JLG Boom Lift X600AJ X20JP Service & Maintenance Manual 31223077 2025

[Hyundai]

Download this document, you need 1605 Gallons

JLG Boom Lift X600AJ X20JP Service & Maintenance Manual 31223077 2025
Size: 19.64 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual
Model: JLG X600AJ X20JP Boom Lift
Part Number: 31223077
Publication Date: 2025
Number of Pages: 326 Pages

Contents:
Safety

General (concept)​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards (task)​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information & Specifications

Specifications​

2.1.1 Machine Specifications​

2.1.2 Machine Dimensional Data​

2.1.3 Engine Data​

2.1.4 Reach Specification​

2.1.5 Function Speed Data​

2.1.6 Hydraulic Pressure Settings​

2.1.7 Major Components Weight​

Machine Temperature Chart​

Serial Number Locations​

2.3.1 Serial Number Location​

Fluids and Lubrication​

2.4.1 General Information​

2.4.2 Hydraulic Oil​

2.4.3 Changing Hydraulic Oil​

2.4.4 Lubrication Specifications​

2.4.5 Capacities​

Machine Characteristics​

Maintenance & Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 General​

3.1.2 Preparation, Inspection, and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventive Maintenance​

Service and Guidelines​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Welding on JLG Equipment​

Preventive Maintenance and Inspection Schedule​

3.3.1 As Needed​

3.3.2 Before starting​

3.3.3 First 50 Hours​

3.3.4 Every 100 Hours​

3.3.5 First 250 Hours​

3.3.6 Every 250 Hours​

3.3.7 Every 500 Hours​

3.3.8 Every 1000 Hours​

3.3.9 Every 1000 Hours or 1 Year​

3.3.10 Every 1000 Hours or 3 Months​

3.3.11 First 2000 Hours​

3.3.12 Every 3000 Hours or Every 7 Years​

Pins and Composite Bearing Repair Guidelines​

Tires and Wheels​

Fuel Tank Inspection​

Boom Inspection and Maintenance​

3.7.1 Wire Rope and Pulleys​

3.7.2 Inspection​

3.7.3 Three Month Inspection​

3.7.4 Seven Year or 3000 Hour Replacement​

3.7.5 Wire Rope Tension Adjustment Procedure​

Hydraulic Filter Replacement​

Engine General Inspection​

Bio Fuel​

Swing Drive​

3.11.1 Structure and Function​

3.11.2 Transporting Swing Drives​

3.11.3 Swing Drive Positioning​

3.11.4 Bolting the Swing Drive​

3.11.5 Maintenance Schedule​

3.11.6 Lubrication​

3.11.7 Maintenance Tasks​

3.11.8 Lubricating the Swing Drive​

3.11.9 Inspecting the Seals​

Wheel Drive​

3.12.1 Wheel Drive​

Rubber Track Maintenance​

3.13.1 Track Tension Check​

3.13.2 Track Tension Adjustment​

3.13.3 Checking the Rubber Tracks​

Battery Maintenance and Charging​

3.14.1 Charge Information​

3.14.2 Lithium Cells​

3.14.3 Battery Charger​

3.14.4 DC-DC Transformer​

3.14.5 Electric Motor​

3.14.6 RPM Regulation System​

3.14.7 RPM Setting​

3.14.8 Temperature Ongoings (Heaters And Fans)​

3.14.9 Diagnostics and Fault Codes​

3.14.10 Battery Charging System​

Testing, Calibrations, & Special Procedures

Special Tools​

4.1.1 General​

4.1.2 Multimeter Basics​

Testing Procedures​

Calibration Procedures​

4.3.1 Calibration Requirement​

4.3.2 Proximity Sensor Adjustment​

Special Procedures​

4.4.1 Cylinder Drift Test​

4.4.2 Fuel Tank Cleaning and Drying​

Wheel Drive Hub​

System Software

JLG Control System​

5.1.1 Introduction​

5.1.2 Machine Ignition​

5.1.3 Platform - Remote Control Station​

5.1.4 LCD Display Icon​

5.1.5 Lithium Only Icons​

5.1.6 Tilt Conditions Drive Cut-Out​

5.1.7 Speed Control Conditions on X Axle​

5.1.8 Pushbuttons​

Analyzer Software Accessibility​

5.2.1 Platform Remote Control Service​

5.2.2 Input Menu​

5.2.3 Language Menu​

5.2.4 Errors Menu​

5.2.5 RAMP Menu​

5.2.6 CURRENT Menu​

5.2.7 Working Hours Menu​

5.2.8 Machine Setup Menu​

5.2.9 Joystick​

5.2.10 Calibrating the Joystick​

Software & Electronic Control Module​

5.3.1 Electronic Control Module (ECM)​

CanBus Communication​

5.4.1 CANBus Diagnostics​

5.4.2 CAN Timeout Menu​

5.4.3 CANBus Device Layout​

5.4.4 SENSORS AND DEVICES NOT COMMUNICATING THROUGH CANBus​

Fault Codes

Fault Codes Introduction​

6.1.1 Fault Codes​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Component​

7.3.1 Hydraulic Components Identification and location​

7.3.2 Boom Component Hydraulic System​

7.3.3 Hydraulic Component Start-Up Procedures and Recommendations​

7.3.4 Pressure Setting Procedure​

7.3.5 Control Valve Turntable Functions​

7.3.6 Outriggers Auto Retraction​

7.3.7 Hydraulic System Pump and Pressure Lines​

7.3.8 Ground Component Hydraulic System​

7.3.9 Outriggers​

7.3.10 Drive Gear Motors​

7.3.11 Tracks Widening​

Torque Values​

Hydraulic Diagrams​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.2 Dielectric Grease Application​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Electrical Component Terminology​

Harness Layouts​

Board Layouts​

Removal and Installation

Rubber Track​

9.1.1 Removal of Rubber Track​

9.1.2 Installation of the Rubber Track​

9.1.3 Checking Tightness of Nuts and Bolts​

Undercarriage Components​

9.2.1 Roller Lower Wheel and Tracks Adjuster Replacement​

9.2.2 Sprocket and Gear Motor Replacement​

Axle Extension Removal​

9.3.1 Removal​

9.3.2 Inspection of Slide Guides​

9.3.3 Installation​

Boom​

9.4.1 Removal​

9.4.2 Inspection​

9.4.3 Installation​

Platform​

9.5.1 Platform Removal/Installation​

9.5.2 Load Cell and Footswitch Removal/ Installation​

SkyGuard​

9.6.1 SkyGuard Installation – One/Two-Person Platform​

Engine​

9.7.1 Thermic Engine Replacement​

9.7.2 Electric Motor Replacement​

Transmission​

Hydraulic Cylinders​

Hydraulic Valves​

Hydraulic Pumps​

9.11.1 Removal​

9.11.2 Installation​

9.11.3 Repair​

Electrical Components​

Disassembly and Assembly

Drive Assembly​

Boom​

10.2.1 Disassembly​

10.2.2 Inspection​

10.2.3 Assembly​

Rotary Actuator​

10.3.1 Disassembly​

10.3.2 Cleaning​

10.3.3 Assembly​

10.3.4 Installing Counterbalance Valve​

Engine Components​

Pumps​

10.5.1 Disassembly​

10.5.2 Assembly​

Transmission​

Hydraulic Cylinders​

10.7.1 Cylinders Disassembly and Assembly​

10.7.2 Cylinders With Sensors​

10.7.3 Cylinder Repair Without Sensor​

Hydraulic Valves​

Hydraulic Components​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 General Tube Type Fitting Assembly Instructions​

11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.​

11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections​

11.1.10 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.11 Assembly Instructions for 45° SAE Flare Fittings​

11.1.12 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings​

11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.20 Double Wrench Method​

11.1.21 FFWR and TFFT Methods​

11.1.22 Adjustable Stud End Assembly​

11.1.23 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematics​

Electrical Schematics​

12.2.1 ELECTRICAL SCHEMATICS MANUALS​