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FOR INTERNAL USE ONLY

Truck Technology:

The Facts You Need (II)

Chassis

The Professor
The professor explains
everything about trucks in a
way thats easy to understand.
He says: Everything youre going
to learn is vital for your work, so I
hope youll pay close attention.
The Assistant
The assistant sees considers
everything from your point of
view and supplements the
professors explanations.
She says: I have a lot to learn, so
Im studying hard.

What trucks are all about

Truck Technology:

Canter
Canter explains Mitsubishi
Fuso technologies.
He says: I hope youll do your
best to understand the
technologies used in trucks like
me.

The Facts You Need (II) Chassis

Contents
What is the chassis? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Whats the structure of a chassis? . . . . . . . . . . . . . . . . . . . 2


2 How does a truck move? . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


1. Whats the clutch? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. What clutch types exist? . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Whats the transmission? . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. What transmission types exist? . . . . . . . . . . . . . . . . . . . . . . 8
5. What is an automatic transmission? . . . . . . . . . . . . . . . . . 10
6. What is overdrive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7. What is a power takeoff (PTO)?. . . . . . . . . . . . . . . . . . . . . 13
8. What is a reduction gear? . . . . . . . . . . . . . . . . . . . . . . . . . 14
9. What is a differential gear? . . . . . . . . . . . . . . . . . . . . . . . . 15
How is a truck steered? . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1. How is the steering gearbox structured? . . . . . . . . . . . . . . 17
2. What is power steering? . . . . . . . . . . . . . . . . . . . . . . . . . . 18
How does a truck stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1. What are hydraulic brakes? . . . . . . . . . . . . . . . . . . . . . . . . 20
2. What types of braking system are used?. . . . . . . . . . . . . . 21
3. How does light pedal action cause
strong brake operation?. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. What types of brake exist?. . . . . . . . . . . . . . . . . . . . . . . . . 23
5. What other kinds of brake exist on a truck? . . . . . . . . . . . . 24
6. What are ABS and ASR?. . . . . . . . . . . . . . . . . . . . . . . . . . 25
What types of tire exist? . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
How does a truck give a comfortable ride? . . . . . . . . . . . 28
1. What suspension spring types exist?. . . . . . . . . . . . . . . . . 29
Where does electricity in a vehicle come from? . . . . . . . 30
1. How is a flat battery dealt with? . . . . . . . . . . . . . . . . . . . . . 31
What technologies are used in the Canter? . . . . . . . . . . 32

3


4

5


6


7


8

CHECK SHEET
INDEX

The Salesman
The salesman wants
to be a great
success with
customers.
He says: Technical
things are hard for me
to understand, but Im
doing my best.

Introduction

What is the chassis?

About the chassis
The structure of a truck can be broadly divided into the chassis and the body.
The chassis includes systems and components that are needed for the truck to
move and be driven.
With a passenger car, the term body refers to the overall covering of the
vehicle. With a truck, though, it refers to the structure or equipment that is
attached to the truck to meet a specific need. It can, for example, be a flatcargo-bed body, a dump-truck body, a cement-mixer body, or a crane body.
Bodies are produced by specialist body makers. Simply stated, the chassis is
the truck without its body.
A chassis completed by Mitsubishi Fuso is known as a bare or nude chassis. It
contains all the components and systems needed for on-road driving, so it can
be driven to a body maker for attachment of a body. When a body has been
attached by a body maker, the vehicle is a complete truck.
The chassis is the structural foundation of the truck, so its important for you to
have a good understanding of it.

Truck body
(produced by specialist body maker)

Chassis
(produced by Mitsubishi Fuso)

Whats the structure of a cha

The makeup of the chassis

The chassis consists of a frame; the engine; systems needed to transmit

the engines power so the vehicle can move; a steering system, a
suspension system, and other systems that are needed for operation of
the vehicle. Lets look at the basic structures and roles of the items that
make up the chassis.

Cab-over-engine type
Cab-behind

Cab
The cab can be either of two types: a cab-over-engine type,
which is mounted above the engine, or a cab-behind-engine type,
which has the engine mounted in front of it.
The cab-over-engine type is more easily affected by engine noise
and vibration because of its position above the engine,
but liquid-filled rubber parts and springs are located between the cab
and frame to ensure good ride comfort. In Japan,
which has regulations on overall vehicle lengths, the cab-over-engine type
which permits more space to be used for the load bed, is more popula

Steering wheel (See page 16.)

The steering wheel is part of the steering system.
It allows the driver to change the trucks direction as desired.

Headlamps
Mitsubishi Fuso trucks have discharge headlamps.
These headlamps have projector lenses,
which help realize long illumination distances,
and they produce light by means of discharge tubes,
which have about twice the brightness and three times
the service life of conventional halogen bulbs.

Engine (See the Engine section for details

In a vehicle with a manual transmission, the clutch
and transmission are located aft of the engine.

Clutch (See page 5.)

In a vehicle with a manual transmission, the engines power is
initially applied to the clutch. Using the clutch pedal,
the driver can make or break the flow of engine power.

Transmission (See page 7.)

The transmission is full of gears, so it is also called a gearbox.
Using many gears of different sizes, it adjusts the torque (rotational force)
and speed of the engines output.

ssis?

Propeller shaft
The propeller shaft transmits power from the output side
of the transmission to the reduction and differential gear.

Reduction and differential gear (See pages 14 and 15.)

This item is generally known as a differential. It contains a reduction gear,
which reduces the rotational speed of the power from the propeller shaft,
thereby increasing the torque. It also contains a differential gear,
which allows the left and right wheels to turn at different speeds
when the vehicle is steered (essential for smooth motion around curves).

Suspension system (See page 28.)

The suspension system works between the frame and wheels.
It absorbs vibration received by the truck from the road surface.

Frame: The frame consists of two side rails and a number of crossmembers.
From above, it looks like a ladder. The body is mounted on the frame.

Crossmember
Side rail

Mitsubishi Fuso Super Frame

The type of frame used on Mitsubishi Fuso trucks is called a
Super Frame because it has a number of unique features. With
the Super Frame, the side rails and crossmembers are joined by
web joints (in other words, they are joined sideways), not by
flange joints (vertical joints). Since the web joints link the
crossmembers to the side rails side surfaces, which are
extremely rigid, they help make the frame extremely strong.
Also, the absence of rivets in the top surfaces of the side rails
allows easier body attachment.

How does a truck

move?
The driveline

?
?

Customer:
The clutch seems to be slipping.
Salesman:
I dont know what you mean. Help!
See

What is clutch slippage? on page 5.

The clutch, transmission, and reduction and differential gear are together known
as the driveline. All of the items in the driveline are essential for propulsion of the
truck. The engines power is transmitted from the clutch to the transmission and is
transmitted from there by the propeller shaft to the reduction and differential gear,
which transmits it to the wheels.

The term 4x4 (or four by four) indicates the total number of
wheels and the number of wheels that are driven by engine
power. In other words, it shows that a vehicle has four wheels
and that all four wheels are driven by engine power.

<Common drive configurations>

Whats the clutch?

About the clutch

The clutch is located between the engine and transmission. It is used to make and
break (as necessary) the flow of power from the engine toward the wheels. The
clutch is used to interrupt the flow of power when the engine is being started, when
gear changes are performed using the transmission, and when the brakes are used
to stop the vehicle. At other times (for example, when the vehicle is driven away
from a standing start), the clutch is used to smoothly transmit power toward the
wheels.
E

The principle of clutch operation

In its simplest form, the clutch can be seen as two discs that are pressed together
or moved apart from each other to transmit power or interrupt the transmission of
power as needed. When the clutch pedal is pressed, the discs move apart from
each other. In other words, the clutch is disengaged. When the pedal is released,
spring force pushes one disc firmly against the other. In other words, the clutch is
engaged. The disc on the engine side is called the flywheel. The disc on the
transmission side is called a clutch disc.

What is clutch
slippage?

Clutch disc
Flywheel

Like the customer talking to the

salesman in the cartoon at the
beginning of this chapter, you
may have heard someone say
that a clutch is slipping. This
means that the friction material
(called the clutch facing) on the
clutch disc has worn so thin that
it does not make good contact
with the flywheel. When a
clutch slips, pressing the
accelerator pedal causes the
engine speed to rise but the
vehicle does not accelerate.
When the clutch facing of a
Canter truck becomes worn, a
warning light illuminates to
inform the driver.

What clutch types

2 exist?
Clutch types
As mentioned on the previous page, the clutch disc of a clutch is pushed against
the other disc by spring force. Clutches are classified according to the type of
spring. There are two types: the diaphragm-spring type and the coil-spring type.
They are also classified according to the number of clutch discs. Although our
examples thus far have mentioned only one clutch disc, some clutches in the real
world have more than one disc. A clutch with one disc is called a single-disc clutch.
A clutch with more than one clutch disc is called a multi-disc clutch.
Heavy-duty trucks have multi-disc clutches because their high engine power necessitates
high power transmission capacity.

Diaphragm-spring type
Most current clutches are of the diaphragm-spring type,
in which clutch engagement is achieved by the pushing
force of a diaphragm spring (a disc-shaped spring).
When the clutch pedal is depressed, the diaphragm
spring is pushed back to disengage the clutch.
[Merits]
The required pedal effort can be made low.
The spring applies pressure uniformly to the disc.
The number of parts is small; the structure is simple.
Since the spring is disc-shaped, it does not deform
when subjected to strong centrifugal force at high
speeds of rotation; its good balance permits
consistent clutch performance.

Dia
ap

Flywheel

Clutch disc

Flywheel

(Clutch engaged)

(Clutch disengaged)

Coil-spring type
Truck clutches are and have been most often of the
coil-spring type. With this type of clutch, engagement is
achieved using the pushing force of a coil spring (also
called a pressure spring). When the clutch pedal is
depressed, a release lever is pushed to disengage the
clutch.
[Merits]
The force that pushes the clutch disc is extremely
great.

Mitsubishi Fuso trucks offer the benefits of both of the types described above. It is usual for
coil-spring clutches to be used in some heavy-duty trucks and for diaphragm-spring
clutches, which have a lighter pedal action and better balance, to be used in other trucks.
With the Super Great (a heavy-duty truck with extremely high engine power), however, a
diaphragm-type clutch is combined with a special device that enables the diaphragm spring
to produce more pushing force than a coil spring.

Whats the
3 transmission?
About the transmission

The transmission combines gears with differing numbers of teeth to change the
torque and speed of the engine power while transmitting the power to the propeller
shaft. There are two transmission types: manual and automatic. With a manual
transmission, the driver manually uses the transmission to change gears. With an
automatic transmission, the transmission automatically performs gear changes as
the vehicle is driven.

The role of the transmission
A vehicle must allow itself to be driven in a wide range of ways. (For example, it must allow itself to be driven away from a
standing start, driven at various speeds, and reversed.) Consequently, the transmission allows the engines characteristics to
be exploited effectively under widely varying driving conditions. Consider a bicycle that has selectable gears. The rider selects
gears in order to lighten the pedal action on uphill roads and to be able to ride fast on level roads. The transmission of a motor
vehicle is basically the same as the gears of the bicycle. It allows gears (actually combinations of gears) to be selected in order,
for example, to realize lots of power for standing starts and on uphill roads and to enable the truck to be driven fast on long
downhill slopes. The terms 1st, 2nd, and 3rd (or low, second, and third) refer to the combinations of gears.
Precise gear changes are necessary with a truck that carries heavy cargo.
For this reason, some Mitsubishi Fuso Super Great models have a 16-gear (or 16-speed) transmission.

Gear ratios
The gear ratio is the ratio between the speed of the engine and the
speed of the propeller shaft. For forward motion, 1st gear has the
highest gear ratio and 2nd and 3rd gears have smaller ratios in that
order.
NOTE
Even if two engines have identical performance, the torque
reaching the wheels can be very different depending on the
transmission gear ratios and the final reduction ratio (see page 14).
A vehicles power performance does not depend on the engine
alone. The transmission gear ratios and the final reduction ratio
must also be taken into account when vehicles are compared.

Torque

Speed

High gear ratio

High

Low

Low gear ratio

Low

High

Reversing a
vehicle

When gears with

different numbers of
teeth are brought
together, the speed of
rotation changes.

sed
urn

In the figure on the left,

for example, four turns
of the small gear on the
left cause two turns of
the gear in the middle
and one turn of the gear
on the right. In other
words, the speed is
reduced to one quarter.
At the same time, the
torque that can be used
to move an object is
increased.

Small force

Adding a gear can reverse the

direction of rotation. This
principle enables a vehicle to
be driven backward.

<Backward>

<Forward>

What transmission types ex

Transmission types

Manual transmissions have been made in different types that bring together their internal gears using
different methods. The synchromesh type is used in todays vehicles.
<Evolution of transmissions>

Sliding-mesh type
This is the most elementary type of transmission. With this type, gears that are turning are directly
brought together. Smoothly meshing gears is not easy for the driver. A grinding sound can occur when
gears hit each other.

Clutch disc

Countershaft

Constant-mesh type
The constant-mesh type is an improvement upon the sliding-mesh type.
The upper gears and lower gears are constantly meshed but turn freely
(not transmitting power) until a sliding gear is meshed.

Clutch disc

Sliding gear

ist?

Synchromesh type
The synchromesh type is the most common type today.
Whereas the constant-mesh type involves directly
meshing a sliding gear, the synchromesh type contains
synchronizer rings (conical clutches) that equalize the
speeds of gears before meshing the gears. Since the
gears are turning at the same speed when they mesh,
the meshing takes place smoothly.

A : Synchronizer ring

How a synchromesh transmission works

(1) Neutral
Power from the engine is transmitted through the gears as
follows: 1 2 3 4 . However, gear 4 is not connected
to the propeller shaft so it turns freely (not transmitting the
power).

(2) Synchronization
When the gearshift lever is moved, gear B moves sideways. A
metal fitting on the inside of gear B (the black part in the figure)
moves sideways together with it, pushing gear A against gear
4 . At this time, gear B is still not meshed with gear A . Owing
to friction that occurs between gear A and gear 4 , gears 4 ,
A , B , and C then gradually start turning together. Thus, the
friction has a synchronizing effect.

(3) Meshing of gears

If the gearshift lever is moved further, gear B moves further
sideways. Owing to the synchronizing effect described above,
gear B and gears A and 4 then turn together and are smoothly
meshed together. The gear change is then complete.

B
A
4
C

B
A
4
C

What is an automatic trans

About automatic transmissions

Whereas a manual transmission requires the driver to continually change gears
while driving, an automatic transmission performs gear changes automatically.
An automatic transmission has two main parts in addition to the actual gearbox:
(1) a fluid coupling, which transmits power from the engine to the gears, and (2)
a torque converter, which boosts the torque received from the engine.

Fluid coupling

Fluid coupling (fan analogy)

The fluid coupling is located between the engine and
gearbox. It transmits power by means of fluid. It
operates in basically the same way as the two fans
illustrated on the left. When one fan (the one on the
engine side) runs, the power transmitted by the air
causes the other fan (the one on the driveshaft side) to
start turning too. In the fluid coupling, there is hydraulic
fluid instead of air. The fluid serves the same purpose
in that it transmits power.

Torque converter
In the fluid coupling described above, rotation of the
engine-side impeller causes fluid to hit the other
(impeller, thereby causing it to turn such that power is
transmitted. Fluid that has hit the driveshaft-side
impeller is then forcefully thrown back toward the
engine-side impeller, assisting its rotation and thereby
boosting the torque. The torque-boosting function is
provided by the torque converter.
Torque converter

[Merits]
Since the engines power is transmitted by fluid, there is no need for the driver to engage and disengage a
clutch. Also, standing starts and later acceleration are smooth and occur without any risk of an engine stall.
[Demerits]
Since the engines power is transmitted by fluid, fuel economy and acceleration are slightly inferior to those
occurring with a manual transmission. Also, the mechanism is relatively complex, heavy, and costly.

10

mission?

INOMAT
(fuzzy-logic-controlled mechanical-type automatic transmission)
The INOMAT is basically a manual transmission that is automatically
controlled by a computer. Unlike a regular automatic transmission, it does
not use fluid to transmit power. Consequently, it has higher transmission
efficiency. And since a computer optimally selects gears to suit driving
conditions, the drivers physical burden is lessened and fuel economy is,
regardless of the drivers skill, enhanced.

INOMAT
The clutch pedal is used for a standing start.
Subsequently, the computer effects control, so the
transmission gives relaxing automatic operation.
Computer

INOMAT

Three pedals
Clutch pedal

INOMAT II
All transmission operation from starting to stopping is
automatically controlled by the computer, so there is no
clutch pedal.

Manual transmission

Two pedals

Further advances in automatic

transmissions

Lockup mechanism
When the vehicle reaches and exceeds a certain speed, a lockup mechanism
engages a clutch in the torque converter to cause direct power transmission for
enhanced fuel economy and exhaust-braking effectiveness.

Power mode and economy mode
These modes can be used to change the timing of upshifts and downshifts for
powerful performance, for delicate standing starts on snowy roads, and for
superior fuel economy.

11

What is overdrive?
About overdrive

A gear that causes the engine and propeller shaft to turn

at the same speed is known as direct drive; the gear
ratio with direct drive is 1. A gear that causes the
propeller shaft to turn faster than the engine is known as
overdrive.
On a level road, resistance is low, meaning that there is
a surplus of torque even in top gear. Selecting overdrive
causes the propeller shaft to turn faster than the engine.
Thus, the engine speed can be kept relatively low for
quietness and fuel economy.

What is overrunning?
Unless the vehicle speed is kept under control when a
vehicle is driven down a steep hill, the vehicle speed
and engine speed can continue to increase such that
the engines maximum speed is exceeded and the
engine emits a severe noise. This condition is known
as overrunning. Overrunning (and engine damage)
can also occur if a gear change is made from 5th to
3rd while the vehicle is moving at high speed. For
every gearshift, a limit on the initial vehicle speed is
specified. The limits must be observed.

Transmission shapes

Box-type case
Transmission

Originally, a transmission was

located in a square case. This kind
of case was structurally simple, but it
was not greatly resistant to twisting
caused by vibration.

Cylinder-type case

Nowadays, a transmission is located in a

cylindrical case. This kind of case has high
rigidity and contributes to suppression of
vibration and noise. It can be made of
aluminum alloy for lightness.
Transmission

12

Mitsubishi Fuso uses

cylindrical-case
transmissions owing to
their benefits in terms
of high rigidity and low
vibration and noise.

What is a power
7 takeoff (PTO)?
About PTOs

A PTO is a device that allows power to be taken from a special-purpose vehicles engine or transmission to
drive equipment that is mounted on the vehicle. There are three types of PTO: transmission PTO; flywheel
PTO; and full-power PTO. Any type of PTO is only optionally available for all chassis types with some
exceptions.

Transmission PTO
A transmission PTO is mounted on the left-hand side of
the transmission. A PTO control lever, which acts
through a control device, allows the takeoff of power to
be turned ON and OFF. This type of PTO is used
mainly while the vehicle is stationary.
[Features]
Low cost; easy installation
[Applications]
Dump trucks; tank lorries, vacuum trucks, garbage
collection trucks; simple crane trucks; ladder (highelevation working platform) trucks

Flywheel PTO
A flywheel PTO is mounted in the top of the engines
flywheel housing. (See page 21 of the Engine section.)
Since power is taken directly from the engine, vehiclemounted equipment can, provided the engine is
running, be driven whether the vehicle is stationary or
moving. When ON-OFF control over the PTO is
needed, an electromagnetic clutch is used.
[Features]
Power is taken directly from the engine. This kind of
PTO can be used on only a limited number of vehicle
types.
[Applications]
Cement mixer trucks, garbage collection trucks

Full-power PTO
A full power PTO can be either of two kinds. One kind
(used on heavy-, medium-, and light-duty trucks) is
located between the clutch housing and transmission.
The other kind (used on light-duty trucks) is located at
the back of the transmission. A full-power PTO uses all
of the engines power, so can be used while the vehicle
is stationary.
[Features]
100% of the engines power is used. However, this kind
of PTO is costly and can be used on only a limited
number of vehicle types.
[Applications]
Fire engines and sludge suction (pumping) vehicles

13

Engine

Engine

Clutch

Clutch
ion

Engine

Clutch
Transmission
n

onal.
A PTO is opti

What is a
8 reduction gear?
About reduction gears

The reduction gear turns the power from the propeller shaft
through an angle of 90 and transmits it to the rear axle
shafts. It also effects a speed reduction and a torque
increase. Since it effects the final speed reduction, it is also
known as a final reduction gear unit and its reduction ratio
is known as the final reduction ratio.

r shaft
on pinion

What types of reduction gear exist?

There are two types of reduction gear: the spiral-bevel-gear type and the hypoidgear type. Mitsubishi Fuso uses the hypoid-gear type.

Spiral bevel gears

The axis of the reduction pinion and the axis of the
ring gear are both on the same centerline. The teeth of
the reduction pinion and the teeth of the ring gear are
curved to create large tooth-to-tooth contact surfaces.
[Merits]
Rotation is smooth with low noise, vibration, and wear.

Rear axle shaft

Hypoid gears
The axis of the reduction pinion and the axis of the
ring gear are offset from each other, and the degree of
curvature of the teeth is great. Gears of this type are
widely used today.
[Merits]
A low center of gravity promotes stability. The tooth-totooth contact areas are large, so meshing is firm and
quiet.

Reduction pinion

Ring gear

Ring gear

Reduction pinion

Final reduction ratio

Since the reduction pinion and ring gear set performs the final speed reduction, it is also
known as a final reduction gear unit. The high-speed rotational output of the engine first
has its speed reduced (and thus the torque increased) by the transmission through
combinations of gears. It then undergoes final reduction to the rotational speed of the
wheels by means of the reduction gear set.
Why is the speed reduction not performed in one step using the transmission?
Its partly because using just the transmission would necessitate a much bigger, heavier transmission
containing many more gears. Also, the torque from the transmission would be so great that the propeller shaft
would need to be thicker.
The gear ratios (1st, 2nd, 3rd, and so on) shown in a catalog indicate the reduction ratios of the transmission.
The final reduction ratio shown in a catalog indicates the reduction ratio of the reduction gear set.
The final reduction ratio indicates the speed ratio of the propeller shaft and rear wheels. The formula for
calculating it is shown below.
Final reduction ratio = No. of revolutions per minute of driving wheels =
No. of revolutions per minute of propeller shaft

14

Number of teeth on ring gear

Number of teeth on reduction pinion

What is a differential
9 gear?
About differential gears

The role of the differential gear

For a truck to smoothly move around a curve, the outer wheels must
travel a longer distance than the inner wheels. In other words, the
outer wheels must turn faster than the inner wheels. Also, allowing
the left and right wheels to turn at slightly different speeds is
essential for smooth progress on uneven road surfaces.
The left and right driving wheels are automatically permitted to turn
at different speeds as necessary for smooth vehicle movements by
the differential gear (also known simply as the differential).

Principle of differential operation
<Straight-line driving>
When the same level of resistance is acting on the
left and right wheels, the left and right wheels turn at
the same speed.

<Negotiating a curve>
When more resistance acts on one wheel than on the
other (on a curve, for example), the central gear in
the illustration (representing the differential pinions)
turns, causing the wheel that is subjected to less
resistance to turn faster and further.

The differentials action

With the left and right wheels turning at the same speed, the
differential pinions, which mesh with the differential gears, do
not turn on their own axes. Consequently, the two differential
gears turn at the same speed as the ring gear.

Differential pinion (Turns on its own axis.)

The differentials action

Since the distance to be covered by the left and right wheels
is different, the inner wheel encounters greater resistance and
slows down. The outer wheel speeds up by the same amount.
Consequently, the differential pinions turn on their axes
(spider shafts), allowing the differential gear that is being
subjected to the greater resistance to turn. A left-right speed
difference is thus created.

Limited-slip differential (LSD)

If, with a regular differential, the driving wheel on one side of the
vehicle slips on ice or sinks into mud, it spins because most of
the torque is transmitted to the wheel with lower resistance. As
a result, moving the vehicle away from that location becomes
extremely difficult. An LSD prevents this problem. When the
driving wheel on one side of a vehicle with an LSD starts to spin
owing to loss of traction, a clutch inside the LSD automatically
restricts the differential action.

15

How is a truck
steered?
The steering system
Customer:
How does power steering lighten the
steering wheel?
Salesman:
I dont know. Help!
See page 18.

A trucks steering system allows the driver to change the trucks

direction as desired. Specifically, it allows the driver to use the steering
wheel to change the direction in which the front wheels are pointing.
The system consists of the three mechanisms described below.

Control mechanism
The direction control mechanism includes the steering
wheel and steering shaft. It transmits rotation of the
steering wheel to the steering gearbox (a gear
mechanism).

Steering gearbox
In the steering gearbox, the rotation of the steering
shaft undergoes a speed reduction and a torque
increase before being transmitted to the link
mechanism.

Link mechanism
The link mechanism includes a pitman arm, a drag link,
a knuckle arm, and tie rods. It transmits movement from
the steering gearbox to the front wheels. It also keeps
the left and right front wheels at the correct angles
relative to each other.

Why are the inner and outer wheels at

different angles?
The steering system is made such that the right
wheel turns through a greater angle than the left
wheel when the vehicle is steered to the right (and
vice versa). This arrangement is necessary
because the left and right wheels follow different
lines as shown in the figure.

16

How is the steering

1 gearbox structured?
About the steering gearbox

The steering gearbox makes the steering wheel feel light to turn and boosts the force that is transmitted from
the steering wheel. There are two types of steering gearbox: the ball-and-nut type and the rack-and-pinion
type.

Ball-and-nut type
Numerous steel balls are enclosed between the contact
faces of a worm shaft (part of the steering shaft) and a
ball nut. The balls transmit the rotation of the steering
shaft to the ball nut. Their rolling action keeps friction
low, thereby allowing the steering wheel to be turned
with little effort. This type of steering gearbox is
characterized by light steering action and high
durability.

Steering shaft
Worm shaft

Ball nut

Rack-and-pinion type
A pinion gear is attached to the end of the steering
shaft and is meshed with a rack gear. Rotation of the
pinion gear causes the rack gear to move sideways. By
means of tie rods, the rack gears sideways movement
causes changes in the directions in which the wheels
point. This type of steering gear is structurally simple
and compact. It tends to transmit shock from the road
surface to the steering wheel, but it gives sharp
directional response to turning of the steering wheel.

Sector shaft

Pitman arm

Steering gearbox

Steering shaft

Mitsubishi Fuso uses

the ball-and-nut type in
heavy- and mediumduty trucks and the
rack-and-pinion type in
some Canter models.

Rack gear
Pinion gear
Tie rod

17

What is power
2 steering?
About power steering
A power steering system is a steering system in which a booster
uses hydraulic pressure to reduce the effort needed to turn the
steering wheel. Typically, the hydraulic pressure is produced by a
dedicated oil pump that is driven by engine power. The oil circulates
back to the oil pump.

Vehicle-speed-sensitive power steering

A vehicles steering action naturally becomes lighter as the vehicle speed rises. For stability, its desirable for
a power steering system to give reduced assistance to steering action at high speeds. With a vehicle-speedsensitive power steering system, therefore, the vehicle speed is transmitted by a sensor as an electrical
signal that causes the booster to adjust the degree of power assistance. Consequently, the steering action
does not become too light as the vehicle speed increases.

At low
plenty vehicle sp
eeds,
o
assis f power
ta
lighte nce is give
n
n
action the steerin to
.
g

,
speeds
vehicle
is
n
At high
o
ti
c
a
ring
the stee light so not
tly
inheren er
ow
much p
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nce is g
ta
is
s
s
a

Power assistance: low

Power assistance: high

18

How does a truck stop?

About the braking system

Four basic functions of

truck performance

Do you know what the basic functions of a trucks performance are?

There are four of them: carrying, running, turning, and stopping. The stopping function
is an extremely important part of a trucks performance.
The braking system that realizes this function is said to be the most safety-critical of a
trucks systems. It must work effectively and reliably, and it must be durable and easy
to inspect and service.

Carrying
Turning

Running
Stopping

The principle of brake operation
A trucks brakes operate on basically the same
principle as a bicycles brakes: They use friction to stop
the wheels from turning. With a bicycle, the friction is
produced by rubber blocks that are pressed against the
wheel rims. With trucks, however, the usual
arrangement involves drums and brake shoes. The
shoes have friction material on them. When the brakes
are applied, the friction material is pressed firmly
against the drums to produce friction that stops the
wheels from turning.

Brake shoe

Drum

19

What are hydraulic

1 brakes?
About hydraulic brakes

Hydraulic brakes
With a bicycle, the strength of the riders hands is sufficient to apply the brakes. With a truck, however, much
greater force is needed. For this reason, hydraulic brakes are generally used on trucks.
The operating principle of hydraulic brakes is as follows: When the brake pedal is depressed, a piston is
pushed, causing the pressure of brake fluid in a master cylinder to increase. The pressurized fluid flows
through brake pipes and acts upon wheel cylinders (one for each wheel). In each of the wheel cylinders, the
pressure pushes a piston that, in turn, pushes the brake shoes against the drum.
Master cylinder

Master Vac
(See page 22.

eel cylinder

If a brake pipe becomes holed and brake fluid leaks out, the brakes served by that pipe can stop working.
Consequently, the hydraulic brakes on a truck are divided into two circuits: one circuit for the front wheels and
one circuit for the rear wheels. If one circuit suffers a fluid leak, the other circuit still enables safe brake
application.

Tandem master cylinder
This kind of master cylinder is internally divided into
two parts that independently produce hydraulic
pressure for the front brakes and rear brakes,
respectively.

Brake chamber
Mitsubishi Fuso uses wedgetype brakes, which give good
responsiveness.
In a wedge-type brake, the
hydraulically pushed wedge
acts directly upon the brake
shoes, meaning that energy
losses are not great.

Tandem master cylinders are

used on current Mitsubishi Fuso
light-duty trucks.

(Wedge-type brake)

20

What types of braking

2 system are used?
Types of braking system

In addition to hydraulic brakes, the types of braking system that are used on
trucks are air-over-hydraulic brakes (these combine pneumatic and hydraulic
functions) and full air brakes.

Air-over-hydraulic brakes
In an air-over-hydraulic braking system, a brake
valve of the kind used for air brakes is combined
with Air Masters (brake boosters using
compressed air). (See page 22.) Compressed air
from an air tank is controlled by a brake valve that
is directly linked to the brake pedal. The air controls
the Air Masters. The brakes beyond the Air Masters
are the same as those of a hydraulic braking
system. Compared with hydraulic braking systems,
air-over-hydraulic braking systems give a lighter
pedal action. Consequently, they are used on
large-sized buses and medium-duty trucks.

Air tank
or

Full air brakes

Compressor

In a full air braking system, the brake pedal itself

forms an open/close valve mechanism. When the
pedal is depressed, the brake valve opens,
allowing compressed air from an air tank to flow to
the brake chambers. The pistons in the brake
chambers are pushed by the compressed air. In
turn, they push the brake shoes against the brake
drums to create braking force. Full air brakes give
an extremely light pedal action and high braking
force, so they are used on all heavy-duty trucks.

Air tank
Brake chamber

Brake chambers
A brake chamber works using the force of
compressed air. There is one brake
chamber just inside each wheel. A
pushrod that emerges from each brake
chamber mechanically pushes the brake
shoes.

21

How does light pedal action

3 cause strong brake operation?
About brake boosters

Since a truck carries heavy cargo and moves at high speeds, appropriately great force is needed to slow and
stop it. And given that the driver applies the brakes hundreds of times each day, a trucks brakes must be
easy for the driver to apply. Otherwise, the driver would, particularly on long journeys, become fatigued.
A brake booster is used to meet the need for a light pedal action and strong braking force. By realizing ample
braking force with a low level of pedal effort, a brake booster keeps driver fatigue low. A brake booster works
using the difference between the atmospheric pressure and a pressure produced by a vacuum pump or an air
compressor. Lets look at the different types of brake booster.

Master Vac
A master Vac uses vacuum pressure. It is built into
the master cylinder. Engine power is used to
maintain a vacuum in chamber A and chamber B of
the Master Vac.
When the brake pedal is depressed, atmospheric
pressure enters chamber B and moves the large
piston inside it, thereby pushing the piston of the
master cylinder to create high hydraulic pressure.
Master Vacs are used in passenger cars and in
Canter trucks.

Power piston

Air Master
An Air Master works using the force of compressed
air. The brake pedal itself forms a valve mechanism.
When the pedal is depressed, compressed air from
an air tank acts directly upon the power piston in the
Air Master. (The compressed air is produced by a
compressor.) As a brake booster, an Air Master has
greater capacity than a Master Vac. Air Masters are
used mainly on medium-duty trucks.

Master Vac

Master cylinder
Tandem master cylinder

Air master

22

What types of brake

4 exist?
About brakes

A vehicles brakes produce braking force using hydraulic pressure or pneumatic

pressure. They can be either drum brakes or disc brakes.

Drum brakes
With a drum brake, a drum rotates with the wheel. Shoes, which are lined with friction material, are pressed
against the inside surface of the drum to stop the wheels rotation. To achieve good effectiveness, there are
various shoe mounting arrangements.

Leading/trailing-shoe brake
The shoes are arranged such that, as
the drum rotates, one of the shoes is
pulled against it for good effectiveness.
The shoe that is pulled against the
drum is called the leading shoe. The
other shoe is, by contrast, pushed
away from the drum, meaning that its
effectiveness is not great. This shoe is
called the trailing shoe. A brake with its
shoes arranged in this manner is called
a leading/trailing-shoe brake.

Two-leading-shoe brake
In this kind of brake, both shoes are
arranged such that they acts as leading
shoes for great effectiveness.

Dual-two-leading-shoe brake
With a two-leading-shoe brake, both
shoes act as leading shoes when the
vehicle is moving forward but not when
the vehicle is moving backward. A
dual-two-leading-shoe brake is
designed such that both shoes act as
leading shoes whether the vehicle is
moving forward or backward.

g shoe
Leading sh

Disc brakes
Drum brakes tend to become too hot internally and
consequently ineffective if they are used continuously
and excessively. Disc brakes were conceived to avoid
this shortcoming. With a disc brake, a disc rotates with
the wheel and is squeezed from both sides by pads to
stop the wheels rotation. Unlike the friction
components of a drum brake, the disc is exposed to the
air, meaning that heat escapes easily. Braking
performance is therefore consistent.

Disc
Pad

Caliper
Pad

The Super Greats brakes are amazingly powerful.

Because a truck carries cargo, it is extremely heavy. Consequently, its brakes have much higher performance than those of a
passenger car. The pads of disc brakes are pushed against the discs by pistons. Conventionally, one piston is used per disc
brake. On the Super Great, however, each disc brake has six pistons. These pistons are pushed by force that has been
boosted by means of compressed air. The disc is 45mm thick. Each disc contains holes for heat dissipation but is extremely
sturdy.

23

What other kinds of

5 brake exist on a truck?

Parking brake (handbrake)

The parking brake is used to prevent the vehicle
from moving when it is parked or otherwise
stationary. One type of parking brake (called the
center parking brake) takes the form of a drum
brake that that is activated by means of a cable
and acts on the propeller shaft. Another type of
parking brake (known as the wheel parking brake)
locks the wheels by means of compressed air that
acts on the wheel brakes.

Engine braking
If the accelerator pedal is released while a vehicle
is being driven, the vehicle slows down owing to
resistance caused by the engine. The effect that
causes the resistance is called engine braking.

Lock brake
A lock brake is a device used for safety on a
vehicle (for example, a crane or cement mixer) that
is used for work while stationary. It is used together
with the parking brake. Whereas the parking brake
acts upon two wheels, the lock brake directly acts
upon all of the wheels to hold the vehicle
stationary.

Exhaust brake
An exhaust brake is basically a valve in the
exhaust pipe. When the valve is closed, it restricts
the flow of exhaust gases, thereby slowing the
engine. The result is more powerful engine braking.

Other brakes

Powertard (See page 31 of the Engine section.)

A Powertard is a device that provides stronger engine
braking.

Retarder
A retarder suppresses rotation of the propeller shaft
by means of the power of an electromagnet or the
resistance of oil.
EZGO
The EZGO is a braking system that incorporates a
device that makes it easy to perform hill starts.
Once the driver has depressed the brake pedal to
hold the vehicle in place on a slope, the device
maintains the braking force acting on the wheels
even the driver releases the brake pedal. The
driver can thus more easily perform a hill start.

Load-sensing valve (LSV)

An LSV is a device that optimizes the balance of
braking force between a vehicles front wheels and
rear wheels. When a truck that has a short overall
length is not carrying cargo and consequently its
rear wheels are lightly loaded, the rear brakes tend
to have a quicker effect than the front brakes. This
can cause the rear of the vehicle to fishtail during
braking. An LSV prevents this problem by sensing
the load (weight) applied to the rear wheels and
adjusting the braking force applied to the rear
wheels in accordance with that load. The LSV
automatically senses the load by monitoring the
extent of sagging of the rear suspension springs,
and it supplies hydraulic pressure or pneumatic
pressure at the level necessary.

[A safety device that aids parking is available as an

option. ]
If the vehicle slips downhill by approximately 50cm
owing to insufficient holding power of the parking
brake, the safety device automatically applies the
wheel brakes to stop the vehicle.

24

What are ABS and

6 ASR?

Antilock braking system (ABS)

Hard braking on a slippery road (for example, a
snow-covered road or a wet expressway) can cause
a vehicles wheels to lock, with the result that the
driver loses control over the vehicles direction. (The
steering wheel becomes ineffective.) An ABS is
intended to prevent this problem. With an ABS, a
computer detects any slipping of the vehicles tires
and modulates the pressure applied to the brakes
so as to help prevent the wheels from locking. The
ABS thereby enhances the vehicles directional
stability.

What is wheel lockup?

Wheel lockup is the term given to the condition in
which a vehicles wheels stop turning but the
vehicle continues moving. Under this condition,
there is a lack of friction between the tires and
road surface and the steering wheel is ineffective.

NOTE
An ABS is intended only to supplement normal brake application. Even in a vehicle that has an
ABS, it is essential to decelerate adequately when approaching curves. The ABS will not
compensate for excessively uncontrolled driving.

Antispin regulator (ASR)

When a standing start is attempted on a slippery
road surface, the wheels can spin, preventing
smooth motion and acceleration. An ASR is
intended to prevent this problem by effecting control
that prevents the driving wheels from spinning
without traction. It is fitted as part of a set with an
ABS. Just as the ABS suppresses wheel lockup
without needing the driver to carefully modulate his
or her brake pedal depression force, the ASR
suppresses wheelspin without needing the driver to
carefully control the exact extent to which he or she
depresses the accelerator pedal.
25

What types of tire exist?

Tire types

Radial tires
A radial tire is a tire in which cloth threads (ply cords)
run radially inside the rubber. The most notable benefit
of radial tires is good grip (and accordingly good
stability) on the road surface even on curves. A steelbelted radial tire is a radial tire in which a steel belt is
added under the tread for reinforcement.
[Merits]
Structurally sturdy
Effective in improving fuel economy

Radial tire

Bias tires
A bias tire is a tire in which cloth threads (ply cords) run
diagonally (at a bias angle to the direction of travel)
inside the rubber. Bias tires are inferior to radial tires in
terms of grip on the road surface, but they are relatively
inexpensive and quiet.
[Merits]
Soft ride
[Demerits]
Inferior to radial tires in terms of tread durability

Bias tire

Steel radial tire

Tubeless tire

Tubeless tires
A tubeless tire does not suffer a sudden air leak when pierced
by, for example, a nail. Most radial tires and bias tires are
tubeless.

26

Tire terminology
(1) Bias tire

Tire section width

7.00 - 15 - 8PRLT

Section width
(7.00 inches
in this case)

Tire structure
(A - indicates
a bias tire.)

(2) Radial tire

Rim diameter
(15 inches
in this case)

Tire strength
(ply rating
(8 in this case))

Tire application
(LT indicates light-duty
trucks. The code for a
truck/bus tire is TB,
but it is not usually written.)

Tire section
tion heig
height

7.00R15 - 8PRLT
Rim
m diame
diameter

Tire structure
(An R indicates a radial tire.)

(3) Low-profile radial tire

225 / 80R17.5 - 14PRLT

Tire width
(225mm
in this case)

Tire structure
(An R indicates
a radial tire.)

Aspect ratio
(80% in this case
[Aspect ratio = tire section height /
tire section width x 100 (%)])

Rim diameter
(17.5 inches
in this case)

Tire tread patterns

The surface of a tire that makes contact with the road surface is called the tread. The tread contains grooves
to help prevent the tire from slipping and to promote heat radiation. The patterns are classified as shown
below.
(1) Ribbed type

(2) Lugged type

Grooves are cut in the circumferential

direction. This pattern is well suited to highspeed driving on good road surfaces. It
resists skidding, gives good controllability
and ride comfort, and creates little noise. It
is widely used on trucks (including lightduty trucks) and buses.

(3) Block type

Grooves are cut sideways across the

tread. This pattern prioritizes towing
capability and braking force. It is intended
for use on rough road surfaces and on
unpaved roads. It is not suitable for highspeed driving. If subjected to high-speed
driving, it is prone to skidding and to
uneven wear. It is widely used on light-duty
trucks (mainly light-duty dump trucks and
other light-duty construction-use trucks).

(4) Ribbed and lugged type

This pattern is well suited to sand, snow,
and soft ground. Since the blocks move
greatly during vehicle movement, however,
tires with this kind of tread wear relatively
quickly.

This pattern is a combination of the ribbed

type and lugged type. The ribs are located
in the center to promote controllability and
help prevent skidding. Lugs are positioned
on either side to provide the traction that is
not adequately provided by the ribs. This
pattern is used mainly on light-duty trucks.

27

How does a truck give

a comfortable ride?
Suspension system

Customer:
Leaf springs are used in suspension systems, arent they? I
know that making a leaf spring shorter makes it stiffer. But
whats the effect of putting leaf springs on top of each other?
Salesman:
I guess it makes them even stiffer?
Customer:
Are you sure?
Salesman:
Sorry, to be honest I dont really know. How embarrassing!

A vehicles suspension system locates springs between the frame and wheels. The
springs support the body while absorbing vibration from the road. The suspension system
thus promotes ride comfort and helps keep the tires positioned properly to grip the road
for handling stability.
Suspension systems can be broadly classified into two types: independent suspension, in
which the left and right wheels move independently of each other, and rigid-axle
suspension, in which the left and right wheels are linked by an axle.

Independent suspension allows

the left and right tires to move
independently of each other
while absorbing shock, so ride
comfort and stability are
superior.

<Rigid-axle suspension>

Resistance

<Independent suspension>

Stabilizer

Stabilizer
A stabilizer is a beam that suppresses the vehicles tendency to roll (tip sideways) when the
vehicle goes around corners. Stabilizers are widely used on front wheels to supplement the
suspension system.

There are various types of spring. They include leaf springs (these have been used since the time of
rickshaws and horse-drawn carriages); coil springs; torsion-bar springs (this type of spring works using
torsion on a steel bar); and air springs (these work using the elasticity of air).

Leaf spring
Trucks typically have leaf springs, which are inexpensive and durable. A leaf spring consists of several steel leaves placed on
top of one another for strength. It works using the elasticity of the steel. Leaf springs with longer and fewer leaves flex more
easily than leaf springs with shorter, more numerous leaves, thereby giving a softer ride. Leaf springs with shorter, more
numerous leaves give a harder ride. To meet different needs for ride comfort and cargo support, leaf springs are available with
various numbers and lengths of leaves.

Helper spring
A helper spring is a secondary spring that works to complement a main spring. If there were only a single spring for each wheel
and the springs stiffness were adjusted to the heaviest cargo the truck might carry, ride comfort would be poor even with the
truck unladen. If the trucks suspension is of a dual spring design consisting of main springs and helper springs, the frame is
suspended only through the main springs when the vehicle is lightly loaded and through both the main and helper springs when
the vehicle is heavily loaded. The problem of poor ride is thus resolved.

28

What suspension
1 spring types exist?
Suspension employing leaf springs

Trunnion-type suspension
Leaf spring

Tires

This type of suspension is used on the rear wheels of

heavy-duty trucks. It is highly durable and is well suited
to operation on uneven road surfaces. The rear axle is
located by torque rods. Each end of the spring slides in
accordance with changes in cargo weight.
[Merits]
Durable; well suited to operation on uneven road
surfaces
Spring strength is high enough to carrying heavy
loads.

Torque rod

Trunnion base

Suspension employing air springs

Air suspension

Two-bag air suspension
Shock absorber

Air spring

Trailing leaf

Four-bag air suspension

Shock absorber

Air spring

Air suspension works using air springs, which exploit

the elasticity of air. It is used for the rear wheels of
trucks, where it is effective at protecting cargo and
promoting ride comfort. If used on a tractor, air
suspension allows the height of the coupler (the
component to which the trailer is hitched) to be varied.
It thus facilitates trailer hitching.
Two-bag air suspension consists of two sets of trailing
leaves that extend from front to rear and a large air
spring on each side. It is structurally simple and light.
(The term bag is commonly used for an air spring.)
Four-bag air suspension uses four air springs on each
side to absorb vibration. It incorporates a relatively
large number of torque rods, so aluminum is used to
mitigate the weight of the structure.

<Shock absorbers>
When a suspension spring that does not have a shock
absorber is compressed, it reacts by extending. It then
reacts again by retracting, and so on; the extension and
retraction continue without soon settling. A shock
absorber is used to effectively damp the up and down
motion. Its damping action is produced by the
resistance that occurs as oil passes through small
holes in a piston.
29

Where does electricity in a

vehicle come from?
Batteries

The power supply used to provide electricity to a vehicles

starting system is the battery. While the engine is running, the
battery is used to complement the supply of electricity
provided by the alternator (generator) to the vehicles
electrical systems.
The battery stores electrical energy by converting it to
chemical energy. As the battery is charged, the proportion of
sulfuric acid in the fluid in the battery increases, causing the
specific gravity of the fluid to increase. As the battery is
discharged, the proportion of water in the fluid increases and
the fluids specific gravity decreases.

Alternator

How to read battery type indications

Example: Canter 2.0-ton truck
Battery (type x quantity)

75D26R x 2

Performance rating
(a number indicating the batterys
performance for driving the starter
(the higher the number,
the higher the performance))
Width x height category
(All batteries in a given category have
the same width x height.)

Terminal polarity
position
(R indicates that
the + terminal is on
the right-hand side.)
Length
(nearest round number
(26cm in this case))

Number of batteries
(The number of batteries
determines the power supply
voltage. One battery is 12V.)

How to read alternator type indications

24 35

(V A)
35: Current (amperes)
(the supply current at a given operating speed)

24: Voltage (volts)

The alternator capacity (generating capacity) is determined taking into account the balance between charging
and discharging. If an electricity consumer is added to the vehicle, the alternator must be replaced with a
higher-capacity one.
30

How is a flat
1 battery dealt with?

How to use booster cables

(1) Stop the engine of the boost-giving vehicle.

(2) Clip one end of the red booster cable onto the + terminal of the boost-receiving
battery and the other end onto the + terminal of the boost-giving battery.
(3) Clip one end of the black booster cable onto the - terminal of the boost-giving
battery and the other end onto the frame of the boost-receiving vehicle at a
point as far as possible from the battery. You must not clip the booster cable
directly onto the boost-receiving battery because of the risk that a spark emitted
at the moment of connection would ignite gas emerging from the battery.
(4) Start the engine of the boost-giving vehicle. Run the engine slightly faster than
idling speed. Next, start the engine of the boost-receiving vehicle.
(5) Disconnect the booster cables in the order opposite to that in which you
connected them. In other words, first disconnect the black cable from the frame.

Handling a battery that is being charged

While a battery is being charged, it emits hydrogen gas. Striking a light or creating a spark
near the gas could cause an explosion. Great care is required.

31

What technologies are used

I hope you
understand
everything.

Youre now ready

to explain everything
to customers.

Direct-injection
4M42 (T1)

Diesel engines

Direct-injection
4M50 (T4)
Direct-injection
4M42 (T2)
Direct-injection
4M50 (T5)
Direct-injection
4M50 (T3)

Diaphragmspring clutch

Rack-and-pinion
steering
Cab-over-engine
configuration
Vehicle-speed-sensitive
power steering

Halogen
headlamps

Discharge
headlamps

DX-specification,
pecification, 118kW or highe
higher
Custom
m vehicles
EZGO

Tandem master
cylinder

Independent
front suspension

Master Vac

32

Disc brakes
Two-leadingshoe brakes

in the Canter?

Five-speed
manual transmission
Six-speed
manual transmission
with overdrive

Synchromesh
transmission

Super Frame

Four-speed
automatic transmission
with torque
q converter

Reduction and
differential gear

INOMAT-II
(five-speed or six-speed)

Electromagnetic
retarder

LSD
Exhaust brake

Dual-two-leadingshoe brakes

ABS

ASR

gs
Battery
75D26R 2
55D26R 2

LSV
Air springs

Steel radial tires

(7.00R15-8 etc.)
Low-profile
radial tires
(205/70R16 etc.)

Bias tires
(6.50-16-10 etc.)

432
434

632

33

Disc brakes

I understand
everything!

CHECK SHEET
Write the correct words in the parentheses (

).

<Engine>
1.

An engine with four cylinders is called a (

2.

The four stroke cycles of an engine are as follows: (

3.

The up-down motion of an engines pistons is converted into rotational motion by the (
(
).

4.

When an explosion occurs in a cylinder, the force of the explosion pushes the piston. The force is then
transmitted by the (
) to the crankshaft, causing the crankshaft to turn.

5.

The indication 210PS/2,900rpm means that the engine produces power of (

revolutions per minute. It has the same meaning as (
) kW/2,900rpm.

6.

The indication 180kgfm/1,200rpm means that the engine produces (

) of 180kgfm at speed of
1,200 revolutions per minute. It has the same meaning as (
) Nm/1,200rpm.

7.

With a gasoline engine, a mixture of fuel and air is drawn into the cylinders and compressed. With a
diesel engine, however, only (
) is drawn into the cylinders and compressed.

8.

If the compression ratio of a gasoline engine and that of a diesel engine are compared, it can be seen
that the compression ratio of the (
) engine is higher.

9.

The combustion chambers of a diesel engine can be one of three types: (

chamber type, or swirl-chamber type.

10. A diesel engine is an OHV type or an (

camshaft.

) engine.
) compression (

) exhaust.
) and

) at a speed of 2,900

) type, precombustion-

) type depending on the positions of its valves and

11. A device that is attached to an engine and effects forced induction is called a (
12. An intercooler is used together with a (
). It cools (
increasing the (
) for more effective forced induction.

).

) that has become hot, thereby

13. If air enters the fuel system of a diesel engine, the engine becomes unstartable, making it necessary to
perform (
).
14. The part of an injection pump that pushes fuel out is called a (

).

15. The device that stabilizes and controls the speed of a diesel engine is called a (
16. The fuel injection timing of a diesel engine is controlled by a (
17. An (

).

).

) uses an engines exhaust gases to boost the engine braking effect.

18. If the brakes are applied continuously, they can become so hot that the friction material on the brake
shoes gets burned and slippery. The brakes then become ineffective for stopping the vehicle. This
phenomenon is called (
).
19. In a water-cooled engine, coolant is continuously circulated around the cylinders. Coolant that has
become hot is cooled by the (
) before being recirculated for further use.
20. To ensure smooth engine operation, engines are supplied with lubricating (
frictional resistance low.

), which keeps

21. The device that charges a vehicles battery and generates electricity as the engine runs is called an
(
).

<Chassis>
1.

A frame consists of side rails and (

2.

Power is transmitted from the transmission to the differential by the (

3.

The clutch makes or interrupts the flow of power as necessary by pushing a (

flywheel or separating it from the flywheel.

4.

Depending on the spring type, a clutch is a coil-spring type or a (

5.

The transmission combines gears with different numbers of teeth, thereby changing the torque and
(
) as it transmits power.

6.

There are three types of meshing arrangement for the gears in transmissions. The most widely used one
is called (
).

7.

An automatic transmission has a fluid coupling function and a (

boosts torque.

8.

A function that makes the propeller shaft turn faster than the engine is called (

9.

A device that takes engine power and allows it to be used to drive equipment that is mounted on a
vehicle is called a (
).

10. A (

).
).
) against the

) type.

) function. The latter function

).

) is also called a final reduction gear unit.

11. A device that allows the left and right rear wheels to turn at different speeds is called a (
12. There are two types of steering gearbox: the (

) type and the rack-and-pinion type.

13. There are three types of braking system: hydraulic brakes; (

14. Compared with drum brakes, (
consistent braking performance.

) gear.

); and full air brakes.

) brakes have better heat-release performance and more

15. A brake that acts upon all of the wheels of, for example, a crane vehicle or cement-mixer vehicle while
the vehicle is stationary and the onboard equipment is operating is called a (
).
16. A suspension system includes springs, stabilizers, and shock absorbers. Among these items, the ones
that prevent unwanted sideways tipping of the body are the (
).
17. The type of suspension in which the left and right wheels are linked by an axle is called (
suspension.
18. (

) suspension gives better ride comfort than rigid-axle suspension.

19. A suspension spring absorbs vibration. Once it has started moving, it tends to continue oscillating up and
down for a while. A (
) is used to damp the oscillation.
20. Truck suspension works using either leaf springs or (
21. Tires can be broadly classified into (

).

) and radial tires.

22. In a 225/80R17.5 14PRLT tire indication, the 80 indicates the (

).

23. A tires aspect ratio is expressed as follows: Tire section height x 100
(
)
24. When using booster cables to draw power from another vehicles battery, you must first connect the
(
) cable.

CHECK SHEET Answers

<Engine>

<Chassis>

1. four-cylinder

1. crossmembers

2. intake, power

2. propeller shaft

3. connecting rods, crankshaft

3. clutch disc

4. connecting rod

4. diaphragm-spring

5. 210PS, 154

5. speed

6. torque, 1765

6. synchromesh

7. air

7. torque converter

8. diesel

8. overdrive

9. direct-injection

9. power takeoff (PTO)

10. OHC

10. reduction gear

11. turbocharger

11. differential

12. turbocharger, air, air density

12. ball-and-nut

13. air bleeding

13. air over hydraulic

14. plunger

14. disc

15. governor

15. lock brake

16. timer

16. stabilizers

17. exhaust brake

17. rigid-axle

18. fade

18. independent

19. radiator

19. shock absorber

20. oil

20. air springs

21. alternator

21. bias tires

22. aspect ratio
23. tire section width
24. + (positive)

This index covers part I Engine and part II Chassis.

[E] denotes the items appearing in the engine section
and [C] denotes those appearing in the chassis section.

Clutch facing .....................................................[C] 5

ABS .................................................................[C] 25

Coil springs .....................................................[C] 28

Air bleeding .....................................................[E] 25

Coil-spring type .................................................[C] 6

Air cooling........................................................[E] 34

Combustion chamber ......................................[E] 18

Air Master..................................................[C] 21, 22

Common-rail system .......................................[E] 29

Air spring .........................................................[C] 29

Compression ratio ...........................................[E] 15

Air suspension.................................................[C] 29

Compressor wheel ..........................................[E] 23

Air-over-hydraulic brakes.................................[C] 21

Connecting rod ................................................[E] 13

Alternator.........................................................[E] 36

Constant-mesh type ..........................................[C] 8

API ..................................................................[E] 33

Control rack .....................................................[E] 27

ASR.................................................................[C] 25

Cooled EGR system........................................[E] 17

Automatic transmission ...................................[C] 10

Cooling fan ......................................................[E] 35

Cooling system................................................[E] 34

Crankcase .......................................................[E] 20

Ball-and-nut type .............................................[C] 17

Crankshaft .................................................[E] 13, 21

Battery ..................................................[E] 36/[C] 30

Crossmember....................................................[C] 3

Bias tires ...................................................[C] 26, 27

Cylinder ...............................................[E] 10, 12, 21

Block type........................................................[C] 27

Cylinder block ..................................................[E] 20

Booster cables ................................................[C] 31

Cylinder head ..................................................[E] 20

Bore.................................................................[E] 20

Cylinder liner ...................................................[E] 21

Bottom dead center .........................................[E] 15

Cylinder-type case ..........................................[C] 12

Box-type case .................................................[C] 12

Brake chambers ..............................................[C] 21

Brake fade .......................................................[E] 31

Diaphragm-spring type......................................[C] 6

Braking system................................................[C] 19

Diesel engine ...........................................[E] 14 - 19

Diesel knock ....................................................[E] 18

Differential gear ...........................................[C] 3, 15

Cab-behind-engine type....................................[C] 2

Direct drive ......................................................[C] 12

Cab-over-engine type........................................[C] 2

Direct injection type .........................................[E] 18

Caliper.............................................................[C] 23

Disc .................................................................[C] 23

Camshaft .........................................................[E] 21

Disc brakes .....................................................[C] 23

Chassis .............................................................[C] 1

Discharge tubes ................................................[C] 2

Clutch ............................................................[C] 2, 5

Distributor type ................................................[E] 26

DPF .................................................................[E] 17

Drag link ..........................................................[C] 16

Halogen headlamps ........................................[C] 32

Driveline....................................................[E] 8/[C] 4

Handbrake .............................................[E] 31/[C]24

Drum brakes..............................................[C] 19, 23

Heater plug......................................................[E] 19

Dual-chamber type ..........................................[E] 19

Helper spring...................................................[C] 28

Dual-two-leading-shoe brake ..........................[C] 23

Horsepower .....................................................[E] 11
How to read alternator type indications...........[C] 30

How to read battery type indications ...............[C] 30

EGR cooler......................................................[E] 17

Hydraulic brakes..............................................[C] 20

Electronic governor .........................................[E] 28

Hypoid gears ...................................................[C] 14

Engine braking......................................[E] 31/[C] 24

Engine oil.........................................................[E] 33

Engine performance curves ............................[E] 11

Ignition point ....................................................[E] 16

Engine speed ..................................................[E] 13

Independent suspension .................................[C] 28

Engines displacement.....................................[E] 20

Injection nozzle..........................................[E] 19, 25

Exhaust brake .......................................[E] 31/[C] 24

Injection pump ...............................[E] 17, 22, 25, 26

Exhaust manifold .............................................[E] 30

Inline engine ....................................................[E] 10

Exhaust system .........................................[E] 22, 30

Inline type ........................................................[E] 26

Exhaust valve ..................................................[E] 12

INOMAT...........................................................[C] 11

EZGO ..............................................................[C] 24

INOMAT II........................................................[C] 11
Intake manifold ................................................[E] 30

Intake system ............................................[E] 22, 30

Feed pump ................................................[E] 25, 26

Intake valve .....................................................[E] 12

Final reduction ratio.........................................[C] 14

Intercooler .................................................[E] 17, 24

Flange joint........................................................[C] 3
Flash point.......................................................[E] 16

Fluid coupling ..................................................[C] 10

Knuckle arm ....................................................[C] 16

Flywheel..................................................[E] 21/[C] 5
Flywheel PTO..................................................[C] 13

Four-stroke-cycle engine .................................[E] 12

Lead ................................................................[E] 27

Frame ................................................................[C] 3

Leading/trailing-shoe brake .............................[C] 23

Fuel filter..........................................................[E] 25

Leaf spring ......................................................[C] 28

Full air brakes..................................................[C] 21

Load-sensing valve (LSV) ...............................[C] 24

Full-power PTO ...............................................[C] 13

Lock brake.......................................................[C] 24
Lockup.............................................................[C] 25

Low-profile radial tire .......................................[C] 27

Gasoline engine ..............................................[E] 14

LSD .................................................................[C] 15

Generator..............................................[E] 36/[C] 30

Lubrication system ..........................................[E] 32

Glow plug ........................................................[E] 19

Lugged type ....................................................[C] 27

Governor .............................................[E] 22, 26, 28

Main combustion chamber ..............................[E] 19

Rack gear........................................................[C] 17

Manual transmission .......................................[C] 10

Rack-and-pinion type ......................................[C] 17

Master cylinder................................................[C] 20

Radial tires ......................................................[C] 26

Master Vac ......................................................[C] 22

Radiator...........................................................[E] 34

Mechanical governor .......................................[E] 28

Reduction gear............................................[C] 3, 14

Multigrade oil ...................................................[E] 33

Retarder ..........................................................[C] 24
Ribbed and lugged type ..................................[C] 27

Rigid-axle suspension .....................................[C] 28

Naturally aspirated engine...............................[E] 23

Nitrogen oxides ...............................................[E] 17

Nox (Nitrogen oxides)......................................[E] 17

SAE .................................................................[E] 33
Sector shaft .....................................................[C] 17

Service brakes.................................................[E] 31

OHC engine.....................................................[E] 21

Shock absorber ...............................................[C] 29

OHV engine.....................................................[E] 21

Side rail .............................................................[C] 3

Oil cooler .........................................................[E] 35

Single-chamber type .......................................[E] 19

Oil filter ............................................................[E] 32

Sliding-mesh type..............................................[C] 8

Oil pan .............................................................[E] 20

Spark plug .......................................................[E] 12

Overdrive.........................................................[C] 12

Spiral bevel gears............................................[C] 14

Overrunning ....................................................[C] 12

Stabilizer .........................................................[C] 28
Starter motor ...................................................[E] 36

Starter switch...................................................[E] 36

Pad .................................................................[C] 23

Starting system ...............................................[E] 36

Parking brake........................................[E] 31/[C] 24

Steel radial tire ................................................[C] 26

Performance classifications (Engine oil)..........[E] 33

Steering gearbox.............................................[C] 16

Pinion gear ......................................................[C] 17

Steering shaft ..................................................[C] 16

Piston ........................................................[E] 12, 13

Steering system ..............................................[C] 16

Piston rings......................................................[E] 21

Steering wheel ................................................[C] 16

Pitman arm......................................................[C] 16

Stroke ..............................................................[E] 20

Plunger ......................................................[E] 26, 27

Suction hose....................................................[E] 25

Plunger barrel..................................................[E] 27

Suspension system .....................................[C] 3, 28

Positive crankcase ventilation (PCV)...............[E] 17

Swirl-chamber type..........................................[E] 19

Power ..............................................................[E] 11

Synchromesh type ............................................[C] 9

Power takeoff (PTO)........................................[C] 13

Powertard .............................................[E] 31/[C] 24

Precombustion-chamber type .........................[E] 19

Tandem master cylinder ..................................[C] 20

Priming pump ..................................................[E] 25

Thermostat ......................................................[E] 35

Propeller shaft...........................................[E] 9/[C] 3

Tie rod .............................................................[C] 16

Pushrod ................................................[E] 21/[C] 21

Timer .........................................................[E] 26, 28

Top dead center...............................................[E] 15

Torque .............................................................[E] 11
Torque converter .............................................[C] 10
Torque rod .......................................................[C] 29
Torsion-bar springs..........................................[C] 28
Transmission .................................................[C] 2, 7
Transmission PTO ...........................................[C] 13
Tread patterns .................................................[C] 27
Trunnion-type suspension ...............................[C] 29
Tubeless tires ..................................................[C] 26
Turbine wheel ..................................................[E] 23
Turbocharger .......................................[E] 17, 22, 23
Turbocharging..................................................[E] 23
Two-leading-shoe brake ..................................[C] 23

V
Valve................................................................[E] 21
Vapor locking ...................................................[E] 31
Vehicle-speed-sensitive power steering ..........[C] 18
Viscosity categories (Engine oil) .....................[E] 33
V-type ..............................................................[E] 10

W
Water cooling...................................................[E] 34
Water jacket....................................................[E] 34
Water pump .....................................................[E] 35
Web joints .........................................................[C] 3
Wedge-type .....................................................[C] 20
Worm shaft......................................................[C] 17

Youre an important part of the

Mitsubishi Fuso team. If there
anything you need to know, dont
hesitate to ask a more experienced
salesperson or someone in
your service department.

Your name

Well do
ne

T-No. 04 - '05

www.mitsubishi-fuso.com