SkyTrak 6036 Service Manual - Manual (Page 157)

Model 6036 S/N 9B0499 and Before 9-44
Section 9. Hydraulic System
e. Assembly
NOTE: Follow general assembly instructions in
paragraph 9.2c.
1. If bearing (7, Fig 9.21) was removed for
replacement, press new bearing into eye of
tube (1). The bearing should protrude the
same distance from each side of the eye.
2. Install new O-ring (10), backup ring (11), wiper
(9), and rod seal (8) on gland (4) as shown in
Fig. 9.21.
NOTE: The wiper lip should be toward the inner
end of the gland and the rod seal toward the outer
end of the gland. Use tools that will not damage
the seal. 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 or
other acceptable holding device. Put a
padded support below and near the end of the
rod to prevent damage to the rod.
4. Push the assembled gland onto the rod (5). If
necessary, use a soft hammer to drive the
gland onto the rod.
5. Install a new O-ring (12) on the inside of the
piston. Carefully install piston (3) on the rod to
avoid damage to O-ring.
6. Apply Loctite ® Primer T and Threadlocker 271
to the nut (2) in accordance with the manufac-
turer’s instructions. Install the nut on the rod
and torque to 400 to 450 lb-ft (544 to 612
N m). Stake the nut in four places.
7. Install new piston seal (13) on the piston.
8. Fasten the cylinder tube (3) in a soft-jawed
vise or other acceptable holding equipment.
Be careful not to damage the tube.
9. Lubricate the inside of the tube, piston, and
gland O-ring (9) with clean hydraulic oil.
10. Apply a compression sleeve or other suitable
tool to the gland in order to compress the O-
ring (10) on the gland. Insert the assembled
piston, rod and the gland into the tube (3).
Using a pin spanner wrench, thread the gland
into the 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 (15) and backup rings (16)
on check valves (1). Use new valve if either
valve was removed for replacement. Lubri-
cate outside of the valves with clean filtered
hydraulic oil. Install the valves and torque to
30 to 35 lb-ft (40,8 to 47,6 N m).
12. If removed, install grease fittings (14).
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 seals. Keep the rod in
line with the tube barrel to prevent binding.
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 maxi-
mum (1750 psi or 120 bar) for the cylinder and
check for external leakage and free movement
in both directions.
15. Prepare the cylinder for installation by retract-
ing the piston and capping and plugging the
ports.
f. Installation
1. Install the side tilt carriage cylinder (1, Fig.
9.21) on the side tilt carriage (7). Secure the
rod end to side tilt carriage (7).
2. Secure the tube end to the pivot base (8) with
snap rings (4).
3. Lubricate the pivot pins with multi-purpose
lithium-based grease.
4. Remove all plugs and caps from the hydraulic
lines and securely tighten the lines to the
cylinder.
5. Start the forklift engine and remove blocking
from the carriage.
6. Tilt the side tilt carriage five times through its
full range or until the operation of the side tilt
carriage is normal (no jerks or spongy feel).
7. Shut down the engine. Check the hydraulic oil
level and fill as described in the Owners/
Operators Manual.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning !