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How to fix Clark forklift brakes

Clark forklift brake systems are fairly straight forward to work on. Some have wet brakes, others utilize traditional brake shoe brake set ups. This tutorial will show you how to replace brakes on a Clark forklift with brake shoes.

Remove hardware

Remove studs

Cap the brake line

Remove wheel cylinder

Spray down and clean assembly with brake parts cleaner

Re-install wheel cylinder

Use Loctite on studs

Most hardware can be re-used.

Re-install brake hardware

Install new brake shoes

Press-in new seals

Re-install new wheel bearing

Re-install brake drum

Re-install cushion tire and wheel

For full video: Click Here


Post by Intella Liftparts

How to replace a Toyota forklift seat

Toyota forklifts with model numbers that begin with 6 or 7 (like 6FGCU25 or 7FGCU25) use unique seats custom designed for Toyota.

Intella offers aftermarket replacements for these seats. There are no replacement cushions available for these seats because of the design of the seat.

It’s super easy to replace a seat yourself, all you need are a socket set and a little mechanical ability.

Swing out the LPG tank. There’s a latch on the back near the tank which will allow you to swing it out.

Slide the old seat all the way forward

Find the hood release and open the hood

Remove 4 bolts from the bottom of the forklift seat deck.

Remove the old seat

Fit the new seat in place. Our seat will fit exactly, no drilling should be required.

Fasten in place with new bolts

For full video: Click here


Post by Intella Liftparts

How to fix Aisan fuel regulator

Aisan fuel systems are used in a variety of different forklifts including Toyota, Hyster, and Yale. Aisan is partly owned by Toyota so you see mostly Aisan in Toyota forklifts.

Rebuilding an Aisan regulator is a bit more difficult than the traditional and popular Impco model J. Depending on your skill level, you might want to simply replace the entire unit.

Remove solenoid from unit

Remove back studs with socket

Remove seals and pad

Remove screws

Remove parts from new Aisan repair kit

Re-install valve parts

Re-install back cover

Install diaphragm

Install o-ring and spring

Re-install pad and oring

Re-install sintered metal filter

Re-install solenoid

For full video: Click Here


Post by Intella Liftparts

How to fix forklift steer axle

Steer axles take a beating on forklifts. There are a number of wear components which wear out and get damaged. In this tutorial you’ll see how to replace some of the most common wear items.

Intella Liftparts also offers complete remanufactured axles as well. This might be the best option if you have extreme wear on the cast portion of the steer axle.

Install new needle bearings

Check fit and install new king pin

Re-install knuckle

Install shims and thrust bearings

Check operation of knuckle

Install bearings on opposite side

Tap out bearing for cylinder mounting

Try fit on dog bone link

Install pins

Install pins and dog bone on opposite side of knuckle

Install grease fittings

Apply grease to each grease fitting

For full video: Click here


Post by Intella Liftparts

How to replace a forklift master cylinder

Forklift brake systems typically use a master cylinder often mounted beneath the operator floor panel. Remove the floor panels, find the master cylinder and go to work. This tutorial will show the replacement of a master cylinder on a Hyster 5000 pound forklift.

Remove old unit

Remove old unit

Remove lines

Install new master cylinder

Re-install pin and retaining clip

Fill reservoir with brake fluid

Test system/make adjustments

Bleed excess air from system

For full video: click here


Post by Intella Liftparts

The most common forklift service call

One of the most common forklift complaints from forklift operators is a noticeable propane gas smell around the forklift. Frequently forklift operators will call service companies complaining that their forklift has a leak. Often the problem is not with the forklift but with the propane tank.

This tutorial will show how to replace 2 o-rings on the propane tank and eliminate one of the most common complaints from forklift operators.

Remove the existing o-rings

There’s a square style o-ring and a round oring

Here’s a cross section view of how the o-rings are placed in the connector

Replace with new o-rings

For full video: click here


Post by Intella Liftparts

How to rebuild Impco model J regulator

The model J regulator is the most popular LPG regulator on the market today, yet it is no longer used in current models of forklifts due to emissions regulations.

Impco model J regulators are found in a most brands of forklifts along with other LPG powered equipment like Tennant or American Lincoln scrubber units and even Zamboni ice resurfacers.

Inside the model J are diaphragms made of hydrin or silicone. These wear out or tear and need to be replaced. The first decision you’ll have to make is if you want to replace the entire model J unit or rebuild the unit with a repair kit. Either decision is fine, it just depends on how you value your time.

You will see in the tutorial below that rebuilding a model J is pretty simple. There are times when a model J might be mounted inside a forklift where it’s easier to rebuild the unit instead replacing the entire unit. It just depends on the location of the model J.

One more note. Model J is Impco’s designation for an entire series of LPG regulators. There’s a method to how the Impco part numbers work:

Model JB = Model J with Blue spring. Blue spring units have Neg. 0.37 kPa pressure. This is the standard and most common model J.

Model JO = Model J with Orange spring. Orange spring units have Neg. 0.12 kPa pressure. This is the lease common model J. You should stick with the model J that is already installed in your forklift.

After the letters JB or JO, you sometimes see a -2 like this: JB-2. The -2 indicates the diaphragms are manufactured from silicone. No letter means the diaphragms are made from black hydrin rubber. Silicone (yellow) diaphragm material is the optional upgrade material that provides excellent flexibility in cold weather climates and is more resistant to chemical contamination. They can be used interchangeably, if you want to upgrade, go with the silicone material.

Remove screws from front of unit. The screws are typically 9-32 x 7/8″ Torx style

Remove diaphragm from inside cover

Remove lever. Screw is also a Torx screw

Remove the screws from the back of the model J unit.

Take the halves apart and remove the old diaphragm.

Re-install the diaphragms and metal seat.

Re-install cover and screws

Re-install cover and screws

For full video: click here


Post by Intella Liftparts

How To Fix Forklift Brakes

Forklift brakes are fairly straight forward to replace, especially for someone with automotive experience.  Forklift brake systems are traditional brake drum/brake shoe set ups, very similar to what an automobile would use in the 1960s and 1970s.  Most forklift manufacturers recommend a complete brake inspection every 2000 operating hours.  Brake system (shoes, drum, etc) are wear items are there’s no typical lifespan.  If you use your brakes a lot, you’ll need to replace brake shoes more frequently.  It probably goes without saying but brakes are only on the front axle on forklifts.  The rear axle does not have brakes.

This tutorial walks you through a typical forklift brake job.  The example forklift was a Toyota 6FGCU18 but the same system will be found on other brands of forklifts as well such as Hyster, Yale, CAT, Mitsubishi and others.  Wet disk brakes are a thing in the forklift industry but somewhat rare.  Clark, Doosan, and CAT used wet disk brakes throughout the years.  If you have a wet disk brake set up, the below tutorial will NOT apply for your forklift.

Block up forklift using a forklift jack

Remove wheel & tire

Remove axle shaft

Remove brake drum

Use aerosol brake cleaner to clean brake components and prepare for removal

Remove springs and hardware

Remove brake shoes

Pull wheel cylinder apart

Remove/re-install wheel cylinder backing plate

Install lever hardware on new brake shoes

Install wheel cylinder pins

Install new brake shoes

Re-install hardware and springs.

Often hardware and springs can be re-used when replacing brake shoes and/or wheel cylinder

Install new oil seal

Remove old gasket material, apply new material

Clean drum, inspect for wear

Remove old seals and tap in new seal

Re-install brake drum

Remove old gasket material, apply new material

Reinstall axle shaft

Tighten bolts

Reinstall tire and wheel

For full video: click here


Post by Intella Liftparts

Sprinter AC Compressors

AC Compressors Features & Benefits:

  • Manufactured using OE specifications & standards
    • High Output
    • Extended Durability
    • Exact Fit
    • Unmatched Reliability
    • Quiet Efficient Operation
  • Decreased horsepower drain due to lightweight piston design
  • 1 Year unlimited mile warranty

MakeModelYearEnginePositionOEM PinDENSO PinType
Dodge2500/35002002-20062.7 I-5 DieselMain (w/o Rr Air)5117666AA471-129310S17C
Dodge2500/3500 2007-20103.0 V6 DieselMainA0012303211471-14347SEU17C
Dodge2500/3500 2007-20103.0 V6 Diesel AuxiliaryA0012307111471-143510S17C
Freightliner2500/3500 2002-2006 2.7 I-5 DieselMain 5117666AA471-129310S17C
Mercedez Benz2500/3500 2014-20152.1L I-4 Diesel Main A0012303211471-14347SEU17C
Mercedez Benz 2500/3500 2014-2015 2.1L I-4 Diesel Auxiliary A0012307111471-143510S17C
Mercedez Benz 2500/3500 2007-20143.0 V6 Diesel Main A0012303211471-14347SEU17C
Mercedez Benz 2500/3500 2007-20143.0 V6 Diesel Auxiliary A0012307111471-143510S17C

Sprinter AC Compressor PDF


Post by Intella Liftparts

Aftermarket New DPF Units for Cummins, Mack, and More

PowerEdge Diesel After-treatment is used to retain soot, a byproduct of diesel engines. In addition, Diesel Particulate Filters, or DPFs, meet 99% of the demand for DPFs. DPFs reduce soot emissions by 85% meaning that they are extremely effective.

PowerEdge uses high end materials to ensure the quality of their DPFs. Materials include:

  • High-grade stainless steel – improve durability
  • Advanced filter coating – reduce active regeneration
  • Tested to reduce backpressure – enhanced performance (85% of DPM, or soot, is removed)
  • Increased thermal efficiency as well as stability
  • Three year / unlimited mileage warranty

Our most popular DPFs include the following part numbers.  Click on the links below to learn more!

Brand – Part Number


Post by Intella Liftparts