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Toyota-Lift of Minnesota
           Planned Maintenance
                             Maintenance
                              plans tailored to
                              your needs
                             Computer
                              tracked and
                              prompted
                             Proactive,
                              responsible, and
                              cost effective


www.ToyotaEquipment.com
                                       Jump to first page
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




                                     Jump to first page
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




                                    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
                               vehicles



www.ToyotaEquipment.com
                                 Jump to first page
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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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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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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Planned Maintenance – For all Fuel Types


 Talk to the Operator or Owner




Listen about concerns, and noteworthy observations


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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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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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Planned Maintenance - Gas, LP and Diesel Units

Check Accessory Drive Belts and Tension




Part of the daily operator’s checklist

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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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Planned Maintenance - Gas, LP and Diesel Units



Fill Coolant to Proper Level




 Part of the daily operator’s checklist




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Planned Maintenance - Gas, LP and Diesel Units


Antifreeze degree of protection checked




 Protection level is noted on PM form

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Planned Maintenance - Gas, LP and Diesel Units


Check Carburetor and Accelerator Linkage




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Planned Maintenance - Gas, LP and Diesel Units


Clean and Inspect Breather Element / PCV Valve




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Planned Maintenance - Gas, LP and Diesel Units


Aisin LP Regulators – Drain tar during PM




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Planned Maintenance - Gas, LP and Diesel Units


LPG Pre-Filter




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Planned Maintenance - Gas, LP and Diesel Units


Check Governor RPM’s & Lock Wire Status




Customer is advised of conditions found

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Planned Maintenance - Gas, LP and Diesel Units


Inspect Overall Wiring Condition




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Planned Maintenance - Gas, LP and Diesel Units


Inspect Battery Fluid Level – Filled if needed




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Planned Maintenance - Gas, LP and Diesel Units


Inspect & Clean Battery Terminals, Cables, and Cable Ends




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Planned Maintenance - Gas, LP and Diesel Units

Inspect Cap, Rotor, Points, Spark Plugs, & Ignition Wires




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Planned Maintenance - Gas, LP and Diesel Units


Change Oil and Filter Element




Toyota recommends service at 170 to 250 hours




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Planned Maintenance - Gas, LP and Diesel Units

Clean All Grease Fittings and Lubricate




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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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Planned Maintenance - Gas, LP and Diesel Units


Inspect Clutch, Inching Pedal Adjustment




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Planned Maintenance - Gas, LP and Diesel Units



Inspect and Fill Transmission and Differential Oil




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Planned Maintenance - Gas, LP and Diesel Units

Hydraulic Return Filter – Change on unit’s first PM service




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Planned Maintenance - Gas, LP and Diesel Units

How to Inspect Hydraulic Oil Levels – 5 Series




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Planned Maintenance - Gas, LP and Diesel Units

How to Inspect Hydraulic Oil Levels – 6 Series




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Planned Maintenance - Gas, LP and Diesel Units

How to Inspect Hydraulic Oil Levels – 7 Series




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Planned Maintenance - Gas, LP and Diesel Units

How to Inspect Hydraulic Oil Levels – 8 Series




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Planned Maintenance - Gas, LP and Diesel Units



Differential fill for the Toyota Box Car Special




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Planned Maintenance – Gas, LP and Diesel Units

Inspect and Fill Brake Master Cylinder




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Planned Maintenance - Gas, LP and Diesel Units

Inspect Brake Operation




Part of the daily operator’s checklist



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Planned Maintenance - Miscellaneous

Inspect Counterweight Bolt Condition




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Planned Maintenance - Gas, LP and Diesel Units

Inspect Steer Axle Assembly for Condition and Operation




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Planned Maintenance - Gas, LP and Diesel Units

Inspect King Pin Condition




                               0 Camber          Negative Camber




                             Positive Camber




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Planned Maintenance - Gas, LP and Diesel Units

Inspect and Lubricate SAS Cylinder




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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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Electric Powered Unit Specifics




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Planned Maintenance - Electric Units


Inspect Wiring Condition




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Planned Maintenance - Electric Units

Inspect Contact Tips




                                  Staining is acceptable as seen above




                                  Pitting or splattering requires replacement


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Planned Maintenance - Electric Units

Check Operation of Forward Reverse and 1A




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Planned Maintenance - Electric Units


Inspect Power Cables




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Planned Maintenance - Electric Units


Inspect and Advise Battery Water Level




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Planned Maintenance - Electric Units


Inspect SB Connector & Tips – Truck & Battery Sides




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Planned Maintenance - Electric Units

Inspect Brake Operation




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Planned Maintenance - Electric Units


Inspect & Fill Brake Master Cylinder




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Planned Maintenance - Electric Units

Inspect and Notate Brush Condition All Electric Motors




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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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Planned Maintenance - Electric Units



Inspect Condition of All Commutators




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Planned Maintenance - Electric Units

Commutator 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 Units


Blow Out Motors and Clean Truck With Compressed Air




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Planned Maintenance - Electric Units

Record Truck Voltage to Facilitate Future Quoting




From data plate information or by counting cells

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Planned Maintenance - Electric Units



Check Radial Rings & Thrust Bearing Adjustment




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Planned Maintenance - Electric Units


Check and Fill Drive Unit




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Planned Maintenance - Electric Units


Differential Fill for 7FBEU




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Planned Maintenance - Electric Units


Clean All Grease Fittings and Lubricate




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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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Planned Maintenance - Electric Units

Drive tire, Caster Adjustment, Load Wheels




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Planned Maintenance - Electric Units



Check Steering Linkage & Steer Chain Adjustment



                             5 Series




                              7 Series




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Planned Maintenance - Electric Units


Check King Pin Condition




                                0 Camber          Negative Camber




                              Positive Camber




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Planned Maintenance - Electric Units


Inspect and Lubricate Steer Axle or Spindle Assembly




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Planned Maintenance - Electric Units


Inspect and Lubricate SAS Cylinder




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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.




                                                        Jump to first page
Mast Inspections




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Planned Maintenance – Mast Inspection


Inspect and Fill Hydraulic Fluid




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Planned Maintenance - Mast Inspection


Check Upright Assembly for Proper Adjustment




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Planned Maintenance - Mast Inspection

Inspect Mast Bearings & Chain Rollers




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Planned Maintenance - Mast Inspection

Inspect Carriage Assembly




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Planned Maintenance - Mast Inspection

Inspect Cylinder Chrome and Check for Leaks




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Planned Maintenance - Mast Inspection



Inspect Hoses & Hose Reels




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Planned Maintenance - Mast Inspection

Inspect Mast Cap Bolts & Trunion Bearings




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Planned Maintenance - Mast Inspection

Inspect Tilt Cylinder Bearings for Wear




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Planned Maintenance - Mast Inspection


Inspect Tilt Cylinder Anchors for Cracks




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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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Planned Maintenance - Mast Inspection

Inspect Load Back Rest




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Planned Maintenance - Mast Inspection

Lube Lift and Carriage Chains




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Planned Maintenance - Mast Inspection


Lube Hydraulic Pump Jack Shaft




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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 Concerns



Inspect Data Plate and Decals




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Planned Maintenance - Safety Concerns

Inspect Seat Belt




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Planned Maintenance - Safety Concerns


Inspect Chain Anchors – Adjust Chain Tension




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Planned Maintenance - Safety Concerns

Inspect Chain Stretch




Use chain gauge as a
reference, measure for
accuracy
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Planned Maintenance - Safety Concerns
Chain Gauge Illustrated




                   The chain illustrated is worn




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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


                                                                                 Jump to first page
Carriage Stop To Mast Stop Clearance




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Carriage Stop To Mast Stop Clearance Chart




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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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Planned Maintenance - Safety Concerns

Inspect Neutral Start Switch




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Planned Maintenance - Safety Concerns


Inspect Horn Operation




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Planned Maintenance - Safety Concerns


Inspect Frame, Mast, and Over Head Guard for Cracks




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Planned Maintenance - Safety Concerns


Inspect Gauge Operation




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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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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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Planned Maintenance – Safety Concerns

Fork Edge Types




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Planned Maintenance - Safety Concerns


Inspect Strobe Light




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Planned Maintenance - Safety Concerns


Inspect Working Lights




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Planned Maintenance - Safety Concerns


Inspect Backup Alarm




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Planned Maintenance - Safety Concerns


Inspect Deadman Switch Operation – Static Return To Neutral




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Planned Maintenance - Safety Concerns

Hood Latch for Function and Availability




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Planned Maintenance - Safety Concerns


Check Tire Pressure On Pneumatic Tires




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Planned Maintenance - Safety Concerns

Tire 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 1/2


Lift trucks depend on good tires to protect personnel, equipment and
product.
                                                                                       Jump to first page
Planned Maintenance - Safety Concerns

Test Drive Truck




                                        Jump to first page
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




                                                                               Jump to first page
Other Suggested Services




Timely, cost effective and pro-active
                                        Jump to first page
Replace Transmission Filter and Fluid




                                        Jump to first page
Replace Hydraulic Filter




Replace 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




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Replace Coolant Fluid if Contaminated




                                        Jump to first page
Change Differential Oil




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Lube Transmission Drive Shaft




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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 Jump to first page
  • 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 Jump to first page
  • 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 Jump to first page
  • 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. Jump to first page
  • 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 Jump to first page
  • 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 Jump to first page
  • 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. Jump to first page
  • 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. Jump to first page
  • 9. Planned Maintenance – For all Fuel Types Talk to the Operator or Owner Listen about concerns, and noteworthy observations Jump to first page
  • 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 Jump to first page
  • 11. Planned Maintenance - Gas, LP and Diesel Units Clean and Inspect Air Filter, Hose and Connections Part of the daily operator’s checklist Jump to first page
  • 12. Planned Maintenance - Gas, LP and Diesel Units Check Accessory Drive Belts and Tension Part of the daily operator’s checklist Jump to first page
  • 13. Planned Maintenance - Gas, LP and Diesel Units Check for Fuel, Oil, and Cooling System Leaks Part of the daily operator’s checklist Jump to first page
  • 14. Planned Maintenance - Gas, LP and Diesel Units Fill Coolant to Proper Level Part of the daily operator’s checklist Jump to first page
  • 15. Planned Maintenance - Gas, LP and Diesel Units Antifreeze degree of protection checked Protection level is noted on PM form Jump to first page
  • 16. Planned Maintenance - Gas, LP and Diesel Units Check Carburetor and Accelerator Linkage Jump to first page
  • 17. Planned Maintenance - Gas, LP and Diesel Units Clean and Inspect Breather Element / PCV Valve Jump to first page
  • 18. Planned Maintenance - Gas, LP and Diesel Units Aisin LP Regulators – Drain tar during PM Jump to first page
  • 19. Planned Maintenance - Gas, LP and Diesel Units LPG Pre-Filter Jump to first page
  • 20. Planned Maintenance - Gas, LP and Diesel Units Check Governor RPM’s & Lock Wire Status Customer is advised of conditions found Jump to first page
  • 21. Planned Maintenance - Gas, LP and Diesel Units Inspect Overall Wiring Condition Jump to first page
  • 22. Planned Maintenance - Gas, LP and Diesel Units Inspect Battery Fluid Level – Filled if needed Jump to first page
  • 23. Planned Maintenance - Gas, LP and Diesel Units Inspect & Clean Battery Terminals, Cables, and Cable Ends Jump to first page
  • 24. Planned Maintenance - Gas, LP and Diesel Units Inspect Cap, Rotor, Points, Spark Plugs, & Ignition Wires Jump to first page
  • 25. Planned Maintenance - Gas, LP and Diesel Units Change Oil and Filter Element Toyota recommends service at 170 to 250 hours Jump to first page
  • 26. Planned Maintenance - Gas, LP and Diesel Units Clean All Grease Fittings and Lubricate Jump to first page
  • 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 Jump to first page
  • 28. Planned Maintenance - Gas, LP and Diesel Units Inspect Clutch, Inching Pedal Adjustment Jump to first page
  • 29. Planned Maintenance - Gas, LP and Diesel Units Inspect and Fill Transmission and Differential Oil Jump to first page
  • 30. Planned Maintenance - Gas, LP and Diesel Units Hydraulic Return Filter – Change on unit’s first PM service Jump to first page
  • 31. Planned Maintenance - Gas, LP and Diesel Units How to Inspect Hydraulic Oil Levels – 5 Series Jump to first page
  • 32. Planned Maintenance - Gas, LP and Diesel Units How to Inspect Hydraulic Oil Levels – 6 Series Jump to first page
  • 33. Planned Maintenance - Gas, LP and Diesel Units How to Inspect Hydraulic Oil Levels – 7 Series Jump to first page
  • 34. Planned Maintenance - Gas, LP and Diesel Units How to Inspect Hydraulic Oil Levels – 8 Series Jump to first page
  • 35. Planned Maintenance - Gas, LP and Diesel Units Differential fill for the Toyota Box Car Special Jump to first page
  • 36. Planned Maintenance – Gas, LP and Diesel Units Inspect and Fill Brake Master Cylinder Jump to first page
  • 37. Planned Maintenance - Gas, LP and Diesel Units Inspect Brake Operation Part of the daily operator’s checklist Jump to first page
  • 38. Planned Maintenance - Miscellaneous Inspect Counterweight Bolt Condition Jump to first page
  • 39. Planned Maintenance - Gas, LP and Diesel Units Inspect Steer Axle Assembly for Condition and Operation Jump to first page
  • 40. Planned Maintenance - Gas, LP and Diesel Units Inspect King Pin Condition 0 Camber Negative Camber Positive Camber Jump to first page
  • 41. Planned Maintenance - Gas, LP and Diesel Units Inspect and Lubricate SAS Cylinder Jump to first page
  • 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 Jump to first page
  • 43. Electric Powered Unit Specifics Jump to first page
  • 44. Planned Maintenance - Electric Units Inspect Wiring Condition Jump to first page
  • 45. Planned Maintenance - Electric Units Inspect Contact Tips Staining is acceptable as seen above Pitting or splattering requires replacement Jump to first page
  • 46. Planned Maintenance - Electric Units Check Operation of Forward Reverse and 1A Jump to first page
  • 47. Planned Maintenance - Electric Units Inspect Power Cables Jump to first page
  • 48. Planned Maintenance - Electric Units Inspect and Advise Battery Water Level Jump to first page
  • 49. Planned Maintenance - Electric Units Inspect SB Connector & Tips – Truck & Battery Sides Jump to first page
  • 50. Planned Maintenance - Electric Units Inspect Brake Operation Jump to first page
  • 51. Planned Maintenance - Electric Units Inspect & Fill Brake Master Cylinder Jump to first page
  • 52. Planned Maintenance - Electric Units Inspect and Notate Brush Condition All Electric Motors Jump to first page
  • 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 Jump to first page
  • 54. Planned Maintenance - Electric Units Inspect Condition of All Commutators Jump to first page
  • 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 Jump to first page
  • 56. Planned Maintenance - Electric Units Blow Out Motors and Clean Truck With Compressed Air Jump to first page
  • 57. Planned Maintenance - Electric Units Record Truck Voltage to Facilitate Future Quoting From data plate information or by counting cells Jump to first page
  • 58. Planned Maintenance - Electric Units Check Radial Rings & Thrust Bearing Adjustment Jump to first page
  • 59. Planned Maintenance - Electric Units Check and Fill Drive Unit Jump to first page
  • 60. Planned Maintenance - Electric Units Differential Fill for 7FBEU Jump to first page
  • 61. Planned Maintenance - Electric Units Clean All Grease Fittings and Lubricate Jump to first page
  • 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 Jump to first page
  • 63. Planned Maintenance - Electric Units Drive tire, Caster Adjustment, Load Wheels Jump to first page
  • 64. Planned Maintenance - Electric Units Check Steering Linkage & Steer Chain Adjustment 5 Series 7 Series Jump to first page
  • 65. Planned Maintenance - Electric Units Check King Pin Condition 0 Camber Negative Camber Positive Camber Jump to first page
  • 66. Planned Maintenance - Electric Units Inspect and Lubricate Steer Axle or Spindle Assembly Jump to first page
  • 67. Planned Maintenance - Electric Units Inspect and Lubricate SAS Cylinder Jump to first page
  • 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. Jump to first page
  • 69. Mast Inspections Jump to first page
  • 70. Planned Maintenance – Mast Inspection Inspect and Fill Hydraulic Fluid Jump to first page
  • 71. Planned Maintenance - Mast Inspection Check Upright Assembly for Proper Adjustment Jump to first page
  • 72. Planned Maintenance - Mast Inspection Inspect Mast Bearings & Chain Rollers Jump to first page
  • 73. Planned Maintenance - Mast Inspection Inspect Carriage Assembly Jump to first page
  • 74. Planned Maintenance - Mast Inspection Inspect Cylinder Chrome and Check for Leaks Jump to first page
  • 75. Planned Maintenance - Mast Inspection Inspect Hoses & Hose Reels Jump to first page
  • 76. Planned Maintenance - Mast Inspection Inspect Mast Cap Bolts & Trunion Bearings Jump to first page
  • 77. Planned Maintenance - Mast Inspection Inspect Tilt Cylinder Bearings for Wear Jump to first page
  • 78. Planned Maintenance - Mast Inspection Inspect Tilt Cylinder Anchors for Cracks Jump to first page
  • 79. Planned Maintenance - For all Fuel Types Check and Adjust Sideshifter Bearings May need attention [grease] between PM’s dependant upon environment Jump to first page
  • 80. Planned Maintenance - Mast Inspection Inspect Load Back Rest Jump to first page
  • 81. Planned Maintenance - Mast Inspection Lube Lift and Carriage Chains Jump to first page
  • 82. Planned Maintenance - Mast Inspection Lube Hydraulic Pump Jack Shaft Jump to first page
  • 83. 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
  • 84. Planned Maintenance - Safety Concerns Inspect Data Plate and Decals Jump to first page
  • 85. Planned Maintenance - Safety Concerns Inspect Seat Belt Jump to first page
  • 86. Planned Maintenance - Safety Concerns Inspect Chain Anchors – Adjust Chain Tension Jump to first page
  • 87. Planned Maintenance - Safety Concerns Inspect Chain Stretch Use chain gauge as a reference, measure for accuracy Jump to first page
  • 88. Planned Maintenance - Safety Concerns Chain Gauge Illustrated The chain illustrated is worn Jump to first page
  • 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 Jump to first page
  • 90. Carriage Stop To Mast Stop Clearance Jump to first page
  • 91. Carriage Stop To Mast Stop Clearance Chart Jump to first page
  • 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 Jump to first page
  • 93. Planned Maintenance - Safety Concerns Inspect Neutral Start Switch Jump to first page
  • 94. Planned Maintenance - Safety Concerns Inspect Horn Operation Jump to first page
  • 95. Planned Maintenance - Safety Concerns Inspect Frame, Mast, and Over Head Guard for Cracks Jump to first page
  • 96. Planned Maintenance - Safety Concerns Inspect Gauge Operation Jump to first page
  • 97. Planned Maintenance – Safety Concerns Inspect Fork Wear Against ANSI Standards Ask for Cascade’s ANSI Fork Safety Poster and wear log Jump to first page
  • 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. Jump to first page
  • 99. Planned Maintenance – Safety Concerns Fork Edge Types Jump to first page
  • 100. Planned Maintenance - Safety Concerns Inspect Strobe Light Jump to first page
  • 101. Planned Maintenance - Safety Concerns Inspect Working Lights Jump to first page
  • 102. Planned Maintenance - Safety Concerns Inspect Backup Alarm Jump to first page
  • 103. Planned Maintenance - Safety Concerns Inspect Deadman Switch Operation – Static Return To Neutral Jump to first page
  • 104. Planned Maintenance - Safety Concerns Hood Latch for Function and Availability Jump to first page
  • 105. Planned Maintenance - Safety Concerns Check Tire Pressure On Pneumatic Tires Jump to first page
  • 106. Planned Maintenance - Safety Concerns Tire 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 1/2 Lift trucks depend on good tires to protect personnel, equipment and product. Jump to first page
  • 107. Planned Maintenance - Safety Concerns Test Drive Truck Jump to first page
  • 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 Jump to first page
  • 109. Other Suggested Services Timely, cost effective and pro-active Jump to first page
  • 110. Replace Transmission Filter and Fluid Jump to first page
  • 111. Replace Hydraulic Filter Replace Oil If Necessary Jump to first page
  • 112. Complete Tune Up Jump to first page
  • 113. Replace Fuel Filter: Gas, LP, Diesel Jump to first page
  • 114. Repack Steer Wheel Bearings and Replace Seals Jump to first page
  • 115. Pressure Check Coolant System and Test Radiator Cap Jump to first page
  • 116. Replace Coolant Fluid if Contaminated Jump to first page
  • 117. Change Differential Oil Jump to first page
  • 118. Lube Transmission Drive Shaft Jump to first page