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.

 

 

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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)  $3000-3300

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

 

Mazda F2 engine (used in Yale and Hyster forklifts)  $3100-3350

Mazda FE engine (used in Yale and Hyster forklifts)  $2700-3000

 

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)  $3000-3200

Mitsubishi 4G63 4G64 (used in Clark, Cat, and Mitsubishi forklifts)  $2900-3200

 

Toyota uses its own 4Y engine in its heart of the line forklift models such as 8FGCU15, 8FGCU25.

Check out pricing on a brand new here!

 


Post by Intella Liftparts