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

Engine: Cummins 4BTA 3.9
8
7
8.9.2

Exhaust System Installation

1. Install the turbo outlet exhaust pipe (13) onto the
engine turbocharger outlet (not shown). Install but do
not tighten the V-band clamp (14) around the turbo
outlet exhaust pipe.
2. Install the exhaust pipe (11), muffler (10) and tail
pipe (8) as a unit to the turbo outlet exhaust pipe
(13). Install the U-type clamp (12) between the
exhaust pipe (11) and turbo outlet exhaust pipe.
Install the U-type clamp (9) between the muffler and
exhaust pipe. Install the 3" heavy duty muffler clamp
(7) between the muffler (10) and tail pipe (8). Align
all components and tighten all clamps.
3. Connect the negative (-) battery cable (4) at the
negative (-) terminal on the battery in the engine side
battery box.
4. Connect the negative (-) battery equalizer cable (5)
at the bottom of the battery equalizer (6). Torque the
nut to a maximum of 100 lbs/in (11 Nm).
5. Replace engine side battery box cover (1). Use the
wing nuts (2) and carriage bolts (3) to secure the
cover in place.
8.26
7
9
9
10
13
12
11
8.10

ENGINE REPLACEMENT

Removal and installation of the engine should be done
with the transmission attached. For information on re-
moving the transmission from, and installing it to, the en-
gine (refer to Section 7.7.1, Transmission Removal ).
14
8.10.1

Engine Removal

WARNING:
DO NOT attempt to remove the engine when
the engine, cooling system and hydraulic sys-
tem are hot. Wait until all parts and systems
are cool before proceeding.
1. Level the vehicle, ground the attachment, place the
travel select lever in NEUTRAL [N], engage the
neutral lock lever, engage the parking brake switch
MM3040
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 ).
Allow the engine, cooling system and hydraulic
system to cool.
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).
5. Remove the engine compartment hood with the help
of at least one assistant (refer to Section 3.7.2,
Engine Hood ).
To avoid severe burns,
Model MMV Rev. 12/04