SkyTrak 8042 Service Manual - Manual (Page 568)

8.153 Model 8042, 10042, 10054 Legacy Rev. 10/03
Hydraulic System
11. Remove the locknut (11) from the rod (1). The
deforming-thread type nut was coated with Loctite
#271 (red) and torqued to 1300-1500 lb-ft (1763-
2034 Nm). Discard the nut.
Note: It may be necessary to apply heat to break the
bond of the sealant between the locknut (11) and the rod
(1) before the piston (4) can be removed. Some parts of
cylinders are sealed with a special organic sealant and
locking compound.
Before attempting to disassemble these parts, remove
any accessible seals from the area of the bonded joint.
Wipe off any hydraulic oil and heat the joint uniformly to
break the bond. A temperature of 300-400° F (149-204° C)
will destroy the bond. Avoid overheating or the parts may
become distorted or damaged. Apply sufficient torque or
pressure for removal while the parts are still hot.
Breakdown of sealant will leave a white, powdery
residue on threads and parts. Clean the residue away
with a soft brass wire brush prior to reassembly, and
wipe with Loctite “T” cleaner before reinstallation.
12. Remove the piston (4) and head gland (2) from the
rod (1).
13. From the head gland (2), remove the deep Z-seal
with rod back-up (12), the sealed outside diameter
heavy-duty rod wiper (13) and the precision
wearbands (14).
14. From the piston (4), remove the small o-ring (15).
c. Outrigger Cylinder Cleaning
1. Remove all hydraulic fluid, dirt and debris from the
inner surface of the cylinder.
2. Discard all seals, back-up rings and o-rings. Replace
with new items from a complete seal kits (16) to help
ensure proper cylinder function.
3. Clean all metal parts with an approved cleaning
solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc.
Note: If a white, powdery residue is present on threads
and parts, it can be removed. Clean the residue away
with a soft brass wire brush prior to reassembly, and
wipe with Loctite “T” cleaner before reinstallation.
d. Outrigger Cylinder Inspection
1. Inspect internal surfaces and all parts for wear, damage,
etc. If the inner surface of the tube (3) does not display a
smooth finish, or is scored or damaged in any way,
replace the tube. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the smooth
surface within the tube.
2. Remove slight scratches on the piston, rod, or inner
surface of the tube with very fine grit emery cloth. Use
the emery cloth in a rotary motion to polish out and
blend the scratch(es) into the surrounding surface.
3. Clean parts with trichlorethylene.
4. Check that the rod (1) is straight. If it is bent, install a
new rod.
e. Outrigger Cylinder Assembly
Note: Follow Section 8.13.3, “General Cylinder
Assembly Instructions.”
IMPORTANT: Use a suitable installation tool or
compression sleeve to help prevent twisting or damaging
the seals and o-rings when installing the piston and head
gland into the cylinder. When sliding the rod and piston
assembly in the tube, DO NOT damage the piston by
scraping it against the threads in the tube. Keep the rod
in line with the tube to prevent binding.
1. Fasten the rod end in a soft-jawed vise, and put a
padded support below and near the threaded end of
the rod to help prevent damage to the rod. Install the
small o-ring (15) in the piston (4).
2. Install the sealed outside diameter heavy-duty rod
wiper (13). The wiper lip (17) should be toward the
outer end of the head gland and the seal lips toward
the inner end of the head gland. Use tools that will
not damage the seals.
3. Install the deep Z-seal with rod back-up (12) in the
head gland (2) orienting the edge (18).
4. Install the precision wearbands (14) into the head
gland (2).
5. Carefully install the head gland (2) onto the rod (1).
6. Carefully install the piston (4) onto the rod (1).
Note: If a white, powdery residue remains on the
threads and parts, clean the residue away with a soft
brass wire brush prior to reassembly, and wipe with
Loctite “T” cleaner before proceeding.
7. Apply Loctite Threadlocker #271 (red) to a new
locknut (11). Thread the locknut onto the rod (1) and
torque to 1300-1500 lb-ft (1763-2034 Nm). The
threads will deform upon tightening, locking the nut
in place.