SkyTrak 8042 Service Manual - Manual (Page 334)

7A.11 Model 8042, 10042, 10054 Legacy Rev. 10/03
Engine: Cummins 4BT3.9 and 4BTA3.9
10. Remove the thermostat housing (10), old gasket
(11), thermostat (12), thermostat seal (13) and
engine lift bracket (14). Clean all gasket surfaces
(15). DO NOT let any debris into the thermostat
opening.
IMPORTANT: ALWAYS use the correct thermostat and
install a new gasket. NEVER operate the engine without
a thermostat, or engine damage will result.
b. Thermostat Installation
Note: Ensure that notched edge (arrow) of thermostat
seal (13) is facing thermostat.
1. Install the engine lift bracket (14), thermostat seal
(13), thermostat (12) gasket (11) and thermostat
housing (10). Secure with the three capscrews (9)
removed earlier. Torque to 18 lb-ft (24 Nm).
2. Raise the alternator (7), and install the upper
alternator mounting capscrew (8) and alternator
lower capscrew 6). Torque to 32 lb-ft (43 Nm).
3. Insert a 1/2" drive ratchet or breaker bar into the into
the square hole (4) in the automatic belt tensioner
housing and lift the automatic tensioner
pulley (3). With the automatic tensioner pulley lifted
out of the way, install the fan drive belt (5).
4. Connect the negative (-) battery cable (16).
5. Open the radiator cap (1), and fill the radiator
completely with a 50/50 mixture of ethylene glycol
and water. Replace and tighten the radiator cap. Add
coolant to the overflow bottle until the bottle is 1/4 to
1/2 full. This overfilling will compensate for any air
trapped in the cooling system.
6. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain,
as necessary.
7A.6.3 Radiator/Oil Cooler and Coolant
Heater Replacement
Before considering radiator or oil cooler replacement for
other than obvious damage, conduct a cooling system
pressure test check the coolant specific gravity, coolant
level, fan belt tension and dash panel temperature
indicator.
• If the engine runs hot, check the temperature of
the upper radiator hose.
• If the hose is not hot, the thermostat may be
stuck in the closed position.
• If the engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
a. Oil Cooler and Radiator Removal
Note: ALWAYS replace elastic locknuts with new elastic
locknuts to help ensure proper fastening.
1. Level the vehicle, ground the attachment, place the
travel select lever in NEUTRAL (N), and engage the
neutral lock lever, engage the parking brake switch
and shut off the engine.
2. Remove the ignition key. Secure accident prevention
tags to the steering wheel and ignition key switch.
Refer to
Section 1.5, “Accident Prevention Tags.”
3. Unlock, unlatch and open the side and rear engine
doors. Allow the engine to cool before proceeding.
Draining the cooling system while the engine is hot
can cause cracks in the engine block.
MS1160
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WARNING:
DO NOT attempt this
procedure when the engine is hot. Wait for the
engine, muffler, and tailpipes to cool down
before proceeding. Failure to do so could result
in severe burns.
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MH4010