POWER TRAIN

Removal and Installation

Engine and Transmission
Removal
The engine can be removed alone but the trans- NOTE
mission has to be removed together with the
engine. These pages are devoted to the explana- Removal and installation of the gasoline
tion of removal of the transmission and engine engine differ from those of the diesel
held together as a unit. engine.

Overhead Guard, Cover and Air Cleaner

3 5 2 6
1

(Diesel models) 8

(Gasoline
models) 9

8 (Diesel models)
4
7
10

(Gasoline models)

207345

Sequence
1 Overhead guard, Head lamps 6 Radiator cover
2 Battery, Cables 7 Front cover, Floor plate
3 Steering wheel 8 Air hose, Air cleaner
4 Gas spring 9 Exhaust pipe
5 Engine hood, Seat 10 Fuel hose

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POWER TRAIN

Suggestions
1. When removing. Battery 2, be sure to discon-
nect the cable from the negative (-) terminal of
the battery 2 first.

2. Remove front cover 7 together with the accel-

erator pedal. For this removal, disconnect the
pedal from the link rod.

3. Disconnect exhaust pipe 9 at the engine side.

4. Before disconnecting fuel hose 10, close the

fuel shutoff valve.

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 POWER TRAIN

Control Linkage

15
(Gasoline models)

15
(Diesel models) 15
(Gasoline models)
15

12

Inching
bracket

11

14

13
207153

Sequence
11 Brake pipes 14 Pedal assembly
12 Inching cable, Clevis pin, Washer, Snap 15 Throttle cable, Accelerator pedal brack-
pin et, Pin, Washer, Choke cable
13 Connector (Brake fluid level sensor,
Stop lamp switch)

Suggestion
To remove inching cable 12, pull out pins and
loosen lock nuts at the transmission and inching
pedal sides of the cable.

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POWER TRAIN

Harness and Cables 16 (gasoline models)

Transmission
solenoid valve
Lamp Battery
Horn

Torque converter
oil temp. unit

Ignition coil

Cable Starter
Engine coolant temp. unit

Alternator
Stop lamp Brake fluid
switches level sensor Alternator
Oil pressure
switch

Lamps

207341

Sequence
Harness and cables
(between transmission case and frame)
Parts to be removed

(1) Already removed.

(2) To be removed.

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 POWER TRAIN

Harness and Cables 16 (diesel models)

Transmission
solenoid valve
Torque converter
oil temp. unit Fuel cut solenoid
Lamp
Battery

Starter

Heater plug
Cable

Sedimenter water Alternator

level sensor
Alternator Engine coolant
temp. unit

Stop lamp Brake fluid

switches level sensor

Oil pressure switch

Lamps

207342

Sequence
Harness and cables
(between transmission case and frame)
Parts to be removed

(1) Already removed.

(2) To be removed.

Suggestion
Disconnect the harness from the engine and trans-
mission at the sockets or terminals. Tie the discon-
nected harnesses to the main harness to prevent
them from damage.

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POWER TRAIN

Piping and Cooling Fan

24

25

25
18

23

21 22
19
26
20

27 17
207154A

Sequence
17 Reservoir 24 Hose (lower)
18 Coolant hoses 25 Cooler hose
19 Fan guard 26 Universal joint (between engine and oil
20 Tensioner, Tensioner pulley pump)
21 Support, Cooling fan 27 Universal joint (between transmission
22 Fan belt and differential)
23 Hose (upper)

Start by: Suggestions

1. Remove the coolant drain plug of the
engine and drain coolant. ( The drain plug
location differs from one model of the
engine to another.)
2. Loosen the cock at the bottom of the radia-
tor and drain coolant.
1. Disconnect cooler hose 18 at the transmis-
sion side, put it on the right side of the
frame.
2. Automatic transmission fluid will flow out
from the cooler when cooler hose 25 is dis-
connected. Catch the fluid in a container
after disconnecting the hose.

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 POWER TRAIN

Engine and Transmission

29
•
Engine coolant
drain plug

•
Engine mount
28
Transmission
mounting bolt
Engine support
▲ ▲

Engine mount
(frame side)
Transmission oil Engine oil 28
drain plug drain plug

204822

Sequence
28 Bolts (for transmission and engine sup- 29 Engine and transmission assembly
ports)

Start by:
Lift the engine and transmission assembly by a
hoist.

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POWER TRAIN

Suggestions
1. When removing bolts 28, lift the engine and
transmission assembly just enough to free
mount cushion. On the engine side, remove
bolts 28 from the engine support.

2. When removing the engine and transmission

assembly, lift it off while moving it backward.
Before lifting the assembly, know the location
of the center of gravity of the assembly.
NOTE
1) Drain transmission oil with the assembly
lifted.

2) The powershift transmission has one drain

plug.

Installation
To install, follow the reverse of removal sequence.
Suggestions Engine side
1. When installing the engine and transmission
assembly, carefully lower it while aligning the 28 Bolt
cushion mounting bolts with their holes on the
transmission side. On the engine side, align Engine
engine support mounting bolts 28 with their support
holes in the frame-side engine mounts.
Cushion

Frame-side
engine mount
204912

2. After connecting the cable between the inch- Unit: mm (in.)

ing pedal and transmission, make sure that the 1 ton 9 to 9.5
plunger projection or readjust if necessary. Plunger models (0.35 to 0.37)
projection 2, 3 ton 6 to 9.5
models (0.24 to 0.37)

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 POWER TRAIN

3. Connect the accelerator pedal to the throttle

cable, and make sure that the injection pump
lever is in the full throttle position when the
accelerator pedal is depressed all the way
(diesel models). On the gasoline models, con-
nect the accelerator pedal to the throttle cable,
and make sure that the throttle lever is in the
full throttle position when the accelerator
pedal is depressed all the way.

4. After connecting the brake pipes, bleed air out

of the fluid lines.

5. When installing the exhaust pipe to the engine,

use a new gasket.

6. Connect the battery cable to the negative (-)

terminal of the battery lastly after making sure
that all the harnesses and cables have been
connected properly.

7. Refill the engine with oil and coolant and the

transmission with oil, and check for leaks.
Unless otherwise specified, use antifreeze of
35% concentration by volume.

8. Prime the fuel system.

9. After completing the inspection, start the

engine, and check it. Move the mast and steer-
ing for a while, and check the oil level in the
hydraulic tank. Also, check the engine oil
level, coolant level and transmission oil level.

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