---===SME_1007_00128_0001.djvu===--- FOREWORD This Shop Manual is published for the information and guid- ance of personnel responsible for maintenance of Mitsubishi ROSA series bus chassis, and includes procedures for ad- justment and maintenance services. We earnestly look for- ward to seeing that full use is made of this manual in order to services vehicles correctly and not waste time. In addition to this manual, you can also refer to the following manuals when performing services: • Diesel Engine ROSA BE6 4D3 ........ ....... ............ ....... .... Pub. No. TWDE0217 • Petrol Engine ROSA BC6 4G64 ........ ....... ............ ....... .... Pub. No. TWDE9507-1 • Chassis ROSA BE6. BC6 ........ ....... ............ ........... Pub. No. TWSE0329 • Electrical ROSA BE6. BC6 ........ ....... ............ ....... .... Pub. No. THSE0314 For more details, please consult your nearest authorized Mitsubishi dealer or distributor. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. Applicable models BE BC Dec. 2003 ©2003 Mitsubisi Fuso Truck & Bus Corporation Printed in Japan GROUP INDEX HOW TO READ THIS MANUAL GENERAL ....... ........................ ......... CLUTCH .......... ........................ ......... MANUAL TRANSMISSION..... ......... PROPELLER SHAFT.. ..................... FRONT AXLE <RIGID>........... ......... FRONT AXLE ................. ......... <INDEPENDENT> REAR AXLE ................ ..................... WHEEL AND TIRE.................. ......... FRONT SUSPENSION <RIGID>...... FRONT SUSPENSION............ ......... <INDEPENDENT> REAR SUSPENSION .. ..................... BRAKE ............ ........................ ......... ANTI-LOCK BRAKE SYSTEM ........ PARKING BRAKE................... ......... STEERING <BALL NUT> ....... ......... STEERING <RACK AND PINION>.. FRAME ............ ........................ ......... HEATER AND AIR-CONDITIONER BODY .. ........................ ..................... ---===SME_1007_00128_0001.djvu===--- FOREWORD This Shop Manual is published for the information and guid- ance of personnel responsible for maintenance of Mitsubishi ROSA series bus chassis, and includes procedures for ad- justment and maintenance services. We earnestly look for- ward to seeing that full use is made of this manual in order to services vehicles correctly and not waste time. In addition to this manual, you can also refer to the following manuals when performing services: • Diesel Engine ROSA BE6 4D3 ........ ....... ............ ....... .... Pub. No. TWDE0217 • Petrol Engine ROSA BC6 4G64 ........ ....... ............ ....... .... Pub. No. TWDE9507-1 • Chassis ROSA BE6. BC6 ........ ....... ............ ........... Pub. No. TWSE0329 • Electrical ROSA BE6. BC6 ........ ....... ............ ....... .... Pub. No. THSE0314 For more details, please consult your nearest authorized Mitsubishi dealer or distributor. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. Applicable models BE BC Dec. 2003 ©2003 Mitsubisi Fuso Truck & Bus Corporation Printed in Japan GROUP INDEX HOW TO READ THIS MANUAL GENERAL ....... ........................ ......... CLUTCH .......... ........................ ......... MANUAL TRANSMISSION..... ......... PROPELLER SHAFT.. ..................... FRONT AXLE <RIGID>........... ......... FRONT AXLE ................. ......... <INDEPENDENT> REAR AXLE ................ ..................... WHEEL AND TIRE.................. ......... FRONT SUSPENSION <RIGID>...... FRONT SUSPENSION............ ......... <INDEPENDENT> REAR SUSPENSION .. ..................... BRAKE ............ ........................ ......... ANTI-LOCK BRAKE SYSTEM ........ PARKING BRAKE................... ......... STEERING <BALL NUT> ....... ......... STEERING <RACK AND PINION>.. FRAME ............ ........................ ......... HEATER AND AIR-CONDITIONER BODY .. ........................ ..................... ---===SME_1007_00128_0002.djvu===--- ---===SME_1007_00128_0003.djvu===--- 1 HOW TO READ THIS MANUAL HOW THIS MANUAL IS STRUCTURED ............................................. 2 TERMS AND UNITS ............................................................................. 12 ---===SME_1007_00128_0004.djvu===--- HOW TO READ THIS MANUAL 2 How This Manual is Structured 23915 23929 21 27 • • • 23916 23917 I'm here to explain how to use this manual. To get the most out of your manual, follow along carefully and read all the notes given by my assistant. Each group is divided into five parts, as shown below. Specifications Specifications, oil quantities, and other information pertaining to system components. Structure and Operation Information on the structure and operation of the overall system and its components. Troubleshooting An item-by-item guide to fault symptoms and their probable causes. On-Vehicle Inspection and Adjustment Instructions for on-vehicle inspec- tion and adjustment operations. Service Instructions (See the next and subsequent pages.) The service instructions are the most important parts of this manual. Starting on the next page, you'll learn more about them. This manual is divided into groups, with one group for each main area of the vehicle. (An index of groups is given on page 2.) By way of example, let's look at Group 21, which covers the clutch. We're here to help you. Group 21 Group 27 Group 31 GROUP 21: CLUTCH SPECIFICATIONS . ... . . ... . . ............................................... STRUCTURE AND OPERATION ................................... TROUBLESHOOTING ................................................... ON-VEHICLE INSPECTION AND ADJUSTMENT Clutch Fluid Replacement and Air Bleeding ................... Inspection of Clutch Booster Functionality .................... Clutch Pedal Play ............................................................... CLUTCH PEDAL ............................................................ CLUTCH MASTER CYLINDER ...................................... CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER...................................................................... CLUTCH POWER CYLINDER ........................................ CLUTCH-PROPER ........................................................ CLUTCH HOUSING ....................................................... CLUTCH DISC WEAR INDICATOR SWITCH ................. ---===SME_1007_00128_0005.djvu===--- 3 23918 26310 20244 1 2 Now, let's take a detailed look at the service instructions. Please follow along carefully. CLUTCH PEDAL ................................................... CLUTCH MASTER CYLINDER ............................. CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER ............................................................. CLUTCH POWER CYLINDER .............................. CLUTCH-PROPER ................................................ CLUTCH HOUSING .............................................. ON-VEHICLE INSPECTION AND ADJUSTMENT • Clutch Fluid Replacement and Air Bleeding ........ • Inspection of Clutch Booster Functionality ......... • Clutch Pedal Play ................................................... The service instructions consist of the parts shown below. Starting on page 6, these parts are described in detail in order of the circled numbers. GROUP 21: CLUTCH SPECIFICATIONS ................................................. Service procedures Name of system or assembly Key numbers List of part names Group number This appears on each right-hand page. 4 Lubricants, fluids and/or sealants This table shows the required brands and quantities of oils, greases and/or sealants. 5 Special tools 6 Service procedure 1 Exploded view This shows the system or assembly in its dis- assembled form. 2 Service standards 3 Tightening torques ---===SME_1007_00128_0006.djvu===--- HOW TO READ THIS MANUAL 4 23922 26312 20245 23921 26311 3 4 5 Look at the exploded view first; it gives an overview of the system or assembly. All other information is given in parts 2 to 6. Basically, you should find the information you need from parts 2 to 6 as you perform the service procedure. Sotheparts2to6can be a kind of data book. But how should I find the information I need? I'll show you on the next page. I see... First I look at the exploded view, then I look at parts 2 to 6. ---===SME_1007_00128_0007.djvu===--- 5 26314 20252 26313 6 Find the information you need using the key numbers. For example, let's assume you're assembling the clutch and need the tightening torque for the bolt 1. To find the tightening torque, just look up key number 1 in the "Tightening torques" table. I see... The key numbers for the exploded view match the key numbers on other parts of the page. To help you find information quickly: Tightening torques are marked with T . Lubricants, fluids and seal- ants are marked with . And every key number that ap- pears in the service procedure is enclosed with a square. ---===SME_1007_00128_0008.djvu===--- HOW TO READ THIS MANUAL 6 2 3 8 6 5 1 1 T 2 3 12 7 8 6 11 5 X 23925 23927 23928 1 8 23926 P P 1 T 12 7 11 X 13 14 9 4 10 13 14 9 4 10 Exploded view Explanatory notes for the exploded view are given below. Explanatory notes for the parts list are given on the facing page. CLUTCH-PROPER <C5> Pressure Plate-and-Lever Assembly P Pre-disassembly operations P21-44 P Disassembly sequence Bolt Lock plate Support nut Pressure spring Pressure spring cap Return spring Release lever plate Clutch cover Release lever pin Support lever pin Support lever Release lever Bushing Pressure plate 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X: Non-reusable part NOTE Do not remove the bushing 13 unless it is defective. P Assembly sequence Reverse the order of disassembly. Repair kit : Clutch release Lever kit P Post-assembly Inspection and adjustment P21-44 This mark indicates a part that cannot be reused. : Indicates dowel pin. So parts without T marks don't have specified tightening torques ? No, they don't. But every bolt and nut must be tightened to a standard torque. A T mark shows either that the part must be tightened to a torque other than the standard torque or that the standard torque cannot be determined from the part's shape or markings. Standard tightening torques are explained at the bottom of the next page. Pressure Plate-and-Lever Assembly This mark indicates that lubricant or sealant must be applied to the part. This mark indicates that a tightening torque is specified for the part. The key number enclosed with a square indicates that the part is men- tioned in the service procedure. ---===SME_1007_00128_0009.djvu===---