Diesel Engine
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or the
section Periodic Maintenance 8000YRM1774.
WARNING
Always disconnect the cables at the battery be-
fore you make repairs to the engine. Disconnect
the cable at the negative terminal first.
1. Remove overhead guard. See section Overhead
Guard Replacement for procedures.
2. Remove floor mast and floor plate.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the sys-
tem. If the system is hot, the steam and boiling
coolant can cause burns.
3. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the ca-
pacity of cooling system under radiator. Remove
radiator cap.
CAUTION
Disposal of lubricants and fluids must meed local
environmental regulations.
4. Open drain plug or disconnect bottom radiator
hose to drain coolant from radiator and engine.
See Figure 30.
5. Remove hood and seat combination and rear side
covers. See section Hood, Seat, and Side Covers
Replacement for procedures.
6. Disconnect ground strap from frame. Remove
three flange bolts and power distribution module
(PDM) from battery tray. See Figure 31.
7. Remove battery and battery tray from lift truck as
described in the steps below:
a. Remove cap, flange nut, and lockwasher from
battery lockdown bar. See Figure 31.
b. Disengage battery lockdown bars and remove
bar from top of battery. See Figure 31.
c. Remove battery from battery tray. See Fig-
ure 31.
d. Remove three capscrews and battery tray from
frame. See Figure 31.
8. Disconnect remaining coolant hoses from radiator
and cap them to prevent leakage. See Figure 30.
9. Remove radiator fan pulley, shroud, and fan as-
sembly. See Cooling System - PSI 2.4L Engine
0700YRM1767 for the removal procedures.
WARNING
All fuels are very flammable and can burn or
cause an explosion. DO NOT use an open flame to
check the fuel level or to check for leaks in the
fuel system.
No smoking.
Breathing fuel vapor may cause nausea, uncon-
sciousness, or death. Long term exposure to gas-
oline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
10. Disconnect fuel lines at engine. Put caps on fuel
lines to prevent fuel leakage. See Figure 30.
11. Disconnect engine harness connectors from
chassis harness connectors. See Figure 29.
Engine Replacement 0100 YRM 1766
30
To Next Page
Loading...