how-to articles Archives

Toyota forklift maintenance reset

.Do you need to reset the service interval on your Toyota forklift?  Read below to learn how to easily reset the service interval after you perform preventative maintenance on your Toyota forklift.

Q: How do I reset the maintenance hour meter on a Toyota forklift?

A: In order to reset the maintenance hour meter on a Toyota forklift, an administrative password must first be entered in order to reach the administrator menu normally inaccessible to general operators. From this menu, the maintenance hour meter can be set.

In order to complete these steps, certain combinations must be entered in the dashboard display shown below. For reference during these instructions, the four buttons used have been labeled A through D. It may help to familiarize yourself with these instructions before attempting to complete the procedure.Dash Labeled


 

Entering the administrative password:

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1. Press and hold buttons B and D simultaneously for 2 seconds. A short beep should sound both at the beginning of the 2 seconds and after 2 seconds has passed.

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2. Press button C within 10 seconds. Another beep should sound. Repeat this by pressing button C once more within 10 seconds, hearing again a short beep.

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3. Within 10 seconds, press and hold buttons B and D simultaneously for 2 seconds. Like before, a short beep sounds when B and D are first pressed, but now after 2 seconds, repeated short beeps sound. The administrator menu should be displayed.Toyota Dash 2

Shown above is an example of how the administrator menu might look. To navigate the menu, button A moves down a  list of settings, buttons B and C move from list to list of settings, and button D selects a setting and moves to its individual screen.

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Resetting the maintenance hour meter:

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1. Locate the setting “MAINTENANCE HR” and use button D to select it. It should look similar to the menu below.Toyota Dash 3

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2. To set the time for the maintenance hour meter, buttons A through D have certain functions. Holding Button A for more than 2 seconds resets the current value selected to 0. Button B reduces the set time for the meter, Button C increases the set time for the meter, and Button D returns to the administrator menu screen.

NOTE: Time can be set in 10-hour increments from 10 to 200 hours, then in 50-hour increments from 200 to 2000 hours. It cannot be set below 10 or above 2000 hours.

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Locking the operator setting menu (DX model only):

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1. Locate the setting “MENU LOCK” and use button D to select it.

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2. Locking this menu limits the setting values that can be changed by general operators. Setting to “YES” will prevent the display of the setting menu for an operator. Button B selects “YES,” Button C selects “NO,” and Button D returns to the administrator menu screen.

 

For further reading, we also offer our article on how to perform basic forklift maintenance.


Post by Intella Liftparts

Forklift chain failures

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There are many ways that chains on forklifts can fail. It is very important to recognize the signs of these many modes of failure before they result in further damage to the forklift, its load, or its operator. Listed below are a few of these types of forklift chain failures.

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Q: What is normal chain wear?

A: This is the wear that is accounted for by the normal life of the chain and is caused by typical use of the chain. The sections of the chain that move over sprockets or sheaves (doing the greatest amount of work) should be most closely monitored for this type of wear.

.Plate Edge Wear

Q: What is plate edge chain wear?

A: When a chain runs over a sheave, the side that is in contact with the sheave can be worn down. This decreases the height of the plate and makes the chain asymmetrical. An example is shown to the right.

 

Q: What are distorted or damaged chain plates?

A: If the plates of the chain are damaged or distorted, it can interrupt the running of the lift chain.

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Q: What are turned or protruding forklift chain pins?Turned Pins

A: Forklift chains are held together by pins placed within plates. If a chain is not sufficiently lubricated or is under unusual tension, its plates can create enough friction to turn a pin. This may cause the pin to protrude from the chain, eventually screwing out of the plates and resulting in failure. An example is shown to the right.

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Q: What is forklift chain pin head wear?

A: If a chain is not aligned correctly, the heads of the pins holding the plates of the chain together can be worn down.

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Q: Why might a chain plate crack?Fig 1

A: There are many reasons that a plate may crack. Fatigue cracking is due to the chain bearing a greater load than it is able to bear, and its cracks begin at the pin hole in the plate or perpendicular to the chain pitch line. Stress corrosion cracking is due to the chain being used in a non-ideal environment. Cracking may also be due to certain combinations of both environmental conditions and stress. An example is shown to the right.

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Q: What is a tight forklift chain joint?

A:  If a joint within a forklift chain is too tight, the chain may not rotate as freely as it should. Friction builds up in the joints of the forklift chain and speeds up the process of wear on the chain. Tight joints can be caused by bent or rusty pins and plates.

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.Fig 4

Q: What is forklift chain tensile failure?

A:  Repeatedly loading a forklift chain beyond its elastic limit can cause tensile failure. This form of failure stretches and bends side plates. It also stretches the plate holes and may cause them to break. An example is shown to the right.

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.Fig 5

Q: What causes enlarged chain holes?

A: Enlarged holes in the plates of the chain are likely due to misalignment of the chain. To fix this problem, replace the forklift chain and fix the misalignment. An example of enlarged holes is shown to the right.

 

Installing new forklift chain?  Check out our how to video on Youtube here.

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Post by Intella Liftparts

How to clear Caterpillar and Mitsubishi forklift error codes

Q: How do I clear Caterpillar and Mitsubishi forklift error codes?

A: Clearing codes for Caterpillar and Mitsubishi forklifts is a very precise process. It helps to be familiar with these steps before attempting to clear forklift codes. It is also suggested that you use a stopwatch to time yourself accurately, as many steps require precise amounts of time before proceeding to following steps. The diagram shown is meant to present these steps visually.    Be patient–even seasoned Caterpillar and Mitsubishi forklift mechanics get tripped up at times on these procedures!

Having trouble with error codes from another brand? Check out these other helpful links:

 


.Diagram1

1. Start the stopwatch and turn the forklift key switch on simultaneously. Do not press the accelerator.

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2. Wait 3 seconds, then press the forklift accelerator five times in
succession, ending the set of five with the pedal released.  You need to do this within 5 seconds–if pushing the accelerator five times in a row takes longer than 5 seconds you risk never clearing the codes.

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3. Wait 7 seconds, then press and hold the accelerator for 10 seconds or more until the malfunction indication light starts flashing.

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4. Immediately release the accelerator pedal. This starts a self-diagnostic test, and the dashboard display will show one or more blinking forklift DTC codes.

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5. Leave the pedal released for 10 seconds or more.

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6. Press and hold the accelerator for 10 seconds or more. Doing so erases the results of the self-diagnostic test, successfully clearing the forklift codes. Only the current hour meter will be displayed on the dashboard; no codes should be present.

SIS forklift radar

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7. Release the pedal and turn the key switch off.

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8. Restart the forklift’s engine and make sure operation of the forklift is normal.

 

Important note!  Any service code related to the pedals themselves (such as brake light switches, etc) will never be cleared by this procedure.  The only way to resolve those codes is with the dealer provided service software.

 


 

Working on a Cat or Mitsubishi forklift?  If you need parts, Intella can help.  We have thousands of parts available for most models of Cat and Mitsubishi forklifts.  Click here for more information.

 

Check out Intella’s Youtube channel for how-to videos and product demonstration videos.

 

 


Post by Intella Liftparts

Forklift engines

Note: Shop Perkins engine parts now!

 

In the United States, counter balanced forklifts are split nearly equally between electric powered models and models powered by internal combustion engines.  In 2013, a total of 52,834 electric powered lift trucks were sold and a total of 66,473 engine powered forklifts were sold.  That’s a split of around 44% for electric and 56% gas powered.

Curious what a rebuilt forklift engine costs?  Click here for some ball park costs and click here for a vast array of forklift engine parts.

 

Although you won’t read it on their websites or brochures, most forklift manufacturers do NOT manufacture their own engine for the forklifts they build.  Here are engines used in various makes and models of forklifts.

 

forklift engines intella liftparts

 

Hyster forklifts:

Hyster models such as S50FT and H50FT will frequently be sold with the GM 2.4L engine.  This forklift engine is built in Brazil by GM for another automotive application.

gm 2.4 vortec intella

 

Mzzda FE forklift engine
Mazda FE forklift engine

Yale offers the GM 2.4 as well in models like GLC050VX or GLP50VX though most Yale dealers have a preference:  the Mazda FE forklift engine.  Yale has used Mazda forklift engines for years and most Yale service personnel will tell you they think it’s a tough, durable engine.  Yale used other models in the past as well: the UA, VA in LPG and gas models and even Mazda diesel forklift engines.

Larger Hyster and Yale forklifts in the 8,000 pound up until 15,000 pound capacity frequently use the GM 4.3 liter forklift engine.  This engine is used in other brands of forklifts as well–even Toyota, Mitsubishi, and “Cat 50 forklift” uses this engine.  It’s a good engine, reasonably priced, made in America, and parts are easy to find.  Forklift manufacturers will rarely reference the brand of engine in their new brochures but you can usually deduce the brand by the displacement–if a forklift has a 4.3 liter engine, there’s a 99% chance it’s a GM 4.3

forklift engine gm intella liftparts

 

 

 

Caterpillar and Mitsubishi forklifts are identical except for the color and decals on the forklifts.  Mitsubishi Caterpillar Forklift builds both brands on its forklifts in Houston, Texas and Japan.  For heart of the line models, MCF used the Mitsubishi 4G63 and 4G64 engine.

These forklift engines were built in Japan and were also used in some other brands of forklifts.

4G64 forklift engine
MITSUBISHI 4G64 forklift engine

 

Mitsubishi, Caterpillar, and Nissan forklift divisions began using the Nissan K21 and K25 engines several years ago.  Typically fitted with a Nikki LPG fuel system, these forklift engines have proven fairly reliable.  K21 is 2.1 liter displacement; K25 is a 2.5 liter displacement engine.

K21 forklift engine
Nissan K21 K25 forklift engine

 

Toyota uses its own 4Y engine in its heart of the line forklift models such as 8FGCU15, 8FGCU25.  This engine has been the workhorse of Toyota forklift models for over 20 years and parts are readily found for it.  It will be typically equipped with an Aisan LPG fuel system.

Toyota 4Y forklift engine
Toyota 4Y forklift engine

 

The point of this posting was to highlight some engines used in forklifts that were built over the past 10-15 years.   In a future post, we’ll consider some of the engines used years ago such as…

 

Continental Y112, F163 (mostly used in Clark)

Ford (mostly used in Hyster)

Waukesha: D176 D155 (used in Clark)

Isuzu: (used in Hyster diesel forklifts)

Perkins: (used in Hyster, Caterpillar and a few others)

Cummins (current diesel engine of choice for Hyster, Yale, Taylor and Kalmar forklifts)

Peugeot XN1P:  this French engine used in Caterpillar forklifts built in the 1980s

Hercules: used in Caterpillar and a few Doosan engines

Hyundai: used in Korean forklift brands such as Samsung, Doosan (a.k.a. Daewoo) and Clark.

Nissan: H20, H25, H20-II mostly used in Nissan, TCM, and Komatsu

Volkswagen: used exclusively in Linde

 

Buy remanufactured forklift engines here!

 

 

 


Post by Intella Liftparts

Impco stuff you probably never knew

Impco is a manufacturer of fuel system components for alternative fuels like LPG/propane gas.  You’ll find Impco in a variety of forklift brands like Hyster, Clark, Yale, Cat, and many others.

The most popular Impco regulator is a model J.  Here’s a picture of it below.

model J
Impco model J

We offer a few different versions of the model J

Model JB The B stands for blue spring.  This is by far the most common model J regulator.  The blue spring offers negative 0.37 kPa (1.5 inches w.c.)  The Impco model JB diaphragm is made of hydrin and is suitable for most applications.

Model JB-2 is similiar to the JB–only difference is that the diaphragm is made of silicone and is suitable for cold climates.

We offer a generic model JB which has a primer button.    Some old models of forklifts still have a primer button on the LP regulator and we’re one of the few online that offer this version.

 

SIS forklift radar

 

REBUILDING MODEL J REGULATORS:

You can repair and rebuild model J regulators using repair kits made of hydrin or silicone.    There’s no limit to how many times you can rebuild a model J regulator.

COBRA

Impco developed the next version of regulator after the model J and called it the model K.  Impco but quickly changed the name to COBRA after learning that the US trademark office would not trademark an alphabetic letter.    The COBRA will work perfectly in place of a model J.  COBRA will work for a model J application but model J should not be used for a COBRA application.

We offer COBRA repair kits and yes you can rebuild COBRA units as many times as you wish.

COMMON QUESTION:  My forklift came with a model JO.  Can I use a model JB or JB-2?    Yes–as long as you understand the difference between hydrin and silicone there’s no problem.

 


Post by Intella Liftparts