Serious Forklift Accident 

A 10T forklift was crossing the lumberyard when the lift chains snapped.  This caused the fork carriage and the mast to dislodge the mast guides.  The damaged lift was moved to an area directly in front of the maintenance shop for service.  The three men involved in this incident are all experienced forklift operators and maintenance men.  Each person is qualified to perform service on this type of machine (according to the Safety Director).  

The first step in repairing this lift was to reinstall the mast guides.  A second fork lift was used to lift the forks and mast while the two injured employees reinstalled the guides.  The operational lift (A) lifted the damaged lift (B)'s fork carriage.  The forks of A slipped from the carriage and "sprang" upward pinning the injured's hand between the fork of A and another part of the carriage of B.  While this was happening the second injured was knocked to the ground, and the forks of lift B fell striking him in the left arm.  The net result was an amputation of the first injured's hand, and fractures to the arm and rib(s) on the second injured.  The second injured also suffered severe vascular damage in his arm.  

Issues:  
1.	Not using the best-suited tools for the job when they are at your disposal.  A hoist is located in the maintenance shop.  There was a chain (at the scene) that could have been used to bind the fork carriers together.
2.	Using you hands to install mast guides.  A tool and procedure has been defined by the account in case of future service.
3.	Qualified service technician Even if you know how to perform a procedure, if you have not performed it in a while you may lose the skill.  Bring in skilled help.  This is now service policy for non-routine lift service.
4.	Best practices reviews prior to performing non-routine services.  This practice must be followed to prevent non-routine service  injuries.  Read the service manual (if there is one), consult the manufacturer, allow the service team to "brain storm" the solution and the potential hazards,  and allow a realistic amount of time to complete the task (do not rush or take short-cuts).
5.	Service intervals,  periodic detailed inspections and service to the lift chains and carriage must be completed (in addition to OSHA reg's for daily inspection).
6.	Yard maintenance,  the lumberyard must remain clear of obstructions and/or holes that may jar and damage lifts.  Reporting, maintenance, and inspection procedures must be implemented. 
7.	Enforce safe lift operation procedures, that among other advantages, reduces the non-routine wear of the lifts, resulting in less service.