UK CPCS Telehandler Theory Exam cheat sheet

Health and Safety at Work etc. Act 1974: general duties of employers to ensure, so far as reasonably practicable, the health, safety and welfare of employees and others affected by work activities.

Lifting Operations and Lifting Equipment Regulations 1998 (LOLER): requires lifting equipment to be strong and stable, marked with safe working load, and thoroughly examined at least every 12 months (6 months for lifting accessories or equipment lifting people).

Provision and Use of Work Equipment Regulations 1998 (PUWER): requires work equipment to be suitable, maintained in efficient working order, inspected as needed, and used only by trained and competent persons.

Management of Health and Safety at Work Regulations 1999: require suitable and sufficient risk assessments, arrangements for planning, control, monitoring and review, and appointment of competent persons.

Control of Substances Hazardous to Health (COSHH) 2002: applies to fuels, oils, hydraulic fluids, battery acid and exhaust emissions; requires assessment, control measures and health surveillance where appropriate.

Environmental Protection Act 1990 and Waste Regulations: duty of care for waste; hazardous waste such as waste oil, filters and batteries must be segregated, stored in bunded containers and consigned to licensed carriers.

Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013 (RIDDOR): report deaths, specified injuries, over-7-day incapacitations, and dangerous occurrences such as lifting equipment collapse or failure.

Supply of Machinery (Safety) Regulations 2008 and PUWER require CE/UKCA marking, guarding, and provision of a handbook in the language of the user; operators must follow the manufacturer's instructions.

LOLER requires that lifting operations are planned by a competent person, appropriately supervised and carried out in a safe manner; for complex lifts a written lift plan is required.

Boom: telescopic sections extended by hydraulic rams; extension reduces safe working load because load radius increases.

Outriggers/stabilisers: increase the machine's footprint and must be fully deployed and on firm ground before lifting near the maximum rated capacity; check the load chart for whether they are required.

Attachment quick-hitch: must be compatible, locked and secured with the manufacturer's locking pin; a visual check of the locking indicator is required before lifting.

Load chart (rated capacity indicator/limiter): a placard or electronic system showing maximum load at given radius, boom angle and configuration (with or without outriggers, with or without jib).

Rated capacity indicator (RCI) or rated capacity limiter (RCL): warns the operator when approaching the rated capacity and may cut out hazardous functions; must never be overridden or disabled.

Tyres: check for correct type, pressure and condition; tyre ballast or foam filling affects stability and must match the manufacturer's specification.

Steering modes: two-wheel, four-wheel and crab steer; the mode affects turning radius and must be selected correctly for the site conditions.

Battery isolator and emergency stop: must be functional and accessible; the isolator should be switched off when leaving the machine unattended.

Forks: must be fitted with a load backrest extension and fork retention pins; fork spacing should be adjusted to suit the load and be within the carriage width.

Pre-use check sequence: walk-around visual inspection (tyres, wheels, forks, boom, hoses, hydraulic rams, guards, labels, lights), then fluid levels, then cab controls and instruments, then functional tests at low speed.

Daily checks include engine oil, coolant, hydraulic oil, fuel, battery condition, tyre pressure and condition, wheel nut indicators, fork pins, and condition of seat belt and anchorage.

Functional tests include service brake, parking brake, steering, horn, lights, beacon, RCI/RCL self-test, emergency stop, and boom lower/raise and extend/retract.

Coolant and hydraulic fluid levels are checked with the machine level and the engine off; the radiator cap is never removed when the engine is hot.

Defects must be recorded in the machine's defect log and reported to the supervisor; a defect affecting safety requires the machine to be taken out of service, tagged and immobilised.

Maintenance intervals (daily, weekly, 500-hour, annual) are specified in the operator's manual; thorough examination under LOLER is at least every 12 months.

Lubrication points, filters and belts are part of routine maintenance; only trained personnel should carry out scheduled servicing.

Wheel nuts should be checked for torque and security after the first few hours of use following a wheel change, and wheel nut indicators checked daily.

A machine that has been damaged, has an inoperative safety device, or has been involved in an incident must not be used until inspected and cleared by a competent person.

Stability is determined by the machine's centre of gravity and the load's centre of gravity; increasing load radius or boom extension raises the combined centre of gravity and reduces stability.

Safe working load (SWL) is the maximum load for a given configuration as stated on the load chart; it must never be exceeded.

Load chart variables: boom length/angle, load radius (horizontal distance from the machine's centre of rotation to the load's centre of gravity), outrigger configuration, and attachment type.

As the boom is extended or lowered, the load radius increases and the SWL decreases; the load chart shows the maximum permitted load at each radius.

The load's centre of gravity must be known; for uneven or long loads, the effective radius is measured to the load's centre of gravity, not the fork heel.

The combined load includes the weight of the load, the attachment and any lifting accessories; these must be added to determine the total load against the chart.

Rated capacity indicator (RCI) gives a warning as the load approaches the limit and may cut out functions; the machine must be operated within the chart, not at the RCI cut-out point.

Dynamic effects: sudden braking, lowering or raising, and travelling with a raised load increase the effective load and can cause instability; keep the load low and travel slowly.

Ground conditions affect stability: the load chart assumes firm, level ground; on soft or sloping ground, the effective capacity is reduced and outriggers may need spreader plates.

Travel with the load low and the boom retracted; the load should be carried as close to the ground as ground conditions allow, typically no more than 300–500 mm above ground, and the boom should be lowered before moving.

On inclines, travel with the load uphill where possible; if the machine must be driven across a slope, the risk of overturning increases and should be avoided.

Maximum permissible slope is specified in the operator's manual; check the machine's gradient limit and never exceed it.

When travelling on slopes, keep the heaviest end of the load uphill and avoid turning on the slope; if turning is necessary, do so slowly.

Site speed limits and pedestrian segregation must be observed; use a banksman when visibility is restricted or manoeuvring in confined areas.

Before moving, check the route for overhead obstructions, ground conditions, excavations, and other vehicles; ensure the load is secured and the attachment is locked.

On uneven ground, reduce speed, keep the boom low, and avoid sudden steering or braking; the machine may tip if a wheel drops into a depression.

When parking, choose level ground, lower the boom and attachment to the ground, apply the parking brake, select neutral or park, and isolate the battery.

Use of mirrors, cameras and audible warnings: ensure they are clean and functional; the reversing alarm and beacon must operate when reversing.

Plan the lift: assess the load weight, centre of gravity, lifting points, route, landing area, and ground conditions; ensure the load is within the machine's rated capacity for the planned configuration.

Use the correct attachment for the load; forks for palletised loads, and a jib or lifting sling for suspended loads with a certified lifting point.

Approach the load squarely, with the forks level and spaced to suit the load; insert forks fully under the load and lift slightly to check stability before moving.

When lifting, raise the boom slowly and keep the load close to the machine; avoid side loading of the forks and never lift a load with the boom extended beyond the chart's limit.

Placing loads: lower slowly to the landing area, ensure the area is clear and the ground can support the load, and check the load is stable before releasing.

Loading and unloading vehicles: check the vehicle's parking brake and wheels are chocked, the load is within the vehicle's capacity, and the delivery vehicle is on firm level ground.

Never allow anyone under a suspended load; keep the area beneath the load clear and use a exclusion zone.

When using a jib, the load must be free to hang vertically and the jib must be rated for the load; the safe working load of the jib and slings must be known.

Communication: use agreed hand signals or radio with the banksman; if visibility is lost, stop the operation until communication is restored.

Overhead power lines: assume all lines are live; the safe clearance distance depends on voltage and must be confirmed with the line owner; for low voltage, a minimum of 3 metres is often cited, but always check.

If the machine contacts an overhead line, the operator should remain in the cab, warn others to stay clear, and contact the electricity supplier; if escape is necessary, jump clear and shuffle away without touching the machine and ground simultaneously.

Exclusion zones: a defined area around the machine, the load and the landing area, kept clear of pedestrians; barriers and signage should be used.

Site hazards include excavations, soft ground, overhead obstructions, other plant, pedestrians, and underground services; a site-specific risk assessment and method statement (RAMS) should identify controls.

Safe system of work: a documented procedure for the lifting operation, including planning, supervision, communication, and emergency arrangements.

Weather: high winds increase the load's surface area and can affect stability; the manufacturer's wind speed limit must be observed, and lifting should stop if conditions exceed it.

Visibility: mirrors, cameras and clean windows are essential; if visibility is impaired, use a banksman and stop if unsure.

Pedestrian segregation: use barriers, walkways and banksmen to keep people out of the machine's working area, especially during slewing and reversing.

Emergency procedures: know the location of the emergency stop, fire extinguisher, first aid kit and spill kit; report all incidents and near misses.

In an emergency, stop the machine safely using the service brake, lower the boom and attachment to the ground, apply the parking brake, and switch off the engine; use the emergency stop if necessary.

Fire: raise the alarm, evacuate to a safe assembly point, and only attempt to fight a small fire if trained and it is safe to do so; use the appropriate extinguisher (dry powder or CO2 for electrical/fuel fires).

Incident reporting: all accidents, near misses and dangerous occurrences must be reported to the supervisor and recorded in the site accident book; RIDDOR-reportable incidents must be reported to the HSE.

Environmental controls: prevent spills by using drip trays, bunded storage and careful refuelling; spill kits should be available and staff trained in their use.

Waste management: segregate waste (oils, filters, batteries, general waste) and dispose of via licensed carriers; never pour oils or chemicals down drains or onto the ground.

Noise and dust: use appropriate controls such as water suppression for dust and maintain silencers; consider nearby sensitive receptors.

Emergency contact numbers and site emergency procedures should be displayed in the cab or carried by the operator.

After an incident, the machine should be isolated and inspected by a competent person before being returned to service; the scene should be preserved for investigation where possible.

Environmental incidents such as spills must be reported and contained immediately; use spill kits and notify the environmental regulator if the spill reaches watercourses.