Slide1 : 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
Slide2 : 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
Slide3 : “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”? : 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? : 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” : 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”
“Turning technique no longer specified” : “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.” The Old Way - The New Way
Operator Training : Operator Training Mandatory portion: WAC 296-24-23025
Non-Mandatory Appendix: WAC 296-24-23037
Slide14 :
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
Slide15 : 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 : 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.
Other Industry Standards Affected : Other Industry Standards Affected WAC 296-56 Longshore, Stevedore and Related Waterfront
WAC 296-155 Construction
WAC 296-307 Agriculture
Slide18 : 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 Fatalities By Percentages
Forklift Accidents By Percentage : Forklift Accidents By Percentage
Overview of Requirements : Overview of Requirements Employers must ensure operators are:
Trained
Competent
Documented
Training Program Implementation : 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 296-24-23025(2)(a)
Training must consist of a combination of: : Training must consist of a combination of: 1. Formal Instruction
2. Practical Training
3. Evaluation
296-24-23025(2)(b)
Practical Training : Practical Training Instructor or designee Demonstration Practical Exercise by Student
Training Program Content : Training Program Content “… 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 WAC 296-24-23025(3
Slide27 : Truck-related topics
General principles
Specific to type
Specific to forks or attachments
Overview of Truck-Related Topics : 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 : 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 296-24-23025(3)(a)
Overview of Truck-Related Topics - Continued : 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: : 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
Truck-Related Topics : 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
Slide33 : Example from an Operator’s Manual
Slide34 : Another Example from an Operator’s Manual
Truck-Related Topics : 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-Related Topics Truck controls and instrumentation
where they are located
what they do
how they work
Truck-Related Topics : Truck-Related Topics Engine or motor operation
Truck-Related Topics : Truck-Related Topics Steering and maneuvering
Truck-Related Topics : Truck-Related Topics Visibility (including restrictions due to loading)
Truck-Related Topics : Truck-Related Topics Other items requiring training:
other attachments
carton grabbers
barrel grabbers
barrel grabbers which rotate
Truck-Related Topics : 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 : Truck-Related Topics Specific to forks or attachments
Truck-Related Topics : Truck-Related Topics Specific to forks or attachments Another example from Operator’s Manual
Truck-Related Topics : Truck-Related Topics Specific to forks or attachments
Truck-Related Topics : Truck-Related Topics Vehicle capability
includes manufacturer’s plate
includes charts indicating de-rating at mast height, etc
Slide47 : Truck-related topics
Can read and explain entries on the name plate The “Quick Check”on what the operator knows:
Slide48 : An older kind of plate: The “Quick Check” on what the operator knows:
Slide49 : Again: Can they read and interpret? The “Quick Check” on what the operator knows:
Slide50 : Truck-related topics
Can read and explain entries on the name plate
Can locate, explain & interpret specification charts on capacity
The “Quick Check” on what the operator knows:
Truck-Related Topics : 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 : Stability of Powered Industrial Trucks (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 Non-mandatory Appendix 296-24-23027
Stability of Powered Industrial Trucks : Stability of Powered Industrial Trucks The Stability Triangle
(5) Longitudinal Stability
(6) Lateral Stability
Slide54 : Load CG Vertical
Stability
Line
(Line of Action) Combined CG Truck CG Load CG Combined CG Vertical
Stability
Line
(Line of Action) Truck CG The vehicle is stable This vehicle is unstable and
will continue to tip over Stability of Powered Industrial Trucks The Stability Triangle
(5) Longitudinal Stability
(6) Lateral Stability
Truck-Related Topics 296-24-23025 (3) (a) : 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
Slide56 : Example: In the simplest form….
Slide57 : Another example:
Slide58 : And another example...
Slide59 : Example
Slide60 : .. To some very specific, detailed items.
Slide61 : Example
Slide62 : Example
Slide63 : 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) : 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) : 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) : 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 : 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) : 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
Workplace-Related Topics 296-24-23025 (3) (b) : 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) : 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) : 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) : Workplace-Related Topics 296-24-23025 (3) (b) Pedestrian traffic in areas where vehicle will be operated
Importance of training on pedestrian traffic: : 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) : 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 : 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) : 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) : 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: : 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
Refresher Training : Refresher Training 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.
WAC 296-24-23025(4)
Refresher Training : Refresher Training
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 : 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 : 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: : “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: : “Quick Check” On Performance of Refresher Training: Does the supervisor know who caused the damage?
Was follow-up evaluation and/or training documented? Bent support
Refresher Training Is Required : Refresher Training Is Required Operator has received an evaluation that reveals the operator is not operating the truck safely.
Refresher Training Is Required : 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 : 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
Avoidance of Duplicative Training WAC 296-24-23025(5) : 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 : 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 WAC 296-24-23025(6)
Operator Restraints WAC 296-24-23027 Powered industrial truck operations : 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.
Slide92 : 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 : Older Models But once they’ve been added they must be maintained and used We don’t require retrofit of operator restraints
Slide95 : 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 : 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 : Order Pickers Acceptable fall protection
Order Pickers : Order Pickers Not acceptable fall protection
Slide99 : Topics Covered:
Clear Rule Writing
Operator Training Requirement
Operator Restraints
Order Pickers
We acknowledge the cooperation of: : 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 : End of Presentation
Components of a Forklift Truck* : Components of a Forklift Truck* *One of the most common types of powered industrial trucks
Classes of Commonly-Used 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 : 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 : Refresher Training Is Required When the operator is assigned to drive a different type of truck:
Refresher Training Is Required : Refresher Training Is Required Are there differences?
Are they significant? When the operator is assigned to drive a different type of truck:
Class I - Electric Motor Rider Trucks : Class I - Electric Motor Rider Trucks
Class I - Electric Motor Rider Trucks : Class I - Electric Motor Rider Trucks Counterbalanced Rider Type, Stand-Up
Truck Classifications : Truck Classifications Specific to type
Type I: Sit-down rider, electric
Class II - Electric Motor Narrow Aisle Trucks : 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 - Electric Motor Narrow Aisle Trucks
Class II - Narrow Aisle Trucks : Class II - Narrow Aisle Trucks
Truck Classifications : Truck Classifications Specific to type
Type II: Electric, narrow-aisle
Class III - Electric Motor Hand or Hand/Rider Trucks : 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 - Electric Motor Hand or Hand/Rider Trucks
Class III - Hand & Hand/Rider Trucks : Class III - Hand & Hand/Rider Trucks
Truck Classifications : Truck Classifications Specific to type
Type III: Electric pallet jack
Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires : Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires Fork, counterbalanced (cushion/solid tires)
Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires : Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires
Class V - Internal Combustion Engine Trucks - Pneumatic Tires : Class V - Internal Combustion Engine Trucks - Pneumatic Tires Fork, counterbalanced (pneumatic tires)
Class V - Internal Combustion Engine Trucks (Pneumatic Tires) : Class V - Internal Combustion Engine Trucks (Pneumatic Tires)
Truck Classifications : Truck Classifications Specific to type
Type V: Internal combustion, pneumatic tire
Class VI - Electric & Internal Combustion Engine Tractors : Class VI - Electric & Internal Combustion Engine Tractors Sit-down rider
Class VII - Rough Terrain Forklift Trucks : Class VII - Rough Terrain Forklift Trucks Straight-mast forklift Extended-reach forklift All rough terrain forklift trucks
Rough Terrain Straight Mast Forklifts : Rough Terrain Straight Mast Forklifts
Rough Terrain Extended-Reach Forklifts : Rough Terrain Extended-Reach Forklifts
Slide127 : Forklifts and Other Powered Industrial Trucks Department of Labor and Industries
WISHA Services Training and Outreach