POWER TRAIN Removal and installation . sree ST Removal of Engine and Transmission Assembly (for Gasoline-engine Trucks) 5-1 Overhead Guard, Covers, Air Cleaner and Other Components 5-1 Controls seve sesso 5-2 LPG system (Dual Fuel Gasoline and LPG Model) 5-3 Radiator and Pipes .... Engine and Transmission Assembly Installation Removal of Engine and Transmission Assembly (for Diesel-engine Trucks) ........ . 7 Overhead Guard, Covers, Air Cleaner and Other Components 5-7 Controls 5-8 Radiator and Pipes 5-2 Engine and Transmission Assembly ......0-seseecnse 5-10Removal and Installation POWER TRAIN 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 independently of the transmission, but the transmission ccan only be removed together with the engine. Overhead Guard, Covers, Air Cleaner and Other Components Sequence 1 Overhead guard, Headlamps Batteries, Cables Steering wheel Gas springs Engine cover, Seat ‘Suggestions for Removal (2) When removing the batteries 2, be sure to disconnect the ground (negative) cable first. (2) Remove the floor plate and mat 7 together with the accelerator pedal after disconnecting the pedal from the linkage rod, (3) Disconnect the exhaust pipe 9 from the engine 6 Radiator cover 7. Floor plate, Floor mat 8 Airhose, Air cleaner 9 Exhaust pipe }0. Fuel hoses (without LPG engine models) (G) Before removing the fuel hose 10, make sure to close the 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.POWER TRAIN Controls | 4 —— 210118 Sequence 1 Brake pipe 4 Connector (Throttle, Stop lamp switches) 2. Inching cable, Clevis pin, Washer, Snap pin 5 Pedal assembly 3. Oiltank © Accelerator bracket ‘Suggestion for Removal To remove the inching cable 2, disconnect the inching pedal end and the transmission end and loosen the lock nuts. Installation Follow the removal sequence in reverse 52POWER TRAIN LPG system (Dual Fuel Gasoline and LPG Model) Disassembly ee @& To engine 4 | 7 A 210120 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) Drain the coolant from the engine by removing the drain plug. (b) Drain the coolant from the radiator by loosening the cock at the bottom of the radiator.POWER TRAIN Radiator and Pipes 209796 Sequence 1 Reserve tank 2 Hose (upper) 3. Hose (lower) 4 Hose (between hydraulic tank and control valve) Hose (between hydraulic tank and ail pump) 6 Hose (between oil pump and steering control valve) Start by: (@) Drain the coolant from the engine by removing the drain plug (note that the position of the drain plug. differs by engine type). (b) Drain the coolant from the radiator by loosening the cock at the bottom of the radiator. ‘Suggestion for Removal Disconnect the cooler hose 7 from the transmission side and temporarily attach it to the right side of the frame. 7 Cooler hose (between radiator and powershift transmission) 8 Cooling fan 9 Fan belt 410. Fan guard 11 Universal joint (between transmission and reduction‘dferential gears) Installation Follow the removal sequence in reverse.POWER TRAIN Engine and Transmission Assembly 209797 Sequence 1. Transmission mounting bolt 3. Engine and transmission assembly 2. Engine mounting bolt Start by: (a) Lifting the engine and transmission assembly with hoist and slings. ‘Suggestions for Removal (2) 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 mounting bolts. (2) Slowly lif the engine and transmission assembly 3 out bby moving it backwards while maintaining its balance, Note: (1) With the engine and transmission suspended, drain the transmission oil and clutch oil (2) There is only one drain plug in the powershift transmission,POWER TRAIN Installation Follow the removal sequence in reverse ‘Suggestions‘or Installation (1) Engine and transmission assembly (2) Slowly lift the assembly (b) On the wansmission side, tighten the bolts of the left and right mounts after aligning them with the holes in the differential case. (©) On the engine side, tighten the bolts of the left and right engine supports after aligning them with the holes in the engine mounts. 2) For powershift transmission trucks, eheek that the clutch valve plunger is pushed out completely when the cable is connected between the inching pedal and the transmission, (3) Bleed the air out of the brake fluid circuit after connecting the brake pipe. (4) When installing the exhaust pipe, use @ new gasket. (5) Connect the ground (negative) cable to the battery only after making sure that all wiring is connected properly. (6) Refill the engine, radiator, and transmission with oilsicoolant, and check for leakage. Unless otherwise specified, use soft water (tap water) mixed with antifreeze at a concentration of 35%. (1) Bleed the air out of the fuel circuit of the engine. (8) After checking the parts, start the engine and check that the clutch booster functions properly (wet-type clutch transmission trucks only). Operate the mast Liitingtiting and steering, and check the hydraulic oil level. Also recheck the engine oil, coolant and transmission ol levels. 56 Engine side Cushion ~Bott Frame-side engine mount Engine support 209798