FJ > (FJY1W) Pub.No.00EHT0046, APRIL 2014 Shop Manual All for you> mets) Sareee ‘MITSUBISHI FUSO TRUCK & 8US CORPORATIONFJ (FJY1W) 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 adjust- ment and maintenance services, We eamestly 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 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. APRIL 2014 Applicable models FuyaW ©2014 Mitsubishi Fuso Truck & Bus Corporation GROUP INDEX General Information Product Information Table of Contents G-85 Transmission... . Propeller Shaft . Rear Axle. . Wheels and Tyres ... 9. Suspension... 10. Brakes 11. Steering 12. Frame 13. Cabin. 14. HVAC, Interior and Exterior PNPOAP YN > 15. Electricals. Periodic Maintenance Scheduleee General Information Introduction This shop 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 safety 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 safely or critical items such as the steering, brakes, suspension or the supplementary restraint system should be carried out by a FUSO dealer/ cettified 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. “CAUTION” used with safety alert symbol indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury. 7 WUT “WARNING” indicates a potentially hazardous situation which if not avoided could result in death or serious injury. The danger, warning, 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. ena od Contents in the manual This manual performing the required service operations. The contains the procedures for procedures are separated important topics. + Model and Serial Descriptions into the following + Technical Specification + Construction Details Shop Manual - General InformationE> OOO * Working Principle * Work tools Information + Troubleshooting * Service Procedure * Periodic Maintenance Schedule 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 system/component. 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 agaregate 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 adequate 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 belore starting any work. + Use FUSO Service Tools when they are required, + Do not allow other people near the vehicle during servicing, + Always engage the parking brake and/or use wheel chocks to prevent the vehicle from moving Shop Manual - General InformationEP OOOO + 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 weer 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. + Blank-off 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 obtained. 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 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 Removal/Disassembly of Parts When removed, each part should be carefully inspected for malfunctioning, —_ deformation, damage, and other problems. Arrangement of Parts All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. disassembled for Shop Manual - General Information A z 8am 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 oil seals, O-rings, Cotter Pins, Lock Washers, Nylon nuts etc should be replaced with new ones if removed. + Specified oilMubricant should be applied to 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 dimensional 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. 4 Shop Manual - General InformationProduct Information Vehicle Identification Vehicle Identification Number The VIN - Vehicle Identification Number is fixed in all vehicles. The VIN is unique for every vehicle. VIN plate is fitted on the closing pillar of the co- driver door. vin Syren Pores The VIN is also punched on the left side of the frame which can be viewed from the gap between the front left side tyre and mudguard. aaa FHOT-006 Tea0s2 How to read Vehicle Identification Number (VIN) MEC OOOOOOD P xxxxxx Trai) JT - ® @C@O8 OO Q]Wii (World Manufacturer Wentifien) code ‘Model @)_ Biz: FAVIWNIR 6 = 2 Wheelbase 5850 mm 216: FIYIWTIR 6 x 2 Wheelbase 7050.min Engine type & power 1: 6520, 170 KW Type of drive Right-hand drive S: Left-hand drive ‘Month /Year of manufacturing Plant code Vehicle serial number Shop Manual - Product Informationz ra Aggregate Identification Engine The engine serial number is also punched on the right side of the engine on the crankcase. The engine serial number plate is fitted on left ° hand side of the engine on the crankcase. HOT.O1T po Vehicle model coding system DOOOMOOO® FJY1WN1R @ [Basic vehicle type |_F_[Cab over truck @ [Gross vehicle weight | J [25 tons With [2280 mm ab variant y Wah CO) aun Length | 2250 mm @ [Chassis structure | 1 [6x2 Rivid iis © |Enaine moder a eS Whee! base 2 T_|7050 mm © [Enaine class + [170 kW [LD Steering = 2 Shop Manual - Product Informationam Table of Contents 1. Safety. 1.1 General Safety.. 1.2 Environmental Safety and Disposal Procedure: 2. Engine. 2.1 Name Plate Locations of Engine Components 2.2 Location Of Engine Serial Number... 2.3 Technical Specification... 2.4 Construction Details ... 2.5 Working Principle... 2.6 System Circuits. 2.6.1 Air Intake and Exhaust System .. 2.6.2 Cooling System .... 2.6.3 Fuel System ... 2.6.4 Lubrication System ... 2.6.5 Engine and Exhaust Brake .. 2.6.6 Breather System .. 2.7 Schematics 2.7.1 Engine Electrical Schematics ., 2.7.2 Engine Electronic Schematics .... 2.8 Work Tools Information 2.8.1 Workshop Equipments . 2.8.2 Measuring Apparatus ... 2.8.3 Testing Equipments ... 2.8.4 Special Tools .... 1 Shop Manualam 2.9 Troubleshooting... 2.10 Removal and Refitment of Engine Assembly from Vehicle... 2.10.1 Engine Assembly Removal Procedure .. 2.10.2 Engine Assembly Refitment Procedure .... 2.11 Removal and Refitment of Sub-assemblies from Vehicle... 2.11.1 Air Intake System Removal and Refitment Procedure .... 2.11.2 Exhaust System Removal and Refitment Procedure ... 2.11.3 Cooling System Removal and Refitment Procedure .... 2.11.4 Fuel System Removal and Refitment Procedure ... 2.11.5 Engine Peripherals Removal and Refitment Procedure .. 2.11.6 Lubrication System Removal and Refitment Procedure ... 2.12 Service Procedure..... 2.12.1 Testing Procedure ... 2.12.2 Dismantling Procedure .... 2.12.3 Cleaning Procedure .. 2.12.4 Inspection Procedure .. 2.12.5 Non-reusable Items . 2.12.6 Reassembly Procedure 2.13 Sealant Details. 2.14 Torque Chart... 3. Clutch... 3.4 Technical Specification 3.2 Construction Details ... 3.3 Working Principle... 3.4 Work Tools Information... 3.5 Troubleshooting... 3.6 Service Procedure... 2 Shop Manualam 3.6.1 Inspection of Clutch Components on Vehicle . 3.6.2 Removal Procedure 3.6.3 Clutch Release Mechanism Removal Procedure .... 3.6.4 Refitment Procedure to Vehicle 3.6.5 Clutch Release Mechanism Refitment Procedure .. 3.6.6 Clutch Master Cylinder Removal and Refitment Procedure .... 3.6.7 Motorized Clutch Bleeding Procedure ... 3.7 Torque Chart .. 4. G-85 Transmission. 4.1 Model Description... 4.2 Location of G-85 Serial Number... 4.3 Technical Specification... 4.4 Construction Details.... 4.4.1 Gearbox ... 4.4.2 Gearshift Linkages .. 4.5 Working Principle... 4.6 Work Tools Information 416 4.6.1 Workshop Equipments . 4.6.2 Measuring Equipments .. 4.6.3 Special Tools ..... 4.7 Troubleshooting... 4.8 Transmission Assembly Removal and Refitment Procedure. 4.9 Gearshift Linkages Removal and Refitment Procedure .... 4.10 Service Procedure..... 4.10.1 Dismantling Procedure ... 4.10.2 Cleaning Procedure ... 4.10.3 Assembly Procedure .... 3 Shop Manual