When inventor Sakichi Toyoda successfully pioneered the automatic loom, he laid the foundation for Toyota Industries and our commitment to kaizen, continuous improvement. For nearly a century, the Toyota name has been synonymous with excellence in quality and innovation with the inventor’s spirit at the heart of our business.

It took only eight years after establishing Toyoda Automatic Loom Works Co., Ltd. – known today as Toyota Industries Corporation – before Toyota produced its first engine in 1934: The A-type engine for automobiles.

But I’m sure if you’re reading this blog you know that Toyota makes much more than cars. In 1956, Toyota began producing forklift engines, a new chapter in the story of Toyota Industries. As material handling needs evolved, so did Toyota’s role in the game. Heavy duty applications called for equipment tough and robust enough to take on high capacity needs. And at the core of these powerful workhorses needed to be an engine with the durability and grit to deliver reliable life and power.

In 1986, Toyota introduced a forklift engine that could take on these heavy-duty challenges: The 4Y industrial engine. Carefully designed and engineered through the core practices of the Toyota Production System, this engine set a new standard of excellence within the material handling industry. Today, millions of these engines have been produced and can be found in forklifts, compressors, gas heat pumps, and more.

But most important, these engines are at the heart of Toyota’s internal combustion forklifts, making them some of the most dependable pieces of equipment on the market. Don’t believe me? The 4Y Engine has helped Toyota forklifts achieve more than 35,000 life cycle operator hours with ease. Some have even reached over 80,000 hours.

It’s an engine that is built to perform, but also engineered with sustainability in mind. The 4Y engine’s emissions system filters carbon monoxide, hydrocarbon, and nitrogen oxide gases, allowing it to surpass federal EPA emission standards.

The 4Y engine is a testament to Toyota’s commitment to the pursuit of improvement and of its dedication to creating a more sustainable future.

Want to learn more about the 4Y engine? Check out this video on 4Y’s perks and history or this video about how the 4Y improves Toyota forklift operation.

By: Anastasia Sistevaris, Communications Copywriter, Toyota Material Handling, USA

There are many different types of forklifts, each carefully designed for specific applications and each offering its own unique set of benefits and features.

Selecting the right forklift for your needs is essential to efficiency and productivity, which is why it is so important to understand the key differences in each class of forklifts. But with seven varying forklift “classes” with subtle differences, it can be difficult to even know where to begin your forklift search.

What are the different types of forklifts?

• Class I: Electric Motor Rider Forklifts
• Class II: Electric Motor Narrow Aisle Forklifts (Reach Trucks, Order Pickers)
• Class III: Electric Pallet Jacks, Stackers, and Tow Tractors
• Class IV: Internal Combustion Cushion Tire Forklifts
• Class V: Internal Combustion Pneumatic Tire Forklifts
• Class VI: Electric/IC Engine Tow Tractors
• Class VII: Rough Terrain Forklifts

Let’s explore the distinct applications, benefits, and features of each of the seven classes:

Class I: Electric Motor Riders

Class I forklifts are electric motor riders. These electric-powered forklifts are ideal for loading and unloading tractor-trailers, handling pallets, and a number of other applications in industries ranging from food storage and retail to factory and general warehousing.

Because they are powered by an electric battery, Class I forklifts are much quieter and create no emissions, making them a popular choice for indoor applications. Batteries on Class I forklifts also function as part of the counterweight to help maintain lifting capacity.

Toyota offers six versatile forklifts in this class, ranging in lift capacity from 3,000 to 40,000 pounds and with electrical systems ranging between 24-volt and 80-volt. Click on each of Toyota’s six Class I forklift models below to learn more about their individual features.

• Core Electric Forklift
• Large Electric Forklift
• 80V Electric Pneumatic Forklift
• 3-Wheel Electric Forklift
• Stand-Up Rider Forklift
• High-Capacity Electric Cushion Forklift

Class II: Electric Motor Narrow Aisle

Class II forklifts are electric, narrow aisle models. As the name suggests, Class II forklifts are designed with maneuverability that allows them to operate in tight spaces and narrow aisles. This class of forklifts is perfect for picking and putting away inventory, and these trucks provide users the ability to increase racking space without expanding their current warehouse.

Toyota offers two Class II forklift models, and you can explore the unique features of each by clicking on the model name from the list below.

• Reach Truck
• Order Picker

Class III: Electric Pallet Jacks / Stackers / Tow Tractors

Class III equipment includes electric pallet jacks, stackers, and tow tractors. This class of equipment comes in both rider and walk behind (“walkie”) models, perfect for unloading deliveries and moving loads to a staging area where they can be handled by other types of forklifts.

Toyota offers 10 Class III models, including three different stackers that are ideal for food and beverage storage industries, among others. Click on each forklift model below to learn more.

• Electric Walkie Pallet Jack
• Counter-Balanced Stacker
• Walkie Reach Truck
• Large Electric Walkie Pallet Jack
• End-Controlled Rider Pallet Jack
• Core Tow Tractor
• Mid-Tow Tractor
• Center-Controlled Rider Pallet Jack
• Walkie Stacker
• Industrial Walkie Stacker

Class IV: Internal Combustion Engine Cushion Tire

Class IV forklifts are internal combustion engine cushion tire trucks. This class of sit-down forklifts is designed for indoor use. Class IV forklifts are powered by internal combustion (IC) engines that run on diesel fuel, LP gas, gasoline, or compressed natural gas. Their solid, cushioned tires provide a smooth ride on indoor surfaces and they’re puncture-proof since they are not air-filled.

These forklifts offer users outstanding versatility for warehousing, distribution, retail, and automotive applications.

Toyota offers seven Class IV models, ranging in lift capacity from 3,000 to 100,000 pounds. Click on each of the forklift models below to learn more about their individual features.

• Core IC Cushion
• Large IC Cushion
• Box Car Special
• Paper Roll Special
• High-Capacity IC Cushion
• High-Capacity Large IC Cushion
• High-Capacity Adjustable Wheelbase

Class V: Internal Combustion Engine Pneumatic Tire

Class V forklifts are internal combustion engine pneumatic tire trucks. Forklifts in this class are similar to those in Class IV, but are designed primarily for outdoor use. These forklifts are highly durable and are ideal for lumberyards, construction sites, and other outdoor applications.

Toyota offers seven forklift models in Class V, ranging in lift capacity from 3,000 to 125,000 pounds. Click on each individual forklift model below to learn more about its individual features.

• Core IC Pneumatic
• Mid IC Pneumatic
• Large IC Pneumatic
• High-Capacity IC Pneumatic
• Empty Container Handler
• Loaded Container Handler
• Reach Stacker

Class VI: Electric/ IC Engine Tow Tractors

Class VI equipment includes electric and internal combustion engine tow tractors. These machines are most commonly used for towing loads rather than lifting. Trucks in this class are ideal for use at airports, but are also commonly used in assembly line areas.

Toyota’s Large Tow Tractor boasts a maximum tugging capacity of over 50,000 pounds and features an extremely tight turn radius. Its AC Drive system enables quicker acceleration, high top speeds, and extended peak operator time.

Class VII: Rough Terrain Forklift Trucks

Class VII forklifts are rough terrain trucks. Trucks in this class feature large, tractor-style tires and are powered almost exclusively by diesel engines for outdoor use in rugged terrain. Class VII trucks are most commonly used at lumberyards or construction sites to lift building materials to elevated work sites.

How to Choose Between IC or Electric Forklifts:

Deciding whether an internal combustion forklift or electric forklift is appropriate for your application can seem like a daunting task. Here are some high-level considerations that you might take into account:

Electric

• Typically less maintenance than I/C forklifts
• Quieter with little emission sounds
• No fuel-storage requirements
• Requires a charging station
• Batteries are large and heavy to change out.  Battery extraction equipment may be required
• No tailpipe emissions
• Lifespan depends on application, use and maintenance
• Better option for smaller, confined areas

Internal Combustion Forklifts

• Operate on gasoline, diesel, compressed natural gas or liquid propane gas
• Primarily used outdoors, but can be used in moderation in some indoor applications
• Can operate in various conditions
• No batteries to recharge
• Toyota’s IC forklift line can lift over 51,000 lbs.
• Lifespan depends on application, use and maintenance
• Noise emissions meet or exceed ANSI B56.1 Standards
• Toyota forklifts are designed to meet EPA Standards for emissions

Forlifts, like cars, require more than just an oil change.  One hour of forklift use is approx. 35 miles of automobile use.  An Annual Service from DTL will keep your lift running safely and smoothly.  Dillon Toyota Lift Service Technicians are here to protect the investment you made in your forklift.  Here is what the annual service includes: 

Electric Forklifts: 

• Drain and flush hydraulic tank, install new hydraulic filter and refill with new hydraulic oil.Install new sump breather cap.

• Drain and flush differential, clean differential with new fluid.

• Inspect condition of all hoses.

• Remove steer wheel bearings, clean and repack with grease and reinstall and set bearing preload.

• Inspect steering system for worn pins and linkage and make minor adjustments as necessary.

• Inspect service brakes for proper operation, leaks and/ or contamination.

• Inspect parking brake for proper operation and condition of cables and linkage.

• Inspect and test the battery, water all cells.

• Clean and inspect the control panel.

• Check for loose connections, corrosion, worn contactor tips.

• Check for proper operation of all motors and insect for brush wear. Blow all motors out.

• Inspect upright, tilt cylinders, forks and associated mountings for any obvious cracks, defects of mission stops, and adjust lift chains.

• Inspect counterweight for proper mounting and that all bolts securing it are in place and tight.

• Inspect for proper operation of all gauges, controls, starting and charging components.

• Pressure wash lift.

Gas, CNG & LP Forklifts:

• Drain and flush hydraulic tank, install new hydraulic filter and refill with new hydraulic oil.Install new sump breather cap.

• Drain and flush transmission and differential, install new transmission filter, clean transmission and differential with new fluid.

• Install new air filter and fuel filter.

• Pressure test cooling system to check for leaks.Inspect cooling system for corrosion, check thermostat for proper operation and test anti-freeze protection level.

• Inspect condition of all belts and hoses.

• Perform engine tune-up with new spark plugs, points, condenser, rotor, distributor cap and ignition wires.

• Adjust valve lifters, install new valve cover gasket and perform engine compression test.

• Remove steer wheel bearings, clean and repack with grease and reinstall and set bearing preload.

• Inspect steering system for worn pins and linkage and make minor adjustments as necessary.

• Inspect service brakes for proper operation, leaks and/ or contamination.

• Inspect parking brake for proper operation and condition of cables and linkage.

• Check for proper operation of clutch or inching circuit and adjust if necessary.

• Inspect upright, tilt cylinders, forks and associated mountings for any obvious cracks, defects of mission stops, and adjust lift chains.

• Inspect counterweight for proper mounting and that all bolts securing it are in place and tight.

• Inspect for proper operation of all gauges, controls, starting and charging components.

• Pressure wash lift.

Doing more with less has become more important than ever in the warehousing industry. While manufacturing and distribution centers are on the rise in the United States, companies are uncovering new challenges when it comes to their warehouse space. There is a need to fit increasing volumes of products into the same warehouse buildings. How are we supposed to do this? Packing all of your product into smaller spaces usually calls for Narrow Aisles (NA) or Very Narrow Aisles (VNA) solutions.

General Aisle Widths

A typical aisle measures 10 ½ feet or more. While narrow aisles range anywhere from 8 ½ to 10 ½ feet, very narrow aisles may be only as wide as 5 to 7 feet. This is why NAs and VNAs can be a challenge when putting product away or stacking orders. Normally, counterbalance forklifts do not fit in these types of spaces, and even if they did, they would not have a tight enough turn radius to avoid hitting the racking. Below are some of the options you can look at to help you solve you narrow aisle problems.

3 Wheel Electric Forklift

The 3 Wheel Electric Forklift is great for narrow aisles. It leads the industry in run time, travel speed, and lift/lowering speeds. Having just one wheel in back allows for a tighter turn radius meaning it doesn’t need as much room as a four-wheel forklift to turn. The 3 Wheel Electric is also available in a “short” model, making it an even better fit for those compact areas. But just because it is smaller doesn’t mean it isn’t powerful. This forklift can lift up to 4,000 lbs.!

6 Series Order Picker

Toyota’s Order Picker is manufactured for specific applications. Order pickers are used to help employees reach goods stored on high racking, but does not necessarily stack products. There is a platform where an operator stands to pick things off of the shelves and place them on the pallet in front of them (that also raises and lowers with the operator). Order pickers allow for very narrow aisles, because they do not need to turn for an operator to put things away. They just reach from side to side, making things accessible for your operator.

Electric Reach Truck

The last piece of equipment we are going to touch on is the Electric Reach Truck. This forklift allows you to put pallets behind each other, by “reaching” out. It comes in a single- or double-reach model, helping you utilize your space more efficiently. The other benefit to using this machine is its ability to lift up to almost 30 feet! And its lift capacity of 4,500 lbs., is ready to take on heavy loads.

These are just a few of the options that Toyota Forklifts offers for those tricky narrow aisles. Take a look at the infographic below to get an idea of the complete range of narrow-aisle equipment available to you. Remember, if you need help deciding on what product is right for you, contact Dillon Toyota Lift, and we will gladly assist you.

Written by:  Lucas Collom, Digital Projects Administrator, Toyota Material Handling, USA