Lift Truck Safety and Warning Guidelines
Lift Truck Safety and Warning Guidelines
◆ In General
The safety rules and regulations in this section Continuing improvement and advancement of
are representative of some, but not all rules and product design may have caused changes to
regulations that apply to lift trucks. Rules are your lift truck which are not included in this
paraphrased without representation and have publication. Whenever a question arises regard-
been reproduced verbatim. ing your lift truck, or this publication, please
Your lift truck was manufactured in accordance consult your Cat lift truck dealer for the latest
with the National Fire Protection Association available information.
(NFPA) No. 505 and the American National All lift truck users should be familiar with their
Standards Institute, Inc./Industrial Truck Local, Regional, and National regulations.
Standards Development Foundation United States users should be familiar with the
(ANSI/ITSDF) B56.1, Safety Standard for Occupational Safety and Health Administra-
Low Lift and High Lift Trucks. Since regula- tion (OSHA), and American National
tions vary from country to country, operate this Standards Industrial Lift Trucks. See
lift truck in accordance with local regulations. [Link] web site for more information
See [Link] web site for more infor- on Regulations (Standards - 29 CFR) Powered
mation on the B56.1 Safety Standards for Low industrial trucks - 1910.178.
Lift and High Lift Trucks. You should also be familiar with areas of use
The most effective way of preventing serious of different types of lift trucks as specified in
injuries, or even death, to you and others, is for the National Fire Protection Association
you to know how to operate the truck properly. (NFPA) 505.
Drive alertly and avoid maneuvers or condi-
tions that can cause accidents. Be professional.
Do not operate a lift truck if it is in need of
maintenance, repair or appears to be unsafe in
any way. Report all unsafe conditions immedi-
ately to your supervisor and contact your
authorized Cat lift truck dealer. Do not attempt
any adjustments or repairs unless you are
trained and authorized to do so.
1 1
SAFETY RULES FOR LIFT TRUCK OPERATORS 2
Inspection/Lubrication chart
Radiator Cap
Warning decal
No Riders Warning decal
Fender Warning
decal
Precautions for
Handling E.C.U. Release Lever for (right front)
decal Mechanical Stopper
Warning decal
Parking Brake
Adjustment decal
105386
2 2
SAFETY RULES FOR LIFT TRUCK OPERATORS 3
Hoist Point
decal
No One Under
Forks decal
Fuel decal
No One on
Forks decal
UL Plate
105387
Capacity plate
3 3
SAFETY RULES FOR LIFT TRUCK OPERATORS 4
Do not stand or ride on the forks. When leaving the lift truck, apply the Do not step on the fender.
Do not stand or ride on a load or pallet parking brake! The parking brake is not
on the forks. automatically applied.
Do not stand or walk under the forks. The alarm will sound if the parking
brake is not applied when you leave the
truck or turn off the key switch.
Located on the mast. Located to the left front of the operator’s seat. Located to the right front of the fender.
Proper operating force:
Unit: N (kgf) [lbf]
250 to 290 (25 to 30) [55 to 66]
5 5
SAFETY RULES FOR LIFT TRUCK OPERATORS 6
! WARNING ! WARNING
Check the coolant level only after the Do not touch, lean on, or reach through
engine has been stopped and the filler the mast or permit others to do so.
cap is cool enough to touch with your Hands off!
hands.
Remove the filler cap slowly to relieve
pressure.
104990 105182
105183 105181
104759
Located on the mast.
6 6
SAFETY RULES FOR LIFT TRUCK OPERATORS 7
To avoid serious injury, do not carry pas- To avoid serious injury, stay clear of the Improper operation or maintenance
sengers. A lift truck is designed for only moving fan. could result in injury or death. Do not
one operator and no riders. operate or work on the lift truck unless
you are properly trained.
Located to the right front of the operator’s Located on the frame of the cooling fan. Located to the right front of the operator’s
seat. seat.
7 7
SAFETY RULES FOR LIFT TRUCK OPERATORS 8
! WARNING ! WARNING
102513 105013
Located inside the top frame member of the Located to the right rear fender.
overhead guard.
105025 104751
8 8
SAFETY RULES FOR LIFT TRUCK OPERATORS 9
• Tipover Warnings
TIPOVER WARNINGS IN CASE OF TIPOVER
! DANGER
1. Side tipover of an unloaded truck can 1. The operator should stay with the truck if
Tipover can occur if truck is improperly occur if the combination of speed and a side or forward tipover occurs. The opera-
operated. Injury or death will result. sharp turn which exceeds the stability of tor should hold on firmly to the steering
the truck. wheel, brace feet, lean forward and lean
2. Side tipover can occur if overloaded, or away from the point of impact.
loaded within capacity and: 2. If the truck falls off of a loading dock or
– The load is elevated. ramp, you should try to stay within the
– Turning and/or braking when traveling confines of the operator’s seat area.
in reverse. Should the landing area present a more
– Turning and/or accelerating when trav- severe hazard, you may find it prudent to
eling forward. leave the truck.
These actions may exceed the stability
of the truck.
Backward tilt and/or off-center positioning of
the load and/or uneven ground conditions will
further aggravate the above conditions.
104840A 3. Forward tipover can occur if overloaded or
when loaded within capacity and the load
Located inside the front frame member of the
is elevated in forward tilt, braking in for-
overhead guard.
ward travel, or commencing reverse travel.
These actions may exceed the stability of 105014
the truck.
4. Serious injury or death can occur if the Located inside the front frame member of the
operator is trapped between the truck and overhead guard.
the ground.
104754
104755
9 9
SAFETY RULES FOR LIFT TRUCK OPERATORS 10
Service brakes
104841
◆ Safety Rules
100870 100605
! WARNING
! WARNING
100604 100989
11 11
SAFETY RULES FOR LIFT TRUCK OPERATORS 12
Unauthorized addition or modification is Know your lift truck and attachments! Shut down engine before servicing!
prohibited! Read and understand the operation, inspection DO NOT service a lift truck while engine is
DO NOT add to or modify the lift truck unless and maintenance instructions in the OPERA- running unless absolutely necessary to do so.
authorized in writing by the manufacturer to do TION & MAINTENANCE MANUAL.
so. Any change to the lift truck could cause
serious injury or property damage.
Know all signals and traffic rules! Avoid being splashed by scalding hot coolant! Exhaust fumes could kill you!
Know who is responsible for signaling. Learn Wait until the engine cools before opening or If you operate a lift truck in an enclosed area,
to tell at a glance what the signal means, and loosening the radiator cap. If you cannot wait, make sure there is adequate ventilation.
what action you should take. use a heavy cloth and gloves to protect your-
self. Stand to the side, protect your face, and
slowly loosen cap.
12 12
SAFETY RULES FOR LIFT TRUCK OPERATORS 13
Inspect your lift truck prior to operation! Always stay healthy on the job! Keep the operator’s compartment clean!
At the beginning of each shift, fill out a daily Be healthy and NEVER operate the truck Keep your hands and shoes, as well as the
inspection sheet. Check for maintenance prob- under the influence of drugs or alcohol that floor and controls (steering wheel, levers and
lems and have repairs made before you oper- may impair your ability to properly operate pedals) clean and free of grease, mud and
ate the truck. the truck. other materials. A slip could cause an acci-
dent.
! WARNING ! WARNING
102517 102522B
DO NOT operate an unsafe lift truck! Know your lift truck is safe!
Inspect a lift truck before you operate it to be DO NOT operate any lift truck that is not safe
sure it is properly maintained and in good to operate.
working order.
13 13
SAFETY RULES FOR LIFT TRUCK OPERATORS 14
! WARNING ! WARNING
ECU
VCM
101754A 104981
DO NOT move the truck until the vacuum For handling ECU, VCM and other con-
brake warning buzzer stops buzzing! trollers!
Otherwise the brake will not apply safely. 1. Do not directly expose these controllers to
washing water, rain, oil or any other liquid.
2. Do not apply force, open or modify these
WARNING controllers or operate the truck without
!
these controllers.
3. Turn key switch OFF. Disconnect battery
cables and these controllers before the fol-
lowing operations:
– Removing these controllers from truck
– Factory-approved welding
103907
14 14
SAFETY RULES FOR LIFT TRUCK OPERATORS 15
Operate only in approved areas! DO NOT operate a damaged or defective Make sure the assist grips are free from
Certain areas such as those containing haz- lift truck! bent or cracked sections!
ardous flammable gases, liquid or other com- If a truck is damaged, take it out of service. Face the lift truck when mounting and dis-
bustibles, should be avoided. Park it in a non-operating area and remove the mounting.
key. Attach a DO NOT OPERATE or similar Maintain a three point contact (one foot and
warning tag to the truck. two hands) with the floor and handholds.
! WARNING
Never get on or off a moving lift truck.
Never jump on or off the lift truck.
DO NOT use the controls or steering wheel as
handholds when entering or leaving the opera-
tor’s compartment.
101115C
15 15
SAFETY RULES FOR LIFT TRUCK OPERATORS 16
Adjust the seat before operation! Make sure your lift truck is in safe operat- Fasten the seat belt properly!
DO NOT adjust the seat while the lift truck is ing condition! If you DO NOT, it may not restrain you in an
in motion. This could cause serious injury. Test the brakes and inching pedal while mov- accident.
ing slowly in a safe area. Make sure the mast
moves up and down smoothly.
Always check overhead clearance! Use lights in dark, dim areas! Stay within the confines of the truck!
Serious accidents may be caused by the mast Even with lights on, DO NOT assume people Keep your arms and legs inside the operator’s
and overhead guard hitting pipes, beams or see you and will move out of your way. compartment.
other overhead obstructions. Watch out for
power lines.
16 16
SAFETY RULES FOR LIFT TRUCK OPERATORS 17
Always be aware of floor capacity! Stay under the overhead guard! Be careful of forks that extend beyond the
Make sure the floor will support the weight of DO NOT hold on to the overhead guard. load!
the loaded lift truck. If the forks extend beyond the load, use extra
caution. Make sure the fork tips do not contact
other material.
20
%
60
%
20
%
Avoid off-center loading! Check fork locking pins for engagement! Check work areas for high risk!
Set the forks as far apart as possible for maxi- If the fork locking pins are not properly When working on docks, ramps, platforms and
mum support of the pallet or load. Too small a engaged, the forks may shift and cause off- other high risk areas, use adequate blocks to
fork spread can cause instability of the load. centered or unstable loads. reduce the risk of the lift truck from falling
off.
17 17
SAFETY RULES FOR LIFT TRUCK OPERATORS 18
Stay away from slippery surfaces! Be aware of the stability of an empty lift Position controls correctly for starting!
– Loose or slippery materials such as sand, truck! Make sure the direction lever is in the NEU-
gravel, ice, mud, etc., on your operating An empty lift truck will tip over more easily TRAL position and the parking brake lever is
surfaces could cause a skid or tipover. than a loaded one in a lowered position. set properly.
Avoid these conditions or slow down.
– Keep your operating surfaces clean and
dry at all times. Wet spots could cause a
skid or tipover. ! WARNING ! WARNING
– You need a greater stopping distance on
wet surfaces. Apply brakes earlier on slip-
pery surfaces than on dry surfaces.
– Do not drive into a flooded area whenever
possible.
101015 100626
DO NOT allow any riders! If you cannot see where you are going, DO
DO NOT allow anyone to ride on the forks or NOT MOVE!
on any other part of the lift truck—at any time. Travel slowly around corners. Sound the horn
at cross aisles and other areas where you can-
not see clearly or where visibility is restricted.
18 18
SAFETY RULES FOR LIFT TRUCK OPERATORS 19
DO NOT pass another truck! DO NOT allow anyone to hold loads! Always look in the direction of travel!
DO NOT pass another lift truck traveling in Always be aware of people near your lift
the same direction at intersections, blind spots truck. DO NOT proceed until they are aware
or at other dangerous areas. of you.
DO NOT engage in stunt driving or horse- Travel in reverse if forward visibility is Obey all traffic rules and warning signs!
play! blocked! Drive carefully, observe traffic rules and be in
Stunt driving and horseplay is hazardous for For better visibility with large loads, travel in full control of the lift truck at all times.
both the lift truck operator and fellow workers. reverse, but always keep a lookout in the
direction of travel.
19 19
SAFETY RULES FOR LIFT TRUCK OPERATORS 20
Travel safely on grades with a loaded lift Be particularly careful when driving up or Travel safely on grades with an empty lift
truck! down a steep slope! truck!
Keep the load upgrade to maintain control Use extreme care to reduce the risk of the tips Keep the counterweight upgrade when travel-
when traveling up or down a grade with a of forks or the bottom of pallet from touching ing up or down a grade with an empty truck.
heavily loaded truck. the ground.
Start lift truck upgrade carefully! DO NOT turn on a ramp or grade! Move your lift truck safely!
When starting the lift truck upgrade, be sure to Turning on a ramp or grade can cause a lift Sound the horn and be sure no people or
use the parking brake. truck, loaded or unloaded, to tip over. objects are in your path before moving.
20 20
SAFETY RULES FOR LIFT TRUCK OPERATORS 21
Allow for counterweight swing distance! A helper should NOT be near the lift truck! Always be alert for tipovers!
When turning in aisles, especially narrow People should be clear of the lift truck operat- Turning sharply with a raised load, even at a
aisles keep as far away as possible from stock ing area. slow speed, may result in a tipover. Realize
and racks. Be cautious near people. that the overhead guard is not designed to pro-
vide total protection in the event of a tipover.
◆ Working Precautions
Danger! Keep out! Be careful of changes in the capacity! Watch out for pedestrians at all times!
DO NOT allow any unauthorized people in the Optional attachments which change the capac-
work area. ity are sometimes installed. Know the capacity
before operating the truck.
21 21
SAFETY RULES FOR LIFT TRUCK OPERATORS 22
Use forks properly! DO NOT speed when approaching loads! DO NOT move when someone’s next to
Fork misuse could cause accidents, serious Bring truck to a full stop in front of a load, truck!
injuries and equipment damage. then approach carefully. If someone is standing next to your truck,
don’t move until they are out of the way.
DO NOT allow anyone to walk or stand DO NOT pick up unsecured loads that Handle only stable loads!
under raised forks! extend above the backrest extension height! If a load is unstable, it can easily shift and fall
on someone.
22 22
SAFETY RULES FOR LIFT TRUCK OPERATORS 23
DO NOT allow unloading from raised DO NOT use damaged pallets! DO NOT abuse your forks!
loads! Make sure pallets and skids are sturdy and in Fork misuse could cause accidents, serious
Failure to follow this rules could cause serious safe operating conditions. injuries and equipment damage.
injury.
Drive onto a trailer carefully! DO NOT allow any riders! DO NOT abuse your equipment!
Make sure the trailer brakes are applied and DO NOT permit riders on the forks or pallet. DO NOT use the forks to open or close the
the wheels are blocked while loading or doors on a railroad car or to move a car.
unloading.
23 23
SAFETY RULES FOR LIFT TRUCK OPERATORS 24
Stay clear of pinch points! Shift the transmission smoothly! Use only specialized equipment designed to
Keep all parts of your body away from moving Avoid sudden changing of traveling direction. safely raise personnel to high work areas!
parts such as the mast, carriage and attach- This could cause damage to the transmission. Do not lift personnel except on a securely
ments. Do not put any part of your body attached, specially designed Work Platform.
between the head guard and the mast. If the Use extreme care when lifting personnel.
mast moves unexpectedly, you could get Place the mast in the vertical position, place
caught between the mast and overhead guard the truck controls in neutral and apply the
and a serious accident could occur. ! WARNING brakes. Lift and lower smoothly. Be available
to operate controls as long as personnel are on
the Work Platform. Never transport personnel
on forks or Work Platform.
100992
24 24
SAFETY RULES FOR LIFT TRUCK OPERATORS 25
102527B 100658A
101044
25 25