---===SME_1203_00005_0001.djvu===--- Pub.No.00ELT0006, JULY 2011 Shop Manual diesel engine ( EURO 5. EURO V ) ---===SME_1203_00005_0001.djvu===--- Pub.No.00ELT0006, JULY 2011 Shop Manual diesel engine ( EURO 5. EURO V ) ---===SME_1203_00005_0002.djvu===--- ---===SME_1203_00005_0003.djvu===--- Pub.No.00ELT0006, JULY 2011 ---===SME_1203_00005_0004.djvu===--- GROUP INDEX GENERAL................................. ........ ENGINE ........................ .................... LUBRICATION.............. ............ ........ FUEL AND ENGINE CONTROL ...... COMMON RAIL SYSTEM ................ COOLING ................................. ........ INTAKE AND EXHAUST .................. EMISSION CONTROL.. .................... BlueTec ® SYSTEM................... ........ FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso 4P10 series diesel engine, 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 Mitsubishi 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. JULY 2011 Applicable models 4P10T2 4P10T4 4P10T6 ( EURO 5. EURO V ) ©2011 Mitsubishi Fuso Truck & Bus Corporation ---===SME_1203_00005_0005.djvu===--- This Shop Manual contains the information classified into the following groups. If any system or equipment has two or more variations with significantly different construction, the variations are handled as different groups. These groups are identified by different alphabets preceded by the same number. 1. ENGINE volume 2. CHASSIS volume 3. ELECTRICAL volume Group No. Group subject 11 ENGINE 12 LUBRICATION 13 FUEL AND ENGINE CONTROL 13E COMMON RAIL SYSTEM 14 COOLING 15 INTAKE AND EXHAUST 17 EMISSION CONTROL 17E BlueTec ® SYSTEM Group No. Group subject 21 CLUTCH 22A TRANSMISSION <M038: DUONIC ® > 22B TRANSMISSION <M038> 22E DUONIC ® 24 TRANSFER 25 PROPELLER SHAFT 26A FRONT AXLE <RIGID LEAF SUSPENSION (FE)> 26B FRONT AXLE <RIGID LEAF SUSPENSION (FG)> 26C FRONT AXLE <INDEPENDENT SUSPENSION> 27 REAR AXLE 31 WHEEL, TIRE 33A FRONT SUSPENSION <RIGID LEAF TYPE> 33B FRONT SUSPENSION <INDEPENDENT TYPE> 34 REAR SUSPENSION 35 BRAKE 35E ABS/ESP ® /ASR (ABS: ANTI LOCK BRAKE SYSTEM, ESP ® : ELECTRONIC STABILITY PROGRAM, ASR: ANTI SPIN REGULATOR) 36 PARKING BRAKE 37A STEERING <RIGID LEAF SUSPENSION> 37B STEERING <INDEPENDENT SUSPENSION> 41 BUMPER, FRAME 42 CAB MOUNTING, TILT 43 DOOR 51 EXTERIOR 52 INTERIOR 52E SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 55 HEATER, AIR-CONDITIONER 55E FULL AUTO AIR-CONDITIONER Group No. Group subject 54 ELECTRICAL ---===SME_1203_00005_0006.djvu===--- 00-1 GROUP 00 GENERAL VEHICLE MODEL CODING SYSTEM ................................................ 00-2 EQUIPMENT TYPE CODES LIST ...................................................... 00-3 POWER TRAIN TABLE ...................................................................... 00-4 HOW TO READ THIS MANUAL ......................................................... 00-8 VEHICLE IDENTIFICATION NUMBER, ENGINE NUMBER AND NAME PLATE.................................................................................... 00-16 PRECAUTIONS FOR MAINTENANCE OPERATION 1. Handling Precautions for Electric Circuits .................................. 00-24 2. Service Precautions for Alternators ............................................ 00-27 3. Intermittent Faults ...................................................................... 00-28 4. Precautions for Arc Welding ....................................................... 00-29 5. Cautions When Handling AdBlue ® .............................................. 00-30 6. Precautions When Repainting .................................................... 00-30 7. Precautions When Handling a Vehicle with DUONIC ® System .... 00-30 8. Precautions on Cleaning When Servicing the Engine and Transmission .............................................................................. 00-31 JACKING UP THE VEHICLE............................................................ 00-34 DIAGNOSIS CODES 1. Diagnosis Codes ........................................................................ 00-36 2. Reading and Erasing the Diagnosis Code................................... 00-42 TABLE OF STANDARD TIGHTENING TORQUES .......................... 00-46 ---===SME_1203_00005_0007.djvu===--- 00-2 1 Basic vehicle type F Cab over truck 2 Driving wheels E 4×2 G 4×4 3 Cab/frame type, development sequence A Standard width cab, frame width: 700mm B Wide cab, frame width: 750mm C Wide cab, frame width: 850mm 4 Chassis, suspension (front/rear), classification of GVW 0 Independent/rigid, GVW: 3.5 tons 5 Rigid/rigid, GVW: 5 -- 6 tons 7 Rigid/rigid, GVW: 6.05 -- 7.5 tons 5 Engine 1 4P10 6 Wheelbase B 2500 mm C 2800 mm E 3400 mm G 3850 mm H 4300 mm K 4750 mm 7 Steering R RHD L LHD 8 Floor height, transmission type 3 High floor, DUONIC ® 4 High floor, Manual transmission 9 Cab configuration S Single cab W Crew cab 10 11 Country code EA EU 12 Engine class 6 4P10(T2) 96 kW 7 4P10(T4) 110 kW 8 4P10(T6) 129 kW 1 7 4 35 2 9 810 6 FEA01BL S 11 12 4E A 6 VEHICLE MODEL CODING SYSTEM ---===SME_1203_00005_0008.djvu===--- 00 00-3 Component Name plate marking Code description Engine 4P10T2 4 P 1 0 T 2 Power version number Turbocharged Order of development within same series Order of development among different series Diesel engine No. of cylinders (4) Transmission M038S5W M 038 S 5 W Variation (W: With directly-mounted transfer) Forward speeds Type of mesh (S: Synchromesh) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the transmission Propeller shaft P3 P 3 Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the propeller shaft Front axle F200T F 200 T I Axle type Vehicle type (T: Truck) Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the front axle Rear axle R035T R 03 5 T Vehicle type (T: Truck) Order of development within same series Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the rear axle Reduction and differential D035H D 03 5 H Tooth profile (H: Hypoid gear) Order of development within same series Load carrying capacity of truck class (tonnage) on which the clutch is primarily used Initial letter of the reduction & differential EQUIPMENT TYPE CODES LIST ---===SME_1203_00005_0009.djvu===---