Forklift Resource Center Archives

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

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

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

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

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

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.

Replacing Brakes Overview

Brakes are vital to an equipment’s efficiency and usability. It’s important to replace brakes when they are worn down to maintain the safety of the operator and the wellbeing of the equipment. Luckily, replacing forklift brakes is not an overwhelming task and can be performed with just a little mechanical skill.

This tutorial will outline how to fix Clark forklift brakes with brake shoes.

clark forklift brake hardware

To start, remove hardware

how to fix clark forklift brake

Next, remove studs

Next, cap the brake line

Next, remove wheel cylinder

Next, spray down and clean assembly with brake parts cleaner

Next, re-install wheel cylinder

Next, use Loctite on studs

fix clark forklift brake

Most hardware can be re-used.

clark brake hardware

Then, Re-install brake hardware

Install new brake shoes

fix clark forklift brake

Press-in new seals

fix clark forklift brake bearing

Re-install new wheel bearing

clark brake drum

Re-install brake drum

Finally, Re-install cushion tire and wheel

Full video: Click Here

Intella Parts Company proudly sells a broad range of forklift parts for many forklift brands, including Clark. In addition, Intella offers industry renowned customer service! Call now at 616-796-6638!

Interested in more help to guides? Intella has a YouTube page!


Post by Intella Parts Company, LLC

How to Replace a Toyota Forklift Seat

A worn out seat is no fun, especially if you’re expected to sit in it for multiple continuous hours. Luckily, Intella offers a selection of replacement seats, and this blog will outline 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.

How to Replace Your Forklift Seat Yourself

It’s super easy to replace a Toyota forklift 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.

replace a toyota forklift seat

Slide the old seat all the way forward

Find the hood release and open the hood

replace a toyota forklift seat

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.

replace a toyota forklift seat

Fasten in place with new bolts

For full video: Click here

Need a toyota forklift seat or want to see our full lineup of our forklift seats? Intella Parts Company can help!

Have a question on how to replace a Toyota forklift seat? Call us at 616-798-6638.


Post by Intella Parts Company, LLC

How to fix an Aisan Fuel Regulator

“How to fix an Aisan fuel regulator” is a common question for equipment owners, so we, at Intella, decided to create an outline on how to fix one. Given how important the fuel regulator is to your equipment, it’s important to keep them well intact. This blog will give step by step directions on how to fix your regulator.


Brief Aisan Fuel Regulator Introduction

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 mainly see these regulators 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.

fix Aisan fuel regulator

Remove solenoid from unit

Remove back studs with socket

Fix Aisan fuel regulator

Remove seals and pad

Remove screws

Remove parts from new Aisan repair kit

Re-install valve parts

fix Aisan fuel regulator

Re-install back cover

Install diaphragm

Install o-ring and spring

Re-install pad and oring

Fix Aisan fuel regulator

Re-install sintered metal filter

Re-install solenoid

For full length YouTube video: Click Here

Looking to purchase an Aisan fuel regulator? Buy one here! If you have any other questions, please call us at 616-796-6638 and speak to one of our industry renowned customer support specialists.


Post by Intella Parts Company, LLC

How to Fix Forklift Steer Axle

This blog will give a picture based guide how to fix your 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 Parts 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.

Fix Forklift Steer Axle

fix forklift steer axle

Install new needle bearings

fix forklift steer axle

Check fit and install new king pin

Re-install knuckle

fix forklift steer axle

Install shims and thrust bearings

fix forklift steer axle

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

If you are looking to purchase a forklift steer axle, Intella Parts offers a wide selection of different options in addition to our massive selection of parts.

Unsure of which one you need? Give us a call at 616-796-6638 to speak with one of our customer support specialists and experience our industry renowned customer service!


Post by Intella Parts Company, LLC

How to Replace a Forklift Master Cylinder

How to replace a forklift master cylinder: Forklift brake systems typically use a master cylinder often mounted beneath the operator floor panel. The master cylinder is vital for your equipment’s brakes. The master cylinder works as a hydraulic pump that puts in brake fluid to convert brake pedal pressure into hydraulic pressure.

Instructions:

To start, 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 with a corresponding full video.

replace a forklift master cylinder

To start, remove your old master cylinder unit

replace a forklift master cylinder

Remove the old master cylinder unit

Next, remove the lines

replace a forklift master cylinder

Then, install the new master cylinder

Re-install pin and retaining clip

replace a forklift master cylinder

Fill reservoir with brake fluid

Test system and make adjustments

Bleed excess air from system

To watch the full video: click here

Parts used in this tutorial:

master cylinder

brake fluid

Need Toyota brake parts? We got them! If you have any questions on how to replace a forklift master cylinder, give Intella a call at 616-796-6638 and experience our industry renowned customer support. Feel free to comment on this blog post, as well.

Intella offers a wide selection of parts, including forklift parts. Visit our website to explore our wide catalog of parts!


Post by Intella Parts Company, LLC