SkyTrak 6036 Service Manual - Manual (Page 142)

Section 9. Hydraulic System
9-29 Model 6036 S/N 9B0499 and Before
2. Inspect inside of the tube (13) for deep 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.
e. Assembly
NOTE: Follow general assembly instructions in
paragraph 9.2c.
1. Install a new O-ring (10), backup ring (11),
wiper (2), rod seal (3), and step seal (17) on
the gland as shown in Fig. 9.12.
NOTE: Wiper lip should be toward outer end of
gland and rod seal lips (3) and the step of step
seal (17) toward the inner end of the gland. Use
tools that will not damage the seals. If the backup
ring (11) is not flat on both sides, the side with the
arc must be toward O-ring (10).
2. Fasten the rod eye in a soft-jawed vise. Place
a padded support below and near end of rod
to prevent damage to rod (1).
3. Slide the assembled gland and seals onto the
rod. If necessary, use a soft hammer to drive
the gland on the rod.
4. Slide the stop tube (9) onto the rod.
5. Install new O-ring (8) inside internal groove on
inside of piston (5).
6. Apply Loctite ® Primer T and Compound 609 to
inside threads of piston in accordance with
manufacturer’s instructions. Carefully screw
piston completely onto the rod.
7. Apply Loctite ® Threadlocker 242 to setscrews
(6 and 7) and install them in the piston.
8. Apply Loctite ® Primer T and Compound 609 to
outside diameter of rod next to piston. Slide
stop tube (9) down the rod and against the
piston. Allow sealants to cure.
9. Install new piston seal (4) on piston.
10. Fasten cylinder tube (13) in a soft-jawed vise
or other acceptable holding equipment.
11. If removed, install two plugs (16) in the bottom
of the cylinder tube.
12. Lubricate inside of the tube and outside of the
piston and gland with clean hydraulic oil.
13. Apply a compression sleeve or other suitable
tool to the gland in order to compress O-ring
(10) on the gland. Insert the assembled
piston, rod and gland into the tube (13). Using
a pin spanner wrench, thread the gland into
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.
14. Install new O-rings (18) and backup rings (19)
on the counterbalance valve (14) and pilot
check valve (15). Use new valves if either or
both valves were removed for replacement.
Lubricate outside of the valves with clean
filtered hydraulic oil. Install the valves and
torque them to 45 lb-ft (61,2 N m).
15. 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.
16. 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.
17. Prepare the cylinder for installation by retract-
ing the piston and capping and plugging the
ports.
f. Installation
1. Using suitable lifting device, install the boom
extend cylinder, Fig. 9.9, on the forklift secur-
ing the base end of the extend cylinder to the
outer boom with a pin and retaining rings.
2. Remove all plugs or caps from the hydraulic
lines and securely tighten the lines to the
cylinder.
3. Have a helper start the forklift engine.
4. Position the extend cylinder so that the rod is
aligned with the rod end mounting holes as
much as possible.
5. Instruct the operator to extend or retract the
cylinder slowly until the rod end eye is aligned
with the intermediate boom mounting holes.
Secure the rod end to the boom with pin and
retaining rings.
6. Install the anti-buckle bar, Fig. 9.11.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning !