Telehandler Types and Their Safety Features

Telehandlers come in two primary types: non-rotating and rotating. Each type offers specific advantages and safety features that make them suitable for different tasks and environments.

Non-Rotating Telehandlers

Non-rotating telehandlers are built on a powered wheeled chassis with a telescopic boom that can be elevated to various angles. These machines are equipped with forks at the boom’s end, allowing them to lift and transport loads. For added stability, many non-rotating telehandlers are fitted with outriggers, especially when working on uneven ground. The automatic levelling feature of the forks ensures that loads remain stable even as the boom is raised or lowered.

Rotating Telehandlers

Rotating telehandlers add another layer of versatility and safety by featuring a rotating superstructure. This design allows the boom and operator’s cab to rotate, enabling precise placement of loads without needing to reposition the chassis. The compact design, combined with enhanced lifting height and increased stability, makes rotating telehandlers ideal for complex tasks in confined spaces.

Attachments

Both types of telehandlers can be fitted with a range of attachments, such as sweepers, buckets, and crane hooks, to suit specific job requirements. It’s crucial to ensure that any attachment used is fully compatible with the telehandler model to maintain safety standards.

Machine Design and Selection Safety Considerations

Choosing the right telehandler for your operations is crucial to ensuring safety and efficiency on the job site. Several factors must be considered before purchasing or selecting a telehandler, each contributing to the overall safety of the machine and the work environment.

Pre-Purchase Risk Assessment

Before acquiring a telehandler, it is essential to assess its suitability for the intended tasks. Considerations should include the size, weight, lifting capacity, and manoeuvrability of the machine, as well as its compatibility with the terrain where it will be used. Older machines may lack modern safety features, so it is advisable to evaluate the condition of the machine, including its braking systems and lifting mechanisms.

Attachment Compatibility

Telehandlers are versatile and can be equipped with various attachments to meet specific job requirements. However, it is vital to ensure that these attachments are designed for the specific model of telehandler being used. Incompatible attachments can lead to safety risks, such as instability or equipment failure.

Cardan Shaft Handbrake: Critical Safety Focus

The cardan shaft handbrake is a crucial component in many telehandlers, responsible for securing the machine when it is stationary. However, industry data has identified the cardan shaft handbrake as a point of potential risk, particularly due to its higher likelihood of failure compared to other braking systems. Given its importance and the risks associated with it, this section highlights the key considerations for ensuring the safe operation and maintenance of telehandlers equipped with a cardan shaft handbrake.

Understanding the Cardan Shaft Handbrake

The cardan shaft handbrake functions by locking the telehandler’s drive shaft, effectively preventing the machine from moving when parked. This braking system is vital for maintaining the stability of the telehandler, especially on uneven or sloped terrain. Despite its critical role, the cardan shaft handbrake can be prone to wear and tear, leading to potential failure if not properly maintained.

Risks and Safety Concerns

Failures in the cardan shaft handbrake can lead to unintended movement of the telehandler, posing significant risks to both the operator and others in the vicinity. These risks are particularly pronounced in older telehandlers, where the braking system may not meet modern safety standards. It is essential for telehandler owners and operators to be aware of these risks and take proactive steps to mitigate them.

Inspection and Maintenance Protocols

To minimise the risk of failure, regular inspection and maintenance of the cardan shaft handbrake are mandatory. This includes checking for signs of wear, ensuring that all components are functioning correctly, and replacing any parts that show signs of deterioration. Maintenance should be carried out by a qualified technician who understands the specific requirements of this braking system.

Recommendations for Telehandler Owners

Owners of telehandlers with cardan shaft handbrakes should prioritise the maintenance of this system. It is advisable to incorporate the inspection of the cardan shaft handbrake into the regular maintenance schedule of the telehandler and to address any issues immediately. Additionally, owners should ensure that operators are trained to recognise potential problems with the handbrake and know the correct procedures for reporting and addressing these issues.

Maintaining Telehandler Safety

Maintaining telehandler safety is an ongoing responsibility that extends beyond the initial purchase and daily operation. It requires regular inspections, adherence to maintenance protocols, and a proactive approach to identifying and addressing potential issues.

Regular Maintenance and Inspection

Routine maintenance is crucial for identifying and addressing any potential issues before they lead to serious safety concerns. Telehandlers should be inspected regularly according to the manufacturer’s recommendations, with particular attention given to critical components such as the braking systems, hydraulic systems, and attachments. The inspection should include both visual checks and functional tests to ensure that all parts of the telehandler are operating as intended.

For telehandlers that are used frequently or in demanding conditions, it may be necessary to conduct more frequent inspections. This proactive approach helps to catch wear and tear early, preventing small issues from escalating into major problems.

Operator Responsibilities

Operators play a key role in maintaining telehandler safety. They should be trained not only in the operation of the machine but also in recognising signs of wear or malfunction. Before each use, operators should conduct a pre-start check, including inspecting the telehandler for any obvious signs of damage or wear, checking fluid levels, and ensuring that all safety features are functioning properly.

If any issues are identified during these checks, the operator must report them immediately and refrain from using the machine until the problem is resolved. This ensures that only fully operational and safe telehandlers are put to work, reducing the risk of accidents.

Reporting and Addressing Issues

When a safety issue is identified, whether during routine maintenance or a pre-start check, it must be addressed as soon as possible. Telehandlers should be powered down and removed from service until the issue is fully resolved. A qualified technician should assess the problem, perform the necessary repairs, and confirm that the telehandler is safe to use before it is returned to operation.

Maintaining detailed records of all maintenance activities, inspections, and repairs is also essential. These records help track the condition of the telehandler over time and provide valuable information for future maintenance planning.

Operating Telehandlers Safely in Various Environments

Operating telehandlers safely requires careful consideration of the environment in which they are used. Whether on a construction site, a farm, or a public road, understanding the specific risks associated with each environment is crucial to ensuring safe operations.

Work Area Considerations

Before a telehandler is put to work, it is essential to conduct a thorough risk assessment of the work area. This assessment should consider the terrain, the proximity of other equipment or structures, and any potential hazards that could affect the safe operation of the telehandler.

For example, operating on uneven or sloped terrain presents unique challenges that can increase the risk of tipping or loss of control. In such environments, it is important to ensure that the telehandler is stable and that any loads are properly secured. Additionally, the use of outriggers or stabilisers may be necessary to enhance stability.

The size and manoeuvrability of the telehandler should also be matched to the work environment. In confined spaces, a rotating telehandler with a compact chassis may be more suitable, as it allows for precise load placement without requiring the machine to be repositioned.

Public Road Operations

When telehandlers are operated on public roads, specific legal and safety requirements must be followed. These include ensuring that the telehandler is registered, roadworthy, and equipped with the necessary safety features, such as proper lighting and reflective markers.

Operators must hold the appropriate driving licence for the telehandler’s weight class, and additional endorsements may be required if the telehandler is equipped with certain attachments, such as forks. It is also essential to follow all road safety regulations, including speed limits and the use of warning signals, such as flashing beacons.

Before taking a telehandler onto a public road, all attachments should be secured or removed to prevent them from obstructing visibility or causing hazards to other road users. If the attachments cannot be removed, they must be properly marked and illuminated, especially if they extend beyond the front of the telehandler.

Safe Operations in Confined or High-Risk Areas

In areas where space is limited or where there are additional risks, such as overhead power lines or uneven surfaces, extra precautions should be taken. The operator should be fully aware of their surroundings and any potential hazards that could affect the safe operation of the telehandler.

Using telehandlers in high-risk areas requires careful planning and coordination with other workers on-site. Clear communication and the use of spotters may be necessary to guide the operator and ensure that the telehandler can be manoeuvred safely without causing damage or injury.

Safety is a fundamental aspect of telehandler operation, and following these guidelines ensures not only the protection of operators but also the efficiency and longevity of the equipment. By selecting the right telehandler, maintaining it rigorously, and adhering to safety protocols, risks can be minimised, creating a safer work environment for everyone involved.

At APS Equipment, we are committed to supporting our customers in achieving the highest safety standards. Whether through regular maintenance, proper training, or implementing comprehensive safety management systems, we are here to assist you in every step of the process. We encourage you to follow these guidelines closely and to reach out to us for any further assistance or information.

For more detailed information, the full Mobile Plant Safety Guide for Telehandlers is available to download here. Safety is not just a requirement—it’s a responsibility. By taking proactive measures and staying informed about the latest safety practices, you contribute to a safer workplace and a more reliable operation.