JLG 680S Boom Lift Service Manual
424 pages · Publication 3121679
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- Models
- 680S
- Manual type
- Service Manual
- Pages
- 424
- Publication
- 3121679
- Condition
- Brand new
What's inside
From the manual's own table of contents: 447 sections, 515 entries. See sample pages (PDF, 615 KB)
General
Hydraulic System Safety
Maintenance4 topics
- Operating Specifications
- Specifications and Performance Data
- Capacities
- Component Data
Engine Data
Battery4 topics
- Tires
- Torque Requirements
- Major Component Weights
- Lubrication
Hydraulic Oil2 topics
- Pressure Settings
- Operator Maintenance
Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief2 topics
- Serial Number Location
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventive Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Show all 447 sections
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Theory
Cylinder Leakage Test
Cylinder Thermal Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
- Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation4 topics
- Lockout Cylinder Bleeding
- Oscillating Axle Lockout Test
- Emergency Towing
- Wheel Drive Assembly (4WD)
Removal
Installation1 topic
- Drive Hub
Disassembly
Cleaning and Inspection
Repair
Assembly1 topic
- Drive Brake
Inspection1 topic
- Drive Motor
Description
Initial Start-up Procedures
Troubleshooting
Shaft Seal Replacement
Loop Flushing Valve1 topic
- Swing Drive
Procedure For Setting Swing Gear Backlash
Swing Drive Lubrication1 topic
- Swing Hub
Roll, Leak And Brake Testing
Tightening and Torquing Bolts
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Drive Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Assembly
Carrier Assembly
Main Drive Assembly
Motor and Brake Assembly
Motor Control Valve Assembly1 topic
- Swing Motor
Disassembly and Inspection
One Piece Stator Construction1 topic
- TABLE OF CONTENTS Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Removal
Swing Bearing Torque Values2 topics
- Rotary Coupling
- Generator
Maintenance Schedule
Overload Protection
Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings
Generator Disassembly and Assembly
Lead Connection List for Generator2 topics
- Deutz Engine
- Deutz Engine - TD2011L04
Glow Plugs
Check Oil Level
Replacing Engine Oil
Replacing the Oil Filter
Replacing the Fuel Filter1 topic
- Deutz Engine - TD2.9L4
Replacing the Primary Fuel Filters3 topics
- Deutz EMR 2
- Counterweight
- Platform
Platform Valve Removal
Platform Valve Installation
Support Removal
Support Installation3 topics
- Rotator and Slave Cylinder
- Main Boom Powertrack
- Powertrack Maintenance
One Piece Bracket Maintenance
Two Piece Bracket Maintenance
Snap Rings and Screws2 topics
- Boom Cleanliness Guidelines
- Main Boom Assembly
Telescope Cylinder/Boom Cable Removal
Telescope Cylinder/Boom Cable Installation2 topics
- Main Lift Cylinder
- Wire Rope
Three Month Inspection
Year or 7000 Hour Replacement
Replacement Criteria3 topics
- Boom Rope Torquing Procedures
- Elevation & Capacity Switches
- Electronic Platform Leveling
Normal Operation
Platform Leveling Fault
CAN Errors
Replacing the Level Sensors
Additional Platform and Jib Valves
Platform Leveling Calibration Procedure1 topic
- Helac Rotary Actuator
Theory of Operation
Tools Required for Assembly/Disassembly
Making a Seal Tool
Before Disassembly
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Testing the Actuator for Internal Leakage
Installation and Bleeding1 topic
- Skyguard
Operation
Functional Test
Diagnostic & Troubleshooting1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Hydraulic Connection Assembly and Torque Specification
Tapered Thread Types
Straight Thread Types, Tube and Hose Connections
Straight Thread Types, Port Connections
Flange Connection Types
Tightening Methods
Assembly and Torque Specifications
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
Assembly Instructions for 37° (JIC) Flare Fittings
Assembly Instructions for 45° SAE Flare Fittings
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
Assembly Instructions for Bulkhead (BH) Fittings
Assembly Instructions for O-Ring Boss (ORB) Fittings
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
Assembly instructions for Adjustable Port End (BSPP) Fittings1 topic
- TABLE OF CONTENTS Assembly Instructions for Flange Connections: (FL61 and FL62)
Double Wrench Method
FFWR and TFFT Methods
Adjustable Stud End Assembly
O-ring Installation (Replacement)1 topic
- Hydraulic Cylinders
Axle Lockout Cylinder
Main Boom Lift Cylinder
Platform Level Cylinder
Steer Cylinder
Telescope Cylinder1 topic
- Pressure Setting Procedure
Set Up of the Function Pump
Adjustments Made at the Main Control Valve Block1 topic
- Start Up Procedures
Start Up After Overhaul or Replacement of Components2 topics
- Hydraulic Schematics
- JLG Control System Analyzer Kit Instructions
Introduction
To Connect the JLG Control System Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Configuration Using the Hand Held Analyzer
Machine Setup
Level Vehicle Description2 topics
- Machine Personality Settings and Function Speeds
- Machine Orientation When Doing Speed Tests
Test Notes1 topic
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation2 topics
- Resetting The MSSO System
- CANBUS Communications
Analyzer Diagnostics Menu Structure2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- AMP Connector
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Electrical Schematics
Operator Maintenance and Lubrication Diagram
Deutz 2011 Engine Dipstick
Filter Lock Assembly
Serial Number Locations
Torque Chart (SAE Fasteners - Sheet 1 of 5)
Torque Chart (SAE Fasteners - Sheet 2 of 5)
Torque Chart (SAE Fasteners - Sheet 3 of 5)
Torque Chart (SAE Fasteners - Sheet 4 of 5)
Torque Chart (Metric Fasteners - Sheet 5 of 5)
Engine Operating Temperature Specifications - Deutz
Axle and Steering Installation
Chassis Component Location
Turntable Component Location
Drive Disconnect Hub
Drive Hub Installation (4WD)
Drive Hub
Drive Brake
Drive Motor Cross Section
Loop Flushing Spool
Plugs, Fittings and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swashplate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swashplate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Removing the Shaft Seal
Swing Drive and Turntable Bearing
Motor Control Valve
Motor and Brake
Hub-Shaft
Carrier
Swing Hub Assembly
Swing Motor and Brake Assembly
Swing Drive Motor
Swing Bearing Torque Sequence
Swing Bearing Tolerance Boom Placement (Sheet 1 of 2)
Swing Bearing Tolerance Boom Placement (Sheet 2 of 2)
Swing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Rotary Coupling Seal Installation
Rotary Coupling Cutaway
Rotary Coupling Port Location (7 Port)
Rotary Coupling Installation
Inspecting Generator Brushes, Replacing Brushes and Cleaning Slip Rings
Generator Troubleshooting Circuit Diagram (Sheet 1 of 2)
Generator Troubleshooting Circuit Diagram (Sheet 2 of 2)
Generator Electrical Circuit Diagram
Power Board PC1 Electrical Circuit Diagram
Power Board PC2 Electrical Circuit Diagram (Sheet 1 of 2)
Power Board PC2 Electrical Circuit Diagram (Sheet 2 of 2)
Deutz T4F TD2.9L Engine Components - Sheet 1 of 2
Deutz T4F TD2.9L Engine Components - Sheet 2 of 2
Deutz D2011 Engine Components - Sheet 1 of 2
Deutz D2011 Engine Components - Sheet 2 of 2
Deutz TD 2.9 L4 GUO III Engine Installation (GB Market Only) - Sheet 1 of 6
Deutz TD 2.9 L4 GUO III Engine Installation (GB Market Only) - Sheet 2 of 6
Deutz TD 2.9 L4 GUO III Engine Installation (GB Market Only) - Sheet 3 of 6
Deutz TD 2.9 L4 GUO III Engine Installation (GB Market Only) - Sheet 4 of 6
Deutz TD 2.9 L4 GUO III Engine Installation (GB Market Only) - Sheet 5 of 6
Deutz TD 2.9 L4 GUO III Engine Installation (GB Market Only) - Sheet 6 of 6
Deutz Engine Dipstick
Engine Oil Viscosity
Location of the Oil Filter
Location of the Primary Fuel Filter
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
Counterweight
Location of Components - Platform Support
Platform Support Torque Values
Location of Components - Rotator and Slave Cylinder
Location of Components - Main Boom Powertrack
Powertrack Installation Main Boom
Boom Assembly Cutaway - Sheet 1 of 2
Boom Assembly Cutaway - Sheet 2 of 2
Boom Components - Sheet 1 of 2
Boom Components - Sheet 2 of 2
Disassembly of Sheave Assembly
Disassembly Wire Rope Routing Procedure
Dimension of Sheaves When New
Proximity Switch Adjustment
Routing Installation of Retract Wire Ropes
Clamping Wire Ropes
Elevation, Dual Capacity and Transport Switch Information - Sheet 1 of 2
Elevation, Dual Capacity and Transport Switch Information - Sheet 2 of 2
Level Switches
Rotary Actuator (Exploded View)
Rotary Actuator (Cutaway View)
Rotator Counterbalance Valve
Skyguard
NPTF Thread
BSPT Thread
JIC Thread
SAE Thread
ORFS Thread
MTBL-MBTS Thread
Bulkhead Thread
MFF-BSPP Thread
ORB-MPP Thread
Torque Wrench Angle
FFWR Method
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Tapered Bushing Installation
Seating the Tapered Bearing
Hydrolock Piston Seal Installation
Piston Seal Kit Installation
Rod Assembly Installation
Spanner Nut Removal
Installation of Piston Seal Kit
Telescopic Cylinder
Control Valve Installation
Main Valve Identification
Platform Valve Identification
Main Valve Cartridge Torque Values
Platform Valve Cartridge Torque Values
Hydraulic Schematic - Sheet 1of 6
Hydraulic Schematic - Sheet 2 of 6
Hydraulic Schematic - Sheet 3 of 6
Hydraulic Schematic - Sheet 4 of 6
Hydraulic Schematic - Sheet 5 of 6
Hydraulic Schematic - Sheet 6 of 6
Hand Held Analyzer
ADE Block Diagram
Analyzer Flow Chart Version 6.X Software -Sheet 1 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 2 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 3 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 4 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 5 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 6 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 7 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 8 of 8
Fault Code Light and Module Location
Analyzer Connecting Points
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Platform Control Module - Sheet 1 of 2
Platform Control Module - Sheet 2 of 2
Voltage Measurement (DC)
Current Measurement (DC)
Application to Plug/Male Contacts
Use of Seal Plugs
Brad-Harrison M12
Phoenix Contact M12
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Schematic - Sheet 1 of 14
Electrical Schematic - Sheet 2 of 14
Electrical Schematic - Sheet 3 of 14
Electrical Schematic - Sheet 4 of 14
Electrical Schematic - Sheet 5 of 14
Electrical Schematic - Sheet 6 of 14
Electrical Schematic - Sheet 7 of 14
Electrical Schematic - Sheet 8 of 14
Electrical Schematic - Sheet 9 of 14
Electrical Schematic - Sheet 10 of 14
Electrical Schematic - Sheet 11 of 14
Electrical Schematic - Sheet 12 of 14
Electrical Schematic - Sheet 13 of 14
Electrical Schematic - Sheet 14 of 14
Operating Specifications
Specifications and Performance Data
Capacities
Deutz D2011L04 Specifications
Deutz TD 2.9 and TD 2.9 L4 GUO III Specifications
Battery Specifications
Tire Specifications
Torque Requirements
Component Weights
Mobilfluid 424 Specs
UCon Hydrolube HP-5046
MOBIL DTE 10 EXCEL 32
Mobil EAL 224H Specs
Exxon Univis HVI 26 Specs
Pressure Settings
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Coupling Port Information Table (7 port)
Deutz Trouble Codes (TD2.9 Engine)
SkyGuard Function Table
NPTF Pipe Thread
BSPT Pipe Thread
37° Flare (JIC)Thread - Steel
37° Flare (JIC)Thread - Aluminum/Brass
45° Flare (SAE) - Steel
45° Flare (SAE) - Aluminum/Brass
O-ring Face Seal (ORFS) - Steel
O-ring Face Seal (ORFS) - Aluminum/Brass
DIN 24°Cone (MBTL & MBTS)
Bulkhead Fittings (BH) - INCH
Bulkhead Fittings (BH) - METRIC
O-ring Boss (ORB) - Table 1 of 6
O-ring Boss (ORB) - Table 2 of 6
O-ring Boss (ORB) - Table 3 of 6
O-ring Boss (ORB) - Table 4 of 6
O-ring Boss (ORB) - Table 5 of 6
O-ring Boss (ORB) - Table 6 of 6
Metric Flat Face Port (MFF) - L Series - Table 1 of 3
Metric Flat Face Port (MFF) - L Series - Table 2 of 3
Metric Flat Face Port (MFF) - L Series - Table 3 of 3
Metric Flat Face Port (MFF) - S Series - Table 1 of 3
Metric Flat Face Port (MFF) - S Series - Table 2 of 3
Metric Pipe Parallel O-Ring Boss (MPP)
British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
Flange Code (FL61 & FL62) - Inch Fasteners
Flange Code (FL61 & FL62) - Metric Fasteners
Cartridge Torque Values
Coil Torque Values
Analyzer Abbreviations
Machine Configuration Programming Information
Machine Configuration Programming Settings
Machine Personality Settings and Function Speeds
Function Speeds (In Seconds)
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
ADJUSTMENTS - Personality Descriptions
Diagnostic Trouble Code Chart (DTC)
Inside this manual
Real pages from this service manual (424 pages). Open the sample pages (PDF, 612 KB)
- Specifications, page 19: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 241: SECTION 4 - BOOM & PLATFORM
- Diagram, page 409: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 191: SECTION 4 - BOOM & PLATFORM
- Color page, page 400: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 680S are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3121679$69.51
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 424 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).