technical info Archives

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.

Let us help you find your code
  • 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

Looking for Hyster forklift 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 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.

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

Looking for Yale forklift 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.


Post by Intella Liftparts

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 Liftparts

How much can my forklift lift?

“How much weight can my forklift lift?”  It’s a common question for many and the answer starts by looking at the forklift data tag on your forklift.

 

Q: What is a forklift data tag?

A: A forklift data tag, also called a nameplate, load plate, or data plate, concisely displays information about the lift truck for the use of its operator. According to OSHA, all operators must be trained in reading a data tag and understanding what it means so as to maintain a safe work environment for all employees near or in contact with the truck. A truck cannot legally be operated without a readable data tag.

 

 

forklift data tag intella forklift parts

Q: What does a forklift data tag look like?

A: A standard data tag is shown to the right. By OSHA regulation, the tag must be durable, corrosion-resistant, and legible. It is often displayed near the driver’s seat for easy accessibility, and it typically includes some sort of warning about proper use of the lift truck. Be sure to read this warning.

 

 

Q: How do I read a forklift data tag?

A: The information on a data tag can look daunting, but with familiarity, reading it can be quite straightforward.

 Model, type, and serial number are often displayed near the top of the data tag.

 Mast information is sometimes displayed on the tag as well. In the example above, it is shown in the bottom half of the tag with the use of a diagram. Other tags may include this information without a diagram in the upper half of the tag. Mast information includes maximum height, number of stages, and sometimes maximum degree of tilt.

 Truck weight is often displayed in the upper half of the tag.

 Capacity and load center are typically shown in a table-like format. They are in table format to include room for the capacity and load center when certain attachments are used.

•  Somewhere on the tag, designation of compliance with safety standard requirements must be present, which is the responsibility of the manufacturer. Often the data tag itself has a type of serial number as well, so that it can be tracked if need be.

 Information on wheels, tires, and batteries may also be included, but this is not necessary by OSHA standards.

Yale data tag intella forklift parts
tag layouts can vary – notice that this one does not have capacity data in table format

Yale data tag intella forklift parts
this Yale tag has a more typical tabular layout, with a diagram to the right

Q: When do I need a new forklift data tag?

A: If you add a new attachment that changes the configuration of the forklift, you need to order a new data tag from the manufacturer.  Some manufacturers provide these at no charge, others charge up to $150 per tag.  When ordering the data tag, the manufacturer will want to know any attachments that have been installed on the forklift after the forklift was shipped from the factory.  Attachments such as side shifters, clamps, rotators, fork positioners, etc change the capacity of the forklift.

 

Q: How do I determine lift capacity from a forklift model number?

A: There are some simple ways of knowing the lift capacity of a forklift without looking at the data tag.  While the data tag is the most reliable method of checking capacity,  the model usually designates the standard lifting capacity of the forklift without any attachments.

 

American manufacturers such as Hyster, Yale, Crown, and Raymond will typically have a number designation in their model which, if multiplied by 100 will equate to the rough lifting capacity of the forklift.  For example, a Hyster S50FT will have a lifting capacity of 5,000 pounds before any attachments are installed.  A Yale GLC120 will have an estimated lifting capacity of 12,000 pounds before any attachments.

 

Toyota 7FGU25 data tag intella forklift parts
this Toyota 7FGU25 has a capacity of 2,500 kg normally – but it has an attachment that changes this capacity

Japanese manufacturers such as Toyota, Nissan, Komatsu, Mitsubishi, TCM, NYK will designate the lifting capacity in metric form.  A Toyota 7FGCU25 will have a lifting capacity of 2,500 kilograms or 2500 x 2.2 pounds per kilogram = 5,500 pounds.  A TCM FCG15 will have a lifting capacity of 1,500 kilograms (x 2.2 for pounds).

 

These are only general guidelines and useful for determining approximate lifting capacity from the model number before any attachments are added.  If you want to know the exact lifting capacity of any forklift, check out the data tag!

 

 

For more information, see www.osha.gov/SLTC/etools/pit/forklift/basicparts/nameplate.html.


Post by Intella Liftparts

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 Liftparts

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


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