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How-To Forklift Articles Archives

How to fix Clark Forklift Brakes

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.

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

For 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.

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.

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

Propane Gas Smell from Forklift

One of the most common forklift complaints from forklift operators is a noticeable propane gas smell from your forklift — this can likely be attributed to the need to replace o-rings. Frequent forklift operators will call service companies complaining that their forklift has a leak. Often, the problem is not with the forklift but rather with the propane tank.

This tutorial will show how to replace two o-rings on the propane tank and eliminate one of the most common complaints from forklift operators and get rid of that pestering gas smell from your forklift.

gas smell from forklift

Remove the existing o-rings

gas smell from forklift

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

Need to purchase o-rings? Navigate to our website and search ‘o-rings’ in the search field! Intella Parts sells all of the parts for your equipment needs. Navigate to our by-type page to filter by part types to fulfill all of your part needs.

Need help on figuring out which o-rings you need for your forklift model? Call us at 616-796-6638 to speak with one of our customer support specialists that can help with part lookups!


Post by Intella Parts Company, LLC

How to Rebuild Impco Model J Regulator

The Impco 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.

Impco Model J regulator

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

Remove diaphragm from inside cover

Impco Model J regulator

Remove lever. Screw is also a Torx screw

Impco Model J regulator

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 Parts Company, LLC

Construction Skills: Resources for Apprentices

What is a Construction Apprentice?

construction apprentice

A construction apprentice is a novice construction worker who is learning the trade. He takes a number of courses to learn the skills required while also working under the supervision of a master construction worker to gain practical experience. Apprentices are usually young—most start directly out of high school at age 18, although some may be older. Most apprentice programs require applicants to have a high school diploma or GED certificate. A worker is usually an apprentice for three to five years, depending on their skill and education.

Apprentices learn a number of different skills, including proper tool use, construction methods, and safety. In the classroom, they study different types of construction and learn the theory behind the different methods. Most apprentice programs offer employment opportunity assistance, and many apprentices are hired full-time by the company they did their training under.

Construction Schools

Portland Building Blueprints

Those who are interested in becoming a construction apprentice will need to find a trade school that offers a program in construction and building. These programs will provide apprentices with a solid foundation in the theory and methods of construction and will develop strong construction skills. While the coursework generally doesn’t include practical skills (those are gained through the on-the-job training portion of an apprenticeship), students do learn things such as the math behind construction, how to read and create blueprints, and what it takes to be a construction manager or independent contractor.

Many construction schools require students to take at least one course that focuses solely on safety on the construction site. This is an extremely important part of an apprentice’s training since safety is of the utmost importance and the most important of the construction skills.

Machinery Schools

Docker on forklift

In addition to construction schools, most construction apprentices will need to go to machinery school. In fact, they may need to attend several different certification programs to gain all of the skills and certifications they need. Many machinery programs do include many of these skills and offer various certifications, however, especially those offered by trade schools and colleges.

Machinery schools will teach apprentices all of the basics needed for operating and maintaining equipment such as forklifts and flatbed trucks. Some may touch on how to make minor repairs to equipment, too. Like construction programs, machinery education also stresses safety. Courses such as forklift operation and safety guarantee that apprentices learn how to operate vehicles and machinery in such a way as to not injure themselves or others.

Resources for Employers Looking for Apprentices

Chemrec 5 - small

Many employers like to hire apprentices for several reasons. First, it provides them with fairly cheap labor. Apprentices do get paid for their practical apprenticeships (if an apprenticeship is not offered paid, he or she should be very leery about taking the job), but they don’t get paid as much as a licensed worker who has several certifications. Taking on apprenticeships allows the employer to form a working relationship with trade schools. This often results in the trade school sending the employer a number of apprentices on a regular basis. The trade school then has a reliable construction company with which to place their apprentices, while the employer can rely on having a number of apprentices to put to work. Everyone benefits.

In addition to reaching out to trade schools, employers can find apprentices through several different methods. Some advertise in their city newspapers or online. Others put the word out that they’re looking to hire new apprentices. Often, word of mouth works surprisingly well. However, it can be unreliable, so many employers turn to resources such as the following.


Post by Intella Parts Company, LLC

Avoiding Common Forklift Hazards

Forklifts transformed the shipping and storage industry. Without them, the process of moving large amounts of heavy products would take much, much longer and many more people. However, even though they are an absolute necessity to the warehouse and shipping industries, forklifts are also dangerous vehicles. There are a number of hazards that are associated with forklifts, and if you aren’t careful, you can easily injure yourself and others while driving one. Here are some of the common hazards associated with forklifts and some ways of avoiding them.

Vehicle Transportation Trailer

Why Forklifts can be Dangerous

Forklifts can be dangerous for many of the same reasons that any vehicle can be dangerous. When driving one, it goes from being a stationary object to a mobile block of heavy metal. If the driver isn’t paying attention, it’s easy to hit someone with the forklift, and while the vehicle may not be moving as fast as a car, it’s still going to hurt and can be fatal. Forklifts can move deceptively fast for their size and weight, especially when they have no load.

Another issue is that forklifts are so heavy that even an impact at slow speeds can be dangerous. What might stop other vehicles may not stop the momentum of the heavy forklift, which means it can cause much more damage than you may think. The long forks in the front are also very dangerous, and beginner forklift drivers often don’t realize exactly how far they stick out.

Common Forklift Hazards

Vehicle Transportation Trailer

There are a host of common forklift hazards that forklift operators need to be aware of. These hazards can lead to a number of accidents, most of which are caused by carelessness.

Visibility is a major issue with forklifts. When carrying large loads on the forks, it can be very difficult for drivers to see what’s in front of them.

Improperly loading the forklift is another common issue that can lead to injury and damage. If the forklift isn’t loaded evenly, it’s very easy for the center of gravity to move too far forward, backwards, or to one side. Then the forklift becomes unbalanced and can tip forward or to the side.

While regulations do outline when forklifts are to be inspected and undergo maintenance, this doesn’t always happen due to negligence, lack of time, or some other reason. This can lead to a forklift parts breaking or malfunctioning in the middle of being used, which can cause the load to fall or be abruptly lowered.

One common hazard that has nothing to do with the forklift itself is improper surfacing or maintenance of such surfaces. A forklift with a heavy load cannot move up or down steep ramps without danger. Ramps that aren’t secured, sturdy, or in good condition may move or collapse under the weight of the forklift, leading to injury and damage.

Older forklifts that have had major issues or have begun showing their age should be retired. Continuing to use these older vehicles can lead to malfunctions in the middle of moving a load.

How to Avoid or Preempt these Common Forklift Hazards

forklift hazards

There are several things operators and supervisors can do to help reduce the chances of these common hazards occurring. The first is proper training and adherence to training and regulations. Operators need to follow all precautions when driving, especially if they know they are in an area that sees a good amount of foot traffic. The same is true when backing up and when making turns or cornering. Forklift seat belts should be worn at all times, mirrors should always be used when backing up, etc.

Forklifts and all forklift parts need to be checked over, maintained, and, if necessary, replaced or repaired on a regular schedule.

Forklifts should never be moved without first making certain that the load is balanced and secure. If the load ever starts to shift, the forklift should be stopped immediately.

No one who has not been trained and certified to operate a forklift should ever be allowed to drive one, even if it’s just to move the vehicle from one place to another without a load on it. Certified operators are the only ones who should ever be in the forklift seat.

Older forklifts or forklifts that have been malfunctioning should never be used. They should be repaired whenever possible or replaced when they can no longer be fixed.

Training and Safety Information

All forklift operators need to have been certified in the operation and maintenance of forklifts. However, a large number of forklift operators do not actually have the training needed to drive the vehicles. In fact, allowing untrained operators to drive a forklift is a very common OSHA violation.

In order to be eligible to drive a forklift, a person must be at least 18 years old and must have completed a certification program. Their employer also has to give them authorization to operate the vehicle. There are a number of different training and certification programs around the nation that employees can enroll in. However, it’s important for operators to be trained on the specific type of forklift they will be operating and not assume that they can drive any forklift just because they’ve been certified.

The following are three training courses that operators may want to look into:

  • IVES Training Group – This group will work with employers to do an in-house training for forklift operators.
  • ProLogistix Certification Services – A professional training company that also helps place operators with employers.
  • Crane Institute of America – They offer a train-the-trainer course in which employers can learn how to train their own employees and become a certified forklift operator trainer.

Conclusion

Forklifts are absolutely vital in many industries, but it’s always important to remember that they are heavy equipment and can be dangerous. With the right training, attention, and caution, however, they can safely be used without incident.

Intella sells the forklift parts you need, including JCB Forklift Parts.


Post by Intella Parts Company, LLC