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JLG Troubleshooting – Aerial Lifts

Note: Click here to find JLG Wheels

 

Fix those codes!

We understand every JLG aerial lift encounters a problem once in a while. That’s why we’ve come up with a troubleshooting page for you, this one specifically for JLG troubleshooting. Listed below are some popular JLG scissor lifts and their corresponding error codes, although not restricted to these models. If you ever need JLG replacement parts or accessories, you can visit our website by clicking here.

 

JLG troubleshooting 1930ES

 

Popular JLG Scissor Lifts:

  • JLG 1930ES
  • JLG 2030ES
  • JLG 2032ES
  • JLG 2630ES
  • JLG 2632ES
  • JLG 2646ES
  • JLG 3246ES

 

 

JLG troubleshooting diagnostic codes:

If the number starts with….. it’s a

2-1 – Power Up Problem

2-2 – Platform Controls

2-3 – Ground Controls

2-5 – Function Prevented

3-1 – Line Contactor Open Circuit              6-6 – Communication

3-2 – Line Contactor Short Circuit               6-7 – Accessory

3-3 – Ground Output Driver                        7-7 – Electric Motor

4-2 – Thermal Output                                 8-1 – Tilt Sensor

4-4 – Battery Supply                                   8-2 – Platform Load Sense

 

 

Popular JLG Troubleshooting Codes

  • Error Code: 212

Fault Message: Faulty Keyswitch

Description: Both platform and ground modes are selected simultaneously.

Check: Key switch function, Check wiring to key switch function.

 

  • Error Code: 221

Fault Message: Horn Permanently Selected

Description: The horn switch was closed during power-up in platform mode.

Check: Check if the horn is damaged, obstructed or jammed.

 

  • Error Code: 226

Fault Message: Accelerator Faulty

Description: The joystick signal is outside the acceptable range of 0.5V – 4.5V.

Check: Center joystick and check to see if a power cycle will clear DTC.

 

  • Error Code: 231

Fault Message: Function Problem – Lift Permanently Selected

Description: The ground control box lift switch was closed up or down, during power up in ground mode.

Check: Check if the lift switch is obstructed or jammed.

 

  • Error Code: 233

Fault Message: Function Problem – Brake Release Permanently Selected

Description: The manual brake release switch was closed during power-up.

Check: Check if brake release switch is obstructed or jammed.

 

  • Error Code: 251

Fault Message: Elev Angle Sensor Faulty

Description: Elevation angle sensor input voltage is outside the acceptable range of 0.10V – 4.50V.

Check: Check that the platform elevation sensor is securely mounted and undamaged, Check the elevation sensor wiring.

 

  • Error Code: 314

Fault Message: Auxiliary Circuit – Open Relay

Description: The auxiliary relay did not close when energized.

Check: Check the auxiliary relay coil and associated wiring.

 

  • Error Code: 441

Fault Message: Battery Voltage Too Low

Description: The power module momentarily measure battery voltage under 14.5V.

Check: Recharge batteries or check for damaged batteries.

 

  • Error Code: 775

Fault Message: Open Circuit Field Wiring

Description: Drive, steer, and lift prevented.

Check: The system module applied field current, but could regulate the desired current. The situation is caused by improper field wiring or a damaged motor.

 

 


 

JLG troubleshooting

Need JLG aerial lift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

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Alligator Forklift Jack by Intella Liftparts

A Mechanic’s Best Friend. The Forklift Jack.

Do you work on forklifts? If yes then you need the Alligator Forklift Jack from Intella! For maintenance and repairs, the alligator jack is your right hand man. From wooden shoes to the Alligator Jack, the Netherlands know how to craft some pretty high quality products and this is one of them. Our jack is uniquely designed to handle the toughest of jobs.

 

alligator forklift jack intella

 

We know what lift truck mechanics need and the Alligator jack has all the features you want:

– custom designed for use on forklift trucks
– max load of 4000kg (8800 pounds)
– minimum height of 60-68mm (2.3-2.7 inches)
– lift height of 420mm (16 inches)
– width of 200mm (7.87 inches)
– weight of 31kg (68 pounds)

 

We have a complete stock of spare parts, making it completely rebuildable.

The Alligator forklift jack comes with a full 1 year warranty.

 

 

Here are a couple pictures of the Alligator Jack in action:
forklift jack intella liftpartsforklift jack intella liftparts

Watch Our Video

 

 


Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

 


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Genie Scissor Lift Charger – stay juiced.

Note: Click here to shop Genie Aerial Wheels

 

Your scissor lift takes a boat load of charged batteries to operate properly. For most of them, that number is four. These battery trays that hold the charging system are set up generally in the same way. Some trays have 4 batteries in a row, others in a 2 by 2 setup. Either way, they feature a 24V battery charger to keep the batteries in shape. A workhorse of the scissor lift, this battery charger needs to be in tip-top shape. When yours starts to get bogged down, do us a favor and check out Intella Liftparts. Intella offers a 24V Genie scissor lift charger capable of servicing many different scissor lifts. The charger will work on almost any scissor lift battery, including one of the most common brands, Trojan.

 

scissor lift battery chargers

Will it work on a Genie? Yes

 

scissor lift battery charger

Will it work on a Sky jack? Yes

genie scissor lift charger

Will it work on a MEC? Yes

 

Genie Scissor Lift Chargergenie scissor lift charger

Part Number – 105739

 

Parts Included:

Two different types of AC power cords depending on your model.

One type has a 90 degree input plug, the other type has a straight input plug.

Disregard whichever plug your Genie doesn’t use.

DC Output cord (positive/negative): approximately 30 inches / 75mm

Features easy to view charge capacity indicator: 50%, 75%, 100%

 

Specs:

Voltage: AC Input – 115V/230V (Automatically selects); DC Output – 24V nominal
Max. Current: AC Input – 9A at 85V/4.5A at 170V; DC Output – Max. 19 ADC
Frequency: AC Input – 60/50 Hz
Phase: AC Input – Single
Output Power Max: DC Output – 600 Watts

 

Dimensions:

Height: 6.25 inches / 160mm
Width: 6.8 inches / 175 mm
Depth: 8.5 inches / 200mm
Weight: 11 lbs

 

Used on the following Genie aerial work platform models:

GR-20           GRC-12         GS-1530      GS-1532
GS-1930       GS-1932        GS-2032      GS-2046
GS-2632       GS-2646        GS-3232      GS-3246
QS-12R         QS-12W        QS-15W       QS-15R
QS-20R         QS-20W        TZ-34/20      TZ-50/30

 

genie scissor lift charger


 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Liftparts

How old is my Toyota forklift? Toyota forklift year.

 

Toyota Forklift Year by Model Number

Decoding forklift model numbers can be difficult to begin with and it seems as though Toyota only makes it harder. Each year Toyota creates a model number with a different set of letters and numbers that all stand for something. These characters make up the engine type, construction features, any model changes, how it’s powered, the load capacity and more. The different characters in the model number are explained in the coding system below. In the example, there are 8 characters in the model number although the coding system shows 9 possible characters. For any empty spot like the one below, it means there is no information applicable to the forklift so you can simply skip that section.

 

Note: You can find a vast array of Toyota forklift radiators here.

 

Toyota forklift year intella liftparts
Click here for a full size representation on how Toyota codes their models.

 

So what is the age of my Toyota forklift?

We have digitized this search now! Check it out:

Intella Liftparts – how old is my Toyota forklift


Need forklift parts? With thousands of parts in stock, quick
shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

toyota forklift year


Post by Intella Liftparts

Mazda Forklift Engine – 2.0L or 2.2L?

It’s never an easy job figuring out what kind of forklift engine you have. Even for a seasoned parts person, it can be troubling. This article will be covering the easiest way to identify your Mazda forklift engine whether it’s an FE, F2SA engine, or F2SM engine.Mazda Forklift Engine

 

The Mazda FE and F2SA engines are used by both Hyster and Yale. TCM uses the F2SA belt drive as well but more often uses the F2SM chain drive with a different type of cylinder head. All three of these engine styles  have either FE of F2 stamped into the corner of the deck on the engine block. The issue with this is that when an engine is resurfaced, the stampings get machined off of the block. Also it’s not the easiest task to find the tab on a hard-worked, dirty engines. The list below will breakdown the different engines so that you can properly identify what Mazda forklift engine you have.

 

Mazda FE – 2.0L Timing Belt

  • If you look at the plastic dust cover or on the inner plate behind the cam sprocket, 2.0L is casted.
  • There are three crankshaft variations, all of which are a shorter stroke than the F2.
    • Pin Type – 1″ crank nose with alignment dowel pin
    • Short Nose Keyed – 1″ crank nose with crank key
    • Long Nose Keyed – 1.9″ crank nose with wedge in hydraulic pump drive hub
  • The oil pump is set in the lower front of the engine. It has four oil pump bolts.
  • The FE engine uses only a belt tensioner.

 

Mazda F2SA – 2.2L Timing Belt

  • If you look at the plastic dust cover or on the inner plate behind the cam sprocket, 2.2L is casted.
  • There are two crankshaft variations, which have the same journal size with a longer stroke than the FE.
    • Short Nose Keyed – 1″ crank nose with crank key
    • Long Nose Keyed – 1.9″ crank nose with wedge in hydraulic pump drive hub
  • The oil pump is set in the lower front of the engine. It has three oil pump bolts.
  • The F2 uses both a belt tensioner and belt idler.

 

Mazda F2SM – 2.2L Timing Chain

  • Only one style crankshaft which has a different crank nose than all the other crankshafts listed. Keep in mind it does have the same stoke as the F2SA crankshaft.
  • The timing chain chain is in an aluminum front cover
  • TCM is the only brand that uses it

 

Mazda Forklift Engine

 


 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service,Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Liftparts

You can’t spell reliable without Renold ANSI Roller Chain

Take your operations further with the Renold ANSI Roller Chain.

Domestic, agricultural and industrial machinery commonly use an downloadANSI roller chain for transmission of mechanical power. One of the most noteworthy applications that people recognize is the chain on a bicycle. Roller chains are also used on conveyors, cars, motorcycles, printing presses and much other machinery. Renold has been manufacturing quality components that exceed ANSI (American National Standards Institute) standards for over 100 years now. Ever since their first chain in 1878, Renold has been advancing chain technology. Renold offers top grade factory lubrication, accurate press fits, and super-straight bushings. As a result, the time needed to break in a new chain is greatly reduced.

 

For those who are looking for a hardworking chain, Intella now offers a select few of these Renolds chains online. All chains come 10 feet in length and there are various dimensions to choose from. We offer a Chinese manufactured roller chain for an economic option. Also offered is a German manufactured roller chain for top of the line quality and reliability.

 

ANSI Roller Chain

 

Intella offers ANSI Roller Chains of a few different dimensions

 

 

Different parts of a roller chain pictured here:

A)   Pitch
B)   Inside Width Min
C)   Roller Diameter Max
D)   Plate Height Max
E)   Inner Plate Thick Max
F)   Outer Plate Thick Max
G)   Pin Diameter Max
H)   Pin Length Max
J)   Connector Link Extra Max

 

ansi roller chain

 


 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Liftparts

Keep Out Zone Light

*NEW SAFETY PRODUCT*  –  Keep Out Zone Light

Our ‘Keep Out’ Red Zone Light does exactly that–Keep Out Zone Light Intella Liftpartskeeps pedestrians away from your forklifts! There are nearly 19,000 forklift related accidents per year involving pedestrians in the USA alone. Help reduce this number with the Keep Out Zone Light to warn pedestrians of forklifts in the area. The light is easily installed on the side of the forklift. When mounted, the product projects a large, red beam of light onto the ground to warn pedestrians in the work area that a forklift is near. The red beam of light projected on the ground is referred to as the ‘keep out zone’ and is not to be entered while the forklift is in operation.

 

When used in conjunction with the Blue Spot Forklift Light, which is mounted on the back of the forklift, pedestrians can have complete awareness of forklift traffic. The Blue Spot Forklift Light warns pedestrians around the corner or down the aisle that traffic is coming. The Keep Out Zone Light helps pedestrians keep a safe distance away from the forklift at all times. The Keep Out Zone Light is similar to the Speaker Model 527 (part no. 0549271). Intella also has an online accessory catalog full of LED work lights suitable for forklifts. You can download that pdf file here.

 

 

 

 

Dimensions
Length: 2.54″
Width: 10.50″
Height: 4.37″
Weight: 2.75 lbs

 

Material
Housing: UV Resistant Thermoplastic (ASA)
Lens: High-Grade Polycarbonate
Heat Sink: Die Casting Aluminum
Mounting Hardware: Stainless Steel

 

Specifications
Rating: 9-33V DC Multi-Voltage
Amps: 1.7 Amps @ 12V
Operating Temperature: -22°F to 149°F
Vibration: 7G
LED Lamp Type: 3W x 12 PCS (615~630mm)
LED Lifespan: 50,000 Hours
Partial Flux: 3000 Lm

 

Area covered by light when mounted at specific height:

Mounting Height at 4ft — 6.1ft width, 1.3ft depth

6ft — 9.1ft width, 2.0ft depth

8ft — 12.1ft width, 2.7ft depth

10ft — 15.2ft width, 3.3ft depth

12ft — 18.2ft width, 4.0ft depth

14ft — 21.2ft width, 4.7ft depth

 

keep out zone light


 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

 


Post by Intella Liftparts

Search for Parts by Forklift Model Number

Search by Forklift Model Number

Big, new feature here at Intella! We’ve made finding forklift parts for just that much easier. At the corporate office that makes up Intella Liftparts, we do our best to fine tune everything that makes up your online retail experience. That’s why we have implemented a new search feature based off of the forklift model number you have. So instead of receiving a list of a thousand different forklift parts, you can narrow down those results specifically to fit your forklift. The first step in the search process is to obtain your forklift model number. If you don’t know it, have no fear the Intella archives are here. Here are a few posts that lay out how to find your serial number based on the model you have.

Forklift Model Number Intella Liftparts

 

 

 

After you have your model number identified, you will click on the icon that pertains to it. You will then find a list of various parts icons, just like what’s pictured below. By clicking on the part you need, an air filter for example, you will be taken to a page that lists all air filters that fit the model forklift you’ve selected.

 

Forklift Model Number Intella Liftpartsforklift model number

 

As of right now, the parts lookup by forklift model number is available for Toyota, Hyster, and Caterpillar. For those with other forklift brands, we are still in development. So don’t worry, more brands are going to be coming soon… we just couldn’t wait to release our new feature! Here’s the links to the part look-ups available right now:

Forklift Model Number Intella LIftparts

 

 

Toyota Parts Lookup By Model Number

 

Hyster Parts Lookup By Model Number

 

Caterpillar Parts Lookup By Model Number

 

 


 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Liftparts

Forklift Battery Troubleshooting

Forklift Battery Troubleshooting: If only they could last forever.

Chances are your battery is going to give you problems at some point in time. When those problems arise, we want to you to be prepared which is why we made this forklift battery troubleshooting guide. Below is a list of common problems associated with forklift batteries that occur over time. Listed are the different battery troubles, the conditions what come with them, what’s causing the problem, and how to collectively act upon it.

 

forklift battery troubleshooting intella liftparts

Short Circuited

Condition:

  • Very low cell voltage and specific gravity during recharging and discharging
  • Low gassing while charging
  • Extreme rise of electrolyte temperature during charging phase
  • Fast drop of gravity after charging

 

Why is this happening? Probable cause:

  • Short circuited due to a dropping of active materials
  • Short circuited due to a broken separator
  • Short circuited due to advancing of broken pieces during manufacturing of battery

 

Where to go from here:

  • Replace the faulty cell with a single charged cell

 

 

Sulfation

Condition:

  • While charging, the voltage and electrolyte temperature are much higher than the standard
  • Gassing is accelerated from charging and the gravity does not rise to normal
  • Voltage drops quickly while discharging
  • In some extreme cases, plates may become whitened

 

Why is this happening? Probable cause:

  • Repeatedly overcharging and discharging of battery
  • Plates exposed to open air for extended period of time
  • Lack of care during storage process
  • Excessively high gravity while using battery
  • Impurities causing excessive self discharge of battery

 

Where to go from here:

  • If the battery is in rather early conditions, remove the probable cause
  • Replace the faulty cell with a single charged cell if damage can’t be fixed

 

 

Excessive Self Discharging

Condition:

  • Quick drop in gravity after charging
  • Charging capacity of battery significantly reduced

 

Why is this happening? Probable cause:

  • Using impure water in the battery
  • Specific gravity higher than it should be
  • Excessively high temperature of electrolytes
  • Battery container has been insufficiently cleaned

 

Where to go from here:

  • Take daily care of the battery
  • Replace the faulty cell with a single charged cell

 

 

Exchange of Polarity

Condition:

  • Polarity switched around in some cells during discharging or high temperature of electrolytes
  • Electrolytes dissolve causing an emission of gas that changes the polarity of the battery

 

Why is this happening? Probable cause:

  • Caused by quick discharge without noticing a low capacity in a cell
  • Ill preparation of certain means like an equation charge

 

Where to go from here:

  • Replace faulty cell
  • Take daily care of the battery

 

Forklift Battery Troubleshooting Intella Liftparts

Other Possible Factors

1. Color of electrolyte has changed to brown

– Due to corrosion of positive plate mixing into electrolytes

– Check voltage and gravity of battery

– Replace electrolyte

 

2. Chlorine smell during charging

– Due to sea water mixing into electrolytes

– Replace electrolyte and charge the battery until the smell is gone

– Replace cells

 

3. Electrolyte excessively reduced

– Battery cells are cracked

– High electrolyte temperature while charging

– Find causes and follow repair procedures

 

4. Unnaturally high electrolyte temperature

– Due to lack of electrolytes

– Due to shorted cells and/or reversed polarity

– Solder battery

 

5. Heat from connector portion

– Bad connector contact

 

Forklift Battery Troubleshooting Intella Liftparts

 


 

 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Post by Intella Liftparts

How to Fix a Forklift

You’ve probably been there before. You discover a problem with your forklift, find the right solution, buy the necessary parts, and then have to call in help to do the rest. But at 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 this list of our ‘how to fix a forklift’ articles for repairs of all kinds. Our work focuses on the most common problems that forklifts can have, ensuring that help for you is as available as possible. Beyond repair tips, we also make it our goal to cover every other aspect of owning a forklift, from proper maintenance to safety training to varieties of forklift tires. Here at Intella, we strive to keep you up to date with the most current information we can provide about your vehicle. You know us as a parts service; now get to know us as so much more. Below you will find links to some of our popular ‘how to fix a forklift’ articles. Clicking on the title will take you right to the article page. You can also click here for a full list of articles on our website.

how to fix a forklift intella liftparts

How to identify and replace electrical contactors

How to select the best battery for your forklift

How to block your forklift prior to performing repairs

How to buy a new forklift

How to troubleshoot a no-start condition

How to maintain your forklift engine (internal combustion and electric)

How to replace a blown fuse

How to pick the right tires for your forklift

How to select a forklift battery charger

How to find the serial number on you forklift

How to avoid common forklift hazards

For more how-to articles and all around product knowledge, click here

how to fix a forklift intella liftpartsOh and if you want to prove to everyone that you’re

the boss, we’ve got just the right t-shirt for you.

 

 how to fix a forklift

 


Need forklift parts?  Need a Toyota forklift seat?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.


Post by Intella Liftparts