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JLG Boom Lifts – Troubleshooting

 

Fix those codes!

So your JLG boom lift isn’t functioning properly? Well that’s alright because we’ve come up with a troubleshooting page for you, this one specifically for JLG boom lifts. Written below are some highly popular JLG boom 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 boom lift troubleshooting

Popular JLG Boom Lifts:

– JLG 400S            – JLG 800’s

– JLG 450A’s          – JLG 860SJ

 – JLG 460SJ           – JLG E300’s

– JLG 600’s            – JLG E400’s

– JLG 660SJ’s        – JLG E450’s

 

Chassis & Turntable Codes 

Listed below are various Diagnostic Trouble Codes and their corresponding descriptions along with the best action to take to resolve it.

 

 

DTC: 116

Fault Message: ECT higher than expected stage 1

Description: Engine Coolant Temperature reading or estimate greater than the stage 1 limit when operating at a speed greater than defined in the diagnostic calibration.

Corrective Action: Sound audible warning or illuminate secondary warning lamp, disable adaptive learning fuel correction during active fault.

 

 

DTC: 117

Fault Message: ECT Voltage Low

Description: Sensor voltage less than the limit defined in the diagnostic calibration.

Corrective Action: Sound audible warning or illuminate secondary warning lamp, disable adaptive learning fuel correction during active fault.

 

 

DTC: 118

Fault Message: ECT Voltage High

Description: Sensor voltage higher than the limit defined in the diagnostic calibration.

Corrective Action: Sound audible warning or illuminate secondary warning lamp, disable adaptive learning fuel correction during active fault.

 

 

DTC: 122

Fault Message: TPS 1 Low Voltage

Description: TPS sensor voltage lower than the limit defined in the diagnostic calibration.

Corrective Action: Sound audible warning or illuminate secondary warning lamp, shut down engine

 

 

DTC: 123

Fault Message: TPS 1 High Voltage

Description: TPS sensor voltage higher than the limit defined in the diagnostic calibration.

Corrective Action: Sound audible warning or illuminate secondary warning lamp, shut down engine

 

 

DTC: 217

Fault Message: ECT higher than expected stage 2

Description: Engine coolant temperature reading greater than the stage 2 limit when operating at a speed greater than defined.

Corrective Action: Sound audible warning or illuminate secondary warning lamp, disable adaptive learning fuel correction during active fault.

 

 

DTC: 219

Fault Message: RPM higher than max allowed

Description: Engine speed greater than the max governor override speed as defined.

Corrective Action: Sound audible warning or illuminate secondary warning lamp, reduce throttle to limit speed.

 

 

DTC: 336

Fault Message: Crank signal input noise

Description: Electrical noise or irregular crank pattern detected causing x number of crank resynchronization events

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp and disable fueling correction for remainder of key cycle.

 

 

DTC: 337

Fault Message:  Loss of Crank Input Signal

Description: loss of crankshaft position signal while valid camshaft position signals continue for x number of cam pulses.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp.

 

 

DTC: 521

Fault Message: Oil pressure high

Description: Oil pressure is indicating high when the engine has been stopped for more than x seconds.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, possibly configure for power derate 1 or low rev limit.

 

 

DTC: 524

Fault Message: Oil pressure low

Description: Engine oil pressure lower than expected while engine has been running for a minimum amount of time

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, generally configured to derate the engine and trigger an engine shutdown.

 

 

DTC: 562

Fault Message: Battery voltage low

Description: Battery voltage to ECM less than x volts while the engine is operating at y RPM or greater

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle.

 

 

DTC: 563

Fault Message: Battery voltage high

Description: Battery voltage to ECM greater than x volts while the engine is running.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle.

 

 

DTC: 642

Fault Message: Sensor supply voltage 1 low

Description: ECM 5 volt output is below the acceptable limit.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp.

 

 

DTC: 643

Fault Message: Sensor supply voltage 1 high

Description: ECM 5 volt output is above the acceptable limit.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp.

 

 

DTC: 1612

Fault Message: Microprocessor failure RTI 1

Description: Internal microprocessor error

 

 

DTC: 1613

Fault Message: Microprocessor failure RTI 2

Description: Internal microprocessor error

 

 

DTC: 1614

Fault Message: Microprocessor failure RTI 3

Description: Internal microprocessor error

 

 

DTC: 1615

Fault Message: Microprocessor failure A/D

Description: Internal microprocessor error

 

 

DTC: 1616

Fault Message: Microprocessor failure Interrupt

Description: Internal microprocessor error

 

 

DTC: 1625

Fault Message: CAN J1939 shutdown request

Description: ECM has received shutdown message from another CAN device and is shutdown on request.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp.

 

 

DTC: 1652

Fault Message: TPS1 loss of communications

Description: ECM is expecting to receive throttle position information from the throttle actuator and is not.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp. Shut down engine.

 

 

DTC: 2111

Fault Message: Unable to reach lower TPS

Description: Throttle command is 20% less than throttle position for 200ms or longer.

Corrective Action: Engine shut down

 

 

DTC: 2112

Fault Message: Unable to reach higher TPS

Description: Throttle command is 20% more than actual throttle position.

Corrective Action: Engine shut down

 

 

DTC: 9999

Fault Message: TPS1 failsafe spring failure

Description: When the key is off, the ECM is expecting the failsafe spring in the actuator to return the throttle position to near 0%.

Corrective Action: Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp. Govern the engine speed to a forced idle speed.

 

 

intella-710x170-jlg

 

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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Budget costs for a rebuilt forklift engine

Forklift smoking?  Think you need a new engine?  Here are some “ball park” estimates for the price of a remanufactured engine.  Keep in mind this does not include labor to replace engine, shipping costs or accessory parts such as new water pump, belts, filters, etc.

 

Prices below do not include labor.  Labor to install a remanufactured engine usually runs around 24 hours.  If your forklift has a cab (making it more difficult to remove the engine), you should add around 8 hours.   Labor usually runs anywhere from $75 – $140 per hour depending on where you are located.  In other words, labor can run anywhere from $1800 – $3360 plus the costs below.

 

Need more help trying to figure out if your old forklift is worth replacing?  Check out this article here.

 

GM  181  (used in Hyster and some limited Yale forklifts)  $2200-2500

 

GM 4.3 engine (used in Hyster, Yale, and Toyota forklifts)  $2400-2700

 

Mazda F2 engine (used in Yale and Hyster forklifts)  $2500-2700

Mazda FE engine (used in Yale and Hyster forklifts)  $2300-2600

 

Nissan H20 (used in Komatsu, TCM, and Nissan forklifts $2000-2300

Nissan K21 or K25 (used in Nissan and Cat/MItsubishi forklifts)  $3000-3500

 

Mitsubishi 4G54 4G52 (used in Clark and Mitsubishi forklifts)  $2200-2800

Mitsubishi 4G63 4G64 (used in Clark, Cat, and Mitsubishi forklifts)  $2500-2700

 

 


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JLG Troubleshooting – Aerial Lifts

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.

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.

 

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?

To find the Toyota forklift year of manufacture, click on the link labeled ‘Intella Liftparts – How old is my Toyota forklift?’ below. Then press CTRL + F and type in your forklift model. Compiled throughout the link are various Toyota forklift models. The search function should take you straight to your model where all you will need is the serial number of your forklift.

Intella Liftparts – How old is my Toyota forklift?

 

 

toyota forklift year

 


 

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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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, or F2SM.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.

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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.

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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.

 

 

Keep Out Zone Light Turned ON      Keep Out Zone Light Turned OFF Keep Out Zone Light Side View Keep Out Zone Light Display on Forklift

 

 

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.

 


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Search for Parts by Forklift Model Number

Search by Forklift Model Number

Big, new feature here at Intella! We’ve made finding parts for your forklift 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