Forklift Guide 2017/18 by Promech Publishing

FORKLIFT GUIDE 2017/8

Also publishers of “Supply Chain Today”

imagine … all parts, one supplier TVH PARTS SOUTH AFRICA (PTY) LTD • HEAD OFFICE JOHANNESBURG sales.southafrica@tvh.com www.tvh.com • T +27 11 281 2700

FOREWORD

Surviving in Times of Economic Chaos Martin Bailey, Chairman, ILS

Clearly the economic and political woes in South Africa are affecting us all. Organisations need to adapt to a shrinking economy; declining Rand and a Government focused on their own self-interest rather than that of industry or the people of South Africa.

e are all under pressure to do more with less. As the Rand declines, the cost of buying lift trucks keeps rising, along with the cost to keep them operational. Every day we are being asked to run our fleets more efficiently. We need to keep our fleets going longer, at a lower cost and we have fewer resources – but we are expected to do more and more. While we may feel powerless to do anything about the political and economic chaos across our land, there is lots we can do to make our warehouses run more efficiently. We can ensure we have the right equipment for the job, drivers are properly motivated and properly

It is a great opportunity to gain market share from those who cannot adjust to changing market conditions trained, equipment is well maintained, infrastructure is well used, and all operations are well planned. Hopefully this Forklift Guide will help you to optimise your operations and improve your efficiencies.

Leaner and leaner

For example, here are some things we can do. Become leaner - better positioned to do well when the market improves. • Use the opportunity to recruit good staff. • Use this time to become a learning organisation that is flexible and intelligent. • It is a great opportunity to gain market share from those who cannot adjust to changing market conditions. • Separate the “nice to do” from the “have to do,” and eliminate nonessential activities.

• Look for opportunities to reduce space. As we ensure our operations grow leaner and leaner we can hopefully look forward to some economic recovery. Just think how well your operations will perform when South Africa moves out of our chaotic dark days? If you can survive the existing storm, your business can only thrive in a recovering economy. Lift trucks have been the core of most unit load materials handling operations for many years, and can support our business operations to help improve productivity and efficiency. These vital machines should not be underestimated.

Broad-based guidelines

The aim of this guide is to assist users, manufacturers and maintenance personnel in the correct choice, use and maintenance of forklifts. These are broad-based guidelines on lift trucks. It must be noted, however, that there are numerous types of forklifts and equipment in the marketplace and new developments may supercede some of the technical guidelines discussed. These guidelines are thus meant to be an illustration of good practice rather than rigid instructions for specific implementations. Lift trucks should be seen in the context of the total facility’s operations and not in isolation. Factors such as the nature of the environment and local conditions should always be evaluated and the standards adjusted accordingly. Most importantly, check on the support and back-up available from the supplier. If in doubt, you should consult a registered professional engineer with good knowledge and experience of the manufacturing, factory and warehouse environments. Often the cheapest purchase is not the best, and you could experience major downtime if you make false economies. I hope you find the Forklift Guide useful and it helps you to operate a world-class facility. Martin Bailey, Email: martin@ils.co.za

Forklift Guide

2017/8

► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l

Forklift Guide

2017/8

Skills on Site

Septmeber 2012

FORKLIFT GUIDE 2017/8

Featured on the Front Cover: TVH, www.tvh.com

Contents

About Promech Publishing GLTC Supply Chain Magazine Wrap_newFA.pdf

Foreword

Forklift Basics

Comparison of Forklifts

Quick Guide to the Most Commonly-used Forklifts

Forklift Survey

2017/08/29

3:24 PM

This guide has been researched and produced by Promech Publishing, under the eye of Martin Bailey of ILS. In addition to our monthly magazine “Supply Chain Today”, we have launched a new website which is invaluable for keeping abreast of developments in the industry.

SUPPLY CHAIN

T O D A Y

October 2017

Endorsed by: CCF l CGCSA l CILTSA l CSCMP l SAAFF l SAEPA l SAPICS l SMART X l

Automated Forklifts

Unusual Forklifts

Reach Truck

Putting it all Together

IC Engine Counterbalanced Forklift Truck

Side Loader and Four way Reach Truck

Pedestrian Stacker

Electric Counterbalancd Forklift Truck

We are proud to be endorsed by:

Powered Pallet Truck

• Afritag (div of Smart Card Society)

Hand Pallet Truck

• CCF (Cold Chain Forum)

Man Up Order Picker

• CGCSA (Consumer Goods Council of SA)

Man Down Order Picker

Articulating VNA Truck

Forklift Truck Attachments

Various Types of Pallets

• SAPICS (The Association for Operations Management of Southern Africa)

The Right Tyre

• CSCMP (Council of Supply Chain Management Professionals)

Battery Facilities

Forklift Truck Daily Checklist

Buying a Forklift

CMY

If you have any suggestions or criticisms regarding this Forklift Guide (especially constructive ones), please contact us as we upgrade and update in the years ahead.

FRAUDSTERS: MIDDLE MANAGEMENT CERTIFYING RACKING LOCALLY

• CILTSA (Chartered Institute of Logistics & Transport: SA) • SAAFF (South African Association of Freight Forwarders) • SAEPA (SA Express Parcel Association)

Susan Custers, Publisher Tel: (011) 781-1401 supplychain@promech.co.za

All rights reserved. No editorial matter published in the “Forklift Guide 2017/8” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, contributors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

imagine … all parts, one supplier

line TVH PARTS SOUTH AFRICA (PTY) LTD • HEAD OFFICE JOHANNESBURG sales.southafrica@tvh.com www.tvh.com • T +27 11 281 2700

Forklift Guide

2017/8

Forklift Basics Doing a little homework up front to ensure you are choosing the best vehicles for your operation will result in optimal utilisation of your space and labour while maintaining a high safety factor.

efore making a decision on the best vehicle for your operation you must have a thorough understanding of the properties of the materials or loads you will be handling, the methods you will use to store these materials and the methods you will use to ship and receive these materials. Once this is done you should familiarise yourself with the variety of vehicles and options available.

Fuel types

Electric forklifts are designed for use on a flat surface only. Their big advantages are the absence of fumes and their quiet operation. If you only intend to use your vehicles indoors, this is the way to go. In multi-shift operations you will need additional batteries and charging/transfer stations. In single shift operations, or, if the truck is not used 100% of the time, you can charge it during off hours. Note that the batteries and chargers for lift trucks are usually priced separately from the lift truck itself. You will also have choices of standard batteries or sealed maintenance-free types, although the latter is very rare.

Battery powered

Basically there are two types of lift trucks, battery powered and IC engine powered. AC (alternating current) motors are being offered by most lift truck manufacturers, and no, this does not mean that you will be driving around with a really long extension cord. AC powered lift trucks run off of DC batteries and convert the DC power back to AC to power the motor. The advantages of AC motors include faster acceleration, higher efficiency, and lower maintenance costs.

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Regenerative braking technology recharges the batteries using the momentum of the lift truck when slowing down (braking). The frequent starting/ stopping of lift trucks makes them an excellent application for this technology. It is similar to the technology used in hybrid automobiles. New technologies in this are a include fast charging which provides a means to reduce or eliminate the need to change batteries on multi-shift operations. The idea here is to quickly recharge the batteries during breaks, lunches, and between shifts (frequently called opportunity charging). It is more expensive than conventional charging systems, and there is currently only one such system in South Africa. The system has lots of power issues and isnâ&#x20AC;&#x2122;t very green.

IC engine â&#x20AC;&#x201C; LP gas powered, Petrol or Diesel

The advantages of using liquid propane (LP) include minimal fumes that you can smell although it still produces CO and other noxious gases (so heavy use indoors is dangerous and requires adequate ventilation), the ability to use it both indoors and outdoors, and the ability to quickly change LP tanks. It is commonly used in indoor/outdoor operations such as lumber yards. Petrol or diesel powered trucks are for outdoor use only. These forklifts are heavily used in construction, scrap yards, truck loading, etc. There are a handful of companies already testing hydrogen fuel cell power sources for industrial trucks. The advantages of hydrogen fuel cell power include the ability to quickly refuel (similar to LP, petrol or diesel) avoiding the hassles and costs associated with battery changing/charging while providing the clean-air benefits of electric. Cost is still an issue at this point, but this is a technology to watch.

Tyre types

There are three types of tyres on the market: solid

(nylon) for warehouse trucks; cushion for general use; and air for rough terrain. Cushion tyres are solid tyres generally with no tread pattern (though tread patterns are available) designed for use indoors on smooth solid surfaces. Pneumatic tyres require air and are designed for use outdoors on uneven and loose surfaces. Pneumatic tyre forklifts will also have higher ground clearance which raises the centre of gravity thus reducing its rated lift capacity.

Lift capacity and lift height

Before you select the best lift truck for the job, you will need to know the maximum weight and dimensions of the loads you will be handling as well as the maximum fork height needed to stack or rack the loads in order to determine the capacity of the vehicle needed. The lift capacity of a truck is affected by lift height and load size. A larger size load moves the centre of gravity of the vehicle/load combination reducing the lift capacity as does the height the load is being lifted. Attachments also affect the capacity of a truck. Every lift truck is required to have a rating plate showing the rated capacities. If there are any changes made to the truck â&#x20AC;&#x201D; like adding an attachment â&#x20AC;&#x201D; the plate must be replaced with one showing the revised capacities. But why spend so much time on capacity? Why not just play it safe and get a higher rated truck? The answer is size. Bigger is not necessarily better in warehousing. A higher capacity truck will be physically larger and require larger aisles than a lesser one.

Mast options

The number of stages a mast has affects the closed height of the truck as well as door heights. Single, double, triple, quad (reflects the number of sections or stages the mast has) are the types of masts available. In many circumstances you will not need to make a choice here since the lift height will dictate the type of mast you will get.

However, in trucks with very high lift heights, you may have an option. Going to a quad mast (which is very, very rare) instead of a triple, rated at the same height, will give you a shorter mast in the lowered position, eliminating overhead clearance issues. However, the more sections to the mast, the more play it will have when extended (the wobble factor).

Aisle types

Lift trucks are classified by the types of aisles they are designed to operate in. Wide Aisle and Narrow Aisle trucks are designed to turn in the aisle while Very Narrow Aisle trucks do not turn within the aisle. Wide Aisle: standard forklifts fall into this category of trucks designed to work in aisles greater than 3.5m wide. Narrow Aisle (NA) forklifts operate in aisles of 2.8m to 3.3m wide. Narrow Aisle (NA) forklifts operate in aisles of 2.6 to 3.3m and are generally vehicles such as Reach Trucks. Very Narrow Aisle (VNA) trucks operate in aisles less than 2m and often use guidance systems (wire, rail, or optical) to travel within the aisles. Types of VNA trucks are Order Pickers, Swing Mast and Turret Trucks (often called Lateral Stackers).

Lift truck types Standard forklift

The standard forklift, also known as a counterbalanced sit-down lift truck, is the vehicle most people think of when they think Lift truck or Forklift. It is available with any of the fuel types and tyre types as well as numerous weight capacities, lift heights and attachment options. The smaller 1 200kg to 2 000kg trucks are the workhorses of most warehouses. If you are running a small operation and will only have one truck, this is probably the vehicle for you. The standard forklift is a wide aisle truck which requires at least 3.3m aisles to turn in. The aisle width is determined by

Forklift Guide

2017/8

the size of the truck, the turn radius, and the size of the load. Available options and attachments include side shifts, fork shifts, hydraulic clamps, and slip sheet attachments, to name a few. Standard forklifts are usually used for lift heights under 6m.

Reach tucks

Unlike the counterbalanced forklift truck, reach trucks carry their loads within their wheelbase. The reach truck is a narrow aisle (2.8 to 3.2m) truck designed specifically for racked pallet storage. It consists of outriggers in front and telescoping forks that use a hydraulic mechanism that allows you to pick up the load and retract it over the outriggers. This reduces the overall truck and load length, allowing you to turn in a narrower aisle.

If you are looking for an inexpensive method for moving loads from point A to point B, a PPT may be the answer The very rare double-deep reach truck uses an extended reach mechanism which allows you to store pallets two deep in specially designed double-deep rack. Reach trucks are designed for racking areas only and do not work for loading trucks or quickly moving loads over distances. Operator training on reach trucks tends to take longer than on other vehicles due to the complexity of the controls. Reach trucks are available with lift heights up to 13m, however, at heights above 11m cameras or height selectors are recommended.

Motorised pallet trucks

Powered Pallet Trucks (PPTs), sometimes referred to as a Walkie, Walkie-rider or Rider motorised pallet truck, are the motorised versions of the pallet jack. The PPT is designed for the operator to walk along with the truck as he or she moves loads, while the Rider has a small platform on which the operator

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stands. The PPTs are great for frequent moving of loads over extended distances within warehouses and manufacturing operations. They are fast and highly manoeuvrable. Minimal controls result in short learning curves for operators although precision turning takes a little practice.

Order picker This truck lifts the operator so he can order pick at higher levels. This truck is designed specifically for manual handling of less-than-pallet-load quantities in racking. The man-up order picker design has fixed forks attached to a platform which elevates the load and the operator to facilitate manual loading and unloading from racking. Order pickers can operate in narrow (guided) or wide aisles. They are also very useful in cycle counting and physical inventories. Order pickers are available in lift heights up to 10m.

Very narrow aisle forklifts

Swing mast turret trucks (lateral stackers) are very narrow aisle (VNA) vehicles designed to work in aisles less than 1.2 to 2.2m wide. A swing mast truck resembles a standard forklift with the exception that there is an additional function to swing the mast to a 90 degree angle to allow storing pallets perpendicular to direction of the forkliftâ&#x20AC;&#x2122;s travel. Many turret trucks are man-up vehicles similar to an order picker with the exception that, rather than fixed forks, the forks are mounted on an additional mast and carriage which operates as a turret turning 90 degrees in either direction facilitating picking and stocking on either side of the aisle. The manup design makes it easer to handle loads in very tall racking up to 18m. Man-down versions of turret trucks are also available. They are less expensive than the man-up versions and are better when rack heights are less than 10m. Very narrow aisle trucks are generally used in conjunction with a guidance system (wire

or rails) within the aisles to increase safety and reduce property damage. Also, man-up turret trucks operating with tall racking require that the floor be extremely flat and level to operate correctly. VNA trucks are more complex and expensive pieces of equipment with more mechanical problems than standard lift trucks and you can subsequently expect more downtime and higher service costs. These costs can be easily offset in large warehouses by the space saved by going to 1.8m aisles.

Articulating Type Machines These machines have a articulating type chassis – and can thereby reduce aisle widths substantially (typically 1.9m to 2.3m). They also have reasonably good lift heights (typically up to 11m). While expensive, they have the advantage of being highly flexible.

Attachments There are an enormous variety of attachments and options available for lift trucks. While most attachments are designed for use on standard lift trucks, some of them are also used on reach trucks and VNA trucks. Most attachments will change the capacity of the lift truck and a new plate should be placed on the truck showing the new specs.

Safety features

There are many safety features that are common to specific types of trucks such as seat belts on sit-down vehicles and dead-man pedals on most stand-up vehicles. In addition, some manufacturers offer additional features such as speed controls that reduce speed based on load height and steering angle.

Service and support

An important part of lift truck selection is making sure you will have access to high levels of service and support. There seem to be new players in the lift truck market every year and while they may offer a nice truck design at a nice price, if they don’t have a local/regional service and support infrastructure, you should be prepared for significant aggravation when the truck goes down (all lift trucks go down at some point). Ideally, you want a local dealer/repair shop with a good supply of parts for the specific make and model you are purchasing. Visit the dealership or repair shop and take a look at the parts room just to try to get some idea of how many parts they stock and ask them “if they don’t have the part, where will it come from?” Hopefully the answer is a nearby, not necessarily local, regional distribution facility. Also, try to get some idea as to how many of those specific models are currently in use in your area. This is especially important for specialty trucks, such as turrets. If there are only a handful of these trucks in use in their service area you should assume they are not stocking many (if any) parts for them and probably have very little experience servicing them. It’s also helpful if there is more than one business in your area that can service your lift truck. This tends to get you better service and pricing. Also important is seeing if they have rentals available that have similar capabilities of the vehicle you are buying. Again, this is very important for specialty vehicles such as turrets especially if you are only running one or two of these vehicles in your operation.

imagine … all parts, one supplier TVH PARTS SOUTH AFRICA (PTY) LTD • HEAD OFFICE JOHANNESBURG sales.southafrica@tvh.com www.tvh.com • T +27 11 281 2700

Forklift Guide

2017/8

New versus used

The selection of used over new is most beneficial in low use operations where you are putting very little wear and tear on the vehicle. In higher use operations, you very well may find that buying used costs more due to significant maintenance/repair costs that will be incurred. Be aware that there is ‘used’ and there is ‘junk’. Don’t by junk. Used does not necessarily mean old. High-volume operations will purchase new forklifts and trade them in every few years, these make for good used purchases because they are still considered current models and will therefore have greater access to parts and service. Safety is also a consideration since older models will not have the same safety functionality as newer models.

Working with dealer reps

Dealer reps can be a great source of information and will assist in determining the appropriate vehicles, however, keep in mind that truck types can vary

significantly from manufacturer to manufacturer (especially on specialty equipment). Obviously the dealer rep will steer you towards something in his line regardless if there is a better alternative available elsewhere. When you have narrowed down the type of vehicle you are interested in, ask the rep to set up a visit to a similar operation using this type of vehicle and consider getting an onsite demo within your own facility. If you are still unsure I suggest renting one for a couple of months, ask upfront if you can deduct a portion of the rental cost from the purchase price if you decide to buy. This certainly does not cover all of the vehicles and options available as there are many other specialty trucks as well as hybrids of the previous listed vehicles. It does cover most of the more popular types of trucks being used today. Remember, an educated decision is a better decision.

Forklifts at a glance Lift Truck Internal combustion (IC) diesel counterbalance Electric 4-wheel FLT Electric 3-wheel FLT Reach truck Turret Walkie stacker Side loader (diesel or electric) Four-way reach truck Powered pallet truck Man-down order picker Man-up order picker Big FLT Reach stacker Straddle carrier Articulating lift truck

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Aisle 4m to 6m

Height Up to 6m

Weight Up to 50 tons

Floor Type Use Flat Works outside

3.3m to 6m 3.2m to 4.2m 2.8m to 3.2m 1.7m to 2.1m 2.2m to 2.8m 2.5m to 3.5 3.2m to 3.8m 2.5m to 3.5m

Up to 6m Up to 5m Up to 13m Up to 17m Up to 5m Up to 7m Up to 8m Up to 150m

Up to 5 tons Up to 2 tons Up to 2 tons Up to 1.5 tons Up to 1.5 tons Up to 30 tons Up to 2.5 tons Up to 3 tons

6m plus 6m plus 3m plus 1.9m to 2.2m

1m to 10m Up to 6 containers Up to 6 containers Up to 3 containers Up to 11m

Up to 500kg Up to 60 tons Up to 60 tons Up to 30 tons Typically 1 ton

Flat Flat Flat Very Flat Flat Variable Flat Flat Flat Flat Good Good Good Flat

Works inside, handles larger loads Works inside, handles smaller loads Warehouse Very high warehouse and narrow aisle Confined warehouse space Ideal for long loads Ideal for long items in warehouse For transporting pallets Picking of goods at ground level Picking of goods above ground level Usually for container handling Usually for container handling Usually for container handling General warehousing

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Up to 12.7m

Up to 16m

9m lift

3,2m

Up to 12,7m lift

2,3 pallets/sq meter

Reach truck

COMPARISON OF STORAGE OPTIONS

9m lift

Up to 5m lift

Maximum lift height

2,2 pallets/sq meter

1,8 pallets/sq meter

Articulated reach truck

2,2m

Stand up reach truck

0,89 pallets/sq meter

Counterbalanced fork lift truck

Maximum pallets/sq meter

Equipment type

up to 5m lift

up to 40m

Comparison of Forklifts

Yale

Up to 16m lift

4 pallets/sq meter

Turret truck

1,9m

Up to 40m lift

6 to 8 pallets/sq meter

S/R crane

1.5m

Quick Guide to the Most Commonly used Forklifts Wide aisle trucks

Stand-up forklift truck (FLT)

Three-wheel electric FLT

Four-wheel electric FLT

Suited to short-distance moves of pallets and other loads that require the operator to frequently mount and dismount the truck. It’s very rare in South Africa but popular in the US.

Made for longer distance travel and operation in restricted floor space, which requires a tight turning radius aided by the single rear wheel.

Used to move loads up to 4 536 kg extended distances and in standard-width storage aisles for put away and picking in racks of various heights.

Electric narrow aisle trucks

Sideloader Designed to handle oversized loads in narrow aisles, the outrigger platforms provide load stability during transportation. The mast does not pivot, making put away and retrieval much like counterbalanced trucks.

Multi-directional (4-way)

Order picker

Usually used inside warehouses to store goods in racks. The load is carried parallel to the direction of travel.

Designed to lift the operator on a platform along with the forks to a storage location for picking items or cases.

Articulating type truck

Turret truck (lateral stacker)

Reach truck

Used to store pallets in narrow aisles to heights of 8m, using a rotating mast that swings 90 degrees to one side or the other side.

Suited to positioning loads in very narrow aisles using rotating forks that face right or left and traverse side-to-side across the front of the truck.

Operating in a “medium” aisle, the reach truck is commonly used for storage of pallets in racking. Aisle widths range from 2,6m to 3,2m and lift eights from 4m to 12m.

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Pantograph type outrigger Built for two-pallet deep storage in narrow aisles using the reach pantograph, which extends into the rack. The pantograph arms provide stability. The truck is very rare in South Africa.

Powered pallet truck (PPT) Made to transport loads longer distances. Platform versions are also available for handling skids and related loads.

Electric Internal stackers & combustion straddle trucks engine trucks

Large lift trucks

All rough terrain forklift trucks FLT, counterbalanced High-lift straddle Built to lift loads to various heights depending on the length of the straddle arms which provide stability for the truck. It’s commonly used with pallets with no bottom stringers.

Intended as a general-purpose lift truck for loads up to 5 000kg. Models come with multi-staged masts for accessing loads at various rack heights. Engines are typically powered by LP-gas or petrol.

Large FLT, counterbalanced Suited to carry loads as heavy as 42 000kg both outdoor and indoor. Pneumatic tyres make for softer rides and greater traction. Multi-staged masts and LP gas, and diesel engines are available

Ruggedized for outdoor conditions and difficult-to-traverse surfaces, these models transport loads that might exceed 7 000kg. They can also be used as the transportation interface between a storage yard and warehouse.

Container lift The container lift or sidelifter can be used to stack two containers on top of each other and to lift and transport containers to awaiting trailers and rail wagons. It allows for the container to be placed on the ground,rather than atop a trailer, at the customer’s premises enabling clients to drive a forklift in and out of the container. Some sidelifters incorporate weigh features.

Low level order picker Designed to carry the pallet load and operator long distances as well as short ones while providing centred access to controls, used for order picking.

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

Truck-mounted forklift Walkie powered pallet truck Intended as an economical, powered lift truck for transporting loads distances that an operator can comfortably walk. Tines raise just a few inches to clear the floor during transport

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

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Forklift Survey Name of Company Number of Employees

A Square Forklift

Avis Forklift Centre

Barloworld Handling

380

Dynamic Battery Goscor Lift Chargers Truck Company 15

Branches in:

Cape Town,

Alberton

Durban

Durban, EL,

Cape Town,

Nelspruit, PE,

Durban, Port

Richards Bay,

Elizabeth

Welkom Nichiyu,

Forklift Brand Name/s

Mitsubishi,

Represented

Combilift

Durban, EL, Johannesburg, Nelspruit, PE,

Cape Town, Durban, Gauteng, PE

Pmb

Hyster, Utilev, Maximal, Liftstar

+/-250

Cape Town,

Cape Town, Alrode South,

1 000

Linde Material Handling

Crown, Doosan,

Combilift,

Bendi, Hubtex

Bradshaw

Linde, Baoli

TYPE OF BUSINESS OPERATIONS l New machine sales

- Distributor

- Agent

l Used machine sales

l Rentals

l Leasing

l Refurbishing

l Repairs

l Attachments

l Walk behind

l Ride-on

l 1.5 to 5.0

l 5.0 to 10.0

l 10.0 to 20.0

l 20.0 to 50.0

l Over 50

l Battery

l Diesel

l LPG

l Petroleum

l In-house training after sales

l Ongoing training

l Battery service contracts

l Engine repair contracts

l Tyre replacement or conversion

l Onboard weighing systems

l Barcode facilities

l Status monitoring

PALLET TRUCKS

Lifting capacity range (tons):

Power options:

Services/extras offered:

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Jungheinrich

Manhand Material Handling

Manitou SA

50+

+/-120

Pretoria Forklifts

Shamrock Handling Concepts

The Forkman

Toyota Industrial Equipment

CT, E.L, George, Cape Town,

Cape Town,

Durban,

Johannesburg

Johannesburg, PE

JHB, Kimberley,

National Footprint Cape Town

Pretoria West

with sub-dealers

Gauteng

throughout SA

KZN, Nelspruit, PE, PMB, Polokwane, Richards Bay, Trichardt, Upington

Manitou, Gehl, Jungheinrich,

Manhand

Ameise

Edge Attachments, Manilift

Nissan/UniCarriers, Doosan, Crown

Moffett, Combilift, Agrimac, AisleMaster

Tailift,

Toyota Forklift, BT,

GTPower,Taitan

Flexi & Raymond

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Automated Forklifts Automated forklifts, called Automated Guided Vehicles (AGV), may one day replace the standard forklift as we know it! Just think about it: • It needs no driver facilities, so will become cheaper to manufacture • With the growth of artificial intelligence (AI) – it can continually learn • It needs no driver • It can charge itself (as it goes) • With new guidance systems it can find its way anywhere in the facility

AGV powered pallet truck

• The software and electronics are getting cheaper and better every day • It works 24 hours a day with no tea or lunch breaks • It never goes on strike • It never crashes • It needs far less maintenance. Certainly, as AGV’s have become cheaper they have become part of mainstream warehouses. Where can AGV be used: • They are ideal in warehouses – or anywhere we use electric vehicles. They can replace forklifts, turret trucks, reach trucks and powered pallet trucks • They are also used, for example, in Rotterdam outside for moving large sea freight containers.

This AGV from Knapp is powered using capacitors rather than batteries

AGV reach truck

Forklift Guide

AGV turret truck

2017/8

AGV with laser guidance

AGV in Rotterdam port

Unusual Forklifts Container handling forklift - container carrier

Straddle carrier for fast handling of containers This forklift is powerd by a Hydrogen fuel cell

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2017/8

Reach Truck Background

Reach trucks are one of the most commonly used industrial trucks for the storage of pallets in warehouses. They differ from counterbalanced forklift trucks in that they carry their load within their wheelbase. This allows the reach truck to operate Designed to handle pallets Smallest capacity reach truck available Largest capacity reach truck available Average lift height Maximum lift (certain models only) Side shift fitted Mast – number of stages Aisle width (depending on pallet, lift & model) Operator position Drive Battery removal Battery size Battery voltage Charger (depending on model type and battery size) Time between charging Gradient with load (depending on model & load) Lift speed with load Travel speed with load Automatic height selection Typical cycle time capacity Typical reach truck cost – 1 000kg capacity 6m lift Refrigeration (cold store) cab available Commonly available from many suppliers Commonly available for hire Commonly used by many organisations Typical features of a reach truck

This plan view of a reach truck shows the standard aisle width calculation. The aisle width also depends on the quality of drivers; speed of operations; quality of pallet; and rack-fit tolerances. If you increase the aisle tolerances there is less chance of rack damage. However, this will lead to poorer space utilisation.

Reach truck turning circle (aisle width)

Forklift Guide

2017/8

Yes 500kg at 600 load centre 2 500kg at 600 load centre 6 to 8m 13m Optional (recommended) 2 or 3 2,7 to 3,9m Standing or sitting Battery - AC or DC Roll out or with crane 350 to 900 Amp Hours 36 to 72 volts 3-phase – 15 to 35A 7 to 12 hours operation Up to 10% (7% preferred) 0,3 to 0,45m/s 2 to 3m/s Certain models only 15 to 38 pallets/hour R300 000 – R550 000 Yes Yes Fairly (1 to 2 ton) Yes

in a smaller aisle than a counterbalanced forklift truck and to lift to greater heights. The reach truck is thus ideally suited to operate efficiently at good space utilisation and high efficiencies. The main advantages of reach trucks include that they are: highly efficient; competitively priced; commonly used and commonly available; relatively simple machine; high lift capability (up to 13m); narrow aisle (2,7 to 3.2m); fast; highly flexible; and reliable. As reach trucks have hard (solid) small wheels they are only suited to indoor applications where floors are fairly good. While reach trucks do not require the very high tolerance floors used by turret trucks, they do require better floors than counterbalanced forklift trucks. All reach trucks are battery powered and many manufacturers supply numerous model types. The most common reach truck applications are for handling of pallets in racking. Reach trucks are not commonly used for block stacking. In recent years, reach trucks have been developed with substantially improved performance capabilities, including increased lift heights (up to 13m).

Trucks get bigger and bigger – ensure there is sufficient space to turn, stage, park, dock, load and manoeuvre vehicles. This may involve big runouts (over 40m!), proper access ways and good quality infrastructures.

This ‘basic’ reach truck provides for an operator who stands. It can typically lift to 6m and can work with a standard 1 x1,2m pallet (1 ton) in a 2,7m aisle. This reach truck is ideally suited to relatively low capacity operations. Stand up operator reach trucks are common in USA. They are not common in Europe or South Africa where sit down operator positions are preferred.

Stand-up operator

This reach truck has a capacity of 2 500kg (at ground level), a lift of up to 13m and fully integrated automated height selection. It also has a tilting cab which allows the driver better visibility at higher levels. Such a reach truck provides excellent space utilisation and high productivity. Note: Reach trucks de-rate significantly as lift height increases. For example, at 11m lift the capacity of this machine decreases from 2 500 to 1 000 kg.

Docks and doors facilitate materials flow – so don’t compromise in this area. Buy the best docks and doors available on the market and make sure they are automated where possible. This improves operations and reduces damage. Also make sure docks are at the right height (regardless of the building costs) and that you have a sufficient number of doors for receiving and dispatch.

A large, sophisticated reach truck

Forklift Guide

2017/8

The operator of this reach truck is storing and retrieving pallets from racking. Reach trucks are ideal for this type of operation.

This reach truck is accessing pallets at 12 levels high. Reach trucks can achieve this due to their inherent stability. However, to operate at these heights one needs a good floor and an appropriate lift truck.

Note: This reach truck operates with pallets that have no bottom stringer due to its design. This reach truck is therefore best suited to handle Euro pallets. Other reach trucks are designed to handle South African pallets.

In a well-run operation, reach trucks can achieve throughputs of up to 40 pallets per hour (in plus out), which makes them a very efficient materials handling device.

The reach truck thus has to be carefully matched to a specific application. Storing and retrieving pallets

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Accessing pallets at 12m high

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FORKLIFT GUIDE 2017/8

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Forklift Guide

2017/8

CELEBRATING ILS’ 30TH BIRTHDAY FANTASTICAL FOUR FORKLIFTS

T O D A Y

Nov/Dec 2017

Putting it all Together Typically, each type of forklift truck is suited to a specific application and specific operational capacity. If we summarise the capacities and suitability of the equipment in terms of pallet type, lift and stack height and aisle width we end up with the following:

Equipment

Common use

Typical max lift height

Typical max stack height of pallets

Typical aisle width (pallet)

Walkie stacker

2,5m

Diesel / LP FLT

4,5m

Electric FLT

5,5m

3,4m

Reach truck

13m

4-way reach truck

2,8m

Diesel side loader

3,5m

Electric side loader

2,8m

Man down turret

11,5m

1,7m

Swivel truck

10m

2.2m

Man up turret

13m

1,8m

S/R machine

40m

1,5m

Standard or Euro pallet

Longer or large pallet storage

With pallet racking

Matching the truck and the pallet

Kwik Stage

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Acrow Flex Beam and Boards

Static Racking

Canti Lever Racking

info@acrow.co.za www.acrow.co.za Arco Walling Panels

Live Carton Racking

Arco Adjustable Column

Driv-In Racking

Forklift Guide

2017/8

The internal combustion (IC) engine counterbalanced forklift truck is one of the most commonly used items of materials handling equipment. It is highly flexible and can be used for many purposes in warehouses, in factories, on building sites or in yards. Typical uses include: loading and unloading trucks; transporting pallets; storage of pallets in block stacks; storage of pallets in rack; and general maintenance work.

Basic operating principal of a forklift truck

The counterbalanced forklift truck carries its load on the outside of its wheelbase and relies on a counterbalance weight (and the weight of the engine) to stop it tipping around the front wheels. The counterweight thus operates like a ‘seesaw’ to stop tipping and ensure stability.

he counterbalanced forklift truck is commonly powered by internal combustion engines, usually fuelled by diesel, petrol or LP gas. Many different forklift trucks are available for different handling applications. These may vary from a 40-ton diesel powered lift truck handling large sea containers to a 1-ton forklift handling pallets in a warehouse. Nearly every factory and warehouse in the world makes use of a counterbalanced forklift. The basic operating principal of the counterbalanced fork lift truck is shown in the diagram below.

Designed to handle pallets

Yes

Smallest capacity forklift truck available

800kg

Largest capacity forklift truck available

40 tons

Average lift height

4 to 6m

Maximum lift (certain models only)

Side shift fitted

Optional

Mast – number of stages

2 or 3

Aisle width (depending on pallet, lift & model)

4 to 8m

Operator position Drive Gradient with load (depending on model & load)

Sitting Battery, petrol, diesel Up to 15%

Lift speed with load

0,10 to 0,25 m/s

Commonly available from many suppliers

Yes

Commonly available for hire

Yes

Commonly used by many organisations

Yes

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Forklift Guide

2017/8

This forklift truck is commonly used in outdoor applications where the terrain is rough and work conditions are difficult.

A typical â&#x20AC;&#x2DC;off-roadâ&#x20AC;&#x2122; forklift truck

This container handling forklift truck is commonly used outdoors for loading, unloading and storing. Container trucks are available in capacities up to 40 tons!

A typical container forklift truck

This forklift truck is the most commonly used lift truck in the industry. It may be used indoors and outdoors for loading, unloading and storing.

A typical 2-ton forklift truck

Forklift Guide

2017/8

Side Loader and Four way Reach Truck Designed to handle pallets & loose goods

Yes

Requires in aisle guidance

Only in some options

Typical capacity

1 000 – 20 000kg

Typical lift height

4 to 6m

Maximum lift height (certain models only)

Side shift fitted to most models

If needed

Mast – number of stages

2 or 3

Aisle width (depending on load, lift & model)

2,5 to 4m

Operator position

Sitting

Power

Battery, diesel, petrol

Gradient with load

1% to 10%

Lift speed with load

0,15 to 0,25 m/s

Typical four way reach truck 7m lift

R400 000

Commonly available from many suppliers

Only diesel

Commonly available for hire

Fairly commonly used

Diesel more common

This four way reach truck is an ideal machine to handle long loads of up to 2 tons and store them in cantilever racks up to 7m high.

Forklift Guide

2017/8

The side loader and the four way reach truck are battery and diesel powered industrial trucks that carry their loads parallel to their direction of travel. This allows them to carry long loads – such as pipes and lengths of timber – in relatively confined spaces.

iesel side loaders are commonly used for rough terrain handling, while electric side loaders and four way reach trucks are used inside warehouses usually storing goods in rack. Diesel side loaders can have capacities of up to 20 tons, while electric side loaders are usually limited to a 5-ton capacity and four way reach trucks to a 2-ton capacity. Typical operating aisle widths are in the order of 2,4m.

Pedestrian Stacker

he pedestrian stacker truck is commonly used inside warehouses for storing pallets. Because the operator needs to walk behind the truck, it is not suited to operations that require high throughput or work over long distances. The pedestrian stacker truck is thus suited to handling relatively low volumes and weights of up to 1 000kg in warehouses where space is confined.

A typical walkie stacker

Designed to handle pallets Type of pallet most suited to stacker

Yes – but ‘prefers’ no bottom stringer on pallet Euro pallet

Smallest capacity truck available

500kg lift

Common maximum capacity practical

800kg lift

Largest capacity truck available

1 800kg lift

Aisle width – Euro pallet

2 400mm

Typical fork length

1 150mm

Average lift height

3 500mm

Maximum lift height (very specialized)

5 000mm

Operator position

Walk behind

Battery capacity

200 to 400 Amp Hour

Gradient with load

Travel speed under full load

1,3m/s

Commonly available from many suppliers

Yes

Commonly used by many organisations

Commonly available for rental

Roll out battery

Optional (possible)

This pedestrian stacker is commonly used in warehouses and factories. It provides a highly efficient method of storage as it operates in fairly narrow aisles. It is not as robust or as fast as a reach truck, but its manoeuvrability makes it ideal for many applications. This pedestrian stacker is commonly used to handle pallets with no bottom stringer and in this example a Euro pallet is shown. This is because the outrigger legs would get in the way of a pallet with bottom stringers. Straddle versions are available and these straddle the pallet allowing any type of pallet to be handled.

Forklift Guide

2017/8

Electric Counter-balanced Forklift Truck Basic operating principal of a forklift truck

The electric counterbalanced fork lift truck is powered by an electric battery and is a commonly used item of materials handling equipment.

Designed to handle pallets Smallest capacity forklift truck available

Yes 800kg

Largest capacity forklift truck available

8 tons

Average lift height

4 to 6m

Maximum lift (certain models only)

Side shift fitted

Optional

Mast – number of stages

2 or 3

Aisle width (depending on pallet, lift & model)

3 to 5m

Operator position

Sitting

Drive

Battery

Battery removal

With crane

Battery size

500 to 800 Amp Hours

Battery voltage

36 to 48 volts

Gradient with load (depending on model & load)

Up to 11%

Lift speed with load

0,10 to 0,25 m/s

Commonly available from many suppliers

Yes

Commonly available for hire

Fairly (1 to 2 ton)

Commonly used by many organisations

Yes

This forklift truck is commonly used in indoor applications for transport and storage operations. With a typical capacity of up to 1,5 tons at 600mm load centre, this forklift con manoeuvre in very tight aisles (3 to 3,5m).

A typical three wheel electric forklift truck

Forklift Guide

2017/8

t is highly flexible and can be used for many purposes in warehouses and in factories. Typical uses include: loading and unloading trucks; transporting pallets; storage of pallets in block stacks; storage of pallets in rack and general maintenance work. It is commonly used indoors and is not as robust as a diesel or LP gas powered forklift. Many different forklift trucks are available for different handling applications. These may vary from an 8-ton special forklift to an 800kg, 3-wheel compact lift truck used in warehouses.

Powered Pallet Truck The powered pallet industrial truck is commonly used inside warehouses for transporting pallets. It is suited to handling high volumes and weights of up to 2 000kg.

Designed to handle pallets

Yes

Smallest 1 000kg lift capacity hand pallet truck available Common maximum capacity practical

2 000kg lift

Largest 3 000kg lift capacity truck available Typical fork length

1100 mm

Maximum fork 3000 mm length

A typical powered pallet truck

This ride behind powered pallet truck is fast and provides a highly efficient method of moving pallets. It is also commonly used for loading trucks and for order picking.

Average lift height

205mm

Operator position

Walk or ride behind

Battery capacity

200 to 400 Amp Hour

Gradient with load

Travel speed under full load

1,4 m/s

Typical cost

R80 000 – R120 000

Commonly available from many suppliers

Yes

Commonly Yes used by many organisations Commonly available for rental

Roll out battery

Optional

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Forklift Guide

2017/8

Hand Pallet Truck

he hand pallet industrial truck is commonly used inside warehouses for transporting pallets. It is suited to handling low volumes and relatively low weights.

Designed to handle pallets

Yes

Smallest capacity hand pallet truck available

500kg lift

Common maximum capacity practical

800kg lift

Largest capacity truck available

3 000kg lift

Typical load centre

600mm

Average lift height

150mm

Operator position

Walk behind

Drive type

Manual

Gradient with load

Minimal

Commonly available from many suppliers

Yes

Commonly used by many organisations

Yes

A hand pallet truck is used to transport pallets around the warehouse/factory and from the storage area into a truck. It can have a platform that can be raised to assist in picking or packing goods. An unusual pallet truck application

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Forklift Guide

2017/8

Man up Order Picker Picking to heights of 9m Smallest capacity truck available Common maximum capacity practical Largest capacity truck available Typical fork length Typical load centre Walk through capability Average lift height Operator position Operator lift Battery capacity Gradient with load Travel speed under full load Lift speed with load Typical cost Commonly available from many suppliers Commonly used by many organisations Commonly available for rental Roll out battery Charger (typical)

Yes 500kg lift 1 000kg lift 1 500kg lift 1 100mm 600mm Optional 4 to 9m Standing Up to 10m 300 to 500 Amp Hour 4% 2,5m/s 0,3m/s R150 000 â&#x20AC;&#x201C; R350 000 Yes No No Optional 20 Amp 3-phase

he man up order picker industrial truck is commonly used inside warehouses for picking loose cases or loose items from pallets at high levels. It is suited to handling medium to low volumes and weights of up to 1 000kg. The man up picking truck provides picking at levels up to 9m.

This man up picking truck allows the operator to efficiently access goods at all levels.

A typical man up picking truck

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Forklift Guide

2017/10/16 3:03 PM

2017/8

Man Down Order Picker Picking from pallets to pallets

Yes

Smallest capacity truck available

1 000kg lift

Common maximum capacity practical

2 000kg lift

Largest capacity truck available

3 000kg lift

Typical fork length

1 100 to 2 400mm

Maximum fork length

3 000mm

Average lift height â&#x20AC;&#x201C; of forks

205mm

Operator position

Ride on (standing)

Operator position

Between forks & battery

Operator lift

Up to 990mm

Battery capacity

200 to 500 Amp Hour

Gradient with load

Travel speed under full load

1,4 m/s

Commonly available from many suppliers

Yes

Commonly used by many organisations

Yes

Commonly available for rental

Roll out battery

Optional

Charger (typical)

15 Amp 3-phase

This man down picking truck allows the operator to access goods at ground and first level efficiently. Here the picking truck is carr ying three roll containers, which allow the picker to assemble a large load.

A typical man down picking truck

Forklift Guide

2017/8

he man down order picker industrial truck is commonly used inside warehouses for picking loose cases from pallets. It is suited to handling high volumes and weights of up to 2 000kg. The man down picking truck provides picking to ground level and level one pallets.

Articulating VNA Truck

n the last few years a whole new range of warehouse equipment has become popular in the marketplace. This is a pivoting Very Narrow aisle (VNA) lift truck. Often referred to as Bendi, Flexi or Aisle Master – they are heavy duty machines that can operate in a narrow aisle – and also work outside the aisle. Typically (depending on capacity & lift height, they can operate in an aisle of 1.8m to 2.2m – and lift up to 9m to 11m. They are quite expensive (priced between the cost of a Reach Truck and a Turret Truck), but have the following benefits:

Easy to install –do not need wire or rail guidance

* * * *

Substantially reduce aisle width Are robust Can work outside the warehouse rack aisle Many suppliers

Forklift Guide

2017/8

Forklift Truck Attachments There are various kinds of attachments that can be fitted on a forklift depending on the application. We discuss the most common attachments below. Fork positioner

Sideshifter

This is the most common attachment and should almost be considered standard equipment.â&#x20AC;Ż The sideshifter is a hydraulic attachment that allows the operator to move the tines (or forks) and the backrest laterally. This makes the placement of a load easier as the truck does not have to be repositioned. Sideshifts will increase productivity and safety as well as reduce product damage by allowing the operator more flexibility in load placement.

Pole

In some locations, like a carpet warehouse, a long metal pole is used instead of forks to lift carpet rolls. Similar but larger devices are used to pick up metal coils.

Carton and multipurpose clamp

These are hydraulic attachments that allow the operator to open and close around a load, squeezing it to pick up. They are used to move items such as cartons, boxes and bales. The forklift truck in this case is sometimes referred to as a clamp truck.

Slip sheet Sid

Slip sheet attachments are used where slip sheets (a sheet of cardboard, paperboard, or plastic) are used rather than pallets.â&#x20AC;Ż The slip sheet attachment has a push/pull mechanism that clamps onto the slip sheet and pulls the load onto a thin platform and then pushes the load off the platform when the truck reaches the destination.

hif

ter

Rotator

Some forklifts are fitted with an attachment that allows the tines to be rotated. This device aids the handling of skids that have become markedly tilted as well as any other speciality materials handling needs. This type of attachment may also be used for dumping containers for quick unloading.

Fork positioner

A fork positioner is a hydraulic attachment that moves the tines together or apart. This means that the operator of the forklift truck does not have to get out of the cab to adjust the tines manually. It is perfect for adjusting to different load sizes and is used primarily in high volume operations where there is a great variety of pallet and crate sizes handled.

Roll and barrel clamp

The roll and barrel clamp attachment is a mechanical or hydraulic attachment which can be used for handling barrels, kegs, or paper rolls. It usually also has a rotate function so that a vertically stored paper roll, for example, can be inserted into the horizontal intake of a printing press.

Telescopic forks

This hydraulic attachment allows the operator to operate in a warehouse designed for double deep stacking. This means that two pallet shelves are placed behind each other without any aisle between them.

Forklift Guide

2017/8

Rotator

Drum handler

This is a mechanical attachment that slides onto the tines. Some are smaller versions of a paper roll clamp while others may engage the upper rim of the drum, or the lower rings.â&#x20AC;Ż Some drum attachments are capable of picking up multiple drums at the same time.

Man basket

A man basket is a lift platform that slides onto the tines and is used to hoist workers. It has railings and brackets for attaching safety harnesses.

Various Types of Pallets Open pallets 4-way entry (EUR)

The most common open pallet is the EURpallet with the dimension 800 x 1 200mm, and in some countries a pallet of the same kind with the dimension 1 000 x 1 200mm. The open side is either the 800 or the 1 000 side. The open side is possible to enter with all kinds of trucks.

Closed pallets 4-way entry

Handling of those pallets is generally not possible with straddle leg trucks.

Closed pallets 4-way entry (USA model)

Handling of those pallets is generally not possible with straddle leg stackers. Note restrictions on height from 2 sides. Not high enough for stackers. Most common measurements are 1 200 x 1 000 or 1 200 x 1 100mm.

Closed pallets 2-way entry

These pallets can be open or â&#x20AC;&#x2DC;closedâ&#x20AC;&#x2122; on the entry side. When closed, itâ&#x20AC;&#x2122;s not possible to use narrow model high lift stackers. Pallet measurements can vary a lot. The most common is 1 200 x 1 000 and 1 200 x 1 200mm.

Forklift Guide

2017/8

Rolltainers

Roll containers are mostly used by food distribution companies. They are normally handled from the side where you have the goods supported. Since the roll container in principle is an â&#x20AC;&#x2DC;open palletâ&#x20AC;&#x2122;, this can be handled by most truck types. Measurements can vary a lot. The most common is 800 x 700mm

Stillages

Various kinds and sizes of stillages are used by the manufacturing industry in particular.

Forklift Guide

2017/8

The Right Tyre Lift truck tyres are one of those under-rated products everyone takes for granted. Yet for the informed user, they represent a way to upgrade a truck’s performance at relatively little cost.

he first common tyre type is a solid or press-on tyre, which is built around a solid band and ‘pressed’ onto the hub or rim of the forklift. These are most often used indoors.

For the outdoors, air-filled or ‘pneumatic’ tyres are most commonly used. There are some exceptions. For outdoor applications with a relatively smooth surface (eg, asphalt) and a high hazard of flats (eg, metal scrapyard), there are some specialty solid tyres. Similarly, if your indoor facility doesn’t have a concrete floor, you may want to look at this issue more closely, starting with type of tyre tread and profile. For proper tyre selection for outdoor uses, the key objectives are to get the most rubber in contact with the most road.

Putting the pressure on

Compared with a solid tyre, an air-filled or pneumatic tyre provides the following benefits: greater ground clearance; air better absorbs shock transfer; and allows more surface contact on uneven ground because of the greater give. But, compared with the solid tyre, one of the biggest disadvantages of an air-filled tyre can be summarised in a single word: flats. To cope with this issue, the tyre industry has

come up with at least two alternative types of flat-proof tyres. The first is a urethane-filled product in which the inner tyre is filled with a urethane foam compound. The second is a solid tyre sometimes called a ‘resilient’ tyre, which resembles a pneumatic tyre. The most important thing to consider when it comes to pneumatic tyre maintenance is simple: proper air pressure. It’s recommended you check the pressure weekly with a tyre gauge when the tyre is cold (at least three to four hours since the last use).

Something solid

There are a variety of solid tyres available for indoor use. From a shape viewpoint they can be classified in two ways: Firstly by tread surface: smooth or non-skid (lugged). Lugged tyres are used for rough surfaces or for combinations of indoor/ outdoor applications where grip is important. However, they’re more prone to chipping and chunking. Secondly by profile: some common profiles include low profile (for high stability), wide profile (for better load distribution) and regular profile tyres, used for standard applications. Another practical tip for really big trucks with dual tyres is to remove stones and debris between the threads. Otherwise, inspect for excessive wear or damage and replace when needed. This step is also useful when considering retreading or rebuilding; a viable and economic strategy, particularly for large, specialty pneumatic tyres. Generally, it’s best to go back to the basic tyre made of natural or synthetic rubber and compounds such as ‘carbon black’, which provide the dark colour. The most common is the non-marking type made of polyurethane.

LEGAL CONSULTING FOR YOU AND YOUR BUSINESS

Polyurethane tyres are used for high-load applications in which energy-efficient or non-marking tyres are desired. The biggest negative to polyurethane tyres is their lack of give, which can create a rough ride for the driver and load, particularly if the surface isn’t smooth. Suppliers may offer rubber non-marking tyres but these tend to wear more quickly. Non-marking tyres, in general, are only effective if the floor is properly scrubbed. If the floor is already marked up, the rubber marking will transfer to the non-marking tyre.

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Forklift Guide

2017/8

Improved performance

Regardless of what you choose, you should always keep tyre maintenance and care in mind. Lift truck tyres should be replaced in the following situations: a maximum wear of five centimetres from the original diameter; abnormal splitting from the inner band; excessive cutting and chunking (that can cause a lift truck to jump when you go forward or reverse); and excessive wear on one tyre (caused by continuous turns in the same direction). For companies with larger fleets of about 15 to 20 trucks there are specialised preventive maintenance inspection programs offered by major tyre suppliers.

Battery Facilities

ith Lean thinking quickly becoming a powerful management tool in the warehouse, why is this new ideology not being extended to battery rooms? Battery room activities are often seen as ancillary to the warehouse’s main business of storing and distributing. Problems associated with the battery room are often considered insignificant. However, a better understanding of the magnitude of waste in the typical battery room will indicate that a poorly-run battery room creates waste throughout the entire warehouse. A key tenet of Lean thinking is that you cannot change or improve what has not been measured. Continuous feedback is required in order to make improvements in an ever-changing environment.

Types of waste

When Battery Bay Rooms are carefully studied, it becomes apparent that six of the eight types of waste found in the warehouse extends to the battery room. These include;

managers need to focus on the three major impacts on battery room operation and maintenance: Rotation, Rightsizing, and Battery Watering.

Rotation

Rotation is the number one cause of reduced battery run time, reduced battery life and waste in the battery room. “…when battery selection is left to an operator, 30 percent of the batteries will be underutilised and 20 percent will be overused.” When correct battery rotation practices are implemented, the results are dramatic. In a study where a company introduced good battery rotation practices in which data was collected for three months before and three months after proper battery rotation procedures, the average battery run time increased from 6 hours 30 minutes to 6 hours 57 minutes – nearly half an hour.

• Transportation waste - including unnecessary trips to the battery room to change batteries due to inadequate or incorrect information on the charge status of the battery. • Inventory - having more batteries and chargers than required • Motion - battery changing and battery watering process that requires more movement than is necessary. • Staff - too many staff watering and changing batteries. • Waiting - operators queuing for battery changes due to poor charging practices and procedures • Defects - operator selection of the wrong battery, which shortens battery life, costing money. Adding too much or too little water during battery watering also limits the battery life and may cause safety concerns. Studies have indicated that waste in the battery room can cost large warehouses and DC’s hundreds of thousands of Rands each year. This extends to smaller operations with as few as 10 to 20 forklifts which may also be losing significant amounts of money.

Battery Organising systems are the single most effective tool for ensuring proper battery rotation and therefore reducing waste in the battery room. For example, iBOS (Intelligent battery organizing system) from Philadelphia Scientific, monitors all batteries in a pool and eliminates operator judgement in battery selection by determining which battery has had the longest cool-timing since charging.

Six basic areas

The Lean approach to rightsizing a battery fleet requires ongoing operations feedback and measurement including the identification of peak and quiet periods, length of cool down time allowed for each battery and battery cycles per week.

In order to maximise a battery’s useful life to its full potential, management should understand the six basic areas of maintenance and use: These include charging, discharging, cycling, watering, cables and connection and washing. To achieve measureable and sustainable elimination of waste,

This picture shows the battery of an electric forklift truck exposed for removal. The battery can be charged in the truck or removed (swapped). Removal is effected using a hoist to lift the battery out of the truck.

Once charged, each battery is placed in a queue. The display tells the operator which battery to take and an audible alarm alerts the operator when the wrong battery is taken. With the IBOS Real-Time monitor, a battery room manager can use an on-site computer to continuously monitor battery selection activities. It signals the manager when one of five alert conditions is triggered.

Rightsizing

Rightsizing a battery room also offers significant potential cost savings by properly matching the size of the battery fleet to the operational needs of the forklift fleet.

Battery Watering

Battery Watering involves determining which batteries need watering. This seems like a simple job but each of the steps is fraught with potential pitfalls. The most common factor contributing to over-and under- watering is the hand watering of batteries which is obviated with automatic watering systems.

Immediate implementation

The Lean Battery Room can be immediately implemented with existing technologies and proper maintenance and operating practices. The potential benefits are enormous with hundreds of thousands of Rands in savings from reduced waste even in small operations. With the correct use and maintenance of power batteries and a Lean approach to the battery facility, management are able to extend the life of batteries, reduce waste, and save money while doing so.

Forklift Guide

2017/8

Forklift Truck Daily Checklist Hour Meter End Hour Meter Start Hours Operated All Trucks Faults Previous Day Obvious Leaks Hydraulic Fluid Levels Mast & Carriage Chains & Fixing Bolts Forks Backrest/Extension Attachments Tyres/Wheels/Nuts Seat & Seat Belt Steering Service Brakes Parking Brake Operating Controls Operating System Warning Lights Gauges/Instruments Lights/Beacon Horn Alarms Other Warning Devices Safety Guards/Covers Bodywork

Date:

Defect

Petrol/Diesel/LPG Fuel Level Fuel Connectors Engine Oil Level Coolant Level Battery Fan/Other Belts Inching Pedal LPG Bottle Security

Defect

Electric Electrolyte Levels Cable Connections General Cleanliness Battery Security

Other Checks A. B. C. D.

Defects Operator

Signature

Supervisor

Signature

Do not use the truck until any faults have been rectified

Daily checks â&#x20AC;&#x201C; what to look for All trucks

Chains and fixing bolts: Visually check for damaged links, obvious stretching and appropriate lubrication. Visually check the fixing bolts for any sign of damage.

heels, or any other sign of damage or excess wear. Check securing pins. Backrest/extension: Visually check for damage or debris. Bent or otherwise damaged metal is weakened and may be dangerous. Attachments: Check for the actual security of the attachment, at its fixing or locking points, and check any hydraulic or other connections. Some attachments may need additional checks. Only check and use attachments if you have been trained to do so. Tyres/wheels/nuts: Check all tyres for obvious damage, including cuts and tread wear. Check pneumatic tyres for the correct pressure. Check wheels for damage, especially to the rims, and check that wheel nuts are tight.

Forks: Visually check for any sign of cracks, especially at the

Seat and seat belt: Check that the seat is correctly fixed

Faults previous day: Check the previous page (or book). This will identify what may have been wrong the previous day or shift. You should check these items carefully to ensure that the fault has been rectified. Obvious leaks: Check the floor, beside and under the truck. Hydraulic fluid level: Check the level in the reservoir. Mast and carriage: Visually check for any damage or foreign items. Check also for appropriate lubrication.

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to the truck and not loose or damaged. Check that the seat belt or other restraint is properly secure and functions correctly. Steering: Check the steering feels normal and there is no undue play or unusual movement. Service brakes: Check the brakes feel normal and work efficiently. Parking brake: Check the parking brake works efficiently and releases correctly. Operating controls: Check that all foot and hand controls operate correctly and are not obstructed in any way. Operating system: If the truck is fitted with computerised systems check to ensure that they have initialised and are working correctly. Warning lights: Check for the correct operation of all warning lights. If a light stays on, and you are not sure of its meaning, check the user manual or seek further advice. Do not use the truck with a warning light illuminated if you do not know it is still safe! Gauges/instruments: Check that all gauges and other instruments are working correctly. Lights/beacon: Check for correct operation. Horn: Check for correct operation. Alarms: Check for correct operation. Other warning devices: Make sure you know what is fitted to the truck. Check all for correct operation. Safety guards and covers: Check all are properly fastened and secured. A flapping cover can be a hazard to your colleagues as well as yourself.

Traction Battery Service 180x130.indd 1

Bodywork: Visually check around the vehicle. Damaged bodywork may indicate other problem areas on the truck. Check the areas carefully. Damaged bodywork may indicate damage to racking or other equipment. Report what you find so that your supervisor can check it out.

Petrol/Diesel/LPG

Fuel level: Check the level and refuel as needed. Remember to wear protective gloves and keep away from cigarettes or other fire hazards. Engine oil level: Check and top up as needed. Coolant level: Check and top up as needed. Battery: Ensure the battery is secure and clean. Check the level of distilled water and top up as needed. Wear eye protection and gloves. Fan/other belts: Check for correct tension and obvious damage. Inching pedal: Check for correct operation. LPG bottle security: Check the bottle is secure and clamps are fully tightened. Ensure connections are secure.

Electric

Electrolyte levels: Check the electrolyte levels of all cells. Cable connections: Check they are clean and properly secure. General cleanliness: Ensure the battery area is clean and clear from debris. Battery security: Ensure the batteries are secure within their compartment and that any protective hatches are properly closed.

Other checks

Other items may need to be checked. These may be listed on a separate sheet. Discuss this with your supervisor and remember, if you are not sure about anything at all, ask your supervisor.

2017/11/02 11:00 PM

Forklift Guide

2017/8

Buying a Forklift Forklift Features

Much like automobiles, forklift pricing varies widely by brand, and pricing does not always correlate to overall quality and reliability. Prices can vary depending on geography, your specific needs, and the seller. Top-tier brands typically cost more and offer advanced technology, higher tolerance of abuse and harsh environments, and greater long-term reliability. Before you start looking at forklift trucks or talking to dealers, determine exactly what you need your forklifts to do. As with any large piece of equipment, safe use should be your top priority. Make sure you review all the safety instructions for the forklift you buy before using it.

Capacity: Knowing Typical Load Weight and Size

In order to select the best forklift for your work situation, determine the typical load weight and size the forklift will be used for. Forklift trucks are rated according to how much weight they can lift, starting at 3,000 lbs and going up to 35,000 lbs and more. While 3,000-lb, 5,000-lb, and 8,000-lb models make up the bulk of the market, 5,000-lb forklifts are the industry standard. The size of your typical load will determine the capacity you need.

Determine the typical load weight and size the forklift will be used for Forklift capacity is usually based on a 24-inch load centre, meaning that the distance from the centre of gravity to the sides of the load is 24 inches. The easiest way to think about this is that a forklift can only lift its maximum weight if the load is a 4-foot cube. If your loads are unusually long or high, the forklift will not be able to safely lift as much. Knowing the typical dimensions and weight of your loads will allow you to work with sellers to determine the exact capacity you need. Also consider variation in your loads. If you constantly produce identical pallets of products, you know exactly what capacity you need; however, in a more mixed environment or one where the load size changes over time, buy a truck with more capacity than you need currently to make sure it gets the job done now and in the future.

Forklift Height: How High Do You Need to Lift a Load?

If you primarily use forklifts to load and unload trucks, you may not need much height. If your warehouse has shelves that are 30 feet high, your forklift will need to reach them. Unlike load

Forklift Guide

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capacity, your height needs are unlikely to change over time, barring new construction or major renovations. Buy for the height you need now. In a warehouse setting, the size of the lift truck may be an issue as well. Standard lift trucks need aisles that are 11 feet wide or larger to be able to operate and turn around. For aisles that are eight feet to 10 feet wide, you will need a narrow aisle (NA) forklift; for aisles down to six feet wide, you will need a very narrow aisle (VNA) truck. NA and VNA forklifts have forks that are turned at a right angle so they can drive straight down the aisle but pick up loads to the side.

Tyres: Where Will You Use Your Forklift?

Forklifts should have tyres appropriate for the location or environment. Knowing the different types of forklift tyres available on the market will ensure that the forklift can accomplish its specific job in the necessary location. • Cushion Tyres: Cushion tyres are made of solid rubber and work best for internal applications. Electric forklifts designed for interior work typically have cushion tyres. • Pneumatic Tyres: Pneumatic tyres are inflated with compressed air and cost more than cushion tyres and also make a better choice for outdoor work. For heavy-duty lifting outdoors on uneven terrain, gasoline- or diesel-fueled forklifts are most commonly found with pneumatic tyres. • Solid Pneumatic Tyres: Solid pneumatic tyres are ideal for outdoor environments where there is a high risk of popping regular pneumatic tyres, such as lumber yards or recycling centres where glass or nails can be scattered. Solid pneumatic tyres combine the solid-rubber construction of cushion tyres with the rough terrain capabilities of pneumatic tyres and typically cost more.

New versus Used Forklifts

Many dealers offer both new forklifts and used forklifts, so you can compare prices easily. Buying used forklifts can save you quite a bit of money up front, usually costing around half the price of a new forklift. As a general rule, businesses that use forklifts for more than four hours each day should invest in new forklifts. With this much use, the operating and maintenance costs for used equipment can quickly cancel out the initial savings gained. If the forklift will be used only a couple of hours per day, you can probably benefit from buying a used forklift. When a dealer gets a used forklift back at the end

of a lease, they usually recondition it with a new paint job, new tyres, a thorough engine tune-up, and any other mechanical repairs that need to be made, so you can feel reasonably confident in the condition of the truck. As-is forklifts can save you even more money, but may have original paint and worn tyres. Used forklifts may experience more downtime and repairs. Make sure to ask about the difference in service plans between new and used models. Once you decide on a forklift, try to stick with one brand for your other forklift purchases. This will allow you to go to one dealer for all your warranty and repair needs, and operators will only need to learn to handle one type of forklift. Since not every manufacturer makes every type of forklift, you may still need to buy multiple specialised machines.

Types of Forklifts: Electric versus Internal Combustion Engine There are two main types of forklifts: Electric forklifts powered solely by an on-board battery, and internal combustion (IC) forklifts, which use a traditional engine that runs on one of several types of fuel. In most cases, an electric forklift will be more expensive than an identically rated IC lift. Operating costs per hour are critical to determining the real cost of your forklift. This includes the cost of fuel, maintenance, and supplies like oil, batteries, and filters.

Electric Forklifts

Electric forklifts are well suited for indoor use and on well-paved parking lots, but they cannot be used in the rain. They are powered by large, heavy lead-acid batteries, the same kind found in a car but considerably bigger and more powerful. Electric forklifts have several advantages over their IC counterparts. Electric forklifts have no fuel storage requirements and the batteries typically provide enough power for one standard eight-hour shift, which translates into five or six hours of constant usage. Keep battery downtime in mind when purchasing an electric forklift, and know that charging a forklift battery takes eight hours, plus eight hours of cooling time

• Zero Emissions: Electric forklifts produce zero emissions, which is an important consideration if you plan to use your forklift indoors. Of the internal combustion models, only propane-fueled lifts can be used indoors, and they require very good ventilation. Gas and diesel-powered models cannot be used inside at all. • Low Fuel Cost: Although electric forklifts have a higher initial cost than internal combustion forklifts (new electric forklifts can cost 20% to 40% more than similarly rated IC forklifts), they have a lower cost per hour of operation. The price of gas and diesel fuels makes IC forklifts more expensive hourly than rechargeable, battery-powered electric forklifts. • Quieter Operation: Electric forklifts produce less noise than IC forklifts, which is a plus for indoor usage. • Long Lifespan: Because electric forklifts have fewer moving parts and are often used in cleaner environments than IC forklifts, they also tend to have a longer lifespan. before it can be used. Due to this slow charging speed, if you need forklifts for two or three continuous shift operations, you will have to buy extra batteries so you can charge the next one. A battery charging station will also be necessary. Chargers should be located in a dry, ventilated, and temperature-controlled location. If you have multiple batteries, you will also need special cranes to change them.

As a general rule, businesses that use forklifts for more than four hours each day should invest in new forklifts Internal Combustion Forklifts

Internal combustion (IC) forklifts can handle the largest loads and are the only choice if you require greater than 15,000 lbs capacity. They typically stand up to certain types of abuse better than electric forklifts. Specifically, when using a forklift to push or tow loads, rather than lifting Forklift Guide

2017/8

and driving, IC forklifts usually have better acceleration and top speeds. IC forklifts also have a lower initial price point but cost more per hour to run than electric forklifts. Forklifts with internal combustion engines run on a variety of fuels, including gasoline, diesel fuel, liquid propane gas (LPG), and compressed natural gas (CNG). For indoor/outdoor use, duel fuel systems are available that let you switch between LPG and gasoline. You can refuel IC forklifts on the fly: simply fill them up at a gas pump or load new LPG canisters and forklifts are ready to continue working in no time. Of the types of IC engines, fuel costs generally are highest for gasoline and lowest for diesel, with LPG in the middle. With

Attachments, Comfort, and Safety

Once you know what forklift features and which fuel type are best for your situation, consider safety features, comfort, attachments, and extras. The following criteria are often features that buyers may not consider immediately in their purchase but will add both comfort and functionality to the machine, making it a high-quality addition to the workplace. None of the following are absolutely necessary (aside from the legally regulated safety features, and employee training). However, this list should be considered before making a purchase to ensure that the forklift you are considering will be capable of the specific jobs you have in mind. • Safety Features: Most forklifts come standard with safety features such as back-up beepers, flashing amber lights, and headlights. Regulations vary; always keep them in mind when you shop. • Ergonomics: They may seem like luxuries, but adjustable seats and comfortable controls can reduce the risk of repetitive stress injuries and make for a more productive workforce. • Attachments: You can tailor your forklift to better handle specific types of materials. There are specific tools to pick up rolls of cable or steel, tongs for handling 55-gallon drums, flat panels for lifting items that are not on pallets, and more. Most attachments are standardised so they can be used on any forklift, so if you only occasionally need to move oddshaped loads, you may be able to buy one attachment and use it with any Acknowledgment: eBay

Forklift Guide

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some IC forklifts, you will have to buy refueling equipment. For example, gasoline and diesel fuel require storage tanks and pumps. LPG requires only space for spare tank storage, which is usually managed by a propane vendor. The choice between gas, diesel, and propane is often made based on existing vehicles and equipment. The wave of the future in forklift power is fuel cells. Hydrogen fuel cells have the advantages of electric power (zero emissions and quiet operation) plus the ability to be refueled as quickly as diesel or gasoline engines with no recharging time. Experimental fuel cell forklifts are already in use, and may start to be more widely available in coming years. of your lift trucks. Attachments like adjustable forks and spool handlers reduce load capacity. Every forklift should have a capacity plate attached to it detailing its capabilities in its current configuration. • Sideshift: Sideshift is a popular option that allows an operator to move a load to the left or right without moving the truck, allowing more precise load placement. Sideshift can reduce load capacity, so again, be sure to check capacity plates. • Tilt Mast: The ability to tilt the mast and forks forward and back greatly simplifies loading the truck on uneven ground. Tilting the mast back slightly also provides greater stability when moving a loaded truck. • Service Plans: With an expense of this magnitude, it only makes sense to purchase adequate protection for it. The majority of forklift buyers choose a preventative maintenance (PM) plan. These PM plans cover oil and filter changes, transmission servicing, and general check-ups at regularly scheduled intervals. For an additional cost, you can purchase a full maintenance plan that covers any breakdowns or needed repairs. For a new forklift, it is unlikely that you will need this type of coverage. You will likely have very few breakdowns in the first couple of years. On older equipment, it may be a useful insurance plan. Unless you have an in-house mechanic to perform these maintenance tasks after every couple of hundred hours of operation, it makes sense to lean on the dealer’s expertise.

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