SkyTrak 6036 Service Manual - Manual (Page 173)

Model 6036 S/N 9B0499 and Before 9-60
Section 9. Hydraulic System
9.4 PUMPS
9.4.1 Main Tandem Pump
a. Removal
1. Engage the park lock, place the travel selector
lever in neutral, and stop the engine.
2. Operate the hydraulic joystick to relieve any
trapped pressure in the 30 gpm section of the
tandem pump. Slowly loosen the upper outlet
port fitting on the 15 gpm pump section to
relieve any trapped pressure.
3. Remove hex head capscrews (5), lock wash-
ers (6), and both clamp halves (4) on the main
pump inlet line. Disconnect the hose elbow
(3) from the pump inlet. Remove and discard
the O-ring (7) from the elbow.
4. Disconnect small pump outlet hose (8).
5. Disconnect large pump outlet hose (9).
6. Remove connector (10) and elbow (11) from
the pump outlets.
7. Remove capscrews (12) and lock washers
(13) that attach the main tandem pump (14) to
the transmission. Remove and discard the
pump gasket (15).
b. Tools Required for Pump Repair
The following tools are required for tandem pump
disassembly and assembly:
1. A bushing puller made from Collet 33863 of
Blind Hole Puller Set 981 by Owatonna Tool
Company or an equivalent puller from another
supplier. Modify this collet as shown in Fig.
9.38.
Warning !
Warning !
b. Disassembly
NOTE: There are no serviceable parts in the
counterbalance valve; do not disassemble.
Remove the counterbalance valve cartridge, Fig.
9.34.
c. Cleaning
Clean metal parts of valve in an approved cleaning
solvent and blow dry.
d. Inspection and Replacement
1. Inspect valve cartridge (Fig. 9.34) for wear,
scoring, damaged seals and other damage.
Replace cartridge if damaged.
2. Discard entire counterbalance valve if dam-
aged.
e. Installation
NOTE: Be sure that all tube and hose connections
to the pressure reducing valve have been made.
Refer to paragraph 9.3.7.
1. Install elbows (6, Fig. 9.36), reducers (7) and
tube nuts (8).
2. Position counterbalance valve (3) under
pressure reducing valve (11) and secure to
mounting plate (14) with two capscrews (1),
lock washers (12) and hex nuts (13).
3. Connect hydraulic hoses to elbows (6).
f. Bleeding Steering System
1. Start the forklift engine and run at idle.
2. 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.
3. Shut down the engine. Check the hydraulic oil
level and fill as described in the Owners/
Operator’s Manual.
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.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning !