Forklifts and Other Powered Industrial Trucks WAC 296

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 1

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 2

• “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 3

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] 4

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

Is This A “Powered Industrial Truck” 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

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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. ” 12

Operator Training Mandatory portion: WAC 296 -24 -23025 Non-Mandatory Appendix: WAC 296 -24 -23037 13

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 14

The Other Part of Operator Training Non-Mandatory Appendix: (para 296 -2423037) • Definitions • General • Basic Principles • The Stability Triangle • Longitudinal Stability • Lateral Stability • Dynamic Stability 15

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. 16

Other Industry Standards Affected WAC 296 -56 Longshore, Stevedore and Related Waterfront WAC 296 -155 Construction WAC 296 -307 Agriculture 17

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

Forklift Fatalities By Percentages 19

Forklift Accidents By Percentage 20

Overview of Requirements Employers must ensure operators are: • Trained • Competent • Documented 21

Training Program Implementation 296 -24 -23025(2)(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 22

296 -24 -23025(2)(b) Training must consist of a combination of: 1. Formal Instruction 2. Practical Training 3. Evaluation 23

Practical Training Instructor or designee Demonstration Practical Exercise by Student 24

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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 26

Truck-related topics • General principles • Specific to type • Specific to forks or attachments 27

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 28

Overview of Truck-Related Topics - Continued 296 -24 -23025(3)(a) � 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 29

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 30

Truck-Related Topics What each covers: “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 31

Truck-Related Topics “Must receive” from WAC 296 -24 -23025(3)(a): – Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate • General instructions forklifts • General safety items • Listed in the operator’s manual 32

Example from an Operator’s Manual 33

Another Example from an Operator’s Manual 34

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! 35

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

Truck-Related Topics Engine or motor operation 38

Truck-Related Topics Steering and maneuvering 39

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

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

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 42

Truck-Related Topics Specific to forks or attachments 43

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

Truck-Related Topics Specific to forks or attachments 45

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

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

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

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

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 50

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 51

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 52

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

Stability of Powered Industrial Trucks The Stability Triangle (5) Longitudinal Stability (6) Lateral Stability Load CG Vertical Stability Line (Line of Action) Combined CG Truck CG The vehicle is stable Truck CG Vertical Stability Line (Line of Action) This vehicle is unstable and will continue to tip over 54

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 55

Example: In the simplest form…. 56

Another example: 57

And another example. . . 58

Example 59

. . To some very specific, detailed items. 60

Example 61

Example 62

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 63

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

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

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” 66

Training Program Content Truck-related topics: 296 -24 -23025 (3) (a) Workplace-related topics 296 -24 -23025 (3) (b) 67

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 68

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 69

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 70

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 71

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

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

Workplace-Related Topics 296 -24 -23025 (3) (b) Narrow aisles Other restricted places; per existing paragraph 296 -2423027(7) – including the inside of semitruck trailers – including the inside of railroad cars 74

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 75

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

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” 77

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 78

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Refresher Training 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. 80

Refresher Training If the operator received all required training – truck-related – workplace-related and is evaluated and found competent, no refresher training is required 81

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 82

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! 83

“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”? 84

“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? 85

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

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

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 88

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. 89

WAC 296 -24 -23025(6) Required Documentation • Operator’s name • Date of training • Date of evaluation • Identity of trainer/evaluator * Strongly recommended: outline of topics - both truck-specific and workplace-specific 90

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. 91

296 -24 -23027(15) An active operator protection restraint device (such as a seatbelt or lap-bar) or system must be used, when provided. 92

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

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WRD 78 -25 A Forklift-type Equipment Used by “Order Pickers. ” This WRD has been included in the standard 95

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 96

Order Pickers Acceptable fall protection 97

Order Pickers Not acceptable fall protection 98

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

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 100

End of Presentation 101

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

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. 103

Class I - Electric Motor Rider Trucks Counterbalanced rider type, stand up Three wheel electric trucks, sit-down Counterbalanced rider type, cushion tires, sitdown (high and low platform) Counterbalanced rider, pneumatic tire, sitdown (high and low platform) 104

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

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

Class I - Electric Motor Rider Trucks 107

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

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

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) 110

Class II - Electric Motor Narrow Aisle Trucks 111

Class II - Narrow Aisle Trucks 112

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

Class III - Electric Motor Hand/Rider Trucks Low lift platform Low lift walkie pallet Reach type outrigger High lift straddle High lift counterbalanced Low lift walkie/rider pallet 114

Class III - Electric Motor Hand/Rider Trucks 115

Class III - Hand & Hand/Rider Trucks 116

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

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

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

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

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

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

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

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

Rough Terrain Straight Mast Forklifts 125

Rough Terrain Extended. Reach Forklifts 126

Forklifts and Other Powered Industrial Trucks Department of Labor and Industries WISHA Services Training and Outreach 127