---===SME_1005_00005_0001.djvu===--- diesel engine, chassis and electrical Supplement Shop Manual Pub.No.TWSE0615-1, JANUARY 2008 For the United Kingdom ---===SME_1005_00005_0001.djvu===--- diesel engine, chassis and electrical Supplement Shop Manual Pub.No.TWSE0615-1, JANUARY 2008 For the United Kingdom ---===SME_1005_00005_0002.djvu===--- GROUP INDEX MODIFICATION SUMMARY ................. ENGINE ................................................. ELECTRONICALLY CONTROLLED FUEL SYSTEM <Common Rail System> ........................... ELECTRONICALLY CONTROLLED FUEL SYSTEM <Vehicle Speed Limitation System (Speed limitation device (SLD) function) ................ COOLING .............................................. INTAKE AND EXHAUST....................... EMISSION CONTROL .......................... MANUAL TRANSMISSION................... INOMAT-II ............................................. ELECTRICAL ........................................ HYBRID ELECTRIC VEHICLE SYSTEM ................................................ FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso truck, and includes procedures for adjust- ment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage. As this Shop Manual is published as a supplement to the following Shop Manuals, please refer to the followings for information not included in this manual. Diesel Engine 4M4 ......... ............ Pub. No. TWDE0512 Chassis .......... .......... .................. Pub. No. TWSE0615 Electrical .. ....... .......... ................... Pub. No. THSE0606 For more details, please consult your nearest authorized Mitsubishi Fuso dealer or distributors. Kindly note that the specifications and maintenance ser- vice figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. JANUARY 2008 Applicable models FE Shop Manual diesel engine, chassis and electrical For the United Kingdom ©2008 Mitsubishi Fuso Truck & Bus Corporation ---===SME_1005_00005_0003.djvu===--- 1 MODIFICATION SUMMARY ---===SME_1005_00005_0004.djvu===--- 2 1. General The following are added to the characteristics of the CANTER ECO HYBRID. The CANTER ECO HYBRID is equipped with a dedicated high voltage battery (350 V) for the hybrid electric ve- hicle system aside from the 24 V battery. High voltage is cut off when the starter switch is OFF and the vehicle is stationary. High voltage is generated in the high voltage circuit when the starter switch is ON or when the gear is engaged and the wheels are rotating. High voltage in the high voltage circuit may be generated irrespective of the vehicle condition during the hybrid electric vehicle system abnormalities (the hybrid electric vehicle warning lamp illuminates). The following are added to the precautions concerning high voltage cable and high voltage devices. DANGER High voltage (350 V) may be generated in the high voltage circuit that consists of various high voltage de- vices (motor generator, motor electronic control unit and high voltage battery box) and cable (orange). Ut- most care is required in handling these parts. When servicing, see Gr72 HYBRID ELECTRIC VEHICLE SYSTEM. Improper use of the high voltage battery may cause electric shock, overheating or fire though it is safe when properly handled. It may explode in the worst case. The following are added to the remedies against vehicle damage by collision or the like. WARNING When the vehicle is on fire, use the ABC fire extinguisher to put out the fire. Since it is dangerous to fight a fire with a small quantity of water, spray a large amount of water from a fire hydrant or wait for the arriv- al of the fire brigade. When the vehicle is soaked in water, do not touch the high voltage devices and high voltage cable includ- ing the safety plug of the high voltage battery box to prevent electric shock. Work on the vehicle after pulling it out of water. Insulate any high voltage terminal that is exposed by damage with vinyl tape or the like to prevent electric shock. CAUTION The electrolyte in the high voltage battery is as flammable as kerosene. If there is any fluid leakage near the high voltage box, wipe up the fluid while keeping fire away from it. Turn the starter switch to OFF to cut off the high voltage system. If it cannot be confirmed that the starter switch is OFF, disconnect the negative side battery cable from the 24 V battery. Then, remove the safety plug of the high voltage battery box with insulated gloves on while referring to Gr72 HYBRID ELECTRIC VEHICLE SYSTEM. In the case of the abnormality described above, replace the defective part referring to Gr72 HYBRID ELECTRIC VEHICLE SYSTEM. The following are added to the precautions at engine start. The engine warning lamp may illuminate if the starter switch is kept turned to the START position for a while with the gear engaged. (Diagnosis code P0016 "No SNSR Offset/Backup Mode" of the engine electronic con- trol unit occurs.) If the engine warning lamp illuminated, place the transmission in neutral and turn the starter switch from OFF to ON four times to turn off the warning lamp. When performing arc welding, after disconnecting the battery cable from the negative side of the battery, remove the safety plug of the high voltage battery box referring to Gr72 HYBRID ELECTRIC VEHICLE SYSTEM. MODIFICATION SUMMARY ---===SME_1005_00005_0005.djvu===--- 3 2. Engine This section describes the differences from those in the Shop Manual diesel engine 4M4 (EURO4) (Pub.No. TWDE0512). When servicing the components which are not covered herein, please refer to the above Shop Manual. Be sure to check the differences described in the following before servicing. Group Contents of different points Service procedure 11 (1) The engine cranking procedure during measurement of compression pressure is different. For the hybrid electric vehicle system, there are two methods of cranking the engine, a con- ventional method using the starter and a method using the motor of the hybrid electric vehicle system. If the engine is cranked with the motor of the hybrid electric vehicle system, measurement of compression pressure may become inaccurate since the engine speed is slightly higher than when the starter is used for cranking. For this reason, engine cranking should be performed using the starter following the procedure below. Turn the starter switch quickly up to the START position before the READY indicator lamp in the meter cluster illuminates. Though the indicator lamp illuminates in several seconds, the starter will keep running. If the starter switch is turned to the START position after the READY indicator lamp in the meter cluster illuminates, the starter will not run and the engine is cranked with the motor of the hybrid electric vehicle system. In this case, turn the starter switch to OFF and try again. The service procedures are the same except those given here. (2) The removal and installation procedures of the engine are different due to the addition of the motor generator. See Gr11. 13EA (1) The INOMAT-II electronic control unit is added to the electronic control unit connection dia- gram in the STRUCTURE AND OPERATION section. The service procedures are the same except those given here. (2) Location of some parts are different. (The differences are only on some parts, however, all the locations of parts are shown.) See Gr13EA. (3) Some parts of electric circuit diagram are different. (The differences are only on some parts, however, the complete electric circuit diagram is shown.) ---===SME_1005_00005_0006.djvu===--- 4 13EB (1) In "INSPECTION OF ELECTRICAL EQUIPMENT" "#352 Inspection of pulse converter" is different. #352 Pulse converter inspection Connect the pulse converter to the tester as shown. Slowly rotate the shaft of the vehicle speed sensor by hand, and measure maximum voltage (high pulse volt- age) and minimum voltage (low pulse voltage) appear- ing between each of OUT terminals and terminal 10 of the pulse converter. If measurements deviate from the specified standard values, replace the pulse converter. (2) Location of some parts are different. (The differences are only on some parts, however, all the locations of parts are shown.) See Gr13EB. (3) Some parts of electric circuit diagram are different. (The differences are only on some parts, however, the complete electric circuit diagram is shown.) 14 (1) The following items are changed since the radiator used is different. The coolant capacity is different. The service procedures are the same except those given here. The tightening torque of the radiator drain cock is different. The radiator hose is different. The radiator shroud and baffle plate are different. The service procedures are the same except those given here. See Gr14. 15 (1) Location of some parts are different. (The differences are only on some parts, however, all the locations of parts are shown.) See Gr15. (2) Some parts of electric circuit diagram are different. (The differences are only on some parts, however, the complete electric circuit diagram is shown.) (3) The hose of the intercooler is different. (4) The exhaust pipe is different. (5) The diesel particulate filter is different. 17 (1) Location of some parts are different. (The differences are only on some parts, however, all the locations of parts are shown.) See Gr17. (2) Some parts of electric circuit diagram are different. (The differences are only on some parts, however, the complete electric circuit diagram is shown.) Group Contents of different points Service procedure Standard value 8-pin pulse output terminals Low pulse voltage 1.5 V or less High pulse voltage 23.5 V or more 25-pin pulse output terminals Low pulse voltage 0.5 V or less High pulse voltage 8V +1.5 --1.0 Item Specifications Coolant capacity dm 3 {L} 15.7 {15.7} Tightening torque (Unit: N·m {kgf·m}) 2.0 {0.2} MODIFICATION SUMMARY ---===SME_1005_00005_0007.djvu===--- 5 3. Chassis This section describes the differences from those in the Shop Manual chassis CANTER (EURO4) (Pub.No. TWSE0615). When servicing the components which are not covered herein, please refer to the above Shop Manual. Be sure to check the differences described in the following before servicing. Group Contents of different points Service procedure 00 (1) The following vehicle is added to the power train list. -- (2) A Vehicle Identification Number (VIN) is added. Europe, Portugal, Mitsubishi Fuso Truck Europe S. A. A: Right-hand Drive, B: Left-hand Drive Vehicle Model Plant (D: MFTE) Model Code (T: from 2005) Serial Number -- (3) A motor number is added. -- (4) Hybrid electric vehicle system is added to the diagnosis codes. (4.1) List of diagnosis code display The service procedures are the same except those given here. (4.2) FMS-E07-3 or the newer version of Multi-Use Tester-III can be used. (4.3) Difference of diagnosis code Vehicle model Engine Clutch Transmission Propeller shaft Rear axle Reduction and differential FE85BG6 4M42-T2 C3W28 M036S5 (5.175/0.715) P3 R035T D035H (5.714) TY A FE85BG6 D T 00001 Warning lamp System Flashing of warning lamp Reference Gr Hybrid electric vehicle system 72 INOMAT-II (Gear shift indicator indication) 22E System Diagnosis code present and past codes discriminated Present and past codes not discriminated Hybrid electric vehicle system -- INOMAT-II -- ---===SME_1005_00005_0008.djvu===--- 6 00 (4.4) The locations of the diagnosis switch and memory clear switch in the hybrid electric vehicle system are added. Diagnosis codes of the battery electronic control unit are sent to the motor electronic control unit and are dis- played along with those of the motor electronic control unit by the diagnosis switch operation. However, some diagnosis codes (minor faults) can be checked only with the Multi-Use Tester. The method of reading and erasing diagnosis codes are the same as the vehicle speed limiting and anti-lock brake system. (4.5) Reading and erasing of diagnosis codes using the gear shift indicator of INOMAT-II are added. Display diagnosis codes using the diag- nosis switch and memory clear switch. NOTE Diagnosis codes are erased by dis- connecting and connecting operation of the memory clear switch. Fully un- derstand the procedures before work- ing. Reading diagnosis codes To read a diagnosis code, check the indi- cation of the gear shift indicator. Example: If the codes are 12 and 34, they will be displayed as shown in the drawing. If the system is normal, the diagnosis code 01 will be displayed. Diagnosis codes will be displayed each code once in the reverse chronological or- der. After the last diagnosis code is displayed, the first code will be displayed again and then the subsequent codes. This will be re- peated. Present diagnosis codes Turn the starter switch to ON. Disconnect the diagnosis switch. The present diagnosis codes will be dis- played on the gear shift indicator. When the diagnosis switch is connected, ECU will stop (terminate) displaying diag- nosis codes. Group Contents of different points Service procedure MODIFICATION SUMMARY ---===SME_1005_00005_0009.djvu===---