Course Title

1. Introduction to Telehandler Operations

• Overview of telehandlers and their operational applications including (construction material placement at height, pallet handling on rough terrain, agricultural bale handling, and industrial site logistics)

• Classification of telehandlers as Class 7 Rough Terrain Trucks under ANSI/ITSDF B56.6: Safety Standard for Rough Terrain Forklift Trucks

• Applicable standards and regulatory requirements including (ANSI/ITSDF B56.6, OSHA 29 CFR 1910.178(l), and local site authority requirements for powered industrial truck operation)

• Operator responsibilities, authorization requirements, and re-evaluation obligations under OSHA 29 CFR 1910.178(l) including (formal instruction, practical evaluation, and three-year recertification requirement)

• Overview of telehandler incidents and primary causes including (tip-overs on gradients, overloads from load chart misinterpretation, boom contact with overhead obstructions, and pedestrian strikes on congested sites)

2. Telehandler Components, Systems, and Controls

• Key structural components and their functions including (chassis, telescopic boom sections, carriage and attachment interface, counterweight, and four-wheel drive system)

• Steering modes and their application including (front-wheel steer, rear-wheel steer, crab steer, and four-wheel steer — and when each is used for maneuverability and stability)

• Boom extension and elevation controls including (single-lever joystick operation, boom crowd and tilt controls, and smooth incremental input for precise load positioning)

• Transmission and drive system including (powershift transmission, differential lock engagement for soft ground traction, and axle oscillation for rough terrain stability)

• Safety systems and devices including (load moment indicator — LMI, stability warning system, boom angle indicator, and operator restraint system)

• Attachment interface including (mechanical quick coupler operation, hydraulic auxiliary line connection, and attachment identification markings)

3. Pre-Use Inspection and Equipment Serviceability

• Pre-use inspection requirements in accordance with ANSI/ITSDF B56.6 including (daily pre-shift walkaround, functional control tests, and fluid level checks before each operating period)

• Structural and boom inspection including (boom section condition and wear pad clearance, carriage and fork wear assessment, counterweight security, and tyre condition and pressure)

• Hydraulic system checks including (fluid level, hose and cylinder condition, boom extension drift test, and auxiliary hydraulic line integrity)

• Safety device verification including (LMI function test, stability warning system check, operator restraint condition, and lights and warning beacon operation)

• Attachment inspection including (fork blade and heel condition, bucket wear and crack assessment, working platform structural integrity, and coupler locking pin security)

• Defect documentation and withdrawal procedures including (tagging out defective equipment, notifying the supervisor, and completing pre-use inspection records)

4. Load Charts, Capacity, and Stability Principles

• Load chart structure and interpretation for telehandlers including (capacity tables by boom angle, extension length, and working radius — and how all three interact to determine safe working load)

• Load centre concept and its effect on capacity including (standard load centre distance, off-centre load derating, and capacity reduction with extended boom)

• Attachment derating including (capacity reduction when using buckets, working platforms, or non-standard forks — and reading attachment-specific capacity charts)

• Stability principles for telehandlers including (the stability pyramid, centre of gravity shift with boom extension and elevation, and the effect of gradient and ground conditions on tip-over risk)

• Factors reducing telehandler stability including (elevated boom during travel, high-speed cornering, uneven or soft ground surfaces, and off-centre or oversized loads)

5. Safe Telehandler Operation

• Pre-operation site assessment including (ground surface and gradient check, overhead clearance confirmation, exclusion zone verification, and pedestrian activity assessment)

• Safe travel techniques on site including (boom in lowered stowed position, differential lock use on soft ground, speed restriction on gradients, and pedestrian right-of-way management)

• Load pick-up and placement under supervision including (accurate approach alignment, fork engagement depth confirmation, smooth lift and boom extension, and controlled placement with LMI monitoring)

• Operating on gradients under supervision including (ascending and descending loaded and unloaded, gradient angle limits per the load chart, and the risk of lateral tip-over on cross-slopes)

• Precision placement at height under supervision including (incremental boom control for final positioning, spotter use for blind placements, and confirming load stability before releasing)

• End-of-shift procedures including (boom lowering and stowage, attachment removal and storage, system shutdown, and post-shift inspection completion)

6. Attachments, Hazard Management, and Emergency Procedures

• Telehandler attachment types and their safe use including (pallet forks for material handling, buckets for loose material, jib attachments for suspended loads, and working platforms for personnel at height — each with applicable capacity derating)

• Working platform operation under supervision in accordance with ANSI/ITSDF B56.6 including (platform load limits, operator harness attachment, boom movement restrictions with personnel on platform, and emergency lowering procedures)

• Application of HIRARC to telehandler operations including (pre-task hazard identification covering ground conditions, overhead obstructions, pedestrian zones, and load weight verification)

• Pedestrian and vehicle segregation on site including (exclusion zones around active telehandler operations, spotter use in restricted visibility areas, and right-of-way protocols at site intersections)

• Emergency procedures including (tip-over response — stay restrained, brace, and lean away from fall direction — LMI alarm response, mechanical failure during elevated load, and load drop procedures)

• Post-incident actions including (scene isolation, supervisor notification, incident documentation, and participation in root cause investigation)

7. HSE, Quality, and Case Studies

• Integration of telehandler operations within the site Health, Safety, and Environment (HSE) management system including (pre-task risk assessments, permit-to-work compliance for working at height with personnel platforms, and incident reporting procedures)

• Quality assurance in telehandler operations including (operator authorization records, pre-use inspection logs, attachment inspection documentation, and OSHA 29 CFR 1910.178(l) re-evaluation compliance tracking)

• Environmental considerations including (hydraulic fluid spill prevention, tyre track damage management on sensitive ground surfaces, and fuel and fluid storage compliance on site)

• Case studies from telehandler incidents in Middle East construction, logistics, and industrial environments including (tip-overs on uncompacted fill material, boom contact with overhead power lines during placement, and overloads from unverified pallet weights) and the importance of proper operator training in preventing fatalities and equipment damage

• Group discussion on lessons learned including (root cause findings related to pre-task hazard assessment failures, LMI bypass practices, and inadequate ground condition assessment before entering soft ground areas)