CPCS A77 Telescopic Handler 360 Slew Course

1. Introduction

This course is designed to provide novice and intermediate operators with the theoretical and practical knowledge to successfully and safely operate telescopic handlers with 360° slew. Novice operators will be trained in line with theory and practical exercises, to successfully pass the CPCS Theory and Practical Tests. This, in turn, will qualify the operator to operate any machine within the telescopic handler with 360° slew category. Intermediate operators, who have a red CPCS trained operator card (red card) and plenty of practical seat time, but no qualification, may also find this course beneficial to successful qualification. This course is not just for operators. Personnel such as slingers/signallers, site supervisors, managers and safety officers, who are or will be involved in 360° slew telescopic handler operations, will learn what duties are being carried out by the operator during the movements, and understand the principles of safe operation. This will help them to ensure lifts are planned and carried out safely and efficiently.

1.1 Course Overview

The A77 course will equip novice and experienced operators with the essential skills and knowledge to undertake their work safely and efficiently. It next steps to the A17D is more challenging and requires steady operation and expertise. Typical candidates will vary from those new to the profession to skilled operators who have no formal training or a Telescopic Handler qualification. National Plant’s A77 course is a 3-5 day course for experienced operators with little or no formal instruction and assessment. This course is ideal for employers who want their workforce to gain a recognized qualification while enhancing their skills. Progressive candidates may choose to undertake the 4-5 day course, which is designed for operatives with little or no experience of Telescopic Handler operation. This course guides the inexperienced right from the very basics through to a recognized qualification. Duration may vary dependent upon the ratio of inexperienced operatives. Inexperienced operators may decide to undertake the intermediate option to allow the consolidation of knowledge and experience prior to assessment.

Upon completing the Telescopic Handler 360° Slew training, the learner will be able to operate the machine safely and competently. They will have a clearer understanding of the 360° Slew Telehandler and be able to comply with the Approved Code of Practice for the rough terrain telescopic forklift (often known as a teleporter). Whether working on site or renewing the Telehandler element on a CPCS card, this is the ideal course for anyone who operates a 360° Slew Telehandler.

1.2 Course Objectives

To provide the theoretical and practical knowledge and skills involved in operating a telescopic handler. By the end of the course, delegates will be able to: operate the machine safely and correctly in accordance with manufacturers’ instructions and accepted good practice and to comply with relevant legislation and other duties imposed by the Health and Safety at Work Act. Have an understanding of the construction plant competence scheme, carry out a pre-shift inspection, implement understanding the effect of load on the machine stability, travel the machine over different types of terrain and slopes, and lift various loads. Understand the basic construction of the machine and the terminology used. This will enable the operator to work out which is the best way to tackle a job and communicate more effectively with supervisors and colleagues. An understanding of duties under relevant legislation to include Provision and Use of Work Equipment Regulations, LOLER, PUWER, HASAWA. This will include the rights and responsibilities of operating a telescopic handler.

1.3 Course Duration

On rare occasions, and where testing can be immediately arranged, someone who is experienced and very knowledgeable with both machines can do a short condensed course and test on the same day. This can be discussed with our advisors at the time of booking and will depend on instructor availability.

Please note that all candidates attending a CPCS course must have a good understanding of verbal and written English. If you feel you would like to improve your knowledge of the terminology used when operating plant machinery or feel that extra revision time is needed, an extra day can be added to your course. This scheme is known as the CPCS+.

For novice operators (with no previous operating experience), a 3 or 4-day duration is available depending on the number of machines covered. For operators with limited operating experience on one or both machines, a 2 to 3-day course is offered depending on the number of candidates and machines being covered. For experienced operators with a good solid history of operating both machines, 1 to 2 days will suffice, again depending on the number of candidates and machines being covered.

2. Safety Procedures

2.1.4 Gloves Wearing gloves reduces the risk of getting cuts, scratches or splinters on the hands. This is particularly important when performing maintenance work by minimising vibration and protecting hands from getting trapped.

2.1.3 High Visibility Jacket This must conform to EN471. It is recommended that operators keep a high vis jacket in the cab, as in some cases the operator may be required to wear one when leaving the cab and working in close proximity to other plant. This is to increase operator visibility to other operators.

2.1.2 Footwear This must have toe and mid-sole protection. Trainers, Sandals and any footwear which does not support and protect the ankle cannot be classed as suitable for driving mobile plant.

2.1.1 Hard Hat This must conform to EN397 and be worn at all times when operating the machine. It is also recommended that site visitors wear hard hats, and banksmen wear hard hats when slinging loads.

Personal protective equipment (PPE) is equipment aimed at protecting the wearer’s body from injury or infection. The CPCS A77 Telescopic Handler 360 Slew Course recommends the following PPE: Hard Hat, Footwear with Midsole and Toe protection conforming to EN345, High visibility jacket, Gloves, Safety Glasses, Waterproofs in poor weather conditions, Sun Cream, Insect Repellent.

2.1 Personal Protective Equipment (PPE)

Plant related PPE and its use, employee and others. Head protection – to be worn at all times. Safety helmets shall comply with regulations and be the type and colour to suit the site specific roles. Eye protection – should be worn at all times. Protective eye wear shall comply with regulations and be suitable for the work being carried out. Audio protection – should be worn at all times when operating within a cab or open machinery where noise is distracting. Suitable audio protection shall be provided and used when necessary. Foot protection – to be worn at all times when operating plant. Safety boots or shoes of a type suitable for the work being carried out shall be supplied and worn. General body protection – to be worn where necessary and when operating certain types of machinery. Protective clothing e.g. high visibility waistcoats/jackets, gloves, dust masks, knee pads etc shall be worn when necessary and suitable for the work being carried out. Safety harnesses will be worn by anyone operating mobile plant and where there is a risk of falling from a height.

2.2 Pre-Operational Checks

Pre-operational checks are a vital part of the safe operation of the telescopic handler. If these checks are not completed and the machine is operated with a fault, serious accidents with the possibility of death or injury could occur to the operator and persons working in the vicinity of the machine. All pre-operational checks should be carried out with the engine switched off and the parking brake applied unless otherwise stated. These checks must be recorded on a pre-shift safety/inspection checklist. The condition of the machine and severity of the defect should indicate that the machine is in a limited or dangerous operating condition and is not fit for purpose until repairs are carried out. The operator is responsible to ensure that a pre-shift inspection is carried out and recorded on a pre-shift safety/inspection checklist on a daily or weekly basis, depending on the user’s opinion. Any defects on the machine or unsafe working conditions should be reported to the site manager or maintenance person and recorded within the defects log book. The machine should also be taken out of service by tagging the keys with the known defect and its operational status, which would identify that the machine is unsafe to use until repairs are carried out.

2.3 Safe Operating Practices

Measures suggested to reduce the incidence of operators being crushed between the telescopic handler and a static/fixed immovable object. This type of accident currently accounts for a large percentage of serious injury accidents involving telescopic handlers, and we feel that many of these accidents can be avoided by increasing the operators’ awareness of the hazard and the implementation of simple control measures.

A code of signals for the safe operation of telescopic handlers and lift trucks. It is our opinion that signal people should be used where large or awkward loads are being moved and that they should be taught the code of signals listed and used in conjunction with the signals card which should be displayed clearly in the cab. We feel that the use of clear, concise signals being given will greatly reduce the operating hazards involved with maneuvering and positioning loads. The use of signallers and the signals card will force operators to become more aware of the need to look and listen to what is happening around them.

Safe operating practice regarding the operation of lift trucks is relatively easy to document. It basically involves the operator ensuring that the area is clear of personnel and that the truck and its load are stable prior to lifting or traveling. These are the fundamental principles and they must be adhered to at all times to ensure the safety of people and the loads being handled. Assessment of individuals operating lift trucks will involve observing this type of work to ensure that the principles are being followed.

2.4 Emergency Procedures

There has been a recorded case of a rear window breaking whilst carrying out reversing manoeuvre, due to the operator not realising that another person was sitting on the rear bonnet. This could have caused serious injury, the safest practice is to always have a banks man for reversing and to avoid at all costs carrying out two operations at opposite ends of the telehandler.

Falls from the telehandler: This can be prevented by not sitting or standing on any part of the telehandler which is unsuitable for supporting a person. This could mean being cautious as to where you store things during maintenance and avoiding sitting on the edge of a platform. Do not attempt to carry passengers at any time on the telehandler, there is only one seat and the rated capacity is only applicable to lifting the load, the 360° slew telehandler is not a suitable lifting device for personnel.

Wrong Mounting / Dismounting: Causes many accidents involving crushing and collision. Ensure all 3 points of contact are maintained when mounting and dismounting the telehandler. Be sure to face the machine and not have your back to an open space, ensure the area surrounding the telehandler is obstruction free. This will prevent an accidental fall to ground level or into a trench.

Never attempt to jump off a moving 360° slew telehandler – the risks are far too great. If the telehandler is about to tip over to the side, you are far safer staying in the cab with your seat belt on, than trying to jump out. Jumping from the cab can be fatal as there is a high risk of the cab or the boom, which may be carrying a load, falling on you. If on a rare occasion you find yourself in a situation where the telehandler is in danger of tipping, and you are able to plan your escape route – aim to move in the diagonal direction that the telehandler is tipping, as this will be the furthest point from the rollover pivot.

3. Telescopic Handler Operations

3.1.3 The ability to handle a load at full extension will depend on the machine stability. A machine with outriggers will have the capability to load at full extension. A machine that has no outriggers but is all the same size will have more overall lift capacity but the load at full extension will be reduced and over the front tyres only. This is an important safety factor that is to be conceded due to the various capacities of the machines and it can often be said that the bigger the machine the less the function.

3.1.2 The handler must have undergone the necessary checks that are to be done at the start and end of each shift and are detailed in Risk Management Plant Assessment for that machine.

3.1.1 Telescopic handler is a very versatile piece of machinery whether it be on a small or large building site. The machine is designed for incorporating the benefits of a fork lift and a crane and is sometimes referred to as a telehandler, hence the telescopic function of the boom unit. The machine should have 4 equal sized pneumatic tyres to ensure the stability of the machine and the operator, the machine should be all wheel steer and have the ability to crab steer for manoeuvring in tight spaces, these steering functions are usually on a switch and are not automatically locked which will mean that driving up a ramp or operation of the boom will be next to impossible whilst the steering function is initiated. Check that the machine is fitted with an ROPS and FOPS cab and check that the operator is able to access the controls whilst within the cab. The function of the machine relies upon its lifting capacity so this must be established prior to commencement of the operations. A telescopic handler will have a lifting hook/hoist attachment and also quick hitch carriage which enables the various attachments for the machine to be changed depending on the desired application, so the correct procedures must be used for the changing of attachments (attachments come in many forms eg: buckets, muck grabs, lift jibs, winches). Heeding to the manufacturer’s handbook will give more specific detail about the machine that is going to be operated.

Equipment Familiarization

3.1 Equipment Familiarization

3.1.2 Location and Function of Major Components A standard format should be adhered to by all operators when explaining the location and function of major components. Start at the rear or front of the machine and work systematically in one direction around the machine explaining where the engine is located and explain the type of engine, fuel type, and cooling system used. Explain the transmission type and how many gears and speeds are available, including the type of drive to the wheels. Explain the location of hydraulic systems and the primary functions of each valve or lever. Explain the steering mechanism, brake system, and location of the machine’s chassis/vin plate. The instructor should explain to the trainees that they can take notes if required.

3.1.1 Basic Machine Design During the familiarization walk around, the instructor should explain the fundamental design of a telescopic handler in that it has a telescopic boom which is hinged to the machine chassis and can extend forwards and upwards from the machine. Some designs of telescopic handlers have a fixed or pivot boom and the extent function may only be the upwards movement of the forks. This type of fixed and pivot boom machine does not fall under the testing criteria for the telescopic handler written and practical CPCS tests and the A17 category is the appropriate category for those machines. The explanation of machine design should be related to the specific machine to be used in training.

The instructor should give trainees a walk around familiarization of the machine to be used in training. During the familiarization, all safety decals should be pointed out and explained. The manufacturer’s specifications and technical data for the machines to be used during the practical training can be found in the operator’s manual provided by the manufacturer of the machine. All students should be made aware of the location of this operator’s manual and encouraged to read any area relating to the machine to be used in training. Telescopic handlers are versatile machines that can be fitted with a variety of lifting and rotating attachments. During the familiarization, the operator should explain that the machine to be used in training is to be used solely with forks and is of the lifting only attachment.

3.2 Controls and Functions

The main operative functions are all in the movement of the main boom and the movement of the attachment. The main boom is moved in and out by using the joystick, where pulling the joystick towards you will retract the boom and pushing the joystick away from you will extend the boom. The attachment is attached to the end of the main boom and it can be either a carriage and pallet forks or a bucket. The attachment is usually fitted with a quick hitch, allowing the operator to change between different attachments efficiently. The main movement of the attachment is up and down, which is usually done with another joystick function or sometimes the operator has the option of using a switch in the cab which can change the function of the joystick between say tipping the bucket and lifting it.

Driving the telescopic handler around site is an operation that requires good skill and judgment because it is usually done in confined areas where there are other workers and various other trades in operation. During travel, the boom should be carried in line with the chassis to ensure the safest travel route and to make sure the load is not too high in the air, as there can be height restrictions.

The telescopic handler is a very versatile machine because it is capable of many functions. The main functions are to lift, lower, and transport loads horizontally to a new location. The telescopic handler has three different steering modes: front wheel, all wheel, and crab. It is important to familiarize with all three steering modes to ensure safe and efficient operation of the machine.

3.3 Load Handling and Stacking

When selecting and travelling with a load, the handler should be driven with the boom and load trailing, with the load as low as possible without it dragging on the ground. Loads should always be carried square to the direction of travel or across slopes. Loads should not be lifted or swung over personnel. When stacking materials ensure that the stack is built on a firm, level surface. The handler should approach the stack with the boom and load trailing. Raised loads should be tilted slightly to avoid losing the load while placing it. The bucket attachment should be removed and pallet forks should be used for block or pallet handling. When handling more than one pallet, the bottom pallet should be laid on the ground in the required position before placing the pallets on top. Inner pallets should be positioned so that the load on the top pallet does not directly overhang the fork frame. When slewing the handler with a load, the same principles apply as for slewing with an empty bucket.

3.4 Slew Techniques

Any tasks with the handler that use excessive height when combined with other requirements will need thorough planning or possibly a method statement and risk assessment. An example of this would be working with a bale spike when stacking bales to a height and then subsequently retrieving them at a later date.

When working in any location with overhead or underground services, the operator should be aware of the height and slew of the machine in relation to the services. When working near overhead services, the machine should be slewed as far back as possible when safe to do so to ensure there is no chance of collision with the item above. A safe distance when working under overhead services is approximately 3 feet. If this is not possible for any task, then the task should be reassessed or if necessary, an alternative method of handling the load should be considered. When handling a load that needs to be positioned close to an item above, the operator should consider the height of the load when fully extended and then work out if the load could be carried at a lower position and lifted to the required height when closer to the destination. This would reduce the risk of collision with the load and the item above.

In order to maintain the correct position in the required direction of travel, the operator must check the position of the rear wheel closest to the desired side of the machine. This is to avoid becoming side-on and overbalancing the machine when working on adverse ground or if the area is restricted with uneven or soft ground. A common fault when side-sloping on adverse ground is cross-locking the machine. This is when the front axle is on one side of an undulation and the rear axle is on the opposite side. To prevent this from occurring, the operator should reposition the machine at the top of each slope or undulation by forward and slewing/side crowding the machine to ensure that all 4 wheels are kept as parallel as possible in line with the direction of travel.

When slewing the machine from one location to another or repositioning the machine having completed a task, the correct technique to adopt in order to achieve 360-degree slewing vision is for the operator to drive the front axle to as close to full reach as possible in the required direction of travel and then to slew the machine to the side, either left or right. It is not essential which way the machine is slewed to in this instance, as long as the opposite rear wheel is following the line of the front wheel that is in the direction of travel. This technique will enable the operator to guide the machine into tight or confined areas and avoid any damage to surroundings or the machine itself.

In this section, you will be shown the correct techniques for slewing the upper structure of the Telescopic Handler. You will be shown the correct positions for traveling in and also reversing out of any location and the correct slew techniques to adopt when there are overhead/underground services or when carrying out specific tasks.

4. Assessment and Certification

From novice to experienced operator, the practical test may vary in time. There is no specific time frame for this test as candidates’ abilities and experience may vary. The practical test is designed to allow operators to demonstrate their ability to operate the machine safely and correctly. All categories require the operator to carry out the pre-shift inspection/maintenance and shut down procedures, as well as their ability to carry out several typical tasks. With regards to new operators (to the category) and novice operators, the tester should provide additional instruction to the candidate if required or demonstrate the correct method for any procedure the candidate has carried out unsafely or incorrectly. This must not be assumed as a fail, and the candidate should be allowed to retry the procedure. This is done under the discretion of the tester.

The theoretical test consists of 15 multiple choice questions and four open questions. Each question has a number of marks available and is based on the underpinning knowledge for the 360 excavator/slew telehandler operative. All the questions are randomly selected, ensuring compliance with an approved test. The theory test may be conducted separately in a classroom situation before the practical test. All the theory questions must be completed within, and the papers must be clearly marked with the candidates’ details. Full marks for the theory test would be 30. 360 Slew Telehandler theory test paper A004.

4.1 Theory Test

This is a verbal test conducted by the tester and consists of 25 randomly selected questions, delivered through a q-card system or verbally. The q-card option can be utilized in cases for special needs candidates, a scribe/reader or foreign language needs (translator to also be provided). The q-card system is a multiple choice answer, however in the event of the candidate selecting the wrong answer, the card will be handed back to the tester for the opportunity for them to prompt the candidate for the correct answer. If this is achieved, the same score will be given. If a verbal test is requested, it must be noted on the theory test notification form. The duration for either test is 30 minutes. In the event of the candidate failing to complete the test within the time, then the test can be carried on in another session or day. This shorter duration is specifically regarding foreign language and special needs candidates, as it was previously mentioned in the plan. Pass mark for the theory test is 20 out of 25, and the successful candidate must then hold a valid health and safety test (within 2 years) before a certificate can be claimed. Any re-sits within the theory test must be another 25 questions that are randomly selected. A candidate cannot get the same questions as a previous test.

4.2 Practical Assessment

Practical Test The CPCS Technical Test consists of a theory test and practical test. You will also be required to undertake a Health and Safety test if you have not achieved a Health and Safety Touch Screen Test within the last two years. Full details of the CPCS Technical tests requirement can be obtained here. The theory test is carried out first and is a touch screen, multiple choice test. This can however be booked independently of the practical test. The practical test will be carried out following successful completion of the theory test. You have 2 years from passing the theory test to attempt a practical test otherwise the theory test will need to be retaken. If you fail the practical test, you will be required to retake and pass the theory test again before a practical test can be undertaken. The practical test can be carried out at any test centre and can be used in substitution for a red card renewal test. Full test details including fees, resit information and location can be obtained from the CPCS website or your local test centre.

4.3 Certification Process

A successful candidate who completes the CPCS A77 Telescopic Handler 360 Slew course is awarded a Red Trained Operator Card. The trained operator card is entry level and only valid for 2 years. The candidate is expected to progress during the 2 years by taking an NVQ within this period. Once the NVQ has been achieved, the candidate can then apply for a Blue Competence Card. The NVQ must be in Plant Operations (Forklift/Telescopic Handler) and the VQ must be in the category of Telescopic Handler – 360 Slew. An experienced worker who has recently achieved the VQ in Plant operations and has sufficient documented evidence to prove ongoing work and experience in operating the telescopic handler 360 slew, which is authenticated by their employer, may be able to obtain a CPCS Red Experienced Operator card. The CPCS Red Experienced Operator card is non-renewable and is valid for two years. The employer has a responsibility to ensure the competency of his workforce. The employer must, in the first instance, register the candidate for CPCS Vocational Qualification (VQ) through a CPCS accredited centre. Once the VQ has been passed, then the employer must ensure the candidate takes and passes the CPCS theory and practical tests.