SkyTrak 8042 Service Manual - Manual (Page 142)

Engine - Cummins QSB3.3T/QSB4.5T
7-10 6036, 6042, 8042, 10042, 10054
the help of an assistant, ensure that the engine clears
the harness during installation.
1. If replacing the engine, attach a lifting strap or chain
to the front and rear engine lift brackets, and lift the
engine clear of the ground.
2. Install the engine mounting brackets. Torque to
93-100 lb-ft (126-135 Nm).
3. Place the engine on a flat, level surface.
4. Position a fork truck behind the engine, and drive
forward, placing the forks underneath the rear
engine mount and front right and left engine mount
brackets. Lift the engine and slowly drive it into the
back of the machine. Have an assistant ensure that
the engine clears all frame, hose and harness
components during installation. Position the engine
brackets over rear and front frame mounts.
5. Secure the rear engine mount (5) to the frame using
the previously used hardware. Torque to 80-90 lb-ft
(108-122 Nm).
6. Secure the front left (4) and right (3) engine mounts
to the frame using the previously used hardware.
Torque to 80-90 lb-ft (108-122 Nm).
7. Install the exhaust pipe mount bracket.
8. Install the radiator overflow tube, overflow tank and
hose support.
9. Install the engine-to-transmission drive shaft. Refer
to Section 5.6.5, “Drive Shaft Installation.”
10. Uncap and connect the previously labeled fuel return
line to the injector pump.
11. Uncap and connect the previously labeled fuel inlet
line to the fuel lift pump.
12. Connect the previously labeled electrical wire
connections on the engine.
13. Uncap and connect the previously labeled heater
hoses to the engine (if equipped).
14. Install the complete radiator assembly. Refer to
Section 7.4.2, “Radiator/Oil Cooler and
Replacement.”
15. Properly connect the battery.
16. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
17. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
Note: Have an assistant stand by with a Class B fire
extinguisher.
18. Start the engine and run to normal operating
temperature then shut off the engine. While the
engine is cooling, check for leaks.
19. Allow the engine to cool. Check the radiator coolant
level, and add coolant if needed. Replace the
radiator cap.
20. Check for leaks from the engine, main hydraulic
pump and lines, transmission, hydraulic reservoir
and fuel tank. Check the levels of all fluids and
lubricants. Fill as required.
Note: During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steering
wheel.
• Keep the transmission in (N) NEUTRAL.
21. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle.
22. Purge the hydraulic system of air by operating all
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
23. Check for proper operation of all components.
24. Turn the engine OFF.
25. Install the side and rear engine covers.
7.10 ISOLATION COUPLER
7.10.1 Isolation Coupler Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the rear door. Allow the system fluids to cool.
4. Properly disconnect the battery.
Note: Rotating the fan belt by hand gives greater
access to removing the drive shaft mounting capscrews.
5. Remove the capscrews and straps that secure the
drive shaft to the transmission yoke.
6. Remove the capscrews and lockwashers securing
the drive shaft to the coupling flange.
Note: It may be necessary to loosen/remove the motor
mounts on either side of the engine to gain access to the
bottom capscrews on the outer half of the coupler. Place