Service Manual User Manual

Section 9
9-100
19. If necessary, install a grease fitting (19) into the
tapped hole in the end of the rod weldment (18).
Lubricate the self-align bearing (17) in the rod end
through the grease fitting (19) with multi-purpose
grease before the boom is operated.
f. Hoist/Lower Cylinder Installation
1. Raise and support the boom to allow installation of
the hoist/lower cylinder (1, Fig. 9– 67).
2. Attach a sling to the hoist/lower cylinder and to a
hoist or an overhead crane. Safely and carefully,
position the hoist/lower cylinder between the frame
rails, aligning the rod and base eyelets with mounting
bosses of the frame and boom.
3. Secure the cylinder with cylinder mount pins,
capscrews and nuts.
4. Connect all hoses according to the labels or other
marks used to identify their location during removal.
5. Operate the vehicle to check all boom functions and
for hydraulic system leaks.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle. Perform the pressure check and
circuit bleeding procedure below.
g. Hoist/Lower Cylinder Pressure Checking
and Circuit Bleeding
1. Attach a 4000 psi (276 bar) gauge to the main control
valve at the extend base port relief to test the hoist/
lower cylinder hydraulic system circuit pressure. The
unit is equipped with test fittings from the factory.
Pressure readings should be 3200 psi ± 100 psi
(220,6 ± 7 bar).
2. With no accessory installed on the quick attach, start
with the hoist and fork tilt cylinders fully retracted.
3. Fully raise and fully extend the boom. Hold the
joystick at full extend while fully raising the hoist
cylinder.
4. Fully retract the fork tilt cylinder. Hold the joystick at
full retract while fully lowering the boom.
5. Repeat steps 3 and 4 five times.
9.10.5 Frame Tilt and Stabilizer Cylinders
The frame tilt cylinder is attached to the right side of the
frame at the front axle and to a cylinder anchor plate on
the axle.
The Stabil-TRAK cylinder is attached to the left side of
the frame at the rear axle and to a cylinder anchor plate
on the axle.
Although the cylinders (Fig. 9– 68) do have different man-
ifold blocks, the cylinders themselves are identical and
interchangeable. The Stabil-TRAK manifold attached to
the stabilizer cylinder at the left rear of the vehicle pro-
vides the operating characteristics for the patented Sta-
bil-TRAK system.
a. Frame Tilt or Stabilizer Cylinder Removal
1. Park the vehicle on a firm, level surface, fully retract
all hydraulic cylinders, ground the attachment (if any),
place the travel select lever in NEUTRAL (N), engage
the park brake switch and shut the engine OFF.
2. Unlatch, unlock and open the engine cover. Allow the
hydraulic fluid to cool.
3. Label or otherwise mark the hydraulic hoses in
relation to the cylinder being removed. Safely
position suitable supports between the frame and
axle to prevent the frame from leaning to one side.
4. Disconnect and cap all hoses and fittings, etc.
5. Use a sling and hoist or other suitable lifting device to
support the cylinder. Remove the nuts, capscrews,
and cylinder mount pins securing the cylinder to the
frame and anchor plate.
6. Remove the cylinder from the vehicle. Wipe up any
hydraulic fluid spillage in, on, near and around the
vehicle.
WARNING: Escaping hydraulic fluid under
pressure can penetrate the skin, causing seri-
ous injury. Relieve hydraulic pressure before
servicing any hydraulic component.
WARNING: Hot hydraulic fluid can cause
severe burns. Wait for hydraulic fluid to cool
before servicing any hydraulic component.
WARNING: Escaping hydraulic fluid under
pressure can penetrate the skin, causing seri-
ous injury. Relieve hydraulic pressure before
servicing any hydraulic component.
Model 3606 • Origin 10/99