Engine Exhaust System; Exhaust System Removal - JLG sky trak mmv Service Manual

8.9

ENGINE EXHAUST SYSTEM

WARNING:
carbon monoxide, a colorless, odorless gas
which is fatal when inhaled in a confined area.
Avoid breathing exhaust fumes and prevent
engine operation from becoming a cause of
toxic emissions. Exhaust system components
reach high temperatures and can cause
severe burns. DO NOT come into contact with
hot exhaust system components.
The exhaust system is supported by the engine and the
vehicle frame to help minimize the transfer of noise and
vibration into the operator's cab. The tail pipe directs ex-
haust fumes to the right side of the vehicle, away from the
cab.
Annoying rattles and noise vibrations in the exhaust sys-
tem are usually caused by misalignment of parts. When
aligning the system, leave all capscrews and nuts slightly
loose until all parts are properly aligned, then tighten all
fasteners working from the front of the system to the rear.
When replacing the muffler, also replace the tail pipe.
Before assembling components, use exhaust system
sealer at all slip joint connections.
When installing exhaust system components, allow suffi-
cient clearance between the components and other vehi-
cle pipes, hoses and wiring that could be adversely
affected by excessive heat.
When installing an exhaust system, provide for parts ex-
pansion when the system is hot.
Whenever performing service on the vehicle, check the
condition of the exhaust system. Check the entire exhaust
system for broken, damaged, missing or improperly
aligned parts, open seams, holes, loose connections and
other deterioration which could permit exhaust fumes to
seep into the operators cab. Correct any damaged areas
immediately.
8.9.1

Exhaust System Removal

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. Secure accident prevention
tags to the steering wheel and ignition switch (refer
to Section 1.5, Accident Prevention Tag Usage ).
Model MMV Rev. 12/04
Exhaust fumes contain
Engine: Cummins 4BTA 3.9
WARNING:
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.
1. Unlatch and open the engine cover. Allow the engine
to cool before proceeding.
2. Remove engine side battery box cover (1). Remove
wing nuts (2) and carriage bolts (3) and set cover
and mounting hardware aside for later re-assembly.
3. Disconnect the negative (-) battery cable (4) at the
negative (-) terminal on the battery in the engine side
battery box.
4. Disconnect the negative (-) cable (5) at the bottom of
the battery equalizer (6).
2
1
3
5. Disconnect and remove the 3" heavy duty muffler
clamp (7) from the tail pipe (8). Disconnect and
remove the U-type clamp (9) from between the
muffler (10) and exhaust pipe (11). Disconnect and
remove the U-type clamp (12) from between the
exhaust pipe and turbo outlet exhaust pipe (13).
Remove the tail pipe (8), muffler (10) and exhaust
pipe (11) as a unit from the turbo outlet exhaust
pipe (13). Loosen the V-band clamp (14) and
remove the turbo outlet exhaust pipe along with the
V-band clamp (8).
DO NOT attempt this
6
5
4
MM2911
8.25