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POWER TRAIN

1. Specifications

6-2

2. Structure

6-3

3. Reduction ratio

6-5

4. Removal and Installation of Engine and Transmission Unit

6-6

4.1 Preparation

6-6

4.1.1 Draining Oil and Coolant

4.2 Removing cover

4.2.1 Removal sequence

4.3 Removing Harnesses

4.3.1 Suggestions for Removal

4.4 Radiator (transmission oil cooler), Pipes and Hoses

4.4.1 Removal sequence

4.5 Other removing

4.5.1 Removal sequence

4.6 Removal of Engine and Transmission Unit

4.6.1 Suggestions for Removal

6-6

6-7

6-7

6-8

6-8

6-9

6-9

6-10

6-10

6-11

6-11

6
6

4.7 Installation

6-12

4.7.1 Installation sequence

6-12

4.7.2 Suggestions for Removal

6-12

4.8

Capacity

6-14

 

6-1

POWER TRAIN

1. Specifications

 

Truck model

P17500

P20000

 

Type

3-element, 1-stage, 2-phase

Torque converter

Maker model

MN16

Stall torque ratio

2.51

 

Operation method

Forward/reverse switching electrical column shift, 1st, 2nd, 3rd, automatic drive

   

1st: 2.402

Forward

2nd: 1.010

Transmission

Gear ratio

3rd: 0.558

 

1st: 2.402

Reverse

2nd: 1.010

3rd: 0.558

Reduction gear

Gear type

Hypoid gear

Reduction ratio

 

5.142

Final drive

Gear type

Planetary gear

Reduction ratio

4.235

 

Housing type

Banjo

Differential

Gear type and num- ber

Large

Straight bevel gear × 2

Small

Straight bevel gear × 2

Front axle type

Full-floating, tubular

Front axle suspension method

 

Fixed to frame

POWER TRAIN

2. Structure

12 11 17 6 4 1 3 2 5 7 8 18 14 10 15
12
11
17
6
4
1
3
2
5
7
8
18
14
10
15
9
16 13

205670A

1 Engine

2 Flywheel

3 Torque converter

4 Transmission

5 Input shaft

6 Forward clutch shaft

7 Reverse clutch shaft

8 1st and 3rd clutch shaft

9 Output shaft

The power transmission system, which serves to transmit power produced by the engine to the drive wheels, consists of the following components. (1) Torque converter 3 The torque converter itself not only works as a clutch but also transmits the increased engine torque to the transmission. (2) Transmission 4 This is a device to change the revolving speed and direc-

10 Speed sensor gear 11 Pump drive gear 12 Hydraulic pump 13 Universal joint 14 Parking brake 15 Front axle 16 Reduction differential 17 Final drive 18 Wheel brake

tion of universal joint from those which are derived from the engine operation. (3) Universal joint 13 Transmits power from the transmission to the reduction differential. (4) Reduction differential 16 Not only reduces the speed but also distribute the power to right and left drive wheels. It also functions as to prevent slipping by differentiating

POWER TRAIN

two (right and left) drive wheels in terms of their num- ber of rotation, when they have a difference in the rotat- ing speed as the result of vehicle's turning to the right or left. (5) Final drive 17 Final reduction system using planetary gears.

POWER TRAIN

3. Reduction ratio

(39) (58) (58) (54) (17) (55) (35) (34) (58) (46) (59) (35) (24) (7) (58)
(39)
(58)
(58)
(54)
(17)
(55)
(35)
(34)
(58)
(46)
(59)
(35)
(24)
(7)
(58)
(36)
(32)
(53)
(56)

205670B

( ) indicates number of teeth.

   

Reduction bevel

   

Truck model

 

Transmission

gear

Final drive

Total gear ratio

 

1st

2.402

( 35/34 × 58/58 × 58/58 × 56/24 )

   

52.318

Forward

2nd

1.010

( 35/34 × 53/54 )

22.007

3rd

0.558

( 35/34 × 58/58 × 58/58 × 32/59 )

5.142

4.235

12.161

 

1st

2.402

( 35/34 × 58/58 × 56/24 )

( 36/7 )

( 55/17 + 1 )

52.318

Reverse

2nd

1.010

( 35/34 × 58/58 × 53/54 )

22.007

3rd

0.558

( 35/34 × 58/58 × 32/59 )

12.161

PTO reduction ratio: 0.907

POWER TRAIN

4. Removal and Installation of Engine and Transmission Unit

Both the engine and transmission should be removed as a unit.

4.1 Preparation 4.1.1 Draining Oil and Coolant Engine coolant Engine coolant drain plug drain plug
4.1
Preparation
4.1.1 Draining Oil and Coolant
Engine coolant
Engine coolant
drain plug
drain plug
Engine oil drain plug
Transmission oil
drain plug
211787

Drain engine oil, transmission oil and engine coolant.

POWER TRAIN

4.2 Removing cover 4 1 3 5 2 211788
4.2 Removing cover
4
1
3
5
2
211788

4.2.1 Removal sequence

(Raise the tiltable cab.)

1 Gas-filled cylinder

4

Exhaust pipe

2 Engine cover

5

Radiator cover

3 Middle cover

POWER TRAIN

4.3 Removing Harnesses

Torgue converter oil thermo-unit Transmission solenoid Travel speed sensor Starter relay Battery Oil by-pass alarm
Torgue converter oil
thermo-unit
Transmission
solenoid
Travel speed sensor
Starter relay
Battery
Oil by-pass alarm
Glow plug
Alternator
Engine oil pressure
switch
Engine thermo-unit
211789

4.3.1 Suggestions for Removal

The harness connected to the engine and transmission should not be completely removed but partially discon- nected at the sockets and terminals. Then, lay it along the main harness to which it is retained so as not to be dam- aged.

POWER TRAIN

4.4 Radiator (transmission oil cooler), Pipes and Hoses

2 4 3 5 1 6 10 8 11 9 7 12 8 14 15
2
4
3
5
1
6
10
8
11
9
7
12
8
14
15
13
211790

4.4.1 Removal sequence

1 Delivery hose

2 Suction hose

3 Intercooler inlet hose

4 Intercooler outlet hose

5 Radiator upper hose

6 Radiator lower hose

7 Exhaust pipe

8 Air inlet hose

9 PCV valve hose 10 Air cleaner hose 11 Compressor inlet hose 12 Compressor outlet hose 13 Fuel hose 14 Oil cooler outlet hose 15 Oil cooler inlet hose

POWER TRAIN

4.5 Other removing

1 3 2 4
1
3
2
4

211791

4.5.1 Removal sequence

1 Propeller shaft

3

Thrust rod (2 parts)

2 Universal joint

4

Cushion (4 parts)

POWER TRAIN

4.6 Removal of Engine and Transmission Unit

211792

211792

4.6.1 Suggestions for Removal

Fasten a hoist to the engine and transmission unit with wire ropes hitched to two lifting eyes on the engine and a sling chain hitched to one eye on the transmission while placing a levelling block under the unit. Adjust the length of the chain sling with the lever block so that the unit is horizontal. Then slowly lift the unit while moving it backward to remove in the upward direction.

Weight of engine and transmission unit

900 kg

(1984 lb)

POWER TRAIN

4.7

Installation

4.7.1 Installation sequence

Install in the reverse sequence of the disassembly proce- dure.

4.7.2 Suggestions for Removal

(1) When mounting the engine and transmission unit on the frame, position it on the mounting brackets such that the universal joint in front of the unit is aligned with the transmission output flange.

(2) Tighten the mounting bolt to the specified torque.

Ref.

Item position

Tightening

No.

Torque

   

145 N•m

1

Cushion rubber and mounting bolt

(14.8 kgf•m)

[107 lbf•ft]

   

60

N•m

2

Mounting bracket bolt

(6.1 kgf•m)

[44 lbf•ft]

   

97

N•m

3

Cushion rubber bolt

(9.9 kgf•m)

[72 lbf•ft]

   

60

N•m

4

Mounting bracket bolt

(6.1 kgf•m)

[44 lbf•ft]

Output shaft Output flange 205457 Engine mount(left shown,right opposite) 4 1 3 206171
Output shaft
Output flange
205457
Engine mount(left shown,right opposite)
4
1
3
206171

Transmission mount(right side)

1 2 3
1
2
3

206172

POWER TRAIN

(3) When installing the engine exhaust pipe, use a new gasket. (4) Make sure that all wires have been connected properly, and then fasten the ground (negative) battery cable to the corresponding terminal. (5) Refill the engine oil, engine coolant, and transmission oil respectively and check for any water or oil leakage. For concentration of antifreeze in coolant, consult your Cat lift truck dealer. (6) Also bleed the engine fuel lines. (7) After checking every part, start the engine and observe its running condition. If the engine vibrates exces- sively, retighten the engine mounting bolts to see if this retightening has an effect. Additionally, operate the mast, forks and steering to check for the level of hydraulic oil, and refill it if necessary. Also check the engine oil, coolant and transmission oil levels, and refill each if necessary.

Transmission mount(left side)

1 2
1
2

3

206173

POWER TRAIN

4.8

Capacity

 

Fuels and Oils

 

Oil Brand

 

Capacity

 

M

Lift long-life coolant

 

Antifreeze

(Genuine Mitsubishi Fuso Dia Queen) long-life coolant

18

Liters

(4.7 U.S. gal.)

Torque converter

Diamond ATF

   

23

Liters

oil

DEXRON II

(6.1 U.S. gal.)

Gear oil (differential gear, front axle final gear)

Diamond firm gear oil B API category, Multi-purpose type GL-5 SAE90, 80

 

20

Liters

(5.3 U.S. gal.)

Brake oil

ENEOS brake fluid FMVSS DOT3 or DOT4

   

240 cc

Hydraulic oil

M

(Genuine Mitsubishi Fuso hydraulic Oil) ISO VG32

Lift hydraulic oil

Level gauge

(N) mark

 

131

Liters

(34.6 U.S. gal.)

 

JIS Extra Grade 3 (-15 ˚ C or lower) JIS Grade 3 (-5 to -15 ˚ C) JIS Grade 2 (higher than -5 ˚ C)

 

175

Liters

Fuel

(46.2 U.S. gal.)

 

M

Lift diesel engine oil

Engine body: 12 Liters (3.2 U.S. gal.)

Oil filter:

(Genuine Mitsubishi Fuso Engine Oil Special) API category CD class or higher

Engine oil

SAE 10W or SAE 10W30 (-10 ˚ C or lower) SAE 20W (-10 ˚ C to 10 ˚ C) SAE 30 (higher than +10 ˚ C)

Total:

4 Liters (1.0 U.S. gal.) 16 Liters (4.2 U.S. gal.)