Skytrak 6036 Service Manual Bedienungsanleitung PDF herunterladen (Seite 190)

Section 9 Hydraulic System

9-40

Model 6036/6036T S/N 9B0500 thru 14833

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 (20), wiper (19), O-ring

(21), backup ring (23) and O-ring (18) on the

head (22) as shown in Fig. 9.20.

NOTE: The wiper lips should be toward the outer

end of the head and the rod seal lips toward the

inner end of the head. 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 (24).

If necessary, use a soft hammer to drive the

head onto the rod.

5. Install new backup ring (16) and an O-ring

(17) into internal groove on the inside of the

piston (13). Carefully push the piston onto the

rod to avoid damage to the O-ring.

6. Apply Loctite

Threadlocker 242 to the

threads on the capscrew (1) in accordance

with manufacturer’s instructions. Install the

capscrew in the rod and torque to 2,250 lb-ft

(311 Nm). Allow Threadlocker to cure.

7. Install a new bearing (14) and seal and

expander assembly (15) on the piston.

8. Fasten the tube (2) 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, bearing (14) and seal and expander

assembly (15) with clean hydraulic oil.

10. Apply a compression sleeve or other suitable

tool to the piston and head in order to com-

press the o-rings, backup rings and seals

while inserting the assembled piston, rod, and

head into the tube (2). Remove the compres-

sion tool. Using a pin spanner wrench, thread

the head into tube.

IMPORTANT: When sliding the rod and piston

assembly into the tube, be careful so that head

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 (8, 10 and 12) and backup

rings (9 and 11) on counterbalance valve (7).

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

(3, 4 and 6) and grease fitting (26).

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 and plugging the

ports.

5. Position the hoist cylinder so that the rod is

aligned with the rod end mounting holes as

much as possible.

6. Instruct the operator to raise or lower the hoist

cylinder slowly until the rod end eye is aligned

with the outer boom mounting holes. Secure

the rod end to the boom with pivot pin and its

locking capscrew and locknut.

6. Raise the boom as far as it will go; then lower

it as far as it will go five times or until the

operation of the boom hoist cylinders is normal

(no jerks or spongy feel).

7. Shut down the engine. Check the hydraulic oil

level and fill as described in the Owners/

Operators Manual.

8. Test boom hoist/lower circuit operation as

described in paragraph 9.2.2.c.

Before starting the engine be sure all hydraulic

connections are tight and all tools are removed

from the forklift.

Warning

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.

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