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How to Paint a Forklift

Need help deciding which paint you need? Click here!

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

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

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

  6. remove install carriage
  7. 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.

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

  9. Remove the cross head (12) from the shaft.
  10. Remove the carriage bolts (13).

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

  12. remove forklift carriage
  13. Remove the carriage from the bottom of the inner mast (15). Carriage (14) weighs 255 lb.
  14. Raise the inner mast to put in the carriage onto the mast and lower the inner mast to cover the carriage (1) bearing fully.
  15. Install the carriage bolts (13).
  16. Now, install the cross head(12) and retaining ring (11).
  17. install forklift carriage
  18. 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.

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

  20. install carriage
  21. 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
  3. Next, remove the four lower roller bearings (3) and the shims from the carriage.

  4. disassemble forklift carriage
  5. 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
  4. 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.

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

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

  10. 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

How to Replace Forklift Mast Rollers

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

How to Calculate Forklift Capacity With Attachments

Calculating the forklift capacity is critical for safely and efficiently operating equipment. To start, let’s define what load center is of a forklift. The load center is the horizontal distance from the center of mass to the forklift itself, or, in simpler terms, the middle of the load.

forklift capacity load center
The load center is located where the arrow is pointing

The load center is relevant as it specifies how far you can place your mass before the forklift will be over in either direction.

Calculate Forklift Capacity

To start, each lift truck is given specific ratings that specify relevant information, these are typically found on the truck name plate. This same principle applies for attachments. The first rating will give the maximum fork height, and the second rating will give the increased capacity amount at a lower fork height.

Each attachment is given a reduction factor that is to be used to calculate the forklift capacity.

Example 1: The image below gives an example of a capacity name plate where the information is already filled out. The attachment that is applied has a reduction factor of 1,500 lbs. Given that the original maximum capacity, without the attachment, is 8,000 lbs, we simply do 8,000 – 1,500 = 6,000 lbs to calculate forklift capacity with the attachment.

forklift capacity name plate
Capacity name plate

Example 2: Technical data sheets give very helpful information as to how to calculate the capacity. Let’s say you add a paper roll clamp on a gas, cushion tire, 6,000 lb. truck that has a mass of 102/228. This would bring us to the last row of the technical data sheet.

The capacity with forklift forks is 4,150 lbs (24″ load center, 228″ fork height) and a rated capacity of 6,000 lbs (24″ load center, 228″ height). For this scenario, let’s say it is given that the reduction factor for a 6,000 lb truck is 1,700 lbs. Because there are more than one rated capacities, you take the lowest after applying the reduction factor. 6,000 – 1700 = 4,300 lbs and 4,150 – 1700 = 2,250

Technical data sheet

Want to learn more about basic lift truck terminology, technical aspects of forklifts, etc?

Click here to read the entire PDF.

An easy on line tool is available for this as well.   Cascade publishes an online tool where you can enter your technical specifications of your existing forklift, specifications from the attachment, and then determine the new, lower capacity of your forklift with the new attachment installed on it.  Click here.


Post by Intella Parts Company, LLC

New Raymond Joystick Parts Offered!

These new Raymond joystick parts are now offered at Intella Parts! Order today.

Part Number Price
828-009-630/019 $782.55
828-009-630/013 $782.55
828-009-630/007 $782.55
114-120-264/004 $944.30
828-006-161/017 $791.60
828-006-161/013 $791.60
828-006-214 $784.30
828-009-630/014 $876.30
154-012-422/003 $863.50
828-006-154/007 $467.79
950-blu/grd $96.81

 


Post by Intella Parts Company, LLC

Avoid injuries changing forklift tanks!

A completely full forklift propane tank weighs nearly 40 pounds! And if your facility requires operators to switch out tanks, it can be a injury waiting to happen! We’ve got the perfect solution. Replace your standard forklift tank bracket with our swing out, tilt down forklift tank bracket.

Newer forklifts such as Toyota, Hyster, Yale, and CAT offer this as an option on their newest forklifts. Now you can add this to older existing forklifts.

LPG tanks can be hard to tank out, that’s why swing out brackets were invented. Swing out and drop down tank brackets offer an easy way to change your LPG tank on your propane forklift. Here is what they look like in action:

Intella offers these brackets at an awesome price. Order today!


Post by Intella Parts Company, LLC

How to Replace Load Wheels

The load wheels of a machine are primarily responsible for carrying the load, and typically carry the braking system making them a vital component of its respective machine, thus making it important to replace load wheels when needed. Depending on the material that your machine drives on will determine what type of material is needed.

Common materials include the following: polyurethane, nylon, steel and rubber. In addition to material type, level of hardness is also a key attribute. With these components comes a difficult decision: which material do I need for MY machinery?

Load Wheels By Brand

Out of convenience, Intella separates them by brand of forklift. We offer load wheels for the following brands: Yale, Clark, Hyster, Toyota, Crown, Raymond, and CAT.

How to Replace Load Wheels

We made a step by step YouTube video on how to replace load wheels. Here are all the steps:

Step 1: Remove Roll Pin and Pivot Pin

replace load wheels

Step 2: Punch New Bearings In

replace load wheels

Step 3: Install Wheel in New Riser

replace load wheels

Step 4: Tap in Roll Pins

replace load wheel

Step 5: Install New Pivot Pin in Riser/Link

replace load wheels

Step 6: Install Riser into Jack. Install New Roll Pins

replace load wheels

Step 7: Apply Grease, Install Riser into Jack

replace load wheels

Step 8: Install New Bearings into Wheels

replace load wheels

Step 9: Install New Wheel

Step 10: Apply Grease

Click here to watch the entire video.


Why Buy?

All of these forklift brands–Yale, Clark, Hyster, Toyota, Crown, Raymond, CAT— don’t manufacture their own load wheels, so when you buy from Intella, you’re most likely buying from the same suppliers as them ensuring that the load wheel you purchase fits the model you use. Intella also offers the best parts prices across the internet!

Need help?

Unsure of which one you need? Give us a call at 616-796-6638 (or email us at [email protected]) for a product lookup and experience our top notch customer service!


Post by Intella Parts Company, LLC

We’ve Reduced our Rates on air Freight!

Intella is pleased to announce that we have reduced our rates on next day air and second day air services.

Our handy shipping calculator which can be found on each product page will give you an estimate of what shipping charges will be.  We ship from over 12 different warehouses in the USA so you can be certain you’ll get your part fast!

If you’re located in Alaska, Hawaii, Guam, Puerto Rico or other USA territories, we also ship USPS.  USPS has very competitive rates to these remote areas.

Where we ship from…

intella air freight

Post by Intella Parts Company, LLC

How Long does an Electric Forklift Last?

Electric forklifts contribute to an electrical revolution– gas vehicle market share is slowly decreasing as EVs are produced– and forklifts are no different. “How long will an electric forklift last” is a very common question, and this blog will outline what factors to look at when deciding whether or not to replace an electric forklift.

1. Cost of Maintenance vs Cost of Replacement

A key factor to consider when considering replacing a forklift, whether electric or not, is cost of maintenance versus the cost of replacement. Once the cost of maintenance exceeds the cost of replacement, it is time to replace your forklift, as all money spent on maintenance is essentially lost money. The primary maintenance cost is battery replacement (which can be very expensive).

electric toyota forklift
Electric Toyota Forklift

2. Amount of Charges

The amount of times that an electric forklift is charged determines how long the forklift will last as the batteries will wear out. On average, an electric forklift lasts 1,400 charges (6-8 hours per charge), which will result in about 5-7 years of usage, depending on how often it is used. If your forklift is getting close to the 5-7 year old range, it might be time to replace it.

3. Heavy vs Light Load

Next, a big factor into an electric forklift’s longevity is daily load. If using a larger load, expect see a 6-12 month decrease in lifespan due to wear and tear. If your forklift typically lifts a heavy load regularly, consider replacing it sooner.

4. Inclement Weather

If a forklift experiences cold weather, rain, or snow often, it will contribute to a decreased lifespan.

5. Quality of Maintenance

Typically, electric forklifts have much less maintenance due to how fewer parts they have than that of an ICE (internal combustion engine) forklift. With that being said, batteries can and do break. A well maintained battery will go a long way in improving an electric forklift’s longevity.

Conclusion

In conclusion, electric forklifts have much less factors to considering than that of an ICE. Replacing a forklift can be hassle, luckily, Intella offers a wide array of electric parts! This includes motors, engine electrical parts, motor brushes, Anderson Battery Connectors, and more!

Unsure of which parts you need? Give us a call at 616-796-6638!


Post by Intella Parts Company, LLC

How Much Does a New Forklift Cost?

Making a decision on which forklift your company should purchase is not an easy and ephemeral one. There are multiple factors that may contribute to a forklift’s cost. This can include: cost of battery or type of engine — depending on if you want an electric forklift or not.

Typical Cost of a New Forklift


Q: How much does a new LPG forklift cost in 2021?Hyster S50FT

A: A new Hyster S50FT LPG forklift would cost $28,500 in 2021.

 

electric forkliftQ: How much does a new electric forklift cost in 2021?

A: A new electric forklift costs $37,000 in 2021.

 

Factors to Consider When Buying a New Forklift

We understand that forklift cost is a key, if not the most important, factor when considering to purchase a forklift. With that being said, there are a number of different characteristics that different forklifts provide that you may need for an optimal forklift experience.

Gas vs Electric

As the world slowly moves from gas vehicles to EVs, the forklift industry is no different. Forklifts are still made as propane-based and are typically cheaper than an electric equivalent.

With that being said, the price of refilling a tank for a propane forklift is much higher than the cost of recharging a battery. In addition, maintenance for a propane forklift is typically higher than that of an electric one.

Brand of Forklift

There are a plethora of forklift manufacturers, all producing quality models. However, each manufacturer offers different manuals and parts numbers, and the quality of this contributes to an important characteristic of ease of getting aftermarket parts. Luckily, here at Intella we offer full customer support and access to parts for every forklift manufacturer.

Operator’s Preference

When purchasing a forklift, it is important to consider the opinion of the operator, as they are the ones that have to ride the machinery for multiple continuous hours.


Have any Questions?

If you have any questions regarding what parts you need or what model of forklift you need, call us at 616-796-6638 or email us at [email protected]!


Post by Intella Parts Company, LLC