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Welcome to Dillon Toyota Lift's blog. Here you will find everything from product features, industry education, operator insights, racking, warehouse design, material handling solutions, safety, trends, best practices and more!
Running a material handling business is a tall task – not only do you have to monitor your product, your sales, and your employees, you also have to ensure your forklift fleet is operating at its best capacity. Malfunctioning and overheating forklifts can skyrocket your operating costs and require expensive repairs. So what do you do if you’ve followed all maintenance suggestions and they are still overheating? Here are three areas that may be the cause of your forklift running hot:
The first area to check is also the easiest to fix: are routine maintenance tasks being completed correctly? Issues such as low coolant levels or worn hoses can contribute to a forklift’s overheating. If your on-site tech stretches parts past their optimal use, such as clogged filters, your forklifts could be choking on thick, dusty air. Worn fans or damaged radiators can also contribute to high running temperatures in material handling equipment.
The same advice for workers in high temperatures applies to your forklifts – give them frequent breaks and make sure their fluids are topped off.
Is your work yard paved or on packed dirt? Excessive dust, debris, and rough terrain can put additional demands on your forklifts and cause unforeseen maintenance problems. If this is a recurrent summer problem then the outside temperature can even be to blame. The same advice for workers in high temperatures applies to your forklifts – give them frequent breaks and make sure their fluids are topped off. If your forklifts are overheating indoors then you’ll want to survey your work area to find issues. Is the floor dusty or dirty? Are pieces of paper, pallet wrap, or other debris being left on the ground where they can clog filters? Once you find these issues then you can optimize your work areas to prevent damage.
If it’s not maintenance or environmental issues causing your overheating problems, then you need to check on how you are driving the equipment. If you are overloading the forklift with loads above capacity, this can cause overheating and create unnecessary risks for product damage and accidents. Are you driving forklifts constantly at top speeds? This can also contribute to high heats.
Many IC forklifts come equipped with an inching pedal to use when maneuvering your forklift while raising the mast to retrieve loads. If you are “riding” this pedal while driving it can cause many problems, as it slightly applies the brakes. The inching pedal should only be used when retrieving loads.
Once you’ve identified the cause of the problem and put a fix in place, ask why it arose in the first place. Are you overworking forklifts due to high expectations? Should your work area floor upkeep be added to existing maintenance plans? Don’t just solve the problem. Find a solution to keep it from happening again.
“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.
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:
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.
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:
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.
Nearly 100 workers are killed each year in forklift related accidents. 24% of these accidents are the result of rollovers. Other accidents include works being struck by the forklift load, by the forklift itself, or workers falling off the forklift. The need to give safety your utmost attention as a business operator is made clear when assessing the statistics associated with forklift accidents. For example:
Keeping these serious and troubling statistics in mind, implementing best practices in your facility in regard to safety is highly important.
Improper forklift operation results in accidents, damage to products and facilities, and is the result of law suits for companies each year. By following OSHA regulations and adopting strict training rules and regulations at your organization, you can prevent these accidents.
While following these procedures can result in an improved safety setting, below are some specific situations where safety questions and concerns continually arise.
Beyond following these rules for safety success, giving special attention to your facilities can help to improve safety in your operations. There are some general pieces of advice that can be followed, but remember, the unique needs and designs of your operation will ALWAYS dictate what safe practice looks like. Be sure to thoroughly analyze the safety of your site before making any major changes.
So, you’ve purchased a 6,000 lb. forklift. That means you can lift 6,000 lbs. at all times, no matter what, right? Wrong.
The capacity rating of a forklift is the maximum weight at which it is able to safely maneuver at a specific load center. If the forks are not at that exact load center, if the mast type has been changed, or if attachments have been added, the forklift is not capable of maneuvering that load safely.
To avoid making the colossal mistake of exceeding your forklift’s maximum capacity, remember the following:
Though forklift accidents are becoming less frequent every year, one main cause of forklift accidents is an operator trying to maneuver loads that exceed the forklift’s capacity rating. Talk to your local Toyota Forklift Dealer to learn more about forklift capacity ratings and which forklift would be best for you and your business.
Forklift safety is no laughing matter. Toyota makes it our priority to ensure that safety is at the forefront of all of our manufacturing processes and training efforts. But while safety comes standard at Toyota, it’s the responsibility of operators and their managers to be sure that Toyota forklifts are being used appropriately. When risks are taken in the name of having fun or joking around, accidents are bound to happen.
Operators should monitor their personal behavior. But a good working environment means that operators are also looking out for each other as well. That means reporting inappropriate behavior when they see it. Here are a few clear examples of inappropriate forklift use for which operators and managers should be on the lookout:
At Toyota, we make industry-leading forklifts with a guarantee of quality, durability, value, and reliability. And our first priority is always your safety. If you or your associates need help recognizing appropriate and inappropriate forklift use, Dillon Toyota Lift offers operator safety training.
A site survey is when a trained warehouse consultant visits a work space to help maximize the business’ work place through racking, equipment, and a multitude of other factors. Their job is to help a business work as efficiently as possible and utilize all the space a company owns. But why should you think about getting one? Below are a few reasons.
Once a warehouse consultant comes on the scene at the time and date arranged specifically for the site survey, it doesn’t take long for them to identify opportunities that can carry already profitable business even further.
For example, let’s say a company is pulling pallets with a reach truck, bringing the pallets down, removing the product, and then putting the pallet back up onto the racking unit. In this case, a Toyota order picker may be a more optimal equipment choice to get the job done.
Often times, companies have already thought of this, but their response as to why they haven’t done it yet is usually: “We’ve always done it this way.” Those words echo through warehouses and distribution centers nationwide, and often deter operations managers from making the moves they must make in order to meet the changing demands of the modern-day distribution environment.
For those companies that do embrace change, a site survey typically starts by inventorying all forklifts and determining how that equipment is being used in the facility.
On the warehouse floor, a site survey can help detect storage problems (e.g., stacks of pallets that are pushed into corners using hand pallet jacks), inventory management issues, and poor use of vertical space. There are times when managers say they don’t have enough space, but only have product stacked 12 feet high in a building with 25 foot ceilings. This is an opportunity for the warehouse to grow up, instead of out. The site survey will also help determine the best equipment for this type of application, such as order pickers, reach truck, or a combination of both.
All of these steps culminate into a complete warehouse optimization package designed to help operations achieve and exceed their customer service, safety, and profitability goals. By getting material handling professionals involved early in the process, these operations may be able to optimize their space and equipment in a way that they may not have been able to handle on their own.
If you would like to learn more about site surveys and warehouse consultations, download our free E-book, “Making the Case for Warehouse Consultants.”
The proper maintenance and handling of forklift batteries is imperative to their longevity. There’s a right way and a wrong way to maintain and handle forklift batteries and doing it properly will ensure your investment is maximized.
Forklift batteries can be heavy and dangerous if not handled properly, so it’s important to be educated on the correct way to handle them. Use these tips for some ideas about handling batteries properly:
Properly charging a battery is all about doing it at the right time, for the right amount of time. Use these tips when charging your forklift battery:
Toyota Forklifts lead the industry with innovative designs and top-of-the-line customer support. At Toyota, safety comes standard, and we spend time each day developing ways to keep everyone in your facility protected, healthy, and productive. We start with the top safety concerns and ask, “what can we do to improve our engineering to help make people safer?” It’s part of our culture of continuous improvement. We’re always pushing ourselves toward what next. And it’s what led us to develop the best safety features in the industry.
Toyota’s forward-thinking engineering is what helps make Toyota Forklifts some of the safest forklifts on the market. Asking the tough questions, we found that tip-overs and falling loads were some of the most common causes of forklift accidents. So Toyota engineers went to work, and, in 1999, introduced the System Active of Stability, which comes standard on most Toyota forklifts. In conjunction with Active Mast Control, Toyota engineering is a must for the most safety-conscious operations managers.
But Toyota’s safety innovation does not stop at these unique features. We employ safety-first thinking in all of our manufacturing, developing the best solutions for features that seem common. The unique-Toyota approach? Safety always in manufacturing:
These innovations in engineering are excellent and can lead to increased safety in your facility. But the best way to make sure your forklift is in optimal working condition is to use a forklift safety checklist as part of your daily walk around on your forklift. Here’s one example of those features on your Toyota Forklift that would benefit from routine checks.
All Toyota forklifts are engineered with safety in mind. That includes every part of the forklift, including one of the most important parts: the forks. But no matter how well a forklifts is engineered, using them appropriately is the responsibility of the operator. The forks can represent a problem area if used inappropriately. Be sure to regularly use a fork caliper to inspect the forks and employ the following best practices:
All warehouses and distribution centers are not created equal. Some have the space for standard width aisles (about 12 feet) and the traditional counterbalance sit down forklifts that can operate in them. Others however, configure their aisles in widths considerably narrower. Because real estate and space is at a premium in these tighter aisle operations many businesses expand in the only direction they can, up rather than out. The fact is aisle widths vary from location to location, that’s why Toyota has a wide range of forklift solutions to meet your variable aisle width needs.
The Toyota Core IC Cushion Forklift is an industry-leading multi-use forklift that easily crosses the boundaries between warehouses manufacturing plants retail and more. With lift capacities from 3,000 to 6,500 pounds and Toyota’s patented System of Active Stability (SAS) the dependable reliable Core IC Cushion forklift typically operates in 12-foot aisles, however, lighter capacity Core IC Cushion models can operate in aisles closer to 11 feet wide.
Then there’s Toyota’s four-wheel Core Electric Forklift. This model provides a smooth ride, is also equipped with Toyota’s SAS system and it’s an excellent solution for most indoor applications. With a compact model available the Core Electric forklift has the same capacity as the Core IC Cushion but with the ability to operate comfortably in 11 foot aisles. Skilled forklift operators with certain models can even work in aisles between ten and a half and eleven feet depending on load size.
Next meet the Toyota 3-Wheel Electric Forklift. This model can tackle big jobs even in small spaces. In leaner aisles and tighter spaces the 3-Wheel Electric is a multi-use forklift that leads the industry in run time, travel speeds and lift lowering speeds. Available in cushion or pneumatic tires it easily navigates ten to eleven foot wide aisles, has a lifting capacity up to 4,000 pounds and a lift height of up to 23 feet. Equipped standard with wet disk brakes the Toyota 3-Wheel Electric forklift is a do everything forklift and an immediate upgrade to any facility. It also provides a quick return on investment with increased productivity and lower maintenance costs.
Next there’s Toyota’s dock to stock star the Stand-Up Rider Forklift. With a lifting capacity of up to 4,000 pounds operating capability and aisles as narrow as 10 feet and a lift height of 23 feet. the capability of the Toyota Stand-Up Rider forklift is at the top of its class and one of the most versatile forklifts in Toyota’s product line. This model is built with the ultimate performance and comfort in mind – delivering improved ergonomics, reliability and durability while reducing service intervals. The Stand-Up Rider operates efficiently at the loading docks, inside trucks and in narrow spaces between tight high racking.
Finally there’s Toyota’s top solution for narrow aisles, the Toyota Reach Truck available in single and double reach models. the Toyota Reach Truck can navigate aisles as narrow as 7 feet depending on model in load size. When exploring narrow aisles our Warehouse Solutions team can help optimize both your warehouse layout and your warehouse equipment. In addition to navigating narrow aisles the Toyota Reach Truck can handle loads up to 4,500 pounds and can reach racks as high as 30 and a half feet. The Toyota Reach Truck is well equipped with over 500 engineering design and performance upgrades including a newly designed mast, additional battery size options to fit unique warehouse and distribution center applications and longer maintenance intervals. The Toyota Reach Truck is a top performer and exemplifies Toyota’s position as a leading solutions provider and partner in the warehouse and distribution center industry. Reach new heights faster in narrower aisles and at less cost with the Toyota Reach Truck.
Whether the answer is narrow or wide, vertical or horizontal, inside or outside, electric or internal combustion Toyota has the right solution for your space and application. and Toyota’s legendary productivity, quality, durability, reliability and value are built into every model.
Every day, forklift operators have a commitment to safety and protection for themselves and those around them. Toyota forklifts have overhead guards designed to help protect operators from falling objects and other obstructions in your facility.
Since their development in the 1960’s, forklift overhead guards have helped to protect operators from falling packages, boxes, and bagged materials. The overhead guard itself is a cage-like sturdy structure covering the overhead of the operator. It is designed with small openings as to not obscure the operators view when looking up to place and retrieve loads. Per OSHA requirements and ANSI standards, they are required for the protection and safety of the forklift operator.
While overhead guards are a vital safety asset to any forklift machine, they are not meant to protect against every possible impact. For example, in the event of a falling capacity load, the support of the overhead guard structure that received the heaviest loading is designed to absorb energy and deform to deflect the falling capacity load. This is a hazardous situation for an operator, as falling loads are unpredictable. Therefore, the specific training and safety procedures and protocol in your facility should be adhered to and overhead guards are not a substitute for good judgment and care in load handling. A daily inspection of the overhead guards to check for anything broken, damaged, or missing could help to prevent serious accidents. Some additional helpful safety measures in overhead guard usage include:.
Certain industries require hard hat usage when operating forklifts. You should analyze your facilities and application to see whether this is a necessary precaution.
Falling objects could come from any direction. It’s vital to keep your whole body within the bounds of the forklift and under the overhead guard. The overhead guard is intended for protection while an operator is within the confines of the seat. Also, operators are prohibited from operating forklifts with their hands, arms, feet, legs or any other body parts around the overhead guard supports or while outside the overhead guard.
Always reach your local dealer with assistance repairing or replacing an overhead guard. It is against OSHA requirements to use a forklift with a damaged overhead guard.
Any modification to the forklift including its overhead guard that alters the specs of the forklift can cause potential hazards. You are required to get manufacturer approval before making alterations to the forklift including its overhead guard that affect safe forklift operation.
Original Post: Anna Harris, TMHU Marketing Intern
The use of LP, CNG, gasoline, and diesel forklifts can provide an increase in efficiency and higher ROI for many different types of operations. Whether moving material between manufacturing steps or increasing throughput in a warehouse, Toyota offers a wide variety of pneumatic tire and cushion tire gas-powered forklifts to fit your needs.
Facility design is one of the most important factors in protecting against the harms of exhaust, but a few key ventilation precautions can greatly reduce the risks from emissions.
But as with any piece of heavy machinery or equipment, proper precautions have to be taken to ensure people are protected from residual impacts of their use. In the case of LP, CNG, gasoline, and diesel forklifts, exhaust fumes can be harmful to employees and products if proper precautions aren’t taken. Facility design is one of the most important factors in protecting against the harms of exhaust, but a few key ventilation precautions can greatly reduce the risks from emissions. Here are a few reminders that you can use in your own facilities or bring to your supervisor’s attention.
In fact, OSHA reported that most complaints of symptoms like dizziness and headache related to LPG forklift use came from warehouses. Performing a proper audit of your warehousing air flow can help to alleviate the possibility of harm from fumes to both people and products. If you run or work in a facility that requires both manufacturing and warehouse storage operation, then it’s important to remember to ventilate both areas.
Many operators have to use forklifts in very tight areas, sometimes for long periods of time. Long exposure to fumes from an LP, gasoline, CNG, or diesel forklift can lead to the possibility of health hazards. When working in spaces like semi-trailers, within the confines of materials that can’t pass air (think cotton bails), or small rooms for storing specialty products, taking breaks is required. Understanding how to offer proper air flow to these areas by opening windows and vents and providing fans can help limit risks. And according to OSHA standard 29 CFR 1912.12(a)(2), operating forklifts onboard a ship requires special precautions to ensure the right levels of oxygen are present in tight spaces.
When things get cold outside, we tend to want to keep heat in. But when you close your windows, doors, or vents, you also have to account for the fumes that might fill your forklift-operating areas. Make sure staying warm doesn’t come at the expense of fume exposure.
Dillon Toyota Lift is the authorized Toyota Forklift dealer in Idaho and Utah, providing solutions to all material handling needs since 1981. We are your full service provider for new and used forklifts, rentals, parts, service, warehousing, racking, and lift truck operator training.
Nampa : (208) 466-8994
Twin Falls : (208) 466-8994
Idaho Falls : (208) 466-8994
Salt Lake : (801) 972-1930
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