SkyTrak 6036 Service Manual - Manual (Page 107)

Section 8. Engine
Model 6036 S/N 9B0499 and Before 8-21
8.7 ENGINE OVERHAUL
Refer to the Perkins Engine Workshop Manual for
the 4.236 Series engines.
8.8 ENGINE INSTALLATION
1. Install two 2.5" (64 mm) guide studs in the
engine housing as shown in Fig. 8.27.
Fig. 8.27 Guide Studs
2. Rotate the engine flywheel to align a drive plate
mounting screw hole with the flywheel housing
access hole.
3. Install a 4.0" (100 mm) long locating stud
(0.375-24 fine thread) in a drive plate nut as
shown in Fig. 8.28.
4. Rotate the drive plate to align the locating stud
with the flywheel drive plate mounting screw
hole positioned in step 2.
5. Position the transmission on the flywheel
housing with the guide and locating studs
aligned.
6. Install the nine capscrews securing the con-
verter housing to the flywheel housing.
7. Remove the two guide studs and install the
remaining two capscrews securing the con-
verter housing to the flywheel housing. Torque
all eleven housing capscrews to 25 to 30 lb-ft
(34 to 41 N m).
8. Using the access hole on the flywheel housing,
remove the drive plate locating stud and install
a capscrew in its place. Snug the capscrew,
but do not tighten it.
9. Rotate the engine flywheel and individually
install the remaining seven flywheel-to-drive-
plate capscrews through the access hole.
Snug the screws, but do not tighten them.
(b) Remove the U-bolt assembly or bearing
straps, Fig. 6.1, attaching the drive shaft
cross assembly to the drop box input shaft
yoke. Slide slip joint towards transmission
so cross slips out of drop box input shaft
yoke.
NOTE: Wrap tape around bearings and cross so
bearings don't drop off cross.
(c) Remove the cap and bolt assembly or
bearing straps securing the drive shaft
cross assembly to the transmission output
shaft yoke.
NOTE: Wrap tape around bearings and cross so
bearings don't drop off cross.
(d) Remove drive shaft assembly from forklift.
18. Detach and remove the hydraulic lines from the
main pump.
IMPORTANT: Be sure main suction line is raised
above level in reservoir.
19. Detach and remove the transmission cooler
lines at the transmission.
20. Remove the engine and transmission from the
forklift frame as follows:
(a) Attach a suitable engine hoist to the lift
plates, Fig. 8.25, on the top of the engine.
(b) Remove both transmission mounts from
the transmission and frame.
(c) Remove the capscrew, vibration mount,
rebound washer, and locknut attaching the
engine mount to the frame.
(d) Pull the engine and transmission out the
rear of the forklift.
21. With the engine and transmission adequately
supported, separate the engine from the
transmission as follows:
(a) Remove one of the two access hole plastic
plugs on the engine flywheel housing.
(b) Remove the eight torque converter drive
plate screws and washers.
(c) Remove the eleven capscrews securing
the converter housing to the flywheel
housing.
(d) Using a suitable engine hoist, separate the
transmission from the engine.
GUIDE STUDS
FLYWHEEL FLYWHEEL
HOUSING
MA0391