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Monthly Archives: March 2022

How to Paint a Forklift

Need help deciding which paint you need? Click here!

Why It is Important to Know How to Paint a Forklift

Knowing how to properly paint a forklift is crucial for maintaining the structure and integrity of the surface. This article will outline how to properly paint a forklift.

how to paint a forklift

Overall Principles

  1. Surface Preparation is Crucial

    Coating performance and longevity is directly related to surface preparation. Approximately 80% of all coating failures can be attributed to improper surface preparation. Choosing which method to use to prepare the surface is dependent on surface material, current paint, pain going to be used, and environment.

  2. Previously Coated Surfaces

    All previous contamination, such as oil, grease, loose paint, dirt, and overall foreign contaminants, needs to be removed before applying a new coat of paint.

  3. Touch-Up, Maintenance, and Repair

    In order for a proper coating to last a long time, scheduled maintenance must be performed to maintain coat integrity. This includes, but is not limited to: inspection of painted areas, removing oils, removing foreign chemicals, and removing all other foreign contaminants.

Removing Previous Coats & SSPC/NACE Standards

  1. SSPC-SP-1 Solvent Cleaning

    This is a method that removes all visible oil, grease, soil, drawing and all other foreign contaminants. Click here to learn more.

  2. SSPC-SP-2 Hand Tool Cleaning

    This method removes all loose mill scale, rust, and other foreign matter. Before using this method, remove all oil, grease, welding residues, and salts. Click here to learn more.

  3. SSPC-SP-3 Power Tool Cleaning

    Similarly to the previous method, Power Tool Cleaning helps remove loose mill scale, rust, and other foreign matter. In that sense, Power Tool Cleaning is nearly identical to the Hand Tool Cleaning method. Click here to learn more.

  4. Blast Cleaning

    The following methods remove all oil, grease, dirt, dust, mill scale, rust, pain, and oxides should all be removed making them extremely effective methods.

    1. SSPC-SP5/NACE1 White Metal Blast Cleaning
    2. SSPC-SP6/NACE3 Commercial Blasting Cleaning
    3. SSPC-SP7/NACE4 Brush-Off Blast Cleaning
    4. SSPC-SP10/NACE2 Near-White Blast Cleaning
  5. SSPC-SP12/NACE5 High and Ultra-High

    This method utilizes high and ultra-high water pressure water jetting to remove various foreign material.

Click here to read full manual

Conclusion

To properly paint a forklift, a proper and thorough paint removal procedure must be employed. This ensures that the next coat of paint will have a long lifespan. Have questions? Leave a comment below or call us at (616) 796-6638!


Post by Intella Parts Company, LLC
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How to Assemble and Disassemble a Forklift Carriage

JUMP-TO LINKS: Assemble Forklift Carriage, Disassemble Forklift Carriage

How To: Remove & Install Forklift Carriage

  1. To start, raise carriage (1), position a wooden block as shown, and lower carriage (1) onto the wooden block.

    2. remove carriage
  2. Next, disconnect two hydarulic lines (4) from side shifter cylinder. Plug and cap all openings to prevent contamination.

    3. install carriage
  3. Then, remove four bolts (8) from the chain guard/hose support assembly. Set the hoses aside away from the cylinder & cross head.

    4. remove install carriage
  4. Remove two bolts (10) from the hose mounting bracket and set the hoses aside. Then, remove the nuts (9) from the chain anchors and set them aside away from the clear of the mast.

  5. Now, use a tool to remove the retainer ring (11) from the cross head shift.

  6. Remove the cross head (12) from the shaft.
  7. Remove the carriage bolts (13).

  8. Raise the inner mast in order to pull out carriage.

    9. remove forklift carriage
  9. Remove the carriage from the bottom of the inner mast (15). Carriage (14) weighs 255 lb.
  10. Raise the inner mast to put in the carriage onto the mast and lower the inner mast to cover the carriage (1) bearing fully.
  11. Install the carriage bolts (13).
  12. Now, install the cross head(12) and retaining ring (11).
    13. install forklift carriage
  13. Put the chains in position over the cross head (12), install nuts (9) onto the chain anchors, and install the bolts (10) onto the hose mounting bracket.

  14. Install the chain guard and hose support assembly (6) and four bolts (8).

    15. install carriage
  15. Finally, connect two hydraulic lines (4) to their original positions. End by installing the backrest and the forks.

How To: Disassemble Forklift Carriage

  1. First, remove the roller pins & pins (2) to disconnect the chains (1).

    2. disassemble carriage
  2. Next, remove the four lower roller bearings (3) and the shims from the carriage.

    3. disassemble forklift carriage
  3. Finally, remove the screw (5) and washer (4) and remove the top roller bearings (6) and the shims.


How To: Assemble Forklift Carriage


Carriage Adjustment (3) Upper bearings. (4) Shims. (5) Bolts. (6) screw. (7) Middle bearings. (8) Lower Bearings. (A) Zero clearance. (B) 6.0-9.0mm. (C) Minimum CLearance.
  1. To start, select lower bearings from the belwo chart to obtain a minimum clearance (B) between bearings and channel leg for full channel length.

  2. Next, find the narrowest point by ruler on the inner mast in the area where the bearings make contact.

    3. assemble carriage
  3. Now, install enough shims (4) that have been equally divided behind the bearings (3). At installation, the should be no contact (zero clearance (A)) between bearings and the narrowest point, as described in step 2.

    4. assemble forklift carriage
  4. Then, do steps 2-3 for the other set of bearings (8) & (9).

    5. assemble forklift carriage
  5. Tighten screw (5) that holds the top bearings carriage. There should be a torque of 34 +/- 7 Nm (newton meters).
  6. Shim stop bolt (11) as required to obtain a 6-9 mm lap with top carriage stop on the inner upright.

  7. Finally, position the chains (6) on the carriage and install the pins (7) and the roll pins.

Got questions?


Give us a call at (616) 796-6638, or leave a reply below.


Post by Intella Parts Company, LLC
Tagged , , ,

How to Replace Forklift Mast Rollers

Purpose

This article will outline how to accurately and efficiently calculate which mast and carriage rollers are needed for a specific model in addition to answering how to replace forklift mast rollers. This includes: mast model, bearing part number, outer diameter size.

Installing Lift Bracket Rollers (for all mast models)

To disassemble, follow the sequence in reverse.

reassembly mast

Sequence:

1. Lift Bracket2. Lift bracket upper rollers3. Lift bracket middle rollers
4. Lift bracket lower rollers5. Side rollers6. Inner Mast

Definitions

Clearance G: clearance between roller side surface and inner mast thrust surface. This is used to determine the amount of shims at the bearing seat. Measure Clearance G between the side of the surface of the roller and inner mast. Measurement range: 0.1 to 0.5 mm (0.004 to 0.020 in.)

Clearance F: clearance between roller circumference and inner mast thrust surface. This is used to determine the proper size of the rollers. Measurement Range: 1.0 mm (0.04 in.) or less

Clearance G1: clearance between side roller circumference and inner mast side roller thrust surface. Measurement Range: 0.1 to 0.5 mm (0.004 to 0.020 in.)

Instructions

  1. Choosing Correct Roller Diameters

    Measure clearance F for upper roller 2, middle roller 3, and lower roller 4. If not in the range, replace the rollers. The rollers should function smoothly.

  2. Adjusting clearance G between the middle roller and thrust plate

    Measure clearance G between the middle roller and thrust plate. If not in the measurement range, adjust clearance G.

    If clearance G is too high, increase the thickness of shims, and vice versa.

  3. Adjusting clearance G between lower rollers and inner mast

    Measure clearance G between the lower rollers and inner mast. Adjust clearance G as described in the previous point.

  4. Installing main rollers

    Use a driving tool to properly install main rollers on shafts. Do not strike the outer roller surface while installing.

  5. Adjusting clearance G1 between the side roller and inner mast

    Measure the clearance of G1 between the side roller’s rolling contact surface and inner mast. If the measure is not in the range mentioned above, adjust the clearance in the following manner: if G1 clearance is excessive, increase the thickness of the shims and vice versa.

Diagram describing how to install main rollers

How to Replace Forklift Mast Rollers (for all mast models)

install mast rollers

Instructions

  1. Measure clearance F between the rollers’ contact surface and masts

    If this value is not in the range (1.0 mm / 0.04in, or less), replace with rollers with the correct diameters listed in the table below (figure 1)

  2. Measure clearance G between the rollers and the masts

    If the measured clearances exceeds the range (0.1 to 0.5mm, 0.004 to 0.020 in.)

All mast rollers are identical in shape and size. Thus, clearance F should be 1.0 mm (0.04 in.) or less and clearance G should be 0.1 to 0.5 mm (0.004 to 0.020 in.). If the measured clearances are incorrect, replace the rollers with the correct diameters listed in the below in figure 1.

If measured value clearance G exceeds the standard value, increase the thickness of shims (e) – (j). Standard values can be seen here:

Item1 ton class (mm)2, 3 ton classes (mm)
Shim (e)21
Shim (f)21
Shim (g)11
Shim (h)21
Shim (i)21
Shim (j)21
mast and carriage main rollers sizes
Figure 1

Where do I find the part numbers?

mast part number location

Have Questions?

Leave a comment below or gives us a call at (616) 796-6638 and we can help calculate your mast and carriage rollers!


Post by Intella Parts Company, LLC
Tagged ,