---===SME_1005_00070_0001.djvu===--- Pub.No.TWSE0329-7, JUNE 2008 ---===SME_1005_00070_0001.djvu===--- Pub.No.TWSE0329-7, JUNE 2008 ---===SME_1005_00070_0002.djvu===--- FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mit- subishi Fuso ROSA series bus chassis, and includes pro- cedures 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. 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 4D3 ......... ............... Pub No. TWDE0217 • Chassis ROSA BE6. BC6 ............. Pub No. TWSE0329 • Electrical ROSA BE6. BC6... .......... Pub No. THSE0314 For more details, please consult your nearest authorized Mitsubishi Fuso dealer or distributor. 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. JUNE 2008 Applicable model BE ©2008 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan GROUP INDEX MODIFICATION SUMMARY ............. CHASSIS BODY ............................................. ELECRTRICAL HOW TO READ THIS MANUAL .... LIGHTING ...................................... METER .......................................... INDICATOR AND WARNING ........ BODY SIDE ELECTRICAL ............ ---===SME_1005_00070_0003.djvu===--- 1 MODIFICATION SUMMARY ---===SME_1005_00070_0004.djvu===--- 2 1. Diesel engine • Enumerated below are the difference from the earlier issued Shop Manual Diesel engine 4D3 (Pub.No.TWDE0217). • When servicing the components which are not covered herein, please refer to the above Shop Manual. Group Contents of different points Service procedure 13 FUEL AND ENGINE CONTROL Adjustment procedure of accelerator control cable is changed in ENGINE CONTROL. [Adjustment] • Turn the starter switch ON, and press down on the accelerator pedal until control lever hits stopper bolt. • Make sure pedal of accelerator pedal assembly is in contact with stopper bolt. • If there is no contact, adjust length A of stopper bolt. A:39mm Same as before except these explained here. MODIFICATION SUMMARY ---===SME_1005_00070_0005.djvu===--- 3 MODIFICATION SUMMARY 2. Chassis • Enumerated below are the difference from the earlier issued Shop Manual chassis ROSA BE6. BC6 (Pub.No.TWSE0329). • When servicing the components which are not covered herein, please refer to the above Shop Manual. Group Contents of different points Service procedure 00 GENERAL POWER TRAIN TABLE is changed. Same as before except these explained here. 21 CLUTCH (1) Service standard is changed in CLUTCH PEDAL. Same as before except these explained here. (2) Inspection and adjustment after assembly is changed in CLUTCH PEDAL. Inspection and adjustment after as- sembly (1) Height of clutch pedal arm • With the engine stopped and the clutch pedal released, measure the height A between the center of the pedal pad and the center of the clutch booster and master cylinder. • If the measurement is out of the standard value, adjust by loosening the lock nut of the clutch booster and master cylinder and turning its operating rod. (2) Stroke of clutch pedal arm • Make sure the full stroke of clutch pedal arm B conforms to the stan- dard value. • If the full stroke does not conform to the standard value, replace clutch pedal assembly. Same as before except these explained here. Vehicle model Engine Clutch Transmission Propeller shaft Final reduction BE637ELMDHAD BE637GLMSHAD BE637GLMDHAD 4D33 (EURO1) 125PS/ 31 kgf?m C4W30 M035S5 (5.380/0.722) P3 D2H 5.714 BE637JLMSHAD BE637JLMDHAD D3H 6.142 Service standards Unit: mm Location Maintenance item Standard value Limit Remedy 16 Installation height of clutch pedal arm (dis- tance between center of pedal pad and center of clutch booster and clutch master cylinder.) 256 ± 3.0 Adjust Full stroke of clutch pedal arm 152.5 Replace ---===SME_1005_00070_0006.djvu===--- 4 Group Contents of different points Service procedure 26A FRONT AXLE <RIGID> (1) Inspection of tie rod end ball joint is added in ON-VEHICLE INSPECTION AND AD- JUSTMENT. Inspection of tie rod end ball joint (1) Play • With the vehicle stationary, hold the tie rod with you hand and move it in longitudinal, lateral and vertical di- rections to check the play in the tie rod end ball joint. Be sure to check both right and left ball joints. • If any play is felt in your hand, re- place the tie rod end. (2) Dust cover • Check the dust cover for wear, crack and damage. They may cause in- gress of water in the ball joint, re- sulting in its premature wear. • If any abnormality is found, replace the tie rod end. Same as before except these explained here. Service standards Unit: mm Location Maintenance item Standard value Limit Remedy Play in tie rod end ball joint 0 Replace MODIFICATION SUMMARY ---===SME_1005_00070_0007.djvu===--- 5 Group Contents of different points Service procedure 26A FRONT AXLE <RIGID> (2) Inspection procedure of wheel hub is added in WHEEL HUB AND BRAKE DRUM <DRUM BRAKE>. Inspection of wheel hub (1) Visual inspection • Check the disc wheel mounting sur- face of the wheel hub visually and by hand. If there is any damage or crack, replace the wheel hub. Check that there is not rust, dust, paint or foreign matter on the disc wheel mounting surface to prevent the wheel nut from loosening. • If any abnormality is found, remove it with sandpaper. (2) Wear in disc wheel mounting part of wheel hub • Clean the wheel mounting surface of the wheel hub before inspection. • Place a straightedge on the hub being in contact with the two hub bolts on the disc wheel mounting surface. • Use feeler gauges to measure the amount of wear at the disc wheel mounting part. Measure at the disc wheel mounting part of every hub bolt. If the amount of wear at any point exceeds the following standard val- ue, check the wheel hub for cracks. Wear standard value: 0.8 mm Same as before except these explained here. (3) Crack check • Check that there is no crack on the entire rounded corner on the root of the flange on the brake drum side of the wheel hub by a magnetic in- spection or liquid penetrant testing. • If a crack is found on the wheel hub bolt, replace it. • If there is a crack or stepped wear on the wheel hub mounting surface of the wheel, replace it. (B Gr31) CAUTION k • The straightedge must not run on the hub bolt. MODIFICATION SUMMARY ---===SME_1005_00070_0008.djvu===--- 6 Group Contents of different points Service procedure 26A FRONT AXLE <RIGID> (3) Lubricant filling up wheel hub is changed in WHEEL HUB AND BRAKE DRUM <DRUM BRAKE>. * 1: For a wheel Same as before except these explained here. (4) Procedures of packing grease inside of wheel hub and outside of wheel hub are added in WHEEL HUB AND BRAKE DRUM <DRUM BRAKE>. Packing grease inside of wheel hub As shown in the illustration, fill the hub body with grease in such a manner that grease covers the out- er races of the outer bearing and inner bearing. Make sure that the grease reaches the outer bearing and inner bearing. Same as before except these explained here. K Lubricant Location Points of application Specified lubricant Quantity 7, 10 Pack the space between the rollers of the outer and inner bearing inner rac- es Wheel bearing grease [NLGI No.2 (Li soap)] As required 9 Oil seal lip Wheel bearing grease [NLGI No.2 (Li soap)] As required 18 Pack interior space of wheel hub Wheel bearing grease [NLGI No.2 (Li soap)] 395±40g * 1 Fill up outside wheel hub (wheel hub cover side) Wheel bearing grease [NLGI No.2 (Li soap)] 65±10g * 1 CAUTION k • Unless this packing procedure is performed, seizure of the wheel hub bearing may result. • For a grease amount, pack the specified amount using a mea- suring cup. MODIFICATION SUMMARY ---===SME_1005_00070_0009.djvu===---