Forklift Planned Maintenance by Toyota Lift of Minnesota
1. Toyota-Lift of Minnesota
Planned Maintenance
Maintenance
plans tailored to
your needs
Computer
tracked and
prompted
Proactive,
responsible, and
cost effective
www.ToyotaEquipment.com
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2. Your “Total Source” Material
Handling 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
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3. Your “Total Source” Material
Handling 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
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4. 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.
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5. 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
vehicles
www.ToyotaEquipment.com
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6. Toyota-Lift of Minnesota
Your 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
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7. 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.
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8. 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.
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9. Planned Maintenance – For all Fuel Types
Talk to the Operator or Owner
Listen about concerns, and noteworthy observations
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10. Planned Maintenance - Gas, LP and Diesel Units
Clean Radiator with Compressed Air – And blow off machine
Air forced through both directions
Part of the daily operator’s checklist
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11. Planned Maintenance - Gas, LP and Diesel Units
Clean and Inspect Air Filter, Hose and Connections
Part of the daily operator’s checklist
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12. Planned Maintenance - Gas, LP and Diesel Units
Check Accessory Drive Belts and Tension
Part of the daily operator’s checklist
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13. Planned Maintenance - Gas, LP and Diesel Units
Check for Fuel, Oil, and Cooling System Leaks
Part of the daily operator’s checklist
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14. Planned Maintenance - Gas, LP and Diesel Units
Fill Coolant to Proper Level
Part of the daily operator’s checklist
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15. Planned Maintenance - Gas, LP and Diesel Units
Antifreeze degree of protection checked
Protection level is noted on PM form
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16. Planned Maintenance - Gas, LP and Diesel Units
Check Carburetor and Accelerator Linkage
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17. Planned Maintenance - Gas, LP and Diesel Units
Clean and Inspect Breather Element / PCV Valve
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18. Planned Maintenance - Gas, LP and Diesel Units
Aisin LP Regulators – Drain tar during PM
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20. Planned Maintenance - Gas, LP and Diesel Units
Check Governor RPM’s & Lock Wire Status
Customer is advised of conditions found
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21. Planned Maintenance - Gas, LP and Diesel Units
Inspect Overall Wiring Condition
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22. Planned Maintenance - Gas, LP and Diesel Units
Inspect Battery Fluid Level – Filled if needed
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23. Planned Maintenance - Gas, LP and Diesel Units
Inspect & Clean Battery Terminals, Cables, and Cable Ends
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24. Planned Maintenance - Gas, LP and Diesel Units
Inspect Cap, Rotor, Points, Spark Plugs, & Ignition Wires
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25. Planned Maintenance - Gas, LP and Diesel Units
Change Oil and Filter Element
Toyota recommends service at 170 to 250 hours
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26. Planned Maintenance - Gas, LP and Diesel Units
Clean All Grease Fittings and Lubricate
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27. Planned Maintenance - Gas, LP and Diesel Units
Clean 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
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28. Planned Maintenance - Gas, LP and Diesel Units
Inspect Clutch, Inching Pedal Adjustment
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29. Planned Maintenance - Gas, LP and Diesel Units
Inspect and Fill Transmission and Differential Oil
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30. Planned Maintenance - Gas, LP and Diesel Units
Hydraulic Return Filter – Change on unit’s first PM service
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31. Planned Maintenance - Gas, LP and Diesel Units
How to Inspect Hydraulic Oil Levels – 5 Series
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32. Planned Maintenance - Gas, LP and Diesel Units
How to Inspect Hydraulic Oil Levels – 6 Series
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33. Planned Maintenance - Gas, LP and Diesel Units
How to Inspect Hydraulic Oil Levels – 7 Series
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34. Planned Maintenance - Gas, LP and Diesel Units
How to Inspect Hydraulic Oil Levels – 8 Series
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35. Planned Maintenance - Gas, LP and Diesel Units
Differential fill for the Toyota Box Car Special
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36. Planned Maintenance – Gas, LP and Diesel Units
Inspect and Fill Brake Master Cylinder
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37. Planned Maintenance - Gas, LP and Diesel Units
Inspect Brake Operation
Part of the daily operator’s checklist
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38. Planned Maintenance - Miscellaneous
Inspect Counterweight Bolt Condition
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39. Planned Maintenance - Gas, LP and Diesel Units
Inspect Steer Axle Assembly for Condition and Operation
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40. Planned Maintenance - Gas, LP and Diesel Units
Inspect King Pin Condition
0 Camber Negative Camber
Positive Camber
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41. Planned Maintenance - Gas, LP and Diesel Units
Inspect and Lubricate SAS Cylinder
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42. Planned Maintenance - Gas, LP and Diesel Units
IC 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
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45. Planned Maintenance - Electric Units
Inspect Contact Tips
Staining is acceptable as seen above
Pitting or splattering requires replacement
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46. Planned Maintenance - Electric Units
Check Operation of Forward Reverse and 1A
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51. Planned Maintenance - Electric Units
Inspect & Fill Brake Master Cylinder
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52. Planned Maintenance - Electric Units
Inspect and Notate Brush Condition All Electric Motors
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53. Planned Maintenance - Electric Units
Brush Condition Chart
Not all tools
fit In the
toolbox.
Technicians are
armed with service
manuals and
numerous technical
sheets
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54. Planned Maintenance - Electric Units
Inspect Condition of All Commutators
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55. Planned Maintenance - Electric Units
Commutator Check Chart
Not all tools
fit In the
toolbox.
Technicians are
armed with service
manuals and
numerous technical
sheets
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56. Planned Maintenance - Electric Units
Blow Out Motors and Clean Truck With Compressed Air
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57. Planned Maintenance - Electric Units
Record Truck Voltage to Facilitate Future Quoting
From data plate information or by counting cells
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58. Planned Maintenance - Electric Units
Check Radial Rings & Thrust Bearing Adjustment
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61. Planned Maintenance - Electric Units
Clean All Grease Fittings and Lubricate
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62. Planned Maintenance – Electric Units
Clean 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
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63. Planned Maintenance - Electric Units
Drive tire, Caster Adjustment, Load Wheels
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64. Planned Maintenance - Electric Units
Check Steering Linkage & Steer Chain Adjustment
5 Series
7 Series
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65. Planned Maintenance - Electric Units
Check King Pin Condition
0 Camber Negative Camber
Positive Camber
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66. Planned Maintenance - Electric Units
Inspect and Lubricate Steer Axle or Spindle Assembly
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67. Planned Maintenance - Electric Units
Inspect and Lubricate SAS Cylinder
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68. Planned Maintenance - Electric Units
Battery PM & Wash Program
Maximize 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.
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76. Planned Maintenance - Mast Inspection
Inspect Mast Cap Bolts & Trunion Bearings
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77. Planned Maintenance - Mast Inspection
Inspect Tilt Cylinder Bearings for Wear
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78. Planned Maintenance - Mast Inspection
Inspect Tilt Cylinder Anchors for Cracks
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79. Planned Maintenance - For all Fuel Types
Check and Adjust Sideshifter Bearings
May need attention [grease] between PM’s dependant upon environment
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81. Planned Maintenance - Mast Inspection
Lube Lift and Carriage Chains
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82. Planned Maintenance - Mast Inspection
Lube Hydraulic Pump Jack Shaft
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83. Safety and OSHA Concerns
Ask about our forklift drivers
training and train the trainer
courses.
See details at our website:
www.ToyotaEquipment.com
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84. Planned Maintenance - Safety Concerns
Inspect Data Plate and Decals
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86. Planned Maintenance - Safety Concerns
Inspect Chain Anchors – Adjust Chain Tension
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87. Planned Maintenance - Safety Concerns
Inspect Chain Stretch
Use chain gauge as a
reference, measure for
accuracy
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88. Planned Maintenance - Safety Concerns
Chain Gauge Illustrated
The chain illustrated is worn
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89. Planned Maintenance - Safety Concerns
Chain 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 2X2
Chain Size Pitch Length X Ten Pitches Stretch Limit of 3% Worn At Must Replace
AL BL 400 1/2 5 0.15 5.15 5 3/16
AL BL 500 5/8 6 1/4 0.19 6.44 6 1/2
AL BL 600 3/4 7 1/2 0.23 7.73 7 3/4
AL BL 800 1 10 0.30 10.30 10 3/8
AL BL 1000 1 1/4 12 1/2 0.38 12.88 13
Pitch Is the distance between two pins
Measure the distance between 11 pins to measure ten pitches
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92. Planned Maintenance - Safety Concerns
Inspect E-Brake Availability and Function
On some electric units, the emergency brake is involved with the dead man seat
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93. Planned Maintenance - Safety Concerns
Inspect Neutral Start Switch
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97. Planned Maintenance – Safety Concerns
Inspect Fork Wear Against ANSI Standards
Ask for Cascade’s ANSI Fork Safety
Poster and wear log
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98. Planned Maintenance – Safety Concerns
Fork 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.
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108. Planned Maintenance
Recommendations
Check– The area required inspection and checked OK
R – Repair needed and not approved, quote needed
® - Repair needed, discussed with customer and work order was created for it
X – Area needed minor adjustment, adjustment done no additional work needed
NR – Repair on next PM, discussed with customer and sold without quote
W – Watch, denotes condition that will soon merit repair
In Summary:
The technician marks any recommended repairs, or
noteworthy concerns seen during the PM. These are
also summarized briefly in the notes area
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