Chapter 5 POWER TRAIN

1. Removal and Installation (MC Models) ................................................. 5-1

1.1 Removal of Engine and Transmission Assembly .................................................... 5-1
1.2 Removal of Engine and Transmission Assembly (for Gasoline-Engine Trucks) ..... 5-1
2. Removal and Installation (FC Models) .................................................. 5-7
2.1 Removal of Engine and Transmission Assembly .................................................... 5-7

5
 POWER TRAIN

Chapter 5 POWER TRAIN

1. Removal and Installation (MC Models)

1.1 Removal of Engine and Transmission Assembly
The engine and transmission are installed as an assembled unit. The engine may be removed independently of the
transmission, but the transmission can only be removed together with the engine.

1.2 Removal of Engine and Transmission Assembly (for Gasoline-Engine Trucks)

1.2.1 Overhead guard, covers, air cleaner and other components

5
6

3
8
4

7
9

10
213529

Removal sequence
1 Head guard 6 Radiator cover
2 Battery 7 Floor plate, Floor mat
3 Steering wheel 8 Air hose, Air cleaner
4 Gas springs 9 Exhaust pipe
5 Engine cover, Seat 10 Fuel hoses

Suggestions for Removal

(1) When removing the batteries 2, be sure to discon-
nect the ground (negative) cable first.
(2) Remove the floor plate 7.
(3) Disconnect the exhaust pipe 9 from the engine.
(4) Before removing the fuel hose 10, make sure to
close the drain cock on the fuel tank.
(5) After disconnecting the harness connectors from
the sockets and terminals on the engine and
transmission they should be attached to the main
harness in order to avoid damaging them.
Be sure to release fuel pressure before disconnecting
the fuel hoses from the electric controlled engine mod-
els as follows:
(1) Remove fuel pump fuse.
(2) Start the engine, and run the engine for a few sec-
onds to release the pressure from the fuel line.
(3) Turn the key switch to OFF, and install the fuel
pump fuse.
(4) To release the pressure from fuel tank, remove
the cap from fuel tank once, and reinstall the cap.

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POWER TRAIN

1.2.2 Controls

2
4

4
6

Electric control engine

5
1

217397

Removal sequence
1 Brake pipe 4 Connector (Throttle, Stop lamp switch)
2 Inching cable, Clevis pin, Washer, Snap pin 5 Pedal assembly
3 Reservoir tank 6 Accelerator bracket

Suggestions for Removal

(1) To remove the inching cable 2, disconnect the
inching pedal end and the transmission end and
then loosen the lock nuts.
(2) For trucks with non-electric control engine, dis-
connect the throttle cable from the engine.

Installation
To install, follow the removal sequence in reverse.
For brake pedal adjustment, refer to Chapter 8 "8.2
Brake (Inching) Pedal Adjustment" and Chapter 11
"3.4 Brake Pedal Adjustment." For inching cable
adjustment, refer to Chapter 8 "8.3 Inching Cable
Adjustment."

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 POWER TRAIN

1.2.3 Radiator and Pipes

13
4 14
5

12

7 1

11

6 3
2

8
10
217201

Removal sequence
1 Reservoir tank 8 Cooling fan
2 Hose (upper) 9 Fan belt
3 Hose (lower) 10 Fan guard
4 Return hose (between hydraulic tank and control valve) 11 Shroud
5 Suction hose (between hydraulic tank and oil pump) 12 Radiator
6 Delivery hose (oil pump to steering control valve) 13 Oxygen sensor
7 Cooler hose assembly 14 Exhaust pipe
(between radiator and powershift transmission)

Start by
(1) Drain the coolant from the radiator by loosening
the drain cock at the bottom of the radiator.
(2) Drain the coolant from the engine by removing the
drain plug. (Note that the position of the drain plug
differs by engine type).

Suggestions for Removal

Disconnect the cooler hose 7 from the transmission
side and temporarily attach it to the right side of the
frame.

Installation
To install, follow the removal sequence in reverse.

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POWER TRAIN

1.2.4 LPG system (Dual Fuel Gasoline and LPG Model)

5
4
2 6

7
3 8

217398

Structure
1 LPG tank
2 Tank bracket
3 LPG hose
4 LPG pipe and Connector assembly
5 Water hose
6 LPG hose
7 Water hose
8 Vaporizer assembly

Start by
(1) Drain the fuel of the line by running the engine
with the valve on LPG tank shut off.
(2) Draining the coolant from engine by removing the
drain plug.
(3) Draining the coolant from the radiator by loosen-
ing the cock at the bottom of the radiator.

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 POWER TRAIN

1.2.5 Engine and transmission assembly

3
2 217204

Removal sequence
1 Transmission mounting bolt 3 Engine and transmission assembly
2 Engine mounting bolt

Start by
Lift the engine and transmission assembly with a hoist
and slings.
Unit: kg [lb.]
Weight Approx. 315 [695]

Suggestions for Removal

(1) Lift the engine and transmission assembly just the
amount necessary to remove the load on the
mounting cushion before removing the mounting
bolts 1 and 2. Remove the engine support mount-
ing bolts.
(2) By hooking wire into 3 hooks, slowly lift the engine
and transmission assembly 3 out by moving it
backwards while maintaining its balance.
Note: 1. With the engine and transmission assembly
suspended, drain the transmission oil and
clutch oil.
2. There is only one drain plug in the powershift
transmission.

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POWER TRAIN

1.2.6 Installation
Follow the removal sequence reverse.

1.2.7 Suggestions for Installation

(1) Engine and transmission assembly
(a) Apply sealant (oil resistant liquid gasket such
as ThreeBond # 1104) to the transmission
mounting surface of the front axle/
(b) Slowly lift the assembly/
Weight of engine and transmis-
315kg (695lb)
sion assembly

(c) While aligning the holes in the rubber cushions

and those in the left and right engine supporte,
lower the lifted assembly. Engine mount bolt
(d) On each side, first insert the engine mounting
bolt and align the bolt holes in the transmission
and front axle, then fasten the bolts (12 Rubber cushion
places).
(e) Fasten each engine mounting bolt with the Engine support
castle nut and lock the nut with the split pin.
(2) Check that the clutch valve plunger is pushed out
Castle nut 217202
completely when the cable connected between
the inching pedal and the transmission.
(3) Bleed the air out of the brake fluid circuit after
connecting the break pipe.
(4) When installing the exhaust pipe, use a new gas-
ket.
(5) Connect the ground (negative) cable to the bat-
tery only after making sure that all wiring is con-
nected properly.
(6) Refill the engine, radiator, front axle, and trans-
mission with oils/coolant, and check for leakage.
Unless otherwise specified, use distilled water
mixed with LLC at a concentration of 35%.

Antifreeze solution is TOXIC. In case of contact with

your skin, FLUSH IMMEDIATELY WITH WATER.
Have your Mitsubishi forklift truck dealer discard anti-
freeze solution drained from the engine.

(7) Bleed the air out of fuel circuit of engine/

(8) After checking the parts, start the engine. Operate
the mast lifting / tilting and steering, and check the 217203

hydraulic oil level. Also recheck the engine oil,

coolant and transmission oil levels.

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 POWER TRAIN

2. Removal and Installation (FC Models)

2.1 Removal of Engine and Transmission Assembly
The main difference between the MC and the FC mod-
els is the control valve operation. In the MC models,
the control valve plunger is operated manually. In the
FC models, the valve operation is electrically con-
trolled by way of a finger-tip control hydraulic lever.
This section provides only the information specific to
removal and installation of the FC model power train.

Suggestions for Removal

(1) Engine cover, Seat FC lever box
When removing the engine cover, disconnect the
connectors behind the engine cover. Be careful
not to damage the FC lever box, emergency stop
button, and other items located to the right of the
engine cover/seat.
Note: For the application of optional five-valve control,
connectors and terminals are changed accord-
ingly.
213543
(2) Harnesses and cables
(between the transmission and frame)
FC model harnesses are added to MC model har-
nesses on both gasoline-engine FC trucks.

5-7