Forklift Guide & Register

FORKLIFT SAFETY GUIDE & REGISTER

Learning the safe way to operate a forklift may save your life

goscorlifttrucks.co.za

World Class Products.

First Class Service Forklifts & Warehousing Specialists trusted since 1984.

WE OFFER • New Sales • Short- and Long-Term Rentals • Pre-owned Equipment • Parts and back-up support World-class, industry-leading forklift brands available direct to you – Competitively priced and quality guaranteed.

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Sole distributors for Bendi, Crown, Doosan and Sunlight batteries

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Diverse forklift and warehousing product range

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Best practice industrial warehousing equipment and solutions

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Lowest cost of ownership when purchasing our equipment

National footprint with branches in: Johannesburg (Head Office) | Cape Town | Durban | Pietermaritzburg | Port Elizabeth | East London | Bloemfontein | Nelspruit

FORKLIFT GUIDE INTRODUCTION 4 All you need to know about Masslift Africa 6 Occupational Health And Safety Act, 1993 driven machinery regulations, 2015

REGISTER GUIDE

INTRODUCTION 1 Daily and pre-operational 2

Operator training

3

Forklift inventory list

4

Daily and pre-operational checklist

20

Deviation detected and corrective actions (daily)

LOAD TESTING 12 Load Testing a forklift

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6 Monthly inspection list

24

Deviation detected and corrective actions (daily)

FORKLIFTS SIGNALS 14 Basic forklift hand signals every operator should know

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Annual performance test results

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Modifications & repairs

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Register: forklift trucks

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Notes

FORKLIFTS SAFETY 8 Operating a forklift safely 10 Warehouse safety tips

FORKLIFTS WEIGHT 16 Estimating the load weight 17 Why do forklifts weigh so much?

TYPES OF FORKLIFTS 18 Types of forklifts FORKLIFTS 20 Should you buy or rent a forklift 22 How to get your forklift license MAINTENANCE 23 How a good maintenance contract will save you money 24 Do’s and Don’ts on a forklift 26 When to repair or replace your forklift BATTERY 28 How to test battery capacity for your forklift 30

EXSTRA ARTICLES

RACKING AND SHELVING PG Centerspread

Copyright © 2022 Lifting Africa All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without permission in writing from the publisher.

Lifting Africa - Forklift Guide & Register

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ADVERTORIAL

All you need to know about Masslift Africa Masslift Africa is the sole distributor of Mitsubishi forklifts in Southern Africa. Since the company’s founding, Masslift has strived to demonstrate how a South African forklift company can play an integral part in the growth and development of South Africa’s economy and people.

I know nothing about a forklift, except that i need one!

Where do i start?

There are a few questions we’d need to be answered in order to spec you the correct forklift: 1) What is the maximum weight you will be lifting?

2) What height do you need to lift your load to?

3) What is the maximum weight at the maximum height?

4) What are the approximate dimensions of your load (width x length x breadth) 5) Do you have any overhead height restrictions?

6) What type of surface will the forklift be working on?

7) What type of fuel do you want? (LPG, Diesel, or electric battery powered.)

Do you sell used forklifts?

Yes we do!

Can i lease/rent a forklift?

Yes, we have a number of different options for rental/ lease and outright purchase of forklifts.

Short Term (1 day to 12 months) Long Term (12 months – 84 months) Can i buy parts for new and old forklifts?

Yes. Most forklift manufacturers and their dealers carry parts for forklifts up to 10 years old.

However, Mitsubishi Forklift has a “vintage” forklift program that enables their dealers to obtain engine and transmission spares for much older forklifts.

If i need technical help on a forklift what should i do?

You should call us at the office on 087 150 8575 or visit our website How do diesel & petrol/lp gas forklift performance

compare with electric powered forklifts?

IC forklifts outperform electric forklifts in both indoor and outdoor applications. They have demonstrated the ability to lift, push and pull heavy loads at full capacity, up and down inclines, for longer periods and with improved ground speed when compared with electric forklifts.

This is not to say that electrics are not robust and reliable, it is just our opinion that an IC forklift is stronger.

What does my all in maintenance contract include and exclude?

The contract includes servicing, repairs and maintenance of the equipment according to the manufacturer’s specifications, provided such repair or maintenance is a direct result of a latent defect or fair wear and tear. Where the equipment breaks down for any other reason, such as collision, impact, fire, flood, misuse or abuse, this is excluded from the contract.

What is a PMA? A Preventative Maintenance agreement is a service plan, which covers all your costs related to services.

You pay a flat rate per service. Any repairs outside of standard service work would be quoted at a discounted rate for PMA customers.

What is a ninja and will it help me pick up the ladies?

The Ninja is Mitsubishi’s answer to a robust, reliable forklift with minimal electronics and at a ridiculously low cost. You can pick up anything with a Mitsubishi Forklift Truck.

How often must i service my forklift?

Mitsubishi Forklift Trucks are manufactured with quality materials under the strictest engineering conditions; this confidence in the product allows your machine to only be serviced every 500 hours or 5 months, whichever occurs first, unlike the industry standard of every 250 hours.

What is the warranty on a Mitsubishi Forklift?

The standard warranty on a Mitsubishi Forklift is 12 months or 2000 hours. Mitsubishi then offers an extended powertrain warranty, which extends to 36 months or 5000 hours.

The terms of the warranty are that Mitsubishi Forklift Trucks will replace any defective major powertrain

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Lifting Africa Africa -- Forklift Forklift Safety Guide & Register Lifting Guide & Registration

ADVERTORIAL

component that fails on a new Mitsubishi Forklift.

Mitsubishi only uses genuine Mitsubishi forklift parts assuring you the best in quality and reliability.

If i drive a ninja forklift, will i have all the abilities of a ninja? Most importantly, will i have the ability to disappear in a cloud of smoke?

The Mitsubishi Ninja does not smoke – you will have to provide your own smoke machine if you are into that kind of thing.

What is an attachment and can i fit it to my forklift?

Attachments are anything that is not standard on a forklift eg: side shifters, paper roll clamps, and carpet poles to name a few.

The answer is yes, these can be bought or manufactured to fit any Mitsubishi Forklift Truck, depending on the attachment you might require additional hydraulic hosing to get all the features to work together. Please contact us for any further info or for an attachment quote Why do i need a load test certificate for my forklift and can you do them for me?

In terms of Local legislation, all forklifts must undergo a Load Test every 12 months. It is up to the owner / LT renter of the forklift to ensure this happens in due course. We use independent load test companies however we can arrange a quote for you.

What types of forklifts does Masslift Africa sell?

We offer Material Handling Equipment to meet almost any logistic requirement. With the sole dealerships for Mitsubishi Forklifts we can supply: Diesel & Petrol/LP Gas Forklifts (1,8 – 15 tons.)

Counter Balance Electrics (1.0 – 3.0 tons.)

Warehouse Equipment (Power pallet trucks / Reach Trucks / Order Pickers & Stackers.)

Can you service my current forklifts?

Yes we can. You just need the details of your current forklift handy in order for us to quote accordingly.

Does the Mitsubishi Forklift comply with emission standards?

The Mitsubishi Grendia (or Green Diamond) fuel efficient and has ultra low emissions, which either complies with or exceeds the latest international (USA, Europe, Japan) environmental standards.

How can i improve on tyre wear?

Mitsubishi Forklift Trucks can offer you a transmission

protection system that reduces your tyre wear by not allowing your driver to wheel spin or change direction without effectively using the brakes.

Do you offer a fleet management system?

Yes, we have complete solution to manage your fleet requires that can monitor the utilization, abuse and daily checks to name a few.

Can i operate my electric forklift in the rain?

Yes, Mitsubishi Forklift Trucks come with an IPX3/4 rating which means they can operate in light-medium rain.

Do you need a license to drive a forklift and can you train my drivers?

Yes, current legislation requires that all forklift operators are certified and licensed. A forklift license needs to be renewed every 24 months. Masslift Africa can provide your drivers with a comprehensive overview on the machine features and functions. We do however refer customers to reputable certified licensing centres.

Can you provide cold storage solutions?

Yes, we can manage all your cold store requirements.

Can you sell me a flame-proof forklift for hazardous areas?

Yes, we can manage all your flame-proofing requirements.

Masslift Africa, +27 (0) 11 786 8524, sales@mlift.co.za, www.mitsubishiforklifts.co.za Lifting Africa Africa -- Forklift Forklift Safety Guide & Register 5 Lifting Guide & Registration

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INTRODUCTION

Occupational Health And Safety Act, 1993 driven machinery regulations, 2015 The contractor, employer, user or manager should adhere to the legal requirements regarding the safe use of forklifts as set out in the Occupational Health and Safety Act and Mine Health and Safety Act. All Forklifts require regular checking and testing at routine intervals. The result must be entered in a register and logbook designed for this purpose.

This Forklift Guide and Register includes detailed task descriptions of the work and provision for control by the responsible person. Inspections must include all working parts of the forklift to be thoroughly examined and subjected to a performance test, as prescribed by the standard to which the forklift was manufactured, by a person who has knowledge and experience of the erection and maintenance of the type of lifting machine involved or similar machine.

Notes: The definition listed the exclusions,Power-driven machines means that a machine is powered by any energy source excluding manpower.

“Lift Truck” means a mobile lifting machine, but does not include • A vehicle designed solely for the purpose of lifting or towing another vehicle.

• A mobile earth -moving machine; or • A vehicle designed solely for the removal of a waste bin.

Definitions “Lifting Machine” means a power- driven machine that is designed and constructed for the purpose of raising or lowering a load or moving it in suspension, but does not include an elevator, escalator or hand -powered lifting device.

This machine is generally known as a forklift • “Lifting Machinery Inspector” means a person who is employed by a Lifting Machinery Entity and who is registered by the Engineering Council of South Africa in terms of the Engineering Profession Act, 2000 (Act No. 46 of 2000).

These are commonly known as LMI and are registered at ECSA on behalf of the Department of Employment and labour • “Safe Working Load” means the mass load applicable to a piece of equipment or system as determined by a competent person taking into account the environment and operating conditions.

The rigger must determine the Safe working load based on the conditions at the time of lifting • “Thorough Examination” means examination or inspection to determine whether the equipment is safe to use.

• “Training Provider” means a training provider for lifting machinery operators approved and registered by the chief inspector in terms of regulation 20.

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Lifting Africa - Forklift Guide & Register

INTRODUCTION DMR 18 (5) (a) The user shall cause the entire installation and all working parts of every lifting machine or hand -powered lifting device, as well as ancillary lifting equipment used with the machine or device, excluding lifting tackle, to be subjected to a thorough examination and a performance test, as prescribed by the standard to which the lifting machine was manufactured, by a lifting machinery inspector of a lifting machinery entity, which shall determine the serviceability of the structures, ropes, machinery and safety devices before they are put into use and every time they are dismantled and re-erected, and thereafter at intervals not exceeding 12 months: provided that, in the absence of a manufacturing standard or a standard incorporated under section 44(1) of the Act, the whole installation of the lifting machine shall be tested with 110% of the safe working load applied over the complete lifting range of such machine and in such a manner that every part of the installation is stressed accordingly. b) The lifting machinery inspector of the lifting machinery entity referred to in paragraph (a) must have knowledge of the erection, load- testing and maintenance of the type of lifting machine or similar machinery involved. (c) Notwithstanding paragraph (a), mobile cranes, selferecting cranes and mobile elevated work platforms shall be excluded from the performance test after each redeployment within the 12 -month period referred to in that paragraph.

(6) Notwithstanding sub regulation (5), the user shall cause all ropes, chains, hooks or other attaching devices, sheaves, brakes and safety devices forming an integral part of a lifting machine or hand-powered lifting device to be subjected to a thorough examination by a competent person at intervals not exceeding six months.

-powered lifting device, and shall ensure that the register is available on request for inspection by an inspector. (b) Every user of a leased lifting machine or hand -powered lifting device shall at all times keep on their premises a register in which the user shall have the latest applicable performance test and service records not older than 12 months. (c) The owner and the lessor of leased equipment shall keep and maintain full service history records on their premises for at least 10 year.

Please note: Under Definitions, the clause on ‘competent person’ has been amended as follows:

(7) (a) Every user of a lifting machine or hand -powered lifting device shall at all times keep on their premises a register in which the user shall record or cause to be recorded full particulars of any performance test and examination referred to in subregulations (5) and (6) and any modification or repair to such lifting machine or hand

“Competent Person” means a person who – • Has in respect of the work or task to be performed, the required knowledge, training and experience and, where applicable, qualifications, specific to that work or task: provided that where appropriate qualifications and training are registered in terms of the provisions of the National Qualification Framework Act, 2008 (Act No. 67 of 2008), those qualifications and that training must regarded as the required qualification and training: and • Is familiar with the Act and with the applicable regulations made under the Act. Lifting Africa - Forklift Guide & Register

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FORKLIFTS SAFETY

Operating a forklift safely Operating new forklifts with latest safety features such as a seatbelt interlockers, overload lockout and speed controls can greatly increase operator and nearby pedestrian safety, whilst also reducing stock and capital equipment damage. mirrors are adjusted to the operator’s needs.

• The operator should not start the forklift until they are correctly seated with their safety belt fastened and all parts of their body are safely inside the confines of the operators cabin or the forklift.

Consider the surrounding environment

Operators must be qualified

• Whilst operating a forklift you must pay attention and follow any work site rules and guidelines.

• The operator must only drive the equipment in the machinery’s designated roadways.

• Observe all signs, especially those on maximum permitted floor loadings and clearance heights.

• Be aware of the height of the load, mast and overhead guard of the forklift when entering or exiting buildings.

• Be careful when operating a forklift near the edge of a loading dock or ramp – the forklift can fall over the edge – keep a safe distance from the edge.

• Do not operate on bridge plates, unless they can support the weight of the forklift and load.

• Individuals who have been trained properly and contain a license to operate the equipment should only do operating forklifts.

Appropriate clothing must be worn • It needs to be ensured that operators wear the appropriate safety work wear; usually consisting of a hard hat, safety shoes and hi-visibility jackets.

• The work wear must be reasonably fitted as any loose clothing can get caught on machinery.

• Don’t operate/hold any of the controls when your hands have grease on them; it may cause them to slide off and cause an accident.

Examine Equipment before use • Operators must do a routine check of the equipment before driving them. Some things you should check for any faults are brakes, steering, controls, warning devices, mast and tyres.

• If there are any noted damages or problems management should be notified and the forklift should not be operated if it needs to be repaired.

• Always consider the ‘journey’s end’ of a load before picking it up. A convenient position of a load from pick up may not be convenient for stacking.

Starting up the forklift • For safety purposes, it’s important for the operator to make use of the steps and hand grabs to seat themselves correctly in the forklift.

• Before starting the forklift it’s important to ensure all the equipment’s controls are in reach and the seat position and 8

Lifting Africa - Forklift Guide & Register

Operate at a safe speed • Never proceed past the speed limit.

• Take corners and any turns slowly to minimise risk of tipping.

• Make any changes in direction or any stops gradually and slowly.

Avoid hazards • Steer clear of any bumps or uneven ground surfaces along with slippery conditions.

FORKLIFTS SAFETY • Steer clear of loose ground objects which could cause loss of control over the equipment or a load to move around.

• Use the horn when closing in on a corner or doorway/ entrance and around people to alert pedestrians or other forklift operators of your whereabouts to avoid any unnecessary collision.

• Keep a safe distance from other trucks in case they move in an unpredictable manner.

• Make sure that you always have enough space to stop safely.

unless another seat is fitted safely to the forklift for a second person.

• If a person has to be lifted, use only a securely attached work platform and cage and follow the appropriate operating instructions.

Keep clear of the mast • Do not authorise anyone to stand or walk under the load or forklift machinery – The load can fall causing injury or death.

• Keep hands and feet clear of the cross members of the mast – Serious injury can be caused if the mast is lowered while your hand is on it.

Ensure your load is stable and secure • Check the loads carefully Safe working load: Even if a working load is marked on Driving on Ramps before moving them for the equipment in question, it is most important that stability and damage.

• When driving up ramps’ a competent person determines the appropriate safe move in a forward direction • It is important to ensure working load, depending on the application and down ramps in reverse, that the load is tilted back especially while carrying loads. with the forks sitting low whilst transporting in order to increase truck stability.

• Do not load or unload goods or turn whilst on a ramp.

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• Check for any overhead objects before lifting or stacking loads.

• Do not lift or move loads that are not safe or stable.

• Make sure loads are correctly stacked and positioned across both forks.

• Stack the load on the pallet or skid safely and correctly.

• Use securing measures such as ropes or bindings if required.

Ensure the forklift is not over-loaded

Make sure you have clear visibility • Operate the forklift in reverse when it improves visibility; except when moving up ramps.

• It is important to make sure you can see the racking clearly in which you are positioning your load.

• If visibility is poor do not continue driving; in some circumstances, you may need a lookout helper to assist you.

Ensure the load is evenly distributed

Forklifts are for carrying loads only • Operators must not let others ride on the equipment

• Do not use the tip of the forks as a lever to raise a heavy load.

• Do not push a load with the tip of the forks.

• Know the capacity of your forklift and any attachments being used and never exceed this capacity.

• An overload can cause the rear tyres to be raised off the ground and may cause the forklift to tip over.

• Do not lift or move a load unless both forks are fully under the load.

• Do not lift a load with one fork. Use pallets and skids that can withstand the weight of the load.

• Do not use damaged, deformed or decayed pallets for holding loads.

Refuelling • A forklift should only be refuelled at specially designated locations.

• Switch off the forklift.

• For IC engine forklifts, no open flame or sparks are permitted, and refuelling should take place in a wellventilated area.

When the shift ends • After use ensure the forklift is parked in a designated or authorised area.

• Fully lower the forks to the floor and apply the park brake.

• Turn the forklift “off” and remove the key.

• Do not leave a forklift running whilst unattended Lifting Africa - Forklift Guide & Register

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FORKLIFT SAFETY

Warehouse safety tips

While proper training is important for fostering a safe place to work, it’s also crucial to adhere to common-sense warehouse safety tips. When used together, forklift training and a comprehensive safety plan is your best bet against preventing workplace calamities.

Learn what the most common forklift accidents are, and what the most important warehouse safety tips are to prevent injuries and fatalities below.

to be reinforced by keeping seat belts fastened, training and constant reinforcement in the form of signs in the workplace.

The Most Common Warehouse Forklift Accidents When proper warehouse safety practices are ignored, accidents involving forklifts are all too common and can cause serious injuries and deaths. Here are a few of the most common kinds of forklift accidents – and how to prevent them from happening in your warehouse: Overturning Tipping over a forklift is probably the single most catastrophic event that can happen to a powered industrial truck. It may occur when travelling on steep slopes, driving over slippery surfaces, being unevenly or heavily loaded, travelling too fast, especially around corners, moving a load at a dangerous height, crossing uneven ground or going over curbs or uneven steps. While these are mostly behavioural issues that can be corrected by proper training, overturning may be prevented by taking measures in the warehouse such as: • Posting speed limits • Installing anti-slip flooring • Minimizing the opportunities for sharp turns

The top warehouse safety tips Gear up Personal protective equipment can make all the difference when it comes to performing a task safely. Safety gloves, hard hats, reflective tape and other attire should be worn at all times..

Define hazard zones The importance of warehouse organisation is often overlooked when it comes to creating a safe work environment. For certain areas in your warehouse, it’s a good idea to keep non-essential employees from entering.

Deploy yellow caution tape, orange cones or even extra personnel to ensure special procedures, heavy loads and other uncommon tasks can be performed without distraction.

Keep it clean

Pedestrian accidents The best way to avoid forklifts coming into contact with pedestrians is to arrange the work area in such a way that the two populations are isolated from each other. A further protective measure is to insist that all pedestrians, employees, visitors, vendors, contractors, etc., wear a reflective high-visibility vest while on the floor where forklifts are operating.

Forklift falls and crush injuries Crush forklift injuries often happen when a forklift tips over and the driver tries to leap free of the vehicle. The Number One rule for reacting to an overturning forklift is to remain inside and keep all parts of the body under the protective canopy. This is against human nature and needs

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Lifting Africa - Forklift Guide & Register

A clean workplace is a safer workplace, and that certainly applies to warehouses. If you notice a spill in the aisle, clean it up immediately.

For larger spills, notify your supervisor. For those areas near truck loading docks, weather can pose unique safety challenges. A slick or wet loading surface is the cause of many warehouse accidents. Assigning dedicated cleaning tasks to each employee can help keep everyone invested in maintaining a safe working environment.

Have an exit plan Does your warehouse have easy-to-read exit signs? This is a frequently overlooked factor, but simply knowing where to exit the warehouse is a matter of life or death during a fire. Should a warehouse evacuation be necessary, you’ll want your team to know where to head well in advance of an emergency.

FORKLIFT SAFETY

Take matters into your own hands

Check your racks & shelves

When it comes to warehouse safety, personal responsibility is everything. Leave nothing to chance and implement your own safety plan that’s above and beyond normal requirements. Ensure each shift has properly trained emergency response personnel available. Offer CPR training. Put extra first aid kits throughout the warehouse.

Preventative action is great, but what happens when something goes wrong? As the only saying goes, “Hope for the best, prepare for the worst.” Of course, the best way to take safety matters into your own hands is to get forklift certified and maintain your certification every three years.

Remember, warehouse safety isn’t all about forklifts all the time. Your cargo and goods need a stable, safe place for storage. This means that your racks and shelves should meet & exceed load standards. Ensure your forklift operators aren’t overloading the maximum capacity requirements – if they are, big problems could be headed your way.

Follow a maintenance schedule Keep a rigorous maintenance program for all of your equipment – forklifts, pallet jacks and more. Many workplace accidents are caused by faulty, defective forklifts. With regular maintenance a part of your daily plan, safety will naturally take care of itself. It’s amazing what you can accomplish with just a few minutes of dedicated maintenance tasks each day.

All clean hands on deck After the daily grind, make sure your floors are clean for the next shift. Fork-mounted brooms are a great idea in this regard. A clean sweep will help the next group of workers enjoy a clean, safer workspace. All spills and hazardous obstacles should be cleared immediately This is a good idea for warehouses, dock areas, shipyards and other areas where forklifts and industrial equipment are active.

Limit forklift operation to only fully trained personnel Even if it’s “just a little job,” no forklift action should be undertaken by someone who isn’t properly instructed and trained. The deadly risks vastly outweigh any minor convenience you might gain from having an untrained colleague help you out.

Remember to break Long shifts, overtime, covering for someone who called off – there are many times when an extra 15 minutes turns into 2 hours out in the warehouse.

Invest in education for your workplace While there is no foolproof way on how to keep your warehouse safe, all of the common causes of forklift fatalities can be remedied by modifying the conduct of everyone on the shop floor. Even the most carefully laidout warehouse is no match for the fallibility of the human.

Lifting Africa - Forklift Guide & Register

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LOAD TESTING

Load testing a forklift Every company or owner of lifting machinery has a lawful obligation to have their lifting machinery load tested annually and inspected 6 monthly.

The Occupational Health & Safety Act, Act 85 of 1993, Driven Machinery Regulation 18 (5) states that: “The user shall cause the whole installation and all working parts of every lifting machine to be thoroughly examined and subjected to a performance test, as prescribed by the standard to which the lifting machine was manufactured, by a person who has knowledge and experience of the erection and maintenance of the type of lifting machine involved or similar machinery and who shall determine the serviceability of the structures, ropes, machinery and safety devices, before they are put into use following every time they are dismantled and re-erected, and thereafter at intervals not exceeding 12 months: Provided that in the absence of such prescribed performance test the whole installation of the lifting machine shall be tested with 110 % of the rated mass load, applied over the complete lifting range of such machine and in such a manner that every part of the installation is stressed accordingly.”

Checklist to ensure the legality of your load test: • The Company is accredited with the Department of Employment and Labour as a Lifting Machine Entity (LME) • The LMI performing the load test must be accredited by ECSA with the correct scope • The load test is done in accordance with SANS 10388 (Inspection, test & examination of lift trucks) It is a requirement by law that all forklifts are subject to a load performance test. “No user shall use or permit the use of a lifting machine unless • It has been designed and constructed in accordance with a generally accepted technical standard; • It is conspicuously and clearly marked with the maximum mass load which it is designed to carry with safety: provided that when this mass load varies with the conditions of use a table showing the maximum mass load with respect to every variable condition shall be posted up by the user in a conspicuous place easily visible to the operator.

Some of the most common causes for failure during testing:

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ITEM

NON COMPLIANCE - REFERENCE SANS10388

Carriage

Carriage wear, stoppers, cracks & excessive play etc

Chains

Stretched, parts missing, side wear etc.

Data Plate

No plate, wrong specs, info not legible etc.

Forks

Heel wear, cracks, straightness, wrong capacity etc.

Horn

Not working

Hoist Cylinders

Leaking, uneven lift, bleeding back etc.

Hoses

Leaks etc.

Load backrest

No load backrest, broken, loose, cracked etc.

Lights

Not working, broken etc.

Mast Channels

Cracked, worn, bent etc.

Parking Brake

Not holding

Safety Devices

Not working, bypassed etc.

Tyres

Worn, cracked through limit ring, chunking etc.

Lifting Africa - Forklift Guide & Register

The user shall cause the whole installation and all working parts of every lifting machine to be thoroughly examined and subjected to a performance test, as prescribed by the standard to which the lifting machine was manufactured, by a person who has knowledge and experience of the erection and maintenance of the type of lifting machine involved or similar machinery and who shall determine the serviceability of the structures, ropes, machinery and safety devices, before they are put into use following every time they are dismantled and re-erected, and thereafter at intervals not exceeding 12 months: Provided that in the absence of such prescribed performance test the whole installation of the lifting machine shall be tested with 110 % of the rated mass load, applied over the complete lifting range of such machine and in such a manner that every part of the installation is stressed accordingly.

Notwithstanding the above mentioned regulation, the user shall cause all ropes, chains, hooks or other attaching devices, sheaves, brakes and safety devices forming an integral part of a lifting machine to be thoroughly examined by a person contemplated in sub regulation (5) at intervals not exceeding six months.

Every user of a lifting machine shall at all times keep on his premises a register in which he shall record or cause to be recorded full particulars of any performance test and examination prescribed by sub regulation (5) and (6) and any modification or repair to the lifting machine, and shall ensure that the register is available on request for inspection by an inspector.

The user shall ensure that every lifting machine is operated by an operator specifically trained for a particular type of lifting machine: provided that in the case of a lift truck with a lifting capacity of 750 kg or more and jib-cranes with a lifting capacity of 5000kg or more at a minimum jib radius, the user shall not require to operate such a lifting machine unless the operator is in possession of a certificate of training, issued by a person or organization approved for the purpose by the Chief Inspector.”

The main purpose of annual forklift load testing is to

LOAD TESTING determine whether your forklift remains safe to operate..

The favourable outcome of the load test confirms that your forklift is in optimal condition for the next 12 months, alternatively, identifies components that are damaged or degrading and require adjustments, maintenance, or complete replacement.

All lifting machines and lift trucks such as forklifts and related driven material handling equipment require a thorough inspection and performance test at 110% of the safe working load over the complete lifting range of the respective forklift.

A performance test must be conducted in such a way that every component of the forklift is placed under stress in order to determine the serviceability and safety of the forklift and its components.

In the event of any incidents and accidents occurring within the workplace and the respective forklift being without a valid forklift load test Everyday operations result in wear, tear, and Forklift Transmission System certificate, this could land damage to your forklift thus impacting its you as a person or entity The forklifts transmission ability to perform safely over the long term into serious trouble for system is a component of non-compliance with the engine assembly that OHSA and the Driven Machinery regulations. connects the engine and wheels so that they can work and rotate in unison.

This could mean being held liable, upon conviction, for a

[

financial penalty or imprisonment for up to 12 months.

Further, forklift load testing must be conducted by an ECSA registered Lifting Machine Inspector (LMI) who are qualified and able to issue your forklift with a valid certificate on the satisfactory outcome of the forklift load test.

What is being checked during a forklift load test?

During the forklift load test, the forklift’s performance is observed and recorded when tested with and without a load. The following is assessed: The engine of the forklift How well does the engine operate at idle and full speed; is the radiator and charging system operating effectively.

Forklift Mast lifting and lowering The forklift mast is the lifting mechanism of the forklift and is responsible for lifting, lowering and positioning loads manipulated by the forks. Common forklift mast problems include slow, jerky lifting and lowering of the mast or no movement at all. Masts can become damaged via everyday operations showing up as misaligned, bent, cracked, twisted or rusted masts which would then require repair or replacement. During the forklift load testing the hydraulic fluid is also checked to determine that there aren’t any leaks in the hoses during operations.

Forklift mast tilting Common forklift accidents such as a forklift tipping over often occur when lifting a heavy load at a height.

The forklift mast tilting angle control must function in such a way to restrict the mast title angle to ensure that the forklift remains stable and does not tilt beyond the vertical position, either forward or backwards which would result in spilling loads or the forklift tipping over.

]

During the forklift load testing procedure, the engagement and disengagement of gears are analysed for any slippage or abnormalities.

Steering

Common forklift steering problems include locked steering, not getting a response from your forklift when trying to turn, to noisy strange sounds when turning the wheels.

Forklift steering issues can come about because of worn gears, misaligned tyres, a rusty steering mechanism, worn pressure valves or low steering fluid.

During the load testing procedure, any defects or concerns are identified with recommendations for repairs and/or replacements so that your forklift does not continue to operate in such condition until it is eventually placed out of commission.

Forklift brakes When it comes to forklift safety, the brakes are heavily utilized to slow down and manage the speed of the forklift or to bring the forklift truck to a stop. Ensuring that the forklift brakes function as they should and remain effective is key to maintaining both the forklift driver’s safety as well as productivity within your operations.

The service and parking brakes are checked during the forklift load testing procedure with recommendations to replace the brakes made, if necessary.

Forklift gradient testing Forklifts operate on many different types of surfaces, including slopes, ramps and inclines. The risk of a forklift tipping over is great and forklift operators are required to be trained on how to correctly manoeuvre a forklift over such surfaces. However, during the forklift load test, observations are made in order to identify any potential risks in the performance of the lift truck.

Lifting Africa - Forklift Guide & Register

13

FORKLIFTS SIGNALS

Basic forklift hand signals every operator should know Forklift signals let operators communicate with spotters while moving heavy loads. In loud, cramped environments, these signals ensure clear communication with anyone RAISE THE TINES LOWER THE TINES behind the wheel of a forklift.

MOVE OSHA Forklift Hand Signals Every year, 11 percent of forklifts will get into a workplace OSHA Forklift Hand Spotters use this signalSigna accident. As such, hand signals for forklift operators play a key role in workplace safety.

when operators need to angle the end of their mast lower to the floor.

Most companies use the seven standard OSHA forklift hand signals.

These gestures all correlate to a forklift’s main components — in particular, they target a forklift’s tines, mast and brakes. Generally, operators only follow instructions from a spotter, but anyone on a work site may call an emergency stop.

OSHA Forklift Hand Signals

OSHA forklift hand signals

RAISE THE TINES

TILT MAST FORWARD

LOWER THE TINES

This signal tells operators to lift their forks, also known as tines.

MOVE TINES (L/R)

RAISE THE TINES

LOWER THE TINES

Forklifts raise their tines when lifting materials to a higher elevation.

Once the tines are high enough, operators can OSHA Forklift safely transfer materials.

And from this position, forklifts can set loads with TINES LOWER THE TINES precision.

TILT MASTgreater FORWARD

A Forklift Hand Signals RAISE THE

Operators lower the tines when bringing their forks closer to the ground.

Hand Signals DOG EVERYTHING

TINES (L/R) TILTMOVE MAST BACKWARD TILT MAST FORWARD

From a lower elevation, their THE tinesTINES can pick upLOWER new THE TINES RAISE materials.

and Signals

NES

MOVE TINES (L/R)

Spotters also use this signal when telling operators to place their loads.

DOG EVERYTHING EMERGENCY STOP LOWER THE TINES MOVE TINES (L/R) TILT MAST FORWARD TILT MAST BACKWARD This is the last forklift signal relating to itsFORWARD tines.

TILT MAST

DOG EVERYTHING TILT MAST BACKWARD

It tells the operator to adjust their tines more to the left or right. This change in position allows the forklift to better distribute the weight from its load.

Alternatively, it lets the operator adjust the material DOG EVERYTHING before placing it.

NES MOVE TINES (L/R) FORWARD TILT MAST BACKWARD DOG EVERYTHING 14

Lifting Africa - Forklift Guide & Register

From this position, materials can easily slide forward onto the ground.

When the mast tilts forward, crew members can also remove a load by hand.

TILT MAST BAC

EMERGENCY STOP

EMERGENCY STOP

This signal angles the end of a mast higher off the ground.

MOVE T

When an operator drives their forklift, a mast that’s tilted back has a more secure grip on the load. It also stabilizes weight distribution, EMERGENCY preventing a forklift from tipping forward.

TILT MAST BACK Dog everything is a signal telling the forklift operator to pause.

Spotters use it when an unexpected safety hazard appears but hasn’t caused harm yet.

If a person or object obstructs a forklift’s path, this signal halts movement until the EMERGENCY operator can continue.

Spotters call an emergency stop when facing imminent danger or after an accident occurs.

This signal immediately ceases operations until the crew deals with their emergency.

Unlike other forklift signals, operators must follow an emergency stop order from anyone on the work site.

FORKLIFTS SIGNALS Other common forklift signals Most forklift hand signals meet most industry standards.

But outside of this list, spotters use other forklift signals to communicate with operators. While not all teams recognize them, these signals allow for more precise communication.

And depending on the project, they can help prevent hazards and accidents.

Similar to raising and lowering the tines, these signals tell operators to adjust their forks’ height. But unlike the standard OSHA signal, it encourages slower movement.

Honk the Horn When approaching corners, intersections, blind spots, other devices or pedestrians, operators sound the horn to prevent a collision.

These signals tell the operator to continue moving forward or to back up. Operators follow this instruction to put their forklift in an ideal position to pick up or drop their load.

Spotters use this signal to show the remaining distance operators need to travel.

The distance between their hands indicates how far the forklift needs to move.

A spotter serves as an extra set of eyes for drivers, equipment operators and individual workers on the site.

Unlike hand signals from spotters, operators sound the horn for others’ safety. Anyone working near a forklift should steer clear when they hear its horn.

These forklift signals all communicate a straightforward action. But without learning each signal’s corresponding motion, spotters and operators put their coworkers in danger. Graphs and tables like the one below can help with memorization — they summarize each hand signal in an easy-to-follow movement.

Forklift accidents represent some of the worst hazards employees face on a job site. But thanks to OSHA’s forklift hand signals, spotters can ensure an entire crew’s safety.

These signals won’t only protect companies from thousands of dollars in damages — they can also preserve the health and safety of everyone lifting materials.

Lifting Africa - Forklift Guide & Register

15

FORKLIFTS WEIGHT

Estimating the load weight You can expect an average forklift weight to be about 4,082 kg. This is about 3 times the weight of an average car. The majority of the weight resides in the rear for the counterweight, which allows for heavy items to be moved in the forks.

Forklift Model

Average Weight

Crown 4520-30

2,709 kg

Komatsu FG18HT-20

2,826 kg

Hyster H40FT

3,472 kg

Toyota 8FGCU25

3,628 kg

CAT C5000

3,678 kg

Clark CMP25

3,744 kg

Yale GLC050

4,089 kg

Load capacity vs gross vehicle weight rating

Generally the heavier a forklift is, the more weight it can handle. Depending if the forklift is electric or gas powered, there may be a slight difference in the total weight.

Common uses to know forklift weight if you need to: • Move it with a truck, rail, or ship • Lift it with a crane • Load it into a ship • Deliver it on a flatbed truck • Operate it on the 2nd or 3rd floor of a building • Design a warehouse layout

16

When going through the manufacturer details, it’s important to take a careful look at the rating. This way, you make proper assessments based on weights.

Load capacity or lift capacity refers to how much weight the forklift can safely lift.

Gross vehicle weight rating (GVWR) refers to the actual total weight of the vehicle and all of its attachments.

How to estimate forklift weight

Example forklift weights

Sometimes you may need to make an estimation of the forklift’s weight without access to all the official information. In this scenario, all you need to know is the load capacity of the forklift.

The following chart features example forklift weights of specific models ranging from light to heavy. Other larger models can even weigh over 10,000 pounds. Additional details can be found on the manufacturer’s websites. Load Capacity vs Gross Vehicle Weight Rating

The actual forklift weight should be close to that figure, based on the physics of a forklift counterweight. Of course, this is a rough standard and manufacturer information with the forklift’s data tag should always be prioritised.

Lifting Africa - Forklift Guide & Register

Take the forklift’s load capacity and multiply it by 2

1

FORKLIFT REGISTER COMPANY FROM DATE TO DATE

DAILY AND PRE-OPERATIONAL DAILY AND PRE-OPERATIONAL CHECKLIST A skilled and/or trained operator/driver must complete the daily and pre-operational checklist daily before his shift starts. He must report any defects to his supervisor. In case of a “NO”, the forklift MAY NOT leave the premises until the problem is corrected, and before the checklist is signed off by his supervisor.

For each “NO”, the DEVIATION DETECTED AND CORRECTIVE ACTION must be recorded on the form designed for this purpose.

6 MONTHLY INSPECTION CHECKLIST SHOULD BE USED IN CONJUNCTION WITH THE DAILY AND PRE-OPERATIONAL CHECKLIST A competent person must inspect equipment every 6 months. All findings should be recorded and available on site.

Write “YES” or “NO” for each finding in this register under the relevant date. In the event of a “NO”, the details of the DEVIATION DETECTED AND CORRECTIVE ACTION must be recorded on the form designed for this purpose.

If the equipment is defective, it must be tagged as DEFECTED and reported to the person responsible for its repairs.

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2 OPERATOR TRAINING

ID number of forklift: ___________________________________________ Name of operator: _____________________________________________ Date certificate of training: ______________________________________ Issued by: ____________________________________________________ Date of re-training: ____________________________________________ Medical certificate attached: ____________________________________ OPERATOR TRAINING

ID number of forklift: ___________________________________________ Name of operator: _____________________________________________ Date certificate of training: ______________________________________ Issued by: ____________________________________________________ Date of re-training: ____________________________________________ Medical certificate attached: ____________________________________ OPERATOR TRAINING

ID number of forklift: ___________________________________________ Name of operator: _____________________________________________ Date certificate of training: ______________________________________ Issued by: ____________________________________________________ Date of re-training: ____________________________________________ Medical certificate attached: ____________________________________

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3 TYPE

AREA/DEPARTMENT

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FORKLIFT INVENTORY LIST

ID NUMBER

DAILY AND PRE-OPERATIONAL CHECKLIST

4 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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DAILY AND PRE-OPERATIONAL CHECKLIST

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DAILY AND PRE-OPERATIONAL CHECKLIST

6 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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DAILY AND PRE-OPERATIONAL CHECKLIST

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DAILY AND PRE-OPERATIONAL CHECKLIST

8 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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DAILY AND PRE-OPERATIONAL CHECKLIST

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DAILY AND PRE-OPERATIONAL CHECKLIST

10 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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DAILY AND PRE-OPERATIONAL CHECKLIST

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DAILY AND PRE-OPERATIONAL CHECKLIST

12 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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13

DAILY AND PRE-OPERATIONAL CHECKLIST

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DAILY AND PRE-OPERATIONAL CHECKLIST

14 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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DAILY AND PRE-OPERATIONAL CHECKLIST

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DAILY AND PRE-OPERATIONAL CHECKLIST

16 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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DAILY AND PRE-OPERATIONAL CHECKLIST

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DAILY AND PRE-OPERATIONAL CHECKLIST

18 Date of inspection: Vehicle identification no: 1. Lubrication adequate?: 2. Switches in good working order?: 3. Gauges in good working order?: 4. Brakes in good working order?: 5. Hoisting mechanisms in good working order?: 6. Horn in good working order?: 7. Lights in good working order?: 8. Pedal rubbers in good condition?: 9. Wheel nuts and bolts secure?: 10. Wheel rims and tyres in good condition?: 11. All pipes in good condition?: 12. Oil and coolant- levels and leaks?: 13. Fan belt/s in good condition and correct tension?: 14. Caps (i.e. oil, petrol etc) secure?: 15. Battery mounting secure?: 16. Control levels in good working order?: 17. Compartment/seat in good condition?: 18. Safety belt in good condition?: 19. Hydraulic oil level correct?: 20. Gas shut-off valve operational?: 21. Gas tank mountings secure?: 22. Reverse siren: 23. Beacon or strobe warning light: FIT FOR USE Signature - Driver Time Out: Time In: Signature Supervisor or Manager:

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19

DAILY AND PRE-OPERATIONAL CHECKLIST

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DEVIATION DETECTED AND CORRECTIVE ACTIONS (DAILY)

20 ID NUMBER

DESCRIPTION OF DEVIATION AND ACTION TO BE TAKEN

RESPONSIBLE PERSON

DATE REPORTED

DATE CORRECTED

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INITIAL

21 DESCRIPTION OF DEVIATION AND ACTION TO BE TAKEN

RESPONSIBLE PERSON

DATE REPORTED

DATE CORRECTED

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INITIAL

DEVIATION DETECTED AND CORRECTIVE ACTIONS (DAILY)

ID NUMBER

6 MONTHLY INSPECTION LIST

22 Date of inspection: Vehicle identification no: Name of competent person: Name of responsible person: 1. Frame free from defects?: 2. Bodywork source (where applicable)?: 3. Overhead guard secure?: 4. Steering ball joints secure/good condition?: 5. Steering centre plate secure?: 6. Steering cable/chain in good condition?: 7. Sheaves in good condition?: 8. Axle mounting in good condition?: 9. Mast channels free from defects?: 10. Mast mounting/bushes in good condition?: 11. Chains in good visual condition?: 12. Chain anchors and sheaves in safe condition?: 13. Hoist cylinders and mountings in good condition?: 14. All hoses and fittings in good condition?: 15. Tilt cylinders in good condition?: 16. Forks in good condition?: 17. Carriage in good condition?: 18. Load back rest in good condition?: 19. Side shift until in good condition?: 20. Drive axle and mountings in good condition?: 21. Radiator fan shroud secure?: 22. Safety limit switches/devices in good condition?: 23. Tow pin and mounting in good condition?: 24. Counterweight securing bolt in good condition?: 25. Maximum mass load notice?: 26. Safety belt in good condition?: 27. Fork blade wear within 10% maximum limit?: FIT FOR USE Signature of competent person: Signature of responsible person:

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23

6 MONTHLY INSPECTION LIST

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DEVIATION DETECTED AND CORRECTIVE ACTIONS (DAILY)

24 ID NUMBER

DESCRIPTION OF DEVIATION AND ACTION TO BE TAKEN

RESPONSIBLE PERSON

DATE REPORTED

DATE CORRECTED

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INITIAL

25 DESCRIPTION OF DEVIATION AND ACTION TO BE TAKEN

RESPONSIBLE PERSON

DATE REPORTED

DATE CORRECTED

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INITIAL

DEVIATION DETECTED AND CORRECTIVE ACTIONS (DAILY)

ID NUMBER

ANNUAL PERFORMANCE TEST RESULTS

26 ANNUAL PERFORMANCE TEST RESULTS DATE OF INSPECTION VEHICLE IDENTIFICATION INITIALS AND SURNAME OF PERSON CONDUCTING TEST EMPLOYER OR PERSON CONDUCTING INSPECTION/TEST INSPECTION/TEST CONDUCTED

RESULTS

REMARKS

FORKLIFT SAFE TO USE?

YES/NO______________MOTIVE__________________________

RESULTS REPORTED TO SIGNATURE AND DESIGNATION OF PERSON RESULTS WERE REPORTED TO

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27

RESULTS

REMARKS

FORKLIFT SAFE TO USE?

YES/NO______________MOTIVE__________________________

RESULTS REPORTED TO SIGNATURE AND DESIGNATION OF PERSON RESULTS WERE REPORTED TO

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ANNUAL PERFORMANCE TEST RESULTS

ANNUAL PERFORMANCE TEST RESULTS DATE OF INSPECTION VEHICLE IDENTIFICATION INITIALS AND SURNAME OF PERSON CONDUCTING TEST EMPLOYER OR PERSON CONDUCTING INSPECTION/TEST INSPECTION/TEST CONDUCTED

MODIFICATIONS & REPAIRS

28 DATE

DESCRIPTION OF REPAIRS/MOODIFICATIONS

WORK ORDER NO

DONE BY (SIGNATURE)

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29 DESCRIPTION OF REPAIRS/MOODIFICATIONS

WORK ORDER NO

DONE BY (SIGNATURE)

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MODIFICATIONS & REPAIRS

DATE

30

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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FRI

SAT

P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

31 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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FRI

SAT

P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

32

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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FRI

SAT

P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

33 OPERATOR: __________________________

1958 African Wire Ropes (Rhodesia) Ltd was formed to distribute in both

Enter seat and mirrors Zambiaand andadjust Zimbabwe.

Gauges before switching on 1960 African Wire Ropes Ltd, Natal Park brake engaged Branch – established in partnership Steering play with Victor Kent Ltd. Started 1 July Ignition key operative 1960. Official opening 24 October 1960.

Gauges after switching on 1961 African Wire Ropes (Natal) Ltd Indicators – 51% held, partner, being Victor Kent Lights the company’s erstwhile Natal selling Horn agent. Became wholly-owned in April Raise & lower - cylinder & chain 1968.

Tilt- cylinder condition 1963position Generaland Wirefork Co (Pty) Ltd – Fork locks acquitted for R60,000 (1 January 1964) Forward and reverse – speciality wire – National Wire Corp Steering lock to lock of SA Ltd – acquired for R28,3750 (1 Foot brake July 1963) spring wire and commercial Hand brake

wire. Both companies were combined on Mobeni, Durban site which was sold Operator signature in 1978. Speciality wire transferred to Supervisor signature CWI, other products to Germiston and Date Jupiter.

1965 African Wire Ropes Ltd – Kitwe

factory opened to manufacture haulage and flex rope. Anglo American told Haggie to update their ropemaking machinery.

1966 Rights issue of 1 for 10 at

R8.00. Issued capital increased from 1.3 million to 1.43 million shares of R2.00

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

FRI

SAT

P R E

develop and sell lightweight, moveable ropeways for the forestry industry.

Copperbelt Rope splicers acquired

by African Wire Ropes Ltd – Zambia.

Rosslyn Steel & Wire Industries (Pty) Ltd – 90% acquired – sold 1970.

Imported the first Wafios Veldspan machine. Manufactured Veldspan initially at Jupiter and later transferred to CWI. African Wire Ropes (Cape) (Pty) Ltd – formed to take over activities of Cape Town branch. The company had been previously represented

by Joseph Curry & Co (Pty) Ltd. Appointed 1962 jointly with Dowson & Dobson. AWH Computer Services (now Haggie Rand Computer Services) was formed as a 50:50 partnership with Hume Ltd. Wholly owned 1974.

1968 PHB Mechanical Handling

(Pty) Ltd – acquired 20% for R38,000 – sold 1972. The object was the development of ropeways and rope utilization transport systems. Wirex (Pty) Ltd – 75% acquired for R976,000 -25 % acquired for R325,000 (1969).

Manufactured high carbon and mild steel wire at Vanderbijl. Established ties with Bekaert.

1969 SA Liquid Meters (Pty) Ltd

– 15% acquired for R22950 (1971) – became wholly owned and sold in 1980. Manufactured domestic and industrial water meters in Pinetown.

African Wire Ropes de Venezuela was formed to service the oil industry. The company still exists to protect a legal position against erstwhile “agent”.

1970 Precision Springs (Pty) Ltd –

20% acquired for R54,000 – sold 1971.

Manufactured valve and other high carbon wire products in P.E sold to the major shareholder. Alucab (Pty) Ltd – 33% purchased for R333,000 – sold 1971 – partners Goldfields of SA and JK Jardine to manufacture ACSR. John Henderson appointed Chairman.

S T A R cost R120,449 – sold 1982. Other T shareholders Bridon and Union Corp.

Ltd – manufactured high carbon wire products. Wire business closed downC and the company became Birkmyre H Canvas – Sold to Bridon. A19 was E installed and commissioned at Jupiter.C Shareholding Bridon 48%, Union CorpK 13%, Anglo and Rand Mines 3% each, J.C.I 4%. Eclipse Engineering Ltd – 5% acquired for R47,500 –sold 1979 – Small investment acquired as an entry into engineering.

1972 Gourock Ropes & Canvas

(Africa) Ltd – assets acquired for R775,000 – became Haggie Industrial O Products Ltd. Remaining part of the P business in Port Elizabeth and DurbanE ‘sail floor” and Johns Mansville agency R for Filter powder. Zimbabwe Wire A & Rope – Kwekwe factory opened.

T Haggie was invited to buy into Cape Gate’s steel mill but was turned down.I N 1973 Wire Industries Ltd was G formed by the merger of Wirex and Wispeco’s wires business. WM Smith Ltd Zimbabwe acquired – became WMC Smith & Gourock – sold 1981.

H 1974 Pietermaritzburg Factory – E cost R9m started. Rights issues of C 25 for 100 at R18.50. Issued capital K from 1.43m to 1.7875m shares of S R2.00. Shareholding after rights issue Bridon 40%, Uni Corp 24%, J.C.I 4% Rand Mines 3%, Haggie family 7%. Technoplastics (Pty) Ltd – acquired for R135000 – part of Haggie Industrial Products Ltd – Closed.

Icaso-Mozambique – 35% acquired for R175000. Computerisation of rope design initiated.

1975 Springfield Industries

Corporation USA initial investment of 49% became 100% in 1986 closed down 1989 as a result of US sanctions.

Your advert can be here!

1976

1967 Timberways (Pty) Ltd formed – closed down 1972 established to

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1971 Blue Strand Industries –

Australia – Initial investment of 10%

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Pietermaritzburg factory closed.

1977 Ian Haggie succeeds John

Henderson as chairman and Donald

REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level 1950 African Wire Ropes Ltd (now Haggiefluid Ltd) was formed by the Brake levels amalgamation of Haggie Son and Brake fluid leaks Love leaks (1936) Ltd and Rand Ropes Ltd. Fuel 600,000 shares were issued to Haggie Fuel levels Son and Love 600,000 to Hydraulic oil shareholders, leaks Rand Ropes shareholders and 100,000 Engine oil leaks top mining houses. Output Germiston Water leaks 5000 tons per annum and Jupiter Fork 15,000condition tons per annum. Shareholders Lad backrest and Corp. carriage Bridon 45%, Union 10%, Anglo, Mast and chain J.C.I, Rand Mines, Central Mining 3 % Hydraulic cylinders each, Haggie family 9%, Love family 8%. and hoses Pipes Transmission oil

Peace retires. Cyril Newnham joins the board as Chief Executive.

1978 African Wire Ropes (Pty) Ltd

– Windhoek formed. Cyril Newnham resigns to join Bridon and Richard Savage joins Haggie and succeeded Cyril Newnham as Chief Executive on 1 January 1979.

1979 First major diversification by

acquiring 75.32% of the issued shares of Samuel Osborn (South Africa) Ltd for R6.5 million. Share split 10 for 1.

The company was listed on the JSE in September at an opening share price of 560 cents. Crusher Plant Manufacturing Ltd, Kitwe, formed. Steel converters in Wadeville were acquired by Cape Gate thus opening the door for Cape Gate to start high carbon wire and rope manufacturing.

1980 Disposal by Bridon Ltd of their

38% interest in Haggie to Scaw Metals and Gencor and the appointment of AMIC nominees Messrs R A Bousted, W G Boustred and EH Dreyer to the board on 23 May 1980. Scaw and Gencor each hold 36% of shares. Messrs Newham, Harry Smith and Watts (all Bridon) resign from the board. Issued share capital increased by 475787 shares in terms of a scheme of arrangement by which Samuel Osborn became a wholly-owned subsidiary of Haggie for R4 million.

Formation of CWI through the merger of Haggie’s Wore Industries Ltd and Iscor’s mild steel wire mill at Pretoria. Share Purchase Scheme established. During the year the share price ranged between 570 and 1010 cents. Mr James Sinton dies at the retirement age of 84.

1981 The acquisition by Haggie of the following: • 45% interest in Macdem (Pty) Ltd • 25% interest in R Jackson Holdings (Pty) Ltd – Sold 1988 • 50% interest in Chloride Holdings SA Ltd acquired for R12.5 million – Sold 1984

Haggie’s 60th birthday with the founding company, Haggie Son & Love, being founded in 1921 and the occasion was appropriately marked by the company’s pre-tax profits reaching R60 million compared with R47 million in 1980.

Share price ranged between 840 and 1150 cents.

1982 Sharp deterioration in the country’s economic situation and very weak prices in the company’s export markets resulting in pre-tax profits declining to R55.5 million. Share price – 850 to 1350 cents.

Haggie Rand was required to give up all export benefits on exports to the USA as a result of countervailing

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duty actions brought against its wire and rope products. Somta Tools acquired the tap and die business of Clarksons on Somta’s adjoining site in Pietermaritzburg. Avon Wire (Pty) Ltd sold by Macdem. 50% of African Zinc Mills (Pty) Ltd sold by Macdem.

1983 The extremely serious drought

and the fall in the gold price resulted in a very difficult trading environment with the result that pre-tax profit declined to R49 million. Share price – 1200 to 1500 cents. Samuel Osborn engineering division merged with Coalequip – Haggie received R5 million plus 50% interest in Osborn Coalequip Engineering.

Despite protectionist measures adopted by the USA the Haggie group continued to be a major exporter with total exports reaching R41 million in 1983. Macdem changes its name to Copalcor. Copalcor and Denver Metal Works merge with A.V.I holding 40%, Haggie 30% and McKenchie U.K 30%. Agreement reached whereby the operations of Mitco Tool Company were merged with Somta Tools with Volkskas as a 26% shareholder.

1984 Despite the continuing harsh

economic climate the group performed exceptionally well and earned a pre-tax profit of R63 million. Share price – 1350 to 1780 cents. During 1984 Macdem and Jacksons became subsidiaries with the group holding 50% plus one share in each company. Haggie’s interest in Osborn Coalequip Engineering was disposed of for R5.7 million and an agreement was reached to withdraw from its investment in Chloride over a period not exceeding 7 years for R12.5 million. Bill Harrison was appointed a director and Campbell McKie Thomson appointed Company Secretary.

1985 Pre-Tax profits reach R79 million

on the back of a declining Rand and an improving economy. Exports by the group in 1985 were more than R85 million brought about partly by a decline in the exchange value of the Rand but a real increase in volumes. Share price – 1525 to 2600 cents. Fascor was acquired

by CWI. In September 1985 Mr Richard Savage left the group and Mr John Feek – who had been managing director of HRL – was appointed group managing director and Messrs Coutts-Trotter, Smart and Tingle appointed directors.

1986 Despite a 3-week strike at Haggie

Rand, poor demand in some of the group’s markets and political uncertainty pre-tax profits of R93.8 million were earned. Share price – 2190 to 3060 cents.

In 1986 Mr Grant Thomas was appointed deputy chairman and Mr Brian Bullett was appointed to the board.

1987 Pre-tax profits of R115.0 million

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earned against a background of static domestic demand, disruption in certain export markets and a stronger Rand.

Share price – 1550 to 2700 cents.

Wirecor (Pty) Ltd was acquired by CWI for R7.6 million. The board decided against purchasing McKinnon Chain for R43.4 million and approved a R5.3 million project for Haggie Rand to manufacture the chain. Haggie acquired the interest of McKenchnie PLC in Macdem thereby increasing Haggie’s holding in Reclam to 100% and Copalcor to 60% for R18.7 million. Gencor’s Investments in Haggie’s transferred to Malbak and Mr Peter Beningfield appointed the board. The remaining 50% of African Zinc Mills (Pty) Ltd held by Copalcor (formerly Macdem) was sold.

1988 Very difficult trading conditions

including cost-cutting on the local market, more effective sanctions and costly production disruptions caused by labour disputes with the result that the pre-tax profit of R114.8 million was little changed from 1987. Share price – 1400 to 2500 cents. Mr Grant Thomas was appointed chairman and Mr Ian Haggie appointed president. Bradbury’s acquired by Copalcor for R5.6 million.

Copalcor became 100% owned and Joacksons Metals sold to VRN for R16.2 million and Osborn Aluminium sold to Huletts for R4 million. The number of working hours lost in 1988 reached unprecedented levels as a result of labour disputes.

1989 A most successful year in a

climate of rising inflation, a stronger gold price and rising mineral prices with turnover reaching R1 billion for the first time and pre-tax profit R140.0 million. Share price – 1850 to 2850 cents.

Samuel Osborn Zimbabwe sold for $7.6 million. Rope & Twines (R16.5 million) and Titan Chain (R3 million acquired by Haggie Rand and the remaining 50% in Fascor acquired and entire shareholding transferred from CWI to Haggie Ltd. 60% of Neil Tools acquired for R5 million.

1990 Pre-Tax profit of R117.4 million

compared with R140 million of 1989.

The decline was brought about by lower demand and lower output in the Jupiter plant as a consequence of the dismissal of the wire mill workforce. Share price – 2000 to 3100 cents. Sisal farm in Hluhluwe was acquired for R4.5 million to secure a strategic supply of sisal.

Somta Tools 26% minority acquired for R6.2 million. General Chipbreaker Drill Company plc and its USA branch acquired R5.3 million.

1991 Pre-Tax profit declines by 27%

to R86 million. Earnings were down by 19% from 363.2 to 295.5 cents but divided maintained at 157 cents. Share

price – 2300 to 3000 cents. Appointment of DC G Murray with effect from 1 April 1991 as group managing director and the resignation of J S Feek in June 1991. Acquisition of Port Elizabeth and East London properties of Chicks for R2.6 million. Acquisition by CWI of the property between the company’s A and C factories at Vanderbijlpark for R2.9 million.

1992 Pre-tax profit unchanged at

R86 million, earnings slightly up at 3004 cents and dividend maintained at 157 cents. Export increase by 16%.

Share price – 2300 to 3000 cents.

Appointment of Mr K V Burger as managing director designate of Somta Tools. Commissioning of Maksal Tubes’ aluminium (R10.0 million) and capillary fittings (R2.5 million) plants. Agreement with Bekaert that they would provide technology for steel cord plant followed by their unexpected withdrawal because of economic/political factors.

Announcement of appointment of G G Russell as managing director designate of Haggie Rand with effect from January 1993. Approval by Haggie Rand of R3 million low relaxation wire proofing line at Germiston and conversion to Unix computer system for R4315 million.

Purchase for R2.5 million of minority shareholder’s 40% interest in Haggie Neill and re-naming the company Somta Saws. Acquisition of Firth Brown Tools for R0.7 million. Competition Board overrules Copalcor/NFM merger.

1993 Mr H F Brown appointed

chairman with Mr GS Thomas remaining on the board. Mr G G Russel appointed managing director of Haggie Rand and director of Haggie Ltd and MR J M Milburn transferred to the holding company as group technical director and the executive director responsible for steel cord. Import duty on all high carbon wire, strand and rope increased from 5% to 15% w.e.f January.

Appointment of Mr KV Burger as managing director of Somta Tools and retirement of MR JB Dalton.

Agreement with GCR Riva Steel to proceed with steel cord project for R65 million and appointment of Mr B D Nelson as General Manager Haggie Steel Cord. Haggie’s chain business merged with that of McKinnon Chain. Publication of 1992 annual repost carrying more disclosure than ever before. NFM/ Copalcor merger over-ruled by Competition Board. 2 August – separate “status” catering facilities discontinued.

Mr P J Malan resigns and Mr C J Cross appointed Managing Director of Copalcor Manufacturing (Pty) Ltd and Mr N D Bingham the Managing Director of Maksal Tubes Division of Copalcor.

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Haggie Rand Ltd wins SEIFSE Golden Jubilee Award.

1994 Bernard Smith resigns from

the Haggie board because of his other responsibilities. Jonathan Melck was appointed managing director designate of CWI. Russel Bedford was appointed managing director of Somta Saws.

Bill Harrison retires 31 March 1994 (at A.G.M). The final dividend cut from R1.10 to 53 cents. Gary Maude was appointed to the Haggie Ltd board.

Mr G S Thomas resigns from board of Haggie Ltd. Haggie Rand wins Tech Top 100 award. Denzil McGlashan was appointed to Haggie Ltd Board.

Jonathan Melck was appointed managing director CWI. Haggie Ltd declares a scrip dividend of 1,5 shares per 100 shares held instead of an interim dividend but with a cash option of 50 cents per share. Haggie’s shares reached 3800 in August on the back of good interim results. Haggie’s shares reaches 4200 in December 1994. Mr WG Scurr appointed Technical Director of Haggie Rand. Mr D C Pope-Ellis resigns on 31 December 1994 and Mr N G Paterson appointed Works Director – Ropes & Twines. Position of Works Director – Germiston vacant. Haggie Rand’s and Copalcor’s Durban branches relocated to Ropes & Twines site and Somta Tools’, Somta Saws’ and Fascor’s Johannesburg branches relocated to Haggie Rand’s Germiston site. Haggie Pension Fund’s accurate rate changed from 2% to 2.5% and pensioners granted a 25% increase with effect from 1 January 1995. Haggie Rand acquires Le Lis in Belgium for R19 million and Reclam acquires Hydrochem Natal (Pty) Ltd for R6.5 million.

1995 Alrode property sold for R2.02

million. Haggie shares reach an all-time high of 4200 in January. Earnings per share up 73% in 1993 from 180 to 312 cents. Dividends increased by 50% from 100 to 150 cents. Capitalism award of 2.9 shares/100 shares held instead of a final dividend of 100 cents. 91% acceptance of capitalisation award. S M Ingledew, a prominent Haggie shareholder, was shot dead. B E Bullet and G Maude resign from broad and L Boyd and C J Cross were appointed with G R Pardoe alternate to L Boyd. The main agreement settled at 11%. Capex of R3.6 million for bedding wire drawing machine for Haggie Rand Ltd (Germiston) approved.

Haggie share drops to 2300 in July 1995.

Haggie declares a scrip dividend of 1 share/49 shares held = R26.95 per share instead of interim dividend but with a cash option of 55 cents per share – an increase of 10%. Interim EPS up 9% at 167 cents. A six-week strike at R &

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T. Bridon buys 75% of Schalkseil (a subsidiary of Thyssen) for £5.9 million.

J M Milbrum resigns from the board.

Somta Saws files interdict against Neil UK.

1996

Mike McNally appointed Works Director HRL (Jupiter) ex Rodney Mahon who takes up the position of General Manager Lifting Services. EPS and dividend upper results announcement.

Share price weakens from 3500 to 2650 during February/March.

Slow start to the year because of: • CWI/Cape Gate price war.

• Decline in local demand.

• GEIS halved costing Haggie Group ± R750 000 in earnings.

• Steel Cord losses worse than budget – R12 million loss for the year expected.

STC reduced to 12.5%. R1.4 million Capex project to centralise galvanising at Jupiter approved. Successful 75th anniversary shareholders day held at Jupiter on 29 March 1996. Rand starts its decline. Share price stabilises around 3100. US$ = R4.35/£ = R6.80.

Successful employees pop concert at Standard Bank Arena to celebrate 75th anniversary. Haggie Pension Fund – 91% of members voted in favour of conversion to defined contribution with effect from 1 July 1996. All companies, except McKinnon and Reclam, have poor half-year because of weakening demand and thin margins. Haggie Rand buys Fast Services and Supplies (Pty) Ltd for R2.2 million to get into the crane servicing business. The decision to sell Mkonge Farm – sold for R3 million w.e.f 1 October 1996.

CWI is still in a price war and losing money. D J K Murray (Ingwe Coal) appointed to board. Net earnings per share on 30 June 1996 decline 24% from 169 cents to 129 cents. Interim dividend reduced from 55 cents to 45 cents.

Share price falls to around 2000. Malbak announces unbundling. Rand continues to decline: US$ = R4.50 and above. £= R7.00 and above. Forward cover contracts expire in August/September.

HRL acquires Alan H Reid in Australia for A$4 million = R15 million. HRL concludes the sale/leaseback agreement with FNB generating R75 million cash. Share price falls to 1750 and then recovers to 2000.

In December, US$ = R4066 and £= R7.81.

HRL approves CAPEX of R6.5 million for the rope plasticization line. 1977 budgeted operating profit of R128 million compared with 1996 F3 of R77 million.

Smith Borkum Hare review Haggie – value Haggie between 2255 and 2535 but do not expect these values to be reached in the short term anticipation of poor 1996 results. Haggie could become an attractive buying opportunity. Rex

Gibsons “Nerves of Steel” published.

Malbak shareholders authorise directors to sell 36% of Haggie shareholding.

1997 EPS down 41% and dividend

reduced to 80 cents. Graham Boustred retires as a director (appointed May 1980) on 27 March 1997. Haggie share starts year trading in R20.00 TO R22.00 range. R6.5 million CAPEX for computer system at Jupiter approved by the board on 27 March 1997. Gordon Russell to satisfy himself that there was 100% endorsement of the project by line management. A board meeting on 26 June 1997 this vote deferred pending further investigation on the need for it.

The vote was finally approved by the board on 28 November 1997. Baan will take 18 months to commission. Amic Industries Ltd – through Scaw Metals – buys 3.4 million of Malbaks shares for R25 per share giving them 52% holding of Haggie.

On 26 June 1997 Hugh Brown and Denzil McGlashan resign as directors and the board reconstituted as follows: I S Haggie (President), A Harris (Chairman), DC G Murray (Group managing), L Boyd (Alternate F E Ferreira), WFE Bragg *, I J Burger, C J Cross, C M Longo, D J K Murray, G R Pardoe (Alternate E K Diack), G G Russell*, WD Smart (*British) Malbaks remaining 20% - 4 210 474 shares – to be placed so that no single shareholder has more than ± 5%. Haggie share is trading at 1830 cents. Haggie Pension Fund transfers pensioners to Sanlam in an R200 million deal. Amic takes their shareholding to 72% making the average price of shares purchased R21.00. Haggie declares an interim dividend of 45 cents or capitalisation award at a 7% premium on the dividend.

G R Pardoe resigns from the board to take up a senior position in AAC and E K Diack was appointed to the board. Waste slippage at Waste Services Bul-Bul landfill site on 8 September 1997.

Southern Healthcare JV appointed to take over administration of Haggie Medical Scheme from Medscheme (after 26 years) with effect from 1 January 1998 to convert HMS into a proper managed health care fund and thereby contain costs. Brian Nelson, General Manager of Haggie Steel Cord, retires on 30 November 1997. Bill Scurr was appointed General Manager of Haggie Steel Cord. Jonathan Malck resigns as MD of CWI and Kevin Burger moves from Somta Tools’ MD to CWI’s MD and Pat O’Dougherty takes over as “caretaker” GM of Somta Tools and Saws. Haggie Steel Cord records a loss of R19.0 million compared with a budgeted loss of R8 million causing serious concern at the board level about the viability of

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the project. In December, Haggie share drops to R14.00 with buyers at R10.00.

HRL reshuffles top management, Alan Crozier succeeds Arie van Esch as financial director, Arie becomes General Manager of Lifting Services and Rodney Mahon succeeds Bill Scurr as technical director. Haggie board starts examining feasibility/mechanism to dispose of noncore businesses to bring Haggie back to the core business of converting steel rod into wire, rope and chain.

1998

Gordon Russell (Managing Director of Haggie Rand Ltd and a director of Haggie Ltd) resigns with effect from 19 January 1998. Chris Murray to take up the reins as Managing Director of Haggie Rand. Gillie Webb, deputy chairman of Haggie from 1962 to 1970, died on 20.01.98 at age of 99.

Rodney Mahon re-appointed Works Director Jupiter, Keith Taylor appointed Works Director Germiston. Amic raises their shareholding to 75.2%.

Maksal Tubes sold for R65 million (NAV + R3 million).Final dividend for 1997 of 105 cents declared. All participants in the Haggie Employees Trust share incentive scheme forfeit their shares because of low share price (R12.00). Reclam Group sold for R85 million with effect from 1 January 1998 (NAV + R33 million) Somta Saws sold for R6.0 million, R3 million less than NAV. Interim dividend for 45 cents declared McKinnon Chains minorities (40%) acquired 1 July 1998 for R60 million making it a wholly-owned subsidiary of Haggie Rand Ltd. G Russell sues Haggie for breach of the employment contract.

Haggie group moves from 20% borrowed to a net cash position. Mike McNally appointed General Manager of Haggie Europe/Le Lis – withdrawn as a director of Haggie Rand on 30 November 1998.

JSE all share index declines by 30% causing a 27% drop in Haggie Pension Fund members ‘fund credits. Jupiter IBU structure (introduced by Russell/ McNally) was dismantled.

BAAN starts running into practical implementation (rope lengths) difficulties. Proposed scheme of arrangement announced in the press and on SENS on Wednesday 25 November 1998 whereby Haggie’s listing on the JSE is terminated on 29 January 1999 (subject to minority shareholder approval at scheme meeting on 14 January 1999) and the company becomes a wholly-owned subsidiary of Amic. Haggie Steel Cord closed on 15 December 1998.

1999 Minority shareholders approve scheme arrangement and Haggie delisted at the close of trading on Friday

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29 January 1999. Capex for R7.9 million Frigerio wire drawing machine for Jupiter approved. Somta Tools sold for R92 million (£4.5 million), R51,3 million (£2.5 million) paid immediately and R41 million (£2.0 million) over 3 years.

Copalcor sold for R41.1 million.

Messrs R C Mahon, D C G Murray, WD Smart and K L Taylor appointed directors of the Scaw Metals Division Board.

Capex for R4503 million Purchase of plant to increase the large diameter rope capacity at Jupiter by 4000 tons BAAN project terminated. On 1 July 1999 the assets and members of Haggie Pension Fund transferred to the Alexander Forbes Retirement Fund – umbrella fund with investment options for members and the AFRF becomes the retirement fund for all new Scaw staff employees.

2000 Capex for R12 million Frigerio

Wire Drawing Machine for Wire & Strand Germiston approved. Sold Haggie Europe (Gen Manager – Mike McNally resigned)

2001 Bill Smart is appointed Group Financial Director of Scaw Metals Group.

Haggie Lifting Services was sold to Toco for R3 million. Since 1999 15% reduction in compliment through retrenchment/ retirement. Kevin Burger resigns and Bushy Botha is appointed to succeed him as General Manager of CWI. Jimmy Lythgoe retired. 1 November 2001 – Haggie Medical Scheme amalgamates with National Medical Plan. Final payment for Somta Tools received giving an additional (forex) profit of R5 million.

Haggie Ltd liquidated 27 March 2001.

2002 PWB Anchor (Australia) was

acquired for R30 million. Rules of Alexander Forbes Retirement Fund changed to make normal retirement age of 60 (not 65) in respect of all employees engaged after 1 May 2002. Ian Haggie dies on 27 June 2002 with his funeral taking place at St Georges Parktown on 2 July 2002.

2003 Last Haggie Exco (formerly

Haggie Board) was held on Tuesday 23 September 2003. This change coincides with the centralisation of all service functions at Scaw Germiston. Decided to transfer “ownership” of Haggie Son & Love Jubilee Trust and J McGill Love Trust to the Haggie family.

Haggie Disability Fund to be dissolved and benefits “outsourced via insurance” wef 1 January 2004. R5 million surpluses (out of total asset of R16 million) on loan to Haggie to be paid to self-insurance fund at Guardrisk. R1.7 million fraud at Mckinnon Chain – biggest fraud ever. Fascor (last non-core business) disposed of for R10 million. Chris Murray retires in December 2003.

2004 Notification of final liquidation of

Haggie Ltd on 28 January 2004 received Master of The High Court. Haggie Employees and pensioners transferred from NMP to AACMED with effect from 1 January 2005 with pensioners being granted a 100% subsidy if electing the Standard Care option. Subsidy of Managed Care continues to escalate at CPIX (4.5% for 2005) GDC Hauliers dispute R34,3 million ($2.3 million) settled in Appeal Court foyer by payment of R3.5 million to Glyn Cohen of GDC. Sale & Leaseback agreements claim by SARS against Haggie Metals (Pty) Ltd withdrawn and R29 000 tax refund due to Haggie Metals repaid. Haggie Metals to be deregistered.

2005 Keith Taylor appointed General

Manager with effect from 1 January 2005 responsible for Steel Wire Rope, Wire & Strand, Distribution and Fibre Products and Rodney Mahon retires.

Wire Rod Products (Haggie) employees and pensioners admitted as members of Anglo Medical Scheme, having previously been members of Haggie Medical Scheme and National Medical Plan. Arie van Esch (International Commercial Marketing Manager) retires early at the request of A Harris on 31 March 2005.

2006 AltaSteel acquired.

2007 Scaw South Africa’s businesses

re-incorporated as Scaw South Africa (Pty) Ltd to facilitate BEE transaction and 26% BEE shareholding which is well documented elsewhere.

2008 Scaw SA and CWI apply to

Competition Tribunal for leniency and conditional immunity in response to the investigation of the steel industry. Scaw acquires Ozz industries for R635 million.

Ozz division listed within Scaw SA wef 1

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July 2008. Scaw acquires Leo Scrap for R30 million. Tony Harris retires and is succeeded by Norman Mbazima as CEO. Chris Davis succeeds Ian Botha as CFO.

and Wire & Strand over housing and service allowance but rejected housing allowance demand. Strike ended on Monday 4 October 2010.

2009

Ithala dispute settled by payment by Scaw of R11.5 million to Ithala. Competition Commission’s investigation in the steel industry, specifically rod, rebar and wire products referred to the Competition Tribunal.

Scaw SA and CWI granted conditional immunity but ArcelorMittal, Cape Gate, Cape Town Iron Steel Works SAISI, Allens Mescho, Hendrick, Agi Wire and Associated Wire Industries were named as respondents facing possible penalties.

2011 Moly-Cop and AltaSteel sold by Anglo for R16,4 billion (US$ 1.1 billion) to OneSteel of Australia. Scaw Pension Fund and Ozz Pension/Provident Fund employees (not pensioners) transferred to Alexander Forbes Retirement Fund.

The normal retirement date of Scaw employees remains 60 whereas Ozz employees retain their 65 age. Employer contributions increased from 11.5% to 12.5%. Tony Harris, retired Executive Chairman of the Scaw Metals Group, died from a long illness on 16 April 2011.

Wayne Thompson resigns as of 30 September 2009 and Mike Borello is appointed to succeed him as Manager, Steel Wire Rope. Anglo American announces its intention to divest the Scaw Metals Group and the move of Scaws CEO, Norman Mbazima, to Anglo Coal. Chris Davis appointed Interim CEO Scaw Metals Group wef 30 November 2009.

Marsha Govender appointed Company Secretary of Scaw SA wef 1 April 2011 to succeed Campbell McKie Thomson who was appointed Company Secretary of Haggie Ltd in 1984 and retires in February 2012.

At Scaw SA board on 30 November 2009, Sipho Pityane, representing BEECO, advised the board: • Anglo must consult with BEECO over the disposal of Scaw.

• Reconstitution of Scaw SA board to be reviewed with BEECO to align with King III corporate governance.

2010 Keith Taylor and Mike Borello

resign wef 30 June 2010. Markus Hannemann was appointed to succeed Keith Taylor as a director of Scaw SA and GM of Wire Rod Products. David Jennings of Anglo London seconded to Scaw SA as acting CFO pending sale of Scaw SA. 2x week legal strike at Jupiter

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2012 Scaw sold to IDC/Government

26% minority BEE shareholders remain.

2016 IDC starts process to sell Scaw as follows: • Haggie businesses, melt shop and scrap to Barnes wire.

• Cast Products to Amsted • Grinding media to Magottheaux • CWI/IDC owns 50% and Arcelor Mittal SA the other 50% 2017 The great Haggie, initially

reduced to a brand name are now likely to disappear forever.

2018 Barnes Fencing concludes the

Purchase of Haggie Steel Wire Rope, Wire & Strand, McKinnon, Scaw Rod Mill and Melt Shop and announces the intention to rebuild the “HAGGIE” brand name.

The founders Gordon S Haggie and James MacGill Love

First Steel Wire Rope manufactured in South Africa. The first order from Tweefontein Colliery for 6000feet of 3/4inch haulage rope. This was coil number one. William Skillings and Mark Mather distribution@haggie.co.za

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Haggie and the Scaw Metals Group: 100 years of history – 1921 to 2021 This is the last in a series about the 100-year history of Scaw Metals Group, which began with Haggie as the frontrunner in 1921.

(The Barnes Group acquired Scaw Metals-Haggie in 2018.)

World leaders then and now Scaw Metals Group is a leading, international, South Africa-based manufacturer of steel products with entities across the world distributing its highly specialised and critical consumable products to the mining, power, offshore oil and gas, construction, commercial and other industrial sectors.

Like its frontrunner Haggie, the Scaw business was established shortly after World War I ended (19141918) and survived the Great Depression (19291933), the Second World War (1939-1945) and many other significant events in history.

The discovery of gold!

The histories of Scaw and Haggie are inextricably linked to the discovery of gold. One summer’s day in 1886, two prospectors discovered gold on the farm Langlaagte outside Johannesburg and 10 years later the Witwatersrand was the richest gold mining town in the world. Among the individuals to be drawn by the business opportunities were Manoel Santiago, Maurice Smollen, James MacGill Love and Gordon Stewart Haggie.

While MacGill Love and Haggie were planning the establishment of South Africa’s first steel wire rope making factory for the manufacture of mining ropes, launched in 1921, Santiago was rolling out Steel Ceilings and Aluminium Works (SCAW) in Eloff Street in downtown Johannesburg (1918).

It was in 1924 that Scaw Metals was founded.

Smollen had joined Santiago to form the limited liability company. Their success attracted the Boustreds, South Africa’s business barons of Anglo American fame, and between 1937 and 1939, the Boustreds bought Scaw and listed it on the Johannesburg Stock Exchange. In 1939, with the business having outgrown the Eloff Street works, Scaw was moved to the Union Junction site in Germiston.

The original product range was discontinued and the business grew into one of the largest foundries in the world. By 1964, when Anglo American Plc bought 100% of Scaw, the Union Junction manufacturing operation was world-renowned for its cast steel railway wheels and locomotive frames, cast and forged grinding media, and high chromium iron castings.

Dominating world markets Together the Scaw and Haggie operations forged ahead to dominate key industries in South Africa and consistently achieve major exports of its reinforcing bar, and low and high carbon wire rod; prestressed concrete wire and strand to the construction industry; steel wire rope and wire products to the deep level, surface level and open cast mining industries, and offshore oil markets; coal grinding components to power stations in Europe, China and Mexico; and cast steel railway components to North America, Taiwan and Africa In 2007, Scaw South Africa was valued at R5.3 billion and became the first steel producer to achieve a BEE rating. Then came a major turn of events.

In 2009, Anglo American announced its intention to sell its majority shareholding in the group.

The government’s financier owns the group for five years It was in 2012 that Anglo sold Scaw South Africa, for R3.4 billion, to an investment consortium led by South Africa’s State-owned Industrial Development Corporation of South Africa (IDC), which is the government’s financier, and Anglo American’s BEE partners in Scaw, being Izingwe Holdings (Pty) Limited, Shanduka Resources (Pty) Limited and the Southern Palace Group of Companies (Pty) Limited. By 2016, due to the organisation’s ongoing commitment to transformation, it was awarded the Most Transformed Company of the Year by the Steel and Engineering Industries Federation of South Africa (SEIFSA).

It was around this time that the IDC announced its intention to restructure Scaw Metals into three standalone entities and secure strategic equity partners for each of the units. By July 2017, the IDC reached an agreement with Barnes Southern Palace (BSP) to buy Scaw’s rolled products and wire rod products businesses, which employed more than half of Scaw’s 3 500 workforces, leading to a new phase in the life of the invincible Scaw-Haggie group, a survivor with proven nerves of steel.

2018: Barnes Group rebuilds the business in two years Rami and Doron Barnes, father and son, took over Scaw on 1 May 2018 and within one year they

stabilised the business. Sadly, Rami passed away shortly after the Barnes Group purchased Scaw.

Doron leads the once again upwardly-mobile steel products’ manufacturer as chief executive officer.

After Scaw had sustained financial losses in the last years leading up to the Barnes’ acquisition, losses were halved in the second year of Barnes’ investment and profit is being made in the third year (2021), and good growth is projected for the future.

How did they do it? Amongst other things, Barnes reinstated the renovation of existing machinery and investment in new machinery throughout its manufacturing operations.

New production improvement programmes are yielding good results in productivity and recording healthy growth of the business. Haggie’s generalpurpose products (fishing ropes, roof anchors, small diameter cord for hoists, etc) have been reintroduced and are already replacing imports into the country and growing the sales portfolio of the group. Things are looking up for the Barnes-Scaw-Haggie business.

A good fit The Barnes Group is a good fit for Scaw, being a global provider of highly engineered products. It is a diversified group of companies that specialises, amongst other things, in the manufacture of wire products.

Barnes Group bought Union Junction’s rod yard, rolling mill (rolled and wire rod products) and melt shop, Haggie’s steel wire rope factory (including fibre rope), wire & strand factory and distribution network, McKinnon Chain division and overseas operations Haggie North America and Haggie Reid in Australia.

It also bought the Scrap Processing division and machinery at the Union Junction operation, the source of the raw, steel material for Scaw’s downstream products.

Scaw’s Grinding Media and Cast Products divisions were sold by the IDC to other strategic equity partners. The IDC has remained a shareholder of the unbundled business with a 25% shareholding.

The best is yet to come Scaw Metals and Haggie have stood the test of 100 years. Under new leadership, the Scaw Metals Group is revitalised, continuing to manufacture to exacting standards and looking forward to a future of continued development, growth and excellence in service delivery. For this survivor of survivors, the best is yet to come.

Haggie, +27 (0) 11 601 8400, distribution@haggie.co.za, www.scaw.co.za

33 OPERATOR: __________________________

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REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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35 OPERATOR: __________________________

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REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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37 OPERATOR: __________________________

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38

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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39 OPERATOR: __________________________

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

40

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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41 OPERATOR: __________________________

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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43 OPERATOR: __________________________

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

44

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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45 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

46

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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47 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

48

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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49 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

50

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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51 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

52

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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53 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

54

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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55 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

56

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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57 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

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REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

58

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

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THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

Your advert can be here!

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59 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

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Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

Your advert can be here!

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P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

Your advert can be here!

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P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

61 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

Your advert can be here!

FRI

SAT

P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

62

REGISTER: FORKLIFT TRUCKS

OPERATOR: __________________________ ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

Your advert can be here!

FRI

SAT

P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

63 OPERATOR: __________________________

TRUCK NUMBER: ______________________________ MON

TUES

WED

THUR

Enter and adjust seat and mirrors Gauges before switching on Park brake engaged Steering play Ignition key operative Gauges after switching on Indicators Lights Horn Raise & lower - cylinder & chain Tilt- cylinder condition Fork position and fork locks Forward and reverse Steering lock to lock Foot brake Hand brake Operator signature Supervisor signature Date

Your advert can be here!

FRI

SAT

P R E S T A R T C H E C K

O P E R A T I N G C H E C K S

REGISTER: FORKLIFT TRUCKS

ITEM TO BE CHECKED MON Hour meter reading Overalls, hard hat and safety shoes General bodywork Driver's compartment Battery terminals and cables Electrolyte levels Tyre pressure and condition Wheel nuts Overhead guard/cab Fuel cap Radiator water level and cap Water pump housing Fan blades and fan belt Engine oil level Hydraulic oil level Brake fluid levels Brake fluid leaks Fuel leaks Fuel levels Hydraulic oil leaks Engine oil leaks Water leaks Fork condition Lad backrest and carriage Mast and chain Hydraulic cylinders Pipes and hoses Transmission oil

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FORKLIFTS WEIGHT

Why do forklifts weigh so much?

The main reason a forklift is so heavy is that it includes an internal counterweight.

This is necessary in order to keep a forklift from tipping over when in use. It helps to maintain forklift balance and a stable center of gravity.

How center of gravity is affected by the weight of a forklift, and its load: As the center of gravity for the load moves forward, the lifting capacity for the forklift decreases. The stated capacity of a forklift only applies to the load center indicated on the data plate. If the load is not centred at the specified position, the forklift's capacity will be reduced.

engine or another non-symmetrical item, care must be taken to estimate the center of gravity. Likewise, a large load may have a load center much farther out than 60 cm.

The data plate located on your lift truck will tell you what your maximum lifting capacity is given a stated load centre and load height. If your load centre is farther out than the load centre for maximum lift capacity for your forklift, then your maximum lifting capacity is reduced, potentially dramatically.

The Forklift's Centre The lift truck also has a centre of gravity, which shifts once the truck picks up a load.

When the load is lifted, the centre of gravity moves forward. Care must be taken to maintain the centre of gravity within the stability triangle of the forklift by not lifting more than the maximum allowable given the load centre.

Operating safely

Any discussion of the basics of forklift trucks would be incomplete without a discussion of the centre of gravity and the stability triangle. One of the hardest things for lift truck operators to learn during training is how to maintain their centre of gravity within their stability triangle.

A forklift has a three-point suspension system. The points are found over both of the two load (front) wheels and midway between the rear wheels. When imaginary lines are drawn to connect them, what's known as the stability triangle is formed. The operator must ensure that the center of gravity of th e combined forklift and load remains within the stability triangle to guard against tipping over.

When working, stability can be best maintained by keeping loads low to the ground and travelling with caution when turning, stopping, and starting. Also, be sure to wear your seatbelt. One area of particular concern is on ramps, slopes, or otherwise uneven terrain. Never raise a load or turn on an uneven surface. In such cases, your centre of gravity will quickly move outside of the stability triangle.

According to experts, overturns are the most common type of forklift accident, accounting for 24 percent of such accidents.

Factors such as heavy and/or unbalanced loads, driving on sloping or uneven terrain, or turning with elevated loads can result in the centre of gravity moving outside of the triangle. The result can be catastrophic.

The Load Centre It's crucial to pay attention not only to the centre of gravity of the load you are lifting but especially to the combined centre of gravity: that of the lift truck and the load it is picking up.

Let’s start by looking at the centre of gravity of the load, which is known as the load centre. For a uniform load, such as palletized goods or a bale of material, this can be easily determined. For example, for a uniform load on a 1,2 m-long pallet, the load centre is at 60 cm, which is a common load centre for many smaller-capacity forklifts.

When a load is uncentered, however, such as with an

While travelling empty on a ramp, your forks should always point downhill. When carrying a load, your forks should always point toward the top of the ramp, so the load will not fall off. If a forklift starts to tip over while you are operating it, do not try to jump clear of the machine.

Experts recommend staying in the cabin of the vehicle and leaning away from the direction, you're falling. Grip the wheel tightly and brace your feet.

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TYPES OF FORKLIFTS

Types of forklifts (Supported by SANS 10388) All forklifts including attachments & special equipment Counterbalance Forklift There are two main variations of counterbalance forklifts: 1. Combustion engine counter balance forklifts 2. Battery electric counter balance forklifts

Large lift trucks All Rough Terrain Forklift trucks Rough Terrain Forklift Also known as a straight mast forklift, the rough terrain forklift is designed specifically for outdoor job sites. These trucks have sturdy pneumatic tires that are oversized and threaded, giving them better balance and stability to safely transport materials on rocky ground.

These rugged machines are designed to be driven over uneven and rocky surfaces, while still transporting a heavy load. Due to size, tyres, and weight capacity, a rough terrain lift is primarily used outdoors.

Large lift trucks

The term counter balance forklift is derived from the design of the unit where the forklift has a heavy counterweight that off-sets the weight of the load being carried on the tyres out in front.

In combustion forklifts, the counterbalance is integrated to the rear of the unit, whilst battery electric forklifts are counterbalanced through the additional weight of the batteries installed into the unit.

As the name suggests, big forklift trucks are a subsection of forklifts that are far larger in scale than their compact cousins. Typically powered by diesel, these large-scale machines are built explicitly for shifting larger loads in larger workspaces.

These trucks are available in capacities ranging from 5 000 to 60kg. They are commonly used for container handling and very heavy loads. Types of trucks in this category include Counterbalanced FLTs, Reach stackers; and Straddle carriers.

Without the counterbalance forklifts would become extremely unbalanced when picking up heavy loads with a heightened risk of the unit tipping forwards or over with the extra weight of the load on the tynes.

Order picking lift trucks Order picker trucks are types of lift trucks that are controlled from a carriage wherein the operator stance can be found. Order picker trucks are like forklift trucks, but instead of forks, these trucks are fitted with a working platform wherein the operator can manoeuvre the machine. Operators ride on an order picker, which lifts them up to the height of industrial storage racks where they can pick items and place them on the machine’s carry deck. This process allows operators to deliver one or two units instead of a full pallet of material. Order picker capacities can range from several hundred kg.

Truck-mounted forklift The truck mounted forklift is a very versatile forklift. It is mounted on the back of a truck and can be carried to the worksite and dismounted there to unload the product right at the site making it unnecessary for the customer to have a forklift at the construction site.

Handy for deliveries, this lift truck offers flexibility and portability for on- and off-loading on site. It’s “piggybacked” on the rear of any truck or trailer combination.

Pallet truck A pallet truck (also known as a Walkie, Walkie-rider or Rider mtorised truck, pump truck or pallet jack) is a wheeled trolley designed to lift and transport pallets. The truck's tapered forks slot underneath the pallet and the pump handle can then be used to raise and lower the load.

Pallet trucks are commonly seen in warehouses, stockrooms, and other environments where wooden pallets are frequently used. There are many different

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TYPES OF FORKLIFTS types of pallet truck available to suit all sorts of different requirements.

The main advantage of reach trucks is that they are very efficient in small spaces, are commonly available and are relatively simple to use.

Side loaders Side loader forklifts are powerful industrial trucks that lift loads from the side, so they are well suited to carry wide or long loads. Narrow aisles, which may be a problem for regular forklift trucks, can be easily navigated through in a side loader.

They come in handy when long loads need to be transported - such as pipes, and lengths of timber.

Diesel side loaders are often used in rough terrain whereas the electric powered models are used indoors on smooth surfaces.

Pedestrian controlled lift trucks These forklifts are very common in warehouses and factories. They are designed to be highly efficient method of storage as they operate in narrow isles.

A pedestrian-controlled lift truck (low-lift platform truck, elevating truck) contains a platform which is supported pivotably via a base frame inner toothed racks and outer toothed racks. This is arranged on both sides below the base frame and is connected via pinion shafts and cranks.

A first motor drive is controlled in such a manner that the inner toothed racks and the outer toothed racks are moved in an opposed direction in order to execute a stepup or step-down movement. A pendulum and two micro switches control a second motor drive in order to move a balancing rod in any direction so that the platform is always held in a horizontally balanced manner when the pedestrian-controlled lift truck is moving up or down steps.

Reach trucks A reach truck is a narrow-aisle, right-angle stacking truck designed for unit load handling with rack interface. These lift trucks are meant to operate in narrow aisles and are best for storing and retrieving pallets in racks. They are engineered with two outer legs that help distribute the load weight, and a single set of wheels in the back.

Telehandlers A telescopic handler or telehandler is a machine that is widely used in the lifting industry.

It is one of the most versatile pieces of equipment you will find on a building site. The telehandler features an extendable boom that can be fitted with a number of attachments in order to increase functionality.

At the end of the boom, the operator can fit one of several attachments such as a bucket, pallet fork, muck grab, or lift table. In some cases, it can even be converted into a crane.

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FORKLIFTS

Should you buy or rent a forklift There are pros and cons for buying and renting. It’s a business individual needs and operations that determine if you should rent or buy.

How many forklifts do you run in a day?

No Usage Limits

The answer to this question will make it clear if you need to buy or rent a forklift. However, there is a number of other variables that should be considered before you rent/buy forklift.

Since you own the forklift, you are free to use it at any time without any obligations. With a rental, you are generally billed on the number of hours you us the lift.

These factors include evaluating your financial capabilities, and cost of renting v/s ownership among other factors.

With all these different variables, it’s best to understand the pros and cons to help you decide which is better for your business needs.

Pros of buying a forklift Ownership Once the sale is complete, you will own the forklift, so you can make any modifications necessary. Maintenance is your sole responsibility, which means you have to ensure problems are fixed immediately.

You do not need to wait for the forklift rental company to address mechanical problems or need permission to make modifications. Since you are the owner, you can sell the forklift once you are done with it, giving you an opportunity to recover some of the initial cost.

Tax Incentives SARS allows you to fully deduct the cost of some of the newly purchased machinery in the first year. If your forklift fails to meet the threshold, you may file for depreciation deduction for it.

Your own employees will also have a better opportunity of mastering it since it is at their disposal any time.

Cons of buying a forklift Higher Initial Cost You will be required to meet a higher initial cost that may be difficult to budget. You may find it also difficult to pay for the forklift all at once.

The higher initial cost may make it impossible to buy the model you want and may force you to buy a lower-cost option.

Maintenance cost You are solely responsible for all maintenance cost, and this can be high depending on the mechanical issues at hand. You could end up burdened with a broken forklift that you cannot sell or return.

Does your forklift warranty cover repairs? Keep an eye to know for how long it is covered.

Getting stuck with an outdated model Even though ownership is probably the biggest advantage to purchasing a forklift, it can also be the main disadvantage. If you buy a high-tech forklift, you run the risk that the machine may become technologically obsolete down the road.

What happens when a forklift becomes technologically obsolete? You will be forced to buy a new forklift long before you had budgeted for.

Pros of renting a forklift Flexibility Renting a forklift gives your business significant flexibility with its operations.

If your business is experiencing a decline in business or rapid growth, you can easily remove or add a forklift rental from your fleet.

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Predictable monthly spending

compared to buying a forklift.

Some rental companies include the cost of forklift maintenance as part of the monthly rental fee. This is known as the maintenance package. What is the benefit of buying a maintenance package? It makes it easy for you to budget since you do not have to deal with any unpleasant surprises from forklift breakdown.

The rental company charges for their equipment since they incur the cost of repairs and depreciation. They have to account for all these expenses and that is why the monthly fee of renting forklift is usually higher.

Test new equipment By utilizing a rental program, you can test new models without having the obligation to buying it. After the rent term, you can decide whether to buy your own or rent it once more.

Improved productivity Most rental programs have frequent replacement schedules aimed at reducing the average age of their client’s fleet. This gives you an opportunity to have relatively new fleet, hence reducing downtime and boosting the likelihood of peak efficiency.

Regular equipment replacement Renting allows for regular equipment replacement. This means you have a chance to use newer models of forklifts.

Your employees will enjoy the safety and productivity benefits associated with newer models.

Lower initial costs Renting helps your business benefit from the high performance of newer technologies without incurring the cost of buying it.

If your business is new, you do not have to incur the high cost of buying forklifts. This flexibility makes it easy to scale your business and offers you room to make adjustments.

If your needs change at any given point in time, you can easily request for a different type of forklift.

Cons of Renting a Forklift High monthly cost Renting a forklift is likely to have a high monthly cost

It doesn’t cater to specialised needs A forklift’s rental company usually supplies the most common types of forklifts. What happens if you have a specialised need? You will have to buy a forklift.

Where is your business located?

Have you considered the location of your company before deciding to rent? If you don’t have a rental provider near you, you may incur huge transportation costs for delivering and picking up the forklift.

Therefore, it is advisable to buy your forklift if your business’s location is a challenge.

There are allowable hours of usage Some rental companies specify the maximum usage hours.

What happens if you exceed a maximum number of hours allowed? Violation is likely to attract penalties.

Fully understand every Pro and Con before renting a forklift Considered alone, any of the above pros or cons could be the determinant factor in your decision.

However, you should take each pro and con into consideration and fully understand each before renting a forklift or buying.

That means, for instance, comparing the relative cost to your business needs or your potential maintenance services might outweigh the cost of your location (or vice versa).

Whatever your decision, just ensure you have a committed forklift rental partner who will make your rental experience more beneficial. Are you looking for products and service for material handling?

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How to get your forklift license

If you’re looking to get your forklift license, now is a great time. The number of forklift driver jobs is escalating due to the increasing usage of counterbalance forklift trucks in the manufacturing and warehousing industries.

A forklift is a lifting truck that uses forks or other attachments for transporting goods over short distances. It is used for loading and offloading.

You can apply for a course at a forklift training school to acquire an operator’s license and certificate.

Forklift training school The best forklift schools are accredited and recognized by TETA/CETA to provide forklift safety training.

But if you’re new to forklifts, you probably have a lot of questions: • How do I become a forklift operator?

• What do I need to study?

• How do I get certified?

In order to get your forklift operator’s license, you must receive: • Formal instruction • Hands-on training and evaluation • Certification Formal instruction “Formal instruction” simply means classroom teaching.

It can consist of a “lecture, discussion, interactive computer learning, video, and/or written material” But the instruction must also cover certain topics to be considered comprehensive.

Basically any training program should cover: • How to operate the different types of truck the operator will be using (instructions, safety precautions, limitations, etc.)

• Forklift capacity, stability, steering, maneuvering, and visibility • How to construct, transport, stack, and unstack loads • Pre-shift inspections and any maintenance the operator will be required to perform • How forklift attachments work • The dangers of operating in confined/hazardous spaces and the necessary precautions drivers should take when doing so • How to refuel (internal combustion trucks) and/or charge batteries (electric trucks) • How to safely operate a fork truck on different surface conditions, ramps, and slopes • How to work safely around pedestrians in the workplace Hands-on training and evaluation This portion of training must consist of “demonstrations performed by the trainer and practical exercises performed by the trainee” In other words, you must be shown how to actually operate a forklift and also be observed doing so.

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the training in one of the accredited skills development providers.

You should apply for the 242974 SAQA Unit Standard titled “Operate counter-balanced lift truck” or the 244365 SAQA Unit Standard titled “Lift and move material and equipment by means of a forklift”.

After the training, the school assesses you to determine whether you are competent.

By the end of the forklift operator training course, you should be able to operate a counter-balanced lift truck safely, conduct pre and post inspections, and handle the loading and storage of freight.

You will get a forklift license after the training that allows you to operate the machine. Forklift training and certification take 1-2 weeks.

Forklift license renewal A forklift license expires after two years in South Africa and can be renewed in a day. You might be required to drive a forklift during the reassessment.

This process is called recertification. Your ID, old forklift license, and certificate are required when renewing your license.

Forklift license codes There are four forklift license codes: F1, F2, F3, and F4 F1: Counterbalanced forklift truck up to a rated capacity of 3000kg F2: Counterbalanced forklift truck up to a rated capacity of 7000kg F3: Counterbalanced forklift truck up to a rated capacity of 15000kg F4: Counterbalanced forklift truck above a rated capacity of 15000kg Do you need a driver's license to operate a forklift?

While it might seem like it, the reality is that a forklift operator license is entirely separate from a driver's license.

That means that you can have one without having the other.

Forklift driver job descriptions Most forklift driver job descriptions contain the following tasks: • Moving or stacking different products or materials within the factory • Carry raw materials to the manufacturing facility and deliver finished products to assigned distribution areas • Perform pre-checks to assure the working capability of the forklift • Reporting any damages that may occur while he is driving the forklift.

• Loading or offloading items from trucks • Stacking materials at the specified locations safely.

MAINTENANCE

How a good maintenance contract will save you money Forklifts, like most things, can decline over time with regular use. When it comes to forklifts, the purchase price is not the only cost to consider. The cost of ownership of your forklift can be affected by fuel, maintenance, labour, electricity and incorrect use of the material handling equipment.

Here are some tips that to lower your forklift operating costs and save your company money

Make sure your batteries and chargers are taken care of if you run electric forklifts

Train your forklift operators

If your material handling warehouse runs on electric forklifts, it is important to take care of your batteries.

A forklift can do a lot of damage to a building, warehouse racking, the operator and or other people if the forklift driver is not fully competent on how to operate a forklift properly.

Damaged batteries, forklifts or injuries can result from improper battery handling. A mistake that often happens is mismatching the voltage size of battery to the charger.

If you are not sure of what voltage the battery is, count the cells and multiply that number by two.

Also, be sure your industrial forklift batteries are watered after five to ten charges depending on the age of the battery.

Prevent expensive repairs with a forklift maintenance For optimal performance, it’s important to take care of the forklifts in your fleet.

For this reason, it is important to properly train all warehouse employees that operate forklifts. This training will not only allow the driver to get familiar with the equipment, it will also teach them what to look for when the truck is not operating in prime condition.

The easiest way to ensure this is by adding a scheduled preventative maintenance plan to your forklift fleet to make sure your forklifts are in prime working condition.

Over time, this preventative maintenance will save you from money lost from downtime and costly major repairs.

Complete your daily checks DMR18 requires that every forklift operator perform a pre-operation inspection prior to their shift to make sure everything is working properly.

Oils, tires, water and safety items like seatbelt, rating plate, and mirrors should be checked before every shift to ensure top performance of your forklift and safety of your employees.

Pay attention to application of your equipment Be sure you are using the correct equipment for the task at hand. You can use data to measure this. Turn on your forklift and take a look at the hour meters.

If the drive motors have considerably more hours than the lift motor, it could mean your lift truck is not being used correctly.

A more appropriate piece of equipment, like a pallet truck or pallet jack, could be used in its place.

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Do’s and Don’ts on a forklift Workplace safety depends on a combination of factors. Attentive supervision helps.

So does comprehensive training, with a keen eye toward DMR 18 rules & regulations.

But at the end of the day, safety is ultimately determined by each individual.

And that means forklift drivers should act in the best interests of total job safety. Sure, performance matters, but safety is the most important part of day-to-day forklift driving.

One of the most important parts of safe forklift operation is training. Without proper instruction, operating powered industrial trucks (forklifts, pallet jacks, man lifts, etc.) is a dangerous undertaking. Accidents and injuries are bound to happen without a comprehensive training program in place What to do – and what not to do on a forklift Safe forklift driving is all about what to keep your eye on – and also, specific things to avoid.

Do carry loads with the lift’s forks tilted back. Forklifts are top-heavy, so you need to ensure that the lift’s forks are approximately 15 – 25cm above the ground to avoid potential ground hazards.

Do use three points of contact when getting on or off a forklift. Use two hands and one foot or one hand and two feet as you climb up or down a lift. In addition, you should always face the lift any time you enter or exit.

Do wear the correct clothing. If you’re driving outdoors in the winter, hats, gloves & extra layers always help.

Don’t think you can brave the cold or harsh elements – a distracted forklift driver is more susceptible to accidents!

Do wear a seatbelt. Buckle up any time you use a lift.

Because, if you fail to do so, you risk falling out of a lift, particularly if you are using the lift on bumpy terrain.

Forklift safety do’s: tips & tricks for drivers When it comes to forklift safety, there are many things that lift operators should do day after day, such as: Do ensure forklift load is secure, especially on inclines and other tricky surfaces. If you operate forklift outside, pay attention to the terrain conditions, especially when it’s raining or snowing.

Do travel with a load at axle height. By keeping the load at axle height, a forklift operator can minimise the risk of an accident.

Do follow your company’s safety guidelines. Established policies & procedures are in place for a reason. They work.

Do take your scheduled break. Fatigue is another big factor in workplace mishaps. Tired forklift drivers are more dangerous forklift drivers. It’s all about avoiding distractions and keeping focus – see “correct clothing” above.

Do get a feel for your surroundings. If you’re working in a new area, take a quick inventory of blind spots, entries & exits, pedestrian walkways and more. The great unknown is never a good place to operate a forklift.

Forklift safety don’ts: what not to do on a forklift Now that you have a good idea of forklift do’s, it’s time to learn about some forklift don’ts.

Don’t carry or raise loads while the lift is moving. Only raise or lower loads when a lift is stopped. Also, loads should never be raised or lowered while a lift is turning.

Don’t exceed a lift’s rated capacity. Weigh a load before you use a lift to raise or lower it. Under no circumstances should a load exceed the lift’s rated capacity; otherwise, if the load is too heavy, it may cause a lift to tip over.

Don’t use a lift if it does comply with operational standards. Use an inspection checklist to verify the quality of a lift and ensure that it meets DMR18 standards. If a lift

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MAINTENANCE is not up to code, the lift should be taken out of use until it is repaired.

Safe drivers always alert their co-workers and supervisors to potential pitfalls.

Don’t leave a forklift unattended. Remember, anyone can access an unattended forklift, which can lead to an accident.

Don’t think everything’s a one-man job. Sometimes, having a spotter or “eyes in the back of your head” can help avoid accidents.

The buddy system works! Many accidents have been caused by not using a spotter or other driver to help with heavy loads, blind spots, and other dangerous scenarios.

Don’t be a follower. Proper safety requires leadership – the willingness to speak out when you think something’s wrong, and also going the extra mile.

Don’t skip forklift maintenance. Many accidents are the direct cause of poorly maintained lifts.

Loose hoses, bald tires, non-working safety signals and more – when talking about forklift do’s and don’ts, maintenance should be at the top of your list.

And speaking of lists, keeping a well-documented checklist of forklift maintenance activities is a great way to ensure all safety checks are accounted for!

Don’t forget your forklift certification renewal. If you’re training credentials are about to expire, make sure you go through the correct protocol for the renewal certificate.

Don’t ignore spills, poor lighting and other hazards.

If you’re serious about safety, take charge of the situation.

Form a safety committee. Sign up for training. Be proactive!

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When to repair or replace your forklift

Forklifts are important machines in many work environments. They perform a variety of jobs that can make a warehouse or other job site more efficient and productive. Yet, they also cost a lot to buy and maintain, and most don’t have a very long service life.

That’s why the decision to repair or replace a forklift is so important.

Most of the time, it is more cost-effective to repair rather than replace. But sooner or later trucks will wear out.

That’s when forklift replacement becomes a safety issue as well as an economic one.

can still do the job. It ends when no amount of repairs can keep it going. The economic life is the time for which it makes economic sense to maintain the forklift. This ends when it costs more to repair the forklift than to purchase a new one.

If an old truck is in good condition and can likely provide two or three more years of use, repairing it may be the better option. After a certain point, older machines will start having performance problems, higher operating costs, and other expenses.

Many companies use planned forklift replacement. This involves replacing a truck when it reaches a certain age, regardless of its condition. This approach takes the guesswork out of repair versus forklift replacement decisions. It makes it easier to budget for the cost of buying or leasing a new truck. It also improves performance and safety by having new and efficient forklifts. The downside to this approach is that you may get rid of trucks that still have several years of service life left in them.

Forklift replacement parts

Forklift replacement: the lifespan of the truck The average lifespan of a forklift is around 10,000 to 12,000 hours. This comes to about seven years of daily use. Some high-end forklifts have a lifespan of 20,000 hours or more.

Many factors can affect how long a truck lasts before needing forklift replacement. These include: • Type of forklift. Electric forklifts tend to last longer than those powered by gas, diesel, or propane. They have fewer moving parts to wear out and need fewer repairs.

• Work application. Forklifts used in rough terrain or harsh environments are exposed to more wear and tear. This results in a shorter lifespan. Frequent accidents can also cause excess wear, which can shorten the life of a truck.

• The average use of a forklift is around 2,000 hours per year. More use than that will require more frequent maintenance and repairs. Forklifts that work longer shifts will wear out sooner.

• This is the biggest factor in the lifespan of a forklift.

Nothing will extend the life of a truck more than regularly scheduled maintenance.

It would seem the best time to replace a forklift is when it reaches the end of its operational life. But this isn’t always the case.

Planned forklift replacement Forklifts actually have two types of lifespans – economic and useful. The useful life is the amount of time the forklift 98

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Timely maintenance will help ensure your forklifts have a long service life. Using forklift replacement parts can also help. Parts most often replaced tend to be engine components. For example, oil and air filters, chains, and spark plugs. Other parts can be replaced as well, ranging from driver seats to tires, forks, batteries, and more.

MAINTENANCE Forklift replacement seats One common forklift replacement part is the driver’s seat.

When seats get worn out they become uncomfortable to the driver. This can cause distractions that lead to accidents. Forklift seats are hard to repair unless the damage is minor. Forklift replacement seats are often the better choice because they improve productivity and safety. Some forklift replacement seats come with built-in safety switches to make sure drivers put on their seat belts before starting a job.

Forklift wheel replacement Worn forklift wheels and tires present a real safety hazard.

They should always be replaced rather than repaired. It’s time for forklift wheel replacement when you spot any of these signs: • Less than 2cm from the lettering on the tyres to the top of the tires • When the tyre is worn down to the safety line • The tyre has damage in the form of chunking, tearing or cracking • Flat spots on the tyre There are different types of forklift tyres. When making a forklift wheel replacement, be sure to get the correct type for your truck. Never have different types of tyres on a forklift.

moves/reverses.

• The fire extinguisher has expired—the seal on the neck has weakened.

• Warning lights do not flash.

• Directional signals and brake lights do not light up.

• Mirrors are broken.

• Look for these signs when inspecting hoses that need repair: • Abrasions; blisters; nicks; cracks; cuts; hardness, or color changes.

• Leaks—look for puddles of fluid around the equipment, low fluid levels in the reservoir, or greasy/dirty hoses.

• Contact with other hoses or metal parts.

• Close proximity to a high heat source.

• Twisting or kinking–make sure there is enough slack to allow for length changes under pressure.

During the tank inspection: • Make sure the fuel tank is not dented in any area.

• Make sure the fuel tank is secure, the valve opens, and check the fuel level.

• Check the hydraulic tank’s oil level for any leaks.

• Additional areas to inspect on a forklift before operating include: • The air cleaner indicator—clean or change it as needed.

• The radiator’s coolant levels and for leaks.

• Make sure the overhead guard isn’t damaged.

Once you’ve finished performing these maintenance checks, you may wonder if they are truly worth it.

Here are a few of the many benefits you can experience with preventative maintenance:

Forklift repairs Forklift repairs are easier and less costly when they are performed as soon as the damage is noticed. The best way to do that is with daily inspections.

When checking the forks, if you see any of these signs, they need to be repaired or replaced:

• Efficient production.

• Improved use of in-shop maintenance personnel with less emergency work.

• Increased control of spare parts inventory and reduced parts usage.

• Less downtime with equipment that is being repaired with scheduled inspections.

• Increased life expectancy of forklifts and other equipment.

• Fewer costs are given to premature purchases of new equipment.

• Reduced repair costs from less frequent equipment breakdowns.

• Reduced number of injuries and fatalities.

Your sound judgment combined with regular checks will ultimately determine when your forklift needs to be repaired and replaced

• Surface cracks.

• The blade or shank isn’t straight.

• The fork angle from the blade to the shank is not straight.

• There is a difference in height.

• The positioning lock isn’t in working order.

• The fork blade shows signs of wear.

• There is wear on the fork hooks.

• The fork marking is not readable Look for these signs when inspecting the safety attachments: • Seat belts and similar restraints are torn.

• Horns and backup alarms do not sound when the forklift Lifting Africa - Forklift Guide & Register

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BATTERY

How to test battery capacity for your forklift To have smooth operations in your warehouse, your motive power equipment must be fully operational at all times. As the power behind your equipment, your batteries must also be operating at optimal efficiency.

Performing routine battery maintenance is the key to keeping your batteries, and therefore your equipment, running as they should be. Battery capacity testing should be an essential part of that care plan. So, here are the basics of why testing battery capacity is so important and how it can be done!

What is battery capacity?

A battery’s capacity is essentially a measure of the energy it can store. When conducting a battery capacity test, you're examining the battery's ability to deliver a “specified amount of current at a constant rate to a specified end voltage for a specified time.”

When you purchase a brand new battery, it will come with a battery rating that identifies its capacity. But, because cells age, that rating will no longer be accurate once the battery has been used more than a few times. So, to get an accurate idea of your battery’s true current capacity, you must perform routine capacity tests.

How to test battery capacity In order to accurately test the capacity of your forklift battery, it’s important to use a battery monitoring device with the right capabilities. It is a compact and wireless electronic device that attaches right to your industrial battery to provide real-time diagnostics on battery capacity, including: • Battery voltage, current, and temperature; • Electrolyte and water levels; • Number of charge cycles; and • Total discharge time.

This data can then be downloaded to any PC or laptop quickly and with ease. You can even consolidate data into various reports so you can analyze your entire battery fleet at one time. This can help you identify patterns in your battery usage. Plus, it reports battery faults and warnings that could easily be missed manually.

Why is it important to test battery capacity?

Keeping your motive power equipment fully operational is essential for ongoing warehouse operations. However, your equipment can’t function properly without a wellmaintained forklift battery. A battery test makes it possible to identify weak cells, faulty intercell connectors, and other red flags that indicate repairs are needed before the battery stops working entirely.

If you don’t prioritise battery maintenance, it can result in decreased productivity for your entire warehouse.

Think about it—if you have to keep stopping operations to switch out underperforming batteries, it results in extra downtime. This ultimately reduces the amount of time your forklifts are actually able to move cargo, which is what generates value for your business.

Battery capacity testing helps you avoid this wasteful downtime by helping you determine where your industrial battery is on its predictable life curve. This way, you’ll know when it is about time to replace a battery. This way, you can acquire new batteries proactively before the old ones stop functioning during use and completely halt your operations Overall, battery capacity testing helps you maximize forklift battery performance so you can get the full useful life out of your industrial batteries.

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A forklift is a powerful tool that allows one person to precisely lift and place large heavy loads Using a tool such as a forklift, cart or hand truck instead of lifting and carrying items by hand can reduce the risk that you will suffer a back injury.

However, there is great risk of injury or death when a forklift operator:

Every year nearly 100 workers are killed and 20,000 are seriously injured in forklift mishaps.

• Has not been trained in the principles of physics that allows a forklift to lift heavy loads, • Is not familiar with how a particular forklift operates, • Operates the forklift carelessly, or • Uses a forklift that is not safe due to malfunctioning, or missing parts.

According to the National Traumatic Occupational Fatalities (NTOF) Surveillance System, 1530 workers died from forklift related accidents between 1980 and 2001.

The top four types of incidents as a percent of the total forklift related deaths are:

A forklift operator was struck and killed by the overhead guard when he attempted to jump as the forklift overturned.

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