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Toyota Skid Steer Loader SGK6 SDK6 SDK8 Factory Workshop Manual download

Purpose and theory (brief)
- A shock absorber is a hydraulic (often gas‑charged) damper whose piston forces hydraulic fluid through valves as the piston rod moves. That controlled flow converts kinetic energy into heat and controls the speed of suspension/arm movement (damping).
- Failure modes: internal seal wear or valve damage (internal bypass -> loss of damping), gas charge loss (reduced response), external oil leaks, bent piston rod, or worn mounting bushings/pins. Symptoms: excessive rebound/bounce, poor bucket/arm control, clunking/noise, visible oil leak, uneven ride or instability under load.
- Replacing the shock restores correct valving, seals and gas charge and replaces worn mounts so damping is returned and the symptoms disappear.

Preparation (short)
- Required tools/parts: correct OEM replacement shock(s), new mounting pins/bolts and bushings/seals as required, retaining clips, jack or lift rated for loader, safety stands/blocks, torque wrench, appropriate sockets, penetrating fluid, wire brush, removal tool for cotters/pins, rags, PPE (safety glasses, gloves, steel‑toe boots).
- Reference OEM workshop manual for exact part numbers, mounting orientation and torque specs. Follow lockout/tagout and manufacturer safety procedures.

Ordered procedure (do these steps in order)
1. Park and secure: Park on level ground, engage parking brake, lower boom/attachments to the ground (or to manufacturer‑specified safe position). Chock wheels. Turn off engine and remove key.
2. Relieve hydraulic and boom loads: Lower implements so springs/pressure are bled. If the shock supports a loaded link, place mechanical support (jack/stands or blocking) under the boom or linkage to take load off the shock before removing it. Never rely solely on hydraulic pressure to hold parts.
3. Disable machine systems: If applicable, disconnect battery negative terminal or follow factory lockout to prevent accidental engine start or hydraulic actuation.
4. Access and inspect: Clean area around mountings. Inspect shock, mounts and link geometry to confirm replacement is required and to identify corroded hardware or damaged brackets.
5. Remove retaining hardware: Apply penetrating fluid to seized bolts/pins. Remove cotter pins/retaining clips. Support the shock with a hand or jack. Remove lower then upper mounting bolt/pin (or vice versa depending on access) while supporting the assembly to prevent sudden movement. Keep removed hardware and note orientation.
6. Remove shock: Withdraw shock from mounts. Inspect mounts, bushings and pins for wear or elongation. Replace bushings/pins if any wear found. Clean and de‑scale mount bores.
7. Prepare new shock: Compare new shock with old for length and mounting type. Fit new bushings/sleeves if required and lightly lubricate sleeves per OEM (usually silicone/zinc‑based grease; avoid petroleum if rubber bushing). Do not compress or extend gas‑charged shocks by force beyond travel.
8. Install new shock: Position shock in mounts, fit upper then lower pin/bolt (or as required). Use new pins/bolts/retainers if specified. Ensure correct orientation (rod end vs body end) per OEM. Hand‑tighten fasteners to hold shock in unloaded but natural position.
9. Torque to spec: With the shock and mounts correctly aligned and the machine on its supports (but after removing temporary supports if instructed by manual), tighten fasteners to the manufacturer’s torque specs using a torque wrench. Do not overtighten. Replace cotter pins/retainers.
10. Remove supports and cycle: If you used mechanical supports under the boom, carefully remove them while an assistant slowly cycles the loader through small movements (engine off or low idle with operator controls disabled per safety) so the shock seats naturally.
11. Functional test: Start engine, operate boom/attachment through full travel slowly and under load. Listen for clunks, check for binding, and watch for leaks. Drive the machine in a controlled test and re‑check mounting fasteners after initial run (retorque if required per manual).
12. Final inspection: Check for oil leaks at new shock, ensure bushings are seated, and confirm normal damping behavior (reduced bounce, smoother control).

How the repair fixes the fault (concise)
- Replacing the shock restores internal valving, seals and gas pre‑charge, preventing uncontrolled fluid bypass and returning correct damping force. Worn or loose bushings/pins allow play and noise; replacing them restores correct shock alignment and load transfer. Together this eliminates excessive rebound, stabilizes the boom/attachment under impact or load, stops clunks from loose mounts, and prevents further wear to linkage components.

Quick diagnostics after replacement
- Bounce test: With machine parked and engine off, apply then release load on the boom; it should settle in 1–2 oscillations (spec varies).
- Leak check: No oil weeping from shock body or rod.
- Operational: No excessive bounce under travel, no clunks, consistent damping both directions of travel.

Safety notes (must follow)
- Always support heavy linkages mechanically before removing load‑bearing components.
- Use the OEM workshop manual for model‑specific procedures, torque values and safety warnings.
- Replace worn pins and bushings—new dampers on old mounts mask failure and shorten component life.
- Dispose of old hydraulic components/oil per local regulations.

That is the ordered procedure plus the theory and how replacement corrects the fault.
rteeqp73

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