Service Manual User Manual

Hydraulic System
9-93
6. Install the capped T-seal (4) onto the piston (5).
Note: The T-seal actually consists of four components; a
wide, flexible inner band, the flexible T-seal band itself,
and two supportive split caps that mount on either side of
the “T” itself.
7. Install the deep Z-seal with rod backup (13),
precision wearband (7), O-ring (14), back-up ring
(13), and O-ring (12) onto the head gland (10).
8. Carefully insert the rod (15) with all attachments
straight into the tube (2).
IMPORTANT: When sliding the rod and piston assembly
in the tube, prevent the threaded end of the tube from
damaging the piston (5). Keep the rod centered within the
tube to help prevent binding. Protect the finish on the rod
at all times. Damage to the surface of the rod can cause
seal failure.
9. Install the locking insert (9) into its hole in the head
gland threads.
10. Using a pin spanner wrench, thread the head gland
(10) into the tube (2). Torque to 250-300 lb/ft
(339-407 Nm).
f. Slave Cylinder Installation
1. Align the slave cylinder with its mounting bosses
within the rear frame uprights.
2. Align the mount pin bolt holes with the slave cylinder
mount holes. Align the self-aligning bearing. Secure
the slave cylinder with the cylinder pins, hex-head
capscrews and nuts. Torque the hex-head capscrews
and nuts to specification. Refer to the fastener torque
chart in
Section 2 General Information, Specifications
and Maintenance Instructions
.
3. Use new O-rings and reattach and secure the
hydraulic hoses to the slave cylinder fittings.
4. Start and run the engine at approximately one-third
to one-half throttle for about one minute without
moving the vehicle or operating any hydraulic
functions.
5. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before con-
tinuing. Add hydraulic fluid to the reservoir as needed.
6. Conduct a pressure check of the attachment tilt/slave
cylinder hydraulic circuit.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle, work area and tools.
8. Conduct a pressure check of the attachment tilt
cylinder hydraulic circuit and bleed the circuit as
outlined below.
g. Slave Cylinder Pressure Checking
and Circuit Bleeding
1. Attach a 4000 psi (276 bar) gauge to the main control
valve at the fork tilt port to test the fork tilt and slave
cylinder hydraulic system circuit pressure. The unit is
equipped with test fittings from the factory. Pressure
readings should be 3700 psi ± 100 psi (255 ± 7 bar).
2. With no accessory installed on the quick attach, start
with the hoist and fork tilt cylinders fully retracted.
3. Fully extend the fork tilt cylinder. Monitor pressure
while fully raising the hoist cylinder.
4. Fully retract the fork tilt cylinder. Monitor pressure
while fully retracting the hoist cylinder.
5. Repeat steps 3 and 4 five times.
WARNING: Avoid prolonged engine operation
in closed areas with inadequate ventilation.
Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.
Model 3606 • Origin 10/99