Engine Repair 100 SRM 322
Engine Repair
REMOVE
WARNING
The lift truck
must be put on blocks for some
types of main
tenance and repair. The removal
of the follow
ing assemblies will cause large
changes in th
e center of gravity: mast, drive
axle, engine
and transmission, and the coun-
terweight. W
hen the lift truck is put on blocks,
put additio
nal blocks in the following posi-
tions to mai
ntain stability:
a. Before remo
ving the mast and drive axle,
put blocks u
nder the counterweight so the
lift truck c
annot fall backward.
b. Before remo
ving the counterweight, put
blocks unde
r the mast assembly so the lift
truck canno
t fall forward.
The surfac
e must be solid, even, and level when
the lift tr
uck is put on blocks. Make sure that
any blocks
used to support the lift truck are
solid, one
-piece units.
1. Disconnec
t the cables at the battery.
2. Remove the
hood. Remove the air cleaner assem-
bly. Disco
nnect the brake fluid reservoir from
the bracke
t. If necessary, remove the overhead
guard. Se
e Overhead Guard Repair.
3. Drain the
coolant from the cooling system. Re-
move the r
adiator. See Radiator Repair.
4. Disconne
ct the drive shaft for the hydraulic
pump at th
e crankshaft pulley.
5. Disconne
ct the exhaust system.
6. Disconne
ct the hydraulic lines at the steering
pump. Put
caps on the open lines.
7. Disconne
ct fuel lines and the throttle linkage.
8. Disconne
ct wires and wiring harnesses at the en-
gine.
9. Connect
a lifting device to the engine. Make sure
the lift
ing device has a capacity of at least 450 kg
(1000 lb
)(engineonly).
10. On units
with a powershift transmission, remove
the caps
crews that hold the torque converter to
the flywheel. Put blocks under the output end
of the transmission. Remove the capscrews that
connect the engine to the flywheel housing.
11. Remove the capscrews that hold the mount at the
fanendoftheenginetotheframe.
12. Carefully lift the engine from the frame. Make
sure all the connections have been removed.
Makesurethetorqueconverterstayswiththe
transmission and does not fall.
INSTALL
1. Connect a lifting device to the engine. Make
sure the lifting device has a capacity of 450 kg
(1000 lb).
2. Make sure the drive plate is installed on the
torque converter. Lubricate the pilot bushing in
the flywheel with multipurpose grease. Install
the engine in the frame. Make sure the torque
converter stays in the transmission. Fit the fly-
wheel on the pilot of the torque converter. Install
the capscrews that hold the flywheel housing to
the engine. Tighten the capscrews to 31 N•m
(23 lbf ft).
3. Install the capscrews and washers for the engine
mount at the fan end of the engine. Install the
capscrews and adjust the mounts at the flywheel
end of the engine. Tighten the capscrews to the
correct torque values as shown on Figure 5.
4. Install the capscrews that hold the drive plate
for the torque converter to the flywheel. Tighten
the capscrews to 44 N•m (32 lbf ft) on all units.
Remove the lifting device.
5. Connect the wiring harness and wires at the en-
gine.
6. Connect the throttle linkage and fuel lines at the
engine.
7. Connect the pipe for the exhaust system.
8. Connect the drive shaft for the hydraulic pump.
9. See Radiator Repair, and install the radiator.
Connect radiator hoses and cooling line for the
powershift transmission.
8
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