SkyTrak 6036 Service Manual - Manual (Page 145)

Section 9. Hydraulic System
Model 6036 S/N 9B0499 and Before 9-32
2. Fasten the piston rod eye in a vise and put a
padded support below and near other end of
rod to prevent damage to the rod.
3. Push the assembled gland onto the rod (12).
If necessary, use a soft hammer to drive the
gland on the rod.
4. Install new O-ring (7) inside of piston (9).
Carefully install piston on rod to avoid damage
to the O-ring.
5. Apply Loctite ® Primer T and Retaining Com-
pound 271 to the threads of the locknut (3) in
accordance with the manufacturer’s instruc-
tions. Install the nut on the rod and torque to
450 to 500 lb-ft (612 to 680 N m). Stake the
nut in four places and allow sealants to cure.
6. Install new piston seal (8) on the piston.
7. Fasten cylinder tube (2) in a soft-jawed vise or
other suitable holding equipment. Be careful
not to damage the tube.
8. Lubricate inside of the tube, piston, and gland
O-ring (6) with clean hydraulic oil.
9. Apply a compression sleeve or other suitable
tool to the gland in order to compress the O-
ring (6) on the gland. Insert the assembled
piston, rod and gland into the tube (2). Using
a pin spanner wrench, thread the gland into
the tube. Remove the compression tool.
IMPORTANT: When sliding the rod and piston
assembly in 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.
10. Apply Loctite ® Primer T and Retaining Com-
pound 609 to outside diameter of bushings (1)
in accordance with manufacturer’s instruc-
tions. Press bushings into both the eye of rod
and eye of cylinder tube so that the bushing is
located an equal distance from each side of
the rod eye. Allow the compound to cure.
11. If removed, install grease fittings (13 and 14).
12. 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.
13. Increase the operating pressure to the maxi-
mum (4000 psi or 275,6 bar) for the cylinder
and check for external leakage and free
movement in both directions.
14. Prepare the cylinder for installation by retract-
ing the piston and capping and plugging the
ports.
f. Installation
1. Lubricate the pivot pin with multi-purpose
lithium-based grease.
2. Using suitable lifting device, install the slave
cylinder, Fig. 9.9, on the forklift securing the
base end to the frame with a pin and snap
rings.
3. Remove all plugs or caps from the hydraulic
lines and securely tighten the lines to the
cylinder.
4. Have a helper start the forklift engine.
5. Position the slave cylinder so that the rod is
aligned with the rod end mounting holes as
much as possible.
6. Instruct the operator to extend or retract the
cylinder slowly until the rod end eye is aligned
with the outer boom mounting holes. Secure
the slave cylinder to the outer boom with its
locking capscrew and locknut.
7. Tilt grille (forks) up fully, then down fully and
then approximately level. Raise the boom as
far as it will go; then lower it as far as it will go
five times while observing the grille. The grille
should hold in the same position during boom
raising and lowering in the last two cycles.
8. Shut down the engine. Check the hydraulic oil
level and fill as described in the Owners/
Operators Manual.
9. Test grille tilt circuit operation as described in
paragraph 9.1.3c.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning !