SkyTrak 6036 Service Manual - Manual (Page 139)

Section 9. Hydraulic System
Model 6036 S/N 9B0499 and Before 9-26
2. Inspect the inside of the tube (7) for scoring
and other damage. If the tube is damaged,
replace with new tube.
3. Remove small scratches on the rod or inside
the tube with emery cloth of very fine grit. Use
the emery cloth with a rotary motion.
4. Remove staking burrs from the nut (8) and the
bottom of piston (9) with a fine file. Clean parts
with trichlorethylene after repair.
e. Assembly
NOTE: Follow general assembly instructions in
paragraph 9.2c.
1. Apply Loctite ® Primer T and Retaining Com-
pound 609 to the outside diameter of the
bushing (18, Fig. 9.10) in accordance with the
manufacturer's instructions. Press the bushing
into position in the eye of rod so that the
bushing is located an equal distance from each
side of the rod eye. Allow the compound to
cure.
2. Install a new rod seal (15), wiper (16), backup
ring (13) and O-ring (12) on the gland (14) as
shown in Fig. 9.10.
NOTE: The wiper lips should be toward the outer
end of the gland and the rod seal lips toward the
inner end of the gland. Use tools that will not
damage the seal or wiper. If the backup ring is not
flat on both sides, the side with the arc must be
toward the O-ring.
3. Fasten the rod eye in a soft-jawed vise. Put a
padded support below and near the other end
of the rod to prevent damage to the rod.
4. Push the assembled gland onto the rod (17). If
necessary, use a soft hammer to drive the
gland onto the rod.
5. Install new O-ring (8) into internal groove on
the inside of the piston (9). Carefully push the
piston (6) onto the rod to avoid damage to the
O-ring.
6. Apply Loctite ® Primer T and Threadlocker 271
to the threads on the nut (8) in accordance with
the manufacturer’s instructions. Install the nut
on the rod and torque to 575 to 625 lb-ft (782
to 850 N m). Stake the nut in four places.
Allow the Threadlocker to cure.
7. Install a new piston seal (10) on the piston.
8. Fasten the tube (7) in a soft-jawed vise or
other acceptable holding equipment. Be careful
not to damage the tube.
9. Lubricate the inside of the tube, outside of the
piston, seal (10) and O-ring (12) with clean
hydraulic oil.
10. Apply a compression sleeve or other suitable
tool to the gland in order to compress the O-
ring (12) on the gland. Insert the assembled
piston, rod and gland into the tube (7). Using
a pin spanner wrench, thread the gland into
tube. Remove the compression tool
IMPORTANT: When sliding the rod and piston
assembly into the tube, be careful so that gland
threads in the tube do not damage the piston
seal. Keep the rod in line with the tube barrel to
prevent binding.
11. Install new O-rings (2) and backup rings (3)
on counterbalance valve (1). Use new valve
if the valve was removed for replacement.
Lubricate outside of the valve with clean
filtered hydraulic oil. Install the valve and
torque to 45 lb-ft (61,2 N m).
12. If removed for replacement, install new plugs
(4 and 6) and grease fittings (5).
13. Following reassembly, test the cylinder at low
operating pressure (100 psi or 6,9 bar) to be
sure the piston and rod are moving freely in
both directions.
14. Increase the operating pressure to the
maximum (4000 psi or 275,6 bar) for the
cylinder and check for external leakage and
free movement in both directions.
15. Prepare the cylinder for installation by
retracting the piston and capping and plug-
ging the ports.
f. Installation
1. Lubricate the hoist cylinder pivot pins with
multi-purpose lithium-based grease
2. Using suitable lifting device, install the boom
hoist cylinder, Fig. 9.9, on the forklift securing
the base end to the frame with pivot pin and
snap rings.
3. Remove all plugs or caps from hydraulic lines
and securely tighten lines to the cylinder.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning !