how-to articles Archives

How to change a Hyster or Yale forklift password

Looking to change the password on your Hyster or Yale forklift? Just follow the instructions below to change your forklift password.  Need Hyster forklift parts?  Click hereHyster Yale forklift password dash display Intella Liftparts

Step 1: enter the Set-Up and Diagnostic Menu

•  Turn the ignition key to the on position.

•  Press the star button (*) three times. The star button is located on the right-hand side of the display.

•  Enter the forklift password and press the star button (*). 

•  Now that you’re in the service menu, press the 4 or 5 button to go back 1 level if need be. These buttons are located on the right-hand side of the display as well, and they likely have arrows on them like in the picture above.

•  Press the star button (*) to show “Main Menu – Passwords.”

•  Use the 4 or 5 button to scroll through the menu items. The star button (*) selects a sub-menu item.

Step 2: edit your forklift password

•  Use the star button (*) to select “Passwords.”

•  Enter your password.

•  Use the 4 or 5 button to scroll to “Edit Password” and select it with the star button (*).

•  Enter your password again.

•  Under “Password Type,” enter your new password.

•  Use the star button (*) to select “Save and Exit.”

SIS forklift radar


Post by Intella Parts Company, LLC

How to locate and read a GM forklift engine serial number

Step 1: Locate the number on the engine block

The serial number of your GM forklift engine will be in a location specific to your model of engine. Below are diagrams showing locations for 2.5/3.0L L-4, 4.3L V-6, small block V-8, and big block V-8 engines, respectively. The big block V-8 engine has two diagrams, indicating serial number location for models both before and after 1991.

We sell new GM 4.3 and GM 2.4 liter engines for forklift applications!

2.5/3.0 L L-4 engine
2.5/3.0L L-4 engine
4.3L V-6 engine
4.3L V-6 engine
small block V-8 engine
small block V-8 engine
big block V-8 engine, pre-1991
big block V-8 engine, pre-1991
big block V-8 engine, 1991 and on
big block V-8 engine, 1991 and on

Step 2: Interpret the number

Once you have located the serial number, you can derive from it information about your forklift engine. As shown in the diagram below, the first letter indicates the source code of the product. The next four digits indicate the month and day the engine was produced, and the last three digits are the engine’s type code.

interpreting your serial number
interpreting your serial number

More about GM engines

A variety of forklift manufacturers have used GM engines in the past.

Hyster‘s history with GM engines goes back many years, all the way back to the 2.4 liter engine as well as the 3.0 “iron duke”, and the 350/4.3 engine.  When the parent company of Yale, “Nacco” purchased Hyster Company, Yale began using GM engines as well.  Recently Nacco has moved away from GM engines to Kubota.

Toyota uses GM engines as well, believe it or not.  The automotive rivals work together somehow as Toyota uses the 4.3L engine.  Toyota did use the 3.0 liter engine for a brief period but it no longer does so in 2015.

Mitsubishi/Caterpillar Forklift uses the GM 4.3 engine in its 8000-12000 pound capacity lift trucks.

SIS forklift radar

Looking for parts for GM engines used in forklifts?  Intella can help.  We carry tune up parts, cooling / water pumps, starters, alternators, distributors, filters, and general rebuild parts.  We know GM engines and we can help you determine what you need.  If you can’t figure out from our website what you need to order, please call us at 616-796-1288.


Post by Intella Parts Company, LLC

Hyster and Yale IFAK Diagnostic Tool

Ifak for Nacco forklifts. Aftermarket parts by Intella LiftpartsYou’ve watched the technician from the Hyster or Yale dealership using his laptop computer and the Ifak cable to diagnose and program your forklift. Pretty cool, right? So how does this help him repair your forklift?

The software reads the on-board diagnostics built into your forklift. It contains a database of all of the possible diagnostics codes in the system and the associated troubleshooting guides. The tools included allow the technician to test individual components right from the computer screen without opening his toolbox. He can also make adjustments to your forklift’s transmission, speed control, operator access, impact monitors and many others. He can look at temperatures and operation history and current status. All of this helps your technician to diagnose and repair your forklift in short order.

Now you want to know where you can get the software and IFAK interface cable. Sorry, they’re not available for sale anywhere we’ve found.  Even if you could purchase one, you wouldn’t have access to the Hyster/Yale website that the dealers use with their laptops.

Ifak for Hyster Yale forklifts. Aftermarket parts by Intella Liftparts

Nacco (the parent company for Hyster and Yale) will only allow access to their software to fully trained and certified technicians that work for their dealerships. It is easy to explain when you understand what is at stake.

The adjustments available to the technician are very complicated and take a great deal of training to understand how to correctly calibrate and adjust your forklift. There are also some options available that are activated through software and must be purchased through your dealer. Nacco technicians are required to take hundreds of hours of factory training to become certified with their software. If an untrained person were to make certain adjustments it could cause an unsafe condition.

The liability for the dealer and the manufacturer would be enormous.

All is not lost. The forklifts built today give the technician or customer access to much of these diagnostics tools through a menu system on the dash. You can access most of the diagnostics codes and make limited adjustments right from the dash display.   Often many dealers technicians don’t even use the IFAK cable–they simply look at the code displayed on the dash.

It is important to remember that many mechanical problems can be diagnosed and repaired in the same way as in the past. Forklifts are still basic machines that have become safer and more efficient thanks to technology.

SIS forklift radar


Post by Intella Parts Company, LLC

Inspecting Impco Systems for High CO Levels

Step 1: Squeeze Hose

Impco VFF30 emissions
Impco VFF30 emissions

Use a needle-nose pliers to pinch the vacuum hose on the VFF-30. If the RPM speed changes, the o-ring seal is bad. If after disconnecting the hose the engine doesn’t die or the o-ring is bad, the Impco VFF-30 needs to be replaced or rebuilt. You can also test this using carbon monoxide readings.

*If you have an electric lockoff in your lift truck, you will also have a vacuum safety or an oil pressure switch. It is against regulations for these to be disconnected (see NFPA Pamphlet 58).

Impco VFF30 exploded view
Impco VFF30 exploded view

Step 2: Prime

impco model J
primer button model J

Push the primer button while the engine is running on the Model J vaporizer-regulator. IMPCO no longer manufacturers a model J with a primer button.  However, primer buttons are available on Impco model J generic units which we offer.  The engine should stall or completely shut off while pushing the button and start back up to idle as soon as you release. If this doesn’t happen or pushing the button causes the engine to speed up, adjustments are needed with the air-fuel mixture in the mixer.  To watch how a Impco model J is rebuilt, check out this video here.  A video on how to rebuild an Impco VFF30 can be found here.

Impco CA55 carburetorStep 3: Air-Fuel Ratio Adjustments

Turn the idle mixture screw (on the mixer) counterclockwise as far as possible. The emissions reading should decrease in carbon monoxide. 

 

CA100 Impco carb mixture screwStep 4: Air Filter

Take out the air filter and inspect it. Replace the filter if there is an increase or decrease in emissions after the air filter is removed.

Step 5: Mixer

If you haven’t had any problems with anything in steps 1-4 and CO levels are still too high, the mixer must be replaced. Usually, you can replace your Impco Model 50 carburetor/mixer with a new Impco Model 100 or 125 with minimal adaptations. If this is not the case for you, go with a Model 55.

Step 6: Air Valve

There are 4 screws holding the Impco Model CA100/125 mixer cover that need to be removed in order to check out the air valve. (It should be part AV1-14-4; if not, replace with the correct part.) Make sure the metering cone is clean on the inside and there are no signs of wear. If you see marks implying the valve is rubbing, either sand the guide gently or replace the air valve. A lean air shim or 2 may be installed at this point if the fuel mixture still isn’t right.  Install the first shim on the metering cone lip and check the emission levels; if only a minor improvement, add the second shim.

*Clean the air valve with a solvent solution. Do not wash the diaphragm or use an abrasive cleaner on any parts. Make sure the gas valve cone is tight in the body housing.

Step 7: Power Mixture Setting

Emissions should be at an acceptable level when the truck is idling. Set the power mixture and load the mast by tilting completely back or forward. If you have a rich condition based on the exhaust analyzer, turn the power valve, or gate valve as its also known, to the “L” position.

desired emission readings_Intella Liftparts


Post by Intella Parts Company, LLC

Forklift Air Filter Storage and Handling Tips

Getting the most life out of your forklift air filter is important. This starts with storage and handling. Before you even start the installation process, make sure the new filter is less than 6 years old (based on the manufacturing date) AND it is clean/undamaged. Here are a few more quick tips to help with your forklift air filter storage:

Air filter forklift filter

1)  Make sure to always store air filters in a box, not out on a shelf where they can pick up dust in the air.

 

2)  If the box isn’t sealed tight, tape it shut.

 

3)  Individually wrapped

 

4)   When transporting air filters, make sure they aren’t rolling around. Throwing them in the back of the truck or the floor boards could cause damage.

 

5)   Don’t store the filters on anything metal. Metal condensates and could cause rust on the filter. Boxes are best.

 

6) Just like with food, put the oldest filters in the front. Make sure you put new stock in the back so you don’t end up with expired filters. (Remember, 6 years from the manufacturing date is the oldest you want to use.)

 

7) Make life easiest by ensuring labels with product information and manufacturing dates are visible.

 

8) Don’t store filters in extreme temperatures or excess moisture. The environment you store your filters in will effect their shelf life.

 

9) When installing or just handling new filters, make sure your hands are clean. Avoid contact with the outlet side of the filter if possible.

 

 

Intella has a complete line of forklift filters.  We carry filters for most brands of forklifts including Hyster, Yale, Toyota, Cat, Kalmar, Taylor Forklift, Nissan Forklift, Komatsu Forklift and most others.

 


Post by Intella Parts Company, LLC

Servicing Forklift Air Filters using restriction indicators

Forklift mechanic changing forklift air filter
Forklift mechanic changing forklift air filter

Servicing a forklift air filter by restriction is the best way to get the most life out of your filter. Proper servicing can save you money and time. Dirty filters do not always mean they are trash. Many times, dirty filters can  go more hours!

Mechanic measuring the restriction to determine if there is a plug in the system
Forklift mechanic measuring the restriction to determine if there is a plug in the system

Don’t want to cause a problem in your air cleaner? Don’t service it too much. The elements in the filters are more efficient as dust builds up on the media. But  avoid dust and other abrasive particles when removing the filter!

There are a variety of choices when it comes to measurement tools to get the most out of your filter.

Restriction measurement tool options
Restriction measurement tool options

Looking for a continuous reading device to see how much life is left in that old filter? Check out The Informer and the Service Gauge for Instrument Panel.

Intella has a complete line of forklift filters for sale.  Easy online ordering allows you to quickly select the filter you need–at a great price!


Post by Intella Parts Company, LLC

Forklift Air Filter Tips and Maintenance

Donaldson airfilterRegular maintenance is crucial to the life of your forklift air filter.  Inlet hoods must not be missing and all openings and tubes must be clear. Dented or damaged units and housings must be fixed or replaced to optimize operations. Make sure there are no leaks in the ducting to provide particles a trail straight to the engine.

Capture5

filter2Cleanliness of the filter is not a sign of life or death. Clean filters can have dirt and carbon deep down in the filter; dirty looking filters may still be working great. Filters are a low-cost investment to keeping things running smooth.

 

Capture3Keep air cleaners closed as much as possible! If there is no filter, there is no barrier between the engine and the outside world. Protect the engine during filter changes by keeping the opening covered. Just because you can’t see the dirt and particles doesn’t mean they won’t affect the engine.

 

Capture4Gaskets that are damaged should be replaced when changing forklift air filters. Be sure to check service instructions on if gaskets need to be replaced at each filter change and don’t use an old one you have laying around. (This is usually the case in EBA and ERA model air cleaners.)

 

 

When changing out lift truck filters make sure to use the same Capture8part number. Filters may look the same but they provide different seals that can affect airflow and can cause serious damage over time. The only time you should change model numbers is when there is an upgrade to an older style.

 

Forklift manufacturers give you recommendations on the roCapture6utine you should follow regarding maintenance of your filters. Each new filter has a different set of recommendations and guidelines. Make sure you are up to date with the newest procedures. Keeping records and following these guidelines are necessary in the likelihood you need to use a warranty claim. It is often helpful to record the filter changes right on the filter itself. It doesn’t matter if you track it by miles or hours, just keep it consistent.

 

Dirty forklift filters can contaminate clean filters during a routine service change. Make sure to wash your hands or remove your gloves after handling the dirty filter and before coming in contact with the new one. It is also helpful to keep the new filter in the box until you are 100% ready to install it.

 

Tightening and inspecting the forklift air cleaner system  connections is the last step. Make sure everything is free of holes and damage; worn spots and damage especially to the elbows, seals and connections must be checked thoroughly. Tighten all clamps and inspect pre-cleaners and inlet hoods. Reset manual filter indicators and make sure to record any and all action you have performed.


Post by Intella Parts Company, LLC

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.

Get all of your toyota forklift parts at Intella LiftParts!


Post by Intella Parts Company, LLC

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 Parts Company, LLC

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 Parts Company, LLC