Heavy-Duty Engine Lifting Bracket Installation. Study Guide. Course Code: 8803
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1 Heavy-Duty Engine Lifting Bracket Installation Study Guide Course Code: 8803
2 2015 Navistar, Inc Navistar Drive, Lisle, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc.
3 1 Heavy-Duty Engine Lifting Bracket Installation Study Guide Table of Contents Introduction... 1 Objectives... 1 Before you Begin... 2 Identifying Applicable Engines... 2 Installing the Engine Lifting Bracket with the Dust Cover... 4 Removing the Engine Lifting Bracket with the Dust Cover... 6 Installing the Engine Lifting Bracket without the Dust Cover... 7 Removing the Engine Lifting Bracket without the Dust Cover... 8 Conclusion... 8 NOTES... 9 THE INFORMATION PROVIDED WITHIN THIS COURSE IS FOR TRAINING PURPOSES ONLY. ALWAYS CONSULT THE LATEST SERVICE, DIAGNOSTIC, AND TOOL INFORMATION, LOCATED ON NAVISTAR S SERVICE PORTAL, PRIOR TO PERFORMING SERVICE ON NAVISTAR ENGINES, VEHICLES, AND EQUIPMENT. Introduction Welcome to the Navistar training course: Heavy-Duty Engine Lifting Bracket Installation. This course is intended to demonstrate the approved procedure for installing the Engine Lifting Bracket on EPA 07 and later heavy-duty engines. Objectives The Engine Lifting Bracket is designed to aid in the removal and / or lifting of engines both with and without an attached transmission. Upon completion of this course, the student will be able to: Identify the engines with a composite valve cover. Prepare applicable engines to have the lifting bracket installed. Safely lift applicable engines using the Engine Lifting Bracket.
4 Heavy-Duty Engine Lifting Bracket Installation Study Guide 2 Before you Begin Park the vehicle on a level surface Set the parking brake Shift the transmission into park or neutral Install a set of wheel chocks Identifying Applicable Engines IT IS IMPORTANT TO IDENTIFY THE TYPE OF VALVE COVER ON THE ENGINE BEFORE ATTEMPTING TO INSTALL THE ENGINE LIFTING BRACKET. FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE ENGINE. There are multiple valve cover designs used on model year 2010 and newer heavy-duty engines. Heavy- Duty engines equipped with a metal upper valve cover and base do not require the upper valve cover to be removed
5 3 Heavy-Duty Engine Lifting Bracket Installation Study Guide However, Heavy-Duty engines equipped with a composite valve cover require a special procedure when installing the Engine Lifting Bracket to avoid damaging the upper valve cover. REFER TO THE APPROPRIATE SERVICE INFORMATION ON NAVISTAR'S SERVICE PORTAL TO IDENTIFY THE PROCEDURE TO PREPARE THE ENGINE, OR ENGINE-AND-TRANSMISSION ASSEMBLY FOR REMOVAL. TO PREVENT ENGINE DAMAGE, DO NOT USE POWER TOOLS TO REMOVE OR INSTALL VALVE COVER BOLTS. THE THREADS WILL BE DAMAGED IF A BOLT OR NUT IS ROTATED TOO QUICKLY. THOROUGHLY CLEAN THE AREA ABOVE AND AROUND THE VALVE COVER BEFORE REMOVING THE UPPER VALVE COVER. FAILURE TO COMPLY MAY RESULT IN DEBRIS ENTERING AND DAMAGING THE ENGINE.
6 Heavy-Duty Engine Lifting Bracket Installation Study Guide 4 AN APPROPRIATE SUBSTITUTE MAY BE USED IF THE DUST COVER IS UNAVAILABLE. While preparing to lift the engine, remove the bolts securing the upper valve cover. Carefully remove the upper valve cover, ensuring not to knock any debris loose that could enter the engine. Installing the Engine Lifting Bracket with the Dust Cover Position the Dust Cover on top of the valve cover base, making sure the holes are properly aligned. Use the fasteners supplied with the Dust Cover to ensure the dust cover will not accidentally fall off of the engine. Connect the engine hoist to the lifting chain assembly at the front of the main engine lifting bracket for engine lifting only. If lifting an engine-and-transmission as single assembly, connect the engine lift to the rear lifting ring.
7 5 Heavy-Duty Engine Lifting Bracket Installation Study Guide Engine Only Lifting Engine and Transmission Lifting Position the main engine lifting bracket through front engine lifting eyelet and secure it with the lynch pin. THE REAR BRACKET BOLTS SHOULD BE LOOSELY INSTALLED TO ALLOW ENOUGH MOVEMENT FOR PROPER BRACKET INSTALLATION. Remove the sensor connectors and mounting plate from the coolant manifold and if equipped, the NOx sensor module, mounting plate, and the mounting stud. Position the rear adapter bracket in front of the rear lifting eyelets on the bell housing and main bracket and loosely install the bolts. Once the Engine Lifting Bracket is installed, carefully lift the engine, or engine-and-transmission assembly.
8 Heavy-Duty Engine Lifting Bracket Installation Study Guide 6 Removing the Engine Lifting Bracket with the Dust Cover REFER TO THE APPROPRIATE SERVICE INFORMATION ON NAVISTAR'S SERVICE PORTAL TO IDENTIFY THE PROCEDURE TO SUPPORT OR INSTALL THE ENGINE, OR ENGINE-AND- TRANSMISSION ASSEMBLY. Once the engine is properly supported, remove the rear adapter bracket and bolts from the rear engine lifting eyelets. Remove the lynch pin from the main engine lifting bracket, and remove the Main Engine Lifting Bracket from the engine. After removing the Engine Lifting Bracket, remove the Dust Cover and fasteners. Place the valve cover on top of the engine, and tighten all bolts to the specified torque value. Close the hood and remove the wheel chocks once all repairs are complete.
9 7 Heavy-Duty Engine Lifting Bracket Installation Study Guide Installing the Engine Lifting Bracket without the Dust Cover Place a clean fender cover over the open valve cover base to prevent debris from entering the engine and secure it in place. Connect the engine hoist to the lifting chain assembly at the front of the main engine lifting bracket for engine lifting only. If lifting an engine-and-transmission as single assembly, connect the engine lift to the rear lifting ring. Position the main engine lifting bracket through front engine lifting eyelet and secure it with the lynch pin. THE REAR BRACKET BOLTS SHOULD BE LOOSELY INSTALLED TO ALLOW ENOUGH MOVEMENT FOR PROPER BRACKET INSTALLATION. Remove the sensor connectors and mounting plate from the coolant manifold and if equipped, the NOx sensor module, mounting plate, and the mounting stud. Position the rear adapter bracket in front of the rear lifting eyelets on the bell housing and main bracket and loosely install the bolts. Once the Engine Lifting Bracket is installed, carefully lift the engine, or engine-and-transmission assembly.
10 Heavy-Duty Engine Lifting Bracket Installation Study Guide 8 Removing the Engine Lifting Bracket without the Dust Cover REFER TO THE APPROPRIATE SERVICE INFORMATION ON NAVISTAR'S SERVICE PORTAL TO IDENTIFY THE PROCEDURE TO SUPPORT OR INSTALL THE ENGINE, OR ENGINE-AND- TRANSMISSION ASSEMBLY. Once the engine is properly supported, remove the rear adapter bracket and bolts from the rear engine lifting eyelets. Remove the lynch pin from the main engine lifting bracket, and remove the Main Engine Lifting Bracket from the engine. After removing the Engine Lifting Bracket, remove the fender cover. Place the valve cover on top of the engine, and tighten all bolts to the specified torque value. Close the hood and remove the wheel chocks once all repairs are complete. Conclusion This concludes the Navistar training course: Heavy-Duty Engine Lifting Bracket Installation. Thank you for your participation.
11 9 Heavy-Duty Engine Lifting Bracket Installation Study Guide NOTES
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