JLG Skytrak 6036 Service Manual page 154

3. Remove small scratches on inside of the tube
with emery cloth of very fine grit. Use the
emery cloth with a rotary motion.
e. Assembly
NOTE: Follow general assembly instructions in
paragraph 9.2c.
1. Fasten rod (3) in a soft-jawed vise.
2. Install new O-ring (8, Fig. 9.19) inside of piston
(2). Carefully install the piston on rod (3) to
avoid damage to the O-ring.
®
3. Apply Loctite Primer T and Threadlocker 271
to the locknut (11) in accordance with the
manufacturer's instructions. Install the locknut
and torque it to 90 to 100 lb-ft (122,4 to 136,0
N m). Allow sealants to cure.
4. Install crown seal (9) on piston (2).
5. Install rod wiper (5), Z-seal (6), and O-ring (7)
on the gland (4).
6. Install the assembled gland and seals on rod
(3).
7. Lubricate all parts and inside of the tube (1)
with clean hydraulic oil.
8. Apply a compression sleeve or other suitable
tool to the gland in order to compress the O-
ring (7) on the gland. Push the rod assembly
straight into the cylinder tube with a steady
even pressure until the gland butts up against
the tube.
9. Locate the hole in the tube and insert lockwire
(10).
10. Using a spanner wrench, rotate the gland 360
degrees to install the lockwire.
11. 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.
12. Increase the operating pressure to the maxi-
mum (4000 psi or 275,6 bar) for the cylinder
and check for external leakage and free
movement in both directions.
13. Prepare the cylinder for installation by retract-
ing the piston and capping and plugging the
ports.
f. Installation
1. Screw the socket assemblies (3, Fig. 9.18)
onto the retracted cylinder (4). Adjust position
9-41
Section 9. Hydraulic System
of the socket assemblies by turning them until
the total length equals the measured length
taken during removal.
NOTE: If there is no accurate recorded cylinder
length, the cylinder can be adjusted as described
in the following steps.
2. Turn the steering knuckle to full inside turn
position on either the left or right side.
3. Adjust the socket assembly position in or out
on the rod end, and also the barrel end if
necessary, so that the retracted length of the
cylinder matches the length required to install
the cylinder
IMPORTANT: Protect the finish on the rod at
all times. Damage to the surface of the rod can
cause premature seal failure.
4. Install nuts (2) securing the cylinder socket
assemblies to the axle carrier (4) and knuckle
(5). Torque the nuts to 140 lb-ft (190 N m)
minimum. Install cotter pins (1).
5. Tighten the socket clamps. Torque the clamp
bolts and nuts to 60 to 70 lb-ft (82 to 95 N m).
6. Turn the other steering knuckle to its full inside
turn position and adjust the cylinder (steps 3
through 5).
7. Remove all plugs or caps from the hydraulic
lines and securely tighten the lines to the
cylinder.
Warning !
Before starting the engine be sure all hydraulic
connections are tight and all tools are removed
from the forklift.
8. Start the engine. Turn the steering wheel fully
left to right and back (lock to lock) several
times in all three steering modes until they
operate smoothly. This should purge the
steering system of air. The maximum number
of turns of the steering wheel should not
exceed 4-1/2 turns lock to lock.
9. Shut down the engine. Check the hydraulic oil
level and fill as described in the Owners/
Operators Manual.
10. Test steering circuit operation as described in
paragraph 9.1.6c.
Model 6036 S/N 9B0499 and Before