With a wide range of maintenance checks that need to be performed on all forklifts, it can be easy to allow some part of your equipment fall out of OSHA or ANSI compliance. One aspect of fork inspection that can sometimes slip between the cracks is ensuring that forks are maintained appropriately in compliance with ANSI 56B (updated in May 2017).

In order to complete the appropriate checks and maintain fork compliance, you’ll need to make appropriate use of a fork caliper. This device can be used in three important ways to help you measure fork deviations and get the appropriate information to make sure you’re following the ANSI standard.

Fork Inspection: Check Fork Angle

The Fork angle deviation must be within a margin of 3 degrees. That means that the angle between the blade and the shank must be between 87 and 93 degrees. To use the caliper to check this, open it and place it between the plate and shank so that all four protrusions are touching. The angle can be read using the marking on the caliper. Any fork angle that falls outside of the degree range must be tagged out until the forks are replaced.

Fork Inspection: Check Fork Hooks

The numbers on the end of the caliper indicate the forklift classes. Use the appropriate protrusion to check if the fork hooks are in compliance. Simply place the protrusion into the hook notch. If the hook hits the back of the caliper, it is out of compliance. If it does not, then the forks are fine for continued use. The above fork is in compliance.

Fork Inspection: Check Fork Blade Wear

Begin by setting the caliper by the thickness of the shank. Place the caliper onto the blade at the point of the fork that receives the most wear, which is usually at its heel, as shown. If the blade passes the inside teeth of the caliper, then the fork is out compliance and must be tagged out until forks are replaced.

Original Post: Jake Stewart, Digital Content Copywriter, Toyota Material Handling, USA

The excitement surrounding the acquisition of a new forklift for your operation is something to be celebrated. We at Toyota are equally excited to help you achieve your goals, and that’s why we work hard to manufacture industry-leading forklifts with legendary reliability. But we also recognize that your forklift success is about more than just the occasional acquisition of a new forklift. Instead, you have unique needs, success measurements, and pain points that need to be addressed throughout the entirety of your forklift’s lifetime.

The Toyota 360 Support promise isn’t just an aftermarket tool for purchase. It’s our promise to integrate with your problems and to help you find material handling solutions wherever possible. When you invest in a comprehensive aftermarket services program with Toyota 360 Support, make sure you’re taking full advantage of that promise and challenge us to fulfill it. You can bet we’re up the task.

Asking Your Toyota Technician

Not only does Toyota promise a four-hour guaranteed turnaround time on maintenance requests, not just anyone will be looking at your forklift. Rather, Toyota Certified Technicians who have been trained on Toyota forklifts, using Toyota Genuine Parts, and comprehensive Toyota dealer training techniques will handle the job. Don’t hesitate to ask your technician about the mechanical operation of your forklift or any efficiency questions you have about its internal function. They are there to help.

Utilizing the Toyota Dealer Network

The extensive Toyota forklifts dealer network is one of the major benefits to all of our customers and an integral part of the Toyota 360 promise. Don’t think of your Toyota forklift dealer as a company there to sell you forklifts. Instead, think of it as a group of people using their collective experience to help you tackle material handling challenges and increase operational efficiencies. We’re most successful when you’re successful, and a partnership built on mutual success is the foundation of the Toyota 360 support promise. From parts needs or warranty claims to consultations regarding proper forklift selection, forklifts’ functionality, capability, or current state of operation, your dealer is there to help with Toyota 360 Support.

Toyota Genuine Parts are the Core of All Repairs

Genuine. It’s that feeling of certainty when you expect fulfilled promises. If the Toyota dealer partnership is the foundation of the Toyota 360 Support promise, then Toyota Genuine Parts are how we deliver on it. Toyota forklifts lead the industry in overall value. Part of that overall value is the sum of the forklift’s Toyota Genuine Parts. And that’s exactly what Certified Toyota Technicians use as part of the Toyota 360 Support promise.

At Toyota, we know that you need more than just a forklift solution. You need solutions to complex operational challenges. Your success is within reach. Our promise is to provide the comprehensive support you need to achieve it.

Original Post:  Jake Stewart, Digital Copywriter, Toyota Material Handling, USA

There are a lot of moving parts on a forklift that are critical to its operation and the mast chains are no exception. As you may already know, a forklift uses hydraulic pressure to raise the mast up by raising the lift cylinders. This, in turn, raises the inner mast channels, but without the lift chains, your forks and carriage aren’t going anywhere. And if your forks aren’t being lifted, you aren’t going to be getting much work done.

So how does it all work? As I explained, the lift cylinders will lift the inner mast rails, but the mast chains are actually responsible for lifting the carriage and forks. Each mast chain is attached to the carriage and then routed up and over a chain wheel that acts as a pulley. The chain is then bolted into a boss that is welded onto the inner mast rail. So when the mast rails raise, the chains also raise and thus the carriage goes up with it.

Mast Chain Wear and Inspection 

As you can imagine, having to carry the bulk of your load weight during thousands of lift and lower cycles can take its toll. This wear will eventually cause the mast chains to elongate or even show other signs of disrepair depending on their age, use, and operating conditions. Since the chains are responsible for holding up the forklift’s carriage and ultimately a potentially large and heavy load, ignoring these warning signs could lead to product damage, injuries, or worse.

Your mast chains should be inspected at the start of every shift as part of your inspection of the forklift’s lift/lower systems. When inspecting the chains, be sure to look out for the following warning signs:
1.Broken Links: Broken links can be caused by abnormal force on the chains whether from dropping a load or working on an uneven surface.
2.Turned Pins: Lack of lubrication will cause pins to turn. If you see one turned pin, it’s likely there will be more. Always make sure the chains are properly lubricated prior to use.
3.Wear or Elongation Over Three Percent**: Over time, forklift chains wear out. You’ll need a chain gauge to measure wear and elongation. If your chain has elongated over three percent, it’s time to replace it.

Be mindful that chain pitch can vary with different chain designs and different pitches have different limits for stretch or elongation. Most chain gages will have wear guides for multiple types and pitches, so be sure you are following the instructions based on your specific type.

If you’re ever in doubt, be sure to reach out to Dillon Toyota Lift for assistance with inspecting your forklifts. They can even schedule planned maintenance with you so that a technician can inspect your forklifts at pre-determined intervals for all of these issues and more.

** Any elongation of your forklift chain should be properly inspected by a qualified technician.

Original Post:  Trinton Castetter, Product Marketing Specialist, Toyota Material Handling, USA

Hydraulic technology is so common we often forget we use it every day. It’s found right in our own homes in our dishwashers. It’s in the cars we drive to work. It’s in elevators, amusement park rides, and airplanes. And in forklifts. But without liquid to fuel the hydraulic systems, none of these things would work.

The main function of hydraulic fluid is to provide energy transmission, so it makes sense that if you don’t have the proper level of liquid, you can’t create the most power. Inadequate levels of hydraulic fluid in a forklift cause decreased lifting and steering capabilities, which is the last thing you want when you have a job to finish.

So, what do you need to know to ensure your hydraulic system is running smooth and fast? Let’s explore some of the common questions you might have about hydraulic fluids and forklifts.

How often should I change the hydraulic fluid for forklifts?

Most forklift manufacturers suggest replacing hydraulic fluid after every 1,000 hours of operation. To monitor levels properly, operators should go through a checklist, which includes checking the hydraulic fluid tank prior to every shift.

Why should I change hydraulic fluid every 1,000 hours of operation?

There are a variety of environments and variables that can affect the rate oil degrades. In lieu of performing an oil analysis every time you think you need to change your hydraulic fluid, most users stick to the manufacturer’s recommendation, which is based on years of service data. Keep in mind that if you decide not to change the hydraulic fluid for an extended amount of time, you risk the service life of every other component on the hydraulic system.

What hydraulic fluid for forklifts should I use?

It depends on your equipment and manufacturer. Consult your forklift operating manual for the specific fluid grade recommended for your particular forklift.

We also recommend paying close attention to the prescribed level to fill the tank. Thermal expansion can occur, which can in turn cause an oil spill and a safety hazard.

Can I change my hydraulic fluid or does my dealer need to?

Changing hydraulic fluid is a fairly simple task. However, we recommend a professional certified forklift technician perform the task. Toyota certified technicians are trained on all make and models of forklifts.

Original Post:  Samantha Horton, Content and Communications Consultant, Toyota Material Handling USA

Keeping a large inventory of spare parts on hand encroaches on both the budget and physical storage space of your business. What happens if your forklift goes down and you don’t have that critical spare part on hand? Your business suffers unnecessary downtime and you may be forced to pay outrageous freight costs to have the parts shipped to you overnight.

How do you determine which forklift parts are critical and which are not?

If you are looking to define a critical spare part, ask yourself the following questions:

• What parts do you purchase most often? This should be your first consideration, especially if you have a fleet of several forklifts. Look back and determine which parts have been consistently replaced in the last few years and keep them in your on-site inventory.
• If your forklift goes down, how quickly will you need the part? If you will need it immediately, then it is a critical part. If you have a backup forklift that can be used or another means of covering the downtime, then it would not be a critical part.
• Will your business be halted or delayed if you don’t have the part? If the answer is yes to this question, then it is a critical part and must be kept in inventory.
• How long will it take you to receive a part if ordered? Find out which parts your local Toyota Forklifts dealer keeps on hand and which ones have to be ordered. Doing so will help you determine how long it will take you to retrieve the new part.
• If you need to have a part repaired, what is the average time it will take for your dealership to make the repair and have it returned? Contact your dealer and determine average repair times for those parts that you define as critical.

Have a backup plan. 

• If you don’t have space for a large inventory of spare parts, work with Dillon Toyota Lift to make sure they have the parts on hand that are critical to your organization.
• Keep a list of those critical parts posted so your technicians know what steps to take to procure that part.
• If you are going to experience a lengthy downtime, will your dealer be able to provide a loaner?

By being prepared and determining which parts are critical, your business could save money and most importantly, time.

Original Post By:  Debi Stanton, Customer Satisfaction Administrator

Equipment downtime is your operation’s worst enemy. Just like a car or house, a forklift requires maintenance and repairs after you purchase it. Taking a reactive approach to maintaining your forklifts can be accompanied by uncertainty and unexpected periods where forklifts are out of service. This can interrupt work flows that need to run smoothly for your business to succeed.

This is why many companies that use forklifts opt for a routine maintenance plan. The two most commonly used maintenance plans in the material handling business are planned maintenance agreements and full maintenance agreements (also referred to as guaranteed maintenance). Both plans are designed to maintain equipment uptime, be proactive on potential repairs before breakdown, and ultimately save you money in the long-run. But is the difference between a planned maintenance agreement and full maintenance agreement? We break that down right here for you.

Proactive with Planned Maintenance

Detailed inspections. Recommended repairs. Flexible billing. Tailor-made schedule. In my experience at a Toyota forklift dealership, these were expectations that come with a planned maintenance agreement. Many service providers have a detailed point inspection checklist the technician uses to inspect repair needs, potential safety risks, wearable items, and routine replacement parts. As technicians work through the checklist, he or she documents recommended repairs and provides service quotes to you for those repairs.  After going through the inspection process and performing any necessary repairs, many dealers will then bill you and schedule in the next appointment based on both hour usage and date cadence. While this process might be slightly different with dealers throughout the Toyota dealer network, maintaining uptime for your forklift is the value of any Planned Maintenance agreement. At Toyota, we believe in the value of planned maintenance so much that we include four PMs in the first year when you invest in Toyota 360 Support Plus. New forklift investment and proactive maintenance should go hand-in-hand.

Free Time with Full Maintenance

Signing up your forklift on a full maintenance agreement is like receiving the royal treatment. At the dealership I came from, you not only received everything included in the planned maintenance agreement, but you also had a plethora of other benefits, including:

• Maintenance records, tracking, and regular reports.
• Pre-paid scheduled and breakdown repairs with the exception of repairs due to misuse, abuse, and wearable items.
• Replacement rental equipment for the covered repairs, without charge.
• Flat monthly payment with the exception of repairs due to misuse, abuse, and wearable items.

With full maintenance, dealerships often take on the burden of overseeing the entire preventive health of your forklift. The true benefit is that the people who work with the equipment daily at the dealership now manage your forklift maintenance. When the dealership is able to work side-by-side with the customer, the dealership personnel is often in the best position to understand when to make repairs and replace parts before it affects your operation. This adds additional peace of mind when owning a forklift fleet. The monthly rate also helps you budget easier as the cost will not fluctuate from month-to-month. Ideally, you wouldn’t have to pay for every scheduled maintenance interval or the unexpected repairs that come with owning the forklift. Full maintenance monthly rates take into consideration a number of factors, such as equipment type, forklift utilization, age, service history, and the environment in which the forklift is operated.

Every service provider may differ in the way that they offer maintenance agreements. Planned maintenance and full maintenance agreements, in general, follow what I outlined above. Define your expectations and take a long, hard look at a proactive maintenance for your forklift fleet. It’s up to you to work with a dealer and tailor the maintenance agreement to meet your needs. 

Written by:  Kenny Trusnik, Marketing Systems & eCommerce Specialist, Toyota Material Handling, USA