EXPANDED EFFICIENCY FOR MARINAS: THE PROBLEM-SOLVER FORKLIFT

Expanded Efficiency for Marinas: The Problem-Solver Forklift 1

For any marina or boatyard, a successful business depends on the handling of boats efficiently. This is particularly true for a drystack facility, where vessels are frequently moved in and out of the water. Downtime for equipment fixes, slow op-erations or the worst-case scenario — boat damage — will hamper productivity and negatively impact the bottom line.

A key component to every marina, and especially a drystack one, is the forklift — the all-important mode of transport for getting boats from storage to the water and back again. The best forklift for the job will address marina-specific issues and help keep a facility running smoothly at a higher level of effectiveness and profitability.

The High-Capacity Marina Forklift from Toyota Material Handling U.S.A. has taken into account the issues marinas and dry storage facilities face, and its purpose-de-signed systems expand efficiency and, under the right circumstances, productivi-ty. Whether the challenge is higher dry storage racks or lower slips, larger capacity loads or precise maneuvering, improved operator sightlines or long-term reliabili-ty, the forklift is expressly suited for the task.

Providing the Lift You NeedWith land at a premium anywhere along the shoreline, the biggest issue most marinas face is space and access to the water. As a result, facilities are building upward rather than outward and want higher and higher applications, says Bob Lunt, Toyota Material Handling U.S.A. high capacity sales manager.

For a 96-inch load center, the High-Capacity Marina Forklift capacity ranges from 15,000 to 55,000 pounds. The forklift can lift smaller vessels up to 75 feet; as you go higher, the capacity decreases. Dry storage facilities traditionally stack larger boats on the bottom and use higher levels for lighter boats.

A specially designed mast provides a standard negative lift down to 20 feet, mean-ing operators are able to pull boats out of lower marina slips. Forklift capacity and height limits (upper and lower) can be customized to match the types of vessels a facility will transport.

To protect boats on the forklift, a “smart” hydraulics system calculates the weight of the vessel and a lift interrupter alerts the driver if it is too heavy. Without an au-tomated system, operators may need to take precious time to ensure they can lift a boat. “A lot of times, if you were lifting a boat that was new to your facility, it wasn’t uncommon that you had to call the manufacturer and find out how much the boat weighed and figure out if you could lift it,” said Lunt.

Instead, the automated system will display how high the forklift can lift a vessel, and a safety interlock will kick in to stop a heavy load from being hoisted too high.

A top safety and economic concern when lifting a boat on a forklift is a hose break or something that would cause the vessel to fall. Utilizing a system that monitors for hydraulics issues, a safety mechanism will stop the truck from dropping in the event of a failure. Boats can then be lowered manually. “The hydraulic monitoring reduces the risk of boats falling,” said Lunt.

Hydraulically controlled swinging forks also help to protect boats. Each fork hing-es open to approximately 60 degrees, so the operator can find the right cradle fit for each vessel. “Every boat hull is different, with a different design. [The swinging

Expanded Efficiency for Marinas: The Problem-Solver Forklift 2

forks] allow for an adjustment based on the hull size, so you get good, solid con-tact,” Lunt said.

The majority of the contact with the boat is at the base of the forks, and protection there further helps prevent damage. A dense, slip-resistant rubber provides pad-ding on the forks and can be replaced in 4-foot sections as needed.

The Operator and Technology Working TogetherA marina or boatyard operation presents many opportunities for unsafe condi-tions, where personnel, property, vessels or customers are at risk. But quality, purpose-built equipment that is properly maintained — combined with good management and precise practices — can enhance a culture of safety.

Inside a dry storage building, space is also at a premium, and many facilities have narrow aisles to maximize storage space. Operators need to be especially mindful of large (and expensive) outboard motors that may stick out of the rack system and are prime for damage from forklifts.

Guidelines recommend that operators always look in the direction they are trav-eling. However, the unique challenges of lifting a boat in a marina dry storage application occasionally call for additional lines of sight. For operators in dry storage facilities, tight racks and narrow slips provide unique challenges that require expert precision. Advances in technology can help to facilitate success in unique drystack marine applications. These include Toyota’s MD4 control sta-tion that gives the operator real-time, on-board digital access to helpful tools such as an estimated rack height calculator and a backup camera. This feature is intended to allow the operator to observe the boat or vessel being lifted while also observing what is behind the forklift. It can assist the operator in unique marine drystack reverse travel situations where they need to be looking at the lifted boat while travelling in reverse. In addition, a border on the screen will flash a red proximity warning and an audible alert will sound to alert the opera-tor of nearby obstacles.

The MD4 display can also be programmed to travel and shift gears faster for en-hanced efficiency or can limit use of the forklift to designated operators. For sit-uations where operation speed needs to be restricted, the forklift speed can be locked at a certain gear.

The system can also customize a pre-operational checklist, display manuals and diagrams to help diagnose technical issues faster and relay data on the screen in words, not codes. Every minute of downtime saved translates to more value and productivity for the facility.

While the open cab design provides good visibility in all directions, the forklift can also be operated remotely in narrow spaces or when pulling a boat off a dock at

Expanded Efficiency for Marinas: The Problem-Solver Forklift 3

low tide. In these cases, the operators may not be able to see around corners or below their normal field of vision. Using the remote allows them to walk where they need in order to sight-check forklift positioning and note potential hazards before proceeding.

The wireless remote can operate functions such as drive, lift/lower, right fork, left fork and tilt. The parking brake will also automatically engage when the operator switches to the remote.

Designed for Smooth OperationOne relatively simple way to help keep a marina running smoothly is by using equipment designed for dependability and low maintenance, as well as for ergo-nomic operation and less stress on the user.

The High-Capacity Marina Forklift allows operators to sit on an air-ride seat, or the cab also permits stand-up operation. The electronic joystick controls make maneuvering intuitive and natural. The two-stage, wide-view mast provides maximum visibility, and the counterweight at the back of the unit is spread in

a low profile to minimize obstruction.

Beyond external design, the components that make up the Toyota promote reli-able operation. The forklift has force-cooled wet disc brakes for stopping power in heavy-duty applications. “The biggest enemy of brakes is heat, so cool hydraulic fluid is forced in and continually cycled,” Lunt said.

From its Axletech planetary drive axle, to its welded steel chassis and heavy-duty cross supports, to its high-impact composite trunions, the forklift is constructed for durability in high-capacity applications.

The forks and carriage are galvanized to prevent corrosion where they enter the water to lift boats. A two-part, rust-inhibiting polyurethane base coat and two-part polyurethane top coat provide protection elsewhere. Fluorescent torque indica-tors on all the wheel lug nuts help operators identify when one gets loose because they look out of place, possibly preventing a problem before it occurs.

At the heart of the forklift, a Cummins 6.7L, 6-cylinder engine offers near-zero emis-sions, meeting today’s increasingly tough standards, and provides maximum torque output for the heaviest jobs. A three-speed powershift transmission and high-capac-ity cooling system help keep the machine performing up to its peak potential.

Trouble-free serviceability is critical for keeping a machine up and running, and the High-Capacity Marina Forklift addresses this with easy access to the drive train, filters and lubrication points. The brakes are serviceable through the wheel ends, and O-ring face seal fittings prevent oil leaks.

On a busy day launching boats, efficient and safe forklift operations can make or break a business, especially for a seasonal facility. Operators need a machine that keeps them comfortable and alert, and marinas and boatyards need one designed to handle the toughest challenges without fail. The High-Capacity Marina Forklift from Toyota has the industry-proven components and technology to meet those needs and solve problems before they start.