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how-to 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

Forklift overhead guards – order online

Forklift overhead guards are very important safety devices which are used on every forklift.  When damaged, they need to be replaced.  Intella Parts offers competitive pricing on new and used forklift overhead guards.  We can offer new overhead guards at competitive prices AND we can provide used overhead guards.

forklift overhead guard used

Used forklift overhead guards come from forklifts which are retired and being “scrapped” for parts.  Often these forklifts will be too costly to maintain but the overhead guard still will be in good condition.  Do you need to obtain a price on a used forklift overhead guard?  Please provide the make, model, and serial number from your forklift.  That information can be found on the forklift data tag.   Once you have that information, please call us at 616-796-6638 or email us with the information.

OSHA has a number of rules on forklift overhead guards which can be found here.  The short answer is that OSHA requires overhead guards on forklifts and it’s not acceptable to remove the overhead guard permanently.  The general rule of thumb for OSHA requirements on safety items on forklifts is this:  if the safety device was included on the forklift when it was originally manufactured, that safety device needs to stay on the forklift and shouldn’t be removed.

Need any of these overhead guards?  We can help.  Used overhead guards are priced on an as-needed basis, availability often changes quickly.  Hyster 1599204, Hyster 1599205, Hyster 1599203, Toyota 51601-U2162-71, Yale 550046736.

Below is a photo of a used overhead guard we recently sold.  As you can see, there’s a bit of rust on the top but it’s still perfectly suitable.  The price of this OHG new was over $4000!  This used forklift overhead guard sold for around half–$2200.00

forklift overhead guard
Example of a used overhead guard sold by Intella

Common questions about forklift overhead guards:

Question: Can I replace my forklift overhead guard with any forklift overhead guard?  Are they universal?

Answer:  No.  Each forklift overhead guard is custom designed to the make and model of each particular forklift.

Question:  Can I replace only certain components of the overhead guard?  For example, I just want to replace one leg of the overhead guard.

Answer:  Usually no, unless the manufacturer designed it that way.  A few manufacturers design their forklift overhead guards to bolt together: the four legs are bolted to a top ‘ceiling’ frame.  It’s a great design because it’s simple to replace one leg in the future but unfortunately most forklift manufacturers built their overhead guards as one welded piece and you have to replace the entire overhead guard.

Question:  are aftermarket forklift overhead guards available?

Answer:  We offer a few aftermarket forklift overhead guards.  They are rare and if you are looking to save money on a replacement overhead guard, a used overhead guard is often the best option.

Question:  How much do forklift overhead guards cost?

Answer:  New forklift overhead guards range from around $1200 – $3000, depending on the size of the forklift and the brand of the forklift.  Used forklift overhead guard prices depend on availability, age, and brand of the forklift but they are typically half or two-thirds the price of new.  Contact us at 616-796-1288 and we can help with your forklift overhead guard problem!

Post by Intella Parts Company, LLC

Forklift Battery Troubleshooting

Forklift Battery Troubleshooting: If only they could last forever.

Chances are your battery is going to give you problems at some point in time. When those problems arise, we want to you to be prepared which is why we made this forklift battery troubleshooting guide. Below is a list of common problems associated with forklift batteries that occur over time. Listed are the different battery troubles, the conditions what come with them, what’s causing the problem, and how to collectively act upon it.

forklift battery troubleshooting intella liftparts

Short Circuited


  • Very low cell voltage and specific gravity during recharging and discharging
  • Low gassing while charging
  • Extreme rise of electrolyte temperature during charging phase
  • Fast drop of gravity after charging

Why is this happening? Probable cause:

  • Short circuited due to a dropping of active materials
  • Short circuited due to a broken separator
  • Short circuited due to advancing of broken pieces during manufacturing of battery

Where to go from here:

  • Replace the faulty cell with a single charged cell



  • While charging, the voltage and electrolyte temperature are much higher than the standard
  • Gassing is accelerated from charging and the gravity does not rise to normal
  • Voltage drops quickly while discharging
  • In some extreme cases, plates may become whitened

Why is this happening? Probable cause:

  • Repeatedly overcharging and discharging of battery
  • Plates exposed to open air for extended period of time
  • Lack of care during storage process
  • Excessively high gravity while using battery
  • Impurities causing excessive self discharge of battery

Where to go from here:

  • If the battery is in rather early conditions, remove the probable cause
  • Replace the faulty cell with a single charged cell if damage can’t be fixed

Excessive Self Discharging


  • Quick drop in gravity after charging
  • Charging capacity of battery significantly reduced

Why is this happening? Probable cause:

  • Using impure water in the battery
  • Specific gravity higher than it should be
  • Excessively high temperature of electrolytes
  • Battery container has been insufficiently cleaned

Where to go from here:

  • Take daily care of the battery
  • Replace the faulty cell with a single charged cell

Exchange of Polarity


  • Polarity switched around in some cells during discharging or high temperature of electrolytes
  • Electrolytes dissolve causing an emission of gas that changes the polarity of the battery

Why is this happening? Probable cause:

  • Caused by quick discharge without noticing a low capacity in a cell
  • Ill preparation of certain means like an equation charge

Where to go from here:

  • Replace faulty cell
  • Take daily care of the battery

Forklift Battery Troubleshooting Intella Liftparts

Other Possible Factors

1. Color of electrolyte has changed to brown

– Due to corrosion of positive plate mixing into electrolytes

– Check voltage and gravity of battery

– Replace electrolyte

2. Chlorine smell during charging

– Due to sea water mixing into electrolytes

– Replace electrolyte and charge the battery until the smell is gone

– Replace cells

3. Electrolyte excessively reduced

– Battery cells are cracked

– High electrolyte temperature while charging

– Find causes and follow repair procedures

4. Unnaturally high electrolyte temperature

– Due to lack of electrolytes

– Due to shorted cells and/or reversed polarity

– Solder battery

5. Heat from connector portion

– Bad connector contact

Forklift Battery Troubleshooting Intella Liftparts

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Need forklift battery chargers ? Intella Liftparts can help.

Post by Intella Parts Company, LLC

How to Fix a Forklift

You’ve probably been there before. You discover a problem with your forklift, find the right solution, buy the necessary parts, and then have to call in help to do the rest. But at Intella Liftparts, our goal is your independence: we’ve helped you with the parts, now let us help with everything else. With that said, check out this list of our ‘how to fix a forklift’ articles for repairs of all kinds. Our work focuses on the most common problems that forklifts can have, ensuring that help for you is as available as possible. Beyond repair tips, we also make it our goal to cover every other aspect of owning a forklift, from proper maintenance to safety training to varieties of forklift tires. Here at Intella, we strive to keep you up to date with the most current information we can provide about your vehicle. You know us as a parts service; now get to know us as so much more. Below you will find links to some of our popular ‘how to fix a forklift’ articles. Clicking on the title will take you right to the article page. You can also click here for a full list of articles on our website.

how to fix a forklift intella liftparts

How to identify and replace electrical contactors

How to select the best battery for your forklift

How to block your forklift prior to performing repairs

How to buy a new forklift

How to troubleshoot a no-start condition

How to maintain your forklift engine (internal combustion and electric)

How to replace a blown fuse

How to pick the right tires for your forklift

How to select a forklift battery charger

How to find the serial number on you forklift

How to avoid common forklift hazards

For more how-to articles and all around product knowledge, click here

how to fix a forklift intella liftpartsOh and if you want to prove to everyone that you’re

the boss, we’ve got just the right t-shirt for you.

 how to fix a forklift

Need forklift parts?  Need a Toyota forklift seat?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Parts Company, LLC