Forklift Full Maintenance: What is it?


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A quick overview of what full maintenance covers and what it does not. Who is responsible for what.

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Forklift Full Maintenance: What is it?

  1. 1. What is it, and what is involved? Toyota-Lift of Minnesota 8601 Xylon Court North Brooklyn Park MN Ph 763-425-9066 TF 800-523-0611
  2. 2. Full Maintenance (also known as Total Maintenance and Repair) programs are designed to free the customer from the challenges associated with the ongoing upkeep of the equipment. The FM program includes all of the manufacturer’s recommended periodic services and repairs for breakdowns of major components. The main advantage to a FM program is the predictable monthly costs. The customer pays a fixed rate and in some cases is offered a complimentary forklift loaner when a service repair experiences an extended downtime. This allows you the customer to easily budget for the costs associated with owning a fleet of forklifts.
  3. 3. We are responsible for maintaining the unit’s records (i.e. dates of service, hours of usage, repairs) and are motivated to reduce costs for the you the customer by identifying abuse damage or needed rotation of the equipment fleet. Before a company arranges a FM program, it should consider the service history of the forklift fleet. If the forklift fleets utilization is low and the costs have been reasonable, predictable and almost always in budget, a FM rate may be too high. FM rates are based on an expected cost per hour over a given time frame. The higher the utilization, the higher the expected costs.
  4. 4. Experienced technicians will catch potential problems early. Customers will avoid safety issues, costly breakdowns and hours of lost productivity. The servicing dealer will also provide the customer with critical documentation including tracking dates of the forklift’s maintenance schedule as well as detailed records of inspections and repairs. In short a full maintenance program takes the user out of the forklift business, putting that responsibility in the hands of the experts. Through teamwork and open communication both the servicing dealer and customer will benefit from the agreement.
  5. 5. Our Maintenance Responsibilities: To keep each unit and attachments or cabs associated with the unit by the provider in good working order, the provider will provide scheduled and unscheduled maintenance and service, and will make all necessary adjustments, repairs and part replacements, caused by normal wear (excluding back-up alarms, light assemblies or bulbs, fire extinguishers, and tires) unless these items are included per the FM agreement.
  6. 6.  Maintain your forklift truck fleet for the term of the agreement.  Determine maintenance frequency by analyzing truck operation and operating         conditions. Perform planned maintenance and most unscheduled emergency repairs promptly on-site. Supply expert mechanics, factory-trained and skilled in state-of-the-art forklift technology. Provide full parts inventory backed by the Toyota Parts Distribution System, the forklift truck industry's largest parts network. Provide service vans, each capable of supporting efficient on-site service and repair. Provide major repairs, labor and equipment as needed for the duration of the agreement. Monitor maintenance costs, hours of usage, equipment condition, and other factors that can affect your forklift truck's on-the-job performance. Maintain a modern fleet of short-term rental trucks to meet your peak season or special handling requirements. Assure you of maximum equipment uptime by keeping your fleet in peak condition.
  7. 7. • Customer's Maintenance Responsibilities: Customer, at its own cost and expense, shall be responsible for the normal needs of the equipment in its daily operation, including: • The making of a routine check of each unit of equipment at the beginning of each shift in accordance with the Routine Checklist Attached; • Supplying and storing of all necessary fuel (gasoline, diesel, electric current, or LP gas) oil and water; • Where applicable, maintain the proper fluid levels between maintenance calls by checking on a daily basis all fluid levels (oil, coolant, brake fluid etc.) and checking weekly the air pressure of pneumatic tires; • Where battery-powered equipment is involved, maintaining the proper level of water in the batteries, properly recharging the batteries and installing equipment necessary to effectuate such recharging;
  8. 8.  Checking before each use of the equipment, the condition and operation of the equipment's safety devices, including but not limited to brakes, automatic shutoffs, seat belts and other restraints, etc. The Customer hereby agrees not to operate the equipment at anytime that a safety device requires repairs or is not operating properly. The customer, at its own cost and expense, shall be responsible for all repairs, maintenance and servicing not expressly made the responsibility of the provider.
  9. 9. The following acts are included as examples of misuse and abuse of a forklift, but are not limited to:  Allowing internal combustion engine forklifts to operate with insufficient oil,      coolant, or other required fluids. Not blowing out the radiator, operating in dusty or lint-filled atmosphere, causing engine or electric motor and/or pump damage and not cleaning out the radiator as necessary. Using opposite to travel transmission action to stop unit or reverse direction. Forward/reverse plugging on battery powered Toyota forklifts is permitted. Excess spinning or sliding of drive tires. Pulling dead/static weight objects from trailers or railroad cars with cable, chain, etc., fastened to load backrest or upright rather than using a proper vehicle. Removal of or modification to the driver's overhead guard or load backrest, allowing falling objects to damage hand steering wheels, gauges, or other components.
  10. 10. The following acts are included as examples of misuse and abuse of a forklift, but are not limited to:  Operating within a zone too close to excessive heat, cold or abnormally strong conditions.  Damage as the result of horseplay, drag racing, or other unsafe operating conditions for which the forklift has not been prepared to operate.  Operating at excessive speed for load conditions.  Operators removing key and not leaving for the next shift, necessitating ignition switch or key replacement.  Operating units under conditions not covered in your company's normal operations.  Breaking of carriage rollers due to lifting or carrying improper loads, pushing or pulling static loads, or abusive attachment use.  Bending or breaking of forks due to overloading, off center loading, or hitting static objects.
  11. 11. The following acts are included as examples of misuse and abuse of a forklift, but are not limited to:  Using attachments improperly.  Pushing or pulling static loads with a lift truck, or objects such as rail cars which are beyond the forklift's capability and may cause mast and/or power train damage.  Burning off excessive rubber build up by spinning wheels rather than proper removal of same.  Operating units with a known service and/or safety problem.  Failure to release forklift for proper planned maintenance service or other repairs.  Missing, damaged, or bent cowling, doors, sheet metal, or safety structures such as driver's overhead guard or load backrest etc.  Cut or damaged hoses or hose fittings for hydraulic attachments.
  12. 12. The following acts are included as examples of misuse and abuse of a forklift, but are not limited to:  Bending of steer wheels, axles, or other components resulting in other structural       damage from overloading. Damaging paint or appearance by graffiti-type marking, necessitating repainting of a unit. Removal and/or purposely damaging all safety equipment, safety decal instructions, and the forklift I.D. plate. Improper fueling of the vehicle, fuel tanks, or cross threading or forcing LP gas couplers/fittings. Falling objects, or wrapping cable chain, or rope around assemblies, not designed for towing stress. Operating with defective or unsafe brakes, resulting in damage to a vehicle property, or persons. Failure to approve tire replacement when so recommended by the servicing agent. Excessive tire wear can result in damaged power train or upright mast, since the bottom of the mast rails may lower too close to the ground surface where they may hit a solid object, breaking mast mounts or bending mast rails.
  13. 13. The following acts are included as examples of misuse and abuse of a forklift, but are not limited to:  Full maintenance does not cover damage to warning devices such as headlights, strobe lights and back up alarm.  Full maintenance does not include fuel or other fluids required by daily inspections and user maintenance.  Industrial batteries and battery chargers are covered by the manufacturer's warranties and are otherwise not included in Full Maintenance Service. Failure to properly check and add battery fluids as needed to keep the battery in proper condition is an abuse. Failure to properly install a battery charger in a safe, well ventilated location is an abuse.  Exposure to ambient air or other operating atmosphere and conditions that have the result of causing the vehicle to corrode or prematurely wear any or all components not specifically exempted by agreement.
  14. 14. Forklifts should be stored in a weather proof shelter when not in use and should not be exposed to salt brine or cleaning chemicals when not in use. Failure to inspect and remove paper, plastic, wire or other debris from brake/axle assembly, engine compartment, radiator, and transmission breather. Failure to immediately clean up corrosive or hazardous substances that have fallen on the forklift and whose substance may cause damage to the forklift.
  15. 15.  Your time, personnel, and plant space are freed from maintenance requirements and can be applied to the more critical jobs of production and management.  Full maintenance allows you to accurately budget a fixed cost to maintain each forklift truck for the duration of the agreement.  With a combination of full maintenance and leasing, one low monthly payment assures full equipment utilization and convenience at the lowest cost.  We professionally survey your application and recommend the minimum number of forklift trucks for best production - at the lowest possible cost.  Our full maintenance program is custom tailored to your needs. Performed on-site, our regular maintenance keeps your equipment in peak condition and assures you virtually continuous uptime  Full maintenance provides optimum equipment utilization, whether you operate one forklift truck or a fleet, and whether your trucks are purchased or leased.  Our service vans are completely equipped to handle unscheduled emergency repairs promptly and on-site.  Full maintenance is supported through the Toyota Dealer System: the world's leading forklift truck manufacturer network, with over 125 Toyota dealer locations.  Full maintenance reduces your need for costly spare or emergency equipment.  Our factory-trained service technicians install genuine Toyota parts for your Toyota forklifts and world class Starlift parts for all competitive forklifts - both backed by a full twelve month warranty which includes labor.
  16. 16. Forklift Full Maintenance Is it a fit for your and your operation? Let’s work together and determine just what is.