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Forklift Planned Maintenance by Toyota Lift of Minnesota
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Forklift Planned Maintenance by Toyota Lift of Minnesota

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A detailed step by step review of how the simple planned maintenance service is done, and done correctly.

A detailed step by step review of how the simple planned maintenance service is done, and done correctly.

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Forklift Planned Maintenance by Toyota Lift of Minnesota Forklift Planned Maintenance by Toyota Lift of Minnesota Presentation Transcript

  • Toyota-Lift of Minnesota Planned Maintenance  Maintenance plans tailored to your needs  Computer tracked and prompted  Proactive, responsible, and cost effectivewww.ToyotaEquipment.com Jump to first page
  • Your “Total Source” MaterialHandling Dealership  Toyota Equipment, new, used and reconditioned  Pneumatic, and cushion electric sit down riders  Order Pickers, reach trucks, and electric pallet jacks  Ask us about Toyota’s exclusive “System of Active Stability”. First in safety Jump to first page
  • Your “Total Source” MaterialHandling Dealership  Taylor-Dunn burden carriers and people movers and stock chasers  Units available from TLM stock  Custom orders are our specialties, build your unit to your needs  Demos available Jump to first page
  • Toyota-Lift of Minnesota  Industrial Battery maintenance and sales  Warehouse racking systems and design  “On-site” lift truck installation  Forklift driver safety training classes  “Train the Trainer” safety classes, take charge of your expenses. Jump to first page
  • Toyota-Lift of Minnesota  Over thirty two years serving Minnesota  ASE and Toyota Certified technicians  Technicians working out of Minneapolis, Mankato, Duluth, Albert Lea, Eau Claire, Rochester and Owatonna  Well stocked and equipped service vehicleswww.ToyotaEquipment.com Jump to first page
  • Toyota-Lift of MinnesotaYour Total Source Dealership New, used, and  Racking systems design and reconditioned lift trucks sales Burden and personnel  Full range of allied material carriers handling product (ask for our Aggressive Toyota financing catalog) available  Through Toyota Equipment’s In house and on site battery Star Lift Program, repair and charger maintenance parts for all makes of lift Industrial battery Planned trucks Maintenance plans  Full Road Service Fleet Fast and economical “On-  Fast delivery systems Site tire installations  Off-Load service available Jump to first page
  • Toyota-Lift of Minnesota Planned Maintenance Reduced Downtime Reduced Operating Costs  Catch minor repairs before they become major.  Schedule repairs to match customer budget and schedule. Timely  Match environment to forklift usage.  Internal combustion and DC electric powered units PM at 250 hours of usage unless circumstances require otherwise  AC powered units done at 500 unless circumstances require otherwise Cost Effective  Reduce labor rate – No travel Controllable  Problems are identified, Costs are assigned and customer decides when and if what repairs are done. Jump to first page
  • Toyota-Lift of Minnesota About Our Technicians Programs of Ongoing Training Toyota Material Handling Certifications Bronze Silver Gold Platinum ASE Certifications Toyota-Lift of Minnesota actively promotes the ASE certification in many study areas for it’s technicians. Jump to first page
  • Planned Maintenance – For all Fuel Types Talk to the Operator or OwnerListen about concerns, and noteworthy observations Jump to first page
  • Planned Maintenance - Gas, LP and Diesel Units Clean Radiator with Compressed Air – And blow off machineAir forced through both directionsPart of the daily operator’s checklist Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsClean and Inspect Air Filter, Hose and ConnectionsPart of the daily operator’s checklist Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsCheck Accessory Drive Belts and TensionPart of the daily operator’s checklist Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsCheck for Fuel, Oil, and Cooling System LeaksPart of the daily operator’s checklist Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsFill Coolant to Proper Level Part of the daily operator’s checklist Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsAntifreeze degree of protection checked Protection level is noted on PM form Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsCheck Carburetor and Accelerator Linkage Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsClean and Inspect Breather Element / PCV Valve Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsAisin LP Regulators – Drain tar during PM Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsLPG Pre-Filter Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsCheck Governor RPM’s & Lock Wire StatusCustomer is advised of conditions found Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect Overall Wiring Condition Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect Battery Fluid Level – Filled if needed Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect & Clean Battery Terminals, Cables, and Cable Ends Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect Cap, Rotor, Points, Spark Plugs, & Ignition Wires Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsChange Oil and Filter ElementToyota recommends service at 170 to 250 hours Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsClean All Grease Fittings and Lubricate Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsClean All Grease Fittings and Lubricate Per repair manual CU030-1, page 0-17, the proper lubrication specification is as follows: Areas to use Molybdenum disulfide (Moly) grease · Mast Support Bushings · Rear axle beam front pin · Rear axle beam rear pin · Swing lock cylinder lower pin · Oil pump drive shaft · Oil pump spline shaft Areas to use Multi-Purpose grease · Tilt cylinder front pin · Front wheel bearing · Tilt steering locking mechanism · Propeller shaft · Steering knuckle king pin · Rear wheel bearing · Tie rod end pin · Rear axle cylinder end pin Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect Clutch, Inching Pedal Adjustment Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect and Fill Transmission and Differential Oil Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsHydraulic Return Filter – Change on unit’s first PM service Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsHow to Inspect Hydraulic Oil Levels – 5 Series Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsHow to Inspect Hydraulic Oil Levels – 6 Series Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsHow to Inspect Hydraulic Oil Levels – 7 Series Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsHow to Inspect Hydraulic Oil Levels – 8 Series Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsDifferential fill for the Toyota Box Car Special Jump to first page
  • Planned Maintenance – Gas, LP and Diesel UnitsInspect and Fill Brake Master Cylinder Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect Brake OperationPart of the daily operator’s checklist Jump to first page
  • Planned Maintenance - MiscellaneousInspect Counterweight Bolt Condition Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect Steer Axle Assembly for Condition and Operation Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect King Pin Condition 0 Camber Negative Camber Positive Camber Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsInspect and Lubricate SAS Cylinder Jump to first page
  • Planned Maintenance - Gas, LP and Diesel UnitsIC Truck Carbon Monoxide [CO] Testing Minnesota OSHA Regulation. 5205.0116 Subparagraph. 2. Tailpipe exhaust gas analysis. The employer shall ensure that powered industrial truck engine exhaust gases do not contain more than one percent carbon monoxide for propane fueled trucks or two percent carbon monoxide for gasoline fueled trucks measured at idle and at three-fourths throttle during final engine tuning in a regular maintenance program. Toyota-Lift of Minnesota CO Program  Needed for a safe work environment  Timely [computerized history]  Effective  Low cost  No travel charges when done with planned maintenance Jump to first page
  • Electric Powered Unit Specifics Jump to first page
  • Planned Maintenance - Electric UnitsInspect Wiring Condition Jump to first page
  • Planned Maintenance - Electric UnitsInspect Contact Tips Staining is acceptable as seen above Pitting or splattering requires replacement Jump to first page
  • Planned Maintenance - Electric UnitsCheck Operation of Forward Reverse and 1A Jump to first page
  • Planned Maintenance - Electric UnitsInspect Power Cables Jump to first page
  • Planned Maintenance - Electric UnitsInspect and Advise Battery Water Level Jump to first page
  • Planned Maintenance - Electric UnitsInspect SB Connector & Tips – Truck & Battery Sides Jump to first page
  • Planned Maintenance - Electric UnitsInspect Brake Operation Jump to first page
  • Planned Maintenance - Electric UnitsInspect & Fill Brake Master Cylinder Jump to first page
  • Planned Maintenance - Electric UnitsInspect and Notate Brush Condition All Electric Motors Jump to first page
  • Planned Maintenance - Electric UnitsBrush Condition Chart Not all tools fit In the toolbox. Technicians are armed with service manuals and numerous technical sheets Jump to first page
  • Planned Maintenance - Electric UnitsInspect Condition of All Commutators Jump to first page
  • Planned Maintenance - Electric UnitsCommutator Check Chart Not all tools fit In the toolbox. Technicians are armed with service manuals and numerous technical sheets Jump to first page
  • Planned Maintenance - Electric UnitsBlow Out Motors and Clean Truck With Compressed Air Jump to first page
  • Planned Maintenance - Electric UnitsRecord Truck Voltage to Facilitate Future QuotingFrom data plate information or by counting cells Jump to first page
  • Planned Maintenance - Electric UnitsCheck Radial Rings & Thrust Bearing Adjustment Jump to first page
  • Planned Maintenance - Electric UnitsCheck and Fill Drive Unit Jump to first page
  • Planned Maintenance - Electric UnitsDifferential Fill for 7FBEU Jump to first page
  • Planned Maintenance - Electric UnitsClean All Grease Fittings and Lubricate Jump to first page
  • Planned Maintenance – Electric UnitsClean All Grease Fittings and Lubricate Per repair manual CU030-1, page 0-17, the proper lubrication specification is as follows: Areas to use Molybdenum disulfide (Moly) grease · Mast Support Bushings · Rear axle beam front pin · Rear axle beam rear pin · Swing lock cylinder lower pin · Oil pump drive shaft · Oil pump spline shaft Areas to use Multi-Purpose grease · Tilt cylinder front pin · Front wheel bearing · Tilt steering locking mechanism · Propeller shaft · Steering knuckle king pin · Rear wheel bearing · Tie rod end pin · Rear axle cylinder end pin Jump to first page
  • Planned Maintenance - Electric UnitsDrive tire, Caster Adjustment, Load Wheels Jump to first page
  • Planned Maintenance - Electric UnitsCheck Steering Linkage & Steer Chain Adjustment 5 Series 7 Series Jump to first page
  • Planned Maintenance - Electric UnitsCheck King Pin Condition 0 Camber Negative Camber Positive Camber Jump to first page
  • Planned Maintenance - Electric UnitsInspect and Lubricate Steer Axle or Spindle Assembly Jump to first page
  • Planned Maintenance - Electric UnitsInspect and Lubricate SAS Cylinder Jump to first page
  • Planned Maintenance - Electric UnitsBattery PM & Wash ProgramMaximize Your Equipment Investment Some of the points covered in our Industrial Battery PM: Voltage Check Specific gravity Total voltage Cable inspection Intercell connector Wash entire battery SB connectors and tips inspected Pressure test cells for leaks Check for positive cell rise Report repairs needed Final inspection and clean work area Disposal of all hazardous materials Batteries are an important investment, don’t neglect their need for ongoing inspection and maintenance. Jump to first page
  • Mast Inspections Jump to first page
  • Planned Maintenance – Mast InspectionInspect and Fill Hydraulic Fluid Jump to first page
  • Planned Maintenance - Mast InspectionCheck Upright Assembly for Proper Adjustment Jump to first page
  • Planned Maintenance - Mast InspectionInspect Mast Bearings & Chain Rollers Jump to first page
  • Planned Maintenance - Mast InspectionInspect Carriage Assembly Jump to first page
  • Planned Maintenance - Mast InspectionInspect Cylinder Chrome and Check for Leaks Jump to first page
  • Planned Maintenance - Mast InspectionInspect Hoses & Hose Reels Jump to first page
  • Planned Maintenance - Mast InspectionInspect Mast Cap Bolts & Trunion Bearings Jump to first page
  • Planned Maintenance - Mast InspectionInspect Tilt Cylinder Bearings for Wear Jump to first page
  • Planned Maintenance - Mast InspectionInspect Tilt Cylinder Anchors for Cracks Jump to first page
  • Planned Maintenance - For all Fuel TypesCheck and Adjust Sideshifter BearingsMay need attention [grease] between PM’s dependant upon environment Jump to first page
  • Planned Maintenance - Mast InspectionInspect Load Back Rest Jump to first page
  • Planned Maintenance - Mast InspectionLube Lift and Carriage Chains Jump to first page
  • Planned Maintenance - Mast InspectionLube Hydraulic Pump Jack Shaft Jump to first page
  • Safety and OSHA Concerns Ask about our forklift drivers training and train the trainer courses. See details at our website: www.ToyotaEquipment.com Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Data Plate and Decals Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Seat Belt Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Chain Anchors – Adjust Chain Tension Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Chain StretchUse chain gauge as areference, measure foraccuracy Jump to first page
  • Planned Maintenance - Safety ConcernsChain Gauge Illustrated The chain illustrated is worn Jump to first page
  • Planned Maintenance - Safety ConcernsChain Styles and Wear Limits AL BL BL 2X 2 3X 4 4X 6 AL = Even Lacing AL AL AL BL = Odd Lacing 4X 4 6X 6 2X2Chain Size Pitch Length X Ten Pitches Stretch Limit of 3% Worn At Must ReplaceAL BL 400 1/2 5 0.15 5.15 5 3/16AL BL 500 5/8 6 1/4 0.19 6.44 6 1/2AL BL 600 3/4 7 1/2 0.23 7.73 7 3/4AL BL 800 1 10 0.30 10.30 10 3/8AL BL 1000 1 1/4 12 1/2 0.38 12.88 13 Pitch Is the distance between two pinsMeasure the distance between 11 pins to measure ten pitches Jump to first page
  • Carriage Stop To Mast Stop Clearance Jump to first page
  • Carriage Stop To Mast Stop Clearance Chart Jump to first page
  • Planned Maintenance - Safety ConcernsInspect E-Brake Availability and FunctionOn some electric units, the emergency brake is involved with the dead man seat Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Neutral Start Switch Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Horn Operation Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Frame, Mast, and Over Head Guard for Cracks Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Gauge Operation Jump to first page
  • Planned Maintenance – Safety ConcernsInspect Fork Wear Against ANSI StandardsAsk for Cascade’s ANSI Fork SafetyPoster and wear log Jump to first page
  • Planned Maintenance – Safety ConcernsFork Tapering and Tip Types Make sure you get the right fork first. Toyota-Lift of Minnesota has many sizes and style in stock ready for quick delivery when you need them. Jump to first page
  • Planned Maintenance – Safety ConcernsFork Edge Types Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Strobe Light Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Working Lights Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Backup Alarm Jump to first page
  • Planned Maintenance - Safety ConcernsInspect Deadman Switch Operation – Static Return To Neutral Jump to first page
  • Planned Maintenance - Safety ConcernsHood Latch for Function and Availability Jump to first page
  • Planned Maintenance - Safety ConcernsCheck Tire Pressure On Pneumatic Tires Jump to first page
  • Planned Maintenance - Safety ConcernsTire Inspection and Measurement – Cushion Tires Height Width ID Wear Life Replace At Height Width ID Wear Life Replace At 9 5 5 1 3/8 7 5/8 17 5 12 1/8 1 11/16 15 5/16 10 4 6 1/4 1 3/8 8 6/8 17 6 12 1/8 1 11/16 15 5/16 10 5 6 1/4 1 3/8 8 6/8 18 5 12 1/8 2 1/16 15 15/16 10 5 6 1/2 1 1/4 8 3/4 18 6 12 1/8 2 1/16 15 15/16 10 6 6 1/4 1 3/8 8 6/8 18 7 12 1/8 2 1/16 15 15/16 10 4 6 1/2 1 1/4 8 3/4 18 8 12 1/8 2 1/16 15 15/16 10 5 6 1/2 1 1/4 8 3/4 18 9 12 1/8 2 1/16 15 15/16 10 1/2 5 6 1/2 1 3/8 9 1/8 20 8 15 1 3/4 18 1/4 10 1/2 6 6 1/2 1 3/8 9 1/8 20 8 16 1 3/8 18 5/8 10 6 6 1/2 1.225 8.775 20 9 15 1 3/4 18 1/4 12 4 8 1 3/8 10 5/8 20 9 16 1 3/8 18 5/8 12 4 1/2 8 1 3/8 10 5/8 21 5 15 2 1/8 18 7/8 12 5 8 1 3/8 10 5/8 21 6 15 2 1/8 18 7/8 12 5 1/2 8 1 3/8 10 5/8 21 7 15 2 1/8 18 7/8 12 6 1/2 8 1 3/8 10 5/8 21 8 15 2 1/8 18 7/8 13 3 1/2 8 1 3/4 11 1/4 21 9 15 2 1/8 18 7/8 13 4 1/2 8 1 3/4 11 1/4 20 8 16 1 3/8 18 5/8 13 5 8 1 3/4 11 1/4 20 9 16 1 3/8 18 5/8 13 1/2 4 1/2 8 1 15/16 11 5/8 22 6 16 2 1/8 19 7/8 13 1/2 5 1/2 8 1 15/16 11 5/8 22 7 16 2 1/8 19 7/8 14 4 1/2 8 2 1/8 11 7/8 22 8 16 2 1/8 19 7/8 14 5 10 1 3/8 12 5/8 22 9 16 2 1/8 19 7/8 A good bad example 15 1/2 5 10 1 15/16 13 5/8 22 10 16 2 1/8 19 7/8 15 1/2 6 10 1 15/16 13 5/8 22 12 16 2 1/8 19 7/8 16 5 10.5 1 15/16 14 1/8 22 14 16 2 1/8 19 7/8 16 6 10.5 1 15/16 14 1/8 22 16 16 2 1/8 19 7/8 16 7 10.5 1 15/16 14 1/8 22 12 17 3/4 1 1/2 20 1/2 15 5 11.25 1 3/8 13 6/8 28 10 22 2 1/8 25 7/8 15 6 11.25 1 3/8 13 6/8 28 12 22 2 1/8 25 7/8 16 1/4 5 11.25 1 3/4 14 1/2 28 14 22 2 1/8 25 7/8 16 1/4 6 11.25 1 3/4 14 1/2 16 1/4 7 11.25 1 3/4 14 1/2 16 1/4 8 11.25 1 3/4 14 1/2Lift trucks depend on good tires to protect personnel, equipment andproduct. Jump to first page
  • Planned Maintenance - Safety ConcernsTest Drive Truck Jump to first page
  • Planned MaintenanceRecommendationsCheck– The area required inspection and checked OKR – Repair needed and not approved, quote needed® - Repair needed, discussed with customer and work order was created for itX – Area needed minor adjustment, adjustment done no additional work neededNR – Repair on next PM, discussed with customer and sold without quoteW – Watch, denotes condition that will soon merit repairIn Summary:The technician marks any recommended repairs, ornoteworthy concerns seen during the PM. These arealso summarized briefly in the notes area Jump to first page
  • Other Suggested ServicesTimely, cost effective and pro-active Jump to first page
  • Replace Transmission Filter and Fluid Jump to first page
  • Replace Hydraulic FilterReplace Oil If Necessary Jump to first page
  • Complete Tune Up Jump to first page
  • Replace Fuel Filter: Gas, LP, Diesel Jump to first page
  • Repack Steer Wheel Bearings and Replace Seals Jump to first page
  • Pressure Check Coolant System and Test Radiator Cap Jump to first page
  • Replace Coolant Fluid if Contaminated Jump to first page
  • Change Differential Oil Jump to first page
  • Lube Transmission Drive Shaft Jump to first page