SkyTrak 6036 Service Manual - Manual (Page 211)

Section 9 Hydraulic System
Model 6036/6036T S/N 9B0500 thru 14833 9-61
f. Installation
1. Screw the socket assemblies (3, Fig. 9.31) onto
the retracted cylinder (4). Adjust position of the
socket assembly by turning until the total length
equals the measured length taken during
removal.
NOTE: If there is no accurate recorded cylinder
length, the cylinder can be adjusted as described in
the following steps.
2. Turn the steering knuckle to full inside turn
position on either the left or right side.
e. Assembly
3. Adjust the socket assembly position in or out
on the rod end, so that the retracted length of
the cylinder matches the length required to
install the cylinder.
IMPORTANT: Protect the finish on the rod at
all times. Damage to the surface of the rod can
cause premature seal failure.
4. Install nuts (2) securing the cylinder socket
assemblies to the axle carrier (4) and knuckle
(5). Torque the nuts to 140 lb-ft (190 Nm)
minimum. Install cotter pins (1).
5. Tighten the socket clamp. Torque the clamp
bolt and nut to 60 to 70 lb-ft (82 to 95 Nm).
6. Turn the other steering knuckle to its full inside
turn position and adjust the cylinder (steps 3
through 5).
7. Remove all plugs or caps from the hydraulic
lines and securely tighten the lines to the
cylinder.
8. Start the engine. Turn the steering wheel fully
left to right and back (lock to lock) several
times in all three steering modes until they
operate smoothly. This should purge the
steering system of air. The maximum number
of turns of the steering wheel should not
exceed 4-1/2 turns lock to lock.
9. Shut down the engine. Check the hydraulic oil
level and fill as described in the Owners/
Operators Manual.
10. Test steering circuit operation as described in
paragraph 9.4.6.c.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning
NOTE: Follow general assembly instructions in
paragraph 9.5.c.
1. Fasten rod (3) in a soft-jawed vise.
2. Install new O-ring (9, Fig. 9.32) inside of
piston (2). Carefully install the piston on rod
(3) to avoid damage to the O-ring.
3. Apply Loctite ® Primer T and Threadlocker 271
to the locknut (5) in accordance with the
manufacturer’s instructions. Install the locknut
and torque it to 160 lb-ft (217 Nm). Allow
sealants to cure.
4. Install a wear ring (12), expander (13), piston
seal (10) and the other wear ring (12) on
piston (2).
5. Install rod wiper (6), U-cup seal (7), back-up
ring (14) and O-ring (8) on the gland (4).
6. Install the assembled gland and seals on rod
(3).
7. Lubricate all parts and inside of the tube (1)
with clean hydraulic oil.
8. Apply a compression sleeve or other suitable
tool to the gland in order to compress the O-
ring (8) on the gland. Push the rod assembly
straight into the cylinder tube with a steady
even pressure until the gland butts up against
the tube.
9. Locate the hole in the tube and insert wire
retainer (11).
10. Using a wrench, rotate the gland 360 degrees
to install the wire retainer.
11. 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.
12. Increase the operating pressure to the maxi-
mum (4000 psi or 275 bar) for the cylinder and
check for external leakage and free movement
in both directions.
13. Prepare the cylinder for installation by retract-
ing the piston and capping and plugging the
ports.