Forklifts and Other Powered Industrial Trucks WAC 296-24-230 From WAC 296-24, Part D Materials Handling and Storage, Including Cranes, Derricks, Etc., and Rigging

Objectives Employers should be able to determine if their Powered Industrial Truck operator training program complies with the new standard’s requirements for Truck-Related Topics Workplace-Related Topics Documentation of Training

Changes “Clear Rule Writing” Operator Training Requirements Non-Mandatory Guidelines Operator Restraints WRD On Order Pickers Included Updated National Consensus Standards Other Glycol no longer specified as the only antifreeze agent Other Industry standards affected

What Is A “Powered Industrial Truck”? “A mobile, power-propelled truck used to carry, push, pull, lift, stack, or tier materials. Powered industrial trucks are also commonly known as forklifts, pallet trucks, rider trucks, forktrucks, or lifttrucks.” [per American Society of Mechanical Engineers -- ASME]

Which Of These Does the New Standard Require Operators To Be Trained On?

Is This A “Powered Industrial Truck”

Is This A “Powered Industrial Truck”

Is This A “Powered Industrial Truck”

Is This A “Powered Industrial Truck”

Is This A “Powered Industrial Truck”

"Clear Rule Writing"

“Turning technique no longer specified” The Old Way - The New Way “Turning technique no longer specified” “While negotiating turns, speed shall be reduced to a safe level, by means of turning the hand steering wheel in a smooth, sweeping motion. Except when maneuvering at a very low speed, the hand steering wheel shall be turned at a moderate, even rate.” “While negotiating turns, speed must be reduced to a safe level.”

Operator Training Mandatory portion: WAC 296-24-23025 Non-Mandatory Appendix: WAC 296-24-23037

Mandatory: -296-24-23025 - Operator Training Safe Operation Training program implementation Training program content Refresher training and evaluation Avoidance of duplicative training Documentation Effective date The Mandatory portions of –24-230 are the legal requirements, like every other WISHA standard. The non-mandatory appendix (modeled after OSHA’s) provides explanations and models to help operators understand and appreciate the principles of physics which make Powered Industrial Trucks (PITs) particularly hazardous.

The Other Part of Operator Training Non-Mandatory Appendix: (para 296-24-23037) Definitions General Basic Principles The Stability Triangle Longitudinal Stability Lateral Stability Dynamic Stability

Effective Date March 1, 2000 Employer must ensure operators are trained, as appropriate, by the effective date of this section. Employees hired on or after the effective date of this section must be trained and evaluated prior to being assigned to operate a powered industrial truck. -No WISHA Special Emphasis Program is anticipated at this time.

Other Industry Standards Affected WAC 296-56 Longshore, Stevedore and Related Waterfront WAC 296-155 Construction WAC 296-307 Agriculture

WHY? Since a large percentage of accidents and fatalities were due to operator inexperience, OSHA mandated that operators must be trained and competent.

Forklift Fatalities By Percentages

Forklift Accidents By Percentage

Overview of Requirements Employers must ensure operators are: Trained Competent Documented Note: WISHA uses the term “Documented”. The word “Certified” is not used in the WISHA standard to avoid implying that the employers must hire or contract out training. 1) Must have completed a structured formal training program initial refresher every 3 years or as required 2) Combination of formal practical evaluation in workplace 3) Trainers must have the knowledge, training and experience to train and evaluate operators. 4) Operators must be evaluated in workplace and must continue to perform safely.

Training Program Implementation (a) Trainees may operate a powered industrial truck only: (i) under the direct supervision of persons who have the knowledge, training and experience to train operators and evaluate their competence; and (ii) Where such operation does not endanger the trainee or other employees

Training must consist of a combination of: 1. Formal Instruction 2. Practical Training 3. Evaluation

Practical Training Practical Exercise by Student Instructor or designee Demonstration Example

Training Program Content

Training Program Content WAC 296-24-23025(3 “… operators must receive initial training in the topics that follow, except in topics that the employer can demonstrate are not applicable to safe operation of the truck in the employer’s workplace.” (a) Truck-related topics (b) Workplace-related topics

Training Program Content Truck-related topics General principles Specific to type Specific to forks or attachments

Overview of Truck-Related Topics General principles “Must receive” from -296-24-23025(3)(a): Operation instructions, warnings, and precautions for the types of truck the operator will be authorized operate; Differences between the truck and the automobile Truck controls and instrumentation: where they are located, what they do, and how they work Engine or motor operation Steering & maneuvering

Overview of Truck-Related Topics - Continued Visibility Fork and attachment adaptation, operation and use limitations Vehicle capacity Vehicle stability Operator-performed inspection & maintenance Refueling and/or battery charging Operation limitations Any other operation instructions, warning, or precautions

Overview of Truck-Related Topics - Continued General principles “Must receive” from -296-24-23025(3)(a) Non-mandatory appendix at 296-24-23037 Definitions related to stability Basic principles The Stability Triangle Longitudinal Stability Lateral Stability Dynamic Stability

Truck-Related Topics What each covers: For Example: “Must receive” from WAC 296-24-23025(3)(a) Fork and attachment adaptation, operation and use limitations Non-mandatory appendix How fork and attachment adaptations change the forklift’s steering characteristics and stability

Truck-Related Topics “Must receive” from WAC296-24-23025(3)(a): Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate General instructions for forklifts General safety items Listed in the operator’s manual

Example from an Operator’s Manual

Another Example from an Operator’s Manual

Truck-Related Topics Differences between the truck and automobile Suggested contents in non-mandatory appendix: 296-24-23037. Rear wheel steering Rear of truck swings out on turns Truck has triangular stability, not four-point Truck may have smaller size, but can have six times the weight!

Truck-Related Topics Truck controls and instrumentation where they are located what they do how they work

Truck-Related Topics Engine or motor operation

Truck-Related Topics Steering and maneuvering

Truck-Related Topics Visibility (including restrictions due to loading)

Truck-Related Topics Other items requiring training: other attachments carton grabbers barrel grabbers barrel grabbers which rotate

Truck-Related Topics Changes in attachments different capabilities of attachment: e.g. from single reach to double reach order picker changes in operator controls how change in attachment affects capacity how change in attachment affects stability

Truck-Related Topics Specific to forks or attachments

Truck-Related Topics Specific to forks or attachments Another example from Operator’s Manual

Truck-Related Topics Specific to forks or attachments

Truck-Related Topics Vehicle capability includes manufacturer’s plate includes charts indicating de-rating at mast height, etc

The “Quick Check”on what the operator knows: Truck-related topics Can read and explain entries on the name plate

The “Quick Check” on what the operator knows: An older kind of plate:

The “Quick Check” on what the operator knows: Again: Can they read and interpret?

The “Quick Check” on what the operator knows: Truck-related topics Can read and explain entries on the name plate Can locate, explain & interpret specification charts on capacity

Truck-Related Topics Vehicle stability Non-mandatory appendix: 296-24-23037 contains diagrams to explain the concept. Other diagrams in OSHA training program, on the Internet: www.osha-slc.gov/Training/PIT

Stability of Powered Industrial Trucks Non-mandatory Appendix 296-24-23027 (1) Definitions to help explain the principle of stability (2) General principles of stability (3) Basic principles - the “physics” of stability; momentum, inertia, gravity (4) The Stability Triangle

Stability of Powered Industrial Trucks The Stability Triangle (5) Longitudinal Stability (6) Lateral Stability

Stability of Powered Industrial Trucks The Stability Triangle (5) Longitudinal Stability (6) Lateral Stability Load CG Load CG Vertical Stability Line (Line of Action) Combined CG Combined CG Vertical Stability Line (Line of Action) Truck CG Truck CG This vehicle is unstable and will continue to tip over The vehicle is stable

Truck-Related Topics 296-24-23025 (3) (a) “Any vehicle inspection and maintenance that the operator will be required to perform.” Should be conducted per manufacturer’s specs: Vehicle condition Condition and thickness of forks Condition of hoses, mast chains, hydraulic rams Effectiveness of parking brake Tire inflation All other listed inspection points 5 year inspection data: 0f 813 citations from 296-24-239, 205 of them (that’s about 25%!) relate to PIT’s being used when unsafe conditions exist -- trucks defective, trucks needing repairs but not taken out of service, etc.

Example: In the simplest form….

Another example:

And another example...

Example

.. To some very specific, detailed items.

Example

Example

Example from OSHA: osha-slc.gov/Training/PIT/pit_checklist.html DAILY INSPECTION CHECKLIST Electric Forklift Truck KEY OFF Procedures •Overhead guard •Hydraulic cylinders •Mast assembly •Lift chains and rollers •Forks •Tires •Examine the battery •Check the hydraulic fluid level KEY ON Procedures •Check the gauges •Hour meter •Battery discharge indicator •Test the standard equipment •Steering •Brakes •Front, tail, and brake lights •Horn •Safety seat (if equipped) •Check the operation of load-handling attachments

Truck-Related Topics 296-24-23025 (3) (a) Refueling and/or charging and recharging of batteries LP bottles Battery charging facilities

Workplace-Related Topics 296-24-23025 (3) (a) Ramps and other sloped surfaces Dock boards Bridge plates

Truck-Related Topics 296-24-23025 (3) (a) “Any other operating instructions, warnings, or precautions listed in the operator’s manual for the types of vehicle that the employee is being trained to operate”

Training Program Content Truck-related topics: 296-24-23025 (3) (a) Workplace-related topics 296-24-23025 (3) (b)

Overview of Workplace-Related Topics 296-24-23025 (3) (b) Surface conditions Composition of loads Load manipulation Pedestrian traffic Narrow aisles and other restricted places Hazardous locations Ramps & other sloped surfaces Potential carbon monoxide hazard locations Other unique or potentially hazardous conditions -Mandatory Requirement -During this presentation, I will occasionally be making references to the non-mandatory appendix (WAC 296-24-2303) for additional information.

Workplace-Related Topics 296-24-23025 (3) (b) Surface conditions: Type(s) of normal driving surface Performance of truck’s tires on normal surface Surface conditions which may be encountered Water, snow, ice Effects on traction, stopping ability Uneven ground and/or potholes Effects on stability Gravel

Workplace-Related Topics 296-24-23025 (3) (b) Composition of loads to be carried Examples, from Non-mandatory appendix 296-24-23037: Irregular shaped loads and/or protrusions Changes to Center Of Gravity Partially filled containers of liquid

Workplace-Related Topics 296-24-23025 (3) (b) Load manipulation, stacking and unstacking For example: Reducing damage to powered industrial truck Avoiding stresses to forks from overload Welds on forks Detection of broken or defective pallets, or pallets with improper repairs

Workplace-Related Topics 296-24-23025 (3) (b) Pedestrian traffic in areas where vehicle will be operated

Importance of training on pedestrian traffic: * * Important reminder that the driver is always the one responsible; never the pedestrian!

Workplace-Related Topics 296-24-23025 (3) (b) Narrow aisles Other restricted places; per existing paragraph 296-24-23027(7) including the inside of semi-truck trailers including the inside of railroad cars

Workplace-Related Topics 296-24-23025 (3) (b) - Hazardous (classified) locations Ref: 296-24-23005 for 11 different designations of powered industrial truck appropriate to locations with explosive/combustible atmospheres

Workplace-Related Topics 296-24-23025 (3) (b) Potential carbon monoxide hazard locations Closed environments Insufficient ventilation Poor vehicle maintenance

Workplace-Related Topics 296-24-23025 (3) (b) “Other unique or potentially hazardous environmental conditions…” Per BLS data: 8% of all fatalities involving forklifts are from “driving off loading dock”

General Workplace Safety Item: One of the most common, yet most hazardous, practices is having people riding on the forks!! This should be addressed in all training programs

When Is Refresher Training Required?

Refresher Training To Begin with: WAC 296-24-23025(4) To Begin with: 296-24-23025(4)(C) An evaluation of each operator’s performance must be conducted at least once every three years…..to determine if they require refresher training.

Refresher Training and is evaluated and found competent, If the operator received all required training truck-related workplace-related and is evaluated and found competent, no refresher training is required

Refresher Training Is Required When the operator has been observed to operate the vehicle in an unsafe manner How do you know? Incident reports Safety committee minutes Maintenance reports Equipment damage “Shipping damage” Employee complaints

Refresher Training Is Required The operator has been involved in an accident or near-miss incident require additional training. documented accidents which don’t have corresponding documentation of refresher training and evaluation are asking for trouble!

“Quick Check” On Performance of Refresher Training: - What mechanism does the company have in place for: Maintenance to report driver-caused damage? Anyone to report a “near miss”?

“Quick Check” On Performance of Refresher Training: Bent support Does the supervisor know who caused the damage? Was follow-up evaluation and/or training documented?

Refresher Training Is Required Operator has received an evaluation that reveals the operator is not operating the truck safely. Evaluation must be documented.

Refresher Training Is Required When the operator is assigned to drive a different type of truck: Are there differences? Are they significant?

Refresher Training Is Required When a condition in the workplace changes in a manner that could affect safe operation of the truck. Operations Products/packaging Construction/remodeling Hundreds of other variables Must be documented.

Avoidance of Duplicative Training WAC 296-24-23025(5) If an operator has previously received training in a topic specified in (3) of this section, and such training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely, within three years.

Required Documentation WAC 296-24-23025(6) Operator’s name Date of training Date of evaluation Identity of trainer/evaluator Strongly recommended: outline of topics - both truck-specific and workplace-specific

Operator Restraints WAC 296-24-23027 Powered industrial truck operations Rule of thumb: Any sit down model of powered industrial truck manufactured since 1993 is required to have an operator restraint provided by the manufacturer.

296-24-23027(15) An active operator protection restraint device (such as a seatbelt or lap-bar) or system must be used, when provided.

Older Models We don’t require retrofit of operator restraints But once they’ve been added they must be maintained and used

Other changes to the standard

This WRD has been included in the standard WRD 78-25A Forklift-type Equipment Used by “Order Pickers.” This WRD has been included in the standard

Powered industrial trucks used as order pickers ... which do not have standard guardrails on all open sides, must be equipped with an approved fall arrest system

Order Pickers Acceptable fall protection

Order Pickers Not acceptable fall protection

Summary Topics Covered: Clear Rule Writing Operator Training Requirement Operator Restraints Order Pickers

We acknowledge the cooperation of: CB Equipment Co, Kent Hyster Sales and Service, Tukwila Bottom Line Loss Control Valley Rentals, Tumwater Home Depot, Lacey Ivy Hi-Lift, Tacoma Nordic Cold Storage, Seattle

End of Presentation

Components of a Forklift Truck* *One of the most common types of powered industrial trucks

Classes of Commonly-Used Powered Industrial Trucks* The Industrial Truck Association has placed powered industrial trucks into 7 classes. Class I - Electric motor rider trucks Class II - Electric motor narrow aisle trucks Class III - Electric motor hand trucks or hand/rider trucks Class IV - Internal combustion engine trucks (solid/cushion tires) Class V - Internal combustion engine trucks (pneumatic tires) Class VI - Electric and internal combustion engine tractors Class VII - Rough terrain forklift trucks * Note that this classification refers to commonly-used vehicles and does not include all powered industrial trucks covered by the OSHA standard.

Class I - Electric Motor Rider Trucks Counterbalanced rider type, stand up Three wheel electric trucks, sit-down Counterbalanced rider type, cushion tires, sit-down (high and low platform) Counterbalanced rider, pneumatic tire, sit-down (high and low platform)

Refresher Training Is Required When the operator is assigned to drive a different type of truck:

Refresher Training Is Required When the operator is assigned to drive a different type of truck: Are there differences? Are they significant?

Class I - Electric Motor Rider Trucks

Class I - Electric Motor Rider Trucks Counterbalanced Rider Type, Stand-Up

Truck Classifications Specific to type Type I: Sit-down rider, electric

Class II - Electric Motor Narrow Aisle Trucks High lift straddle Order picker Reach type outrigger Side loaders, turret trucks, swing mast and convertible turret/stock pickers Low lift pallet and platform (rider)

Class II - Electric Motor Narrow Aisle Trucks

Class II - Narrow Aisle Trucks

Truck Classifications Specific to type Type II: Electric, narrow-aisle

Class III - Electric Motor Hand or Hand/Rider Trucks Low lift platform Low lift walkie pallet Reach type outrigger High lift straddle High lift counterbalanced Low lift walkie/rider pallet

Class III - Electric Motor Hand or Hand/Rider Trucks

Class III - Hand & Hand/Rider Trucks

Truck Classifications Specific to type Type III: Electric pallet jack

Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires Fork, counterbalanced (cushion/solid tires)

Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires

Class V - Internal Combustion Engine Trucks - Pneumatic Tires Fork, counterbalanced (pneumatic tires)

Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

Truck Classifications Specific to type Type V: Internal combustion, pneumatic tire

Class VI - Electric & Internal Combustion Engine Tractors Sit-down rider

Class VII - Rough Terrain Forklift Trucks Straight-mast forklift Extended-reach forklift All rough terrain forklift trucks

Rough Terrain Straight Mast Forklifts

Rough Terrain Extended-Reach Forklifts

Forklifts and Other Powered Industrial Trucks Department of Labor and Industries WISHA Services Training and Outreach