Jlg 680S Service Manual manuals

Jlg 680S Service Manual User Manual (332 pages)

Brand: Jlg | Category: Special machinery | Size: 32.54 MB |

English

Table of contents

P/N - 3121234

1

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

5

10

LIST OF FIGURES

11

SECTION 1. SPECIFICATIONS

17

1.3 CAPACITIES

18

1.4 COMPONENT DATA

18

Engine Data

18

1.5 TIRES

19

Test Notes

20

1.7 TORQUE REQUIREMENTS

20

1.8 LUBRICATION

20

Hydraulic Oil

20

1.9 PRESSURE SETTINGS

21

1.10 MAJOR COMPONENT WEIGHTS

21

1.11 OPERATOR MAINTENANCE

22

SECTION 1 - SPECIFICATIONS

23

Regulator

27

1.12 SERIAL NUMBER LOCATION

29

SECTION 2. GENERAL

37

2.2 SERVICE AND GUIDELINES

38

Safety and Workmanship

38

Cleanliness

38

SECTION 2 - GENERAL

39

3.1 TIRES & WHEELS

49

Tire Inflation

49

Tire Damage

49

Tire Replacement

49

Wheel Replacement

49

Wheel Installation

50

3.2 WHEEL DRIVE ASSEMBLY, 2WD

50

Removal and Disassembly

50

Assembly and Installation

51

3-4 – JLG Lift – 3121234

52

3-6 – JLG Lift – 3121234

54

3121234 – JLG Lift – 3-7

55

3-8 – JLG Lift – 3121234

56

3-10 – JLG Lift – 3121234

58

Shaft Seal Replacement

59

Loop Flushing Valve

60

3121234 – JLG Lift – 3-15

63

3-16 – JLG Lift – 3121234

64

3121234 – JLG Lift – 3-17

65

Slipper retainer

67

Ball guide

67

3121234 – JLG Lift – 3-21

69

3-22 – JLG Lift – 3121234

70

3121234 – JLG Lift – 3-23

71

3-24 – JLG Lift – 3121234

72

Initial Start-up Procedures

73

3.5 TORQUE HUB

74

3121234 – JLG Lift – 3-27

75

3-28 – JLG Lift – 3121234

76

3-30 – JLG Lift – 3121234

78

3121234 – JLG Lift – 3-31

79

3-32 – JLG Lift – 3121234

80

3121234 – JLG Lift – 3-33

81

3.6 WHEEL DRIVE ASSEMBLY, 4WD

82

INTEGRAL BRAKE)

83

Roll, Leak and Brake Testing

83

Tightening and Torquing Bolts

83

Main Disassembly

84

3121234 – JLG Lift – 3-37

85

Input Carrier Disassembly

86

Output Carrier Disassembly

87

Housing-Spindle Disassembly

88

Spindle-Brake Disassembly

89

Input Carrier Sub-Assembly

90

3121234 – JLG Lift – 3-43

91

Output Carrier Sub-Assembly

92

3121234 – JLG Lift – 3-45

93

Spindle-Brake Sub-Assembly

94

3121234 – JLG Lift – 3-47

95

Housing-Spindle Sub-Assembly

96

DW2B Integral Brake Check

96

3121234 – JLG Lift – 3-49

97

Main Assembly

98

3121234 – JLG Lift – 3-51

99

3-52 – JLG Lift – 3121234

100

3121234 – JLG Lift – 3-53

101

3-54 – JLG Lift – 3121234

102

3121234 – JLG Lift – 3-55

103

3-56 – JLG Lift – 3121234

104

3121234 – JLG Lift – 3-57

105

3-58 – JLG Lift – 3121234

106

3121234 – JLG Lift – 3-59

107

3-60 – JLG Lift – 3121234

108

3121234 – JLG Lift – 3-61

109

3-62 – JLG Lift – 3121234

110

Oscillating Axle Lockout Test

111

3.10 SWING DRIVE HUB

112

Disassembly

112

Main Assembly Procedure

112

3121234 – JLG Lift – 3-65

113

3-66 – JLG Lift – 3121234

114

Hub Shaft Sub-Assembly

115

3-68 – JLG Lift – 3121234

116

Carrier Sub-Assembly

117

3-70 – JLG Lift – 3121234

118

3121234 – JLG Lift – 3-71

119

3.11 SWING BRAKE

120

Assembly

120

3121234 – JLG Lift – 3-73

121

3.12 SWING MOTOR

122

Disassembly and inspection

122

3121234 – JLG Lift – 3-75

123

3-76 – JLG Lift – 3121234

124

3-78 – JLG Lift – 3121234

126

3121234 – JLG Lift – 3-79

127

3-80 – JLG Lift – 3121234

128

3-82 – JLG Lift – 3121234

130

3121234 – JLG Lift – 3-83

131

3-84 – JLG Lift – 3121234

132

3121234 – JLG Lift – 3-85

133

3-86 – JLG Lift – 3121234

134

3121234 – JLG Lift – 3-87

135

One Piece Stator Construction

136

BACKLASH

137

3-90 – JLG Lift – 3121234

138

3121234 – JLG Lift – 3-91

139

3-92 – JLG Lift – 3121234

140

3.14 SWING BEARING

141

3-94 – JLG Lift – 3121234

142

3121234 – JLG Lift – 3-95

143

Wear Tolerance

144

Swing Bearing Removal

144

3121234 – JLG Lift – 3-97

145

Swing Bearing Installation

146

Swing Bearing Torque Values

146

3.15 ROTARY COUPLING

147

3-100 – JLG Lift – 3121234

148

3121234 – JLG Lift – 3-101

149

3.16 GENERATOR

150

Every 250 hours

150

Every 500 hours

150

Overload Protection

151

3-104 – JLG Lift – 3121234

152

3.17 DEUTZ EMR 2

153

3-106 – JLG Lift – 3121234

154

3121234 – JLG Lift – 3-107

155

3-108 – JLG Lift – 3121234

156

3121234 – JLG Lift – 3-109

157

3-110 – JLG Lift – 3121234

158

3121234 – JLG Lift – 3-111

159

3-112 – JLG Lift – 3121234

160

3121234 – JLG Lift – 3-113

161

3-114 – JLG Lift – 3121234

162

3121234 – JLG Lift – 3-115

163

3-116 – JLG Lift – 3121234

164

3121234 – JLG Lift – 3-117

165

Maintenance of the Drive Belt

166

Changing The Engine Oil

167

3-120 – JLG Lift – 3121234

168

Fuel Filter

169

Electric Lock Off

169

EPR Assembly

169

Low Pressure Regulator (LPR)

170

Air Fuel Mixer

170

Engine Control Module

171

3-124 – JLG Lift – 3121234

172

3121234 – JLG Lift – 3-125

173

3-126 – JLG Lift – 3121234

174

Assembly Replacement

175

(TMAP) Sensor

176

3121234 – JLG Lift – 3-129

177

MIXER REPLACEMENT

178

Coolant Hose Replacement

178

Vapor Hose Replacement

178

Replacement

179

Fuel System Description

180

Diagnostic Aids

180

DIAGNOSIS

180

3121234 – JLG Lift – 3-133

181

3-134 – JLG Lift – 3121234

182

3121234 – JLG Lift – 3-135

183

3-136 – JLG Lift – 3121234

184

3121234 – JLG Lift – 3-137

185

3-138 – JLG Lift – 3121234

186

3121234 – JLG Lift – 3-139

187

3-140 – JLG Lift – 3121234

188

3121234 – JLG Lift – 3-141

189

3-142 – JLG Lift – 3121234

190

3121234 – JLG Lift – 3-143

191

3-144 – JLG Lift – 3121234

192

3121234 – JLG Lift – 3-145

193

3-146 – JLG Lift – 3121234

194

4.1 BOOM MAINTENANCE

195

Boom Disassembly

196

3121234 – JLG Lift – 4-3

197

4-4 – JLG Lift – 3121234

198

3121234 – JLG Lift – 4-5

199

4-6 – JLG Lift – 3121234

200

3121234 – JLG Lift – 4-7

201

4-8 – JLG Lift – 3121234

202

Inspection

203

4-10 – JLG Lift – 3121234

204

Installation

205

4.2 POWERTRACK MAINTENANCE

206

One Piece Bracket Maintenance

206

3121234 – JLG Lift – 4-13

207

Two Piece Bracket Maintenance

208

Snap Rings and Screws

209

4-16 – JLG Lift – 3121234

210

3121234 – JLG Lift – 4-17

211

Lift Cylinder Removal

212

Lift Cylinder Installation

212

4.3 WIRE ROPE

213

Three Month Inspection

213

Seven Year Inspection

213

Replacement Criteria

213

Torque Procedures

214

3121234 – JLG Lift – 4-21

215

4-22 – JLG Lift – 3121234

216

Description

217

4-24 – JLG Lift – 3121234

218

Normal Operation

219

Platform Leveling Fault

220

3121234 – JLG Lift – 4-27

221

CAN Errors

222

Replacing the Level Sensors

222

3121234 – JLG Lift – 4-29

223

4.7 HELAC ROTARY ACTUATOR

224

Theory of Operation

224

3121234 – JLG Lift – 4-31

225

4-32 – JLG Lift – 3121234

226

4-34 – JLG Lift – 3121234

228

3121234 – JLG Lift – 4-35

229

4-36 – JLG Lift – 3121234

230

4-38 – JLG Lift – 3121234

232

3121234 – JLG Lift – 4-39

233

4-40 – JLG Lift – 3121234

234

3121234 – JLG Lift – 4-41

235

Testing the Actuator

236

Installation and Bleeding

236

Troubleshooting

237

4.8 LOAD SENSING DEVICE

238

Calibrating the Load Sensor

238

3121234 – JLG Lift – 4-45

239

4-46 – JLG Lift – 3121234

240

SECTION 5. HYDRAULICS

241

Dip Method

242

Spray Method

242

Brush-on Method

242

5.2 CYLINDER REPAIR

243

Cleaning and Inspection

244

SECTION 5 - HYDRAULICS

246

Set Up of the Function Pump

251

5.4 START UP PROCEDURES

258

Components

258

6.1 INTRODUCTION

259

Introduction

259

6-2 – JLG Lift – 3121234

260

3121234 – JLG Lift – 6-3

261

Using the Analyzer

262

3121234 – JLG Lift – 6-5

263

Analyzer

264

3121234 – JLG Lift – 6-7

265

Machine Setup

267

Level Vehicle Description

267

6-10 – JLG Lift – 3121234

268

3121234 – JLG Lift – 6-11

269

6-12 – JLG Lift – 3121234

270

3121234 – JLG Lift – 6-13

271

6-14 – JLG Lift – 3121234

272

3121234 – JLG Lift – 6-15

273

6-16 – JLG Lift – 3121234

274

3121234 – JLG Lift – 6-17

275

Machine Personality Settings

276

3121234 – JLG Lift – 6-19

277

4150384-E

278

3121234 – JLG Lift – 6-21

279

6-22 – JLG Lift – 3121234

280

3121234 – JLG Lift – 6-23

281

6-24 – JLG Lift – 3121234

282

3121234 – JLG Lift – 6-25

283

6-26 – JLG Lift – 3121234

284

3121234 – JLG Lift – 6-27

285

6-28 – JLG Lift – 3121234

286

3121234 – JLG Lift – 6-29

287

6-30 – JLG Lift – 3121234

288

3121234 – JLG Lift – 6-31

289

4150364-14

290

6-34 – JLG Lift – 3121234

292

3121234 – JLG Lift – 6-35

293

6-36 – JLG Lift – 3121234

294

3121234 – JLG Lift – 6-37

295

6-38 – JLG Lift – 3121234

296

3121234 – JLG Lift – 6-39

297

6-40 – JLG Lift – 3121234

298

3121234 – JLG Lift – 6-41

299

6-42 – JLG Lift – 3121234

300

3121234 – JLG Lift – 7-1

301

Resistance Measurement

302

Continuity Measurement

302

Current Measurement

303

COMPOUND TO ELECTRICAL

303

CONNECTIONS

303

7.4 AMP CONNECTOR

304

AMP Connectors

304

3121234 – JLG Lift – 7-5

305

Wedge Lock

306

Service - Voltage Reading

306

3121234 – JLG Lift – 7-7

307

7.5 DEUTSCH CONNECTORS

308

DT/DTP Series Assembly

308

DT/DTP Series Disassembly

308

HD30/HDP20 Series Assembly

309

HD30/HDP20 Series Disassembly

309

7-10 – JLG Lift – 3121234

310

3121234 – JLG Lift – 7-11

311

7-12 – JLG Lift – 3121234

312

3121234 – JLG Lift – 7-13

313

7-14 – JLG Lift – 3121234

314

3121234 – JLG Lift – 7-15

315

7-16 – JLG Lift – 3121234

316

3121234 – JLG Lift – 7-17

317

7-18 – JLG Lift – 3121234

318

3121234 – JLG Lift – 7-19

319

7-20 – JLG Lift – 3121234

320

3121234 – JLG Lift – 7-21

321

7-22 – JLG Lift – 3121234

322

3121234 – JLG Lift – 7-23

323

7-24 – JLG Lift – 3121234

324

3121234 – JLG Lift – 7-25

325

7-26 – JLG Lift – 3121234

326

3121234 – JLG Lift – 7-27

327

7-28 – JLG Lift – 3121234

328

3121234 – JLG Lift – 7-29

329

7-30 – JLG Lift – 3121234

330

JLG Worldwide Locations

332

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