SkyTrak 6036 Service Manual - Manual (Page 202)

Section 9 Hydraulic System
9-52 Model 6036/6036T S/N 9B0500 thru 14833
14. 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.
15. Prepare the cylinder for installation by retract-
ing the piston and capping and plugging the
ports.
f. Installation
1. Lubricate the rod end pin with a good grade of
multi-purpose lithium-based grease.
2. Using a suitable lifting device, install the grille
tilt cylinder, Fig. 9.18, on the forklift securing
the tube end to the gooseneck, Fig. 9.25, with
a pin and snap rings.
3. Remove all plugs or caps from the hydraulic
lines and securely tighten the lines to the
cylinder.
NOTE: Wiper lip should be toward outer end of
gland and seal lips toward the inner end of the
gland. Use tools that will not damage the seals. If
the backup ring is not flat on both sides, the side
with the arc must be toward the O-ring.
3. Fasten the eye of the rod in a soft-jawed vise.
Put a padded support below and near end of
rod to prevent damage to the rod.
4 Push the assembled gland onto the rod (11).
If necessary, use a soft hammer to drive the
gland onto the rod.
5. Install new O-ring (5) inside of piston (4).
Carefully install the piston on the rod to avoid
damage to the O-ring.
6. Apply Loctite® Primer T and Threadlocker 271
to the nut (2) in accordance with the manufac-
turer’s instructions. Install the nut on the
piston rod and torque to 450 to 500 lb-ft (610
to 678 Nm). Stake the nut in four places.
Allow the compound to cure.
7. Install new piston seal (3) on the piston.
8. Fasten the tube (1) in a soft-jawed vise or
other acceptable holding equipment. Be
careful not to damage the tube.
9. Lubricate inside of the cylinder tube, piston,
and gland O-ring (6) with clean hydraulic oil.
10. 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 (1). Using
a pin spanner wrench, thread the gland into
the tube. Remove the compression tool
IMPORTANT: When sliding the rod and piston
assembly into 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.
11. Install new O-rings (16) and backup rings (17)
on the counterbalance valve (13). Use new
valve if the valve was removed for replace-
ment. Lubricate outside of the valve with
clean filtered hydraulic oil. Install the valve
and torque to 45 lb-ft (61 Nm).
12. If removed, install grease fittings (14 and 15).
13. Following reassembly, test the cylinder at low
operating pressure (100 psi or 6,8 bar) to be
sure the piston and rod are moving freely in
both directions.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning
4. Have a helper start forklift engine.
5. Position the grille tilt cylinder so that the rod is
aligned with the rod end mounting holes in
quick attach as much as possible.
6. Instruct the operator to extend or retract the
cylinder slowly until the rod end eye is aligned
with the quick attach mounting holes. Secure
the rod end of the cylinder to the quick attach
with pin, capscrew and locknut.
7. Raise the boom up so that you can observe
the grille. Tilt the grille all the way back, then
all the way forward. Repeat this cycle at least
five times or until the operation of the grille tilt
circuit is normal (no jerking or spongy feel).
8. Tilt grille (forks) up fully, then down fully and
then approximately level. Raise the boom as
far as it will go; then lower it as far as it will go
five times while observing the grille. The grille
should hold in the same position during boom
raising and lowering in the last two cycles.
9. Shut down the engine. Check the hydraulic oil
level and fill as described in the Owners/
Operators Manual.
10. Test grille tilt circuit operation as described in
paragraph 9.4.2.c.