It is important to understand overhead guards are not designed to take the impact of a full capacity load dropped from an elevated height. Some overhead guards are designed to “crush and deflect.” While they protect the operator from partial or small loads, when heavy loads impact the overhead guard the leg receiving the heaviest impact is designed to crush and deflect the load to one side.

ANSI (American National Standards Institute) does not test deflection capability but does test crush or maximum deformation. A bundle of lumber of a certain weight and size is the designated test load. The load is dropped from a specified height and the overhead guard must maintain minimum distances between the seat and steering wheel.

Welding an overhead guard is not an acceptable repair and additions to overhead guards such as brackets for inventory control equipment, radios, weather protection or lights should be mounted by clamp brackets or other methods approved by the manufacturer. The design and testing of overhead guards helps to better understand why damages such as a crack in the weld, loose or missing mounting bolt or bent legs are safety concerns and result in the replacement of the overhead guard.

Click here to learn OSHA’s overhead guard requirements and recommended practices.

To discuss the replacement of your lift truck’s overhead guard, contact ProLift to speak to a consultant today.

Walkie Jack
A powered pallet jack that you walk behind (“walkies”) is helpful when operator fatigue is a concern. Although the equipment moves at the same pace of the operator, it does not slow down with longer distances or excessive usage. Walkies are ideal for distances 40-100 feet and are often found in the back of stores, small manufacturing with low volume and delivery trucks. Customers purchasing walkie jacks often need few features but require a powered unit for one of the many reasons described above.

Walkie Rider Jack
If your application requires frequent use or longer travel distances, the walkie rider jack can help reduce operator fatigue and increases safety. With travel speeds of about 8MPH it is more than two times faster than a walking pace. Found often in warehouses and distribution centers with higher volume, this equipment can be used for low lever order picking. With a relatively low acquisition cost, if you are only looking for horizontal movement, it can be an economical replacement for a standard forklift.

Click here to learn more about ProLift and its Class III product line or contact us to speak to a consultant. Read more about the benefits of owning Class III equipment.

6 Great Reasons to Upgrade

1.  Energy Savings:  High-intensity discharge (HID) lamps need temperatures above 500 degrees Fahrenheit to reach their operating status, taking up to three minutes to “warm up.” Compared to HID lamps, high efficiency lighting uses less wattage. This decrease in wattage results in lower electric bills and can be especially advantageous to companies running more than one work shift. Another example of energy savings is the replacement of HID lamps in an air-conditioned warehouse. For every 8 HID lamps that are replaced, 1 ton of air conditioning will be saved. 

2.  Improve Light Quality:  Over time, the amount of light given off by a HID bulb will diminish. HID lamps lose up to 60% of their light output over the life of the bulb. High efficiency lighting is more consistent. They lose only 5% of their luminosity over their life span. The upgraded bulb also gives lighting choices for your operation, offering three spectrums – soft, medium and bright.

3.  Reduce Maintenance Costs:  Because of the longer life cycle of high efficiency lighting, replacement of bulbs is less frequent. While HID lamps last 7,500 to 20,000 hours, high efficiency lighting operates 25,000 to 35,000 hours. Maintenance costs are also reduced due to the cost of bulbs. Many companies use coated HID lamps because of the explosion risk of lamps reaching the end of their life cycle. HID lamps can cost $17-35 each compared to high efficiency lamps that cost under $4 each.

4.  Reduce Fire Risks:  High efficiency lighting operates at a cooler temperature than HID lights, decreasing the possibility of a fire risk. HID lamps average an operating temperature of 750 degrees. The high efficiency lighting operates with much less heat. Reaching a little over 100 degrees, it is easily touchable after operation.

5.  Increase Property Value:  For companies owning and leasing warehouse space, high efficiency lighting can be a plus when advertising to tenants. The energy savings will benefit their operation costs. High efficiency lighting also provides better aesthetics and security as well as quieter operation.

6.  Federal Tax Incentives:  Many companies can reduce the capital expenditure of high efficiency lighting by applying for federal and state energy credits, deductions and rebates. Working with a reputable supplier will ensure knowledge of current programs.

If you think your company is a good candidate for high efficiency lighting, contact ProLift today. Our consultant will provide you with a facility survey and analysis to determine long-term energy savings.

This year, 15 winners earned the coveted award  and were acknowledged at Toyota’s National Dealer Meeting in Phoenix, Ariz.

“The President’s Award provides TMHU with a way to recognize our dealers that went above and beyond to demonstrate top quality service and support,” said Jeff Rufener, president of TMHU. “The winning dealers clearly exemplify Toyota’s dedication to their customers and set the bar for industry excellence.”

The winners are:

• Atlas Toyota Material Handling, Schiller Park, Ill. – Al Rawson
• Bell Fork Lift, Inc., Clinton Township, Mich. – Wayne Bell
• Brodie Toyota-Lift, Lawrence, Mass. – Ron McCluskey
• Conger Toyotalift, Green Bay, Wis. – Anika Conger-Capelle
• Florida Lift Systems, LLC, Tampa, Fla. – Jeff Fischer
• JRC Toyota-Lift, Worthington, Ohio – Sam Swartz
• Lift Pro Equipment Co., Inc., Sioux Falls, S.D. – Bob Overby and Craig Schoen
• Madland Toyota-Lift, Inc., Bakersfield, Calif. – Mary Madland
• Nationwide Lift Trucks, Inc., Hollywood, Fla. – Joe Conte
• ProLift Industrial Equipment, Louisville, Ky. – David Graffy
• Shoppa’s Material Handling, Ltd., Fort Worth, Texas – Jim Shoppa
• Summit ToyotaLift, North Haven, Conn. – Larry McKevitt
• Toyota Lift of South Texas, San Antonio, Texas – Leslie Doggett and Ken Townsend
• ToyotaLift of Houston, Houston, Texas – Leslie Doggett and Jim Flowers
• Westquip, Inc., Oklahoma City, Okla. – Fred Stanley

The President’s Award, TMHU’s highest honor, has been awarded to select dealers since its inception in 1990 to acknowledge their outstanding business accomplishments. To demonstrate the company’s appreciation, each President’s Award recipient received an exquisite Tiffany & Co. crystal award. TMHU also is hosting a trip to the Bahamas for the award recipients.

About Toyota Material Handling, U.S.A., Inc.

Celebrating 45 years of established operations, Irvine, Calif.-based TMHU is the supplier for the No. 1 selling lift truck in North America since 2002. In addition to the full line of high-quality lift trucks sold under the Toyota brand, the company’s extended industrial equipment solutions include Automated Guided Vehicles and tow tractors.

Quality is the hallmark of the Toyota Production System practiced at all Toyota manufacturing facilities, including Toyota Industrial Equipment Mfg., Inc. (TIEM), a zero-landfill facility in Columbus, Ind. TIEM, named a 2011 North American Best Plant by IndustryWeek magazine, is a member of the National Safety Council, complies with the ISO 14001 standard from the International Organization for Standardization and has produced more than 400,000 Toyota lift trucks since its opening in 1990.

Toyota’s commitment to excellence in customer service extends throughout the U.S. and Canada. With more than 70 authorized Toyota Industrial Equipment dealers and more than 220 dealership locations throughout North America, Toyota dealers offer comprehensive customer service and support, including one-stop shopping for both new and used lift trucks, rentals, parts and service, fleet servicing and financing. For more information on TMHU, please visit www.toyotaforklift.com, www.facebook.com/ToyotaForklift or twitter.com/ToyotaForklift or call 1-800-226-0009.

There are 2-4 levels of OSHA ratings for forklifts dependent on the fuel used. The forklift’s rating will be stamped on the data (capacity) tag under the heading of “Truck Type.”

• Gasoline forklifts are rated G or GS
• LPG forklifts are rated LP or LPS
• Diesel forklifts are rated D, DS or DY
• Electric forklifts are rated E, ES, EE or EX

Each increased level of the rating requires changes to the forklift to reduce the possibility of causing a fire. As an example, diesel “D” rated forklifts are standard. A “DS” rated forklift would have some sealed components and electrical connections such as a starter and alternator to reduce the possibility of an electrical arc. A “DY” rated forklift would have no electrical system. Instead it would have an air operated starter, an air tank to power the starter and many other safeguards. “DY” forklifts have brass coated forks and load back rests. They may also feature a squeeze bicycle horn or bell in place of an electric horn.

When modifying or adding accessories to forklifts, there is a possibility the UL rating could be voided. For example, adding a static chain or strap to the forklift’s frame is crucial to prevent static electricity from interfering with the forklift’s computers. On electric forklifts, adding a steel static chain to an “E” or “ES” forklift is acceptable. However, if the forklift is rated “EE” or “EX”, a steel chain is not approved because it may cause an external spark. On “EE” or “EX” rated forklifts a brass chain or rubber static strap would have to be used.

Click here for more information about OSHA 1910.178 and forklift ratings. If you are concerned about your current lift and its rating, contact a ProLift consultant for help today.

OSHA CFR 19010.178(m)(4) states: The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck.

It can be said an accident with a forklift mast is worse than losing a limb to a guillotine because at least a guillotine has a sharp edge. A mast assembly can destroy muscle and crush bone, leaving nothing for a doctor to repair or save.

For a technician, getting a service call regarding a mast jammed or stuck in an elevated position should be approached with extreme caution. He/she should use hard wood blocks first and then safety chains, keeping his/her distance as much as possible. Hooked pry bars, wedge bars and locking pliers can assist in placing safety chains so arms are kept out of the mast assembly. As an extra precaution park forklifts with the forks and carriage elevated over the top of a sufficient structure to stop a mast from suddenly dropping.

The design of some smaller forklifts (i.e. stand-up lifts) place the operator within reach of the forklift mast. As operators move an unstable load, the temptation exists to reach through the mast assembly and stabilize the shifting load. Pre-shift examinations and hose/chain inspections also tempt an operator to reach in for a closer hands-on review.

Education & Prevention

The hazards of forklift mast assemblies are real. The resulting injury can be devastating or fatal. While walking through your manufacturing or warehouse operation, watch for dangerous practices such as reaching through or being under a mast assembly. Be explicit with operators this is strictly prohibited for their safety. Ensure all service repairs are made by authorized personnel only and educate your forklift operators about the reality of the hazards when using unsafe practices.

Need help with forklift service and repair? Click here to learn more about ProLift’s capabilities. We can also assist you with forklift operator training.

Requirements of your forklift
The battery’s weight accounts for a large percentage of the forklift’s capacity and installing an undersized battery can cause stability issues. Research the counterweight requirement by reviewing the forklift’s data tag and measure the maximum space available in the battery compartment.

Also learn the level of voltage the forklift is designed to handle. Battery capacity is rated in ampere (amp) hours. The higher the amp hour, the more power the battery will deliver under specified conditions of temperature, rate of discharge and final voltage. To maximize the production and run time of your forklift, purchase the highest rated amp hour capacity battery that will fit into the battery compartment.

Understand battery connector choices
Give your supplier details of the connector, including where the battery plugs into the truck and the length of the battery cable required. Also note the color of the battery connectors to ensure the correct charger is used to charge a specific battery. The battery connectors are color coded and will only plug into a like color. Once the connector color has been determined, the connector size should be identified.

Know the battery charger specifications
The battery charger must be designed for your forklift’s battery voltage and amp hour rating. Review the forklift’s data tag with your supplier and confirm the charger is compatible with the battery. If it is a reconditioned charger, calibrate it to the original factory specifications.

After identifying a battery, your supplier can help determine the number of batteries to purchase for the forklift. If your production runs more than one shift, it may be necessary to have 2-3 batteries dedicated to keeping the forklift running. Many suppliers can also discuss the option of using reconditioned batteries.
Click here  for more information about ProLift’s batteries, chargers, accessories and maintenance options.

1. Source the forklift battery from the same supplier as the charger. During a battery malfunction, the source of the problem is not always clear. Whether the battery or charger is the problem, sourcing both items from the same supplier ensures their technical support.

2. Determine the total cost of the charger. Most forklift battery chargers are sold without the cables that connect the charger to an electrical supply. The cost of these cables and the cost to have an electrician connect the charger should be considered.

3. Check your electrical supply. It should have capacity to handle the normal operating amperage draw as well as the start-up amperage draw. When a forklift battery charger initially starts during the charge cycle, it draws a large amount of current. If the electrical service is inadequate, other electrical products in your facility can be affected.

4. Give attention to the output cables. The output cables that connect the charger to the forklift are usually supplied with the forklift battery charger. However, they may not be long enough to suit the location of the charger in relation to the location of the forklift during battery charging. It is important to house the charger and its output cables off the ground to prevent damage by the forklift.

5. Match the charger to the forklift battery to prevent irreversible damage to the battery. When replacing a forklift battery for your current forklift, confirm the battery technician adjusts the charger to match the characteristics of the replacement battery. Skipping this step will likely shorten the life of the battery and/or limit the charge that can be extracted due to chronic under- or overcharging.

6. Match the output voltage of the charger to the voltage of the battery and the forklift’s electrical system. This will avoid battery damage.

7. Confirm the charger is compatible. It should match the connector on the battery and its forklift.

8. Purchase an auto start/auto stop charger. It is designed to stop the charging process when the battery is fully charged.

9. Look for a charger that monitors battery temperature and adjusts the charge rate when the temperature falls outside of the normal operating range. High battery temperatures will have a direct impact on the life of a forklift battery.

10. Choose a forklift battery charger with the ability to equalize the battery. Equalization is needed to keep a battery from accumulating excessive lead sulfate on the plates, which is known to result in a reduction of battery capacity and overall life.

Have more questions about batteries and chargers? Contact ProLift to speak to a consultant or click here to learn about our capabilities for batteries, chargers, accessories and maintenance.

Fleet management is not a small project. Without a dedicated resource to manage the project, knowing the real cost of your forklift fleet is nearly impossible. While a vendor specializing in fleet management can be secured, understanding the program and justifying the costs can be daunting.

Below are questions a fleet management program can answer:

Do you operate the right equipment?
Equipment must be suited for the weight and size of the transported product as well as the available warehouse space and racking.

Is every forklift in use?
Based on the hour meter and the number of warehouse shifts, it is important to determine if every forklift is optimized. Every forklift will be located in the warehouse and analyzed for how often it is operated. A forklift used in a lower usage area may be periodically swapped with a forklift used in a high production area.

Do you have too many or too few units?
After determining the usage of each forklift, it will be decided if the size of your fleet is appropriate for your production.

Are forklift operators driving safely?
Unsafe operation results in damage and needed repairs of the equipment. Incidents found to be abuse are not covered under warranty, generating unexpected maintenance costs. Regular forklift training classes and consistent safety messages can be implemented to decrease the amount of incidents.

Are repair and maintenance invoices consistent and accurate?
Determining the budget for repair and maintenance can be difficult. Many administrative hours can be spent processing purchases orders and invoices for the equipment. A thorough review of each invoice for consistency and accuracy will answer if your company spends additional dollars for a lift having the same repair as another lift at a different cost. Analysis of the planned maintenance (PM) frequency can also point to inefficiencies and additional cost. Planned maintenance done too frequently or not often enough can both have negative cost implications.

Do you know why downtime occurs?
Research of downtime may show how the issue originated. Reviewing trends by department, operator and type of equipment can point to areas of opportunity.

When is it time to replace equipment?
Understanding the true cost of ownership is the key to determining whether it is in the best financial interests of the organization to keep or replace existing equipment. A fleet management program will help track the cost per hour of existing equipment while simultaneously running a comparison of the costs associated with acquiring a new unit with comparable specifications. The guess work is eliminated and replaced with concrete data to aid in the decision making process.

Learn more details about ProLift’s fleet management program. Contact us today to speak to a consultant.

Electric Forklifts
The forklift industry has experienced a shift in sales, with electric forklifts now counting for 60% of the market’s purchases.

Electric forklift advantages might include:

•  Better for the environment – Electric forklifts have zero emissions, which eliminate an employee’s exposure to contaminated air and the need for warehouse ventilation. They use no disposal waste (i.e. engine and transmission fluid) and a high percentage of battery lead is recycled.
• Operator ergonomics – Less noise and vibration is generated by the electric forklift, reducing operator fatigue.
• Decreased repair costs – Electric forklifts have less moving parts to maintain and repair. AC motor technology further eliminates brushes to create no spark hazard and better speed control.
• Lower fuel costs – Batteries for the electric forklift can be recharged.

With these advantages come other factors to consider. Although electric forklifts have lower lifetime fuel costs, the initial cost is higher. In addition to the cost of the battery, an area for charging, watering and cleaning must be arranged. Electric forklifts are at a disadvantage when using the forklift in an outdoor application, especially if the environment is wet. Downtime can also be experienced if the battery is not charged or equalized properly.

IC Forklifts
The market is still strong for IC forklifts. They account for about 40% of the market and are dominant in outdoor, around-the-clock or high throughput applications.

IC forklift advantages might include:

• Flexible application – IC forklifts are good indoors and outdoors. They operate well in rain and other inclement weather.
• When throughput requirements are high – The fuel savings associated with electric trucks is greatly diminished or negated when multiple batteries are required to keep an operation running. Furthermore, electric trucks have slower travel speeds and acceleration which may necessitate additional equipment and personnel to move the same amount of product.
• Lower initial cost – Only the investment of propane tanks and their storage area is needed to operate the forklift.
• Easy to refuel – IC forklifts running out of fuel do not require a lengthy charging period. An operator can easily replace the propane tank in 5 minutes and then continue production. This is especially important with a multi-shift operation.

Other factors to consider when purchasing an IC forklift include providing ventilation in the warehouse due to emissions, operator fatigue due to noise and vibration and the physical requirements of changing propane tanks. Finally, if the operation does not require an IC forklift you should consider the lifetime costs of maintenance, repairs and fuel cost when compared to an electric forklift.

To compare electric forklifts versus IC forklifts for your company, email ProLift at info@proliftequipment.com to request a Costs Summary spreadsheet.