SkyTrak 8042 Service Manual - Manual (Page 564)

8.149 Model 8042, 10042, 10054 Legacy Rev. 10/03
Hydraulic System
10. Secure the rod eyelet in a soft-jawed vise or other
suitable holding device. Place a padded support
below the threaded end of the rod to help prevent
damaging the rod.
11. Apply Loctite Threadlocker #271 (red) to the locknut
(15) in accordance with Loctite instructions. Install
the nut onto the threaded end of the rod. Torque the
nut to 1175-1400 lb-ft (1593-1898 Nm).
IMPORTANT: Avoid using excess force when clamping
the cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder tube (16).
12. Fasten the cylinder tube (16) in a soft-jawed vise or
other suitable holding device.
13. Lubricate the o-rings and the inside of the tube,
piston and head gland with clean, filtered hydraulic
oil. This will aid in installation.
IMPORTANT: Use a suitable installation tool or
compression sleeve to help prevent twisting or damaging
the seals and o-rings when installing the piston (13) and
head gland (2) into the cylinder. When sliding the rod
and piston assembly in the tube, DO NOT damage the
piston by scraping it against the threads in the tube.
Keep the rod in line with the tube to prevent binding.
14. Keep the rod (10) straight and carefully insert the rod
into the tube (16). Avoid scratching, nicking or
damaging the tube while installing the rod.
15. Apply Loctite #242 (blue) to the threads of the head
gland (2) and thread into the tube (16). Use a
suitable pin spanner wrench to thread the head
gland (2) completely into the tube (16). Torque the
head gland to 300 ±50 lb-ft (407 ±68 Nm).
16. Apply Loctite #242 (blue) to the threads of the lock
screw (17) and thread into the flange of the head
gland (2). Torque to 3-4 lb-ft (4-5 Nm).
17. Using new oiled o-rings, thread the two pilot-operated
check valves (18), the pressure reducing valve (19)
and the five solenoid valves (20 and 21) into the
manifold block (22). Torque the five solenoid
cartridges (20 and 21) to 20-25 lb-ft (27-34 Nm).
Torque the check valves (18) and the pressure
reducing valve (19) to 35-40 lb-ft (47-54 Nm). Place
the solenoid coils on the cartridges and torque the
solenoid nuts to 4-6 lb-ft (5-8 Nm).
18. Test the cylinder (23) at low operating pressure [100
psi (7 bar)] to verify that the piston and rod move
freely in both directions.
19. Increase the operating pressure to the maximum for
the cylinder [4000 psi (275 bar)] and check for
external leakage and for free movement in both
directions.
20. Retract the piston fully
f. Stabilizer Cylinder Installation
1. Lubricate the cylinder pins with multi-purpose,
lithium-based grease.
2. Use a sling and hoist or other suitable lifting device
to help install the cylinder. Orient the cylinder with
the cylinder eyelet on top and the rod eyelet on the
bottom.
3. Install the upper cylinder pin. Drive the lubricated
cylinder pin through the cylinder eyelet, frame mount
and self-aligning bearing. Secure the pin with a
capscrew and hex locknut. Torque to 18 lb-ft (24 Nm).
4. Use new flat-faced oiled o-rings when installing the
upper and lower hydraulic hoses. Install and tighten
the hoses onto the appropriate fittings on the
manifold.
g. Stabilizer Cylinder Pressure Checking and
Circuit Bleeding
1. Attach a 4000 psi (276 bar) gauge to the test fitting
on the main control valve to test the system
pressure. Pressure readings should be
3000 ±100
psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic
System Testing.” To check the cylinder pressure,
consult the factory.
2. Start the vehicle. Level the frame.
3. Sway the vehicle fully left. Hold the joystick at full
sway left for several seconds, then sway the vehicle
fully right and hold the joystick at full sway right for
several seconds. Observe the readings on the gauge
during the frame sway operations.
4. Level the frame. While leveling the frame, check the
pressure reading on the gauge.
5. Repeat Steps 3 and 4 five times.