Heavy Equipment Safety Basics

Heavy equipment kills operators through rollovers, and kills ground workers through struck-by and caught-between incidents. These rules apply to every machine.

• Construction
• General Industry

For operators

• You are trained and authorized for this machine, and you’ve read the operator’s manual
• Walk-around inspection before each shift: tires/tracks, fluids, leaks, lights, mirrors, cameras, horn, backup alarm, brakes, steering, attachments and pins
• Report defects and don’t operate unsafe equipment
• Wear the seatbelt on any machine with a rollover protective structure (ROPS). The ROPS only works if you stay inside it.
• Use three points of contact getting on and off. Face the machine. Never jump.
• Know the ground: slopes, soft soil, trench edges, underground utilities and overhead lines

Training and authorization

OSHA doesn’t issue a general “heavy equipment license,” but employers must make sure operators are trained and competent on each machine. Forklifts and telehandlers require formal training and evaluation every 3 years, and cranes require certification. Many employers use operator evaluations, union apprenticeship programs or manufacturer training. Don’t run a machine you haven’t been trained on, even “just to move it.”

Mounting and dismounting

Falls getting on and off equipment are among the most common operator injuries. Clean mud and ice off steps, use the grab handles, keep three points of contact, face the machine, and never jump down, even from the bottom step. Don’t use the controls or steering wheel as a handhold.

Before leaving the seat

1. Lower buckets, blades and attachments to the ground.
2. Set the parking brake and put controls in neutral or park.
3. Shut off the engine (and remove the key if leaving the machine unattended).
4. Chock wheels if parked on a slope.

For workers on foot

• Stay out of the swing radius and away from blind spots. If you can’t see the operator’s eyes, they can’t see you.
• Make eye contact and get a signal before approaching a machine.
• Wear high-visibility clothing.
• Never ride on equipment unless there’s a seat and seatbelt for a passenger.

Site planning

• Haul roads and travel paths laid out, separate from pedestrian walkways
• Swing radius and work zones barricaded where people pass
• Underground utilities marked and overhead lines identified
• Edges, slopes and soft ground marked
• Spotter and signal rules agreed before work starts
• Refueling area set up away from ignition sources, with spill kits

Maintenance and repairs

• Lower or block every raised part (bucket, blade, bed, boom) before working under it.
• Lock out the machine: remove the key, tag the controls, and follow the manufacturer’s procedures for stored hydraulic and spring energy. See Lockout/Tagout.
• Use the articulation lock on articulated machines.
• Let hot engines, exhaust and hydraulic oil cool. Never check for hydraulic leaks with your hand; pinhole leaks can inject oil under the skin.

Last updated: October 1, 2026