I got called in to diagnose a cold start running problem and found another neglected forklift in my service area.
The unit runs rough only when cold. I connected the diagnostic tool to monitor engine data and found all data available was within specifications.
I pulled the air filter to find it completely clogged and replaced it. I inspected for vacuum leaks and found the PCV valve was stuck and replaced that also.
I inspected the spark plugs and found them to be very worn out and replaced them too!
See what I mean by a neglected forklift? I mean the oil level was not showing on the stick and the oil hasn’t been changed since 2020. This was confirmed by a date found on the oil filter. I changed the oil.
I then tested fuel pressure and found it was lower than specified by the manual. After letting the unit sit for a while, I came back and retested to find the fuel pressure to be very low on startup and then gradually increasing to help the engine run close to normal.
At this point I condemned the fuel pump and started shopping around. I could not find a suitable replacement from the aftermarket forklift parts suppliers, so I contacted the local Caterpillar dealer and found this.
Well, at least I now have a part number to research. After trying to cross the part number, I did manage to find an aftermarket fuel pump assembly for a pretty good savings, However, that still was not good enough for the customer. See below.
Yeah, That is still a lot of money! So I continued to research. The fuel gauge sending unit was still showing an accurate reading on the fuel level, so I decided to disassemble the pump assembly and find a match for the internal pump. I did find numbers on the pump and went to a local auto parts store that had some patience to deal with this and started plugging the numbers.
After about 20 minutes, we came up with a compatible fuel pump and strainer.
This is the level of customer service Accelerated offers to its customers.
CHECK OUT THE SAVINGS!
All of the work performed including labor was cheaper than both the dealer and the aftermarket part.
