Power solutions will deliver the next generation of forklift efficiency. Toyota is dedicated to staying ahead of the curve in power technology innovations – testing new power sources and energy integrations that will continue to maximize the value of all Toyota Forklifts.

Lithium-ion forklift battery technology is one example of the advanced thinking driving Toyota. Lithium-ion forklift batteries provide a wide variety of efficiency advantages that can offer excellent return on investment when managed appropriately. From consistent power delivery to quicker charging capabilities, exploring lithium-ion forklift battery options can reveal your next steps in operational efficiency.

As the manufacturer of North America’s most expansive material handling product line, Toyota recognizes its responsibility in leading the charge in efficient power solutions. With almost every product in Toyota’s electric line offering lithium-ion compatibility*, you can take advantage of our industry-leading innovation now and into the future.

Key Advantages of Lithium-Ion Forklift Batteries

Lithium-ion batteries can offer your operation an advantage by increasing efficiency. If the conditions are right for the investment and the space is available for charging, there are several key factors that may lead you to adopting this energy solution.

Consistent Power: Whether you have a single-shift, single-forklift operation or a large fleet working 24-hours a day, one important factor in delivering results and projecting milestones is consistent power throughout the charge of the battery. Lithium-ion forklift batteries deliver consistent power and battery voltage throughout the full charge; lead-acid battery charges deliver declining power rates as the shift wears on.

Faster Charging Speeds: In the context of day-to-day operations, lithium-ion forklift batteries offer significantly faster charging speeds and don’t require charging cooldown. This can help optimize daily productivity or even reduce the number of forklifts needed to complete objectives.

Opportunity Charging: Lithium-ion forklift batteries can be opportunity charged in any setting, eliminating the need for time-consuming battery swaps.

Fewer Required Batteries: Lithium-ion forklift batteries can remain in equipment longer where one battery can take the place of three lead-acid batteries in a multi-shift use setting. This helps eliminate the cost and storage space required for additional lead-acid batteries.

Virtually Maintenance Free: Lithium-ion batteries are virtually maintenance free, requiring none of the watering, equalizing, and cleaning needed to maintain lead-acid batteries.

The Future of Lithium-Ion Forklift Battery Technology:

As the industry pushes to revolutionize, Toyota is committed to fully outfitting our electric product line with lithium-ion solutions. Toyota Material Handling was the first manufacturer to offer a UL-E and UL-EE certified integration of lithium-ion batteries and forklifts. Available on Toyota 3-Wheel Electric and 4-Wheel Electric Models, UL-certification is just the first in a long line of planned innovations.

With Toyota Material Handling, the revolution is here. 

*Only specific lithium-ion battery brands/models are compatible with specific Toyota material handling products.

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

The TuffCab Panel Cab Enclosure comes complete with windshields, roofs and rear panels that can be purchased and installed individually or in sets. They are simple, easy to install and cost effective. TuffCabs are made of durable heavy gauge steel and tempered safety glass construction. Windshields include a 12V wiper. They offer excellent visibility with a large roof view and rear window panel for backup protection.  The TuffCab is available for Toyota Models 8FGU25, 30 and 35 as well as Toyota Models 8FG40U, 45U and 50U.

The TuffCab Forklift Panel Cab Enclosure features:
1. Durable Steel & Safety Glass Construction
2. Easy Clamp-On Installation
3. Easy Fold-Up Curtains for Operator
4. Fast Lead-times
5. Full Enclosure or Individual Components Available
6. Windshiled Includes 12V Wiper

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Sakichi Toyoda, born in 1867, was the son of Ikichi and Ei Toyoda. From an early age, Sakichi had a passion for learning and a desire to contribute to society through the creation of new and useful inventions. Through hard work and perseverance, he quickly become known as a prominent inventor in Japan after obtaining patents for the Toyoda wooden hand loom and Toyoda power loom.

Over the years, Sakichi continued to invent more sophisticated and advanced looms and eventually established Toyoda Automatic Loom Works, Ltd. in 1926. Although their primary function was the invention and manufacture of looms, the company had larger aspirations of broader research and inventions outside of the textile industry. This drive is what led to the company’s significant business diversification efforts that resulted in the eventual design and production of engines, automobiles, air compressors, and, of course, forklifts.

Toyoda began development of their first lift truck in 1955 and by 1956, the model LA 1-ton internal combustion engine counterbalanced forklift was launched through Toyota Motor Sales Co. (currently Toyota Motor Corporation). The name change from “Toyoda” to “Toyota” actually occurred because the latter can be written with eight strokes in Japanese katakana and eight is regarded as a lucky number in East Asian culture.

The lift truck market grew rapidly in the 1960’s, and in 1970 Toyota established a dedicated factory for production of industrial vehicles in Takahama, Japan on an over 1 million square foot parcel of land. This facility is still used to this day as Toyota forklift’s headquarters and main manufacturing facility. In 1970, Toyota systemized the Toyota Production System (TPS) based on two main ideologies: “Just-in-Time” and “Jidoka (automation with a human touch)”. While TPS has evolved over time, it is currently a world renowned philosophy that is practiced at all Toyota production facilities across the world.

Throughout the 1960’s and 1970’s, more diversified products began to be designed and manufactured including diesel and electric forklifts, models with lift capacities up to 40 tons, and even an extensive lineup of forklift attachments and options. Increasing global demand for these products led to the first Toyota forklift sale in the United States in 1967.

As the number of exports to the US grew, the need for an overseas manufacturing facility became apparent. In 1988, Toyota Industrial Equipment Manufacturing (TIEM) was established as a joint venture with Toyota Motor Sales in Columbus, Indiana with production beginning in 1990. By 1995, Toyota forklift production had reached 1 million units globally and was still going strong. The acquisition of BT Industries AB of Sweden and introduction of the world’s first AC powered electric forklift in 2000 further bolstered sales and market share.

In order to unify manufacturing and marketing and sales operations, Toyota Material Handling was established in 2001 under Toyota Industries Corporation (TICO) with separate divisions across the globe, including Toyota Material Handling, USA (TMHU) in North America. That same year, Toyota attained first place in global market share and by 2002 had also attained first place in US market share, both distinctions that are still held to this day.

In April of 2006, Toyota Material Handling Group (TMHG) was created to facilitate integration of Toyota Material Handling and BT Industries Group. This joint venture improved global competitiveness and allowed the companies to realize synergies by mutually supplying each other’s products, engaging in joint development, reorganizing sales and service networks, and sharing production expertise.

These synergies allowed Toyota to continue to position itself as a true full line supplier of material handling equipment. Reach trucks, order pickers, tuggers, pallet jacks, and more joined Toyota’s line up of premier sit-down counterbalanced products throughout the 2000’s. In 2003, the AICHI Corporation became a subsidiary of Toyota, adding a diverse offering of aerial work platforms and construction equipment to the product mix. Cascade Corporation, the world leader in design and manufacture of material handling attachments and accessories, was later acquired in 2013.

In addition to being a full line supplier of material handling equipment, Toyota also continues to position themselves as premier material handling solutions providers. TICO’s acquisition of Bastian Solutions, LLC and Vanderlande in 2017, for example, signifies Toyota’s strategic ambition to increase their presence in automated material handling, systems integration, and advanced logistics technology.

This dedication to innovation and diversification started with Sakichi Toyoda’s vision over 100 years ago. What started as one man’s dream and a small loom manufacturing company has evolved into one of the largest and most recognized companies in the world. Sakichi passed away in October 1930 after dedicating 63 years to invention, but his spirit still lives on in all Toyota companies. His lasting legacy will continue to inspire us all for years to come.

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

Construction, maintenance, and facility enhancements offer complex needs, especially when they occur in areas that are already in use. Current infrastructure can block access to a needed area. Equipment use of varied sorts can cause task execution headaches. And the people in high traffic environments challenge operators to move carefully to remain productive while remaining unobtrusive, allowing people to use those spaces with little interruption. A vertical mast lift offers one answer to help meet each of these challenges.

What is a Vertical Mast Lift?

Vertical mast lifts are a type of aerial work platform intended to provide access to high reaching tasks while allowing for tight fitting access and a small space footprint. While similar to scissor lifts, vertical mast lifts utilize a multi-stage mast that accommodates a smaller footprint than traditional personnel lifts like scissor lifts. They come equipped with platform extensions that extend beyond the base of the vehicle.

Navigating Existing Infrastructure with a Vertical Mast Lift

Facility designers often pay close attention to the long term maintenance needs of the operation. Sometimes those designers consider what equipment can be used to fulfill those needs. But over the lifetime of any evolving work environment, unexpected infrastructure changes arise – as do unexpected maintenance needs.

A vertical mast lift can help meet high reaching maintenance needs when original or new facility infrastructure can be difficult to navigate. With a width of only 30 inches and a length of four and a half feet, the AICHI Vertical Mast Lift can fit through standard doorways, in between tight racking, or in other spaces obstructed by infrastructure. Have a need to fit between ducts for heating and cooling work or pipes to fix facility plumbing? The platform dimensions of a vertical mast lift are built to access these spaces. And with many models like the AICHI Vertical Mast Lift equipped with zero-degree turn radius, versatility in maneuvering is optimal for tight locations. Has a new rack appeared directly beneath an electrical box you need to access? Position an AICHI Vertical Mast Lift next to the rack and use its 15-inch platform extension to reach over the rack and get to the task.

Integrating Vertical Mast Lifts with Other Equipment

Smart operations managers and construction project managers plan routing of their equipment carefully to make the most use of the space and assist operators in maintaining efficient operation. When maintenance needs arise in areas with high traffic from other equipment, a vertical mast lift’s small footprint can help optimize space. By working close to exterior walls of a facility or on the outside perimeter on a construction site and taking up little space, other industrial equipment can maintain optimal operation and efficiency.

Using Vertical Mast Lifts in Public Places

Maintenance in and around buildings that grant public access is a common need. While proper precautions need to be exercised when performing maintenance around non-facility personnel/operators, vertical mast lifts come equipped with features to assist in the protection of both the operator and passersby. The AICHI Vertical Mast Lift features systems like anti-rollback and lift interlock when a steep grade is detected. Standard pothole protectors and reduced travel speed when elevated also enhance the protection provided to the operators when working at height.

Vertical mast lifts are versatile and offer an excellent solution for accessing difficult to reach areas for maintenance. While they do provide a flexible solution, key considerations such as platform height need and weight requirements must be considered. As these requirements increase, consider investing instead in an AICHI Scissor Lift for increase height and weight capacity with a slightly larger physical footprint.

Original Post:  Mark Faiman, Product Planning Manager, Toyota Material Handling

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.

2.  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.

3.  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.

4.  #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.

5.  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.

Click here to learn more about why you should consider choosing a Toyota forklift from Dillon Toyota Lift.

Forklift accidents can happen anywhere, but because loading docks are typically narrow and elevated, they’re one place where extra caution should be used. Common loading dock incidents include falling off the edge of the dock, and skidding or slipping due to wet or icy conditions. So how can the risk of loading dock accidents be reduced?

First and foremost, make sure the trailer is secured to the dock using a locking device, either on the trailer’s rear impact guard or rear wheel.  One common and dangerous issue that can arise when loading and unloading trailers in a loading dock, is the truck driver not realizing the forklift is still in the truck and pulling away, which causes the forklift to roll out. “Trailer Creep”, which happens when trailers gradually move away from the dock because of constant movement inside them, can also happen. The only way to prevent these two things from happening is to completely secure the trailer with a locking device on the trailer’s rear impact guard or rear wheel.

Clean off the surface of the loading dock. One common cause of accidents involving forklifts and loading docks is ice or water covering the dock. Clean the dock off before operating the forklift on it to help prevent sliding issues.

Also, remember to always maintain a safe distance from the edge of the loading dock. OSHA doesn’t recommend a specific measurement between a forklift and the edge of a loading dock, but you should implement good judgment to avoid falling off the side of the loading dock. Painting the edges of the loading dock a bright color is one thing you can do to help forklift operators stay aware of dock edges.

By doing the three things above, you’re well on your way to reducing accidents on loading docks, but keep these things in mind too:

• Anyone operating a forklift should be trained. Proper operating training is the number-one way to prevent accidents.
• Implementing a daily loading dock inspection is important to the safety of operators and truck drivers alike.
• Keep the product secure on your pallets by covering them in plastic or metal.
• Double check floors of trailers before driving on them to ensure they’re sturdy enough to handle the weight of the forklift.
• Consider creating a dock shelter to keep rain and snow off loading docks, which can cause them to be slippery.

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

Electric forklifts are awesome! Electric forklifts are low-emission vehicles that are less maintenance than an internal combustion forklift, while maintaining a similar workload as its internal combustion counterpart. This is due to the high-powered forklift battery. With that said, electric forklifts require some unique care that other types of equipment might not require. Failing to take the proper precautions with electric equipment can lead to breakdowns that cost time and money.

1. High Temperatures’ Impact on Forklift Battery Life

Heat is a battery’s arch nemesis. Heat from forklift operation causes the lead within the industrial battery to deteriorate. If you use the forklift and battery for an entire shift, make sure you let the battery charge properly and sit long enough to cool down before using it again in the forklift. Also, while you are charging, you will want open the hood to provide proper ventilation. This will help cool the forklift’s battery. Simply, the heat can take years off the battery’s life if not appropriately managed.

2. Over AND Under Charging Damages Forklift Battery Life

Your forklift needs a good night’s rest just like the rest of us. If you don’t get enough sleep, you might be frazzled for the day, but if you over sleep, you still might still feel worn out. If you don’t charge the forklift’s battery just right, you risk harming your battery’s lifespan. If you over charge your forklift battery, you risk excess heat, causing the battery to deteriorate (heat is not your battery’s friend, as we talked about before). You do not want to under charge your battery either, because undercharging leads to plate sulphation and battery breakdown. Under charging can drastically shorten the lifespan of the battery.

3. Watering for Increased Forklift Battery Life

Is watering your battery like watering your garden? Well, kind of. Your battery requires watering to provide the appropriate discharge to power your forklift. Lead-acid batteries used in forklifts typically have a mixture of 35% lead acid and 65% water within its cells. You can see that water is very important for powering the battery. During discharge, water evaporates, but the lead acid does not. The evaporation creates disproportionate levels of water and acid. So, you need to replace that water. In this case, you need to water your battery. Easy enough right? Not quite. If the battery is topped up with water at any stage other than fully charged, you risk the battery spilling water and acid on top of the battery and onto the floor. This causes the battery oxidize and lose acid, ultimately losing capacity for operation. Simply put, you only want to water the battery after it has been fully charged.

Original Post:  Kenny Trusnik, Marketing Systems & eCommerce Specialist, Toyota Material Handling, USA