JLG 680S Parts Manual

Illustrated Parts Manual

Model

680S

3121235

January 17, 2014

NOTES:

MODULE ON MACHINES

“WITHOUT UGM”

(UNIVERSAL

GROUND MODULE)

MODULE ON MACHINES

“WITH UGM” (UNIVERSAL

GROUND MODULE)

GROUND MODULE MODULE IDENTIFICATION

REVISION LOG

REVISION LOG:

July 15, 2006 - Original Issue Of Manual (Edited to B/M 0010575 Revision 70)

October 5, 2006 - Revised Manual (Edited to B/M 0010575 Revision 70)

March 1, 2007 - Revised Manual (Edited to B/M 0010575 Revision 73)

June 14, 2007 - Revised Manual (Edited to B/M 0010575 Revision 79)

October 5, 2007 - Revised Manual (Edited to B/M 0010575 Revision 81)

March 1, 2008 - Revised Manual (Edited to B/M 0010575 Revision 81)

August 22, 2008 - Revised Manual (Edited to B/M 0010575 Revision 96)

January 1, 2009 - Revised Manual (Edited to B/M 0010575 Revision 96)

June 15, 2009 - Revised Manual (Edited to B/M 0010575 Revision 104)

November 4, 2009 - Revised Manual (Edited to B/M 0010575 Revision 104)

May 3, 2010 - Revised Manual (Edited to B/M 0010575 Revision 110)

November 30, 2010 - Revised Manual (Edited to B/M 0010575 Revision 119)

April 21, 2011 - Revised Manual (Edited to B/M 0010575 Revision 124)

July 22, 2011 - Revised Manual (Edited to B/M 0010575 Revision 127)

October 14, 2011 - Revised Manual (Edited to B/M 0010575 Revision D)

January 10, 2012 - Revised Manual (Edited to B/M 0010575 Revision D)

June 15, 2012 - Revised Manual (Edited to B/M 0010575 Revision E)

August 2, 2012 - Revised Manual (Edited to B/M 0010575 Revision E)

January 4, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)

April 2, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)

June 28, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)

September 23, 2013 - Revised Manual (Edited to B/M 0010575 Revision E)

3121235 680S A

REVISION LOG

January 17, 2014 - Revised Manual (Edited to B/M 0010575 Revision AL)

B 680S 3121235

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE . . . . . . . . . . . . . 1-2

1-2 AXLE AND STEERING INSTALLATION WITH TOW PACKAGE . . . . . . . . . . . . . . . . 1-6

1-3 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 DRIVE HUB/BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-5 DRIVE MOTOR ASSEMBLY (4 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-6 DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-7 FRAME VALVES & SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1-8 TOW PACKAGE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 SWING MOTOR/BRAKE/HUB ASSEMBLY (PRIOR TO SN 0300134352) . . . . . . . . 2-10

2-5 SWING MOTOR/BRAKE/HUB ASSEMBLY (SN 0300134352 TO PRESENT) . . . . . . 2-16

2-6 CATERPILLAR ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-7 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-8 GM ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-9 PUMP ASSEMBLY (SAUER-DANFOSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

2-10 PUMP ASSEMBLY (EATON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2-11 LOAD SENSING PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

2-12 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

2-13 LP TANK INSTALLATIONS (GM ENGINE MACHINES ONLY) . . . . . . . . . . . . . . . . . . 2-60

2-14 ROTARY COUPLING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

2-15 GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) . . . . . . . . . . . . . . . . . . . . . 2-66

2-16 GROUND CONTROL BOX ASSEMBLY (WITH UGM) . . . . . . . . . . . . . . . . . . . . . . . . 2-70

2-17 LIMIT SWITCHES, LIGHTS & ALARM INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 2-74

2-18 HOODS INSTALLATION (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

2-19 HOODS INSTALLATION (STEEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84

2-20 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . 2-90

2-21 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-94

2-22 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL) . . . . . . . . . . . 2-98

2-23 ENGINE TRAY JACK INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . 3-2

3-2 MAIN BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 MAIN BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4 ROTATOR ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-5 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . 3-14

3-6 BOOM CABLE CLAMPS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 CONTROLLER ASSEMBLY (LIFT AND SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

3121235 680S i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-3 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-4 STEER CYLINDER ASSEMBLY (PRIOR TO SN 0300142666) . . . . . . . . . . . . . . . . . .5-10

5-5 STEER CYLINDER ASSEMBLY (SN 0300142666 TO PRESENT) . . . . . . . . . . . . . . .5-12

5-6 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2 DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-3 DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-4 MANUAL DESCENT HYDRAULIC DIAGRAM (OPTIONAL) . . . . . . . . . . . . . . . . . . . .6-12

6-5 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-6 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) . . . . . . . . . . . . . . . . .7-4

7-3 HARNESS COMPONENTS INSTALLATION (WITH UGM) . . . . . . . . . . . . . . . . . . . . .7-20

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 DECAL INSTALLATION (AUSTRALIAN & CE SPEC) . . . . . . . . . . . . . . . . . . . . . . . . .8-2

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

ii 680S 3121235

SECTION 1

FRAME

3121235 680S 1-1

SECTION 1 FRAME

1213101

117

112

116

115

9 14 15

119

107

210

215

203 212

207

209

205

218

212

213

203

204

211

212

208

401

407

404

403

402

307

408

309

302

316

405

406

410

411

412

409

214

203

202

106

110

106

114

104

118

107

103

113

111

109

220

217

216

102

201

101

201

105

201

204

201

304

219

206

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

1-2 680S 3121235

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0258286 Ref FIXED AXLE INSTALLATION C

1 0100011 AR Compound, Locking 2 0681608 4 Bolt 3/8in-16NC x 1in (Grade 8) 3Not Used 4 0641820 2 Bolt 1/2in-13NC x 2-1/2in 5 0642212 1 Bolt 3/4in-10NC x 1-1/2in 6 0962102 2 Bushing, Garmax 7 3422703 1 Pin, Axle Pivot 8 3538047 2 Shim, Wear

9 3539877 2 Plate, Stop 10 3539878 2 Plate, Stop 11 3841287 1 Keeper, Pin 12 4070878 AR Shim 1/16in 13 4070879 AR Shim 1/8in 14 4070944 AR Shim 1/16in 15 4070945 AR Shim 1/4in 16 4711600 4 Flatwasher 3/8in Thin 17 4740472 1 Washer, Special 18 Not Used 19 4845658 1 Axle Weldment

0274571 Ref OSCILLATING AXLE INSTALLATION C

101 0100011 AR Compound, Locking 102 0100019 AR Compound, Locking 103 0641608 4 Bolt 3/8in-16NC x1in 104 0642212 1 Bolt 3/4in-10NC x 1-1/2in 105 0681608 4 Bolt 3/8in-16NC x1in (Grade 8) 106 0962102 2 Bushing, Garmax 107 1683078 2 Lockout Cylinder Assembly (See CYLINDER SECTION for

Breakdown) 108 Not Used 109 3422702 2 Pin 110 3422703 1 Pin, Main Pivot 111 3422755 2 Pin 112 3538047 2 Shim, Axle Wear 113 3841143 4 Shaft, Keeper 3/8in Dia x 3in 114 3841287 1 Shaft, Keeper 3/8in Dia x 6in 115 4070878 2 Shim, Axle Wear 116 4070879 2 Shim, Axle Wear 117 4711600 4 Flatwasher 3/8in Thin 118 4740472 1 Washer, Special 119 4845658 1 Axle Weldment

3121235 680S 1-3

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0272003 Ref STEERING INSTALLATIONS (2WS) E

Ref Note: Before ordering king pin kit, verify that machines is

equipped with the original components (king pin with 4 bolt holes) or service kit components (king pin with 8 bolt holes).

- If the king pin hole in the axle measurement exceeds 2.252in OD or is elongated, use King Pin Kit p/n 1001137261.

201 0100011 AR Compound, Locking 202 0362726 1 Tie-Rod 203 0641608 6 Bolt 3/8in-16NC x 1in 204 0641810 16 Bolt 1/2in-13NC x 1-1/4in 205 0962152 2 Bearing 206 4 Bearing Options:

0962448 Bearing, Garmax - Composite (Prior to SN 0300150055)

1001112651 Bearing, Bronze Limited - Aluminum/Bronze (SN 0300150055

to Present)

207 2 Steer Cylinder Assembly Options (See CYLINDER SECTION for

Breakdown):

1683740 Prior to SN 0300142666

1001097243 SN 0300142666 to Present 208 3422701 2 Pin, Steer, Spindle Attach 209 3422702 2 Pin, Tie-Rod 210 3422754 2 Pin, Attach 211 3422849 4 Kingpin 212 3841143 6 Shaft, Keeper 3/8in x 3in 213 4130389 1 Spindle Weldment (RH) 214 4130390 1 Spindle Weldment (LH) 215 4740111 4 Washer, Special 216 4740256 4 Thrustwasher 217 4740463 2 Washer, Special 218 4740473 2 Thrustwasher 219 1001103810 2 Thrustwasher (SN 0300134352 to Present) 220 3020029 AR Grease, Bearing

0273378 Ref HUB INSTALLATION (2WD ONLY) E

301 Not Used 302 0100019 AR Compound, Locking 303 Not Used 304 0682016 16 Bolt 5/8in-16NC x 2in (Grade 8)

305 to 306 Not Used

307 2780229 2 Hub Assembly (See Items 401-412 for Breakdown) 308 Not Used 309 3300007 20 Lugnut

310 to 315 Not Used

316 4892000 16 Flatwasher 5/8in Hardened

1-4 680S 3121235

SECTION 1 FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780229 Ref HUB ASSEMBLY (2WD ONLY) A

401 7017052 2 Spindle (1 per Assembly) 402 7017053 2 Housing (1 per Assembly) 403 7010404 2 Cup, Bearing - Inner (1 per Assembly) 404 7010405 2 Cone, Bearing - Inner (1 per Assembly) 405 7017056 2 Cup, Bearing - Outer (1 per Assembly) 406 7017055 2 Cone, Bearing - Outer (1 per Assembly) 407 7010406 2 Seal, Lip (1 per Assembly) 408 7000265 20 Stud (10 per Assembly) 409 7017054 2 Dust Cap (1 per Assembly) 410 7017051 2 Washer, Special (1 per Assembly) 411 7017057 2 Washer, Tanged (1 per Assembly) 412 7017058 2 Nut, Bearing (1 per Assembly)

3121235 680S 1-5

SECTION 1 FRAME

106

110

106

114

104

118

107

103

113

111

109

105

117

112

116

115

119

228

230

229

107

212

205

225

218

220

218

211

204

227

213

227

213

218

210

401

407

404

403

402

307

408

309

302

316

405

406

410

411

412

409

219

204

202

231

224

214

221

204

218

209

223

209

217

207

221

226

207

222

208

215

204

203

218

102

201

101

201

101

201

218

216

201

304

206

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

1-6 680S 3121235

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0274572 Ref OSCILLATING AXLE INSTALLATION C

0271352 Ref STEERING INSTALLATION H

Ref Note: Before ordering king pin kit, verify that machines is

equipped with the original components (king pin with 4 bolt

holes) or service kit components (king pin with 8 bolt holes).

- If the king pin hole in the axle measurement exceeds 2.252in

OD or is elongated, use King Pin Kit p/n 1001137261.

201 0100011 AR Compound, Locking 202 0362726 1 Tie-Rod 203 0641508 1 Bolt 5/16in- 18NC x 1in 204 0641608 7 Bolt 3/8in-16NC x 1in 205 0962152 2 Bearing, Garmax 206 4 Bearing Options:

0962448 Bearing, Garmax - Composite (Prior to SN 0300150055)

1001112651 Bearing, Bronze Limited - Aluminum/Bronze (SN 0300150055

to Present) 207 0962292 2 Bearing, Garmax 208 0962348 1 Bearing, Garmax 209 2 Steer Cylinder Assembly Options (See CYLINDER SECTION for

Breakdown):

1683740 Prior to SN 0300142666

1001097243 SN 0300142666 to Present 210 3422567 1 Pin, Steer Spindle Attach (RH) 211 3422701 1 Pin, Steer Spindle Attach (LH) 212 3422702 2 Pin, Tie-Rod 213 3422972 4 Kingpin 214 3422754 2 Pin, Attach

3121235 680S 1-7

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

215 3422813 1 Pin 216 3422848 1 Pin, Hitch 217 2573001 1 Link, Connecting 218 3841143 8 Shaft, Keeper 3/8in x 3in 219 4130390 1 Spindle Weldment (LH) 220 4130388 1 Spindle Weldment (RH) 221 4740111 6 Washer, Special 222 4740155 2 Thrustwasher 223 4740256 4 Thrustwasher 224 4740463 2 Thrustwasher 225 4740473 2 Washer, Special 226 4846935 1 Bar, Pivot 227 0641810 16 Bolt 1/2in-13NC x 1-1/4in 228 0741609 4 Screw 3/8in-16NC x 1-1/4in 229 3340966 2 Pad, Stop 230 4071059 4 Shim 231 3020029 AR Grease, Bearing

0273378 Ref HUB INSTALLATION (2WD ONLY) E

301 Not Used 302 0100019 AR Compound, Locking 303 Not Used 304 0682016 16 Bolt 5/8in-16NC x 2in (Grade 8)

305 to 306 Not Used

307 2780229 2 Hub Assembly (See Items 401-412 for Breakdown) 308 Not Used 309 3300007 20 Lugnut

310 to 315 Not Used

316 4892000 16 Flatwasher 5/8in Hardened

2780229 Ref HUB ASSEMBLY (2WD ONLY) A

501 Ref FRAME WELDMENT OPTIONS

2360687 2WD 2360688 4WD

1-8 680S 3121235

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121235 680S 1-9

SECTION 1 FRAME

102

104

107

103

106

105

101

DETAIL OF

VALVE STEM

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

1-10 680S 3121235

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref WHEEL DRIVE INSTALLATION 0273378 Ref 2WD E 0273704 Ref 4WD D

Ref Note: 2WD Qty Shown. For 4WD, Double Qty Shown.

1 0100011 AR Compound, Locking 2Not Used 3 3311801 4 Nut 1/2in-13 NC 4 0682016 16 Bolt 5/8in-11NC x 2in (Grade 8) 5 2300016 AR Fluid, Hydraulic (Not Shown) 6 2780272 2 Drive Hub Assembly (See DRIVE HUB ASSEMBLY for

Breakdown) 7 3020008 AR Lubricant (Not Shown) 8 2 Drive Motor Assembly Options (See DRIVE MOTOR

ASSEMBLY for Breakdown):

3160308 2 2WD Rear (Prior to SN 0300098924) 3160347 2 2WD Rear (SN 0300098924 to Present))

3160266 4 4WD Front & Rear (Prior to SN 030009864)

3160348 4 4WD Front & Rear (SN 0300098641 to Present)

9 3300007 20 Nut, Wheel

10 to 12 Not Used

13 4891800 4 Flatwasher, 1/2in Hardened 14 4892000 16 Flatwasher 5/8in Hardened

Ref TIRE AND WHEEL INSTALLATIONS

0270885 Ref 15-625 NHS Pneumatic (Available on All Specs Except

Australian & CE Specs)

0272322 Ref 15-625 NHS Pneumatic with Sealant (Available on ANSI Specs

Only)

0270886 Ref 15-625 NHS Foam-Filled (Available on All Specs) C 0270888 Ref 18-625 NHS Foam-Filled (Available on All Specs) C 0271419 Ref 41/18LLx22.5 Sand & Turf Foam-Filled (Available on All

Specs)

0271083 2 15-625 NHS Pneumatic Left Side 0271084 2 15-625 NHS Pneumatic Right Side 0272334 2 15-625 NHS Pneumatic with Sealant Left Side 0272333 2 15-625 NHS Pneumatic with Sealant Right Side 0271085 2 15-625 NHS Foam-Filled Left Side 0271086 2 15-625 NHS Foam-Filled Right Side 0271090 2 18-625 NHS Foam-Filled Left Side 0271091 2 18-625 NHS Foam-Filled Right Side 0271419 4 41/18LLx22.5 Sand & Turf Foam-Filled

Ref Note: Assemblies may require ballast/foam filling to

manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

101 1702701 1 Decal, 95 PSI/6.5 Bar (15-625 Tires - Pneumatic Only)

3121235 680S 1-11

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

102 1 Tire Options:

4520252 15-625 Tire 4520253 18-625 Tire

4520256 41/18LLx22.5 Sand & Turf Tire 103 4640113 1 Valve, Air 104 1 Rim, Wheel Options:

4860224 13 x 24.5 Rim (Use with 15-625 Tires)

4860225 15 x 24.5 Rim (Use with 18-625 Tires)

4860230 22.5 x 14 (41/18LLx22.5 Sand & Turf Tires) 105 1705364 AR Decal - Tire Sealant (With Sealant Only) 106 1300019 AR Chemical, Tire Sealant (Green) (With Sealant Only) 107 1120552 AR Cap, Valve Stem (Green) (With /Sealant Only)

1-12 680S 3121235

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121235 680S 1-13

SECTION 1 FRAME

105

111

110

112

121

102

119

122

123

104

103

101

109

107

108

114 113

116

115

118

117

120

27191A

1B1C1D

1N1G1F1E1H

151515

1512133B3F3C3D3C3B

106

200A

200B

201D

201C

201B

201A

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY

1-14 680S 3121235

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780272 Ref DRIVE HUB/BRAKE ASSEMBLY B

2780227 Ref Hub Assembly B

1 See Note 1 Spindle/Housing Assembly (Note: Not Available - Purchase

Individual Components.)

1A 7010464 1 Spindle

1B 7000236 1 Seal 1C 7000273 1 Cone, Bearing 1D 7000272 1 Cup, Bearing 1E 7000275 1 Cone, Bearing 1F 7000274 1 Cup, Bearing 1G 7017033 1 Housing 1H 7000239 1 Thrustwasher

1I 7000240 1 Ring, Retaining

1J 7001928 1 Plug, Pipe 1K Not Used

1L Not Used 1M Not Used 1N 7000265 10 Stud, Wheel

2 7024782 1 Gear, Ring 3 See Note 1 Carrier Assembly (Note: Not Available - Purchase Individual

Components.)

3A 7024147 1 Carrier 3B 7001901 6 Thrustwasher, Tanged 3C 7001902 96 Bearing, Needle 3D 7001903 3 Spacer, Thrust 3E 7024146 3 Shaft, Planet 3F 7024148 3 Gear, Cluster 3G 7001906 3 Rollpin

4 7024151 1 Gear, Internal 5 7000224 1 O-Ring 6 See Note 1 Cover Assembly (Note: Not Available - Purchase Individual

Components.)

6A 7024155 1 Cover 6B 7024783 1 Cap 6C 7000220 4 Bolt 1/4in-20NC x 3/4in 6D 7000231 1 Cap, Disengage 6E 7000235 1 Rod, Disengage 6F 7000213 1 O-Ring 6G 7000238 1 O-Ring 6H 7017048 1 Plug, Pipe

7 7000282 2 Thrustwasher 8 7000283 1 O-Ring

9 7000284 1 Ring, Retaining 10 7000285 1 Ring, Retaining 11 7024781 1 Shaft, Input 12 7024154 1 Spacer, Input 13 7024149 1 Gear, Sun 14 Not Used

3121235 680S 1-15

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

15 7000287 4 Thrustwasher 16 7000288 2 Thrustwasher 17 7000289 12 Bolt 3/8in-16NC x 2-1/2in (Grade 8) 18 Not Used 19 7000290 1 Coupling 20 7017047 2 Pin, Dowel 21 7017050 1 Thrustwasher

22 to 25 Not Used

26 7024182 1 Brake Assembly (Includes Items 101-123) 27 7024763 2 O-Ring 28 7024717 2 Stud 1/2in-13NC x 4-5/8in 29 7024718 2 Nut 1/2in-13NC 30 Not Used 31 7000731 1 Gasket

7024182 Ref BRAKE ASSEMBLY

101 7024189 1 Shaft 102 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.) 103 Use 7024193 2 Plate, Friction 104 Use 7024193 1 Plate, Pressure 105 7000731 1 Gasket 106 Use 7024193 2 Plate, Outer 107 See Note 1 Gasket (Note: Use Items 200B, 201C or 201D) 108 7024191 1 Cylinder 109 7024192 1 Piston 110 Use 7024197 1 Bearing, Ball 111 Use 7024197 1 Ring, Retaining 112 Use 7024197 1 Seal, Shaft 113 See Note 6 Capscrew (Note: Not Available for Purchase.) 114 See Note 6 Lockwasher (Note: Not Available for Purchase.) 115 Use 7024196 1 O-Ring 116 Use 7024196 1 Ring, Back-up 117 Use 7024196 1 O-Ring 118 Use 7024196 1 Ring, Back-up 119 7024190 2 Pin, Dowel 120 See Note 1 Plug (Note: Not Available for Purchase.) 121 See Note 2 Plug (Note: Not Available for Purchase.) 122 Use 7024196 10 Spring Kit (Natural) 123 Use 7024196 2 Spring Kit (Blue)

Ref KIT OPTIONS:

200 AR Seal Kit Options: 200A 7017068 1 Seal Kit - Hub (Includes Items 1B,1I, 5, 6F, 6G, 15 & 16) 200B 7024194 1 Seal Kit - 7024182 Brake (Includes Items 105, 107 & 215-218)

1-16 680S 3121235

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

201 AR Repair Kit Options:

201A Use 7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural Colored

Springs) (was p/n 7024195)

Note: Spring Kit no Longer Available, Purchase Kit p/n

7024196.

201B

201C

201D 7024197 1 Bearing Kit - 7024182 Brake (Includes Items 107 & 110-112)

7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural & 2 Blue

Colored Springs)

7024193

Friction Disc Kit - 7024182 Brake (Includes Items 103, 104, 106 & 107)

3121235 680S 1-17

SECTION 1 FRAME

393837

3536324021

100

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (4 BOLT ASSEMBLY)

1-18 680S 3121235

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (4 BOLT ASSEMBLY)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref DRIVE MOTOR ASSEMBLY 3160308 Ref 2WD C 3160266 Ref 4WD D

1 7022302 2 Bearing, Journal 2 Use 7022328 1 O-Ring 3 Use 7022328 1 O-Ring 4 7007446 1 Pin 5 7007438 2 Ring, Retaining 6 1 Swashplate Options:

7024861 2WD 7022305 4WD

7 Use 7022328 1 O-Ring 8 AR Pin Options:

7027435 2 2WD

Not Required 0 4WD

9 1 Cylinder Block Kit (Includes Items 11-19) Options:

7027740 2WD 7023907 4WD

10 1 Plate, Valve Options:

7024862 2WD 7023908 4WD

11 See Note 1 Block, Cylinder (Note: Use Item 9) 12 1 Guide, Slipper Retainer Options:

See Note 2WD (Note: Use Item 9)

7021277 4WD

13 7021275 3 Pin, Slipper Hold Down 14 9 Piston Assembly Options:

7024865 2WD

See Note 4WD (Note: Use Item 9)

15 1 Retainer, Slipper Options:

See Note 2WD (Note: Use Item 9)

7022310 4WD

16 7022311 1 Ring, Retaining 17 1 Spring Options:

7024867 2WD 7022312 4WD

18 1 Washer

7022313 2WD

See Note 4WD (Note: Use Item 9) 19 7022314 1 Retainer, Spring 20 7023910 1 Shaft 21 7007439 1 Ring, Retaining 22 1 Cap, End - Axial Options:

See Note 2WD (Note: Not Available - Purchase Complete Assy.)

7022367 4WD 23 7022368 4 Screw 24 7021249 1 Bearing, Needle 25 7022321 1 Plug (Includes Item 26)

3121235 680S 1-19

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (4 BOLT ASSEMBLY) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

26 Use 7022328 1 O-Ring 27 7007420 1 Plug (Includes Item 28) 28 Use 7022328 1 O-Ring 29 7007419 2 Plug (Includes Item 30) 30 Use 7022328 2 O-Ring 31 1 Seat, Spring Options:

7027741 2WD 7022372 4WD

32 1 Housing Options:

7024870 2WD

7022370 4WD 33 7007419 2 Plug (Items Item 34) 34 Use 7022328 2 O-Ring 35 7022321 1 Plug (Items Item 36) 36 Use 7022328 1 O-Ring 37 Use 7022328 1 O-Ring 38 Use 7022328 1 Ring, Seal 39 1 Piston, Servo Options:

7024871 2WD (Includes Items 37 & 38)

7022323 4WD (Piston Only - Does not include items 37 & 38) 40 7007437 1 Bearing 41 7022326 1 Spring 42 Use 7022328 1 Seal, Lip 43 7022371 1 Washer, Support

Ref KIT OPTIONS:

100 7022328 1 Seal Kit (Includes Items 2,3,7,26,28,30,34,36,37,38 and 42)

1-20 680S 3121235

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (4 BOLT ASSEMBLY) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121235 680S 1-21

SECTION 1 FRAME

303433

323132

129107A131615

100

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)

1-22 680S 3121235

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref DRIVE MOTOR ASSEMBLIES: 3160347 Ref 2WD B 3160348 Ref 4WD B

1 7022302 2 Bearing, Journal 2 7007446 1 Pin 3 7007438 2 Ring, Retaining 4 1 Swashplate Options:

70000794 2WD

7022305 4WD

5 See Note 2 Pin (Note: Not Available for Purchase.) 6 Use 7022328 1 Gasket 7 1 Cylinder Block Kit (Includes Items 7A & 9-17)

7027740 2WD 7023907 4WD

7A See Note 1 Block, Cylinder (Note: Not Available - Purchase

Complete Cylinder Block Kit.)

8 1 Plate, Valve Options:

7024862 2WD 7023908 4WD

9 1 Guide, Slipper Retainer Options:

See Note 2WD (Note: Not Available for Purchase.)

7021277 4WD

10 7021275 3 Pin, Slipper Hold Down 11 See Note 9 Piston Assembly (Note: Not Available - Purchase Complete

Assy.)

12 1 Retainer, Slipper Options:

See Note 2WD (Note: Not Available for Purchase.)

7022310 4WD

13 1 Retainer, Hold Down Pin Options:

Not Required 2WD

7021276 4WD

14 7022311 1 Ring, Retaining 15 1 Spring Options:

7024867 2WD 7022312 4WD

16 1 Washer Options:

7022313 2WD 7024868 4WD

17 7022314 1 Retainer, Spring 18 7023910 1 Shaft 19 7007439 1 Ring, Retaining 20 1 Cap, End - Axial Options:

70000795 2WD

70000797 4WD 21 7022368 5 Screw 22 7021249 1 Bearing, Needle 23 2220886 1 Plug (Includes Item 24) 24 Use 7022328 1 O-Ring

3121235 680S 1-23

SECTION 1 FRAME

FIGURE 1-6. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

25 2220883 1 Plug (Includes Item 26) 26 Use 7022328 1 O-Ring 27 2220888 2 Plug (Includes Item 28) 28 Use 7022328 2 O-Ring 29 1 Seat, Spring Options:

7027741 2WD

7022372 4WD 30 See Note 1 Housing (Note: Not Available - Purchase Complete Assy.) 31 2220883 2 Plug (Items Item 32) 32 Use 7022328 2 O-Ring 33 2220886 1 Plug (Items Item 34) 34 Use 7022328 1 O-Ring 35 Use 7022328 1 O-Ring 36 Use 7022328 1 Ring, Seal 37 1 Piston, Servo Options (Includes Items 35 & 36):

7024871 2WD

7024854 4WD 38 7007437 1 Bearing 39 7022326 1 Spring 40 Use 7022328 1 Seal, Lip 41 7022371 1 Washer, Support

Ref KIT OPTIONS:

100 7022328 1 Seal Kit (Includes Items 6,24,26,28,32,34,35,36 and 40)

1-24 680S 3121235

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