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Shop Manual 
chassis 
Pub.No.TWLE0607, FEBRUARY 2006 
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Shop Manual 
chassis 
Pub.No.TWLE0607, FEBRUARY 2006 
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GROUP INDEX 
GENERAL ............................................... 
CLUTCH .................................................. 
MANUAL TRANSMISSION 
<M10, M12>............................................. 
MANUAL TRANSMISSION 
<M120, M130>......................................... 
PROPELLER SHAFT.............................. 
FRONT AXLE .......................................... 
REAR AXLE ............................................ 
WHEEL AND TIRE.................................. 
FRONT SUSPENSION ............................ 
REAR SUSPENSION 
<SHACKLE LINK TYPE> ....................... 
REAR SUSPENSION 
<TRUNNION TYPE> ............................... 
BRAKE 
<AIR OVER HYDRAULIC BRAKE> ....... 
BRAKE 
<FULL AIR BRAKE> .............................. 
ANTI-LOCK BRAKE SYSTEM ............... 
PARKING BRAKE 
<CENTER PARKING BRAKE>............... 
PARKING BRAKE 
<WHEEL PARKING BRAKE> ................ 
STEERING .............................................. 
BUMPER AND FRAME........................... 
CAB MOUNTING AND TILT ................... 
DOOR ...................................................... 
EXTERIOR .............................................. 
INTERIOR................................................ 
HEATER, AIR-CONDITIONER 
AND VENTILATION ................................ 
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. 
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. 
FEBRUARY 2006 
Applicable models 
FP, FV 
©2006 Mitsubishi Fuso Truck & Bus Corporation 
---===SME_1007_00019_0003.djvu===---
00-1 
GROUP 00 GENERAL 
MODEL CODING SYSTEM................................................................ 00-2 
EQUIPMENT MODEL CODING SYSTEM ......................................... 00-3 
POWER TRAIN TABLE ..................................................................... 00-4 
HOW TO READ THIS MANUAL ........................................................ 00-6 
CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE ........ 00-11 
PRECAUTIONS FOR MAINTENANCE OPERATION ..................... 00-12 
JACKING UP THE VEHICLE ........................................................... 00-22 
DIAGNOSIS CODES......................................................................... 00-24 
TABLE OF STANDARD TIGHTENING TORQUES ......................... 00-30 
---===SME_1007_00019_0004.djvu===---
00-2 
1 Basic vehicle type 
F 
Cab-over engine truck 
2 Drive system 
P4 
×2 
V6 
×4 
3 Development sequential number 
5 
4 Suspension 
1 
Leaf suspension 
5 Engine 
5 
8DC9 
76 
D 
2 
4 
6 Wheel base 
F 
3500 to 3800 mm 
G 
3800 to 4100 mm 
H 
4100 to 4400 mm 
J 
4400 to 4700 mm 
K 
4700 to 5000 mm 
L 
5000 to 5300 mm 
M 
5300 to 5600 mm 
N 
5600 to 5900 mm 
P 
5900 to 6200 mm 
R 
6200 to 6500 mm 
S 
6500 to 6800 mm 
T 
6800 to 7100 mm 
U 
7100 to 7400 mm 
V 
7400 to 7700 mm 
7 Chassis arrangement for use 
None Standard use 
D 
Dump use 
F 
Fire engine use 
MM 
i 
x 
e 
r 
R 
Semi trailer use 
8 Engine type 
None Natural aspiration 
1, 2 Turbo charged 
9 Steering position 
L 
Left-hand drive vehicle 
R 
Right-hand drive vehicle 
10 
to 
12 
Export specification 
1 
7 
4 
35 
2 
9 
810 
6 
FV5 15HRL 
11 12 
MODEL CODING SYSTEM 
---===SME_1007_00019_0005.djvu===---
00 
00-3 
Model code indica- 
tion in this manual 
Model code indication on name plate 
Code explanation 
Engine 
6 
D 
2 
6D24--T 
1 
Classification of turbocharger (T : with turbocharger) 
Intra-series sequence of development 
Sequence of development by series 
Diesel engine 
Number of cylinders (6 cylinders) 
8DC 
8 
DC 
9 
Intra-series sequence of development 
Sequence of development by series 
Diesel engine 
Number of cylinders (8 cylinders) 
Clutch 
C8W40 
C 
8W40 
Disc outside diameter 
Facing material (W: Woven, M: Cera-metallic) 
Typical load capacity (tonnage class) of vehicle 
Initial letter of "clutch" 
Transmission 
M10S5 
M10S 
5 
Number of forward speeds 
Meshing (S: Synchromesh) 
Typical load capacity (tonnage class) of vehicle 
Initial letter of "transmission" 
M120S2 × 5 
M120 
S2×5 
Number of forward speeds 
High-and-low two step 
Meshing (S: Synchromesh) 
Version number 
Typical load capacity (tonnage class) of vehicle 
Initial letter of "transmission" 
Propeller shaft 
P11 
P11 
Typical load capacity (tonnage class) of vehicle 
Initial letter of "propeller shaft" 
Front axle 
F090T 
F090 
T 
Type of vehicle (T: Truck) 
Version number 
Typical load capacity (tonnage class) of vehicle 
Initial letter of "front axle" 
Rear axle 
R10TT 
R10T 
T 
Axle type (T: Tandem axle, D: Dead axle) 
Type of vehicle (T: Truck) 
Typical load capacity (tonnage class) of vehicle 
Initial letter of "rear axle" 
Reduction and differential 
D10HT 
D10HT 
Tandem axle 
Tooth form (H: Hypoid gear) 
Typical load capacity (tonnage class) of vehicle 
Initial letter of "differential" in reduction and dif- 
ferential 
EQUIPMENT MODEL CODING SYSTEM 
---===SME_1007_00019_0006.djvu===---
00-4 
DESTINA- 
TION 
MODEL NAME ENGINE CLUTCH 
TRANSMIS- 
SION 
PROPEL- 
LER 
SHAFT 
FRONT 
AXLE 
REAR 
AXLE 
REDUC- 
TION & 
DIFFEREN- 
TIAL 
GENERAL 
EXPORT 
FP517FDL 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517FDR 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517HL 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517HR 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517JFL 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517JFR 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517JL 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517JR 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517LFR 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517LL 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517LR 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517NL 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517NR 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FV515JDCL 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515JDCR 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515JMCL 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515JMCR 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515MCL 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515MCR 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515MFCL 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515MFCR 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PCL 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PCR 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PFCL 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PFCR 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515SCL 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515SCR 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FP515GRL 
8DC9 C12W43 M120S2 × 5 
P12 
F090T 
R12T 
D12H 
FP515GRR 
8DC9 C12W43 M120S2 × 5 
P12 
F090T 
R12T 
D12H 
FV515HRL 
8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
FV515HRR 
8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
ECUADOR 
FV517HR2LNRA 6D24-T2 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
FV517JD2LNRA 6D24-T2 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
FV517P2LNRA 6D24-T2 C12W43 M120S6 
P12/P8 F090T R10T(T) D10H(T) 
EGYPT 
FP517FDLBH1 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517HLBH1 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
ETHIOPIA 
FV517JD1LB9A 6D24-T1 C12W43 M120S6 
P12/P8 F090T R10T(T) D10H(T) 
FV517HR1LB9B 6D24-T1 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
FV517JD1LB9B 6D24-T1 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV517JM1LB9B 6D24-T1 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV517P1LB9B 6D24-T1 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV517PP1LB9A 6D24-T1 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
KENYA FV515HRRB11 
8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
POWER TRAIN TABLE 
---===SME_1007_00019_0007.djvu===---
00 
00-5 
SAUDI 
ARABIA 
FP517GR2LADA 6D24-T2 C12M41 M120S2 × 5 
P13 
F090T 
R12T 
D12H 
FP517HLADA 
6D24 C10M39 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517JLADA 
6D24 C10M39 
M10S5 
P11 
F090T 
R10T 
D10H 
FV515JDLADA 
8DC9 C12M41 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PLADA 
8DC9 C12M41 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FP517GR2LADB 6D24-T2 C12M41 M120S2 × 5 
P13 
F090T 
R12T 
D12H 
FP517HLADB 
6D24 C10M39 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517JLADB 
6D24 C10M39 
M10S5 
P11 
F090T 
R10T 
D10H 
FV515JDLADB 
8DC9 C12M41 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PLADB 
8DC9 C12M41 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
GCC 
FP515GRLGSA 8DC9 C12W43 M120S2 × 5 
P12 
F090T 
R12T 
D12H 
FP517GR2LGSA 6D24-T2 C12M41 M120S2 × 5 
P13 
F090T 
R12T 
D12H 
FP517HLGSA 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517JLGSA 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517NLGSA 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FP517NLGSB 
6D24 C8W40 
M10S5 
P11 
F090T 
R10T 
D10H 
FV515HRLGSA 8DC9 C12W43 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
FV515JDCLGSA 8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515MCLGSA 8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PCLGSA 
8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PFCLGSA 8DC9 C12W43 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
TANZANIA FV515PPRBGA 8DC9 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
SOUTH 
AFRICA 
FP517GR2RBJ1 6D24-T2 C12W43 M130S2 × 5 P140 
F090T 
R12T 
D12H 
FV517JD1RBJ1 6D24-T1 C12W43 M130S7 P140/P10 F090T R10T(T) D10H(T) 
FV517JR2RBJ1 6D24-T2 C12W43 M130S2 × 5 P140/P10 F090T R10T(T) D10H(T) 
FV517P2RBJ1 6D24-T2 C12W43 M130S2 × 5 P140/P10 F090T R10T(T) D10H(T) 
INDONESIA 
FV515KDCRDKA 8DC9 C12M41 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515KMCRDKA 8DC9 C12M41 
M10S6 
P12/P8 F090T R10T(T) D10H(T) 
FV515PCRDKA 8DC9 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
FV517HR2RDKA 6D24-T2 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
VENEZUELA FV517HR2LNGA 6D24-T2 C12M41 M120S2 × 5 P13/P10 F090T R10T(T) D10H(T) 
PERU 
FP517J1LNFA 6D24-T1 C12W43 
M10S5 
P10 
F090T 
R10T 
D10H 
FV517JD1LNFA 6D24-T1 C12W43 M120S6 
P12/P8 F090T R10T(T) D10H(T) 
DESTINA- 
TION 
MODEL NAME ENGINE CLUTCH 
TRANSMIS- 
SION 
PROPEL- 
LER 
SHAFT 
FRONT 
AXLE 
REAR 
AXLE 
REDUC- 
TION & 
DIFFEREN- 
TIAL 
---===SME_1007_00019_0008.djvu===---
00-6 
This manual consists of the following parts: 
Specifications 
Structure and Operation 
Troubleshooting 
On-vehicle Inspection and Adjustment 
Service procedures 
On-vehicle Inspection and Adjustment 
Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de- 
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for 
looseness, play, backlash, crack, damage, etc. 
Service procedure 
Procedures for servicing components and parts off the vehicle are described centering on key points in their re- 
moval, installation, disassembly, reassembly, inspection, etc. 
Inspection 
Check items subject to "acceptable/unacceptable" judgement on the basis of service standards are all given. 
Some routine visual checks and cleaning of some reused parts are not described but must always be included in 
actual service work. 
Caution 
This service manual contains important cautionary instructions and supplementary information under the following 
four headings which identify the nature of the instructions and information: 
Terms and Units 
Front and rear 
The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred to 
as the rear. 
Left and right 
Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and 
right. 
Standard value 
Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance 
between two parts when assembled, and the standard value for an assembly part, as the case may be. 
Limit 
When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must 
be replaced or repaired. 
DANGER 
Precautions that should be taken in handling potentially dangerous substances 
such as battery fluid and coolant additives. 
WARNING 
Precautionary instructions, which, if not observed, could result in serious injury or 
death. 
CAUTION 
Precautionary instructions, which, if not observed, could result in damage to or de- 
struction of equipment or parts. 
NOTE 
Suggestions or supplementary information for more efficient use of equipment or 
better understanding. 
HOW TO READ THIS MANUAL 
---===SME_1007_00019_0009.djvu===---