SkyTrak 6036 Service Manual - Manual (Page 198)

Section 9 Hydraulic System
9-48 Model 6036/6036T S/N 9B0500 thru 14833
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.
6. Install new piston seal (8) on the piston.
7. Fasten cylinder tube (2) in a soft-jawed vise or
other suitable holding equipment. Be careful
not to damage the tube.
8. Lubricate inside of the tube, piston, and gland
O-ring (6) with clean hydraulic oil.
9. Apply a compression sleeve or other suitable
tool to the gland in order to compress the O-
ring (6) on the gland. Insert the assembled
piston, rod and gland into the tube (2). Using
a pin spanner wrench, thread the gland into
the 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.
10. Apply Loctite ® Primer T and Retaining Com-
pound 609 to outside diameter of bushings (1)
in accordance with manufacturer’s instruc-
tions. Press bushings into both the eye of rod
and eye of cylinder tube so that the bushing is
located an equal distance from each side of
the rod eye. Allow the compound to cure.
11. If removed, install grease fittings (13 and 14).
12. 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.
13. 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.
14. Prepare the cylinder for installation by retract-
ing the piston and capping and plugging the
ports.
f. Installation
1. Lubricate the pivot pin with multi-purpose
lithium-based grease.
2. Using suitable lifting device, install the slave
cylinder, Fig. 9.18, on the forklift securing the
base end to the frame with a pin and snap
rings.
3. Remove all plugs or caps from the hydraulic
lines and securely tighten the lines to the
cylinder.
4. Have a helper start the forklift engine.
d. Inspection, Repair and Replacement
1. Check that the rod (12, Fig. 9.24) is straight. If
the rod is bent, install new rod.
2. Inspect inside of the tube (2) for scoring and
other damage. If there is any damage to tube,
replace it 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.
4. Remove staking burrs from the nut (3) and the
bottom of piston (9) with fine file. Clean parts
with trichlorethylene after repair.
e. Assembly
NOTE: Follow general assembly instructions in
paragraph 9.5.c.
1. Install new O-ring (6, Fig. 9.24), backup ring
(5), wiper (11), and rod seal (10) on the gland
(4) as shown in Fig. 9.24.
NOTE: Wiper lip should be toward outer end of
gland and piston seal lips toward the inner end of
the gland. Use tools that will not damage the seal.
If the backup ring is not flat on both sides, the side
with the arc must be toward the O-ring.
2. Fasten the piston rod eye in a vise and put a
padded support below and near other end of
rod to prevent damage to the rod.
3. Push the assembled gland onto the rod (12).
If necessary, use a soft hammer to drive the
gland on the rod.
4. Install new O-ring (7) inside of piston (9).
Carefully install piston on rod to avoid damage
to the O-ring.
5. Apply Loctite ® Primer T and Retaining Com-
pound 271 to the threads of the locknut (3) in
accordance with the manufacturer’s instruc-
tions. Install the nut on the rod and torque to
450 to 500 lb-ft (610 to 678 Nm). Stake the
nut in four places and allow sealants to cure .