SkyTrak 6036 Service Manual - Manual (Page 143)

Section 9. Hydraulic System
Model 6036 S/N 9B0499 and Before 9-30
Warning !
Warning !
7. Extend the boom as far as it will go; then the
retract it as far as it will go five times or until
the operation of the boom extend cylinder is
normal (no jerks or spongy feel).
8. Shut down the engine. Check the hydraulic oil
level and fill as described in the Owners/
Operators Manual.
9. Test boom extend/retract circuit operation as
described in paragraph 9.1.2c.
Relieve hydraulic pressure before servicing any
hydraulic component. Escaping hydraulic fluid
under pressure can penetrate the skin causing
serious injury.
Wait for the hydraulic fluid to cool before servic-
ing any hydraulic component. Hot hydraulic fluid
can cause severe burns.
9.2.3 Slave Cylinder
a. Removal
1. Raise the boom as required to provide access
to the slave cylinder, Fig. 9.9.
2. Engage the park lock, place the travel select
lever in neutral, and stop the engine.
3. Operate the hydraulic controls after the engine
has stopped to relieve any trapped pressure.
4. Support the slave cylinder with a sling or other
suitable device
5. Remove the capscrew and locknut securing
the slave cylinder rod to the outer boom.
6. Start engine and fully retract slave cylinder.
7. Disconnect the hydraulic lines from the
cylinder and cap or plug open connections.
8. Remove the retaining ring and pin securing
the slave cylinder tube to the frame.
9. Remove the cylinder from the forklift using a
strap sling and hoist or other suitable lifting
equipment.
b. Disassembly
1. Remove all dirt and grease from cylinder.
2. Fasten the cylinder in a soft-jawed vise or
other acceptable holding equipment. Do not
damage the tube.
3. If necessary to replace, remove grease fittings
(13 and 14, Fig. 9.13)
NOTE: It may be necessary to apply heat to
break the bond of the sealant between bushings
(1) and rod (12) and tube (2) before the bushings
can be removed. Refer to paragraph 9.2a.
4. Carefully press or drive out the bushings (1).
5. Using a pin spanner wrench, unscrew the
gland (4) from the cylinder tube (2).
IMPORTANT: Protect the finish on the rod at
all times. Damage to the surface of the rod can
cause premature seal failure.
6. Pull the rod (12) and attached parts straight
out of the tube.
IMPORTANT: When sliding the rod and piston
assembly out of the tube, be careful so that gland
threads in the cylinder tube do not damage the
piston (9). Keep the rod in line with the tube barrel
to prevent binding.
7. Remove the piston seal (8) from the piston .
8. Fasten the eye end of the rod in a soft-jawed
vise and put a padded support below and near
the other the end of the rod to prevent damage
to the rod.
NOTE: It may be necessary to apply heat to
break the bond of the sealant between nut (3) and
rod (12) before the piston can be removed. Refer
to paragraph 9.2a.
9. Remove the nut (3), piston (9), and gland (4)
from the rod.
10. Remove the O-ring (7) from inside of the
piston.
11. Remove the O-ring (6), backup ring (5), wiper
(11) and rod seal (10) from the gland (4).
c. Cleaning
1. Discard all seals and backup rings. Replace
with a complete new seal kit.
2. Clean all metal parts in an approved cleaning
solvent such as trichlorethylene. Be sure to
carefully clean all cavities and grooves.