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

2. 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

3. 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

4. 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]

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

6. Is This A “Powered Industrial Truck”

7. Is This A “Powered Industrial Truck”

8. Is This A “Powered Industrial Truck”

9. Is This A “Powered Industrial Truck”

10. Is This A “Powered Industrial Truck”

11. "Clear Rule Writing"

12. “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.”

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

14. 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 – 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.

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

16. 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.

17. Other Industry Standards Affected
WAC Longshore, Stevedore and Related Waterfront
WAC Construction
WAC Agriculture

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

19. Forklift Fatalities By Percentages

20. Forklift Accidents By Percentage

21. 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.

22. 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

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

24. Practical Training Practical Exercise by Student
Instructor or designee Demonstration
Example

25. Training Program Content

26. Training Program Content
WAC (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

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

28. Overview of Truck-Related Topics
General principles
“Must receive” from (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

29. 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

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

31. Truck-Related Topics What each covers:
For Example:
“Must receive” from WAC (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

32. 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

33. Example from an Operator’s Manual

34. Another Example from an Operator’s Manual

35. Truck-Related Topics Differences between the truck and automobile
Suggested contents in non-mandatory appendix:
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!

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

38. Truck-Related Topics
Engine or motor operation

39. Truck-Related Topics
Steering and maneuvering

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

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

42. 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

43. Truck-Related Topics
Specific to forks or attachments

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

45. Truck-Related Topics
Specific to forks or attachments

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

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

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

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

50. 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

51. Truck-Related Topics Vehicle stability
Non-mandatory appendix: contains
diagrams to explain the concept.
Other diagrams in OSHA training program,
on the Internet:

52. Stability of Powered Industrial Trucks
Non-mandatory Appendix
(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

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

54. 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

55. 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 , 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.

56. Example: In the simplest form….

57. Another example:

58. And another example...

59. Example

60. .. To some very specific, detailed items.

61. Example

62. Example

63. 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

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

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

66. 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”

67. Training Program Content
Truck-related topics: (3) (a)
Workplace-related topics
(3) (b)

68. 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 ) for additional information.

69. 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

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

71. 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

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

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

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

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

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

77. 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”

78. 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

79. When Is
Refresher
Training
Required?

80. Refresher Training To Begin with:
WAC (4)
To Begin with:
(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.

81. 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

82. 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

83. 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!

84. “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”?

85. “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?

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

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

88. 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.

89. 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.

90. Required Documentation
WAC (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

91. 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.

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

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

94. Other changes
to the
standard

95. 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

96. 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

97. Order Pickers
Acceptable fall protection

98. Order Pickers
Not acceptable fall protection

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

100. 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

101. End of Presentation

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

103. 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.

104. 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)

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

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

107. Class I - Electric Motor Rider Trucks

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

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

110. 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)

111. Class II - Electric Motor Narrow Aisle Trucks

112. Class II - Narrow Aisle Trucks

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

114. 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

115. Class III - Electric Motor Hand or Hand/Rider Trucks

116. Class III - Hand & Hand/Rider Trucks

117. Truck Classifications
Specific to type
Type III: Electric pallet jack

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

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

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

121. Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

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

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

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

125. Rough Terrain Straight Mast Forklifts

126. Rough Terrain Extended-Reach Forklifts

127. Forklifts and Other Powered Industrial Trucks
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