into overturning, brake failure or hydraulic runaway accidents.
| Check the items | Specific inspection content | Why is it important? | Dealing with problems after finding them |
| Tires and wheels | Tire pressure, cut, tread shedding, side wall damage, rim bolt loosening . | It directly affects the stability and steering control. | Disable the device and it can only be used after repair or replacement.
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| Fork and connecting frame | Cracks, fork tip bending, heel wear, locking pin, alignment The damaged fork may break under load. | The damaged fork may break under load. | Deactivation of the listing, test according to the maintenance standard. |
| Hydraulic system | Leakage, hose wear, cylinder damage, oil level | Hydraulic failure may cause the load to fall or drift. | Stop using it immediately and work after repairing. |
| Braking and steering | Pedal feel, steering response, parking brake holding force | Driving safety depends entirely on braking and steering. | Do not operate before troubleshooting |
| Security apparatus | Horns, lights, reversing alarms, rearview mirrors, seat belts, indicator lights灯 | Protect the operator and the surrounding personnel | Enter the operation site after repair. |
| Arm frame and structure | Cracks, deformation, abnormal noise, wear-resistant mat | Structural integrity is very important in the fully extended state. | Stop the machine and wait for the technician to test. |
| Load table and identification | Whether it is in place, clear and readable, and matches the model and belonging | The operator needs accurate load information. | Replace missing or blurred labels |
| Fuel and liquid level | Fuel oil, hydraulic oil, engine oil, coolant liquid level | Prevent shutdown or equipment damage in the middle of the operation | Supplement according to the manufacturer’s specifications |
After sitting down, adjust the seat, rearview mirror and steering wheel position to ensure comfortable control and good visibility. Fasten the seat belt, confirm that the parking brake has been pulled up, and check all the warning lights on the dashboard. Turn the key to the power-on position, and wait for the on-board computer to complete the self-test process before completely screwing the key to start the engine.
All-Wheel Steer; Four wheels are deflected at the same time, with the smallest turning radius, which is suitable for flexible maneuver in narrow fields. But the stability is low when driving at high speed.
Two-Wheel Steering; rear wheel locking, only front wheel steering, similar to the control feeling of ordinary vehicles, suitable for road driving and large radius turns, with the best stability.
Crab Steer; The four wheels are deflected in the same direction at the same angle, so that the whole machine moves diagonally, which is suitable for escaping from a narrow position or lateral alignment of the operation point.
After switching the steering mode, be sure to confirm that the wheels are correctly aligned before moving. The wrong steering pattern is one of the common causes of collisions and overturns.
When driving with no load, the boom is completely retracted and lowered to a position close to the ground. This can not only maintain a low center of gravity, but also prevent the arm from blocking the sight ahead. Use low-speed gear on rough terrain to avoid sudden acceleration, sudden braking and fast turning. Statistics show that most accidents in telescopic forklifts occur during the driving, turning or repositioning stages, not during the final lifting action itself. When driving on the ramp, follow the driving direction specified by the manufacturer – usually the load should be in the direction of the slope, but the specifics of the operation manual shall prevail.
Never guess the weight of the load. Before picking up the goods, the actual weight must be confirmed in the following ways: check the packaging label, shipping documents, number of pallets, list of materials or ask the on-site supervisor. At the same time, estimate the position of the load core to ensure that the fork spacing is appropriate and fully inserted under the load. If the load center is offset or the fork is not inserted enough, even if the weight is within the rated range, it may cause it to run out of control.
When picking up goods, tilt the door frame (connection frame) later to stabilize the load, and only lift it to a height sufficient to drive off the ground. When you need to lift the load, park the equipment on the horizontal ground as much as possible. Extend and lift the boom smoothly, and observe the posture and load status of the whole machine throughout the whole process. If the arm or load blocks the view, a spotter must be arranged to command. It is strictly forbidden for any person to be under the suspended load.
When placing the load, the action should be gentle. After confirming that the load has been firmly supported, withdraw the arm frame, and then drive away. If you feel that the load is unstable, the rear wheel is lighter or the alarm system is triggered during the lifting process, you should stop the operation immediately and re-evaluate – you may need to replace the equipment, adjust the position or change the lifting scheme.
After the operation, lower the arm completely, put the gearbox in neutral gear, pull up the parking brake, turn off the engine and pull out the key. Don’t let the equipment running the engine be unattended. If the equipment is parked on the ramp, the wheel bumper should also be placed under the wheel.
Although the connection methods of different accessories are slightly different, the general quick hitch installation process is as follows.
The Load Chart is the most important decision-making tool for telescopic forklift operators. It details the maximum weight allowed by the equipment to be lifted under different arm heights, forward extension distance, equipment configuration and support conditions. Unfortunately, many accidents occur precisely because the operator ignores the load gauge and judges whether it can operate only by the advertised number of “maximum lifting weight”.
Find the intersection corresponding to your target height and forward extension distance on the correct load table, and read the allowable load value of this position. The actual load must be lower than this value. If it exceeds, don’t try to “make do” or “just stretch a little”. The law of physics will not give in because of the tight construction schedule. The correct practice is to replace the equipment with a larger tonnage, replace the lighter equipment, adjust the position of the equipment to shorten the forward extension distance, or change the lifting scheme.
As the arm extends forward, the allowable load will drop sharply. For example, a device that can lift 3 tons near the front wheel may only lift less than 1 ton at the maximum forward distance. Never use the “maximum weight” in the brochure to judge any actual work.
Whether it is no-load or carry-load, the boom should be retracted and lowered when driving. Driving at a high level not only blocks the view, but also greatly raises the center of gravity, and it is very easy to overturn when turning or bumping. Avoid sudden acceleration, sudden braking and fast steering. The load of the telescopic forklift will produce an inertial swing under sudden movement, which may instantly break through the stability limit. Use progressive and controllable manipulation input. When you need to adjust the boom, stop the equipment completely first, complete the adjustment, and then continue driving. Stretching your arms while opening is a common cause of overturning accidents.
When driving with load, tilt the door frame later, so that the load is leaning towards the arm frame and keeping the center of gravity stable. Make sure that the fork passes through the load completely, so as to avoid forking only a part of it and causing the load to tilt or slip. If the load itself is asymmetrical, adjust the fork spacing or use special equipment to balance it. Pay attention to whether the rear wheel tends to lift during driving and lifting. The lightening of the rear wheel is a clear signal that it is about to overturn. Once it appears, the load should be reduced and the arm frame should be retracted immediately.
Before driving the equipment, walk through the driving route and operation area, and mark the soft ground, potholes, slopes, underground pipelines, ditch covers and excavation edges. Pay attention to overhead obstacles and look up to check wires, pipes, sprinkler systems, steel beams and low ceilings. When working indoors or under the structure, be sure to measure the airspace height. The legs will produce a high concentrated load on the ground. If necessary, use pads to disperse the pressure.
It is strictly forbidden to drive horizontally and operate horizontally for telescopic forklifts, which is the first iron rule of slope operation. All slope driving and operations must go straight along the slope. When going uphill, the head of the car is facing up and driving steadily at low speed. When carrying uphill, the material should be forward and the center of gravity should be moved forward to avoid the rear end warping. When going downhill, the head of the car should be facing down and slow down at low speed. It is strictly forbidden to glide in neutral and overspeed downhill. When downhill with loads, the material should be controlled at a low level to prevent the material from tipping forward and falling. The slope operation angle is strictly forbidden to exceed the rated inclination angle of the equipment. The maximum safe operation slope of the general equipment should not exceed 15°. When the slope is large, the road surface must be paved and the slope must be reduced before operation.
Construction site passages, indoor warehouses, foundation pits and other narrow space operations have limited vision, dense obstacles, and limited operating space. Before the operation, it is necessary to clean up the debris in the passage in advance, measure the width of the passage and the height of the operation space, and confirm that it meets the needs of equipment passage and operation; drive at the lowest speed throughout the whole process, and a special person will command and monitor the whole process, and eliminate blind area operation; the telescopic arm expansion and angle adjustment actions should be carried out slowly, and large-scale operation is strictly prohibited.
Soft soil, muddy after rain, and insufficient bearing capacity of the stagnant water site are very easy to cause tires to sink and equipment to tilt. Before the operation, it is necessary to pave steel plates, gravel and road substrates, harden the operation ground, and improve the bearing capacity of the ground; give priority to the four-wheel drive mode to operate, increase the grip of tires, and reduce slipping and sinking; drive at low speed and uniformly throughout the whole process, and it is strictly forbidden to accelerate, brake suddenly, and hit the direction in place to avoid tire slipping and ground collapse.
High-altitude lifting and long-distance cantilever operation are the worst stable conditions, and the load and operation amplitude must be strictly controlled. Before the operation, compare the load chart, greatly reduce the operation load, and reserve sufficient safety margin; the arm body is stretched, lifted, and angle adjustment are operated step by step. Each adjustment is paused to observe the stability of the equipment, and confirm that there is no tilt and no abnormality before continuing the operation; during high-altitude operation, the equipment is strictly prohibited from moving, turning, and adjusting the line. In the driving state, the arm can only be operated after the equipment is completely stationary.
In most countries and regions around the world, the operation of telescopic boom forklifts requires formal training, evaluation and certification. The following is a comparison of the regulatory requirements of major markets.
| Country/Region | Regulatory authorities/standards | Core requirements | Re-examination cycle |
| United States | OSHA 29 CFR 1910.178 | Employers must ensure that operators receive formal training and practical assessment, covering specific models, site conditions and the use of equipment. | Retraining every 3 years, additional training is required after the accident or equipment replacement. |
| UK | CPCS / NPORS | CPCS/NPORS You need to hold a recognized training card (CPCS blue card or NPORS) to prove your operational ability. | The CPCS card is usually valid for 5 years and needs to be renewed. |
| EU | EN standards / national regulations | It needs to meet the relevant standards of EN, and the specific certification systems of different countries are slightly different. | According to the regulations of various countries, usually 3-5 years
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| Australia | High-risk Work Permit (HRW) | HRW license is required to operate telescopic forklifts (especially when using specific equipment) | Usually 5 years |
If an unlicensed operator causes an accident, the employer may face huge fines and lawsuits. In the United States, OSHA can fine up to tens of thousands of dollars for serious violations; in the United Kingdom, HSE (Health and Safety Administration) can file criminal proceedings against businesses. For individual operators, unlicensed operation may lead to the loss of legal protection and even personal legal responsibility in the event of an accident. The cost of training is usually between $300 and $1,000, which is the most valuable safety investment compared to casualties, equipment damage and legal compensation caused by accidents.
Safe operation cannot be separated from standardized equipment maintenance. Daily maintenance, aging and failure of parts, and oil deterioration and loss are the invisible triggers of equipment failure and safety accidents. The establishment of a timed, quantitative and standard maintenance system can greatly reduce the probability of equipment failure, extend the service life of equipment, and ensure the safety of long-term operation. The maintenance of telescopic arm forklift is divided into four standard cycles: daily maintenance, 250-hour maintenance, 500-hour maintenance and 1000-hour maintenance.
Daily maintenance is pre-service maintenance. The core content is the whole car cleaning, appearance inspection, oil and liquid inspection, pipeline inspection, functional testing, cleaning up the dust and debris of the car body, checking for leakage, damage and loosening hazards, and ensuring that the appearance of the equipment is intact and the function is normal.
250-hour basic maintenance, including the replacement of engine oil and oil filter, checking the fastening screws, pins and connectors of the whole car, lubricating the telescopic structure of the arm body, the steering structure, the walking hinge part, checking the wear status of the brake pad, and adjusting the brake clearance.
For 500-hour mid-term maintenance, it is necessary to replace the air filter, fuel filter and hydraulic oil filter, check the quality of hydraulic oil, supplement or replace hydraulic oil as needed, check the status of transmission oil and coolant, detect the accuracy of the circuit, sensor and safety alarm system, and debug the load monitoring and tilt protection device to ensure the safety system. Sensitive and effective.
1000 hours of in-depth maintenance, comprehensively test the pressure of the hydraulic system, the engine condition, the performance of the transmission system, check the wear of the arm structure, the deformation of the frame, overhaul the core parts of the braking system and the steering system, replace the aging hydraulic pipeline, seals, belts and other wear parts, and complete the accurate debugging of the whole car.
Q1: What tests need to be done before daily operation?
A comprehensive pre-operation inspection must be carried out before operation every day, including: winding inspection (structure, tires, hydraulic system, moving arm, lighting, etc.), liquid level inspection (engine oil, coolant, hydraulic oil, transmission oil, etc.), cab inspection (seat belt, instrument, control device, etc.) and accessory inspection.
Q2: How should I drive on the slope?
When no-loaded, the fork runs in the downhill direction (the rear of the equipment is the “heavy end”); when loaded, the fork runs in the uphill direction (the front of the equipment is the “heavy end”). When going downhill, you should downshift and use the driving brake, and do not slide in neutral gear. Avoid turning or parking on the slope.
Q3: How often do you need to carry out maintenance?
Daily (every 10 hours) liquid level inspection, lubrication and basic inspection; weekly (every 50 hours) more detailed inspection; monthly (every 250 hours) replacement of oil and filter maintenance; quarterly (every 500 hours) comprehensive maintenance.
Q4: Can you carry people to lift it?
Yes, but an approved manned work platform must be used, and the corresponding load diagram must be displayed in the cab. It is forbidden to drive equipment when personnel are on the working platform. Platform occupants must wear appropriate personal protective equipment.
Q5: What should I do if I find a device failure?
If a safety critical failure, fork damage, hydraulic leakage or warning system defect is found, stop using the equipment immediately. Contact the authorized dealer to report the problem and arrange a diagnosis and repair. Never bypass the load management or interlock system.
Q6: How should the stabilizer be used correctly?
Position the equipment at the approved station, lower the arm and apply the parking brake, place the appropriate pad where needed, unfold the stabilizer to the allowed configuration, level the equipment within the scope of the system, and confirm the correct load diagram or load management mode. Only after setting the stability can the lifting begin. Do not change the stabilizer configuration when the load increases.
Q7: What is the difference between different steering modes?
All-wheel steering makes all wheels rotate with the steering wheel to improve mobility; two-wheel steering locks the rear wheel and only the front wheel steers, which is more stable when driving and cornering on the road; crab steering makes all wheels rotate in the same direction at the same angle, which is convenient for entering and exiting in narrow positions. The switching mode can only be switched when the device is stationary.
The telehandler is one of the most productive equipment in modern construction sites, agricultural farms and industrial facilities, but its versatility also comes with unique risks. Safe operation is not a certain step or a certain rule, but a complete system: from careful inspection before operation to strict compliance with the load table; from smooth operation habits to extra caution in restricted space; from personal certification training to the employer’s commitment to safety management.
The safety of engineering machinery is not a trivial matter. Every standardized operation is awe of life and responsibility for the project. Strictly implement the step-by-step safety operation process of the telescopic handler forklift, implement the safety control of the whole process, and fundamentally avoid the vast majority of safety accidents, ensure the safety of personnel life, the safety of equipment, the safety of engineering construction, and realize the normalized construction operation of compliance, efficiency and stability.
