Chapter 5 POWER TRAIN

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

1.1 Removal of Engine and Transmission Assembly (for Gasoline-Engine Trucks) .....5-1
1.2 Removal of Engine and Transmission Assembly (for Diesel-Engine Trucks) .........5-7
2. Removal and Installation (FC Models) ................................................ 5-11
2.1 Removal of Engine and Transmission Assembly .................................................. 5-11

5
 POWER TRAIN

Chapter 5 POWER TRAIN

1. Removal and Installation (MC Models)

1.1 Removal of Engine and Transmission Assembly (for Gasoline-Engine Trucks)
The engine and transmission are installed as an
assembled unit. The engine may be removed indepen-
dently of the transmission, but the transmission can
only be removed together with the engine.
1.1.1 Overhead guard, covers, air cleaner and other components

5
6
1

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

1.1.2 Controls

2
4

4
6

Electric control engine 5

1

217335

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

To remove the inching cable 2, disconnect the inching
pedal end and the transmission end and then loosen
the lock nuts.

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."

5-2
 POWER TRAIN

1.1.3 Radiator and Pipes

4 5
7

6
3
2 1

11

8
10
9
213533

Removal sequence
1 Reservoir tank 7 Cooler hose
2 Hose (upper) (between radiator and powershift transmission)
3 Hose (lower) 8 Cooling fan
4 Hose (between hydraulic tank and control valve) 9 Fan belt
5 Hose (between hydraulic tank and oil pump) 10 Fan guard assembly
6 Hose (oil pump to steering control valve) 11 Universal joint
(between transmission and reduction/differential gears)

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.

5-3
POWER TRAIN

1.1.4 LPG system (Dual Fuel Gasoline and LPG Model)

1
5

3
2
To engine

A
To engine

4
7

To engine
8
A
217353
Sequence
1 LPG tank 5 Water hose
2 Tank bracket 6 LPG hose
3 LPG hose 7 Water hose
4 LPG pipe 8 Vaporizer assembly

Start by:
(a) Draining the coolant hose from the engine by
removing the drain plug.
(b) Draining the coolant from the radiator by loos-
ening the cock at the bottom of the radiator.

5-4
 POWER TRAIN

1.1.5 Engine and transmission assembly

3
* *

* Lifting position 217408

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. 250 [551.2]

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.

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POWER TRAIN

Installation
To install, follow the removal sequence in reverse.

Suggestions for Removal

Engine side
(1) Engine and transmission assembly
(a) Slowly lift the assembly. Cushion
(b) On the transmission side, tighten the bolts of
the left and right mounts after aligning them Bolt
with the holes in the differential case.
(c) On the engine side, tighten the bolts of the left
and right engine supports after aligning them Engine support
with the holes in the engine mounts.
Unit: N·m (kgf·m) [lbf·ft]
59.8 ± 6
Tightening torque (6.1 ± 0.6)
Frame-side
[44.1 ± 4.4]
engine mount

213535

(2) For powershift transmission trucks, check that the

clutch valve plunger is pushed out completely
when the cable is connected between the inching
pedal and the transmission.
(3) Connect the accelerator pedal link on the floor
plate to the throttle cable. Check that the throttle
lever is at the full-open position when the acceler-
ator pedal is fully depressed.
(4) Bleed the air out of the brake fluid circuit after con-
necting the brake pipe.
(5) When installing the exhaust pipe, use a new gas-
ket.
(6) Connect the ground (negative) cable to the bat-
tery only after making sure that all wiring is con-
nected properly.
(7) Refill the engine, radiator, and transmission with
oils/coolant, and check for leakage. Unless other-
wise specified, use soft water (tap water) mixed
with antifreeze at a concentration of 35%. During
an engine overhaul, replace the coolant in the res-
ervoir tank.
(8) Bleed the air out of the fuel circuit of the engine.
(9) After checking the parts, start the engine. Operate
the mast lifting/tilting and steering, and check the
hydraulic oil level. Also recheck the engine oil,
coolant and transmission oil levels.

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 POWER TRAIN

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

The engine and transmission are installed as an
assembled unit. The engine may be removed indepen-
dently of the transmission, but the transmission can
only be removed together with the engine.
1.2.1 Overhead guard, covers, air cleaner and other components

6 1

4 8

10
217409

Removal sequence
1 Head guard 6 Radiator cover
2 Battery 7 Front cover, 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.

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POWER TRAIN

1.2.2 Controls
This section describes only removal and installation
procedures specific to diesel-engine trucks. Follow the
instructions for the gasoline-engine trucks in the pre-
ceding sections for the common procedures. 1

Removal sequence (specific to diesel-engine trucks)

1 Throttle cable

213539

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 POWER TRAIN

1.2.3 Radiator and Pipes

5
7

3
8 2 1

11

6
10

213541

Removal sequence
1 Reservoir tank 7 Cooler hose
2 Hose (upper) (between radiator and powershift transmission)
3 Hose (lower) 8 Cooling fan
4 Hose (between hydraulic tank and control valve) 9 Fan belt
5 Hose (between hydraulic tank and oil pump) 10 Fan guard assembly
6 Hose (oil pump to steering control valve) 11 Universal joint
(between transmission and reduction/differential gears)

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.
Before connecting hoses to pipes, clean the mating
joint surfaces of pipes and hoses.

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POWER TRAIN

1.2.4 Engine and transmission assembly

213542

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

Start by Installation
Lift the engine and transmission assembly with a hoist This section describes only removal and installation
and slings. procedures specific to diesel-engine trucks. Follow the
Unit: kg [lb.] instructions for the gasoline-engine trucks in the pre-
Weight Approx. 350 [771.6] ceding sections for the common procedures.

Suggestions for Removal Suggestions for Installation (specific to diesel-

engine trucks)
(1) Lift the engine and transmission assembly just the
Connect the accelerator pedal linkage on the floor
amount necessary to remove the load on the
plate to the throttle cable. Check that the injection
mounting cushion before removing the mounting
pump lever is at the full-open position when the accel-
bolts 1 and 2. Remove the engine support mount-
erator pedal is fully depressed.
ing bolts.
(2) 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.

5-10
 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 and diesel-
engine FC trucks.

5-11