SkyTrak 6036 Service Manual - Manual (Page 188)

Section 9 Hydraulic System
9-38 Model 6036/6036T S/N 9B0500 thru 14833
2. Inspect the inside of the tube for scoring and
other damage. If the tube is damaged,
replace 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 and the
bottom of piston with a fine file. Clean parts
with trichlorethylene after repair.
d. Assembly
NOTE: Follow general assembly instructions in
paragraph 9.5.c.
1. Apply Loctite ® Primer T and Retaining Com-
pound 609 to the outside diameter of the
bushing (18, Fig. 9.19) in accordance with the
manufacturer’s instructions. Press the
bushing into position in the eye of rod so that
the bushing is located an equal distance from
each side of the rod eye. Allow the com-
pound to cure.
2. Install a new rod seal (15), wiper (16), backup
ring (13) and O-ring (12) on the gland (14) as
shown in Fig. 9.19.
NOTE: The wiper lips should be toward the outer
end of the gland and the rod seal lips toward the
inner end of the gland. Use tools that will not
damage the seal or wiper. If the backup ring is not
flat on both sides, the side with the arc must be
toward the O-ring.
3. Fasten the rod eye in a soft-jawed vise. Put a
padded support below and near the other end
of the rod to prevent damage to the rod.
4. Push the assembled gland onto the rod (17).
If necessary, use a soft hammer to drive the
gland onto the rod.
5. Install new O-ring (11) into internal groove on
the inside of the piston (9). Carefully push the
piston (9) onto the rod to avoid damage to the
O-ring.
6. Apply Loctite ® Primer T and Threadlocker 271
to the threads on the nut (8) in accordance
with the manufacturer’s instructions. Install
the nut on the rod and torque to 575 to 625 lb-
ft (782 to 850 Nm). Stake the nut in four
places. Allow the Threadlocker to cure.
7. Install a new piston seal (10) on the piston.
8. Fasten the tube (7) in a soft-jawed vise or
other acceptable holding equipment. Be
careful not to damage the tube.
9. Lubricate the inside of the tube, outside of the
piston (9), seal (10), and O-ring (12) with clean
hydraulic oil.
10. Apply a compression sleeve or other suitable
tool to the piston and gland in order to com-
press the o-rings, backup rings and seals
while inserting the assembled piston, rod, and
gland into the tube (7). Remove the compres-
sion tool. Using a pin spanner wrench, thread
the gland into tube.
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 (3) and backup rings (2) on
counterbalance valve (1). Use new valve if
the valve was removed for replacement.
Lubricate outside of the valve with clean
filtered hydraulic oil. Install the valve and
torque to 45 lb-ft (61.2 Nm).
12. If removed for replacement, install new plugs
(4 and 6) and grease fittings (5).
13. 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.
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 or plugging the
ports.
e. Installation
1. Lubricate the hoist cylinder pivot pins with
multi-purpose lithium-based grease.
2. Using suitable lifting device, install the boom
hoist cylinder, Fig. 9.18, on the forklift securing
the base end to the frame with pivot pin and
snap rings.
3. Remove all plugs or caps from hydraulic lines
and securely tighten lines to the cylinder.
4. Have a helper start the forklift engine.
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
Warning