f-S (EuRO3) (FUX3W) Pub.No.00EHT0080, AUGUST 2015 Shop Manual All for you> Fuso oo neu no av BU oRPORTN| FJ (EURO3) (FJX3W) Shop Manual FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of FUSO Fi 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 oF distributors. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be elfected trom time to time in the future AUGUST 2015 Applicable models FuxXaWK2L ©2015 Mitsubishi FUSO Truck & Bus Corporation GROUP INDEX General Information Product Information Safety Table of Contents 4, 6131 Transmission 5. Propeller Shaft .. 6. Front Axle 7. Rear Axi 8. Wheels and Tyre: 9. Suspension. 10. Brakes. 11, Steering. 12, Frame 13, Cabi 14, HVAC .. ing System ic Maintenance Schedul| 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 satety signs used and general information on removal and assembly, inspection, adjustment and trouble shooting. installation, disassembly and Important Instructions Individuals who undertake repairs should have essential skills or training. Any repaits 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/ 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 (0 highlight information that are important to the technician to properly complete the service procedure. “WARNING” indicates 2 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 ine Callouts and Indicator lines are inserted into an illustration, when some details or part needs to be emphasized with action. Indicator ns ev. cLaasa “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Co Mm, + 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 ite deseription Technical Specification ives 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 Informat 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 relitment 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 aggregate 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 crinding 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 tor 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 they are required. + Do not allow other people near the vehicle during servicing. Shop Manual - General Information+ Always engage the parking brake and/or use wheel chocks to prevent the vehicle trom 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 othor 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, keop a suitable fire oxtinguishor readily available Preparation before Dismantling the Vehicle Parts * Clean components and surrounding area prior {0 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 di + Close the open ends of vil ways, exposed by component removal with tapered hardwood plugs or readily visible plastic pluys. + 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, partic hydraulic system parts. A particle of dirt or cloth fragment ean dangerous ‘malfunction if trapped inside the system. larly brake, fuel or + Blow out all tapped holes, crevices, oilways 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 (0.9. roller bearing components) + Label parts which are to be renewed and those which requi 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 disassembled for replacement or repair, After removing the part, plug all holes and ports to prevent entering of foreign materials. Disassembly of Parts Hf the further inspection before issembly procedure is complex and jes many parts to be disassembled, all parts should be temporarily marked in a place that will nol 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 All disassembled parts should be carefully arranged. for reassembly. Be sure to separate or otherwise idontiy tho parts tobe replaced from those that will Removal/ Shop Manual - General Information q cy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 auliered to while reassembling the parts. + Parts such as oil seals, O-rings, Cotter Pins, Lock Washers, Nylon nuts ete should be replaced with new ones if removed. + Specified oillubricant should be applied to the moving components or parts. + Specified the prescribed. loc: belore reassembly Adjustment of Parts Use recommended/appropriate gauges and testers while making adjustments. General Inspection + Never inspect a component for wear or imensional 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. or grease should be applied at s such as oil seals + Reject a component if its dimensions are outside the quoted limits, or if damage is apparent. A part may however be refitted i its critical dimensions are given to the prescribed size limits, and is otherwise satistactory. 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 codriver door, DAIMLER INDIA COMMERCIAL VEHICLES PVT LTD TYPO OGDOIONK VIN( MEG XXX0X00000C = Dicv.geN2765 Dicv-cEN-2614] The VIN is also punched on the left side of the frame which can be viewed from the aap between the front left side tyre and mudguard. cv-sen20s How to read Vehicle Identification Number (VIN) MEC P XXXXXX b b dd466 ‘WMI (World Manufacturer Identifier) code Model DAL:FIXSWKAL 6x 4 ‘Wheelbase 4950 mm Engine type & power ©loeo 2: 6520, 208 KW ‘Type of drive B: Right-hand drive Re Lefthand drive ‘Month’ Year of manufacturing Plant code Ae © Vehicle serial number (= Wy Shop Manual - Product InformationSerta Aggregate Identification Engine The engine serial number plate is fitted on left hand side of the engine on the crankcase DICV.GEN2730 The engine serial number is also punched on the right side of the engine on the crankcase. DICv-GEN-2796] Vehicle model coding system DOO®OOO®D FJX3WK2L Basic vehicle type F Cab over truck O (J sian @]cowin — | x (| Chassis structure [3 | 64, Construction [@) Frame woant | w fen (| wheel base K | 4950mm [@)[frmeams | 2 Pron (Ce) Steering L | LHD Shop Manual - Product Information| 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. Dicv-00N906-000) + Service technicians must be alert to potential hazards during servicing the components. waa Dicv.0Mv06-000 + Service technicians must be efficiently trained to correctly partorm the requ the aggregates. red functions of + First aid kit and fire extinguisher should be kept near the working environment in order to be prepared for emergency or accidents, Cec — Dicv.0§906.0004 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. Shop Manual - Safetyra 6 + Wear a hard hat, protective glasses, and other protective equipment as required during service operation. a = 0 OO & Dicv.00906.000 we & & + 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, icv-o0906-0005 Service technicians should wear aprons in order to protect themselves from corrosive liquids and grease during overhauling the equipments, Dicv.0Ms06-000 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. Dicv.ows06.9007 into glass liable to Never put maintenance fluids containers. Glass containers are 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, Shop Manual - SafetyMm, * 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.0109906 0009 + Search for leaks with a piece of a cardboard during testing high pressure pipelines. Protect hands and body from high pressure fluids. vicv-owvve 0005 Continuous exposure to exhaust fumes can cause sickness or death, Ensure the workshop is properly ventilated in order to avoid inhaling poisonous gases. Dicv.0M906. 0010 Extreme care should be taken while working with heavy parts, Failure to follow will c: severe personal injury or death. Keep emergency numbers of doctors, ambulance service, hospital, and fire department near your telephone. Always park the vehicle with parking brake in ‘ON’ position to avoid accidents. Mave the vehicle when the parking brake is completely released (minimum of 6 bar prassure on the lina). Chock the wheels with wheel stopper to prevent the vehicle from maving during overh: injuries and accidents. ng, thus avoiding Cleaning of brake linings or clutch finings: should not be carried out in open atmosphere. The dust from these components vould affect our respiratory system. 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. Keep the Adblue away from other operational fluids such as coolant, engine oil, transmission oil, hydraulic oil and brake oil and not to be used in same containers and collecting pans, if mixed with a small amount of Adblue — can damage the functional components like thermostats, sensors etc, Shop Manual - Safety Cec| Environmental Safety and Disposal Procedure Introduction Environmental safety should be considered before disposing any waste component in order to avoid land/ain/water pollution and health hazards. The aggregates should be operated, serviced and repaired in environmental friendly responsible DIcv.00906.0018 The procedures associated with aggregates. maintenance and repair, may cause physical or health hazards and other risks to environment. Precautions should be strictly followed to avoid these hazards. Environment Care During Operation The components have been designed and incorporated with certain features considering the environmental care, lo ensure environmental compatibility throughout their life cycle. The following conditions should be adhered during vehicle operation, in order to avoid polluting the environment. + Do nat keep the engine in idle state for long duration, + During initial warm up of engine ensure that the engine is not in idle speed more than 2 to 3 minutes, + Switch off the engine during long waiting periods imposed by operations. + Strictly follow the practical guidance given to the truck operators and drivers, in order to reduce fuel consumption and emission of gases. + The coolants are biodegradable substances, so carefully dispose the coolants according to waste water disposal regulati Environment Care During Service The technicians can contribute tothe environmental protection by handling or maintaining the components in a proactive manner during service and repair, Ensure that tho used components aro disposed under the condition of not affecting the environment, surroundings and human beings. It is the responsibility of the end user to identify the hazardous material by reading the labol on cach product, and to ensure appropriate and legally acceptable mothod of disposal. + The technicians must be aware of environmental hazards before overhauling aggregates. + Carefully dismantle the aggregates after lubricant or coolant draining process, and dispose the waste according to local or government rules and regulations. + Clean the aggregates in a designated washing area, Carefully dispose empty packaging and used cleaning materials in environmentally rosponsiblo manner, + Do not dispose the parts such as battery, used gaskets, oll containers (empty or with used oil), etc, that are replaceable in the course of regular maintenance, along with the house hold waste + Do not use food or beverage container to drain the oil. Failure to follow the instruction may mislead someone to drink the oil by mistake. + Remove the filter and drain the fueVoil for 24 hours to ensure that the fuel has boon completely removed. + Spilled Adblue can be flushed away with sufficient water into the sewage system ‘without any problems due to its good biodegradability. Shop Manual - SafetyMm, + The incorrect disposal of used components will cause damage to the land and aquatic environments. Recycling Recycling of used water from vehicle wash area would reduce the risk of contamination of land and water resources. However, it is important to follow the proper method of recycling and adhere to local administrative regulation. > a Cen D1cv.00906-0013 Legal Aspects The workshops should comply to all the health and safety laws and regulations within the country, which are published by both national and local authorities, The laws and regulations relating to environmental safety in the use and disposal of materials and equipment in a workshop should be strictly followed, to maintain a safe working environment and to avoid environmental pollution. ° Shop Manual - Safety1 Technical Specification Engine Engine Description The technical data provided below is applicable to the engine at ambient conditions +25°C/1013 mbar. Please note that the deviations by variants/options are possible in the data provided. ry Peery Compression Ignition, four stroke, direct injection, Turbocharged inter Type cooled engine Model 6520 No. of Cylinders 6 Cylinders Bore mm | 102 Stroke mm | 130 Displacement cc | 6370 Compression Ratio (of) . Pressure te Firing Order 153-624 Direction of Rotation (View From Flywheel) Counterelockwise Direction Air Intake System Turbo charged with Charge air cooling (air/ain) Turbocharger Turbocharger with Wastegate Combustion Process Direct Diesel Injection Injection Pump Unit Injection Pumps, mounted on Crank Case Cooling System Re-circulated Coolant Valves 2 Inlet Valves and 1 Exhaust Valve for each Cylinder Gear Drive Located at Flywheel End Belt Drive System Y-ribbed Single Belt with Automatic Belt Tensioner Engine Brake System Constant Throttle Valve with Exhaust Brake Valve 4 ‘Shop Manual - Technical SpecificationPower, Torque i ess Rated Power Kw @ 2200rpm 205 Torque, max. Nm @ 1200-1600rpm 1100 Low Idling Speed 600 Maximum no Load Speed 2750 Dimension, Weight Dimension according to the engine type = a Length: mm | 1074 co = , = EB | Weignt-bry Ke | 800 EM Charge Air System i SL BM | Charge Air Pressure (Over pressure, stat) aller Turbocharger i — cae ia = Cooling System a Thermostat - Begin of Opening vc | 83 Full Opening at sc | 95 Pressure Cap Opening Pressure Bar 1 it it Non AC - 12.5L coolant + 12.5 water Coolant Capacity Utes | Ac. 13.8 coolant + 13.9L water Coolant Grade FUSO genuine coolant Temperature differ and outlet, Max. \ce between Engine inlet Coolant temperature, Max. °c | 95 12 ‘Shop Manual - Technical SpecificationLubricating System ron Pee Engine oil Capacity (max. Litres | 26.30 Engine Oil Filter Capacity (max) Litres Engine Oil Grade SAE 1540 Oil Pressure al Engine Operating Temperature and Low Idle, min. | 0.5 Bar Auxiliaries oy Pee Alternator - Output Voltage V Starter Motor - Voltage v | 24 Starter Motor- Rating Kw 4 ‘Air Compressor cc | 318/water cooled Electrical System v | 24 Clutch Clutch Cover Assembl Y Dry - Single plate, Hydraulic actuated control with servo assistance Clutch type Clutch diameter mm | 396: ich Dise ; " Organic Facing material Facing thickness mm | 10.6 Friction contact sutace | a4 ‘Actuation Hydraulic operated with Pneumatic assistance (Fork operated! ‘Actuation type " Ps ‘ * 2 Fluid tank capacity ml | 400 Oil Grade DOT3 Master cylinder size mm | 26.125/35 13 ‘Shop Manual - Technical SpecificationBooster size Clutch fluid grade DoT Pedal Travel mm | 140 Clamp Load N_ | 21000 G 131 Transmission Model Gist Input Torque Nm | 1300 Oil Grade ‘SAE 80 / SAE 80W - 85W / SAE 90 (Rored EPA) FR © Capacity liters | 37 page E Weight Ke | 210 (without oil) FAM | Housing intertace SAE 1 and SAE 2 ME | Gear Shitt Assist Mechenica/Pneumatie Shift System eg Gear Ratios Crawler 1457 1 0.478 ond 6.635 a 4.821 an 3.687 sh 2.585 ah 1.81 im 1.315 ath 1.00 Reverse 13.862 “Revers Idler Gear Teeth's - 18 14 Shop Manual - Technical SpecificationPropeller Shaft rot Perera Tube outside diameter mm | 120 Tube thickness mm |4 No. of propeller shaft 2 Wheelbase mm | 3600 Length of propeller shaft mm | 1730.5 Length of propeller shaft mm | 5135 Front Axle Model 1F-6.6 Type Reverse elliot Capacity ka | 6000 Steering angle of inner wheel ° | 48 Steering angle of outer wheel ° | 335 King pin inclination “le King pin spacing mm | 1790 Camber angle ofa Wheel track mm | 2040 ‘Axle Beam Dimension mm | 100% 90x 17 Drop mm | 50+8 Spring track mm | 840 King pin diameter mm | 4 Hub No. of wheel mounting studs 10 Hub Bearing Construction Tapper roller - 2Nos, Hub Grease 395 g/ Hub 15 ‘Shop Manual - Technical Specification| Rear Axle Rear Axle-1 Model IRT 390 Type Fall floating, Topoid gears Capa hg | 10,200 ‘Axle housing dimension mm | 160% 135 (HxW) Differential lock Inter-wheel as a standard fitment ABS Optional Coupling flanges D180 KV with serrated flanges EM | Ratio 4778 E Oil grade SAE 80W90 / SAE 90 (Rored HDA) i ll Capacity liters | 11 (SAE BOWS0) / 14 (SAE 90) BM Rear Axie—2 Fy Model 1R 390 r Type Full Floating Capacity ka 10200 Oil grade SAE 80W90 / SAE 90 (Rored HDA) Oil Capacity liters 11 (SAE BOW90) / 14 (SAE 90) Hub Grease 200 g/ Hub Wheels and Tyres rend Pee Tyre and disc wheels Single front and dual rear Tyro sizo 11.00 x 20, 16 PR ‘Ture type Cross ply, tube ‘Tread pattern Front Rib Rear (driven axle) Lug 16 Shop Manual - Technical Specificationrend Rear (non-driven axle) Lug Number 1" Disc Wheel Type - offset - thickness 7.80 x 20- 165-13 ‘Type of construction 3 piece Spare tyre Rib type mounted at LH side of chassis ‘Tyre pressure (kPa) - Laden Single tyre (cross ply/radial) 795/830 Twin tyre (cross ply/radial) Rear tyre -1 = 550/590 Rear tyre~2 = 585/620 Tyre pressure (kPa) - Unladen Single tyre (cross ply/radial) 520/520 ‘Twin tyre (cross ply/radial) Rear tyre -1 = 520/520 Rear tyre-2 = 525/520 Wheel Rim Run Out Chart Rim size 75x20 Suspension Front Suspension System Front Spring ‘Type Parabolic tapered profile leaf spring No. of leaves 4 Dimension (span x thickness x width) 1800 x 23 x 90 Shock absorber Hydraulic double acting Anti-roll bar Provided as standard fitment re ‘Shop Manual - Technical SpecificationRear Suspension System reas Perrine Rear Spring Inverted Semi Elliptic Bogie) - Multi leaf spring Type Rear spring -1 (No. of leaf x span xthickness) 12. 1350 x 20% 100 Rear spring -2 (No. of leaf x span xthickness) Radius rod at bottom 2 Nos for each rear axle ‘Anti-roll bar position Rear of the last drive axle Brakes Fm | Parameters Ea | Brake type Full air Scam Dual Circuit Fam | Lining grade RAF 7 (BM) Lining width mm — | 180 Standard Size 16.5 Useful lining thickness mm Oversizeliner 11.5 Brake Lining to Brake Drum oto 14 Clearance mm Lining area/brake Sqm | 1183 Service Brake Front Brake size 410x180 Rear Brake size 410 «160 Front chamber size Type 24 Rear 1 chamber size Type 24/24 Rear 2 chamber size Type 20/24 Parking Brake Spring actuated on rear both axles with graduated hand control valve at cab) Air tank capacity 35435419 Air compressor capacity 23860 18 ‘Shop Manual - Technical SpecificationItem Peer Air dryer Air dryerwith inbuilt unloader valve Air line Nylon tube with Voss Connections ABS Optional Steering Steering column Telescopic and tilt steering column with steering lock, hydraulic power assisted Steering gear Tyee Integral power assisted Model ZF/Rane TRW) '8046/HFB 72 Ratio (7F/Rane TRW) 22.4/042 Operating pressure bar | 130/150 Steering wheel diameter mm — | 500 Steering Pump Vane pump Type Flow Ipm | 16 Maximum pressure bar | 150 Steering Oi Type DEXRON Il/ Ii Oil capacity 3.5L ‘Supplier Gulf ATF MX Frame Peering Type Dimensions (Side member) Ladder type channel section with cross members Depth mm | 284 Flange mm | 70 Thickness mm | 9 Width of frame at front mm | 900 18 ‘Shop Manual - Technical Specificationgq a 2 ie Cea Width of frame at rear mm | 760 Towing pin (front) Removable type FUPD Integral part of frame front end Chassis Grease (Including 118 kingpin) Capacity a Chassis Groase (Inclu NLGI-2 kingpin) Oil grade Lisoap base Cabin Dimension (Lx Bx H) mm | 2250 x 2490 x 2960 Cabin Berth Type Day Tilt angle dogrocs | 67° Cab Tilt Type Hydraulic Assisted — Fully tiltable tyoe Cab Interior Colour Appearance Dual toned (Grey/ Black) Ventilation Blower with forced circulation Seat adjustments Backrest reclining, Forward-Backward sliding and variable Driver Seat height position Co-Driver Seat Foldable recline seat Wind shield Glass PU coated Sleeper berth Cushion type Cab Body col Bright red, Active yellow, Artic white, Golden brown, Portside ‘ab Body colours Blue, Coral Orange Cab Tilt Oll Capacity mi | 300 Cab Tilt Oil grade DEXRON 1/1 HVAC Air mass flow rate 14 kg/min Cooling Refrigerant R134a (Tetratluroethane - CF3CH2F) 110 ‘Shop Manual - Technical SpecificationRefrigerant Capacity 1.2kg Refrigerant temperature 40°C to + 135°C Air Cond AC performance The internal cab temperature must be down from 40°C to 25°C. within 10 minutes Gonoral operating tomporaturo Windshield defrost 40°C to 90°C (am ) 10 minutes after test start 80% of area A ace. EU 78/317(AIS 084 ‘when implemented) must be defrosted, 20 minutes after test start 95% of area B ace. EU 78/317 (AIS 084 when implemented) must be defrosted Windshield demist 5 minutes after test start 90% of area A acc. EU 78/317 (AIS 084 ‘when implemented) must be dried. 5 minutes after test start 90% of area B acc, EU 78/317 (AIS 084 when implemented) must be dried. AC OnOff Switch ‘Temperature Control Knob HVAC Controls Mode Control Knob [Blower SpeedControlKnob [acvet Electricals oy pT Starter System Voltage V 28 Current A 35/80 Relay Series Internal Resistance 24.20 ohm Charger System Voltage V 24 Rating Kw a 1 ‘Shop Manual - Technical Specificationren Ceca Battery Voltage V 2x12 Current Ab 120 Tipping System ry Peer Make HYVA Cylinder: HYVA FE 129 Floor 6mm-ST52 ‘Sidewall 4mm-ST52, g Head board 4mm-ST52 Fl | Std Body Capacity (16 cu.m) & Dimension (L x B x H) m | 4.82% 2.3 x 1.46, EB sta Body Capacity 14 cum) iH Dimension (L x B x H) m = 4.82x23x 1.3 Tipping Oil Capacity liters | 5 Tipping Oi! grade vee + Technical ation 12| 2 Engine 2.1 Name Plate Locations .. 2.2 Location Of Engine Serial Number. 2.3 Construction Details... 2.4 Working Principle... 2.5 System Circuits... 2.5.1 Air Intake and Exhaust System 2.5.2 Cooling System. 2.5.3 Fuel System 2.5.4 Lubrication System . 2.5.5 Engine and Exhaust Brake... 2.5.6 Breather System. 2.6 Schematics 2.6.1 Engine Electrical Schematics 6 # 2.6.2 Engine Electronic Schematics.. 2-35 2.7 Work Tools Information .. 2.7.1 Workshop Equipment . 2.7.2 Measuring Apparatus . 2.7.3 Testing Equipment.. 2.7.4 Special Tools. 2.8 Troubleshooting... 2.9 Engine Assembly Removal and Refitment Procedure. le. 2.10 Removal and Refitment of Sub-assemblies from Vel 2.10.1 Air Intake System Removal and Refitment Procedure 2.10.2 Exhaust System Removal and Refitment Procedure. 2.10.3 Cooling System Removal and Refitment Procedure. 2.10.4 Fuel System Removal and Refitment Procedure 2.10.5 Engine Peripherals Removal and Refitment Procedure 2a ‘Shop Manual - EngineCf 2.10.6 Lubrication System Removal and Refitment Procedure. 2.11 Service Procedure. 2.11.1 Testing Procedure...... 2.11.2 Disassembly Procedure. 2.11.3 Cleaning Procedure... 2.11.4 Inspection Procedure... 2.11.5 Non-reusable Items 2.11.6 Assembly Procedure. 2.12 Guidelines for Attending Toppled Vehicle 2.13 Sealant Details ... 2.14 Torque Chart... 22 ‘Shop Manual - Engine2.1 Name Plate Locations Alternator Engine ECU picv-om9oe-1473 28 ‘Shop Manual - EnginePower Steering Pump picv-ompoe- 1479 2a ‘Shop Manual - Engine2.2 Location Of Engine Serial Number picv-omgo0 038 Diesel Engine Power Output in Kw Emission ECU Version DE 170 BS3/ 0-00 400 . 950 D XXXXXXX Engine Serial Number Location of Manufacturing Plant Model Type DIcv-oMo05-08814 26 ‘Shop Manual - Engine Pee cg2.3 Construction Details Crankcase picv-omeoe.0015 Cylinder Head bicvompo6.0014 + Engine has a compact and noise optimized crankcase, + The Liner less, crankcase is of High carbon cast iron alloy. * Crankcase with top surface induction hardened increases the life. + Crankcase supports crankshaft and Side mounted camshait + Unit injection pumps are mounted on crankcase and operated by camshaft lobes and lubricated by engine oil, + Fuel and oil passages are integrated in the crankcase ensures leak free circuit and avoids external routings. + Engine is supported on chassis with 2 front mounts integrated to cranks case near 2nd cylinder wall, externally. + In addition to fly wheel, the timing gears, air compressor and starter motor is housed in the rear crankease and flywheel housing. Cylinder head made of grey cast iron is mounted over the crankcase with a gasket and secured with cylinder head bolts. to withstand the high pressures during compression & combustion an unique three layer integrated gasket head gaskets is provided along with four head bolts for each cylinder. This eliminates rettightening of head bolts during its ideal life cycle. + Cylinder head made of cast Iron + Cylinder head machined with a compact 4 valve ports & one nozzle port per cylinder. + 2 Intake valve, one exhaust valve and one constant throttle valve ensures fuel efficient engine with high power & de-compression during rapid braking. + 3 Layer integrated head gasket is provided for better sealing, + Cooling passages around valves and injectors provides better cooling. 26 ‘Shop Manual - EngineCrankshaft viev.om906.0017 Camshaft Connecting Rod otsan| picv-omvos.oni5 + Crankshaft made of forged steel translates ocating 1 of piston to rotary motion of Flywheel + Crankshaft journals and the fillet radius are induction hardened, + Trimetal bearing shells used for journals on stressed sides, * Counter weights are crankshaft and balanced, integrated with + Oil passages are drilled on crank journal to crank pin for lubricating connecting rod bearings. + Damper is mounted to crankshaft to roduco vibration. + Thrust washers provided on rear end journal to control end play. + Trtmetal bearing bearings. shell used as journal + Camshaft is made of forged steel and lobes are case hardened. + Camshaft is mounted inside the crankcase on. seven journals with bush bearing, + Three cam lobes are provided for every cylinder to operate Intake valves, exhaust valve and operate constant throttle valve. + Camshaft also operates fuel teed pump which is mounted on its front end through a drive pin. Connecting rod is of forged steel and is located in between the piston and crankshaft. The small end is located in the piston with a fully floating piston pin and the big end bearing is coupled with crankshaft with half shell bearings. an unique technology is used to manufacture the big end of the connecting rod. The big end is made in circular shape and then split at a predetermined fractured line called “cracking” process, * Connecting rod is made of forged steel which connects the piston and crankshaft, * Big end of connecting rod is manufactured in a circular shape and then split based on a predetermined fractured line called as “cracking” process. + Connecting rod small end is coupled with piston through a fully floating piston pin and the big end to the crankshaft with a shell bearing 2a ‘Shop Manual - Engine roEngine ECU (MR Controller) c1cv.0m906-0020) Fuel Injection Pump (FIP) T Piston and Piston Rings vicv.om906 0022 + Engine ECU also called as MR Controller controls the engine function based on inputs from various sensors. + It is mounted on LH side of engine assembly between unit pump and engine mount. + It controls the fuel delivery and timing based on the inputs received, + Ensures smoother performance and optimizes the variation in between cylinder, + It has an inbuilt solf diagnostic feature and ensures function of engine being unaffected. + The fault is displayed on the instrument panel and an alert pops up as fault code. ‘+ The fault code can be diagnosed and rectified. + Fuel injection system has a individual unit pump for each cylinder mounted on the top LH side of the crankcase. + Unit pumps are connected to the injectors through high pressure pipes and delivery tube, + Unit pumps are driven by camshaft and lubricated by engine oil. ‘+ Maximum pressure during delivery is 1800 bar. + Fuel is injected into the combustion chamber through 6 spray holes of an injector. + The quantity of the fuel and exact timing of \iection is decided by the MR control u + Pistons are made of aluminum alloy to withstand high temperatures. + Piston crown and piston skirts are graphite coated for botter lubrication, + Pistons have 3 ring grooves, for two compression rings and one oil scraper ti + The first ring groove is reinforced to withstand high pressures and temperatures. + Piston pin support is trapezoidal in shape to withstand pressure loads. Groove 1: Compression ring is made out of cast iron keystone with plasma spray of chrome- ceramic, spherical lapped. Groove 2: Compression ring with oil-scrapper action is chrome plated taper faced rina with internal angle at the bottom. Groove 3: Oil scraper ring is chromo plated and taper outer face with garter springs in the middle, 28 ‘Shop Manual - EngineTurbocharger + Turbocharger is a centrifugal air pump driven by the engine exhaust gases. + Mounted on RH side of engine on the exhaust manitold + Turbocharger draws the fresh air charge, compresses and delivers to the engine inlet manifold through an intercooler + It has a turbine wheel which is operated by exhaust gases and a compressor wheel to compress the fresh air charge. Both the wheels are coupled on to @ common shalt which is supported on bush bearings and lubricated by engine oil + Awaste gate is provided to optimise the turbo charger turbine wheel speed and the boost pressure, + At higher engine speeds the waste gate valve opens allowing the partial flow of exhaust gases directly to the exhaust pipe. Valve Train * Valve train consists of camshaft operated tappets, push rods, valves, rocker arms, rocker il shafts etc, * Each cylinder of engine has two inlet valve, one exhaust valve and a constant throttle — engine brake valve operated hydraulically + A floating valve bridge links and actuates both the inlet valves together. Diev.oMs06.0029 Engine Brake + Engine has a constant throttle valve in the cylinder head. x + A.small vahve is mounted on the cylinder head f facing into the combustion chamber operated by engine oil prossuro. * Constant throttle valve is hydraulically operated based on the condition that the engine speed is above 900 rpm, Exhaust brake switch is in ‘ON’ condition ‘and whon the accelerator or clutch pedal is not pressed + A constant throttle solenoid receives. the signal from FR controller and allows the prossurizod engine oil to oporato the engine brake valve. + When constant throttle valve is opened, the fuel injection is discontinued and’ the combustion is stoppod. As tho oxhaust brake flap valve is in closed condition the deceleration is very effective. Diev-owvoe-0024 28 ‘Shop Manual - Engine PorExhaust Brake Exhaust brake assists in vehicle braking when switched on by the operator Exhaust brake cylinder with butterfly valve is mounted on the exhaust pipe from turbocharger When all conditions (clutch engaged, _ transmission engaged, engine RPM more than 900RPM) are satistied FR controller sends signal to exhaust brake solenoid which supplies pressurized air from auxiliary tank to exhaust brake cylinder The butterfly valve blocks the exhaust gas flow from turbocharger, creating a back pressure which slows down the engine. viev.omsv6.0029 Oil Filter The oil filter housing is installed on the top - right hand side of the engine. The oil filter housing consists of oil filter element, drain valve, filter bypass valve and oil retention valve. When the oil filler cover is removed, oil in the filter tlows back to the oil sump through the drain valve. Drain valve Drain valve is located below the oil filter element and opens when the oil filter cap is opened allowing any oil in the filter to flow back to the oil sump. This allows a clean filter replacement by draining oil from the filter housing. fer Bypass Valve The filter bypass valve is located on the top dome of the filter insert. It is normally in the closed position, It allows (opening pressure 1.8-2.6 bar) the unfiltered oil to flow through the main oil gallery when the oil filter is blocked or clogged. This allows engine lubrication at all times even if filter is choked. Oil Retent The oil retention valve (opening pressure 0.03 - 0.07 bar) prevents oil from flowing back to the oil sump when the engine is stopped. This ensures the oil ducts are always filled with oil, thus providing efficient lubrication to all engine components when engine is restarted. Fuel Filter Engine uses a conventional fuel filter for better filtration of fuel. It is mounted on the top - left hand side on the crankcase. Before fuel is supplied to the unit pumps from the fuel pump it enters the fuel filter where it is filtered. A throttle in filter prevents formation of valve lock when the engine is turned off. n Valve 240 ‘Shop Manual - Engine2.4 Working Principle Overview of Engine Engine is a 900 series 6 cylinder In-line, direct Injection, turbo charged diesel Engine with electronically controlled fuel injection system, which meets BS Ill emission norms, that gives maximum power output and torque. an ‘Shop Manual - EngineGeneral Working Principle In Engine, like any other 4 stroke 6 cylinder diesel engine, the fresh filtered charge air is supplied/provided by the wastegate turbocharger and charge air cooler. To achieve better volumetric efficiency the charge air is fed through a double intake valve which is operated by the side cam mechanism during the suction stroke, This unique camshaft which is mounted on the crankcase actuates twin intake valve, exhaust valve and the unit injection pump of each cylinder. o1ev.014906.0027 22 ‘Shop Manual - EngineMm, At the end of compression stroke, atomized fuel is injected into the combustion chamber to develop very high thrust on the pistons to perform the power stroke. The exhaust aas drives the turbine of turbocharger and the noise reduced exhaust gas is allowed to the atmosphere safely. The engine exhaust system is also fitted with an exhaust brake to control the vehicle speed during down hill operation and rapid braking. o1cv.o1906 0074 248 ‘Shop Manual - Engine‘A closed crankcase ventilation type breather system recycles the blow by gas, which is treated for Separation of engine oil and the residual fumes at the chamber. The un-burnt fuel fumes are re- circulated and allowed into inlet manifold to get mixed with fresh air charge. This helps in reducing the pollutants for cleaner emission, icy. oMgas.0029} Another unique feature is the constant throttle valve mechanism intearated to the cylinder head which acts as an engine brake system. A solenoid actuated, hydraulic operated small poppet valve opens automatically during rapid braking to vent out the compressed charge instantaneously there by reducing the piston speed. Exactly at this moment, the engine MR control unit stops further injection, so that the fuel is not wasted. This decompression effect increases the braking effect thereby allowing the driver to stop the vehicle within a shortest possible extent. 246 ‘Shop Manual - Engine2.5 System Circuits 2.5.1 Air Intake and Exhaust System... 2.5.2 Cooling System 2.5.3 Fuel Syste 2.5.4 Lubrication System 2.5.5 Engine and Exhaust Brake. 2.5.6 Breather System. 6 a 245 ‘Shop Manual - Engine| 2.5.1 Air Intake and Exhaust System ‘Air intake system of the vehicle ensures supply of clean air to the engine for combustion and exhaust system forms a safe passage for the exhaust gases tv pass out of the system afler combustion. — 4 l= \ T te | — rH ' u t : | mspoo one Lo —— > | rerepan TRAE Wan t t Dicv.owpoe. 1872 246 ‘Shop Manual - Engine| | Main Components 1. Snorkel 5. Intake Manifold 2. Air cleaner housing 6. Exhaust Manifold 3. Turbocharger 7. Silencer 4. Charge air cooler Front arill of snorkel profile does not allow any heavy dust particles and water in the incoming atmospheric air to enter the system. Water and dust separation happens in the dirty side piping and air cleaner Separated water and dust are collected and expelled to atmosphere through the evacuator valves available fon dirty side piping and air cleaner, Clean air is let to turbocharger through the clean side piping. Restriction indicator mounted on the air cleaner housing outlet port informs the operator if filter elements are clogged. Air entering the turbocharger is compressed and sent to charge air cooler for cooling, cooled air then flows to combustion chamber during intake stroke through intake manifold. After combustion, exhaust gases exit the engine during exhaust stroke and flows oul to alimusphere through exhaust manifold and silencer pipes through turbocharger. o1ev.o1906. 1233 247 ‘Shop Manual - Engine2.5.2 Cooling System Cooling System Overview Cooling system maintains the engine operating temperature. Cooling System Circuit H A A scan eg picv-00906-0031 248 ‘Shop Manual - EngineMain Components 1. De-aeration tank 4, Thermostat 2. Radiator 5. Oil cooler 3. Water pump 6. Coolant temperature sensor Initial Filling When coolant is filled in the de-aeration tank it flows to radiator bottom tank and water pump through make-up line, This bottom-up filling pushes any air molecules in the system to exit to atmosphere through the pressure relief valve in the de-aeration tank. During Running Coolant drawn from radiator bottom tank is pumped to cylinder block by water pump. Oil cooler mounted on RH side of the cylinder block gets coolant circulation to cool the engine oil circulating between the fins of oil cooler. Coolant then flows around cylinder and then to cylinder head, for cooling. After absorbing heat from engine components, coolant from cylinder head flows to thermostat mounted at the top of water pump. Depending upon the coolant tomperature, thermostat opens or closes the by pass port Thermostat Closed (Coolant Temperature < 80°C) When coolant temperature is below 80°C thermostat stays closed and coolant is recirculated to engine. 249 ‘Shop Manual - Engine PeeThermostat Open (Coolant Temperature > 83°t0 93° C) Dicv.01906-003 When coolant temperature is above 80°C thermostat starts to open the passage to radiator and partially blocks the bypass port, allowing partial flow of coolant to radiator top tank for cooling and opens fully when the coolant temperature reaches 93°C. A coolant hose mounted on water pump supplies coolant to air compressor, coolant outlet trom air compressor is directed to cylinder head. 2.20 ‘Shop Manual - Engine2.5.3 Fuel System The fuel system injects precise amount of atomized and pressurized {uel into the engine cylinders, at regular intervals for combustion process. port Dicv.omgn6.0032 ‘Shop Manual - Engine 221Main Components 3. Fuel filter 1. Fuel tank with fuel float unit 4, Unit Pumps 2. Primary Filter/Water Separator 5. Fuel Injectors Fuel Flow Process When fuel feed pump operates, the fuel inside the fuel tank is drawn through the suction strainer and flows into the fuel filter cum water separator. It separates any water content present in the fuel and settles down in the transparent bowl. Any dust particles present in the fuel are filtered by the filter cartridge. Filtered fuel then flows to the filter which is integral part of the main filter - mounted on the engine block, where dust particles are removed. Then the fuel is drawn into the fuel feed pump and the pressurized fuel is delivered to main filter, where fine dust particles are removed. The fuel is then delivered to Electronic Unit pump through fuel supply ral Fuel delivery quantity and ining are controlled by unit injection pump based on the input signal received from engine ECU (MR control unit). The high pressure fuel pipe carries the fuel to the injector nozzles Unough a delivery pipe, mounted on the cylinder head. Fuel is injected (al nozzle opening pressure of 220- 330 bar) into the combustion chamber at 1600 bar pressure in an atomized state for proper combustion. The fuel leak off from injectors and unit pumps return (o main filter through fuel return rail and then flows back to the fuel tank. Main filter stem has drain holes to drain out the fuel in the casing when the filter is being removed Fuel filter casing inlet and outlet pipes are fitted with plug-on valves, wl hoses are being removed. 1 avvid fuel leakage when the Fuel float uni the fuel tank senses the level of fuel in the tank and notifies the operator of the fuel level 22 ‘Shop Manual - Engine2.5.4 Lubrication System Ty Dicv-0M1906-0033| 2.28 Shop Manual - EngineMain components 1. Oilsump. 9. Oil pressure switch 2. Oil strainer 6. Oil temperature sensor 3. Oil pump 7. Oilfilter assembly 4. Oil cooler System Overview The oil pump is driven by the crankshaft gear The oil pump draws oil from oil sump through an oil strainer which performs the first stage of filtration, il then passes through the oil cooler located on the right side of the crankcase, where the oil is allowed to pass through the cooler plates where heat transfer to coolant occurs. Thus the engine oil is cooled and maintained at required temperature (engine operating temperature). Oil temperature sensor mounted on the oll cooler inlet passage measures the temperature of the engine oll and sends the input signal to the engine ECU (MR controller). Cooled oil from oil cooler outlet passage flows to oil filter for further filtration, Filtered oil then flows to the main oil gallery. Oil from main oil gallery is fed under pressure into the crankshaft main bearing and camshaft bushing through the internal passage in the crankcase for lubrication. Oil flows to connecting rod bearing through drilled passages in crankshaft, Engine oil is supplied to oil spray nozzles from the main oil gallery, in order to cool the piston from the bottom. Oil pressure switch fitted on the main oil gallery measures the oil pressure and indicates the operator if the oil pressure is low. Engine oil thon flows from the main oil gallery to the auxiliary gallery, air compressor and cylinder head. Auxiliary gallery supplies oil to fuel injection pumps for lubrication and constant throttle valve solenoid to operate engine brake, Oil flows to rockor arm assembly through internal passages in crankcase and cylinder head for lubricating the valve train components. Engine oil then flows back to the oil sump, through the oil roturn holes in the cylindor hoad and crankcase. o a Main oil gallery also supplies oil to turbocharger for lubricating turbo shaft bearings. A drain passage and drain line alloyrs oil to return to the oil sump after passing through the turbo bearings. A bypass valve fitted in the oil filter housing in normally closed position. Bypass valve directs oil to main oil gallery if oil filter clogs and the oil pressure reaches P2 to ensure engine is lubricated at all times, The pressure relief valve located under the vil puinp opens: if the oil pressure exceeds the allowable pressure P1 Wd allows the oil to flow back to the oil sump, The oil retention valve (opening pressure - P3) is placed in the oil filter housing and is intended to prevent the engine oil in the oil ducts from flowing back into the oil sump when the engine is stopped. The oil ducts are therefore always filled with oil. When the engine is restarted, this ensures that components always receive optimal lubrication immediately. 228 ‘Shop Manual - Engine2.5.5 Engine and Exhaust Brake Engine is equipped with an engine and exhaust brake in addition to conventional wheel brakes. Engine brake Is mounted over each cylinder in cylinder head. It consists of a piston and valve assembly operated by hydraulic pressure. These brakes are operated by the operator if required through a switch available in the dash board. It is used to activate and deactivate engine brake. When the operator switches on the engine/exhaust brake switch, a signal is sent to engine ECU (Electronic Control Unit) which energizes the solenoid, Exhaust brake is mounted near the turbocharger. It consists of an exhaust brake cylinder which operates a butterfly valve mounted inside the front exhaust tail pipe. An exhaust brake solenoid operates the exhaust brake cylinder. When the engine/exhaust brake switch is activated, a signal is sent to the vehicle ECU (FR Control Unit) which energizes the exhaust brake solenoid. If the following three conditions are satistied. + Gear should be in engaged position. + Clutch should not be pressed (engaged position). + Engine RPM should be above 900 RPM. 228 ‘Shop Manual - EngineEngine Brake System Dicv-om906-0034) Main Component Constant throttle solenoid valve System Overview When constant throttle solencid valve is energized by engine ECU (MR controller) oil from auxilia gallery is allowed to flow to constant throttle valve piston through the loop connection hose, which is mounted near fourth cylinder on the cylinder head and supplige oil to all conetant throttle cylinders simultaneously, 2.26 ‘Shop Manual - EngineEngine oil pressure operates the constant throttle valve piston downwards opening the constant throttle valve in the cylinder head and allows the gases of the combustion chamber to exit to the atmosphere through the exhaust valve irrespective of the piston position, Oil then flows back to the oil sump through the loop hoses and constant throttle valve solenoid. Engine oil flows into the constant throttle valve chamber from cylinder head for lubrication and flows back to the oil sump. Exhaust Brake System MR CONTROL UNIT | (AUXILIARY ) EXHAUST BRAKE EXHAUST BRAKE AIR TANK ISOLENOID VALVE[”“] CYLINDER EXHAUST GAS, o, 5 TURBOCHARGER BUTTERFLY VALVE picv.o1906- 1204 Main Components Exhaust Brake Solenoid Valve Butterfly Valve Exhaust Brake Cylinder System Overview When the exhaust brake solenoid is energized by the FR control unit (Vehicle ECU), it allows the compressed air from the auxiliary air tank to flow to the exhaust brake cylinder mounted near the turbocharaer. Exhaust brake cylinder closes the normally open butterfly valve mounted inside the front exhaust pipe, thereby restricting the flow of exhaust gases to the muffler. This restriction creates a back pressute in the combustion chamber thereby stowing down the engine speed. A partial flow of exhaust gases always flows out even when the butterfly valve is closed through a small vent hole in the valve, 227 ‘Shop Manual - Engine Pee2.5.6 Breather System Main Component Oil Separator ‘System Overview Partial combustion gases escapes through piston and rings enters the crankcase bottom section during combustion. These gases are called blow-by gases. Eventually pressure inside the crankcase bottom section builds up. This pressure needs to be relieved or else it could damage oil seals and gaskets causing oil leakage or the oil would come up through the dipstick. The blow by gases collected in the crankcase travels to the cylinder head tappet cover through cylinder block push rod passagos. Engine is equipped with an oil separator in tappot cover, to filtor the oil content in blow by gases. Mesh filter in the tappet cover filters the oil from the blow-by gases. Oil then drains back to tho oil sump through the oil drain hole in the tappet cover and through first push rod passage in cylinder head. Diaphragm spring allows filtered blow-by gases from oil separator to the inlet of turbocharger, when tho gas prossure exceeds the diaphragm spring prossuro in tho oil separator. Introduction Breather system relieves pressure built up in the crankcase during combustion. 228 ‘Shop Manual - EngineMESH FILTER a 110 TAPPET. > COVER a CYLINDER HEAD 1 PUSH ROI HOLE INTAKE y* MANIFOLD CYLINDER BLOCK TURBOCHARGER pd CHARGE AIR ay > OL PAN lL FLOW BLOW BY CAS D> | iureren stow By cas [> | FILTERED ATMOSPHERIC AIR COMPRESSOR A ONISNOH Y3NY3TO BY Wous uly C331 DIcv-0m906-0035| 229 ‘Shop Manual - Engine2.6 Schematics 2.6.1 Engine Electrical Schematic: 2.6.2 Engine Electronic Schematics. 230 ‘Shop Manual - EngineMm 2.6.1 Engine Electrical Schematics Engine electrical schematics mainly deals about the starter and charger system Starter system: HOLD ON COIL COUTTS I PULLIN COIL RELAY COCCTO™ 3 4 ae BATT | FIELD COILS The solenoid starter consists of + Hold-in coil + Contact plate + Armature (field winding) 2 Pull-in coil at The pull in coil is made of a heavy gauge wire and terminates at the field connection “Motor Stud” q This coil has a high amperage draw and creates a RELAY o strong magnetic field. Ite primary function fe to i t induce enough force on the moveable core “Plunger” to shit the starter drive into the ring gear 231 ‘Shop Manual - Engine Penis’'51(Stalk switch)) (Relay Coil] [Rel Coil (MRContolUnt) (Holdin con) [Putin con) (Relay } Ground) (Armature Winging) Ground Operating principle * When the ignition key is turned from the terminal 15 (ON position) to terminal 50 (Start position) the signal from the drive switch(S1) passes simultaneously to the CPC control UunitA3) and MR control unit (A6) + CPC control unit (A3) sends a signal (start command) to the MR control unit (AG) via the CAN Bus. + When the MR control unit receives the signal from tho terminal 50 and from the signal (start command) from the CPC control unit, it actuates the startor relay which in turn engages the contact plates (1 and 2) due to the eloctromagnetic field created by the relay coil + When the contacts points at 1 and 2 are close, the battery current flows to the hold-in coil and the pulkin coil via the contact point (1 and 2) + The current from the pull-in coil flows to the armature coil via field coil, rotating the motor at low speed. + Due to tho current flow in the coils an electromagnetic force is generated around the pullin coil and the hold.in coil, this magnetizes the pole core and so the plunger of the magnetic switch is pulled in to the pole core. + By this pull-in operation, the pinion gear is pushed out and engages with the ring gear and the contact plate turns the main contact ‘on at points § and 3. If there i an open circuit in the pulkin coil, the starter can not be started because the plunger cannot be pulled in, If there is no operational sound from the starter then the pullin coil might be faulty For further details please refer “Electrical” chapter of the Shop Manual. 232 ‘Shop Manual - Engine| eer | Charger system: a My 13 ia — et Xia (a) u| a “ xi zl ° TOSE A zu 1 . auremavor | ite me a xo xa2 a 7 z mat STATOR I: po oaas a6 com Ic x Se TowUN.Box | 8+ ToT i @ oa ROTORCO A3— - CPC control unit. W - Speed. AB MR control unit(16 pin) X21 - Inter-connector D+ -Waming lamp, X92. -Inter-connector G5. - Generator compact. X74 -Interconnector GB.1_ - Generator B+ (0/p terminal). x9 - Inter-connector. M1.1 - Solenoid battery terminal X10. - Ai Base module, The circuit shows the connection of the charger with the vehicle (CPC) control unit, the starter, the ignition system, and the engine (MR) control unit (16 pin connector), There ate inter-connectors X2.1 and X2.2 between the IC regulator and A3 CPC control unit and X9 between ‘AT Base Module (X10) and CPC control unit. The three pins 1, 2 and 3 of the alternator's 4 pin connector (G6) are connected to CPC ECU pins 11, 13 and 3 respectively in order to regulate the alternator speed, control the warning lamp and connect the ignition switch and the fourth pin is connected to the MR ECU through Starter K1.30 (M1.1). The function of the pins are as follows. 233 ‘Shop Manual - Engine Penis’1 Gives the alternator speed to the CPC for controlling the field coxcitation current to the rotor col D+ signal gives the charging voltage to the CPC. Basically it controls the lamp. actuation signal. It there is a problem with the charging system wherein 2 there is no output from the stator then the voltage generated at terminal 2 will be OV. Normally with all electrical of, the voltage should be same as the battery voltage The voltage is supplied from the ignition switch. It generates the magnetic field in the rotor and passes through the IC regulator. The voltage regulator monitors 3 the voltage coming out of the alternator and, when it reaches a limit, the regulator reduces the current in the rotor to weaken the magnetic field. When the voltage drops below the limit, the current to the rotor is increased. Physical connection is there but it does not have any functionality associated with that particular wire. When the battery reaches a state of full charge, the electromotive force becomes strong enough to ‘oppose the current flow from the alternator at the output terminal G6.1. When more electrical power is used, the electromotive force will reduce and alternator amperage will increase. This force (Speed) is controlled through (W) CPC control unit. For further details please refer “Electrical” chapter of the Shop Manual. 288 ‘Shop Manual - Engine