---===SME_1007_00011_0001.djvu===--- Shop Manual chassis Pub.No.TWSE0611, AUGUST 2006 ---===SME_1007_00011_0001.djvu===--- Shop Manual chassis Pub.No.TWSE0611, AUGUST 2006 ---===SME_1007_00011_0002.djvu===--- GROUP INDEX GENERAL ............................................... CLUTCH .................................................. MANUAL TRANSMISSION..................... TRANSFER ............................................. PROPELLER SHAFT .............................. FRONT AXLE <RIGID LEAF SUSPENTION (FB, FE)> ........................ FRONT AXLE <RIGID LEAF SUSPENTION (FG)> ............................... FRONT AXLE <INDEPENDENT SUSPENTION (FB)> ............................... REAR AXLE ............................................ WHEEL AND TIRE.................................. FRONT SUSPENSION <RIGID LEAF TYPE> ........................................... FRONT SUSPENTION <INDEPENDENT TYPE (FB)> ............................................. REAR SUSPENSION .............................. BRAKE .................................................... ANTI-LOCK BRAKE SYSTEM (ABS) .... PARKING BRAKE................................... STEERING <MANUAL GEAR> .............. STEERING <POWER STEERING (Except FB70)>....................................... STEERING <POWER STEERING (FB70)> .................................................. BUMPER, FRAME AND REAR BODY ... CAB MOUNTING AND TILT ................... DOOR ...................................................... EXTERIOR .............................................. INTERIOR................................................ HEATER, AIR-CONDITIONER AND VENTILATION ................................ FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso truck, and includes procedures for adjust- ment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage. For more details, please consult your nearest authorized Mitsubishi Fuso dealer or distributors. Kindly note that the specifications and maintenance ser- vice figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. AUGUST 2006 Applicable models FB, FE, FG ©2006 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan ---===SME_1007_00011_0003.djvu===--- 00-1 GROUP 00 GENERAL VEHICLE MODEL CODING SYSTEM ............................................... 00-2 EQUIPMENT MODEL CODING SYSTEM ......................................... 00-3 POWER TRAIN TABLE ..................................................................... 00-4 HOW TO READ THIS MANUAL ........................................................ 00-6 CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE ....... 00-10 PRECAUTIONS FOR MAINTENANCE OPERATION ..................... 00-12 JACKING UP.................................................................................... 00-22 DIAGNOSIS CODES 1. Connecting Multi-Use Tester-II ................................................. 00-24 2. Accessing / Erasing Diagnosis Codes ...................................... 00-25 TABLE OF STANDARD TIGHTENING TORQUES ......................... 00-28 ---===SME_1007_00011_0004.djvu===--- 00-2 1 Basic vehicle type F Cab-over engine truck 2 Load capacity, drive system B 1.5tonclass,4×2 E 2tonclassandover,4×2 G 2tonclassandover,4×4 3 Cab type 7 Standard-width cab 8W i d e c a b 4 Vehicle variations, Suspension 0 Independent front suspension Light duty vehicle (Playload from 1500 kg) 1 Rigid axle Light duty vehicle (Payload 1500 to 2000 kg) 3 Rigid axle Light duty vehicle (Payload 1500 to 3000 kg) 4 Rigid axle Light duty vehicle (G.V.M. 6000 to 6900 kg) 5 Rigid axle Light duty vehicle (G.V.M. 7000 kg or more) 5 Engine A 4M40, 4M40T C4 D 3 3 P 4D34, 4D34T4, 4D34T5, 4D34T7 6 Wheelbase B FB, FE 2500 mm C FE 2750 mm FG 2860 mm D FE-Z 2910 mm E FE 3350 mm FG 3460 mm G FE 3850 mm FE-Z 3870 mm H FE-Z 4170 mm 7 Chassis arrangement for use None Standard use D Dump use N Straight frame ZW i d e f r a m e 8 Rear tire arrangement, Payload 0 Lowest deck/rear double Playload from 1500 kg 4 Rear double Payload 2000 kg 6 Rear double Payload 3000 kg to 4000 kg 8 FB Rear single Payload 1500 kg FE Rear single Payload 2000 kg 9 Vehicle specification None Standard use S With turbocharger WC r e w c a b 10 Steering position L Left-hand drive vehicle R Right-hand drive vehicle 1 7 4 35 2 9 810 6 FE7 1PB VEHICLE MODEL CODING SYSTEM ---===SME_1007_00011_0005.djvu===--- 00 00-3 Model code indication in this manual Model code indication on name plate Code explanation Engine 4M40T 4 M 4 0 T With turbocharger Intra-series sequence of development Sequence of development by series Diesel engine Number of cylinders (4 cylinders) 4D34T4 4 D 3 4 T 4 Power version number With turbocharger Intra-series sequence of development Sequence of development by series Diesel engine Number of cylinders (4 cylinders) Clutch C3W28 C 3 W 28 Disc outside diameter Facing material (W: Woven) Typical load capacity (tonnage class) of vehicle Initial letter of "clutch" Transmission M025S5 M 025 S 5 Number of forward speeds Meshing (S: Synchromesh) Typical load capacity (tonnage class) of vehicle Initial letter of "transmission" Propeller shaft P2 P 2 Typical load capacity (tonnage class) of vehicle Initial letter of "propeller shaft" Front axle F200T F 200 T Type of vehicle (T: Truck) Typical load capacity (tonnage class) of vehicle Initial letter of "front axle" Rear axle R020T R 02 0 T Type of vehicle (T: Truck) Intra-series sequence of development Typical load capacity (tonnage class) of vehicle Initial letter of "rear axle" Reduction and differential D2H D 2 H Tooth form (H: Hypoid gear) Typical load capacity (tonnage class) of vehicle Initial letter of "differential" in reduction and dif- ferential EQUIPMENT MODEL CODING SYSTEM ---===SME_1007_00011_0006.djvu===--- 00-4 Vehicle model Engine Clutch Transmission Propeller shaft Rear axle Reduction & differ- ential FB70AB0S 4M40T C2W26 M015S5 P2 R010T No.7 FB71AB8 4M40 C2W26 M015S5 P2 R015T D1H FE71PB8 4D34 C3W28 M025S5 P2 R020T D2H FE71PBD4 4D34 C3W28 M025S5 P2 R020T D2H FE71PBN4 4D34 C3W28 M025S5 P2 R020T D2H FE71PBNS 4D34T5 C3W28 M025S5 P2 R020T D2H FE73PB6 4D34 C3W28 M025S5 P2 R020T D2H FE73PE6 4D34 C3W28 M025S5 P2 R020T D2H FE83PC6 4D34 C3W28 M025S5 P2 R020T D2H FE83PC6SLGP 4D34T5 C3W28 M025S5 P2 R030T D3H FE83PC6SRDEA 4D34T5 C3W28 M025S5 P2 R020T D2H FE83PCD6 4D34 C3W28 M025S5 P2 R020T D2H FE83PE0SRDEA 4D34T5 C3W28 M025S5 P2 R020T D2H FE83PE6 4D34 C3W28 M025S5 P2 R020T D2H FE83PE6S 4D34T5 C3W28 M025S5 P2 R020T D2H FE83PE6W 4D34 C3W28 M025S5 P2 R020T D2H FE84PC6 4D34 C3W28 M025S5 P2 R020T D2H FE84PC6LADA 4D34 C4W30 M035S5 P3 R030T D3H FE84PCD6LGSA 4D34 C4W30 M035S5 P3 R030T D3H FE84PE6 4D34 C3W28 M025S5 P2 R020T D2H FE84PE6LADA 4D34 C4W30 M035S5 P3 R030T D3H FE84PE6LNG1 4D34 C4W30 M035S5 P3 R033T D033H FE84PE6S 4D34T4 C4W30 M035S5 P3 R033T D033H FE84PE6SLNF 4D34T5 C4W30 M035S5 P3 R033T D033H FE84PE6WLGSA 4D34 C4W30 M035S5 P3 R030T D3H FE85CDZLADA 4D33 C4W30 M035S5 P3 R040T D040H FE85CGZ 4D33 C4W30 M035S5 P3 R040T D040H FE85CHZ 4D33 C4W30 M035S5 P3 R040T D040H FE85CHZLADA 4D33 C4W30 M035S5 P3 R040T D040H FE85PC6 4D34 C4W30 M035S5 P3 R035T D035H FE85PE6 4D34 C4W30 M035S5 P3 R035T D035H FE85PG6 4D34 C4W30 M035S5 P3 R035T D035H FE85PG6RBJ1 4D34 C4W30 M025S5 P3 R035T D035H FE85PG6S 4D34T4 C4W30 M035S5 P3 R035T D035H FE85PG6SLNF 4D34T5 C4W30 M035S5 P3 R035T D035H FE85PG6SRBJ1 4D34T4 C4W30 M035S5 P3 R035T D035H FE85PG6SRDE 4D34T7 C4W30 M035S5 P3 R035T D035H FE85PHZSLNR 4D34T4 C4W30 M035S5 P3 R040T D040H FG83PC6 4D34 C3W28 M035S5 Front : P2 Rear : P3 R030T Front : D1H Rear : D3H FG83PE6 4D34 C3W28 M035S5 Front : P2 Rear : P3 R030T Front : D1H Rear : D3H FG83PE6W 4D34 C3W28 M035S5 Front : P2 Rear : P3 R030T Front : D1H Rear : D3H FG84PE6RBJ1 4D34 C3W28 M035S5 Front : P2 Rear : P3 R033T Front : D1H Rear : D033H POWER TRAIN TABLE ---===SME_1007_00011_0007.djvu===--- MEMO 00-5 00 ---===SME_1007_00011_0008.djvu===--- 00-6 This manual consists of the following parts: Specifications Structure and Operation Troubleshooting On-vehicle Inspection and Adjustment Service procedures On-vehicle Inspection and Adjustment Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de- scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedure Procedures for servicing components and parts off the vehicle are described centering on key points in their re- moval, installation, disassembly, reassembly, inspection, etc. Inspection Check items subject to "acceptable/unacceptable" judgement on the basis of service standards are all given. Some routine visual checks and cleaning of some reused parts are not described but must always be included in actual service work. Caution This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: Terms and Units Front and rear The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred to as the rear. Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right. Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. DANGER Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives. WARNING Precautionary instructions, which, if not observed, could result in serious injury or death. CAUTION Precautionary instructions, which, if not observed, could result in damage to or de- struction of equipment or parts. NOTE Suggestions or supplementary information for more efficient use of equipment or better understandings. HOW TO READ THIS MANUAL ---===SME_1007_00011_0009.djvu===---