SkyTrak 6042 Service Manual - Manual (Page 224)

Engine: Cummins 4BT3.9
7.30 Model 6042 Legacy Origin 7/02
7.11.2 Engine Disassembly, Inspection and
Service
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Cummins
4BT3.9 service manual. Several special engine service
tools are required to properly service the Cummins
engine. Contact a local Cummins parts distributor for
further information.
Note: If the engine is being replaced, there may be
external components that will be required to be
transferred from the original engine to the replacement
engine. These parts depend upon who you purchase the
new engine from and the configuration of your replacement
engine. Refer to the appropriate Cummins user manual
for detailed procedures that cover the transfer of original
engine components to the replacement engine.
7.11.3 Engine Installation
Note: Always discard used elastic locknuts and install
new elastic locknuts.
Note: Refer to Section 2.3, “Torques,” for specific
fastener torque specifications.
1. If replacing the engine, attach a lifting chain to the
front (Fig. 7 -38, 13) and rear (14) engine lift
brackets, and lift engine clear of the ground.
Note: Inspect the rear engine mounting bracket isolator
mounts (Fig. 7-38, 16 and 17). Replace isolators if
cracked or worn.
Note: Apply Loctite
®
242 threadlock to the engine
mount bracket hex-head capscrew threads before
installation.
2. If previously removed, install the upper rear
(Fig. 7-38, 2) and lower rear (12) engine mount
brackets to the engine.
3. Install the muffler bracket (Fig. 7 -38, 15), front right
(7) and left (8) engine mounting brackets to the
engine.
4. Install all radiator and oil cooler components to the
engine mounting bracket (Fig. 7-38, 12). Refer to
Section 7.6.3, b. “Radiator and Oil Cooler
Installation.”
5. Place engine on a flat, level surface.
6. Position a fork truck behind the engine, and drive
forward placing the forks underneath the upper rear
engine mount (Fig. 7-38, 2) and front right (7) and
left (8) engine mount brackets. Lift the engine and
slowly drive it into the back of the vehicle. Have an
assistant ensure that the engine clears all frame,
hose and harness components during engine
installation. Position engine brackets over rear (23)
and front frame mounts (24).
7. Install the hex-head capscrew (Fig. 7-38, 6), engine
isolator (5), rebound washer (4), and new elastic
locknut (3) to the front right (7) and left (8) support
brackets, but DO NOT tighten.
8. Align the lower rear engine bracket (Fig. 7-38, 12)
over the four rear frame mounting studs. Install the
engine hold-down plates (11), flat washers (10) and
new elastic locknuts (9). Tighten all fasteners.
9. Install the right side exhaust pipe mount bracket
(Fig. 7-38, 1), hex-head capscrews (23) and
lockwashers (24) to the upper rear engine mount (2).
10. Install the radiator overflow bottle (Fig. 7-38, 18) and
overflow hose (19).
11. Install the left and right side oil hose clamps to
engine.
12. Install the oil cooler input (Fig. 7-38, 20) and output
(21) hose fittings to the oil cooler (22).