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This training textbook describes some basic knowledges of construction/operation for truck & bus. The
purpose of the textbook is to provide simple technical information for staff who is not in charge of service
activities, such as part staff, sales staff and administration staff in distributors/dealers. The mentioned
staff are required to acquire the knowledges described in the textbook to achieve successfully the
assigned tasks.
All information in the textbook is current as of the time publication. We, however, reserve the right to
make changes at any time without prior notice or obligation.
December 2005
INTERNATIONAL SALES & SERVICE OFFICE
MITSUBISHI FUSO TRUCK & BUS CORPORATION
- General -
1. Truck -----------------------------------------------------------------------------------------------1
2. Truck tractor --------------------------------------------------------------------------------------4
3. Bus--------------------------------------------------------------------------------------------------7
4. Mitsubishi Fuso products in Japan market---------------------------------------------- 10
5. Part names of truck--------------------------------------------------------------------------- 14
6. Drive train of truck and bus ----------------------------------------------------------------- 15
- Engine -
1. Types of engines ------------------------------------------------------------------------------ 21
2. Engine performance-------------------------------------------------------------------------- 22
3. Power generation mechanism ------------------------------------------------------------- 24
4. Operation of diesel engine------------------------------------------------------------------ 26
5. Emission control for diesel engine -------------------------------------------------------- 30
6. Combustion chamber of diesel engine -------------------------------------------------- 33
7. Structure of engine body -------------------------------------------------------------------- 35
8. Accessories that enhance the engine performance ---------------------------------- 37
9. Fuel system------------------------------------------------------------------------------------- 42
10. Air intake and exhaust system------------------------------------------------------------- 50
11. Engine oil---------------------------------------------------------------------------------------- 53
12. Engine cooling system----------------------------------------------------------------------- 55
13. Engine electrical------------------------------------------------------------------------------- 57
14. CHECK SHEET <Engine section> ------------------------------------------------------- 59
- Chassis -
1. Clutch -------------------------------------------------------------------------------------------- 60
2. Transmission ----------------------------------------------------------------------------------- 63
3. Final reduction gear -------------------------------------------------------------------------- 75
4. Differential gear-------------------------------------------------------------------------------- 77
5. Steering system ------------------------------------------------------------------------------- 79
6. Brake system----------------------------------------------------------------------------------- 83
7. Tire------------------------------------------------------------------------------------------------ 95
8. Suspension ------------------------------------------------------------------------------------- 99
9. Battery ----------------------------------------------------------------------------------------- 102
10. Warning and indicator lamps ------------------------------------------------------------- 104
11. Air conditioner-------------------------------------------------------------------------------- 105
12. Cab and frame ------------------------------------------------------------------------------- 106
13. CHECK SHEET <Chassis section> ---------------------------------------------------- 109
Memo:
- GENERAL -
1. TRUCK
Medium truck
G.V.W. 8,500 kg-15,100 kg
Large truck
G.V.W. of 15,100 kg or more
-1-
- GENERAL -
Cargo Dump
Fire Engine
-2-
- GENERAL -
Body
(Built by body manufacturer)
Chassis
(Manufactured by
Mitsubishi Fuso)
2. TRUCK TRACTOR
The part that tows the loaded vehicle is called a tractor, and the loaded vehicle to be towed is
called a trailer.
A truck tractor that shares a part of the weight of the trailer is called a semi-trailer truck tractor
(semi-trailer in common) and the one that does not share the weight is called a full trailer truck
tractor (full trailer in common).
FP515GR (4X2)
FV515HR (6X4)
-4-
- GENERAL -
-5-
- GENERAL -
Check it for your reference. You will learn how the model code is applied.
-6-
- GENERAL -
3. BUS
Similar to trucks, Mitsubishi Fuso bus is also classified into small bus (BE, Rosa bus in com-
mon), medium bus (MK) and large bus (MP, MS) according to G.V.W. In addition, there is a bus
chassis (BM, RK and RP) without the body.
Rosa
MK
MS
-7-
- GENERAL -
-8-
- GENERAL -
Check it for your reference. You will learn how the model code is applied.
-9-
- GENERAL -
7. FG 4X4 2 to 3 tons
Part time 4WD truck
Canter Guts
1. FA 4X2 1.5 tons
Truck using LPG as fuel. Low engine noise is suit-
able for driving in urban areas or residential areas.
2. FB 4X2 1.5 tons
Excellent in tight turning ability. It is suitable for FG type full-time 4WD truck is the on-road type
collection and delivery in short distances. low floor vehicle most appropriate for collection
3. FD 4X4 1.5 tons and delivery.
- 10 -
- GENERAL -
(3) Fighter
1. FP 4X2 8 tons
Suitable for driving on general roads and compati-
3. FM 4X2 7 to 8.8 tons ble with special equipment.
Vehicle handling is equivalent to FK vehicle and the
available loading capacity is 8.8 tons. It is compati-
ble with all special equipment vehicles as well as
collection and delivery vehicles for short and
medium distances.
- 11 -
- GENERAL -
2. FW 6X6
4. FT 6X2 11.5 to 12 tons 10-ton class all wheel drive high-speed snow-
Applicable to good road, high speed and long dis- blower
tance transportation. The chassis weight is lighter
than that of FV vehicle. (6) Super Great truck tractor
2. FV 6X4
Applicable to transportation of heavy items with
rear 2-axle drive and excellent in stability for bad
road and snow road.
6. FV 6X4 11 to 11.5 tons
Applicable to transportation of heavy items with
rear 2-axle drive and excellent in stability for bad
road and snow road. Various engines with features
of fuel economy, torque, etc. are available.
- 12 -
- GENERAL -
1. FV-P 6X4
Used for transportation of long items. 1. MM 4X2
(9) Rosa Large class short body. It is suitable for small
group tour of short and medium distances.
2. MP 4X2
Suitable for sightseeing of short and medium dis-
tances.
3. MS 4X2
Body that is excellent in aerodynamics is used.
1. BE 4X2 Suitable for long distance sightseeing.
Short body (capacity of 26 passengers) and long (13) Aero Queen
body (capacity of 29 passengers) are available.
2. BG 4X4
4WD vehicle of BE class
(10) Aero Midi
1. MS 4X2
This represents the Mitsubishi Fuso large sightse-
eing bus. We have always met new requirements
exemplified by the front wheel independent sus-
1. MJ 4X2 pension system. It is suitable for long distance
The overall length is 7 m or less. It is positioned sightseeing or a long distance regular bus.
between BE class and MK class. The horizontal
rear engine and the T-drive method are used.
2. MK 4X2
This is main model for medium size class.
- 13 -
- GENERAL -
Before studying the truck in detail, learn the part names first.
(1) Appearance
Windshield
Front garnish
Front turn
signal lamp
Headlamp
Front grille
Rear combination lamps
Front bumper
Clearance lamp Front fender
Battery
Step
Meter cluster
Radio
Air conditioner
control knobs
Glove box
Steering wheel
Driver's seat
Shift lever
Combination switch
(Windshield wiper, Exhaust brake)
- 14 -
- GENERAL -
Tire
The rotation of
tires on the
ground from the
engine power
can drive a truck.
Propeller shaft
It is a "rotating shaft"
that transmits the
Transmission power from the trans-
A combination of gears in various mission to the rear
sizes allows effective transmission wheels.
Engine
It generates the power to drive a of the engine power. It has the
truck. How the power is gener- same function as the bicycle
ated and how the power is trans- "gear".
mitted are explained later in
detail.
- 15 -
- GENERAL -
- 16 -
- GENERAL -
Question 1
Write the appropriate terms in ( ) for the classification of trucks according to G.V.W.
( ) truck ( ) truck
G.V.W. 3,500 kg-8,000 kg G.V.W. 8,500 kg-15,100 kg
( ) truck
G.V.W. 15,100 kg or more
Question 2
Write the appropriate names of truck in ( ) of the figure below.
( ) ( )
( ) ( )
( )
- 17 -
- GENERAL -
Question 3
Write the appropriate terms that represent the truck structure in ( ) of the figure below.
( )
( )
Question 4
Write the appropriate names of truck tractors in ( ) of the figure below.
( )
( )
Question 5
Write the appropriate part names of truck in ( ) of the figure below.
( ) ( )
( )
( )
- 18 -
- GENERAL -
Question 6
Write the appropriate part names of truck in ( ) of the figure below.
( ) ( )
( ) ( )
Question 7
Write the appropriate names of major parts that consist of the truck drive train in ( ) of the
figure below.
( ) ( )
( )
( )
( )
( )
( )
- 19 -
- GENERAL -
Question 8
Write the appropriate names that represent the drive system in the figure below.
( ) system ( ) system
Question 9
The figure below is Mitsubishi Fuso FV truck and its rear wheel 2 axles are drive wheels. What
is <Total number of wheels x Number of drive wheels> for this vehicle?
( )( )
- 20 -
- ENGINE -
1. TYPES OF ENGINES
An engine shows its shape with the piston arrange-
ment and the number of cylinders containing pis-
tons.
Cylinders in a row are called the in-line type, and the V-shape viewed
from the front is called the V type.
4 cylinders make a 4-cylinder engine, and 8 cylinders make a 8-cylin-
der engine.
V-type 8-cylinder engine means that 8 cylinders, 4 on each side, are
assembled in a V shape.
Mitsubishi Fuso has a number of engine types. Engine examples for
each shape are as follows:
- 21 -
- ENGINE -
2. ENGINE PERFORMANCE
The engine is the source that generates the power to drive a vehicle.
In other words, it is a heart of the vehicle.
Power curve
Torque curve
- 22 -
- ENGINE -
zPower
Power refers to the horsepower. It acts on the
maximum speed of the vehicle.
One horsepower is the force needed to lift the
weight of 75 kg to 1 m for one second. Usually,
the vehicle power is indicated by amount of
work PS (horsepower) performed by the
engine for the specified time.
For example, the meaning of maximum output
210 PS/2,900 rpm is that 210 horsepower is
achieved at 2,900 engine revolutions per
minute.
Conversion of unit:
1PS = 0.7355kW
zTorque
Torque is the rotational force performed by the
engine. It acts on hill climbing ability or start-
up of a vehicle.
Torque (kgf-m) is indicated by the number of
kg force at 1 m from the crankshaft center.
The maximum torque of 180 kgf-m/1,200 rpm
means that the maximum torque of 180kgf-m
is obtained at 1,200 engine revolutions per
minute.
Conversion of unit:
1kgf-m = 9.80665Nm
- 23 -
- ENGINE -
What is 4-cycle?
A 4-cycle engine accurately refers to a 4-stroke 1-cycle
engine.
With 4 strokes (stroke: upward/downward movement of
piston) of intake, compression, combustion and
exhaust, 1 cycle is completed to generate the power. In
general, this is called a 4-cycle engine for short.
In addition to the 4-cycle engine, a 2-cycle engine is
available. Due to emission control, only a 4-cycle engine
is used for trucks.
- 24 -
- ENGINE -
- 25 -
- ENGINE -
- 26 -
- ENGINE -
Advantages
Disadvantages
zNoise and vibration have recently been
zNoise and vibration improved.
zManufacturing cost zMuch daily maintenance is not required.
is high zDiesel oil is inexpensive.
zHeavy zFuel consumption is low.
Origin of name:
The diesel engine is named after Dr. Rudolph Diesel, a German, who developed
the 4-cycle engine in 1897.
The 4-cycle gasoline engine was invented by Nicholas August Otto in 1876.
Piston stroke
A+B
Compression ratio =
A
- 27 -
- ENGINE -
<Example>
Obtain the compression ratio using the 4D34 engine on the Canter as an example.
The cylinder diameter (cylinder bore diameter) of the 4D34 engine is 10.4 cm, the piston stroke
is 11.5 cm and the capacity of the combustion chamber (capacity of area A on the previous
page) is 59.2 cc.
1. First, obtain the capacity of area B, where the piston moves from the bottom dead center (the
lowest position) to the top dead center (the highest position).
Capacity of area B = (Cylinder bore diameter) (Cylinder bore diameter) circle ratio 4 x (piston stroke)
= 10.4 10.4 3.14 4 11.5
= 976.4 cc
2. Put the capacities of A and B in the calculation formula to obtain the compression ratio.
Compression ratio = (A + B) A = (59.2 + 976.4) 59.2
=17.5 is thus obtained. Do you remember the circle ratio?
What is the cylinder capacity?
- 28 -
- ENGINE -
Refining of oil:
First, water or soil is removed from the crude oil. Then, the oil is put through the normal or
reduced pressure distilling system to fraction into gasoline, kerosene, diesel oil, etc. using the
difference of boiling point.
In fraction distillation, oil distillated at 30 200 C is generally gasoline, oil distillated at 160
280 C is kerosene, and oil distillated at 200 350 C is diesel oil. Heavy grade oil that cannot
be distillated can be obtained from the bottom of the distilling system.
Further distillation of heavy grade oil at reduced pressure can be fractioned into materials such
as various gear oil, wax, heavy oil that is fuel for boilers, etc.
- 29 -
- ENGINE -
Harmful gas discharged from automobiles is exhaust gas and blowby gas as shown in the
figure below.
Discharge location of
harmful substance
Blowby gas is the gas that goes In general, major harmful substances contained
from the clearance between the in exhaust gas of the diesel engine are:
piston and the cylinder to the zCarbon monoxide (CO)
crankcase. Components of this zHydrocarbon (HC)
gas are burned gas and unburned zNitrogen oxides (NOx)
zParticulate matter (black smoke and
gas of the air-fuel mixture. The
unburned hydrocarbon)
main harmful substance is HC.
- 30 -
- ENGINE -
1. CO (carbon monoxide)
CO is a highly toxic gas without taste, odor and color generated from incomplete combustion of carbon or
carbon compound. The gas has an affinity to hemoglobin in blood 250 times the oxygen. When it is absorbed
in a human body, transferability of oxygen in the body becomes poor, causing anoxic conditions.
Table 1 shows the poisoning symptoms for CO hemoglobin concentration in blood.
Hemoglobin Red pigment protein that transfers oxygen in blood. It is also called blood pigment.
Table 1
2. HC (hydrocarbon)
It is a generic name of an organic compound consisting of carbon and hydrogen. HC here refers to unburned
gas or fuel vapor gas due to misfire or incomplete fuel combustion. HC at a low concentration only gives
irritation to the respiratory system. If oxidation is insufficient, HC may become aldehydes, giving strong irri-
tation to mucous membranes or eyes.
It reacts with NOx or ozone in the atmosphere, resulting in photochemical smog.
Table 2
4. PM (suspended particulate matter)
This is discharged mainly from diesel engines. The main component is black smoke, so-called diesel smoke,
which is a carbon particulate.
Combustion heat made this carbon in the fuel loose. When it is discharged in the atmosphere, it becomes
suspended particulate matter and makes visibility poor. The PM also contains soluble organic fraction (SOF),
sulfate, etc.
Suspended particulate matter is said to contain a trace of carcinogens.
- 31 -
- ENGINE -
<Countermeasure>
Various measures are taken to reduce discharging harmful substances. The figure below is a
summary of these measures. The basic policy is as follows:
1. Achieve combustion status that minimizes harmful substances with modification of parts
including the engine.
2. Control the injection volume, injection timing, etc. to the most appropriate status with an
electronic control fuel injection system.
3. Seal the crankcase opening to prevent the blow-by gas from escaping to the atmosphere
and return it with intake air to the combustion chamber for re-combustion.
Appropriate valve timing
Modification of inlet manifold
Modification of pre-combustion
EGR device chamber (swirl chamber type)
- 32 -
- ENGINE -
Question 1
Write the appropriate terms that indicate each stroke in the figure below.
Question 2
What are harmful gases A and B emitted from automobiles in the figure below?
A B
A: ( )
B: ( )
- 34 -
- ENGINE -
Cylinder head
Crankcase
(cylinder block)
Oil pan
- 35 -
- ENGINE -
<What is Valve?>
Valves are classified into an intake valve and exhaust valve.
Valves open and close with the motion of the engine, and they are driven by the camshaft.
An engine has camshaft located next to the crankshaft, and its only valves are placed above
the cylinder, the engine is called OHV (overhead valve) type.
An engine has the camshaft and the valves above the cylinder, it is OHC (overhead camshaft)
type engine.
Camshaft
Valve
Valve
OHC type
Push rod
Camshaft
Crankshaft
OHV type
- 36 -
- ENGINE -
Turbocharger
Intake device
Governor
Injection pump
Exhaust device
Turbocharger
- 37 -
- ENGINE -
(1) Turbocharger
zEffect of supercharging
You may understand that an engine with a large displacement has
larger power than the engine with a small displacement.
This is explained by the fact that a large intake of air into the cylinder
provides an injection of a large amount of fuel, resulting in a large
explosion force.
However, the expansion of the engine body size to increase the
displacement is limited, considering engine space or weight.
Without changing the engine size, compression of intake air is used
to obtain a large explosion. "Supercharging" is thus invented.
The compression of the intake air and the concentrated density of
intake air can burn a lot of fuel. The same effect for a larger engine
displacement can be obtained.
- 38 -
- ENGINE -
(2) Intercooler
zOperation of intercooler
When air is compressed, its temperature increases. However, the
density of air becomes low at high temperatures.
Even though air is compressed with the turbocharger, a large effect
cannot be obtained due to the low air density.
The intercooler reduces the air temperature compressed with the tur-
bocharger to increase the air density.
It is a super machine that achieves high power output, fuel economy
and low pollution at the same time with the improved turbocharger
function by cooling air.
- 39 -
- ENGINE -
Turbocharger
To exhaust pipe
From air cleaner
Valve
- 40 -
- ENGINE -
Question 1
Write the appropriate names of the engine body parts in ( ) of the figure below.
( )
( )
( ) ( )
( )
( )
( )
( )
( )
( )
( )
- 41 -
- ENGINE -
9. FUEL SYSTEM
Fuel filter
Overflow
valve
Fuel tank
Overflow valve
Fuel tank
Injection nozzle
(Injection of fuel to each cylinder
Feed pump according to the injection order)
- 42 -
- ENGINE -
Drain plug
Feed pump
Air bleeding
When fuel runs out, air comes into the fuel system. If the fuel is replenished later, the
engine cannot be started. In this case, bleed air in the fuel line.
After loosening the air bleeding plug on the fuel filter, loosen the priming pump on the feed
pump. Pump (move up and down) it to purge air in the fuel system from the air bleeding
plug.
When air bubbles do not come out with the fuel, air bleeding is completed.
Then, tighten the air bleeding plug and press down the priming pump to return to the
original condition.
- 43 -
- ENGINE -
Injection nozzle
zStructure of injection pump
The injection pump has a camshaft that is
interlocked with the engine crankshaft, and it
is designed to pressure and feed the fuel to
each cylinder using the camshaft revolutions.
Inside the injection pump, there are compo-
nents of the plunger that feeds pressurized
Injection pump Plunger
fuel, the camshaft that provides the plunger
Fuel filter with vertical motion interlocked with engine
revolutions and the unit that controls the fuel
Feed pump injection amount of the plunger. They are
manufactured with a precision control mecha-
Fuel tank
nism.
Camshaft
- 44 -
- ENGINE -
Fuel intake/
exhaust port
Lead
When the plunger goes When the plunger goes up When the plunger goes up fur-
down, fuel is taken into the and the fuel intake/exhaust ther and the lead of the plunger
plunger barrel from the fuel port is closed, pressure reaches the fuel intake/
intake/exhaust port. feed of fuel starts. exhaust port, fuel in the
plunger barrel starts reverse
flow from the vertical hole at
the center of the plunger to the
fuel intake/exhaust port
through the lead. Pressure
feed of fuel is completed.
- 45 -
- ENGINE -
- 46 -
- ENGINE -
(6) Governor
The governor settles and controls the engine revolution so that stable idling revolution is main-
tained or that the engine revolution does not exceed the allowable revolution due to excessive
effort on the accelerator pedal.
The governor controls the control rack position so that the plunger deliver the necessary
amount of fuel for each engine speed.
Due to the difference in mechanism, the following types of governors are available:
zMechanical governor
Revolution is mechanically con-
trolled with centrifugal force of
flyweight (weight). When the
engine speed is too high, the
revolution of the camshaft that is
interlocked with the engine
crankshaft increases. The fly-
weight at the end of the camshaft
goes outward with the centrifugal
force. This motion returns the
<Principle of a governor>
control rack to reduction of fuel
based on the principle of lever-
age.
zElectronic governor
It is the latest electronic control system that determines the optimum injection amount by taking
into consideration not only the engine speed, but also information such as the engine load,
coolant temperature, etc. by processing them in the computer.
Control rack The figure on the left shows the actuator
Control rack position sensor
of the electronic governor assembly. It
consists of the linear DC motor, link and
control rack position sensor. This actua-
tor electrically operates the control rack.
Linear DC motor
Coil assembly
- 47 -
- ENGINE -
(7) Timer
The timer controls the injection timing of the injection pump together with the outward move-
ment of the flyweight, using the centrifugal force of the flyweight (weight) mounted on the
engine revolution shaft.
When the engine revolution increases, the revolution to drive the injection pump goes faster.
Then, the flyweight moves outward with the centrifugal force while compressing the timer
spring.
The camshaft of the injection pump revolves faster for this to make the injection timing earlier.
- 48 -
- ENGINE -
(8) Common rail fuel injection system
Mitsubishi Fuso's engine employs the computer controlled common rail
type fuel injection system to reduce NOx or PM (particulate matter) and
to achieve the optimum combustion.
The common rail fuel injection system pressure feeds fuel, with the
application of super-high pressure with the supply pump, to the accumu-
lator (common rail) and injects the high-pressure fuel from the injection
nozzle (injector). It promotes atomization of injection fuel in the cylinder
and achieves the optimum air-fuel mixture.
In addition, the number of fuel injections, timing and injection amount are controlled in detail,
incomplete combustion is eliminated to reduce NOx or PM and ideal combustion is achieved
from the low speed to high speed range.
Engine performance and ease of driving as well as fuel economy are also improved.
- 49 -
- ENGINE -
Oil bath
- 50 -
- ENGINE -
In addition to the above, the engine brake with the engine or the exhaust brake with exhaust
gas is available.
zDoes an engine act as a brake?
When the accelerator pedal is released while driving a vehi-
cle, the engine revolution goes down and the vehicle speed
decreases. This is referred to as engine brake. The braking
effect is better for lower gears. A low gear is used on a long
downhill slope to apply an effective engine brake.
zExhaust brake
It is the system that increases the engine brake effect
using exhaust gas. A valve is provided on the engine
exhaust pipe to increase the engine revolution resis-
tance by closing the exhaust pipe.
In a large diesel engine, the exhaust brake can reduce
the speed about 1.5 to 2.5 times the engine brake.
- 51 -
- ENGINE -
Question 1
Write the appropriate names in ( ) of the figure below indicating the fuel injection system.
( )
( )
( )
( )
( )
( )
( ) ( )
( ) ( )
( )
( )
( )
( )
- 52 -
- ENGINE -
The engine is operated with friction of components such as piston, cylinder, crankshaft, cam,
etc. For smooth operation of these components, lubricant is required.
- 53 -
- Engine -
<Classification of performance>
The stronger the oil film is, the better the engine oil is.
Oil performance is graded (classified) by a test. It is important to use oil suitable for engine
characteristics. CC grade (CD grade for turbocharger) or better is specified for Mitsubishi
Fuso's engines as shown below.
- 54 -
- ENGINE -
Reservoir tank
Cooling fan
Thermostat
Water jacket
(Water channel for coolant)
Radiator
Water pump
Oil cooler
(1) Radiator
The radiator is built with many tubes. Air going
through clearances of these tubes radiates
heated coolant after circulation in the engine
and the coolant returns to the water channel in
the engine.
- 55 -
- ENGINE -
- 57 -
- ENGINE -
Starter switch
Starter motor
Battery
- 58 -
- ENGINE -
1.CLUTCH
It is located between the engine and the transmission. This system trans-
fers or shuts off the engine power to the drive wheels as required.
When the engine is started, the transmission gear is shifted (gear
change) or the vehicle is stopped by braking, it temporarily shuts off the
engine power or smoothly transfers the power at the start.
- 60 -
- CHASSIS -
[Advantages]
- Effort on the clutch pedal can be reduced.
- Applied pressure can be uniform.
- The number of parts is limited, and the structure is simple.
- Even if the centrifugal force is stronger at high-speed revolution, the spring deformation is
limited due to its disc shape, and the stability is high with good balance.
Diaphragm spring
- 61 -
- CHASSIS -
[Advantages]
- The applied force to push the clutch disc is very strong.
Coil spring
Transmission
Clutch disc
Flywheel
(The condition that the
clutch is engaged)
- 62 -
- CHASSIS -
2. TRANSMISSION
<Role of transmission>
A vehicle must be capable of various uses such as stop, start, low speed, high speed and
reverse driving. The role of the transmission is to use the engine performance effectively to
meet various conditions.
Imagine a bicycle with a gear shifter. Gears are shifted one after another to ease the pedal effort
on an uphill slope and to increase the speed on a flat road.
The transmission is basically equivalent to this bicycle. Gear combinations are changed to
obtain a large amount of power at the start or on an uphill slope and to obtain speed on a flat
road. So-called 1st, 2nd and 3rd speeds (low, second, third) refer to the combination of gears.
- 63 -
- CHASSIS -
<Gear ratio>
It is the ratio between the engine revolution and the pro-
peller shaft revolution.
In the forward gears, the 1st gear has the largest ratio. It
becomes smaller in the order of the 2nd and 3rd gears.
* Even if the engine has the same performance, the drive
force varies on a different gear ratio of the transmission
or different final reduction gear ratio.
The driving performance is usually referred only for the engine performance, but the gear ratio
and the final reduction gear ratio also need to be considered.
The weight
of 1 rotation
The weight
of 4 rotations
Using the number of gears to be
engaged, their rotation is reversed.
Large force
Small force
- 64 -
- CHASSIS -
<What is overdrive?>
The gear that makes the engine revolution the
same as the propeller shaft revolution is called
direct drive. The gear ratio is 1. When the gear
ratio is smaller than 1, which has larger pro-
peller shaft revolution than the engine revolu-
tion, it is called overtop or overdrive.
zWhat is overrun?
If you are driving down a steep downhill
slope, the engine revolution increases
without reducing the vehicle speed. It then
exceeds the maximum revolution and a
large noise can be heard. This is called
overrun.
If you are driving at a high speed, you may
have made a shifting error from 5th gear to
3rd gear. The engine revolution suddenly
increases and overrun occurs, resulting in
damage to the engine. Each shifting gear
has the limit vehicle speed, it is important
to observe the speed.
- 65 -
- CHASSIS -
Drive pinion
Mainshaft
Countershaft
- 66 -
- CHASSIS -
zSynchromesh method
It is called the synchronous engagement method. In this method, a cone-shaped clutch, called
a synchronizer ring, comes in contact with the gear before engagement. When the revolution
is the same, the gears are engaged. It features smooth engagement of the gears.
Shifter fork
Synchronizer ring
4th gear
Drive pinion
Shifting key
Shifting key spring
Mainshaft
Synchronizer hub
Synchronizer sleeve
A: Synchronizer ring
B: Sleeve
C: Hub
1: Main drive gear
2: Countershaft gear (front)
3: Countershaft gear (rear)
4: Mainshaft gear
- 67 -
- CHASSIS -
<Synchronous action>
When the gear shift lever is operated,
gear B moves to the right side.
The fitting (black part) inside gear B
also moves to the right side and
presses gear A to 4.
(At this point, gear B that is moved is
not engaged with A.)
The friction force of A and 4 gradually
starts rotation of 4, A, B and C together.
This action of synchronous rotation with
the friction force is called synchroniza-
tion.
<Engagement of gears>
Further operation of the gear shift lever
gives B additional movement.
At this time, gears of B, A and 4 are
already rotating with the synchronous
action described above. Smooth
engagement is made. Now, shifting
gears is completed.
The flow of engine power is:
1234ABC. It leads to the
propeller shaft.
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(2)Automatic transmission
In contrast to the manual transmission (M/T) that changes the gear with the hand for driving, it
is the system that automatically changes the transmission gear.
The basic structure of the automatic transmission (A/T) is:
(1) Torque converter that transfers the engine revolution to the next gear mechanism, and
(2) Gear mechanism using the planetary gear.
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Carrier
zShift pattern
While driving in the D range, the speed is automatically changed from 1st to 4th gear according
to the vehicle speed and the throttle opening (for 4th speed A/T).
The figure below shows how upshifting occurs as the vehicle speed increases.
When the throttle opening is small, upshifting occurs at a low speed. When the throttle opening
is large, upshifting occurs at a high speed.
In the electronic controlled A/T vehicle, the shift pattern can be selected from economy mode
or power mode.
Throttle opening
Power pattern
Economy pattern
Vehicle speed
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Transmission PTO
It is mounted at the side of the transmission. With
the PTO operation lever, the power takeoff can be
turned ON/OFF through the control unit.
It is used when the vehicle is not in motion.
This PTO is the most popular and widely used.
[Feature] The unit has a low cost and it is easily
mounted.
[Vehicle] Dump truck, tanker, vacuum car, garbage
truck, simple crane vehicle, lift platform vehicle, etc.
Flywheel PTO
It is mounted on top of the engine flywheel housing.
Since the power is taken directly from the engine,
the equipment can be moved as long as the engine
is on when the vehicle is not in motion or while driv-
ing.
In particular, to turn ON/OFF the PTO operation,
use the electromagnetic clutch.
[Feature] Power is taken directly from the engine.
The vehicle models are limited.
[Vehicle] Mixer vehicle, garbage truck, etc.
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Transmission PTO
The transmission PTO is the unit that takes the power from the transmission. It is usually
mounted on a dump truck or various equipment vehicles requiring power when the vehicle is
not in motion.
Shift sleeve
Output shaft
Air cylinder
Shift fork
Flywheel PTO
The flywheel PTO is mainly used for a mixer truck. While the engine is running, the power can
be taken out whether or not the vehicle is in motion.
Flywheel PTO with electromagnetic clutch
Flywheel housing
Flywheel housing
Crankshaft gear
Transmission
Mainshaft
Rear mainshaft
PTO input shaft
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Question 1.
Write the appropriate names in ( ) of the figure below.
( ) ( )
( ) ( )
Question 2.
In figures (A) to (F) below, which shows engagement and disengagement of the power?
Clutch pedal
Clutch pedal
Engagement of power ( )
Disengagement of power ( )
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Question 3.
In the figure below, gear (A) turns clockwise. Complete the following sentences by choosing the
appropriate word in ( ).
In comparison with gear (A), the revolution of gear (C) is (fast, slow) and the revolution torque
is (large, small).
The revolving direction is (clockwise, counterclockwise).
Question 4.
In comparison to the manual transmission, what are features of the automatic transmission?
Itemize them below.
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The final reduction gear changes the power from the propeller shaft perpendicularly and trans-
fers it to the rear axle shafts. It also reduces the speed to increase the torque. From the final
reduction of the speed, it is called final reduction system.
The reduction gear ratio is also called the final reduction gear ratio.
Two reduction gears are available: spiral bevel gear and hypoid gear.
Mitsubishi Fuso is using hypoid gear.
Reduction pinion
<Hypoid gear>
The centerline of the reduction pinion is engaged offset with the centerline of the ring gear. With
a large twist of the teeth, this gear is widely used.
[Advantage] The gravity center of vehicle is low, and vehicle stability is improved. Since the
gear contact area is large, engagement is wide and the operation noise is quiet.
Reduction pinion
Ring gear
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Final reduction gear ratio = Revolutions per minute of propeller shaft / Revolutions per
minute of drive wheel = Number of ring gear teeth / Number of reduction pinion gear teeth
Now, we will study how the vehicle characteristics are changed according
to the change of the final reduction gear ratio.
<Example>
Obtain the final reduction gear ratio of the following (1) and (2) final reduc-
tion gears.
(1) The number of ring gear teeth is 40, and the number of reduction
pinion gear teeth is 7.
Final reduction gear ratio =
(2) The number of ring gear teeth is 37, and the number of reduction
pinion gear teeth is 6.
Final reduction gear ratio =
In Canter truck, FE515BN4 is using the final reduction gear in (1), and FE515BD4 is using the
final reduction gear in (2).
Both vehicles are mounted with the 4D32 engine and the M015S5 5-speed manual transmis-
sion. With final reduction gears using different final reduction gear ratios, specifications suitable
for the vehicles are obtained.
FE515BD4 that has the final reduction gear ratio in (2) is a dump truck. This vehicle often
carries cargo to construction sites, urban areas or mountain areas at a low or medium speed.
Therefore, driving performance with good response together with large power at start-up and
acceleration is required for this vehicle.
In this way, a final reduction gear with larger final reduction gear ratio is used.
Instead, the maximum speed is low.
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4. DIFFERENTIAL GEAR
Propeller shaft
Ring gear
Reduction pinion
Differencial gear
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<When turning>
When tires at one side have a larger road resistance than the other at a curve, the differential
pinion gear turns to move the outside wheels additionally.
The inside wheels have a larger road resistance than the outside wheels do, and their speed is
reduced.
The differential pinion gear rotates on the spider and drives the differential gear with smaller
road resistance to give differential action.
Longer distance
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5. STEERING SYSTEM
The steering system changes the moving direction of a
vehicle as desired. By turning the steering wheel, the
direction of the front wheels is changed.
The system has the following three mechanisms:
<Operation mechanism>
Steering wheel Operation force of the steering
wheel is transferred to the gear
Steering shaft mechanism. (Steering wheel, steer-
ing shaft, etc.)
Steering gearbox
<Link mechanism>
This transfers movement of the
Tie rod gear mechanism to the front wheels
and maintains the left and right
wheels at a constant state.
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Reservoir tank
Oil pump
Power steering
gearbox
Piston
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- CHASSIS -
Assistance/small Assistance/large
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6. BRAKE SYSTEM
Loading
Turning Running
Stopping
<Principle of brake>
The principle of the truck brake is basically the
same as that of the bicycle brake. It stops the
rotation of wheels with friction.
On a bicycle, wheels are stopped with friction
between the rim and the rubber. On a truck,
the drum and the friction material on the brake
shoe are used to stop wheels. This is the drum
brake used in general. When the brake is
applied, the friction material on the brake shoe
comes in close contact with the drum, causing
friction to stop the rotation of the wheels.
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Wheel cylinder
If the fluid leaks due to a hole in the brake pipe, the brake may not be
effective. In the hydraulic brake, the hydraulic circuit is divided into
two systems: front wheels and rear wheels. If one brake circuit has a
fluid leak, the other brake circuit functions for safety reasons.
Brake fluid
Brake fluid has additives to prevent oxidation and metal corrosion in addition
to glycol ether, which is used as a viscosity control solvent into polyglycol, etc.
Therefore, it is far different from oil, and it is similar to antifreeze. It is appro-
priate to call it brake fluid, not brake oil.
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Air tank
Dual brake valve
Compressor
Air master
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- CHASSIS -
Air tank
Compressor Brake chamber
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- CHASSIS -
zMaster vac
Master vac uses a vacuum. It is integrated
with the master cylinder. When the brake
pedal is not depressed, chambers A and B of
the master vac are always in a vacuum with
the engine power.
When the brake pedal is depressed, air
enters into chamber B, and the atmospheric
pressure moves the large piston in the cham-
ber. It pushes the piston of the master cylin-
der to generate a high hydraulic pressure.
This is mainly used for passenger cars and
the Canter.
zAir master
The air master is a system that uses com-
pressed air. The brake pedal itself has a valve
mechanism. When the brake pedal is
depressed, compressed air builted by the
compressor is directly sent from the air tank,
which generates a high hydraulic pressure.
The capability as the brake servo unit is
higher than the master vac. It is mainly used
for medium-sized trucks.
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<Drum brake>
The brake shoe with friction material is pressed outward against the brake drum, which is turn-
ing together with the tire, to stop the rotation.
The drum brake has some types of brake shoe arrangement for an effective brake perfor-
mance.
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<Disc brake>
Since the drum brake pressed the brake shoes inside the drum, heat tends to be stored. Con-
tinued use of the drum brake for a long time may result in ineffective braking. To improve this
problem, the disc brake system was invented.
It is a system that clamps the disc, which is rotating with the wheel, with pads from both sides
to stop rotation. Different from the drum brake, the disc is exposed to the air. Heat is easily
radiated and stable braking performance is obtained.
Disc Caliper
Pad Pad
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- CHASSIS -
Brake cable
Center brake
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- CHASSIS -
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- CHASSIS -
Question 1.
Write the appropriate names in ( ) of the figure below.
( )
( )
( ) ( )
( )
( )
( )
Question 2.
Write the appropriate names in ( ) of the fig- ( )
ure on the right.
( )
( )
( )
( )
( )
( )
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- CHASSIS -
Question 3.
Write the appropriate names in ( ) of the figure below.
( )
( )
( )
( )
( ) ( )
( )
( )
( )
( )
( )
( )
( )
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Question 4.
Write the appropriate names in ( ) of the figure below.
( )
( ) ( )
( )
(A)
( )
(B)
( ) ( ) ( )
Question 5.
What are the brake system names of figures (A) and (B) in question 4?
(A);
(B);
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7. TIRE
A tire is assembled with the disc wheel, and it supports the total weight of the vehicle. It main-
tains sufficient contact with the road, reduces slip with the road due to drive force or braking
force, absorbs part of the shock from the road and reduces vertical movement of the vehicle
together with the spring suspension.
(1) Structural function of tire
zTread
It is the area that has direct contact with the
road. The rubber thickness in this area is the
thickest. It is strong enough to withstand wear
or impact/damage from roads.
zCarcass
It is the frame to hold the air pressure inside
the tire and to maintain the tire shape.
Cord cloths are overlapped with each other.
zBreaker
Cord layer between the carcass and tread.
zShoulder
The portion is between the tread and the side-
wall portions.
zSidewall
It is the side continuing from the tread. The
rubber thickness is thin, and this area is sub-
ject to load impact during driving.
zBead
(2)Types of tires It stabilizes a tire on the wheel rim.
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Cross-sectional
(4) Nominal designation of tires width of tire
In principle, the nominal designation methods
of tires are classified into the ISO method that
uses the tire dimension (cross-sectional width,
Height of tire
aspect ratio, rim diameter), structure, operat-
ing conditions (load capability index, speed
code, application), and the conventional desig-
nation method that uses the nominal size and
the ply rating. The nominal designation method
of tires has recently been standardized to the Rim diameter
ISO method.
10.00 R 20 - 14PR
Ply rating
Designation of rim diameter (inch)
Tire structure code (radial)
Designation of cross-sectional width (inch)
10.00 - 20 14PR
Ply rating
Designation of rim diameter (inch)
Designation of cross-sectional width (inch)
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- CHASSIS -
8. SUSPENSION
The suspension uses springs between the vehicle body and the tire and
supports the vehicle body, while absorbing vehicle vibration. It has both the
functions of improving driving comfort and improving ground contact, i.e.,
driving stability.
The available structures are the independent suspension type that allows
independent operation of each wheel and the rigid axle suspension type that connects the left
and right wheels with one axle.
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- CHASSIS -
[Advantages]
- Excellent in durability and appropriate for driving
on rough road.
- Since the spring is strong, it is suitable for trans-
portation of heavy items.
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- CHASSIS -
(4) Stabilizer
It is a stabilizing bar mounted to prevent roll of
the vehicle body when turning a corner.
It is often used for front wheels to assist the
suspension.
Automobile spring
Available types of automobile springs are leaf
spring, which has been used for the horse cart
and rickshaw, spiral coil spring, torsion bar
Coil spring Torsion bar spring spring using torsion of steel rod, air spring
using air elasticity, etc.
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- CHASSIS -
9. BATTERY
Quantity of battery
Performance rank The dimention to be connected
of length in series
Width X height Polar position of a terminal
The capacity (generating capacity) of the alternator is determined considering the balance of
charge and discharge. If large fog lamps that consume a lot of electricity are installed later, the
alternator and battery need to be replaced with a large capacity type.
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- CHASSIS -
- 103 -
- CHASSIS -
- 104 -
- CHASSIS -
- 105 -
- CHASSIS -
The chassis consists of the frame, the engine, the drive train, steering system, suspension, cab,
and other systems necessary for driving.
Now, we will study the basic structure and role of cab and frame.
Cab
Available types of truck cab are the cab-over type that has the engine
under the cab floor, and the bonnet type that has the engine in front of
the cab.
In the cab-over type, engine vibration and noise are directly transferred
in comparison with the bonnet type. Rubber or spring with fluid is used
between the cab and the frame to improve driving comfort.
Since the overall vehicle length is regulated in Japan, cab-over type,
which can use a large cargo space, is mainly used.
Frame
The frame is a combination of two side rails (vertical
member) and several crossmembers (lateral mem-
ber).
It has a ladder shape when viewed from above. The
body is mounted on this frame.
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Question 1.
What are the names of tires for (A) and (B) in the figure below?
(A) (B)
Question 2.
Write the appropriate names in ( ) of the figure below.
( )
( )
( )
( )
( )
( )
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- CHASSIS -
Question 3.
Read the tire code in the figure below and answer the questions.
Tire width: ( ) mm
Aspect ratio: ( )
Rim diameter: ( ) inch
Question 4.
Write the appropriate names in ( ) of the figure below.
( )
( )
( ) ( )
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- CHASSIS -
- 109 -
Memo: