How much does your forklift weigh?

How much does your forklift weigh? It’s important to know the weight of your forklift when transporting it, driving it on trailers, moving it in an elevator, or using it in multi-story buildings. You don’t want your forklift to drop through the floor, causing thousands of dollars of damage and injuring workers!

 

The service weight of a forklift is different than its lift capacity.  Service weight refers to the actual weight of the forklift, including its battery and any attachments it has.  The best place to find the service weight of a forklift is on the forklift’s data tag.  Alternatively, you can search forklift manufacturer websites for product specification pages, but the truck’s data tag is typically preferred over this option. In addition, an industry rule of thumb is that the service weight of the forklift will generally be 1.5 to 2 times the lifting capacity of the forklift.  For example, if your forklift can lift 5,000 pounds, generally the weight of the forklift will be somewhere between 7,500 and 10,000 pounds.  But remember, this is simply a rough standard, and manufacturer information or the forklift’s data tag should always be prioritized.

 

See below for the weight of some of the most common models of the most widely-used forklift brands. The downloadable table lists the weight in pounds of Hyster, Komatsu, Crown, Toyota, Caterpillar, Yale, Clark, and Nissan forklift models. For starters, here are the weights of the most common models from these manufacturers.

 

blue forklift light

 

Q: How much does a Hyster H50FT forklift weigh?

A: 8,924 lbs.  (with NL; 3-stage, 189″ mast height)

 

Q: How much does a Komatsu FG18HT-20 forklift weigh?

A: 6,340 lbs. (2-stage, standard mast)

 

Q: How much does a Crown 4520-30 forklift weigh?

A: 5,974 lbs. (standard truck w/o battery)

 

Q: How much does a Toyota 8FGCU25 forklift weigh?

A: 8,000 lbs. (2 stage, 131.5” mast height)

 

Q: How much does a Caterpillar C5000 forklift weigh?

A:  8,157 lbs. (standard truck, empty)

 

Q: How much does a Yale GLC050 forklift weigh?

A: 9,016 lbs. (standard estimate)

 

Q: How much does a Clark CMP25 forklift weigh?

A: 8,254 lbs. (standard)

 

Download a PDF of the full table here: forklift weights by Intella Liftparts


Post by Intella Liftparts

GE EV-100 codes explained

Q: What is the EV-100 control system?

A: General Electric manufactured the EV-100 control system for a number of years and it was, at least for a while, in the running for the best selling electric forklift control system of all time.  Today forklift technology has moved on and the EV-100 system is a relic from the past.

However, if your EV-100 system still works as it should, you’ve come to the right place for any parts you may need.  Intella carries transistors, diodes, contactors, rectifiers, and most other replacement parts for the EV-100 system. See some of these parts below, and see our full catalog of forklift parts here.

 

 

forklift transistor Intella Liftparts EV-100forklift diode Intella Liftparts EV-100forklift contactor GE Intella Liftparts

forklift rectifier Intella Liftparts

 

The GE EV-100 LX/LXT forklift system displays certain codes when the lift isn’t working correctly.  Wondering how to interpret one of these error codes? Look no further. View or download the attached PDF file for a chart of common error codes, their symptoms, their causes, and their possible solutions.

 

GE EV-100 error codes by Intella Liftparts

 


 

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

 

If you need parts, Intella can help.  We have thousands of parts available at great prices and would be happy to help you find what you’re looking for.  Click here for more information!

 

Also you can check out Intella’s YouTube channel for how-to videos and product demos


Post by Intella Liftparts

Hyster forklift error codes explained

Yale MPB40-E forklift
Yale MPB40-E forklift
Hyster W40Z forklift
Hyster W40Z forklift

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are the error codes on your Hyster W40Z or Yale MPB40-E pallet jack confusing you? Keep reading to learn what problems these codes indicate and how you can solve them.

 

Yale dash display Intella Liftparts forklift parts

Q: How do I read Hyster W40Z or Yale MPB40-E pallet jack codes?

A: Hyster and Yale forklifts use the same control system, so error codes on Hyster forklifts are the same as those on Yale forklifts. These error codes can actually appear in many ways. While they can be communicated with flashes of a red LED bulb on the jack’s controller, this blog will cover the error codes presented on the jack’s dash display. Sometimes, an error code can mean one of many potential issues. In these cases, it may be necessary to use a special handset or PC to determine which of the problems is the cause of the error code.

 

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

 


 

Below are interpretations for the following error codes: no LEDs, no alarm, AL66, AL99, AL01, AL02, AL4, AL5, AL6, AL7, AL8, AL10, and AL94.

 

SIS forklift radar

 

  • Dash display: no LEDs or LCDs on
    Condition: inoperative
    Cause: B+ and/or B- missing at controller, defective battery charger, or defective battery charger
    Solution: make sure battery is connected, the key switch is on, and the brake override circuit is in the run position; also test your battery charger and motor controller and replace any nonworking parts

 

  • Dash display: no LEDs or LCDs on
    Condition: forklift functions as normal
    Cause:  open connection between display and controller, defective display, or defective LEDs
    Solution: make sure harnesses are connected at MDI and connector B on controller; test the dash display by connecting a handset to it and testing for communication; test LEDs by disconnecting them, connecting the handset, and testing the handset; replace any nonworking parts

 

  • Dash display: no LEDs or LCDs on
    Condition: forklift functions as normal
    Cause:  Because this condition is similar to the last, it will take a handset to determine its cause. If the handset displays “NO COMMUNICATION,” the controller is defective.
    Solution: replace controller

 

  • Dash display: no alarm
    Condition:  traction and hydraulic functions not working
    Cause: improper startup sequence by jack operator
    Solution: check brake switch, accelerator, steer handle, and hydraulic inputs

 

  • Dash display: AL66
    Condition: hydraulic function not working
    Cause: battery voltage is low or controller voltage calibration is incorrect
    Solution: charge or replace battery; otherwise, use handset to determine the voltage read by the controller and compare it to an actual voltmeter reading; replace controller if the two readings differ by more than 1.5 volts

 

  • Dash display: AL99
    Condition: traction and hydraulic functions not working
    Cause: incorrect battery selected, damaged battery, or damaged connection to batter
    Solution: check that you have the right voltage for your truck, manually check the voltage of your battery, inspect it for any damage, and check its connecting crimps and cables for damage as well

 

  • Dash display: AL01
    Condition:  traction and hoist functions not working
    Cause: control card throttle or lift/lower calibration is out of range; control card is damaged or defective
    Solution: use the tester function on a handset to see if either calibration is greater than 1 volt at neutral; replace control card if damaged or defective, which can be checked by seeing if both “forward switch” and “backward switch” are on at the same time when testing

 

  • Dash display: AL01
    Condition: traction and hoist functions not working
    Cause: incomplete connection between control card and controller; traction reversing switch not connected; damaged or defective tiller card
    Solution: check connections between control card and controller; use a handset to test for operation of traction reversing switch; replace control card if tiller card is damaged

 

  • Dash display: AL02
    Condition: traction and hydraulic functions not working
    Cause: main contactor tips are welded closed or motor field circuit is broken
    Solution: disconnect power leads at contactor and test for an open circuit; check connections between motor field and controller

 

  • Dash display: AL4
    Condition: traction and hydraulic functions not working
    Cause: damaged connection to lowering valve; damaged lowering coil or lowering valve cartridge
    Solution: check electrical connection between valve coil and controller; check lowering valve coil for resistance, replace if not approximately 17.7 ohms; replace lowering valve cartridge if necessary

 

  • Dash display: AL5
    Condition: traction and hydraulic functions not working
    Cause: damaged connection to brake or brake coil damaged
    Solution: check connection between electric brake and controller; check brake coil for resistance in both directions and replace if not between 27.36 and 30.24 ohms

 

  • Dash display: AL6
    Condition: traction and hydraulic functions not working
    Cause: damaged connection to traction motor; traction motor armature resistance is too low; field wires are loose or damaged; motor field winding is shorted or too low
    Solution: check electrical connection between traction motor, field wires, and controller; check traction motor armature for shorts; check motor field resistance and correct if not between 0.5 and 1.5 ohms; check contactor coil for resistance of 52 ohms

 

  • Dash display: AL7
    Condition: traction functions reduced below 14°F or above 167°F and not working above 194°F
    Cause: controller temperature is too hot or cold; controller temperature is not calibrated correctly; controller sensor or controller itself is damaged
    Solution: move truck to a warmer or cooler location; use a handset to check that controller temperature matches room temperature (if not, replace controller)

 

  • Dash display: AL8
    Condition: traction and hydraulic functions not working
    Cause: over current in driven component
    Solution: check main harness for damaged connections to main contactor, brake, and electric valve coils; check contactor, brake, and electric valve coils for correct resistance (52 ohms for contactor, between 27.36 and 30.24 ohms for brake coil, and 17.7 ohms for electric valve coils)

 

  • Dash display: AL10
    Condition: traction and hydraulic functions not working
    Cause: controller is damaged; damaged wire connection; short circuit in harness; ground between motor windings and chassis; motor field winding is shorted to chassis; field current driver circuit has failed; watchdog hardware circuit is damaged
    Solution: cycle key switch off and on and replace controller if problem not solved; check wire connections at contactor, pump motor, and traction motor; check main harness for shorts; check for grounds or shorts between motor windings and chassis; check motor field resistance (should be about 1.5 ohms); measure voltage between F1 and B- and F2 and B- on field current driver (should be half the voltage between B+ and B-)

 

  • Dash display: AL94
    Condition: traction and hydraulic functions not working for one minute
    Cause: no fault is occurring – the controller is installing hour meter memory from MDI display if controller has been replaced
    Solution: no solution needed; truck will operate as soon as data transfer is complete

 


 

Working on a Hyster forklift? If you need parts, Intella can help.  We have thousands of parts available at great prices and would be happy to help you find what you’re looking for.  Click here for more information!

 

Also you can check out Intella’s YouTube channel for how-to videos and product demos.


Post by Intella Liftparts

How to view a Hyster or Yale forklift hour meter

Want to view the hour meter on your Hyster or Yale forklift? Just follow the instructions below.Hyster Yale forklift 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. This button is located on the right-hand side of the display.

•  Enter the service 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: view the hour meter

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

•  A list of hours should be shown. These include engine, system, hydraulic, and starter hours.

 

This information applies to Hyster FT series models (like H50FT or S50FT) and Yale VX series models (like Yale GLC050VX or GLP050VX).


Post by Intella Liftparts

How-to forklift videos!

You’ve probably been there before. You find a problem with your forklift, figure out the right solution, buy the necessary parts, and then… have to call in help to do the repairs. With 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 our library of original how-to videos for forklift repairs of all kinds. Our videos focus on the most common problems that forklifts can have, ensuring that assistance for you is as available as possible. Check out the list below for more details.

how-to forklift videos Intella Liftparts
Head over there! Just click the image.

Intella Liftparts forklift repair tutorials:

•  Problems with your pallet jack? How to replace a pallet jack load wheel and riser assembly right here.

•  Need help rebuilding your Impco VFF-30 fuel lockoff? Got you covered.

•  What about an Impco model J regulator? Yup. Rebuilding that too.

•  Just keep rebuilding with this Aisan forklift fuel regulator rebuild.

•  To prevent forklift breaks, make sure your forklifts are operating safely with this tutorial on how to fix forklift brakes.

•  Keep your operators comfortable by watching how to properly replace a Toyota forklift seat.

•  New propane tank? Here’s how to replace the old one.

•  Have you been smelling propane gas around your forklift lately? Don’t worry: your forklift probably isn’t leaky, and it doesn’t need to be serviced. Its propane tank simply needs new O-rings. Check out how to replace these rings here.


Post by Intella Liftparts

Burned out lights? Why LEDs are just plain better

 

There’s no question: LED forklift lights are superior to any other type of forklift light. To understand why, let’s first look at some examples of other available lights.

 

sealed beam Intella Liftparts forklift parts

•  sealed beams: A sealed beam light consists of three key components: a parabolic reflector, one or more lighting filaments, and a glass or plastic lens. It is called a sealed beam because these components are all permanently attached (sealed) together. While these lights are cheap and readily available, they have relatively short lives (about 300 hours), are easily broken during shipping, and are relatively dim (typically about 500 lumen). Perhaps not the best choice.

 

 

halogen lamp bulb Intella Liftparts

 halogen lamp: A halogen lamp is essentially a special version of a sealed beam. Inside, it contains a halogen gas (usually iodine or bromine) that reacts with the filament to increase the life of the filament and keep it from decomposing and clouding the lens. These bulbs are bright, compact, and easy to install, but they still have relatively short lives and can be damaged by seemingly harmless things like oil from a fingerprint. They must be handled with care.

 

 

This brings us to the LED, the best light currently on the market. Why is it so great? Here goes:

forklift-LED-bright

 

 

LEDs are bright. They can put out more than 1,000 lumens, which is double the competition (think of the puny sealed beams).

 

 

 

compact forklift LED Intella Liftparts

 

 

 

For their brightness, LED bulbs are extremely compact and very efficient.

 

 

 

 

long lasting forklift LED Intella Liftparts

 

 

LEDs last a long time. They typically have lifespans of over 10,000 hours, which you may realize is more than an entire year of constant output. This is compared to the 300-hour life of a sealed beam (only 3% of the lifespan of an LED). 300 hours won’t get you even two weeks of light.

 

 

 

cheap forklift LED Intella Liftparts

 

 

These forklift lights are getting cheaper. Yes, they’re currently more expensive than both the sealed beam and the halogen lamp, but because of their many other advantages, they are becoming more popular. Competition in the market drives down prices and increases quality, and that’s good for you, the consumer.

burned sealed beam Intella Liftparts
Poor halogen doesn’t stand a chance.

 

 

Still not convinced? Click here to watch our video comparing forklift sealed beams and LEDs.

 

 

Intella Liftparts bluespot light
That’s more like it. Intella’s signature BlueSpot® blue forklift light
LED strobe light amber Intella Liftparts forklight parts
A strobe LED, also available from Intella

 

strobe LED light red Intella Liftparts forklift parts
Available in other colors too!

Post by Intella Liftparts

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 Liftparts

How to decode Hyster forklift serial and model numbers

Note: Looking to locate your Hyster serial number?  Click here.

Sick of overpriced Hyster parts? We can help!  Click here.

 

Hyster forklift serial numbers

Q: How do I decode my Hyster forklift serial number?

A: Post-1957 Hyster forklift serial numbers come in four parts and give information about four different things: the design series of the lift, where the lift was manufactured, the sequence of the lift, and the year it was made. See below for an example of how to read a Hyster forklift serial number.

 

Hyster serial number model Intella Liftparts forklift parts

Part 1: This section should be a combination of letters and numbers. This sequence refers to the design series and model of the lift, according to the table to the right. Click the table for a larger image.

 

Part 2: This section should be a single letter. It identifies the manufacturing plant of the forklift, as described below.

•  A = Irvine, Scotland

•  B = Craigavon, Northern Ireland

•  D = Danville, IL, USA

•  E = Nijmegen, The Netherlands

•  F = Flemington, NJ, USA

•  G = government contracts

•  L = Lenoir, NC, USA

•  N = Greenville, NC, USA

•  R = OBU, Japan (OBU-SHI, Aichi-Ken, 474 IT)

•  S = Sulligent Mfg Plant; Sulligent, AL, USA

•  T = Masate, Italy

•  V = Berea, KY, USA

•  W = Schaeff; Sioux City, IA, USA

•  X = Modena, Italy

 

Part 3: This section should be a number sequence. It indicates the sequence of manufacture at the manufacturing plant of the lift truck. The numbering of production models for each plant begins at 1501.

 

Part 4: This last section should be a single letter. It indicates the year that the lift was manufactured. 1957 began with letter A, 1958 being B, 1959 being C, and etc. The full alphabet is used, except for I, O, and Q. Below are some recent years for reference.

•  X = 2000              •  D = 2006              •  K = 2012

•  Y = 2001              •  E = 2007               •  L = 2013

•  Z = 2002              •  F = 2008               •  M = 2014

•  A = 2003              •  G = 2009              •  N = 2015

•  B = 2004              •  H = 2010

•  C = 2005              •  J = 2011

Check out the image below for REALLY old years.  Remember, if the last digit of your serial number is one of these letters then that’s the age of the forklift.    Remember Hyster re-uses letters every 20 years.

aftermarket forklift parts Intella
Ancient Hyster serial number years

 

Hyster forklift model numbers

Q: How do I decode my Hyster forklift model number?

Similar to a serial number, Hyster forklift model numbers also have four parts: the type of truck, the truck’s capacity, the design series of the truck, and a further indicator of type for electric truck models.

 

Part 1: The first part is a single letter. This letter identifies the series of the lift, according to the following list.

•  B = electric walkie/rider

•  C = electric walkie, center control

•  E = electric lift truck: counterbalanced rider, cushion tires

•  H = pneumatic tire lift truck (IC)

•  J = electric lift truck: counterbalanced rider, pneumatic tires

•  N = electric narrow aisle truck

•  R = electric order picker truck

•  S = cushion tire lift truck (IC)

•  T = electric tractor

•  V = very narrow aisle

•  W = electric walkie

 

Part 2: This section is either a number or a combination of numbers and letters, and it indicates the capacity of the lift truck. If the capacity is in the inch system, multiply the number in the model code by 100. This capacity is in pounds. For example, if this section of the code is “30,” the capacity of the truck is 30 x 100 lbs, or 3,000 lbs.

If the capacity is in the metric system, look at the number within this section. This gives the capacity directly in metric tons.

 

Part 3: This section is a single letter, and it designates the design series of the truck. The first design used is represented by A, the second by B, the third by C, and so on through the alphabet. The letters D, G, I, and O are not used.

 

Part 4: Finally, the last section is either a single letter or two letters that indicate further the specific type of an electric truck model. Note that XL and XM describe design concepts and can be disregarded.

•  A = straddle

•  C = center control – standrive

•  H = pneumatic

•  L = low level pallet

•  R = reach

•  R = rear standrive

•  S = short wheelbase

•  S = stepped battery compartment

•  T = high level pallet

•  T = three-wheel

•  DR = double reach

•  MD = man down

•  MU = man up


Post by Intella Liftparts

How to decode Toyota forklift model numbers

Related Articles:

 

Q: How do I decode my Toyota forklift model number?

A: There’s no denying it: Toyota forklift model numbers can be complicated. Each class of Toyota lift truck has a model number of a different length and is interpreted in a different way. Things can get confusing. Hopefully, however, the diagrams below may help in properly reading your Toyota forklift model number.

 

This diagram includes information for forklifts of classes I, II, II stand-up electric rider, III, IV, and V. Notice that there are nine sections on the diagram, but not all classes have information in their model numbers for each section. In these cases, the sections that are “not present” for your forklift’s class are simply skipped. To see an example of how to use the diagram, look at the second image. Click either image below to see a larger version. A PDF version of the main diagram available for download is also attached below.

Toyota forklift model code diagram Intella Liftparts forklift parts

A PDF version of this diagram is available for download here: Toyota forklift model codes diagram by Intella

 

SIS forklift radar

 

Below is the example of decoding a class IV forklift with model number 42-8FGCU25.

Toyota forklift model code diagram Intella Liftparts

CLASS WARFARE:  In the forklift industry when you hear the term “class” mentioned, it may mean two different things.

ITA forklift class:  ITA (Industrial Truck Association) created a class system for the type of forklift.  Class 1 is electric rider, class 4 is cushion sit down engine powered, etc.  That’s not to be confused with carriage class.  Class 3 forklift forks could fit on an ITA class 4 forklift.  Confused yet?    Just ask for clarification.  Is the person or website referring to forklift type class or carriage class.

 

Once you have your model number, visit our Toyota Forklift Parts Manual to get the parts you need.


Post by Intella Liftparts

How to decode Yale forklift serial and model numbers

Note: If you’re looking to locate your Yale forklift serial number, check out our guide here.  Need Yale forklift parts?  Intella is your source.

 

Yale forklift serial numbers

Q: How do I decode my Yale forklift serial number?

A: Yale forklift serial numbers consist of four parts, and each part gives information about the lift truck to which the serial number is assigned. These four parts are the design series, the manufacturing plant, the sequence of manufacture, and the year of manufacture of the lift truck. This system of numbering  has been in place since 1995. (If these instructions look familiar, it is because Yale and Hyster forklift serial numbers are interpreted the same way. Another blog post covers the basics of reading Hyster serial and model codes.)

Yale serial number model Intella Liftparts forklift parts

 

Part 1: This section should be a combination of letters and numbers. This sequence refers to the design series and model of the forklift, according to the table to the right. Click the table for a larger image.

 

Part 2: This section should be a single letter. It identifies the manufacturing plant, as described below.

•  A = Irvine, Scotland

•  B = Craigavon, Northern Ireland

•  D = Danville, IL, USA

•  E = Nijmegen, The Netherlands

•  F = Flemington, NJ, USA

•  G = government contracts

•  L = Lenoir, NC, USA

•  N = Greenville, NC, USA

•  R = OBU, Japan (OBU-SHI, Aichi-Ken, 474 IT)

•  S = Sulligent Mfg Plant; Sulligent, AL, USA

•  T = Masate, Italy

•  V = Berea, KY, USA

•  W = Schaeff; Sioux City, IA, USA

•  X = Modena, Italy

 

Part 3: This section should be a number sequence. It indicates the sequence of manufacture at the manufacturing plant of the lift truck. The numbering of production models for each plant begins at 1501.

 

SIS forklift radar

Part 4: This last section should be a single letter. It indicates the year that the lift was manufactured. 1995 began with letter S, 1996 being T, 1997 being U, and etc. The full alphabet is used, except for I, O, and Q. Below are some recent years for reference.

•  X = 2000              •  D = 2006              •  K = 2012

•  Y = 2001              •  E = 2007               •  L = 2013

•  Z = 2002              •  F = 2008               •  M = 2014

•  A = 2003              •  G = 2009              •  N = 2015

•  B = 2004              •  H = 2010

•  C = 2005              •  J = 2011

Notice that, yes, a letter can refer to multiple years. For example, “S” can refer to either 1995 or 2018. Typically, though, you will be able to tell if your forklift is 20 years old or brand new.

Shortcut on Yale models:  If the model contains the letter C, it will have cushion forklift tires.  if the model contains the letter P, it will have pneumatic forklift tires or pneumatic shaped solid forklift tires.

 

Yale forklift model numbers

Yale model table Intella Liftparts forklift parts

Q: How do I decode my Yale forklift model number?

A: The first step to reading a Yale forklift model number is to understand which models fall under which types of Yale trucks. To the right is a table detailing which models are electric three wheels, electric four wheels, and ICEs. Click the table for a larger image.

 

 

Once you know which type of forklift you have, use the following chart to determine what the letters and numbers in your model number mean. Click on the chart to view a larger image. To download a PDF version of this chart, click here: Yale forklift model codes diagram Intella

Yale model number decoder Intella Liftparts forklift parts


Post by Intella Liftparts