JLG 680S, Service And Maintenance Manual

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SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
3121234 5-59
6. To assemble cradle sub-assembly, install bushing onto
cradle retaining with button head capscrews. Torque
button head capscrew 14 to 16 in. lbs. (1.6 to 1.8 Nm).
7. Place cradle sub-assembly into housing making sure
cradle is completely seated into housing. Retain cradle
sub-assembly with two capscrews. Torque capscrews 20
to 24 ft. lbs. (27 to 33 Nm).
8. To install shaft, place exterior retaining ring, thrust race,
thrust bearing, second thrust race, and second retaining
ring onto shaft. Position washer and shaft seal or spacer
onto shaft.
9. Install shaft assembly into front of housing for units with
spacer, retain with interior retaining ring and go on to
step 10. For units with shaft seal. seat seal into position
with seal driver and retain with interior retaining ring.
10. Install servo piston follower onto swashplate dowel pin.
Install swashplate carefully onto bushing (coat bushing
surface with hydraulic oil), aligning servo piston follower
with slot in servo piston assembly.
NOTE: Refer to “Rotating Kit Assembly” for reassembly of rotating
kit assembly.
11. To install rotating kit assembly, leave housing and shaft
in the horizontal position. Holding swashplate into posi-
tion with screw driver thru controller linkage passage-
way at the top of housing. place rotating kit assembly
over shaft and into housing until pistons are in against
swashplate. Make sure all parts are in housing com-
pletely and properly positioned. Return the pump to the
vise with open end of housing up. clamping housing on
the outer portion of the flange.
12. Install gasket on to housing.
13. If necessary, press new bearing and roll pin in endcover
to dimension shown in figure 1-3. Bearing installed with
the numbered end outward. Roll pin installed with split
oriented away from bearing.
14. Install new o-ring on relief valves. Install relief valve in its
original cavity in endcover that it was removed. Torque
100 to 110 ft. lbs. (136 to 149 Nm).
15. Install new o-ring on bypass valve or plug. Install bypass
valve or plug into endcover.
NOTE: Make sure paddle of bypass valve is perpendicular to relief
valve axis prior to installing or damage could result.
16. Apply a small amount of petroleum jelly to the steel side
of valve plate to hold in place for installation. Aligning
the index pin, place the valve plate in position onto the
endcover, with steel side against endcover.
17. Install endcover assembly onto housing assembly. Make
sure ports are positioned correctly, valve plate and gas-
ket stay in place.
18. Install key and inner ring gerotor onto shaft or coupler
assembly. Lubricate inner ring gerotor.
NOTE: Refer to “Charge Pump Adapter Assembly” for assembly of
charge relief valve in adapter plate.
19. Insta ll o-ring and outer ring gerotor onto adapter plate.
Lubricate both a-ring and outer ring to hold in position
during assembly of adapter plate. Install adapter plate
onto endcover. Make sure o-ring and gerotor ring stay in
place.
20. Retain endcover and adapter plate (when used) with
four capscrews, Torque 27 to 31 ft. lbs. (37 to 42 Nm).
NOTE: Refer to “Manual Servo Control Basic Assembly” for reas-
sembly of manual servo control assembly.
21. Install control housing gasket onto housing. Install ori-
fices into control assembly and retain in position with
petroleum jelly. Position the feedback link at 90 degrees
from control housing. Install manual servo control
assembly onto housing making sure feedback link
entered small groove in servo piston assembly.
22. Retain control assembly with six capscrews, torque 40 to
48 in. lbs. (4.5 to 5.4 Nm).
23. Install control arm onto control assembly input arm.
Retain with lock washer and nut, torque 4 to 6 ft. lbs.
(5 to 8 Nm).
24. Install new o-rings on all plugs. Install plugs into hous-
ing. Torque 3/4 in. plug 21 to 24 ft. lbs. (28 to 32 Nm).
Torque 1-1/4 in. plug 40 to 45 ft. lbs. (54 to 61 Nm).
25. Refer to “Start-up Procedure” .