Forklift Battery Troubleshooting

June 30, 2016

Need forklift battery chargers ? Intella Liftparts can help.

Forklift Battery Troubleshooting: If only they could last forever.

Chances are your forklift battery is going to give you problems at some point in time. When those problems arise, we want you to be prepared which is why we made this forklift battery troubleshooting guide. Below is a list of common problems associated with forklift batteries that occur over time. Listed are the different battery troubles, the conditions that come with them, what’s causing the problem, and how to collectively act upon it.

forklift battery troubleshooting intella liftparts

Short Circuited

Condition:

Very low cell voltage and specific gravity during recharging and discharging
Low gassing while charging
Extreme rise of electrolyte temperature during charging phase
Fast drop of gravity after charging

Why is this happening? Probable cause:

Short circuited due to a dropping of active materials
Short circuited due to a broken separator
Short circuited due to advancing of broken pieces during manufacturing of battery

Where to go from here:

Replace the faulty cell with a single charged cell

Sulfation

Condition:

While charging, the voltage and electrolyte temperature are much higher than the standard
Gassing is accelerated from charging and the gravity does not rise to normal
Voltage drops quickly while discharging
In some extreme cases, plates may become whitened

Why is this happening? Probable cause:

Repeatedly overcharging and discharging of battery
Plates exposed to open air for extended period of time
Lack of care during storage process
Excessively high gravity while using battery
Impurities causing excessive self discharge of battery

Where to go from here:

If the battery is in rather early conditions, remove the probable cause
Replace the faulty cell with a single charged cell if damage can’t be fixed

Excessive Self Discharging

Condition:

Quick drop in gravity after charging
Charging capacity of battery significantly reduced

Why is this happening? Probable cause:

Using impure water in the battery
Specific gravity higher than it should be
Excessively high temperature of electrolytes
Battery container has been insufficiently cleaned

Where to go from here:

Take daily care of the battery
Replace the faulty cell with a single charged cell

Exchange of Polarity

Condition:

Polarity switched around in some cells during discharging or high temperature of electrolytes
Electrolytes dissolve causing an emission of gas that changes the polarity of the battery

Why is this happening? Probable cause:

Caused by quick discharge without noticing a low capacity in a cell
Ill preparation of certain means like an equation charge

Where to go from here:

Replace faulty cell
Take daily care of the battery

Shop Forklift Battery Chargers

Other Possible Factors

1. Color of electrolyte has changed to brown

– Due to corrosion of positive plate mixing into electrolytes

– Check voltage and gravity of battery

– Replace electrolyte

2. Chlorine smell during charging

– Due to sea water mixing into electrolytes

– Replace electrolyte and charge the battery until the smell is gone

– Replace cells

3. Electrolyte excessively reduced

– Battery cells are cracked

– High electrolyte temperature while charging

– Find causes and follow repair procedures

4. Unnaturally high electrolyte temperature

– Due to lack of electrolytes

– Due to shorted cells and/or reversed polarity

– Solder battery

5. Heat from connector portion

– Bad connector contact

Need forklift parts? With thousands of parts in stock, quick shipping and great customer service, Intella Parts Company can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Need forklift battery chargers? Intella Liftparts can help.

Post by Intella Parts Company, LLC

How to Fix a Forklift

June 28, 2016

Fix a Forklift Yourself

You’ve probably been there before. You discover a problem with your forklift, find the right solution, buy the necessary parts, and then have to call in help to do the rest. But at Intella Liftparts, our goal is your independence: we’ve helped you with the parts, now let us help with everything else. With that said, check out this list of our ‘how to fix a forklift’ articles for repairs of all kinds. Our work focuses on the most common problems that forklifts can have, ensuring that help for you is as available as possible. Beyond repair tips, we also make it our goal to cover every other aspect of owning a forklift, from proper maintenance to safety training to varieties of forklift tires. Here at Intella, we strive to keep you up to date with the most current information we can provide about your vehicle. You know us as a parts service; now get to know us as so much more. Below you will find links to some of our popular ‘how to fix a forklift’ articles. Clicking on the title will take you right to the article page. You can also click here for a full list of articles on our website.

More Resources to Help You Fix Your Forklift

How to identify and replace electrical contactors

How to select the best battery for your forklift

How to block your forklift prior to performing repairs

How to buy a new forklift

How to troubleshoot a no-start condition

How to maintain your forklift engine (internal combustion and electric)

How to replace a blown fuse

How to pick the right tires for your forklift

How to select a forklift battery charger

How to find the serial number on you forklift

How to avoid common forklift hazards

For more how-to articles and all around product knowledge, click here

Oh and if you want to prove to everyone that you’re

the boss, we’ve got just the right t-shirt for you.

Need forklift parts? Need a Toyota forklift seat? With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Parts Company, LLC

My Forklift Battery Smells Funny

June 23, 2016

My forklift battery smells a lot like rotten eggs – Why?

We hate to be the bearer of bad news but the smell of rotten eggs
coming from your forklift battery is not a good thing. The unpleasant smell resembling that of expired eggs is actually sulfur. Forklift batteries are made from lead plates that are covered in a lead oxide paste. This then sits in a pool of sulfuric acid. Almost every vehicular battery, regardless of the application, will at some point get a bad cell. When one of these battery cells stop taking a charge, the battery charger will throw everything it’s got at it to try and bring up the voltage. This causes the cell to get very hot and will boil the sulfuric acid stored inside the battery. When sulfuric acid gets cooked, you’re left with the rotten egg smell. Now if you’ve got an internal combustion forklift, the alternator could be overcharging your battery also resulting in the funky smell.

So now I know why it smells, but what do I do now?

First thing’s first: Turn that charger off and let the battery cool down. No one likes boiling sulfuric acid. For safety reasons, place a tag on the battery to make sure no one uses it. Get in contact with a professional to check out your battery and charger. Have the professional replace the bad cell. If you can’t replace the cell, replace the battery. Following the replacement of the battery or the battery cell, check to see if your charger is working properly. No one wants to buy a new battery only to have it ruined by a bad battery charger.

What caused my battery to fail?

Assuming that it wasn’t your battery charger that was the problem, there are a few things that may have caused your battery to fail.

Water – If the water that you add to the battery is full of dissolved minerals, the minerals can accumulate making it rather difficult for the battery to take a charge. This can cause the cell to overheat.
Warehouse Floor – Working on an uneven floor can jar the forklift battery, knocking the oxide paste off of the plates causing them to short out.
Manufacturer’s Defect – Every now and then a battery may flat out under-perform. This can be due to a defect in the battery. Check with the manufacturer of the battery in regards to warranty information as many times they will be covered for a certain number of years.

Where to go from here.

Thinking your forklift battery charger is the problem?

Here are some helpful links:

Guide to selecting a new battery charger

Battery charger catalog

Need forklift parts? With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Parts Company, LLC

How old is my Taylor Dunn?

June 22, 2016

So how old is my Taylor Dunn vehicle?

Taylor Dunn shipped off their first commercial vehicle back in 1949. Being that they have been in business for 67 or so years, they have released a variety of different models and vehicle types. To make your life easier and to solve the mystery of when your vehicle was made, we have provided a chart that displays vehicle history by serial number starting with 1965. The chart shows all the serial numbers created for each year. For example, in 1994 the first serial number is 107340 and the last serial number is 112189. If your vehicle has a serial number either matching those numbers or is in between those numbers, it’s a 1994 model. That chart is available here: TD Vehicle History by Serial Number

Popular replacement parts for Taylor Dunn vehicles:

The parts listed below are all best sellers for Taylor Dunn vehicles. Click on the product name to learn more about the selected part. Going from left to right: Solenoid, Non-Asbestos Brake Pads, Ball Bearing, Sliding J Hook Bar, 10A Circuit Breaker, Hex Bolt.

Need parts for a Taylor Dunn vehicle? With thousands of parts in stock, quick shipping and great customer service, Intella Parts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Looking for more taylor dunn parts? Intella Parts can help!

Post by Intella Parts Company, LLC

Tagged forklift, taylor dunn

Forklift Forks: Everything you need to know

June 13, 2016

What good is your forklift without a great pair of forks??

Forklift forks will start to get worn the first day of use. If you’re company is one that often uses a lift truck, then it’s a very, very good idea to regularly inspect the forks. Now there are a few things to look for while inspecting the forks. The thickness of the fork blade should match the thickness of the back of the fork. The heel of the fork must be checked for cracks. Make sure there is no differentiating height of the fork tips. You must be able to read the factory markings of the forks. Also, the hooks of the forks must be checked for any deformations. If a problem occurs with any of these inspection points, the forks must be replaced. Lucky for you, Intella Parts carries all sorts and sizes of quality forklift forks and accessories. Our forks are manufactured to meet or exceed two major specifications: ISO2330 and ANSI (The American National Standards Institute). Intella also offers a variety of special application forks which discussed later in the article.

Not sure what class your forks are in? Check out our video below.

Common Class 2 Forks:

1.50 x 4 x 42 Forklift Forks

We can use your own carrier for shipping as well. Please call us at 616-796-6638

Lift capacity per pair (2 forks): 5500 pounds at 20 inch load center.
Price is per pair of forklift forks.

1.75 x 4 x 48 Forklift Forks

We can use your own carrier for shipping as well. Please call us at 616-796-6638

to arrange for shipping this way.

Lift capacity per pair (2 forks): 5720 pounds at 20 inch load center.
Price is per pair of forklift forks.

Specialty Forklift Forks:

We know there are many different jobs out there and basic forks may not get the job done. That’s why here at Intella we offer a list of different forklift fork types that can be special ordered so you can tackle that task at hand. Below is a list of all the different types of forks and their general applications. For more information on where to order these special application forks, visit our website here: http://store.intellaliftparts.com/c/Forks.html

Anti-Slip Forks

Durable abrasive coating applied to top of blade
Designed to be used for handling pallets made of plastic
Provides a jagged surface to properly grip the pallet
Adds minimal thickness while ensuring the safety of product while moving and stopping

Block Forks

Used for lifting large concrete or cement blocks
The heel is forged enlarged for maximum strength upon lifting
Heel can be ordered “concave” in order to reduce damage of the product
Can be ordered in any length needed to complete job at hand

Bolt-On Forks

Attached to the fork carrier with bolts instead of using hooks or a tube
Allows for more stable forks and limits movement when loaded
Reduces overall deflection in the upright of fork
Can be either bolted from the front or the back

Coil Forks

Primarily used to move steel coils, reels, and concrete pipes
Can be forged to have either chamfer or radius edges on the blades
Top of the upright can also be rounded in order to reduce possible damage
Chamfer and radius edges have different lifting capacities

Corrugated Forks

Blade reduced in thickness down to an edge at the tip
Used to wedge under and lift corrugated sheets resting on a flat surface
Polished and fully top tapered blade allowing for easy transition in thickness
Also available with full bottom taper and in many different widths

DAGS Magnetic Fork Covers

Used in situations where products could be damaged from contact with bare forks
Features a rubber layer, iron core, and magnetic layer
You can install or remove them in seconds

Drum Forks

Made for lifting one or two drums at one time
Both blades have an arc on the inside edge to match with the diameter of the drum
Usually used for moving standard 44/55 Canadian and US gallon drum
Can still be used to lift conventional loads

Folding Forks

Designed to fold at the heel of the fork and placed vertically.
Allows for storing forklift in restricted work environments and easier transportation
Contains chain that attaches to pin that wraps around the blade, keeping it secure

Fully Tapered FTP Forks

Fully tapered and polished forks are used in lumber, gypsum and finely finished goods
Have one long taper that starts past heel and extends down to tip
Polished with a smooth finish so that no material catches or drags on the fork
Usually thinner than standard taper and can be refined to chisel tip

Gypsum Forks

Forks are used to protect the product at hand, especially gypsum wallboard
Fork upright contains a durable slide pad, made of either polyurethane or neoprene
Polished blade with sharp corners removed
Hook or shaft type mountings available

Inverted Forks

Forks mounted upside down typically used for lifting large bags that have loops above product
Upper load bearing hook fitted relative to the back die radius
Top of the blade is rounded not to harm the straps of the bags
Capacity rating of the forks are reduced by 15% due to inverted angle

Offset and Inset Forks

Offset forks designed to enable the forks to be wider than the carriage
Inset forks designed to enable the forks to be narrower than the carriage
By doing this, load capacity must be re-evaluated

Peek-A-Boo (PAB) Forks

Created to expand the visibility of the driver
Wide fork type, used mostly in the lumber industry
Shank width is reduced which is possible due to diminished stress exerted on the fork
Can be custom ordered for fit

Quick Detach Forks

Designed to be quickly and easily removed from the carriage
Have an upper hook that allows for removal of forks without having to take off fork retaining bar
Have an open style hook which can fit on either a round or square carriage bar

Shaft Forks

Allow for a floating function for use in areas of uneven grounds
Usually used on larger lift trucks and construction machinery
Pin suspension of fork is used to guide it on a shaft previously mounted on machine

Spark Retardant Forks

Used on forklifts operating in hazardous conditions
Other than upright backing, fork is coated in brass to retard sparks
Common in chemical plants, grain elevators, mines, paint plants, munitions and arsenal manufacturing

Tin Plate Forks

Primarily used to load can forming machines
Tapered and offset tips allow for easier access into small skids
Option of a neoprene or polyurethane slide-in pad to protect product
Can be mounted with hooks or tubes

Tire Forks

Used for lifting tires of all different shapes and sizes
Forks have a custom radius on top inside of blade, finished with rounded edges to prevent damage
Can have an economical 45 degree edge or tire contour on the edge of blade

Two-Stage Taper Forks

Forks designed for increased stability when handling longer or deep stacks of lumber
Shorter but more durable tip for easier entry into lumber stack
20% from fork tip is 50% of full thickness which can reduce fork deflection
Option of polishing top of fork blade

Frequently asked questions regarding forklift forks:

http://store.intellaliftparts.com/FAQS.html

Need forklift forks? Intella Parts has what you need.

Post by Intella Parts Company, LLC

Tagged forklift forks

Impco Model J Regulator and Friends

June 9, 2016

The Impco Model J Regulator is a fantastic product, but like all machine parts, get worn out and need care. This blog page is dedicated to repairing and/or replacing your regulator. Impco is a manufacturer of fuel system components that has been around since 1958. Impco works with fuel system components for alternative fuels like LPG/propane gas that allow for a cleaner environment. You can find Impco parts in a variety of different forklift brands such as Hyster, Nissan, Toyota, Yale and many others. Intella carries the most popular pressure regulator, the Impco Model J, along with a few other models, accessories and kits.

How to Repair and Rebuild Your Impco Model J Regulator:

Full Replacements:

So your regulator is on it’s way to the forklift graveyard? Have no fear. Here at Intella we have a couple different models so you can find the perfect replacement to get your forklift running smooth again.

Classic model: Impco Model J Regulator

The Impco Model J regulator/vaporizer delivers reliable performance and pressure output consistency. It’s reliability, especially with questionable fuel quality, has made it an industry standard for many years. Two vapor outlet pressures are available. The standard Impco Model JB (this version, meaning blue spring) provides -1.5″wc (0.37 kPa). The optional JO (J-orange) provides 0.5″ wc (0.12 wPa). The port size and mounting pad locations are identical to the Impco Cobra regulator and include a primary pressure test port and “left” or “right” fuel outlets.

Replaces:
Hyster 0213549
Nissan 16310-90H71
Nissan 16310-90H72
Toyota 23530-U2000-71
Toyota 23530-U2001-71
Yale 517079800

Base model: Generic Model JB Regulator

The generic model JB regulator and the Impco Model J are similar in build, although a noticeable difference would be the primer button found on the generic model JB. Impco no longer manufactures Model J’s with a primer button but the generic model JB does have one. The primer button can allow for a shot of propane into the engine for starting purposes. The “B” stands for blue spring. This is by far the most common model J regulator. The blue spring offers negative 0.37 kPa (1.5 inches w.c.). The Impco Model JB diaphragm is made of hydrin and is suitable for most applications.

Repair Kits:

Don’t think you need a brand new regulator? Save some money and pick up a rebuild kit. You can repair and rebuild Model J Regulators using kits made of hydrin or silicone. You can rebuild a Model J regulator as many times as you can get your paws on a rebuild kit. Oh and you’re in luck because here at Intella, we regularly stock a few different kits.

What’s the difference between hydrin and silicone you ask?

Well to start off, silicone performs better in colder climates than hydrin. This is due to the fact that the silicone diaphragm stays noticeably more flexible in colder weather. The physical makeup of silicone is actually lighter than hydrin too, making a little bit more responsive. Lastly and very advantageous, is that silicone has a better resistance to being damaged from fuel.

Classic Kit: Impco Model J Repair Kit

Most common Impco regulator repair kit, mostly used on forklift propane fuel systems. Repair kit for the popular Model J forklift LPG regulator. Includes hydrin diaphragm, secondary seats, gaskets and primary diaphragm. Exactly what you need to rebuild an Impco Model J regulator.

If you need parts, Intella can help. We have thousands of parts available at great prices and would be happy to help you find what you’re looking for. Click here for more information! Also you can check out Intella’s YouTube channel for how-to videos and product demos.

Post by Intella Parts Company, LLC

Tagged impco lpg, impco model j, impco regulator

Forklift Parts: The People’s Favorites

June 3, 2016

Note: Shop JCB parts online now!

Forklift Parts – Who Knew Some Parts Could Be So Popular?

Maybe not the high school quarterback, but almost just as popular, these forklift parts are some of the most sought out products here at Intella. This week’s blog from your favorite parts dealer will be discussing the most searched upon terms. What’s everyone really looking for when clicking on that trusty Google Search bar? Well keep reading to find out!

Intella Forklift Blue Light

When working with heavy and possibly dangerous products, I’ve always been told safety first. This principle seems to hold true as the Intella Blue Spot Light is one of the most searched about forklift parts we sell here at the Intella headquarters. Since 2012, we’ve actually sold more blue lights than anyone else in the USA. Not bad I’d say, but it’s not our marketing department doing the work. These Blue Spot Lights really speak for themselves. They are UL listed and created for the toughest of environments, built with a metal casing and stainless steel hardware. Not to mention you can use this light on almost any forklift, whether electric, LPG or diesel powered. This LED light is also extremely long life, with a span greater than 20,000 hours.

*Maybe you just drank 3 pots of coffee and 2 Red Bulls one Friday afternoon and decide you want to jump the loading dock with your forklift. Well here’s some good news since this stunt will probably end with bad news; the Blue Spot has a 12 month warranty so we’ll replace it for you (just not the rest of the forklift).

BLUE SPOT SPECS: Click Here

Tie Rod (includes bearing and nut)

Your forklift’s engine can be in great working condition for years on end. This is great! Unfortunately, the rest of the forklift does not have the same capability. Every time you use your steering wheel (nearly every time you use your forklift), it puts stress on the tie rod ends. So as you can see, they must be replaced over time due to wear and tear. This tie rod end is a direct replacement for Hyster part number 185870. This part also includes the bearing and nut needed for proper assembly.

Intella Single Phase 36V/140A Lift Truck Battery Charger

If you don’t have a working battery, it’s a safe assumption that you aren’t going to be moving very far and if you can’t move, neither will your product. With a quality battery charger this problem can be diminished. Coming up 3rd for the most sought out forklift parts would be this 36 volt 140 amp single phase charger.

Tech:
• Charging profile suitable for single and double shift operations
• Automatic equalizing/preservation
• Charging profile control by microprocessor
• Automatic start, charging process and shut off
• Advanced visualization by 5 LED’s /Date storage memory
• External optional keypad for programming and diagnostic.
• Delayed start to avoid sparks

A little fuzzy on how to pick the right forklift charger? Don’t worry we’re here to help. Click here for a free guide.

12-24V LED Worklamp

It’s time to brighten up your day with this high performance LED work light. It’s no wonder these are such a popular product here at Intella. With 5 LED’s putting out 1050 lumens, you can really boost your workplace productivity. This light is easy to install and remove from your lift truck. A clear acrylic lens protect the LED’s along with a black painted aluminum shell. This light can be operated within a range of 12 volts to 24 volts.

Amp draw: 0.9 amp at 12 volts

0.47 amp at 24 volts

LED WORKLAMP SPECS: Click Here

Impco Model J Regulator

The Impco Model J Regulator. From it’s consistency year to year to it’s reliable performance in all situations, much can be said about this product. This has given Impco an industry standard image for it’s various models. The Impco Model J features a silicone diaphragm and a blue spring. It also has three vapor outlet pressures.

This regulator replaces:

Hyster 0213549
Nissan 16310-90H71
Nissan 16310-90H72
Toyota 23530-U2000-71
Toyota 23530-U2001-71
Yale 517079800

Another commonly searched upon product is the rebuild kit for the Model J. For details on that product, click here. Also, for those wondering how to do repairs on a Model J, you can watch the video below.

If you need parts, Intella can help. We have thousands of parts available at great prices and would be happy to help you find what you’re looking for. Click here for more information!

Also you can check out Intella’s YouTube channel for how-to videos and product demos.

Post by Intella Parts Company, LLC

Tagged blue spot light, forklift battery charger, forklift blue light, forklift tie rod, forklift worklamp, impco model j, impco regulator, LED work light, single phase charger, tie rod end

Toyota Forklift Parts: Top 5 Selling Products

June 1, 2016

The first ever Toyota forklift was produced in 1956. It has been some time since then and things have changed. Toyota forklifts today receive some of the highest brand ratings so it’s no wonder why we sell so many of their parts and replacements. To compliment the company’s work, we will cover the top 5 selling Toyota forklift parts in today’s market.

1) Toyota 2 Sided Key

Toyota forklift parts — 2 Sided Key – part no. 57591-23330-71

At number 1, we have a Toyota key to start off the list (no pun intended). We here at Intella know you jump for joy when you see your forklift. You want to hop in and get cruising around a fast as possible, we get it. Well with the help of the aftermarket double sided key, you can start your lift truck just that much quicker. Not long ago, forklifts came with one sided keys until it was decided the teeth would be cut into both sides. This allows for a quicker start, reducing the time you may be fumbling around with a traditional key. This key is most commonly used on the 7 and 8 series Toyota forklifts.

2) Toyota Forklift Seat

Forklift seats can take a beating and often need to be replaced. That might give some reason as to why this replacement Toyota forklift seat ranks number 2 on our list of parts. Although designed for Toyota 6 and 7 series forklifts, this seat can be made to fit on almost all forklift brands with a little work. Featuring a wingback style seat, driver safety is increased as you are more protected from sliding off the forklift. This is a black vinyl, semi-suspension seat equipped with a retractable seat belt. This low cost, high quality seat also includes mounting rails.

*Two thumbs up*

For an inside look, check out our video:

For those who have this seat or are thinking about

purchasing one, you can see how to properly install it here:

3) Toyota LPG/Propane Filter Pad

Coming in at number 3 on our list of Toyota forklift parts is the LPG/Propane Filter Pad. If your fuel regulator isn’t running as it should be, try picking up a new filter pad for a quick and also cheap fix. Ranking 3rd on the list of most sold Toyota forklift parts, it’s clear this pad is replaced from time to time.

For those who have picked up this filter pad or are thinking

of doing so, check this video out on how to quickly replace it:

4) Toyota LPG/Propane Filter Kit

Big number 4 on our list of Toyota forklift parts would be the LPG/Propane Filter Kit. A new fuel regulator can be expensive, and from what I’ve learned, spending less money is a good thing. Instead of trashing your regulator, check out the Toyota filter rebuild kit. Sometimes a new set of filters is all you need to get your regulator running correctly again.

For those who have purchased the kit or are

thinking about it, here’s a short installation video:

5) Toyota Forklift Oil Filter

Not all products sold are glamorous ones, but the filter pictured here sure is an effective one. At number 5 we have a top quality, replacement Toyota oil filter. This filter is a spin-on type filter designed for Toyota 4Y engines.

You can get your Toyota parts online along with a bunch of other forklift brands at store.intellaliftparts.com. We have thousands of forklift parts online. Call us today 616-796-6638.

Post by Intella Parts Company, LLC

Tagged toyota forklift key, toyota forklift oil filter, toyota forklift parts, toyota forklift parts online, toyota forklift seat, toyota forklift seats, toyota key, toyota keys, toyota oil filter, toyota replacement key