Do your forklifts ever get a break? And for how long?

This is one of the most important factors in determining the right energy source for your forklifts.

And it makes sense. Just consider those days when you’re constantly running from morning till night time. You need ALL the coffee to stay awake, energized, and ready to go. Whereas, on those more “normal” days, you can probably get by on just one or two cups in the morning.

In the same way, your forklift fleet will have different energy needs depending on the shift cycles you run them on throughout the day. While you’ll always want to consider a wide variety of options and work with an integrated solutions provider like one of Toyota’s authorized dealers, this guide can help you make a preliminary diagnosis of whether to explore electric or internal combustion options.

Single Shift Operations

While internal combustion forklifts can provide the power and efficiency needed to run a successful single shift operation, electric forklifts should be seriously considered. Operating on a single shift, you’ll be able to take full advantage of energy efficiency savings because you can allow the forklift to sit and the battery to charge while your facility is closed.

At the same time, it may take you longer to achieve a full return on your investment in electric forklifts due to your lower utilization — a key factor in determining operation and labor cost.

Multi-Shift and Continuous-Shift Operations

You will need to consider several variables when weighing lead-acid battery and internal combustion options. The efficiency savings of lead-acid batteries are reduced the most in these operations because they are faced with needing to buy battery exchanging equipment and additional batteries — typically one for each shift. This translates into increased acquisition costs, storage space, maintenance areas, and swap times.

In this case, an internal combustion forklift option deserves serious consideration. While it is a more expensive fuel option, replacing a propane tank is quicker and requires less facility space than swapping and charging a battery.

Lithium-Ion Forklift Batteries and Shift Cycles

Lithium-ion batteries offer considerably faster charge speeds, and they can stay in the truck for multiple shifts while being opportunity charged during breaks. This means that they deliver a significant operational advantage over their lead-acid counterparts and can be considered a suitable electric option to replace propane in multi-shift operations.

However, because lithium-ion can cost up to 3x more than lead-acid, they might not be right for every operation. Single-shift operations are just one example in which efficiency returns may not outweigh the upfront costs.

View original post HERE

One of the main reasons that Toyota has gained the reputation for having the highest quality forklift in the industry is that the buying a Toyota forklift means you’re also getting a Toyota engine. Years of engineering Toyota’s world-renowned 4Y engine and all of our other engines means our internal combustion forklifts are unmatched.

How does a Toyota Forklift Engine Work?

Every Toyota IC forklift engine has the same basic functionality. Toyota Certified Technicians are trained in this process so they can more easily understand the exact point of need when maintenance is required. Here’s an inside look about how an IC forklift engine works.

An ignition battery and gear-driven starter forces the engine to “crank over,” starting the internal combustion process. The carburetor mixes a combustible, liquid fuel with air and injects it into the cylinders through a valve. Within the cylinder, the piston is attached to a rod, which in turn is attached to the crankshaft.

Mechanical energy is produced when the spark plug introduces a spark to the compressed fuel/air mixture, igniting the explosion. The explosion drives the piston and rod down in the cylinder. Because of the way the crankshaft is designed, it will convert the downward energy of the piston and rod to the mechanical energy (RPMs).

A series of these cylinders are connected to the crankshaft in the block. The block contains other mechanisms, like the cam shaft, which uses the RPMs to open and close the valves in precise timing sequence. This mechanical energy also drives the alternator or generator (found mounted to the engine and driven by a belt) which supplies current to the forklift’s electrical components. Additionally, the electricity produced in this way is used to drive the power steering and lift/tilt hydraulic pumps.

From Forklift Diesel Engines to Gasoline, Toyota Has Forklift Engine Fuel Types Covered

Internal combustion engines come in four main types, each categorized by the type of fuel they burn. Deciding between them depends on your specific forklift application and operational strategy

• Forklift gasoline engines use the same fuel as an automobile.
•  Forklift Liquefied Petroleum Gas (LPG) engines run on a gas that occurs naturally. LPG is commonly used for gas grills.
• Compressed Natural Gas (CNG) engines use the same fuel supplied to homes and businesses to power stoves, furnaces and other appliances.
• Diesel engines use diesel fuel, a lower grade fuel not as refined as gasoline and therefore, not as combustible.

Each type of fuel provides different advantages that will then impact the operation of the forklift. Consider the below list that shows which forklifts can come equipped with forklift diesel engines and CNG engines and ask your locally authorized Toyota dealer about what choosing one can mean for your operation.

CNG Options:

• Core IC Cushion(up to 6,500 lb. capacity)
• Core IC Pneumatic(up to 6,500 lb. capacity)

Diesel Engine Options

• Mid IC Pneumatic (8,000-11,000 lb. capacity)
• Large IC Pneumatic (13,500-17,500 lb. capacity)

Diesel Engine Only:

• High-Capacity IC Pneumatic(22,000-125,000 lb. capacity)
  • Shorter load centers available in LP

Knowing the Difference between Forklift Engines – The Toyota 4Y Engine and More

But which engine comes in each of our forklifts? The below guide will help you understand the differences between each Toyota forklift engine. But one thing that’s consistent across every forklift engine we produce? Expert engineering.

Four forklift engines are distributed across our internal combustion line

4Y Forklift Engine
Core IC Cushion | Core IC Pneumatic

1ZS Forklift Engine
Core IC Diesel Pneumatic

1FS Forklift Engine
Large IC Cushion | Box Car Special | Paper Roll Special | Mid IC Pneumatic | Large IC Pneumatic

1KD Forklift Engine
Mid IC Diesel Pneumatic | Large IC Diesel Pneumatic

But what exactly is the difference between these forklift engines that come in each of these models? Here’s a breakdown of each to help you choose the best available option.

Toyota 4Y Engine

The Toyota 4Y Engine was introduced in 1986, and it has been one of the industry’s longest lasting, most durable forklift engines ever since. The 4Y Engine is unique in that it is the cleanest engine in the industry, and its emission standards rival the emission standards of any competitive internal combustion engine.

• The Toyota 4Y Engine is extremely efficient, which makes it tolerant of extreme temperatures. From outdoor applications in Minnesota, to paper mills in Georgia, this engine runs smoothly.
• Due to its compact design, this engine works well in Toyota’s Core Products, such as the Core IC Cushion and Core IC Pneumatic.
• It is common to find Toyota Forklifts operating with 4Y Engines that have run for more than 30,000 hours and haven’t had a major overhaul.

Here’s deeper dive into how the Toyota 4Y Engine functions:

Toyota 1FS Engine

The Toyota 1FS Engine is based off the well-known 3Z diesel engine. It’s a robust powerhouse that can handle your toughest jobs.

• The 1FS is built with special electronics that all lead to better fuel efficiency and low emissions.
• Special measures have been taken (including a smaller engine footprint to help reduce the under-hood temperature, which leads to durability and longevity.

Toyota 1ZS Diesel Engine

The Toyota 1ZS Diesel Engine powers the Toyota Core IC Diesel Pneumatic, with less displacement than the previous model for lower emissions and fuel costs.

• The 1ZS is a 3-cylinder inline engine.
• The Toyota 1ZS requires no exhaust maintenance.
• This engine is a tough 53 horsepower with 128 lbs./ft. torque.

Toyota 1KD Diesel Engine

The 1KD Diesel Engine has been developed for the Toyota Mid and Large IC Diesel Pneumatic Forklifts. The 1KD is a four-cylinder engine that helps decrease fuel consumption and emissions.

• This engine is turbo charged which provides advantages including superior power and efficiency.
• With this engine model, horsepower and torque have significantly increased while fuel consumption has significantly decreased.
• The current 1KD engine has approximately 20 fewer internal moving parts than the previous model, making it easier to maintain and own.

Takeaway Reasons to Trust Toyota Forklift Engines

Need a few quick reasons that Toyota forklift engines lead the way? Here a few quick take aways:

Contact Us for more information about any Toyota forklift engine or to request a quote

BYD is an innovator in the marketplace. Trusted and reliable, BYD (Build Your Dreams), the world’s premier manufacturer of batteries, celebrates #BatteryDay today and every day.

Founded in 1995 as a pioneer in battery technology, BYD’s mission is to change the world by creating a complete, clean-energy ecosystem that reduces the world’s reliance on petroleum. BYD’s innovative products are leaders in multiple sectors, including battery-electric automobiles, buses, medium- and heavy-duty trucks and forklifts; the SkyRail monorail system; solar power generation and energy storage systems; and consumer electronics.

BYD always aims to make battery safety its key indicator of quality. BYD puts its batteries through rigorous safety tests, from burning, to overheating, dropping, perforation, crushing, and even shooting nails through their casings. Throughout these tests, BYD batteries have proven extremely safe, never overheating or exploding.

BYD forklifts can fully charge in under 90 minutes and can run 10 hours per day, seven days a week. The reliable batteries in BYD forklifts require zero maintenance and come with a 10 year warranty. 

BYD’s new forklift charger also sets a high bar for the industry. Thanks to the device, BYD forklifts can be fully powered using a 110V charger that requires no extra wiring and can be connected to a standard wall plug.

View BYD Forklifts

There are many different forklift types, each carefully designed for specific applications and each offering its own unique set of benefits and features. Below is a list of the six most common types of forklifts: 

1. Electric forklifts

2. IC forklifts

3. Order pickers

4. Reach trucks

5. High-capacity forklifts

6. Pallet jacks

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 Forklift types?

• 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 of forklifts:

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 lift trucks 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 (gas powered) 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 when choosing between a gas powered and electric powered forklift:

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

BYD forklifts are 100% electric forklifts built for the highest reliability in indoor & outdoor operations. Enjoy a seamless integration between all systems since BYD manufactures the forklift, battery and charger. Combine industry leading runtimes with fast anytime charging and you get a true one battery 24/7 solution. They operate across multiple shifts without the need to change or replace batteries.

• 80V AC Technology
• Up to 18 Hour Run Time
• Iron Phosphate Battery - no gassing or acid, better for the environment
• Rapid, Restriction-Free Charging
• Recharged in as little as 90-minutes
• No Battery Maintenance Required
• 10-Year or 20,000-Hour Battery Warranty (industry leading) 

Ready to challenge the status quo and get rid of your battery room?  Learn More

A Revolutionary Approach to Your Energy Needs

What powers your operation now? What energy sources will keep your business moving efficiently and cost-effectively in the future?

However you answer these questions, Toyota Industrial Energy Solutions is our promise to continually be at the forefront of new technological development, providing reliable solutions for your ever-evolving energy needs.

As you work to optimize your fleet amid increasing environmental standards and throughput expectations, Toyota Industrial Energy Solutions is your partner at every step of the journey. We deliver service and expertise — as only Toyota can — through our commitment to quality, forward-thinking innovation, and the support of the largest dealer network in North America.

Here are five tools and services Toyota Industrial Energy Solutions offers you:

1)    On-Site Consultation for Forklift Energy Solutions

Toyota Forklift dealers offer free, on-site consultation services to help identify the best practices and energy management solutions that will work for you.

Utilizing the resources made exclusively available through Toyota Industrial Energy Solutions, Toyota dealers are uniquely positioned to optimize your operation with the latest technological innovations tested and approved by Toyota, such as:

• Toyota’s first-to-market UL-E/EE approved sit-down forklift and lithium-ion battery combination
• Our more than 50 tested and approved alternative energy source models across electric rider forklifts, electric narrow aisle lifts, and warehouse equipment

2)    Electric Forklift Batteries and Alternative Energy Sources

An extensive selection of lead acid and TPPL batteries, as well as approved alternative energy sources (including lithium-ion batteries), allows Toyota to uniquely pair up the best forklifts in the industry with the most efficient and cost-effective power sources. Some of the potential benefits include:

• Increased charging efficiency
• Higher, more stable voltage supply
• Reduced maintenance
• Eliminate battery storage areas and charging equipment
• Increased cycle and shelf life

3)    Forklift Battery Chargers & Accessories

Your Toyota Forklift dealer can help you increase energy efficiency and lower operational cost — simply by matching your chosen energy source with an optimal charger! They’ll use battery monitoring equipment to pinpoint efficiencies that can be gained through an appropriate battery/charger combination.

Some charger considerations include:

• Frequency – Higher-frequency charges, which increase charge rates and can allow for opportunity and fast charging.
• Energy Efficiency – Converting power from your facility with greater energy efficiency can lower your electric bill.
• Multi-Voltage – Chargers with multiple voltage capabilities can reduce the total number of chargers needed.
• Smart Functionality – Wireless communication and other smart functionality can allow expert control of charging efficiency and timing.
• Size & Weight – Smaller, lighter-weight chargers can decrease your storage footprint and are easier to move.

4)    Service & Repair with Toyota Industrial Energy Solutions

Peace of mind. That’s what you get with Toyota Industrial Energy Solutions — because you’ll know:

• 3,500+ expertly trained Toyota Certified Technicians are at the ready to minimize your downtime — not only on your equipment, but on the energy sources that power them.
• You’ve got a variety of alternative energy source options that have been tested and approved by Toyota as compatible with your forklift’s electrical systems.
• Your equipment’s warranty will remain intact should you choose a Toyota-approved alternative energy source for power.

5)    Environmental Support

Keeping up with increasingly stringent emissions regulations has never been simpler. Your Toyota Forklift dealer can assist you with CARB fleet averaging and optimizing your product mix to fit your unique application and regulatory needs.

Dillon Toyota Lift can help you apply and benefit from the energy-saving and waste-reducing practices Toyota is known for, including lean thinking and the Toyota Production System. 

Original Post: Shannon Potelicki, Content & Communications Copywriter, Toyota Material Handling

“The Heat Is On” is more than just a popular song by Eagles lead singer Glenn Frey, it’s also a great metaphor for forging and casting applications. And the heat isn’t just on the street, it’s also on your forklift and on forklift operators. Luckily, there are a number of ways you can combat these high temperatures to increase productivity and reduce the possibility of premature wear on your equipment.

Foundry Package

Toyota has specially designed packages to help alleviate problems associated with high-heat applications and the foundry package is a great place to start. Toyota’s foundry package typically includes the following features depending on the model and truck configuration:

• Protection for external wires and sensors using heat-resistant sleeves
• Hydraulic cylinders wrapped in heat-resistant wrap
• Heat shield for mast hoses
• Perforated belly pan

This package is available through special design request and is designed to provide the most common heat-resistant features normally required in the forging, foundry, and casting industries. It is a great starting point for applications where hydraulic failures are a concern due to high ambient temperatures.

Engine Protection

As you can imagine, high heat and high cycle applications can be harmful to your forklift’s engine and powertrain components. This is one reason why Toyota’s 8-series IC forklifts come standard with built-in engine protection. This system uses the forklift’s controller to monitor engine coolant temperatures and other potential malfunctions. When a malfunction is detected, the engine power is limited to prevent further damage to the engine. It’s a great feature that reduces the possibility of failure due to prolonged use or operator error.

Cooling and Ventilation

High ambient temperatures can create a lot of heat buildup throughout the forklift, so it’s best to outfit your forklift with specific optional features as needed. One concern in this type of environment is operator safety and comfort in high-heat conditions. Options such as an enclosed cabin, air conditioning, and fans can keep operators cool and increase productivity by lowering ambient temperature in the cab.

You also have to consider the effect the temperature can have on your internal components. Toyota’s engine protection system certainly helps, but proper cooling and ventilation can go even further to reduce downtime and maintenance. Toyota offers a wide variety of options and special designs to fit your application’s needs, including:

• High capacity cooling package
• Premium ventilation package
• Hood vents
• Vented radiator cover
• Perforated belly pan
• Dedicated transmission oil cooler

These are just a few of the most common ways to deal with high heat, but each application is unique and has exacting demands. We are here to help determine what is best for your facility and outfit your forklifts accordingly. A simple site survey could mean the difference between sweating it out and being as cool as a cucumber.

1. • A History of Excellence and Leadership: Toyota’s forklift division began in 1956 in Japan with the introduction of the first Toyota forklift. Today, Toyota is the world leader in forklift sales.

• • Safety Innovation: Toyota introduced the world’s first and only System of Active Stability (SAS). The system electronically monitors the forklift’s operations to help reduce the likelihood of both lateral and longitudinal tip-overs.

• • Technical Innovation: In 2000, Toyota became the first major forklift manufacturer in the United States to offer AC technology to provide high performance and efficiency. The AC motor contains no springs, brushes, commutators or directional contractors, making is virtually maintenance free.

• • #1 in Quality, Durability, Reliability, Value and Lowest Cost of Ownership: Toyota forklifts are ranked number one in numerous studies conducted by Peerless Research Group.

• • More Than a Forklift Manufacturer, Toyota is a Full-Line Supplier: In addition to a full line of high-quality forklifts, Toyota offers other industrial equipment products including narrow aisle solutions, walkie stackers, automated guided vehicles (AGV’s) and tow tractors.