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Loading condi

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Published by SALUS

Loading Conditions and Operational Limits =========================================

Date: 2025-08-25

Duration: \[DURATION] minutes

Presenter: \[PRESENTER NAME]

Location: \[LOCATION]

Objective

The objective of this talk is to ensure everyone understands the importance of adhering to the specified loading conditions and operational limits for safe and efficient operation.

Introduction

This toolbox talk covers the safety procedures for understanding loading conditions and operational limits of our equipment. It is crucial to operate within these limits to prevent accidents, injuries, and damage to equipment.

Key Points

Consult the Load Chart: Always consult the load chart to confirm that the load is within the rated capacity of the machine for the required configuration. The load chart provides essential information about the safe lifting capacity at various boom angles and extensions. Ignoring the load chart can lead to exceeding the machine's limits, resulting in instability and potential tip-over. [10]

[11] [12]

Level the Machine: Ensure the machine is level before lifting any loads. Use the level gauge to verify the machine's position, and utilize the frame sway control when the boom is horizontal or lower to make necessary adjustments. Lifting loads on uneven ground can significantly reduce stability and increase the risk of accidents. [10]

[11] [12]

Secure the Load: Before performing a lift, double-check that the load is secure on the forks or attachment. If necessary, rearrange the load to ensure it is stable and balanced. An unsecured load can shift during lifting, leading to loss of control and potential dropping of the load. [10]

[11] [12]

Transport Loads Safely: When transporting a load, keep the boom at or below horizontal and as close to the ground as possible. This minimizes the risk of instability and provides better visibility. Avoid sudden movements or sharp turns, which can cause the load to shift or the machine to become unstable. [10]

[11] [12]

Maintain Clearance from Power Lines: Always maintain a safe distance from power lines. Refer to the provided chart for minimum safe approach distances based on voltage. Contact with power lines can result in electrocution or serious injury. [10]

[11] [12]

Hazard Identification

Exceeding load limits: Machine tip-over, structural failure, dropped load, serious injury or death.
Operating on uneven ground: Reduced stability, increased risk of tip-over, loss of control.
Unsecured loads: Load shifting, dropped materials, damage to property, injury to personnel.
Contact with power lines: Electrocution, burns, equipment damage, fire.
Obstructed visibility: Collisions with objects or personnel, misjudged distances, accidents.

Control Measures

Use the load chart to verify the load is within the machine's capacity for the specific configuration.: Consult the load chart before each lift, considering boom extension, angle, and any attachments. Ensure you understand how to read and interpret the load chart correctly. [10]

[11] [12]

Level the machine before lifting loads.: Use the machine's level indicator and frame sway control to ensure the machine is properly leveled. Only use the sway control when the boom is horizontal or lower. [10]

[11] [12]

Secure all loads before lifting.: Use appropriate straps, chains, or other securing devices to ensure the load is stable and will not shift during lifting or transport. Rearrange the load if necessary to improve stability. [10]

[11] [12]

Maintain a safe distance from power lines.: Be aware of the location of overhead power lines and maintain the minimum safe approach distance as specified in the equipment manual. If working near power lines is unavoidable, contact the utility company for assistance. [10]

[11] [12]

Ensure clear visibility.: Keep the load as low as possible during transport to maintain good visibility. Use a spotter if necessary, especially in congested areas or when visibility is limited. [10]

[11] [12]

Personal Protective Equipment (PPE) Requirements

Seat Belt: Always wear a seat belt when operating the machine to minimize injury in case of a tip-over or collision. [1]

[2] [3] [4] [5] [6] [7] [8] [9]

Hard Hat: Wear a hard hat to protect against falling objects and head injuries.
Safety Glasses: Use safety glasses to protect your eyes from dust, debris, and other potential hazards.
Work Boots: Wear appropriate work boots with slip-resistant soles to provide stability and protection.

Group Discussion

Discuss the following questions:

What are some factors that can affect the stability of the machine?
How do you properly read and interpret a load chart?
What should you do if you encounter a situation where the load exceeds the machine's capacity?

Emergency Procedures

In case of a tip-over, remain inside the cab with your seatbelt fastened.
If a load drops, immediately clear the area and ensure no one approaches until the situation is assessed.
In the event of contact with a power line, do not touch the machine and warn others to stay away. Contact emergency services immediately.

Summary

Recap of main points:

Always check the load chart before lifting any load. [10]

[11] [12]

Ensure the machine is level and the load is secured. [10]

[11] [12] [10] [11] [12]

Maintain a safe distance from power lines and ensure clear visibility. [10]

[11] [12] [10] [11] [12]

Always wear required PPE, including a seat belt, hard hat, safety glasses, and work boots. [1]

[2] [3] [4] [5] [6] [7] [8] [9]

Report all hazards, near-misses, and incidents to your supervisor immediately.

Safety powered by SALUS

12 source record(s)

Sources used for this answer

[1] TEREX TH528C (manufactured from 2/14/2001 to 9/14/2002) - Operator's Manual (PN 236498)

Page 27

Open source document

Source excerpt

# OPERATION # OPERATION AND SAFETY GUIDELINES ## WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate. All equipment has limitations. Understand the speed, braking, steering, stability, and load chart characteristics of the machine before operating. Read the Operator's Manual and ask questions of your supervisor until you know machine limitations. It is very important to read, fully understand, and follow these operation and safety guidelines. 1. DO NOT operate the machine while people and /or property are within a 50 foot (15.24 m) minimum radius. Falling objects from the forks or attachment can cause property damage and/or serious personal injury. This 50 foot (15.24 m) minimum radius should be used only as a guideline. Enlarge minimum working area if warranted by working conditions. 2. ALWAYS remain completely within the cab enclosure while operating machine. Falling debris can cause serious personal injury or death. 3. NEVER extend a load beyond the load chart band. Machine turn over, component damage, injury or death could occur. 4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS. 5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur. 6. INSPECT and clear working area of any obstructions (rocks, fence, wire, etc.) that could cause machine damage. If obstructions cannot be cleared, mark obstructions with a stake or other marker that will be clearly visible to the operator. 7. DO NOT check engine coolant level if engine has recently been run. Injury could occur from escaping hot pressurized coolant. 8. ALWAYS wear seat belt when operating machine. 9. ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out of the ordinary. Repair and/or replace any worn, damaged or leaking…

[2] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 4/28/2003 to 12/17/2003) - Operator's Manual (PN 236501)

Page 41

Open source document

Source excerpt

# OPERATION # OPERATION AND SAFETY GUIDELINES ! ## WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate. All equipment has limitations. Understand the speed, braking, steering, stability, and load chart characteristics of the machine before operating. Read the Operator's Manual and ask questions of your supervisor until you know machine limitations. It is very important to read, fully understand, and follow these operation and safety guidelines. 1. DO NOT operate the machine while people and/or property are within a 50 foot (15.24 m) minimum radius. Falling objects from the forks or attachment can cause property damage and/or serious personal injury. This 50 foot (15.24 m) minimum radius should be used only as a guideline. Enlarge minimum working area if warranted by working conditions. 2. ALWAYS remain completely within the cab enclosure while operating machine. Falling debris can cause serious personal injury or death. 3. NEVER extend a load beyond the load chart band. Machine turn over, component damage, injury or death could occur. 4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS. 5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur. 6. INSPECT and clear working area of any obstructions (rocks, fence, wire, etc.) that could cause machine damage. If obstructions cannot be cleared, mark obstructions with a stake or other marker that will be clearly visible to the operator. 7. DO NOT check engine coolant level if engine has recently been run. Injury could occur from escaping hot pressurized coolant. 8. ALWAYS wear seat belt when operating machine. 9. ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out of the ordinary. Repair and/or replace any worn, damaged or leaking par…

[3] Terex Square Shooters Series SS-636C / SS-644C / SS-842C (manufactured after 2/13/2001) - Operator's Manual (PN 236495)

Page 29

Open source document

Source excerpt

# OPERATION # OPERATION AND SAFETY GUIDELINES ! ## WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate. All equipment has limitations. Understand the speed, braking, steering, stability, and load chart characteristics of the machine before operating. Read the Operator's Manual and ask questions of your supervisor until you know machine limitations. It is very important to read, fully understand, and follow these operation and safety guidelines. 1. DO NOT operate the machine while people and /or property are within a 50 foot (15.24 m) minimum radius. Falling objects from the forks or attachment can cause property damage and/or serious personal injury. This 50 foot (15.24 m) minimum radius should be used only as a guideline. Enlarge minimum working area if warranted by working conditions. 2. ALWAYS remain completely within the cab enclosure while operating machine. Falling debris can cause serious personal injury or death. 3. NEVER extend a load beyond the load chart band. Machine turn over, component damage, injury or death could occur. 4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS. 5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur. 6. INSPECT and clear working area of any obstructions (rocks, fence, wire, etc.) that could cause machine damage. If obstructions cannot be cleared, mark obstructions with a stake or other marker that will be clearly visible to the operator. 7. DO NOT check engine coolant level if engine has recently been run. Injury could occur from escaping hot pressurized coolant. 8. ALWAYS wear seat belt when operating machine. 9. ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out of the ordinary. Repair and/or replace any worn, damaged or leaking parts i…

[4] Terex Square Shooters Series SS-1056C / SS-1048C - Operator's Manual (PN 236505)

Page 29

Open source document

Source excerpt

# OPERATION # OPERATION AND SAFETY GUIDELINES ! ## WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate. All equipment has limitations. Understand the speed, braking, steering, stability, and load chart characteristics of the machine before operating. Read the Operator's Manual and ask questions of your supervisor until you know machine limitations. It is very important to read, fully understand, and follow these operation and safety guidelines. 1. DO NOT operate the machine while people and /or property are within a 50 foot (15.24 m) minimum radius. Falling objects from the forks or attachment can cause property damage and/or serious personal injury. This 50 foot (15.24 m) minimum radius should be used only as a guideline. Enlarge minimum working area if warranted by working conditions. 2. ALWAYS remain completely within the cab enclosure while operating machine. Falling debris can cause serious personal injury or death. 3. NEVER extend a load beyond the load chart band. Machine turn over, component damage, injury or death could occur. 4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS. 5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur. 6. INSPECT and clear working area of any obstructions (rocks, fence, wire, etc.) that could cause machine damage. If obstructions cannot be cleared, mark obstructions with a stake or other marker that will be clearly visible to the operator. 7. DO NOT check engine coolant level if engine has recently been run. Injury could occur from escaping hot pressurized coolant. 8. ALWAYS wear seat belt when operating machine. 9. ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out of the ordinary. Repair and/or replace any worn, damaged or leaking pa…

[5] TEREX TH1048C / TH1056C - Operator's Manual (PN 236506)

Page 14

Open source document

Source excerpt

# OPERATION SAFETY (cont.) ! ROUGH TERRAIN FORK LIFT SAFETY ! # OPERATION SAFETY 12. Maintain an appropriate clearance from electrical power lines. See the chart below for minimum safe approach distances. <table><tr><th colspan="2">Minimum Safe Approach Distance</th></tr><tr><td>Power Line Voltage</td><td>Required Clearance</td></tr><tr><td>0 to 50 kV</td><td>10 ft. (3.00 m)</td></tr><tr><td>50 to 200 kV</td><td>15 ft. (4.60 m)</td></tr><tr><td>200 to 350 kV</td><td>20 ft. (6.10 m)</td></tr><tr><td>350 to 500 kV</td><td>25 ft. (7.62 m)</td></tr><tr><td>500 to 750 kV</td><td>35 ft. (10.67 m)</td></tr><tr><td>750 to 1000 kV</td><td>45 ft. (13.72 m)</td></tr></table> 13. Lifting Loads: i. Using the load chart, confirm that the load is within the rated capacity of the machine for the required configuration. ii. Level the machine using the level gauge before lifting loads. Use the sway control to level the machine only when the boom is at horizontal or lower. Using the sway control with the boom above horizontal may cause the machine to overturn. iii. Verify that the load is secured on the forks before performing a lift. Rearrange the load if necessary. iv. Before lowering a maximum load, always retract the boom completely. V. Use proper attachments, such as a truss boom, to lift suspended loads. 14. If the load to be lifted exceeds the capacity of the machine for the given configuration: i. Move the machine closer to the load so that the weight of the load will be within the allowable load chart specifications. ii. Divide the load into smaller pieces. iii. Get a larger machine capable of handling the load. 15. Always move a load so that you have maximum machine stability and visibility is not obstructed. Keep the boom at or below horizontal, with the load close to the ground. 16. Tilt the forks back towards the machine slightly during travel to ensure stability of the load. 1-10

[6] TEREX TH528 - Operator's Manual (PN 236496)

Page 27

Open source document

Source excerpt

[7] TEREX TH644C / TH842C / TH844C (manufactured after 7/15/2004) - Operator's Manual (PN 236504)

Page 14

Open source document

Source excerpt

# OPERATION SAFETY (cont.) ! ROUGH TERRAIN FORK LIFT SAFETY ! # OPERATION SAFETY 12. Maintain an appropriate clearance from electrical power lines. See the chart below for minimum safe approach distances. <table><tr><th colspan="2">Minimum Safe Approach Distance</th></tr><tr><td>Power Line Voltage</td><td>Required Clearance</td></tr><tr><td>0 to 50 kV</td><td>10 ft. (3.00 m)</td></tr><tr><td>50 to 200 kV</td><td>15 ft. (4.60 m)</td></tr><tr><td>200 to 350 kV</td><td>20 ft. (6.10 m)</td></tr><tr><td>350 to 500 kV</td><td>25 ft. (7.62 m)</td></tr><tr><td>500 to 750 kV</td><td>35 ft. (10.67 m)</td></tr><tr><td>750 to 1000 kV</td><td>45 ft. (13.72 m)</td></tr></table> 13. Lifting Loads: i. Using the load chart, confirm that the load is within the rated capacity of the machine for the required configuration. ii. Level the machine using the level gauge before lifting loads. Use the sway control to level the machine only when the boom is at horizontal or lower. Using the sway control with the boom above horizontal may cause the machine to overturn. iii. Verify that the load is secured on the forks before performing a lift. Rearrange the load if necessary. iv. Before lowering a maximum load, always retract the boom completely. V. Use proper attachments, such as a truss boom, to lift suspended loads. 14. If the load to be lifted exceeds the capacity of the machine for the given configuration: i. Move the machine closer to the load so that the weight of the load will be within the allowable load chart specifications. ii. Divide the load into smaller pieces. iii. Get a larger machine capable of handling the load. 15. Always move a load SO that you have maximum machine stability and visibility is not obstructed. Keep the boom at or below horizontal, with the load close to the ground. 16. Tilt the forks back towards the machine slightly during travel to ensure stability of the load. 1-10

[8] TEREX TH636C / TH644C / TH842C / TH844C (manufactured before 4/28/2003) - Operator's Manual (PN 236500)

Page 41

Open source document

Source excerpt

[9] TEREX TH528C (manufactured before 2/14/2001) - Operator's Manual (PN 236497)

Page 27

Open source document

Source excerpt

[10] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 12/18/2003 to 2/25/2004) - Operator's Manual (PN 236502)

Page 14

Open source document

Source excerpt

# OPERATION SAFETY (cont.) ROUGH TERRAIN FORK LIFT SAFETY ! # OPERATION SAFETY 12. Maintain an appropriate clearance from electrical power lines. See the chart below for minimum safe approach distances. <table><tr><th colspan="2">Minimum Safe Approach Distance</th></tr><tr><td>Power Line Voltage</td><td>Required Clearance</td></tr><tr><td>0 to 50 kV</td><td>10 ft. (3.00 m)</td></tr><tr><td>50 to 200 kV</td><td>15 ft. (4.60 m)</td></tr><tr><td>200 to 350 kV</td><td>20 ft. (6.10 m)</td></tr><tr><td>350 to 500 kV</td><td>25 ft. (7.62 m)</td></tr><tr><td>500 to 750 kV</td><td>35 ft. (10.67 m)</td></tr><tr><td>750 to 1000 kV</td><td>45 ft. (13.72 m)</td></tr></table> 13. Lifting Loads: i. Using the load chart, confirm that the load is within the rated capacity of the machine for the required configuration. ii. Level the machine using the level gauge before lifting loads. Use the sway control to level the machine only when the boom is at horizontal or lower. Using the sway control with the boom above horizontal may cause the machine to overturn. iii. Verify that the load is secured on the forks before performing a lift. Rearrange the load if necessary. iv. Before lowering a maximum load, always retract the boom completely. V. Use proper attachments, such as a truss boom, to lift suspended loads. 14. If the load to be lifted exceeds the capacity of the machine for the given configuration: i. Move the machine closer to the load so that the weight of the load will be within the allowable load chart specifications. ii. Divide the load into smaller pieces. iii. Get a larger machine capable of handling the load. 15. Always move a load so that you have maximum machine stability and visibility is not obstructed. Keep the boom at or below horizontal, with the load close to the ground. 16. Tilt the forks back towards the machine slightly during travel to ensure stability of the load. 1-10

[11] Terex Square Shooters Series SS-1056C - Operator's Manual (PN 236489)

Page 29

Open source document

Source excerpt

# OPERATION # OPERATION AND SAFETY GUIDELINES ! ## WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate. All equipment has limitations. Understand the speed, braking, steering, stability, and load chart characteristics of the machine before operating. Read the Operator's Manual and ask questions of your supervisor until you know machine limitations. It is very important to read, fully understand, and follow these operation and safety guidelines. 1. DO NOT operate the machine while people and /or property are within a 50 foot (15.24 m) minimum radius. Falling objects from the forks or attachment can cause property damage and/or serious personal injury. This 50 foot (15.24 m) minimum radius should be used only as a guideline. Enlarge minimum working area if warranted by working conditions. 2. ALWAYS remain completely within the cab enclosure while operating machine. Falling debris can cause serious personal injury or death. 3. NEVER extend a load beyond the load chart band. Machine turn over, component damage, injury or death could occur. 4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS. 5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur. 6. INSPECT and clear working area of any obstructions (rocks, fence, wire, etc.) that could cause machine damage. If obstructions cannot be cleared, mark obstructions with a stake or other marker that will be clearly visible to the operator. 7. DO NOT check engine coolant level if engine has recently been run. Injury could occur from escaping hot pressurized coolant. 8. ALWAYS wear seat belt when operating machine. 9. ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out of the ordinary. Repair and/or replace any worn, damaged or leaking pa…

[12] Terex Square Shooters Series SS-636C / SS-644C (manufactured before 2/14/2001) - Operator's Manual (PN 236494)

Page 29

Open source document

Source excerpt

# OPERATION # OPERATION AND SAFETY GUIDELINES ! ## WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate. All equipment has limitations. Understand the speed, braking, steering, stability, and load chart characteristics of the machine before operating. Read the Operator's Manual and ask questions of your supervisor until you know machine limitations. It is very important to read, fully understand, and follow these operation and safety guidelines. 1. DO NOT operate the machine while people and /or property are within a 50 foot (15.24 m) minimum radius. Falling objects from the forks or attachment can cause property damage and/or serious personal injury. This 50 foot (15.24 m) minimum radius should be used only as a guideline. Enlarge minimum working area if warranted by working conditions. 2. ALWAYS remain completely within the cab enclosure while operating machine. Falling debris can cause serious personal injury or death. 3. NEVER extend a load beyond the load chart band. Machine turn over, component damage, injury or death could occur. 4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS. 5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur. 6. INSPECT and clear working area of any obstructions (rocks, fence, wire, etc.) that could cause machine damage. If obstructions cannot be cleared, mark obstructions with a stake or other marker that will be clearly visible to the operator. 7. DO NOT check engine coolant level if engine has recently been run. Injury could occur from escaping hot pressurized coolant. 8. ALWAYS wear seat belt when operating machine. 9. ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out of the ordinary. Repair and/or replace any worn, damaged or leaking parts i…

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Publisher: SALUS
Final reviewer: Francis Langlois
Original answer: Aug 25, 2025

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