PPM 103

Morbark
Ford 6.2 Engine
Post Production Modification
(PPM-103)
Note: Make sure you read and
understand these instructions
before performing the procedure. If
you are confused or uncertain about
the contents of this document,
contact your local dealer or Morbark
directly at 800-255-8839.
Publish Date: 03/29/2022
Last Revised: -Created by: AB
Total Pages: 10
PPM#
103
Overview
This document describes the steps required to identify what modifications are required
to your specific machine to remedy any instances of engine overheating and include the
following:
•
Replace current radiator (debris) screen with Assembly #40861-451
•
ECM replace or update
•
Replace rear and top engine enclosure panels if thermal insulation is present.
•
Adjust exhaust tube “Y-Pipe” for clearance to firewall (Note: Replace U bolt
clamps with Morbark PN: 29323-598 as required)
•
Purge cooling system to remove any trapped air
•
Replace radiator fan if existing fan exhausts air from engine assembly instead of
“pulling” air INTO engine assembly.
Affected Machines
•
Any of these models that use the Ford 6.2L engine: EB 1821 (Pre
Ser# 26469), EB 1922 (Pre Ser# 52783), EB 2131
Verify and Obtain Parts from this List
Note: Not all of these parts will be required to upgrade your machine. Inspect your
machine and create a checklist of all parts that need to be ordered for your machine.
Place an “X” if associated item(s) apply
Assy/Part No.
Order if existing panel HAS thermal insulation. 40780-451
Order if existing panel HAS thermal insulation. 30501-451
Order if existing exhaust clamps are “U Bolt”
type
Order if existing fan is configured to pull air
AWAY from engine instead of INTO engine
assembly (see Note 1)
This item must be replaced for all machines.
29323-598
Description: Qty:
Rear Panel
1
Top Panel
Clamp,
Exhaust
1
29119-013
Fan, Puller
1
40861-451
Debris
Screen
1
Note 1: Refer to Appendix at back for fan identification photos.
Contact Morbark Service at 800-255-8839 if you
have ANY questions or need clarification.
Page 1
3
PPM-103
Safety
Dangers, Warnings and Cautions
A Danger explains hazards that will result in personal injury or
death.
A Warning explains hazards that might result in personal
injury or death.
A Caution explains hazards that could cause damage to
equipment and/or machinery.
Personal Protective Equipment (PPE)
For your safety, always adhere to the following guidelines when performing this
procedure:
•
Always wear personal protective equipment (hard hat, safety
goggles/weld mask, work/weld gloves, hearing protection, etc.)
when working on this equipment.
•
Know and avoid pinch/ crush points.
•
Clean all oil spills, and debris around work area to reduce the risk
of slips, trips and falls.
•
If lifting or leveraging equipment and/or assemblies always make
sure all ramps, hoists, lift straps/chains, jacks, jack stands, etc., are
rated and approved for the weights being carried/lifted.
Page 2
PPM-103
Engine Modification Procedure
1) See Figure 1. Remove the Debris Screen (1), Access Panel (2), Engine Air
Intake Assembly (3), Exhaust Heat Shield (4), Muffler Assembly (5) and Rear
Panel (6) in the order as numbered and set aside.
4
6
3
5
1
2
Figure 1
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PPM-103
2) See Figure 2. Remove Exhaust Pipe (1), Engine Enclosure Top (2) and
Chimney Weldment (3) in the order as numbered and set aside.
2
3
1
Figure 2
3) See Figure 3. Assemble new Chimney Weldment (1), Engine Enclosure Top
(2) and existing Exhaust Pipe (3) in the order as numbered using existing
hardware. Note: See Figure 4 (next page) for exhaust pipe details before
installing.
2 (Part #30501-451)
1 (Part #40780-451)
3
Figure 3
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PPM-103
NOTES:
•
•
•
•
•
When changing the fans, adjust the exhaust Y-pipe so it is straight up and down.
We initially had these clamped to the firewall but this allowed too much heat to
pass through the firewall.
Loosen the exhaust manifold joints and pull the pipe back away from the fire wall
and re-torque.
The Catalyst assembly can be adjusted forward and back to allow better fitment
of the 90 degree exhaust elbow. Here are some pictures of what it should look
like.
Also remind anyone running a Ford 6.2 liter to only use 5w-30 motor oil. Using
a thicker oil with a higher winter weight (10w, 15w) in the winter may cause
timing chain damage.
Double check that all wiring harnesses are tied back away from any heat
sources like the exhaust manifolds.
NOTE: Do NOT reuse U bolt
clamps when re-installing
Y-pipe.
Make sure pipe is aligned
so that there is even
clearance between pipe and
chimney weldment as
shown
Use 3” band clamp.
Make sure elbow is
fully seated and
there are no leaks at
slots.
Figure 4
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PPM-103
4) See Figure 5. Install Rear Panel using existing hardware.
Figure 5
5) See Figure 6. Install Muffler Assembly, Radiator Cover, Access Panel, and
Engine Air Intake Assembly using existing hardware then install replacement
debris screen as shown.
#40861-451
Figure 6
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PPM-103
Update or Replace ECM
To update existing ECM contact Art Wicks EDI Service Manager ([email protected]) to
update existing ECM.
•
Calibration: 5380R35D_GAS_TSC1_1200-3200
Or, to replace ECM do the following:
1)
See Figure 7. Remove screws.
2)
Disconnect wire harnesses.
3)
Remove ECM.
4)
Install new one in reverse.
Figure 7
Page 7
PPM-103
Purging Air from Radiator Coolant
Note: You can drain and vacuum fill the system or use the following procedure, which would require a
spill-free funnel. (See links below)
Cooling system purge:
https://www.lislecorp.com/specialty-tools/spill-free-funnel-606
Lisle 24680 Spill-Free Funnel [IMPROVED]
1)
Using correct adaptor insert funnel into radiator.
Figure 8
2)
Add fluid coolant (USE: Peak Cool 50/50 Pre-diluted Extended Life anti-freeze
and coolant, 150,000 mile protection, or equivalent that meets or exceeds
WSS-M97B51-A1, ASTM D3306). NOTE: Make sure the funnel is no more than
one-third full to avoid overflow when engine heats up.
3)
Start car. Let engine idle until engine temperature reaches 205°F. Trapped air
will escape through funnel.
Figure 9
4) Shut down the engine and let cool.
5) Repeat Steps 3 and 4 up to four times to cycle air out.
Page 8
PPM-103
6) Squeeze radiator hose then insert the stopper. Remove funnel and install
radiator cap.
Figure 10
7) Transfer remaining coolant to reservoir.
Figure 11
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PPM-103
Appendix - Fan Identification/Verification
Wrong fan – Arrow points to right.
Page 10
Correct fan – Arrow points to left.
PPM-103