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Monthly Archives: February 2015

Forklift Air Filter Storage and Handling Tips

Getting the most life out of your forklift air filter is important. This starts with storage and handling. Before you even start the installation process, make sure the new filter is less than 6 years old (based on the manufacturing date) AND it is clean/undamaged. Here are a few more quick tips to help with your forklift air filter storage:

1)  Make sure to always store air filters in a box, not out on a shelf where they can pick up dust in the air.

2)  If the box isn’t sealed tight, tape it shut.

3)  Individually wrapped

4)   When transporting air filters, make sure they aren’t rolling around. Throwing them in the back of the truck or the floor boards could cause damage.

5)   Don’t store the filters on anything metal. Metal condensates and could cause rust on the filter. Boxes are best.

6) Just like with food, put the oldest filters in the front. Make sure you put new stock in the back so you don’t end up with expired filters. (Remember, 6 years from the manufacturing date is the oldest you want to use.)

7) Make life easiest by ensuring labels with product information and manufacturing dates are visible.

8) Don’t store filters in extreme temperatures or excess moisture. The environment you store your filters in will effect their shelf life.

9) When installing or just handling new filters, make sure your hands are clean. Avoid contact with the outlet side of the filter if possible.

Intella has a complete line of forklift filters.  We carry filters for most brands of forklifts including Hyster, Yale, Toyota, Cat, Kalmar, Taylor Forklift, Nissan Forklift, Komatsu Forklift and most others.


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Servicing Forklift Air Filters using restriction indicators

Best Way

Forklift mechanic changing forklift air filter
Forklift mechanic changing forklift air filter

Servicing a forklift air filter by restriction is the best way to get the most life out of your filter. Proper servicing can save you money and time. Dirty filters do not always mean they are trash. Many times, dirty filters can  go more hours!

Too Much Servicing

Don’t want to cause a problem in your air cleaner? Don’t service it too much. The elements in the filters are more efficient as dust builds up on the media. But  avoid dust and other abrasive particles when removing the filter!

Forklift mechanic measuring the restriction to determine if there is a plug in the system
Forklift mechanic measuring the restriction to determine if there is a plug in the system

Measurement Tools

Restriction measurement tool options
Restriction measurement tool options

There are a variety of choices when it comes to measurement tools to get the most out of your filter.

Looking for a continuous reading device to see how much life is left in that old filter? Check out The Informer and the Service Gauge for Instrument Panel.

Intella has a complete line of forklift filters for sale.  Easy online ordering allows you to quickly select the filter you need–at a great price!


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Forklift forks: technical details on Intella’s range of fork arms

Intella Parts’ forklift forks are manufactured to meet or exceed two major specifications.

Major Specifications:

ANSI

ANSI (The American National Standards Institute) has published standard number B56 11.4 revision 2013 entitled “Hook type forks and fork carriers for powered industrial fork trucks.”  This standard encompasses standards relating to hook type forks up to 24,000 pound lifting capacity.  Intella’s forklift forks are built to meet this standard.  It’s important to note that ANSI doesn’t “approve” or “endorse” certain products–they simply publish a standard for manufacturers to adhere to.  For more information on this standard, and to download and read the standard click here.  You may download a PDF of the standard for no charge by submitting your name and email address.

forklift forks intella liftpartsISO2330

ISO2330 is the world standard for forklift forks.  This International Standard specifies manufacturing, testing and marking requirements for solid-section fork arms, for quantity production and with all types of mounting.  Here’s the main difference between ANSI B56 and ISO2330.    Manufacturers “self-certify” to the ANSI B56 standard–ANSI publishes standards, they don’t approve or disapprove products that claim to be built to that standard.  ISO2330, on the other hand, actually is an audited standard–if manufacturers advertise that they build forklift forks to ISO2330, they must pay for an extensive on-site audit.  Once the auditors certify that the standard is met, the manufacturer receives an ISO2330 certificate.

The first ISO2330 test is a yield test.  For forklift forks built to a load capacity of less than 5500 kilograms (12,100 pounds), the test load is 3 times the load capacity.  For forklifts forks built to a load capacity of greater than 5500 kilograms (12,100 pounds), the test load is anywhere between 2.5 and 3 times the load capacity of the fork.

The second ISO2330 test is an impact test.  In this test, cross sections of steel are removed from the forklift fork according to ISO 683-1.  They are then impact tested according to ISO148 at -20 celsius.

The third ISO2330 test is a fatigue test.  In this test, the sample forklift fork is load tested 1,000,000 (one million) times (!!).  The load is 1.25 times the lifting capacity of the fork.   The fork can’t fail, and there can be no cracks after the test.

All three of these tests are performed under the auspices of the ISO auditor.  This is a major difference from the ANSI specification.  You can rest assured that Intella forklift forklifts are manufactured to top international standards and suitable for any industrial forklift.

The last ISO2330 requirement is that each forklift fork is stamped on its side with the following:

– fork arm capacity in kilograms

– load center in millimeters

– manufacturers designation

– date code or serial number code

SORRY Americans used to inches and pounds!  Since this is a global standard, it’s all metric on the forks

Lifting Capacity

forklift forks markings

In this photo, you see 2500×500.  What this means is that the fork has a lifting capacity of 2500 kilograms (5,500 pounds) at a 500 mm (20 inch) load center.  This is the forklift fork capacity per fork not per pair.  In this example, if you had two of these forks on a forklift, your forklift forks have a lifting capacity of 5,000 kilograms (11,000 pounds).  This should not be confused with the lifting capacity of your forklift.  Consult the manufacturer’s data tag on your forklift to determine the lifting capacity of your forklift.

Measuring Forklift Forks

Forklift forks are measured and ordered by knowing length, width, and height.  To learn more about measuring forklift forks, check out this Youtube video:

.

Looking for forklift forks? Intella Parts Company can help!


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Forklift Air Filter Tips and Maintenance

Donaldson airfilterRegular maintenance

Crucial to the life of your forklift air filter.  Inlet hoods must not be missing and all openings and tubes must be clear. Dented or damaged units and housings must be fixed or replaced to optimize operations. Make sure there are no leaks in the ducting to provide particles a trail straight to the engine.

Capture5

filter2Cleanliness

A clean filter is not a sign of life or death. Clean filters can have dirt and carbon deep down in the filter; dirty looking filters may still be working great. Filters are a low-cost investment to keeping things running smooth.

Capture3

Keep air cleaners closed as much as possible! If there is no filter, there is no barrier between the engine and the outside world. Protect the engine during filter changes by keeping the opening covered. Just because you can’t see the dirt and particles doesn’t mean they won’t affect the engine.

Gaskets

Capture4Gaskets that are damaged should be replaced when changing forklift air filters. Be sure to check service instructions on if gaskets need to be replaced at each filter change and don’t use an old one you have laying around. (This is usually the case in EBA and ERA model air cleaners.)

Filters

When changing out lift truck filters make sure to use the same Capture8part number. Filters may look the same but they provide different seals that can affect airflow and can cause serious damage over time. The only time you should change model numbers is when there is an upgrade to an older style.

Forklift manufacturers give you recommendations on the roCapture6utine you should follow regarding maintenance of your filters. Each new filter has a different set of recommendations and guidelines. Make sure you are up to date with the newest procedures. Keeping records and following these guidelines are necessary in the likelihood you need to use a warranty claim. It is often helpful to record the filter changes right on the filter itself. It doesn’t matter if you track it by miles or hours, just keep it consistent.

Dirty forklift filters can contaminate clean filters during a routine service change. Make sure to wash your hands or remove your gloves after handling the dirty filter and before coming in contact with the new one. It is also helpful to keep the new filter in the box until you are 100% ready to install it.

Air Cleaner System

Tightening and inspecting the forklift air cleaner system  connections is the last step. Make sure everything is free of holes and damage; worn spots and damage especially to the elbows, seals and connections must be checked thoroughly. Tighten all clamps and inspect pre-cleaners and inlet hoods. Reset manual filter indicators and make sure to record any and all action you have performed.


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Toyota 4Y Engine Specs: Deciphering the Engine Codes

Toyota has used its 4Y engine for forklifts with size capacities between 1.5 and 3.0 tons since the early 1990s.   Toyota forklifts with models proceeded with the number 42 all are equipped with the 4Y engine.

 

Toyota 4Y Engine Specs

 

The Toyota 4Y engine dates all the way back to the 1970s.  It was first seen in small light duty trucks such as the Toyota Stout, Hilace, Daihatsu Delta, and Australian built Toyota 4Runners.  Virtually every gasoline or LPG engine used in forklifts today were originally used in automobiles.   The Mazda FE and F2 engines used in Hyster and Yale forklifts were used in Mazda B2000 pickup trucks.  The Mitsubishi 4G63 engine used in Cat and Mitsubishi forklifts was used in Mitsubishi Lancer and Gallant models.  The GM 4.3 liter engine has been used in a variety of Chevy and GMC trucks.  And the Nissan H20 engine was used in a variety of different Nissan car models.  So no surprise that the Toyota 4Y engine got its start in the automotive world.

The 4Y engine has a 2.2 liter displacement with 4 inline cylinders.    It’s typically fitted with an Aisan fuel system of some sort, depending on the emissions rules in the country it’s sold in.  Need firing order, spark plug gap, and other technical info?  Detailed technical specifications can be found here

Toyota owns a portion of many of its suppliers so it comes as no surprise that Aisan is owned by the Toyota group.  The distributor, ignition parts, and electrical system used on the 4Y is made by Toyota owned Denso, and it can truly be said that the majority of the engine and surrounding components are manufactured by either Toyota or Toyota owned suppliers.

Intella offers a variety of parts for the 4Y engines.  We offer overhaul gasket kits, replacement heads, tune up parts.

If your data plate shows a model like these, you can be assured you have a 4Y engine in your forklift:

42-6FGCU15  (42 = 4Y engine code)

If you’re wondering how to determine if your Toyota forklift has a 4Y engine, you can usually figure it out from the data tag of the forklift.

Toyota forklift models typically look like this:  42-6FGCU25.  Let’s decode those letters and numbers.

First off, the first two digits indicate the type of engine in the forklift.  Here are common engine codes

42 = Toyota 4Y engine LPG and gasoline

02 = Toyota  1DZ diesel engine

52 = GM engine typically 6 cylinder 4.3 engine

Now for the rest of the model 6FGCU25

6 is design series.  Toyota started with no number (the first models were simply FGC25, then they moved to 2FGC25, 3FGC, etc, etc)

FGC stands for Forklift Gas (can be gasoline of LPG/propane) Cushion tires.

FDC stands for Forklift Diesel Cushion tires.  FBC Forklift Battery (electric powered) Cushion.

No tire code = pneumatic tires on forklift (default type of tires.  Cushion tires are really only used in North America).

The U designates the factory the forklift was built in.  U = United states, F = France, no letter = Japan.

The number represents the lifting capacity in kilograms/100.  A 25 = 2500 kg lifting capacity.  An 18 = 1800 kg capacity, etc, etc.

So a 42-6FGCU25 Toyota would be equipped with a Toyota 4Y engine, it’s a 6 series model, it uses either gasoline or propane, it has cushion tires, was made in the United States, and has a lifting capacity of 2500 kilograms.

We have the Toyota forklift parts you need at Intella Parts Company. If you’re needing to find the age of your forklift, check out our guide on finding the VIN. 


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