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POWER TRAIN Removal and Installation ..................................................................... 5 – 1 Removal of Engine and Transmission Assembly ........................................ 5 – 1 Overhead Guard, Covers, Air Cleaner and Other Components .............. 5 – 1 Controls ................................................................................................ 5 – 3 Batteries ................................................................................................ 5 – 4 LPG system (Dual Fuel Gasoline and LPG Model) ................................ 5 – 5 Cooling, Exhaust and Hydraulic ............................................................. 5 – 6 Front Wheel and Front Axle Shaft .......................................................... 5 – 7 Engine and Transmission Assembly ....................................................... 5 – 8 Installation ................................................................................................ 5 – 9

5

POWER TRAIN

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

Overhead Guard, Covers, Air Cleaner and Other Components

1 4

3 6

8 2 5 9 7

210745

Sequence 1 2 3 4 5

Overhead guard, Headlamps Steering wheel Seat Radiator cover Gas spring

6 7 8 9

5-1

Engine cover Floor plate, Floor mat Air hose, Air cleaner Fuel hoses (without LPG engine models)

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POWER TRAIN Suggestions for Removal 1. Overhead guard, headlamps 1

(1) Disconnect the headlamp harness connectors, then remove the overhead guard.

(2) Lift and remove the overhead guard using a hoist and slings as shown in the illustration.

Weight of overhead guard

70 kg (154 lb), approx.

2. Steering wheel 2

Remove the steering wheel referring to “GROUP 11 STEERING WHEEL.�

NOTICE: The steering shaft need not be removed.

3. Gas spring 5 and hood 6

!

WARNING

Be sure to hold open the engine cover when removing the gas spring. Failure to do so could result in your hands being injured by falling engine cover.

4. Floor plate and mat 7

Remove the floor plate and mat 7 together with the accelerator pedal.

5. Air hose, air cleaner 8

After removing the air hose and air cleaner 8, cover the intake port of the engine and the air cleaner in order to prevent dust and other foreign matter from entering them.

6. Fuel hose 9

Before removing the fuel hose 9, make sure to release the line pressure using service tool and close the cock on the fuel tank.

7. Harness connectors

The harness connectors disconnected from the socket and terminal on the engine and transmission should be attached to the main harness, in order to avoid damaging them.

5-2

210746

POWER TRAIN

Controls

3 2

4

4

6

5 1

1

210747

Sequence 1 2 3

Brake pipe Inching cable, Clevis pin, Washer, Snap pin Brake fluid reserve tank

4 5 6

Connector (Stop lamp switches) Pedal assembly Accelerator lever assembly

Suggestion for Removal

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

Inching cable

210748

5-3

POWER TRAIN

Batteries Structure 1 2 3 4 5 6 7

5

Fuse box Relay box Battery cable (negative) Battery cable (positive) Battery clamp, Clamp rod Battery, Battery case Battery seat

5 3 5 4

6

2 6 1

7 210749

Suggestions for Removal 1. Removing fuse box 1 and relay box 2

While opening the claws that lock the fuse box and relay box, raise and remove both boxes. Place the fuse box and relay box together outside the frame with the harnesses connected.

2. Removing battery cable 3, 4

Be sure to disconnect the negative (ground) cable first.

210750

5-4

POWER TRAIN

LPG system (Dual Fuel Gasoline and LPG Model) Structure 1 2 3 4 5 6 7 8

LPG tank Tank bracket LPG hose LPG pipe and Connector assembly Water hose LPG hose Water hose Vaporizer assembly

1

2

Start by:

(a) Drain the fuel of the line by running the engine with the valve on LPG tank shut off.

3

(b) Draining the coolant from engine by removing the drain plug. (c) Draining the coolant from the radiator by loosening the cock at the bottom of the radiator.

5

4

6

7

8

210751

5-5

POWER TRAIN

Cooling, Exhaust and Hydraulic

13

4

14

12

5

7 1

11 3 2 6

9 8 10 210752

Sequence 1 2 3 4 5 6

Reserve tank Hose (upper) Hose (lower) Return hose (between hydraulic tank and control valve) Suction hose (between hydraulic tank and oil pump) Delivery hose (between oil pump and steering control valve)

7 8 9 10 11 12 13 14

Cooler hose assembly (between radiator and powershift transmission) Cooling fan Fan belt Fan guard Shroud Radiator Oxygen sensor Exhaust pipe

Start by:

Suggestion for Removal

(a) Draining the coolant from the engine by removing the drain plug.

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

(b) Draining the coolant from the radiator by loosening the cock at bottom of the radiator.

5-6

POWER TRAIN

Front Wheel and Front Axle Shaft

2

1 3

210753

Structure 1

Wheel nuts

2

Front wheel

Refer to “GROUP FRONT AXLE” for removal and installation of each part.

5-7

3

Front axle shaft

POWER TRAIN

Engine and Transmission Assembly

1

4

6

5 3

2 210754

Sequence 1 2 3

Front axle mounting bolt Split pin Slotted nut

4 5 6

Start by:

Lifting the engine and transmission assembly with a hoist and slings.

Suggestion for Removal

Slowly lift the engine and transmission assembly 5 out by moving it backwards refrring to the balance.

Weight of engine and transmission assembly

315 kg (700 lb)

5-8

Engine mounting bolt Engine and transmission assembly Engine mount

POWER TRAIN

Installation Follow the removal sequence in reverse.

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 transmission assembly

315 kg (700 lb)

(c) While aligning the holes in the rubber cushions and those in the left and right engine supports, 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 places).

Rubber cushion

(e) Fasten each engine mounting bolt with the castle nut and lock the nut with the split pin.

Engine support

(2) Check that the clutch valve plunger is pushed out completely when the cable connected between the inching pedal and the transmission.

210755

Castle nut

(3) Bleed the air out of the brake fluid circuit after connecting the brake pipe.

(4) When installing the exhaust pipe, use a 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, front axle, and transmission with oils/coolant, and check for leakage. Unless otherwise specified, use distilled water mixed with LLC at a concentration of 35%.

!

WARNING

Antifreeze solution is TOXIC. In case of contact with your skin, FLUSH IMMEDIATELY WITH WATER. Have your MITSUBISHI fork lift truck dealer discard antifreeze solution drained from the engine.

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

(8) 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.

5-9

100899

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DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL