Heavy Equipment & Material Handling

Telehandler Load Charts & Attachments

Leader guideSuggested discussion: 8-12 minPrintable sign-off included

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Leader note: Do not read this sheet word-for-word. Pick the sections that match today’s task, point to the actual equipment/work area, and get the crew to answer the questions out loud.

Why this matters

Before work starts, use this Telehandler Load Charts & Attachments talk to cover overload, tip-over and attachment mismatch. Point out the equipment, work zone and controls the crew will rely on today. Heavy equipment injuries are rarely about speed alone. Blind spots, changing ground conditions, unexpected pedestrian movement and poor communication put people where operators cannot see them or cannot stop in time.

A scenario to discuss

The crew starts Telehandler Load Charts & Attachments on firm, open ground. Later the machine has to work closer to an edge, slope, overhead obstruction, or pedestrian route than planned. What operating limits and spotter controls need to be rechecked?

Before work starts

Walk the equipment route and mark pedestrian separation, blind corners, edges and overhead hazards.
Complete the operator/pre-use inspection and confirm seat belt, alarms, mirrors/cameras and controls are functional.
Agree on spotter positions and the stop signal before the machine moves.
Use the load chart for the exact machine, boom position and attachment.
Verify the attachment is approved and properly secured.

Common failure points

Backing or swinging with a blind area that has not been cleared or controlled.
Operating near edges/slopes/overhead hazards without a deliberate route and spotter plan.
Assuming pedestrians will see or hear the machine and stay out of the way.

Safe work sequence / controls

Use the load chart for the exact machine, boom position and attachment.
Verify the attachment is approved and properly secured.
Level/set stabilizers as required before lifting at reach.
Do not guess capacity based on how the machine “feels.”
If conditions change, stop long enough to make sure the control for overload, tip-over and attachment mismatch still works for the job in front of you.

Stop and reset the plan if...

The operator loses a clear travel path, spotter communication or required visibility.
Ground conditions, slope, overhead hazards or edge conditions are outside the planned operating limits.
Pedestrians, vehicles or other trades enter the equipment operating zone unexpectedly.

Questions worth asking the crew

What are the operator's blind spots in today's setup, and exactly where must pedestrians stay out?
What ground, slope, edge, overhead, or clearance condition could put this machine outside its safe operating limits?
When visibility is restricted, who is spotting and what exact signal means STOP?
How does the risk change when the machine is loaded, backing, turning, or using the planned attachment?
Has anyone had a pedestrian, blind spot or ground condition surprise an operator? What control would have caught it sooner?

Make it real on the job

Stand where a pedestrian could be missed and make sure the operator/crew understand that blind spot.

Close the talk

Before the crew starts, everyone should be able to explain the hazard, point to the control being used today, and name the condition that would make the work stop.

Related authoritative reference

29 CFR 1926.602 - Material Handling Equipment · Open reference ↗

This is a practical discussion guide, not a substitute for required training, a competent person, permits, manufacturer instructions, employer procedures, or applicable federal/state/local requirements. Adapt it to the actual task and conditions.