SkyTrak 6036 Service Manual - Manual (Page 230)

Section 9 Hydraulic System
9-80 Model 6036/6036T S/N 9B0500 thru 14833
g. Installation of Control Valve in the Vehicle
NOTE: Be sure that the boom is retracted and
supported in a horizontal position with blocking.
Be sure that the forklift is in a secure position
before installation.
1. Position the main control valve (4, Fig. 9.42)
on the forklift and secure it to the frame using
capscrews (1), lock washers (3) and nuts (2).
NOTE: Lines were tagged at disassembly to allow
for proper assembly. Refer to Figure 9.43 for
proper line installation.
2. Remove caps or plugs used to protect hydrau-
lic system, and replace all hoses. Check all
lines to be sure they are secure.
3. Start the engine.
Warning
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
4. Inspect connections at the control valve for
leakage.
5. Operate the joystick to test the operation of
the control valve and the hydraulic system.
Refer to the following paragraph 9.6.2.h for
control valve adjustments.
6. Perform full system calibration.
h. Control Valve Adjustments
Perform adjustments of the control valve in
vehicle.
Park forklift on a level surface and engage parking
brake. Retract the boom and support it in a
horizontal position with blocking. Place travel
select lever in neutral and stop the engine. Be
sure the forklift is in a secure position before
servicing.
Pilot Pressure Checks
Since pilot pressure is the net pressure available
above reservoir pressure to the pilot stage, both
pressure values are significant. It is recom-
mended to use pressure gauge(s) with a range no
higher than 500 psi
(34,5 bar). If a differential
pressure gauge or two standard pressure gauges
are available, reservoir pressure and pilot pres-
sure can be measured at the same time which is
desirable since time and effort are saved. If one
pressure gauge is used, proceed as follows:
Warning
Relieve hydraulic pressure before servicing any
hydraulic component. Escaping hydraulic fluid
under pressure can penetrate the skin causing
serious injury. Operate the control valve
manually by threading a 3/8 NC x 2" long
capscrews into the spool shift collar of each
hydraulic function, Fig. 9.46. Actuate all of the
hydraulic functions (boom raise/lower, extend /
retract) after the engine has stopped to relieve
any trapped pressure.
Warning
Should it be necessary to remove parts for
service, be sure the area around the parts is
cleaned thoroughly with an accepted solvent
before removing any parts from the control
valve to prevent system contamination.
1. Remove the plug (9, Fig. 9.44) from the
control valve. Install the pressure gauge in the
port.
2. Start the engine. Note and record the reser-
voir pressure reading on the pressure gauge.
3. Shut OFF the engine and relieve system
pressure.
4. Remove the pressure gauge from the control
valve and install the plug (9, Fig. 9.44).
5. Remove the plug (5, Fig. 9.47) from the inlet
section of the control valve. Install the pres-
sure gauge in the port.
6. Start the engine. Note pilot pressure reading
on the pressure gauge. The difference
between the pilot pressure and reservoir
pressure (step 2) should be 205 - 215 psi
(14,1
- 14,8 bar). If the pressure differential is not
correct, pilot shims (6, Fig. 9.45) must be
added (to increase pilot pressure) or removed
(to decrease pilot pressure). This must be
done after the system has been secured.
Check pilot pressure after any repair.
7. Shut OFF the engine and relieve system
pressure.
8. Remove the pressure gauge from the control
valve and install the plug (5, Fig. 9.47).
9. Perform Calibration 1 after repair.