100 SRM 449
Engine Repair
Engine Repair
REMOVE
NOTE:
The lift truck can have a powershift or a man-
ual transmission. The powershift transmission and
the torque converter are attached to the engine. The
engine and powershift transmission are normally re-
moved as a unit. The manual transmission is at-
tached to the drive axle housing. This engine is re-
moved without removing the manual transmission.
1.
Put the lift truck on blocks. See the Operating
Manual or the Periodic Maintenance 8000
SRM 393 for the correct procedures to put the
lift truck on blocks. Remove the overhead guard,
hood, transition plate, and access door. See the
Hood Repair, Remove section for more details.
Remove the floor plates.
2.
Disconnect the cables at the battery. Remove the
battery, air cleaner inlet duct, and battery tray.
Disconnect the brake fluid reservoir and engine
crankcase breather lines.
3.
Remove the fan and fan shroud. Disconnect the
exhaust pipe at the exhaust headers.
4.
Disconnect the fuel lines at the engine. Discon-
nect the throttle linkage at the engine. Discon-
nect the wires and wiring harnesses at the engine
and powershift transmission.
5.
Disconnect the oil lines at the hydraulic pumps.
Drain the hydraulic tank and put plugs in the
open ports. Disconnect the oil cooler lines from
the powershift transmission.
6.
Powershift transmission.
Do the following
procedure:
a. Disconnect the linkage between the trans-
mission and the pedals at the transmission.
b. Disconnect the hydraulic lines to the brake
booster.
c.
Disconnect the brake line at the booster. Dis-
connect the electrical wiring.
d. Remove the pedal bracket.
e.
On units without the MONOTROL
®
pedal,
disconnect the direction control linkage at
the transmission.
f.
Disconnect the drive line at the universal
joint.
7.
Manual transmission. Do the following proce-
dure:
a. Disconnect the drive line at the universal
joint near the clutch.
b. Disconnect the hydraulic and brake lines.
Disconnect the push rod to the brake booster.
Disconnect the electrical wiring.
WARNING
Do NOT leave the clutch pedal free in the up
position with the over-center spring installed.
The spring is under tension and can cause an
injury. Fasten the clutch pedal so that it can-
not move down, remove the spring or carefully
move the pedal to the down position to remove
the tension.
c.
Remove the brake booster. Disconnect the
clutch push rod from the clutch cover.
8.
Connect a lifting device to the engine. Make sure
the lifting device has a capacity of at least 450 kg
(1000 lb). Remove the four motor mount bolts.
Raise the engine from the frame. Be careful of
the hydraulic pump. Make sure that all wires
and hoses are disconnected. Put the engine in a
position so that it has stability and will not fall.
9.
Remove the powershift transmission from the en-
gine as described in the Two Speed Powershift
Transmission-Troubleshooting and Repairs
1300 SRM 325. On units with the manual trans-
mission, remove the oil clutch housing and clutch
cover from the engine.
INSTALL
1.
Install the engine mounts on the engine as fol-
lows (see Figure 8):
a. GM V-6: Tighten the capscrews that hold the
engine mount to the fan end of the engine to
30 N•m (22 lbf ft). Tighten the bolts that
hold the engine mounts to the mount plate
to 65 N•m (48 lbf ft).
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