FJ —SEEE (FJX4W) Pub.No.00EHT0066, JANUARY 2015 Shop Manual All for oa Fuso varus Fuso muck 4oUsconeCOATENFJ (FuX4W) Shop Manual FOREWORD ‘This Shop Manual is published for the information and guidance of personnel responsible for maintenance of FUSO FJ series truck, and includes procedures for adjustment | 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 FUSO dealer or distributors. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. JANUARY 2015 Applicable models FUXAw ©2015 Mitsubishi FUSO Truck & Bus Corporation GROUP INDEX General Information Product Information Safety Table of Contents 4. Technical Specificati 2. ENGINE nner el Be Chest Piasssessesenssorsnnssenenenarsereanensesssanisemarcoremnrens SAD 4. G85 Transmission eecmnnnnnnnnennendel 5. Propeller Sha urnnrmnnnnnnnnnnen Sel 6. Front AXI@ ener 7. Rear Axle. 8. Wheels and Tyres... 9. Suspension. 10. Brakes. 11. Steering.. 12, Fram 13. CabiGeneral Information Introduction This workshop manual is designed to assist technicians to repair and maintain FUSO vehicles. Even before when a technician proceed to repair or maintain the vehicle or any of the aggregate it is important to know safety related aspects and information to perform the activity. This section of shop manual provides an insight about various safely signs used and general information on removal and installation, disassembly and assembly, inspection, adjustment and trouble shooting. Important Instructions Individuals who undertake repairs should have essential skills or training. Any repairs related to safety or critical items such as the steering, brakes, suspension or the supplementary restraint system should be carried out by a FUSO dealer/ certified technician only. Following correct service methods and repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual while carrying out the work. This manual cannot possibly predict all such variations and offer warnings or cautions as to each. Deviation from the instructions provided in this manual could lead to personal injury or damage to the vehicle. [== Notice “NOTICE” is used to highlight information that are important to the technician to properly complete the service procedure. “WARNING” indicates a potentially hazardous situation which if not avoided could result in death or serious injury. The danger, warming, caution and notice are included wherever it is required. Anyone using the service procedures or tools must make sure that neither personal safety nor vehicle safety is compromised. Illustration Callout and Indicator ine Callouts and Indicator lines are inserted into an illustration, when some details or part needs to be emphasized with action. Coen ICV. Osea “CAUTION” used with safety alert symbol indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury. Contents in the manual This manual contains the procedures for performing the required service operations. The procedures are separated into the following important topics. + Model and Serial Descriptions + Technical Specification + Construction Details Shop Manual - General Informationa S * Working Principle * Work tools Information + Troubleshooting * Service Procedure + Pe Model and Serial Descriptions This topic discusses the Model Number Description of each aggregate and location of the serial number on the aggregate and its description. Technical Specification This section gives the technical specification of the systenvcomponent. laintenance Schedule Construction Details This topic discusses the material, construction details and the fitment layout of an aggregate. Working Principle Working principle of an aggregate is discussed in this topic. Troubleshooting Chart Trouble shooting chart list downs the symptom of complaints, its probable cause and the corrective actions. Work Tools Information The work tools information lists down the tools used to repair an aggregate. Service Procedure Removal and Installation This section gives information on removal and refitment of components from a vehicle. Disassembly and Assembly This section gives information on disassembling and assembling a component and/or a system, wherever applicable. Torque Specification This section gives the torque values applicable to the specified components while tightening them, wherever applicable. Periodic Maintenance Schedule This topic lists down the various service check points for an agoregate and the frequency at which it needs to be serviced. Workshop Tools and Equipment It is essential that all tools and equipment are maintained in good condition. Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in fatal failure when the equipment is used another time. Do not use damaged tools or equipment, mainly high-speed equipment such as grinding wheels. The damaged grinding wheel can break up without warming and cause serious injury. Wear suitable eye protection when using the grinding or sand blasting equipment. Wear a suitable breathing mask when using the abrasive blasting equipment, working with asbestos-based materials or while using the spraying equipment. Make sure there is aclequate ventilation to control dusts, mists and fumes. Always maintain the tools, in a neat and good condition for quality repairs. Always Keep the tools and equipment calibrated. Guidance to safe working Always follow the safety instructions provided by the respective manufacturers for all the equipment, tools, safety gears etc. used in the workshop. Precautions for repairing a vehicle in the workshop When working on the vehicle in the workshop always follow the below mentioned procedures: + Make sure that the area has adequate ventilation to disperse exhaust gases such as. carbon monoxide and other fumes. + When the engine is running, use adequate ventilation or an extraction hose to remove exhaust fumes. + Make sure that the work area such as floors, workbenches, tools are clean and free from debris and clutter, * Be sure that all necessary tools and measuring equipment are available before starting any work. + Use FUSO Service Tools when required + Do not allow other people near the vehicle during servicing. they are Shop Manual - General Information* Always engage the parking brake and/or use wheel chocks to prevent the vehicle from moving, * Ensure there is adequate space around the vehicle to lift the vehicle and remove the wheels, if necessary. * Do not let fuel, coolant and other fluids spill over electrical and hot vehicle parts. * Avoid repeated contact with fluids. * The battery should be disconnected while, working on the engine, underneath the vehicle or if the vehicle is raised. * Cover seats and carpets, wear aprons and wash hands or wear gloves before working inside the vehicle. * Avoid spilling hydraulic fluid or battery acid on paint work. Wash off with water immediately on contact. Use Polythene sheets to protect carpets and seats. * Protect temporarily exposed screw threads by fitting plastic caps. * While using the welding equipment on the vehicle, keep a suitable fire extinguisher readily available. Preparation before Dismantling the Vehicle Parts * Clean components and surrounding area prior to removal. * Blankoff any openings exposed by component removal using grease proof paper and masking tape. * Using plastic caps or plugs immediately to seal fuel, oil or hydraulic lines when separated to prevent loss of fluid and entry of dirt. * Close the open ends of oil ways, exposed by component removal with tapered hardwood plugs or readily visible plastic plugs. * Before dismantling the component, clean it thoroughly with a recommended cleaning agent, Check whether the agent is suitable for all materials of the component. * After a component is removed, place it in a suitable container/tray. Use a separate container/tray for each component and its associated parts. Dismantling of the vehicle parts + Observe cleanliness while dismantling the components, particularly brake, fuel or hydraulic system parts. A particle of dirt or cloth fragment can cause dangerous malfunction if trapped inside the system. + Blow out all tapped holes, crevices, oil-ways and fluid passages with an air line. Ensure that any O-rings used for sealing are correctly replaced or renewed. + Use marking ink to identify mating parts and ensure correct reassembly, If a centre punch or scriber is used they may initiate cracks or distortion of components. + Wire the mating parts to prevent accidental interchange (e.g. roller bearing components). + Label parts which are to be renewed and those which require further inspection before reassembly. Place these parts in separate containers from those containing parts for rebuilding + Do not discard a part due for renewal until it has been compared with the new part, to ensure that its correct replacement has been oblained, Removal of Parts While correcting a problem, try to determine its root cause. Begin to work only after first learning which parts and subassemblies need to be removed and sssembled for replacement or repair. After removing the part, plug all holes and ports to prevent entering of foreign materials. Disassembly of Parts If the disassembly procedure is complex and requires many parts to be disassembled, all parts should be temporarily marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed with ease and efficiency. Inspection during Disassembly of Parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. Arrangement of Parts Al disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will Removal/ Shop Manual - General Information g Sbe reused. Cleaning of Parts All parts to be reused should be carefully and thoroughly cleaned by using the appropriate cleaning agent and method, Installation of Parts + Standard values, such as torques and certain adjustments, must be strictly adhered to while reassembling the parts + Parts such as cil seals, O-rings, Cotter Pins, Lock Washers, Nylon nuts ete should be replaced with new ones if removed. + Specified oiVlubricant should be ap the moving components or parts. + Specified oil or grease should be applied at the prescribed locations such as oil seals before reassembly. Adjustment of Parts Use recommended/appropriate gauges and testers while making adjustments. General Inspection + Never inspect a component for wear or mensional check unless it is absolutely clean. Slight smear of grease can conceal an incipient failure. + When a component is to be checked dimensionally against figures quoted for it, use correct equipment (surface _ plates, micrometers, dial gauges, etc.) in serviceable condition. Makeshift checking equipment is dangerous. * Reject a component if its dimensions are outside the quoted limits, or if damage is apparent. A part may however be refitted if its critical dimensions are given to the prescribed size limits, and is otherwise satisfactory. d to iy 4 Shop Manual - General InformationProduct Information Vehicle Identification Vehicle Identification Number The VIN is also punched on the left side of the frame which can be viewed from the gap between The VIN - Vehicle Identification Number is fixed in the front left side tyre and mudguard, all vehicles. The VIN is unique for every vehicle. VIN plate is fitted on the closing pillar of the codriver door. DAIMLER INDIA COMMERCIAL VEHICLES PVT LTD How to read Vehicle Identification Number (VIN) Pues mec QOIOOIO0B ep xxxxxx 6 6 db66 6 [| wnt word Manufacturer Kdentifen code U a Hy c ‘Medel 212: FIXAWJIR 4X2 Wheelbase 4500mm 214: FJXAWLIR 4x2 Wheelbase §100mm 216: FJXAWPIR 4x2 Wheelbase 6000mm Engine type & power J) 1: 6520, 170 KW DICy-GeN 7614 ‘Type of drive C: Right-hand drive S: Left-hand drive Month/ Year of manufacturing Plant code Vehicle serial number 4 Shop Manual - Product InformationA 2 Fa Engine The engine serial number plate is fitted on left hand side of the engine on the crankcase. Daimier India Commercial Vehicles Pvt.Ltd. Dicv.cen.2780 The engine serial number is also punched on the right side of the engine on the crankcase. picucen2re Vehicle model coding system ODAODOOOA OODOOOO®E FosoxK 4 WJ 4 R [| Basic veicie ype | F_ | Cab over tuck Gross vehicle 25 tons 2)) weight 4 x Wiath | 2280 mm (3) cab veriant x ~ Length | 1830 mm_ @] crassisstuctue [4 [axe Raid (@J Eroine moder | w | ese0 3 | 4500 mm 6) me (©) wheet base L_ | 5100 mm P| 6000 mm (TI ercrectess ft | row ~ Lf un (@) steesing | | R | RHD Shop Manual - Product Informationem Safety General Safety Accidents that occur during any kind of service procedures are mainly caused when the safety rules are not followed. Most of these accidents can be avoided if potentially hazardous situations are identified and proper precautions are. observed, The service technician should be aware of the following safety precautions and the possibility of hazards during service or maintenance. The technician should perform service or maintenance operation only after proper training and clear understanding of the service procedures of the vehicle to avoid serious personal injury or health hazard. The technician should use proper tools and equipment, in order to avoid personal injury or property damage. * A dust free environment is essential during overhauling equipments. n1ev.c1906-000) Service technicians must be alert to potential hazards during servicing the components. aa picy-ongo8-o00%] Service technicians must be efficiently trained to correctly perform the required functions of the aggregates. First aid kit and fire extinguisher should be kept near the working environment in order to be prepared for emergency or accidents. bicv-onga6 0009 Service technicians must be alert to potential hazards and efficiently trained to correctly perform any workshop operation and well trained to perform first aid in case of injury. 4 ‘Shop Manual - Safety3 8 * Wear a hard hat, protective glasses, and other protective equipment as required during service operation. 3 3 ae & Diev. 04906 000 * Avoid wearing loose clothing or jewelry that can get caught on controls or on other ‘components, * Service technicians should wear leather shoes during servicing the components in order to avoid absorption of chemicals and hazardous material, Dicv.01N906-000 Service technicians should wear aprons in order to protect themselves from corrosive liquids and grease during overhauling the equipments, bicv-on906 000d) ‘Avoid welding or soldering near charged high pressure pipelines. Flammable spray can be generated by heating near pressurized fluid lines. Failure to follow this instruction will result in severe burns to yourself and bystanders. bicv-omso6 cacy Never put maintenance fluids into glass containers. Glass containers are liable to break during usage. Do not attempt to remove the air compressor and/or the air lines until relieving pressure from the system. Failure to follow these instructions could cause serious personal injury, Make sure that the soles of shoes of the technician are free from dirt, grease, oil or moisture before using, 12 ‘Shop Manual - SafetyDe * Do not work on the aggregate until it is off and cooled down to atmospheric temperature, because the temperature within the system is extremely high. Failure to comply with this instruction will cause serious personal injury or even death. D1cv.010906 0004 * Search for leaks with a piece of a cardboard during testing high pressure pipelines. Protect hands and body from high pressure fluids, D1ev- 01906-0003 Continuous exposure to exhaust fumes can cause sickness or death. Ensure the workshop is properly ventilated in order to avoid inhaling poisonous gases. bicv-om906 oar Extreme care should be taken while working with heavy parts, Failure to follow will cause severe personal injury or death. Keep emergency numbers of doctors, ambulance service, hospital, and fire department near your telephone. Always park the vehicle ON’ position to avoid ace Move the vehicle when the parking brake is completely released (minimum of 6 bar pressure on the line). Chock the wheels with wheel stopper to prevent the vehicle from moving during overhauling, thus avoiding injuries and accidents. Cleaning of brake linings or clutch linings should not be carried out in open atmosphere. The dust from these components would affect our respiratory system. Pome ‘Avoid working under vehicle supported only with hydraulic jack. It should be supported with both tripod stand and hydraulic jack to ensure safety and avoid injuries. 13 ‘Shop Manual - Safety