Skytrak 6042 Service Manual User Manual download pdf (Page 337)

8.105

Model 6042 Legacy Origin 7/02

Hydraulic System

6. Fasten the rod end in a soft-jawed vise and put a

padded support below and near the threaded end of

the rod to help prevent damage to the rod.

7. Remove the locking insert (Fig. 8-69, 6) from its hole

in the head gland threads. Pry or drill out the insert

as required. DO NOT damage the head gland

threads. A new locking insert will be required for

reassembly.

8. Remove the o-ring (Fig. 8-69, 7), back-up ring (8),

and o-ring (9) from the head gland.

9. Remove the precision wearband (Fig. 8-69, 10) and

the capped T-seal (11) from 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.

10. Remove the locknut (Fig. 8-69, 12) from the rod (3).

The deforming-thread type nut was coated with

Loctite #271 (red) and torqued to 675-750 lb-ft

(915-1.017 Nm). Discard the nut.

Note: It may be necessary to apply heat to break the

bond of the sealant between the locknut (Fig. 8-69, 12)

and the rod (3) before the piston (5) can be removed.

Some parts of cylinders are sealed with a special organic

sealant and locking compound.

Before attempting to disassemble these parts, remove

any accessible seals from the area of the bonded joint.

Wipe off any hydraulic oil and heat the joint uniformly to

break the bond. A temperature of 300-400° F (149-204° C)

will destroy the bond. Avoid overheating or the parts may

become distorted or damaged. Apply sufficient torque or

pressure for removal while the parts are still hot.

Breakdown of sealant will leave a white, powdery residue on

threads and parts. Clean the residue away with a soft

brass wire brush prior to reassembly, and wipe with

Loctite “T” cleaner before reinstallation.

11. Remove the piston (Fig. 8-69, 5) and head gland (4)

from the rod (3).

12. From within the head gland (Fig. 8-69, 4), remove the

precision wearbands (13). Remove the square ring

(14), the sealed outside diameter heavy-duty rod

wiper (15) and the deep Z-seal with rod back-up (16).

13. From within the piston (Fig. 8-69, 5), remove the

back-up rings (17) and the small o-ring (18).

c. Slave Cylinder Cleaning

1. Remove all hydraulic fluid, dirt and debris from the

inner surface of the cylinder.

2. Discard all seals, back-up rings and o-rings. Replace

with new items from a complete seal kit (Fig. 8-69, 19)

to help ensure proper cylinder function.

3. Clean all metal parts with an approved cleaning

solvent such as trichlorethylene. Carefully clean

cavities, grooves, threads, etc.

Note: If a white, powdery residue is present on threads

and parts, it can be removed. Clean the residue away

with a soft brass wire brush prior to reassembly, and

wipe with Loctite “T” cleaner before reinstallation.

d. Slave Cylinder Inspection

1. Inspect internal surfaces and all parts for wear, damage,

etc. If the inner surface of the tube (Fig. 8-69, 2) does

not display a smooth finish, or is scored or damaged in

any way, replace the tube. Often, dirty hydraulic fluid

causes failure of internal seals and damage to the

smooth surface within the tube.

2. Remove slight scratches on the piston, rod or inner

surface of the tube with very fine grit emery cloth. Use

the emery cloth in a rotary motion to polish out and

blend the scratch(es) into the surrounding surface.

3. Clean parts with trichlorethylene.

4. Check that the rod (Fig. 8-69, 3) is straight. If it is

bent, install a new rod.

e. Slave Cylinder Assembly

Note: Follow Section 8.13.3, “General Cylinder

Assembly Instructions.”

IMPORTANT: Use a suitable installation tool or

compression sleeve to help prevent twisting or damaging

the seals and o-rings when installing the piston and head

gland into the cylinder. When sliding the rod and piston

assembly in the tube, DO NOT damage the piston by

scraping it against the threads in the tube. Keep the rod

in line with the tube to prevent binding.

1. Fasten the rod end in a soft-jawed vise and put a

padded support below and near the threaded end of

the rod to help prevent damage to the rod.

2. Install the small o-ring (Fig. 8-69, 18) and the back-

up rings (17) in the piston (5).

3. Install the deep Z-seal with rod back-up (Fig. 8-69, 16)

in the head gland (4) orienting the edge (21).

4. Install the sealed outside diameter heavy-duty rod

wiper (Fig. 8-69, 15). The wiper lip (20) should be

toward the outer end of the head gland and the seal

lips toward the inner end of the head gland. Use

tools that will not damage the seals. Install the

square ring (14).

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Skytrak 6042 Service Manual User Manual Page 337

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Skytrak 6042 Service Manual User Manual Page 337

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