---===SME_1007_00019_0001.djvu===--- Shop Manual chassis Pub.No.TWLE0607, FEBRUARY 2006 ---===SME_1007_00019_0001.djvu===--- Shop Manual chassis Pub.No.TWLE0607, FEBRUARY 2006 ---===SME_1007_00019_0002.djvu===--- GROUP INDEX GENERAL ............................................... CLUTCH .................................................. MANUAL TRANSMISSION <M10, M12>............................................. MANUAL TRANSMISSION <M120, M130>......................................... PROPELLER SHAFT.............................. FRONT AXLE .......................................... REAR AXLE ............................................ WHEEL AND TIRE.................................. FRONT SUSPENSION ............................ REAR SUSPENSION <SHACKLE LINK TYPE> ....................... REAR SUSPENSION <TRUNNION TYPE> ............................... BRAKE <AIR OVER HYDRAULIC BRAKE> ....... BRAKE <FULL AIR BRAKE> .............................. ANTI-LOCK BRAKE SYSTEM ............... PARKING BRAKE <CENTER PARKING BRAKE>............... PARKING BRAKE <WHEEL PARKING BRAKE> ................ STEERING .............................................. BUMPER AND FRAME........................... 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. FEBRUARY 2006 Applicable models FP, FV ©2006 Mitsubishi Fuso Truck & Bus Corporation ---===SME_1007_00019_0003.djvu===--- 00-1 GROUP 00 GENERAL 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 ........ 00-11 PRECAUTIONS FOR MAINTENANCE OPERATION ..................... 00-12 JACKING UP THE VEHICLE ........................................................... 00-22 DIAGNOSIS CODES......................................................................... 00-24 TABLE OF STANDARD TIGHTENING TORQUES ......................... 00-30 ---===SME_1007_00019_0004.djvu===--- 00-2 1 Basic vehicle type F Cab-over engine truck 2 Drive system P4 ×2 V6 ×4 3 Development sequential number 5 4 Suspension 1 Leaf suspension 5 Engine 5 8DC9 76 D 2 4 6 Wheel base F 3500 to 3800 mm G 3800 to 4100 mm H 4100 to 4400 mm J 4400 to 4700 mm K 4700 to 5000 mm L 5000 to 5300 mm M 5300 to 5600 mm N 5600 to 5900 mm P 5900 to 6200 mm R 6200 to 6500 mm S 6500 to 6800 mm T 6800 to 7100 mm U 7100 to 7400 mm V 7400 to 7700 mm 7 Chassis arrangement for use None Standard use D Dump use F Fire engine use MM i x e r R Semi trailer use 8 Engine type None Natural aspiration 1, 2 Turbo charged 9 Steering position L Left-hand drive vehicle R Right-hand drive vehicle 10 to 12 Export specification 1 7 4 35 2 9 810 6 FV5 15HRL 11 12 MODEL CODING SYSTEM ---===SME_1007_00019_0005.djvu===--- 00 00-3 Model code indica- tion in this manual Model code indication on name plate Code explanation Engine 6 D 2 6D24--T 1 Classification of turbocharger (T : with turbocharger) Intra-series sequence of development Sequence of development by series Diesel engine Number of cylinders (6 cylinders) 8DC 8 DC 9 Intra-series sequence of development Sequence of development by series Diesel engine Number of cylinders (8 cylinders) Clutch C8W40 C 8W40 Disc outside diameter Facing material (W: Woven, M: Cera-metallic) Typical load capacity (tonnage class) of vehicle Initial letter of "clutch" Transmission M10S5 M10S 5 Number of forward speeds Meshing (S: Synchromesh) Typical load capacity (tonnage class) of vehicle Initial letter of "transmission" M120S2 × 5 M120 S2×5 Number of forward speeds High-and-low two step Meshing (S: Synchromesh) Version number Typical load capacity (tonnage class) of vehicle Initial letter of "transmission" Propeller shaft P11 P11 Typical load capacity (tonnage class) of vehicle Initial letter of "propeller shaft" Front axle F090T F090 T Type of vehicle (T: Truck) Version number Typical load capacity (tonnage class) of vehicle Initial letter of "front axle" Rear axle R10TT R10T T Axle type (T: Tandem axle, D: Dead axle) Type of vehicle (T: Truck) Typical load capacity (tonnage class) of vehicle Initial letter of "rear axle" Reduction and differential D10HT D10HT Tandem axle 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_00019_0006.djvu===--- 00-4 DESTINA- TION MODEL NAME ENGINE CLUTCH TRANSMIS- SION PROPEL- LER SHAFT FRONT AXLE REAR AXLE REDUC- TION & DIFFEREN- TIAL GENERAL EXPORT FP517FDL 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517FDR 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517HL 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517HR 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517JFL 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517JFR 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517JL 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517JR 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517LFR 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517LL 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517LR 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517NL 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517NR 6D24 C8W40 M10S5 P11 F090T R10T D10H FV515JDCL 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515JDCR 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515JMCL 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515JMCR 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515MCL 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515MCR 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515MFCL 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515MFCR 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PCL 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PCR 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PFCL 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PFCR 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515SCL 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515SCR 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FP515GRL 8DC9 C12W43 M120S2 × 5 P12 F090T R12T D12H FP515GRR 8DC9 C12W43 M120S2 × 5 P12 F090T R12T D12H FV515HRL 8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) FV515HRR 8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) ECUADOR FV517HR2LNRA 6D24-T2 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) FV517JD2LNRA 6D24-T2 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) FV517P2LNRA 6D24-T2 C12W43 M120S6 P12/P8 F090T R10T(T) D10H(T) EGYPT FP517FDLBH1 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517HLBH1 6D24 C8W40 M10S5 P11 F090T R10T D10H ETHIOPIA FV517JD1LB9A 6D24-T1 C12W43 M120S6 P12/P8 F090T R10T(T) D10H(T) FV517HR1LB9B 6D24-T1 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) FV517JD1LB9B 6D24-T1 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV517JM1LB9B 6D24-T1 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV517P1LB9B 6D24-T1 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV517PP1LB9A 6D24-T1 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) KENYA FV515HRRB11 8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) POWER TRAIN TABLE ---===SME_1007_00019_0007.djvu===--- 00 00-5 SAUDI ARABIA FP517GR2LADA 6D24-T2 C12M41 M120S2 × 5 P13 F090T R12T D12H FP517HLADA 6D24 C10M39 M10S5 P11 F090T R10T D10H FP517JLADA 6D24 C10M39 M10S5 P11 F090T R10T D10H FV515JDLADA 8DC9 C12M41 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PLADA 8DC9 C12M41 M10S6 P12/P8 F090T R10T(T) D10H(T) FP517GR2LADB 6D24-T2 C12M41 M120S2 × 5 P13 F090T R12T D12H FP517HLADB 6D24 C10M39 M10S5 P11 F090T R10T D10H FP517JLADB 6D24 C10M39 M10S5 P11 F090T R10T D10H FV515JDLADB 8DC9 C12M41 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PLADB 8DC9 C12M41 M10S6 P12/P8 F090T R10T(T) D10H(T) GCC FP515GRLGSA 8DC9 C12W43 M120S2 × 5 P12 F090T R12T D12H FP517GR2LGSA 6D24-T2 C12M41 M120S2 × 5 P13 F090T R12T D12H FP517HLGSA 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517JLGSA 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517NLGSA 6D24 C8W40 M10S5 P11 F090T R10T D10H FP517NLGSB 6D24 C8W40 M10S5 P11 F090T R10T D10H FV515HRLGSA 8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) FV515JDCLGSA 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515MCLGSA 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PCLGSA 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PFCLGSA 8DC9 C12W43 M10S6 P12/P8 F090T R10T(T) D10H(T) TANZANIA FV515PPRBGA 8DC9 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) SOUTH AFRICA FP517GR2RBJ1 6D24-T2 C12W43 M130S2 × 5 P140 F090T R12T D12H FV517JD1RBJ1 6D24-T1 C12W43 M130S7 P140/P10 F090T R10T(T) D10H(T) FV517JR2RBJ1 6D24-T2 C12W43 M130S2 × 5 P140/P10 F090T R10T(T) D10H(T) FV517P2RBJ1 6D24-T2 C12W43 M130S2 × 5 P140/P10 F090T R10T(T) D10H(T) INDONESIA FV515KDCRDKA 8DC9 C12M41 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515KMCRDKA 8DC9 C12M41 M10S6 P12/P8 F090T R10T(T) D10H(T) FV515PCRDKA 8DC9 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) FV517HR2RDKA 6D24-T2 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) VENEZUELA FV517HR2LNGA 6D24-T2 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) PERU FP517J1LNFA 6D24-T1 C12W43 M10S5 P10 F090T R10T D10H FV517JD1LNFA 6D24-T1 C12W43 M120S6 P12/P8 F090T R10T(T) D10H(T) DESTINA- TION MODEL NAME ENGINE CLUTCH TRANSMIS- SION PROPEL- LER SHAFT FRONT AXLE REAR AXLE REDUC- TION & DIFFEREN- TIAL ---===SME_1007_00019_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 understanding. HOW TO READ THIS MANUAL ---===SME_1007_00019_0009.djvu===---