Service Manual User Manual

Hydraulic System
9-111
9. Install new O-rings and backup rings on the
counterbalance cartridge (12) and direct-acting relief
valve (13). Lubricate the cartridge, valve, and rings
with clean, filtered hydraulic oil. Install and torque to
30-35 lb/ft (40,7 to 47,5 Nm).
10. Install the orifice (14) into the valve block.
11. Test the cylinder at low operating pressure (100 psi,
or 6,9 bar). Verify that the piston and rod move freely
in both directions.
12. Increase the operating pressure to the maximum for
the cylinder (3000 psi, or 207 bar). Verify that the
piston and rod move freely in both directions.
13. Retract the piston fully and cap the hydraulic hose
ports. Install the cylinder on the carriage.
f. Swing Tilt Carriage Cylinder Installation
1. Install the swing tilt carriage cylinder onto the swing
tilt carriage at the pivot mount. Secure the rod end to
the swing tilt carriage.
2. Secure the tube end to the pivot base with snap
rings.
3. Lubricate the pivot pins with multi-purpose grease.
4. Remove all plugs and caps from the hydraulic lines
and securely tighten the lines to the cylinder.
5. Start the engine and remove any blocking from the
carriage.
6. Operate the swing carriage five times through its full
range or until operation of the swing tilt carriage is
normal (no jerks or spongy feel).
7. Shut the engine OFF. Check the hydraulic level and
fill as required.
g. Swing Carriage Cylinder Installation
1. Install the swing carriage cylinder(s) (1, Fig. 9– 71) on
the pivot mount (5). Secure the rod ends to the pivot
mount using the shims (9) and bearings (8). Insert
the pin (4) and secure with the bolt and nut.
2. Secure the tube end to the mount plates (11) using
the shims (10 and pins (7). Secure with snap rings.
3. Lubricate the tube ends with multi-purpose lithium-
based grease.
4. Remove all plugs and caps from the hydraulic lines
and securely tighten the lines to the cylinder(s).
5. Start the engine.
6. Swing the carriage five times through its full range or
until the operation of the swing carriage is normal (no
jerks or spongy feel).
7. Shut the engine OFF. Check the hydraulic level and
fill as required.
h. Swing Carriage 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 swing
carriage 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. Start with the swing carriage cylinders balanced; that
is, with the carriage centered.
3. Swing the carriage fully left. Hold the joystick at full
swing left for several seconds, then swing the
carriage fully right and hold the joystick at full swing
right for several seconds. Observe the readings on
the gauge during the carriage swinging operations.
4. Center the carriage. While centering the carriage,
check the pressure reading on the gauge.
5. Repeat steps 3 and 4 five times.
WARNING: Risk of severe personal injury.
Before starting the engine, verify that all
hydraulic connections are properly tightened
and that all tools are removed from the vehicle.
WARNING: Risk of severe personal injury.
Before starting the engine, verify that all
hydraulic connections are properly tightened
and that all tools are removed from the vehicle.
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