Teletruk / Telescopic FLT Refresher Course Pack

Legislation & Regulations

• HSWA 1974 — General duties on employers and employees. Sections 2, 7, 8 most relevant to operators.
• PUWER 1998 — Work equipment must be suitable, maintained, inspected. Operators must be trained and competent. Reg. 5 (maintenance), Reg. 6 (inspection), Reg. 9 (training).
• LOLER 1998 — Lifting operations must be planned, supervised, carried out safely. Equipment must have thorough examination at prescribed intervals (Reg. 9). Reports must be available.

Risk Assessments

• Employer must carry out suitable and sufficient risk assessment before work begins (Management of Health and Safety at Work Regulations 1999, Reg. 3).
• Operator should be aware of site-specific risks, control measures, and emergency procedures.
• Dynamic risk assessment: operator continuously assesses changing conditions during work.

Components & Controls

• Telescopic boom — 2 or 3 section, hydraulically operated, provides lift height and forward reach.
• Carriage & forks — mounted on boom head, may have side-shift, fork positioning, tilt. Quick-hitch for attachment changes.
• Stabilisers — extend to widen the support base and increase stability during heavy/high lifts. Not all Teletruks have stabilisers.
• ROPS/FOPS — Roll-Over Protective Structure / Falling Object Protective Structure. Part of cab design. Never modify.
• RCI / Load Moment Indicator — electronic system monitoring boom angle, extension, and load weight. Provides warnings and may cut functions at overload.
• Steering modes — front-wheel steer (road/transport), 4-wheel steer (tight turns), crab steer (sideways movement). Selected via switch or lever.

Operator's Manual

• Must be available with the machine. Contains manufacturer's operating instructions, load charts, maintenance schedules, safety warnings.
• Operator should be familiar with the manual for the specific model being operated.

Pre-Use Inspection (3 Stages)

1. Walk-around (external) — Visual check of boom, chassis, tyres, wheels, hydraulic hoses/fittings, lights, mirrors, cab damage, fluid leaks, load chart present and legible.
2. In-cab — Seatbelt, seat adjustment, mirrors, controls (steering, brakes, hydraulics, boom), instrument panel/warning lights, horn, beacon, RCI display.
3. Operational test — Engine start (check warnings clear), test boom functions (raise, lower, extend, retract), test steering in all modes, test brakes (service and parking), test all lights and horn.

Thorough Examination vs Daily Checks

• Thorough examination — LOLER Reg. 9. Carried out by competent person (usually insurer's engineer). At least every 12 months for non-lifting equipment, every 6 months for lifting equipment, or per examination scheme. Report must be available on-site.
• Daily checks — Operator's responsibility before each shift. Using a checklist. Report defects immediately. Do not operate if unsafe.

PPE

• Safety footwear (steel toe), high-visibility vest/jacket, hard hat (where site rules require), gloves (for handling), hearing protection (if noise levels exceed limits).
• Seatbelt must be worn at all times when operating.

Environmental Considerations

• Fuel/oil spills — use spill kits, report immediately, do not wash into drains.
• Exhaust emissions — avoid prolonged running in enclosed spaces.
• Noise — be aware of noise levels, use hearing protection where required.
• Ground conditions — soft ground, gradients, uneven surfaces all affect stability.

Stability Principles

• Centre of gravity (CoG) — The point at which the total weight of the machine and load acts. Moves forward and upward as the boom extends and rises.
• Stability triangle/envelope — defined by the axle pivot points and the ground contact of the wheels/stabilisers. The CoG must remain within this area for the machine to be stable.
• Boom extension effect — Extending the boom moves the load's CoG forward, reducing the restoring moment and increasing the overturning moment. The further forward, the less stable.
• Dynamic forces — Braking, turning, and driving on uneven ground all create additional forces that shift the effective CoG. These compound the effects of boom extension.

Travelling With & Without Loads

• With load: Boom retracted, forks low (150–300mm clearance), load tilted back against carriage. Travel speed appropriate for conditions.
• Without load: Boom retracted, forks low, tilted slightly back. Same speed and observation rules apply.
• Never travel with the boom raised or extended. This dramatically reduces stability.
• Visibility: If the load obstructs forward view, travel in reverse or use a banksman.

Steering Modes

• Front-wheel steer — Normal road/transport mode. Rear of machine is fixed. Most stable mode for higher-speed travel. Use for road travel and long-distance site travel.
• 4-wheel steer — All four wheels turn. Provides a very tight turning circle. Used for manoeuvring in confined spaces. Be aware of significantly increased rear-end swing.
• Crab steer — All wheels turn in the same direction, moving the machine sideways. Used for fine positioning alongside loads, trailers, or structures. Low speed only.
• Mode selection: Only change steering mode when the machine is stationary or at very low speed. Ensure you know which mode is selected before moving.

Proximity Hazards

• Pedestrians — maintain exclusion zones, use horn, never assume people have seen you.
• Overhead obstructions — power lines (minimum 9m clearance for voltages up to 275kV), building structures, doorways, racking.
• Other vehicles — give way at junctions, maintain safe following distances.
• Edges — excavations, dock edges, loading bays. Maintain at least 2m from unprotected edges.

Weather & Surface Conditions

• Wet/icy surfaces — reduce speed, increase braking distances, avoid sudden steering inputs.
• Wind — affects stability especially with loads at height or large surface-area loads. Cease work in high winds (typically above 25mph for working at height).
• Visibility — use lights in poor visibility, consider stopping work in fog/heavy rain if safe operation cannot be maintained.
• Soft/muddy ground — increases risk of sinking, bogging, and uneven support. May need ground mats or alternative route.

Road vs Site Travel

• Road travel requires: valid road registration, insurance, appropriate licence category, road-legal lighting and markings, speed limiters where applicable.
• Site travel: follow site traffic management plan, one-way systems, speed limits, designated routes.
• When transitioning between road and site: adjust steering mode, check site-specific rules, ensure correct PPE.

Load Assessment

• Identify the load — type, weight, dimensions, centre of gravity, any hazards (fragile, dangerous goods, unstable packaging).
• If load weight is unknown, weigh it or obtain documentation. Never guess.
• Check load is suitable for forks — palletised, banded, secured. Reject loads that are damaged, unstable, or cannot be safely engaged.

Load Centre & De-rating

• Load centre — the horizontal distance from the fork heel (carriage face) to the load's centre of gravity. Standard load centre is typically 500mm or 600mm.
• Loads with a greater load centre than the rated centre reduce the truck's capacity. Consult the load chart for the actual load centre.
• De-rating: Attachments, non-standard load centres, boom extension, and height all reduce the rated capacity below the machine's maximum.

Capacity Charts & Indicators

• Load charts are specific to the truck model, tyre type, and attachment fitted. A chart for standard forks does not apply when a bucket or jib is fitted.
• Charts show capacity at various boom heights and reach distances. Capacity reduces as reach and height increase.
• RCI/LMI — provides real-time monitoring but does not replace the need to plan lifts and check charts. Some systems are advisory (warning only), others cut hydraulic functions at overload.

Attachment Effects

• Each attachment has its own weight, which reduces the available capacity for the load.
• Attachments alter the effective load centre (e.g., a jib extends the load centre significantly).
• Different load charts are required for different attachments.
• Operators must be trained on each attachment they use.

Stacking & De-stacking

• Approach square to the stack, stop, check stack stability, check overhead clearance.
• Raise boom to required height, extend to position, place load carefully, retract and lower.
• De-stack: check load is free before lifting (not caught, interlocked, or frozen), lift clear, retract boom before lowering and travelling.
• Never stack higher than the racking/stack design permits. Consider floor loading capacity.

Work Near Structures & Edges

• Maintain safe distances from buildings, racking, parked vehicles.
• Use banksman when placing loads in confined areas or near structures.
• Never operate near unprotected edges (dock, excavation, platform) without barriers or stop blocks.
• Be aware of overhead hazards — power lines, building eaves, gantries, pipework.

Shutdown Procedure

1. Park on firm, level ground in designated parking area.
2. Lower boom fully, retract completely.
3. Lower forks/attachment flat to the ground.
4. Select neutral gear.
5. Apply parking brake firmly.
6. Allow engine to idle briefly (if manufacturer recommends), then switch off.
7. Remove ignition key.
8. Exit cab safely using three-point contact.

Post-Use Inspection

• Visual walk-around: check for new damage, leaks, tyre condition, loose items.
• Note any defects or changes observed during the shift.
• Clean off excessive mud/debris if required (especially from cab, steps, mirrors, lights).

Safe Parking

• Park in designated area only — never block fire routes, exits, or access points.
• Forks flat on the ground, boom lowered and retracted.
• If parking on a slope is unavoidable: chock wheels, forks pointing downhill.

Refuelling / Recharging

• Diesel: engine off, no smoking, use designated refuelling area, avoid spillage, use spill kit if needed.
• LPG: follow gas changeover procedure, check for leaks, secure cylinder correctly.
• Electric (if applicable): follow charging procedures, ensure ventilation, check battery condition.

Reporting & Isolation

• Report all defects to supervisor/maintenance — verbal and written (defect report form).
• If defect is safety-critical: isolate the machine (remove key, attach out-of-service tag), inform supervisor immediately.
• Never leave a defective machine for the next operator to discover.

Vehicle & Container Stability

• Ensure vehicle is parked, engine off, handbrake applied, wheels chocked.
• Trailer legs/landing gear must be down and secure. Check the trailer cannot "tip" when loaded at one end.
• If loading a curtainsider, ensure curtains are fully open and secured. Check the vehicle floor condition.
• Container doors must be fully open and secured back.

Load Distribution

• Plan the loading sequence to distribute weight evenly. Heavy items low and central.
• Consider axle weight limits for the vehicle — do not overload individual axles.
• Stack loads securely to prevent movement during transit.
• Leave no gaps that could allow loads to shift.

Clearances & Access

• Check overhead clearance (container headers, vehicle headboards).
• Check side clearance — loads must not foul container walls or vehicle sides.
• Ensure adequate access for the truck — ground surface, gradient, turning space.
• Lighting — adequate illumination inside containers/vehicles.

Securing Loads

• Loaded goods may need strapping, netting, or dunnage to prevent movement.
• The driver is legally responsible for the security of their load on the road, but the loader shares responsibility for safe loading.

Communication & Banksman

• Use a banksman when visibility is restricted, when loading from blind side, or when working near pedestrians/other vehicles.
• Agreed hand signals must be established before operations begin.
• Only one person should give signals to the operator. The banksman must remain visible at all times.
• If the banksman moves out of sight — stop immediately.

Movement Risk

• As loads are removed, the vehicle's weight distribution changes. A trailer may become unstable (nose-heavy or tail-heavy).
• Re-check trailer stability as unloading progresses, especially when removing the last/heaviest loads.
• Ensure the vehicle cannot move during unloading (chocks, brakes, communication with driver).

Unloading Sequence

• Plan the sequence to maintain vehicle stability throughout.
• Remove loads in reverse order to loading (last in, first out) where practical.
• Check each load before attempting to lift — is it free, accessible, not interlocked with other items?
• Withdraw forks/load carefully to avoid catching on vehicle structure.

Damaged Loads

• Inspect loads visually before handling. Look for: broken pallets, split packaging, leaking containers, shifted/tilted loads.
• If a load appears damaged or unstable — stop, report, seek guidance before attempting to handle.
• Hazardous materials: check labels/markings, follow COSHH procedures, use appropriate PPE.

Access Risks

• Trailer/container floors may be damaged, slippery, or have debris.
• Dock edges and ramps — ensure the truck does not approach closer than the safe edge distance.
• Dock levellers must be correctly positioned and rated for the truck weight plus load.
• If entering a container on a trailer: check the floor will support the truck's weight.

Responsibilities

• Loading/offloading a machine onto a transporter is a lifting/handling operation — it must be planned and supervised.
• The operator loading, the transporter driver, and the site supervisor all share responsibility for safety.
• A risk assessment and method statement should be in place for machine transport.

Ramp & Deck Checks

• Ramps must be rated for the machine weight, be in good condition, and properly secured to the transporter.
• Ramp gradient should be suitable — not too steep for the machine to safely drive on/off.
• Deck must be clean, free from oil/ice, and rated for the machine weight.
• Check for overhead clearance (bridges, doorways, cables) if the machine is tall on the transporter.

Machine Configuration

• Boom fully retracted and lowered.
• Forks/attachment lowered.
• Steering mode set to front-wheel steer (unless otherwise specified).
• Travel slowly up/down ramps — never change direction on the ramp.
• Once positioned: parking brake on, engine off, key removed.

Tie-Down & Securing

• Use the manufacturer's designated tie-down/lashing points only. Never lash to boom, forks, or non-structural components.
• Securing must be carried out by a competent person using appropriate rated equipment (chains, straps, tensioners).
• Check the securing meets transport regulations (number of lashings, break strength, angle of pull).
• Chock wheels on the transporter deck.

Legal Road Requirements

• Transporter must comply with road traffic regulations (weight limits, lighting, markings, escort vehicles if over-width/over-height).
• If the machine itself is being driven on the road: valid registration, insurance, appropriate licence, road-legal lighting, compliance with Construction and Use Regulations.
• Speed limits for the machine type must be observed.