FOR INTERNAL USE ONLY

Truck Technology:W

ha t t r u c k s a r e a l l a b o ut

The Facts You Need (I) The Facts You Need (I) – Engine –

Understanding and remembering everything about themechanisms used in specially equipped or special-purpose trucks and various other kinds of trucks is noteasy. However, most truck users are knowledgeableabout such vehicles. So it’s essential for salespeoplewho deal directly with such users to have a basicunderstanding of the way trucks move, the basicstructures of trucks, and other aspects of thesevehicles.

Having a basic knowledge of trucks is vital forcommunication with customers. And further increasingyour knowledge will enable you to give customersappropriate advice.

As a first step, we’ll look at the basics of engines andchassis. This text describing the engine is the first ofthe truck basics series consisting of part 1 ‘Engine’and part 2 ‘Chassis’.

Introduction

The ProfessorThe professor explainseverything about trucks in away that’s easy to understand.He says: “Everything you’re goingto learn is vital for your work, so Ihope you’ll pay close attention.”

CanterCanter explains MitsubishiFuso technologies.He says: “I hope you’ll do yourbest to understand thetechnologies used in trucks likeme.”

The SalesmanThe salesman wantsto be a greatsuccess withcustomers. He says: ”Technicalthings are hard for meto understand, but I’mdoing my best.”

The Assistant The assistant sees considerseverything from your point ofview and supplements theprofessor’s explanations. She says: “I have a lot to learn, soI’m studying hard.”

What trucks are all about

ContentsBasics

1. What truck types does Mitsubishi Fuso make? . . . . . . . . . . 2

2. How do trucks and passenger cars differ?. . . . . . . . . . . . . . 4

3. The names of truck parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4. How does a truck move? . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. What engine types does Mitsubishi Fuso have? . . . . . . . . 10

�What is an engine? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. How does an engine produce power? . . . . . . . . . . . . . . . . 12

2. Why is up-down motion turned into rotation?. . . . . . . . . . . 13

�Diesel engines and gasoline engines:What’s the difference? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1. Are diesel engines economical? . . . . . . . . . . . . . . . . . . . . 16

2. Are diesel engines becoming more advanced? (1) . . . . . . 17

Are diesel engines becoming more advanced? (2) . . . . . . 18

Are diesel engines becoming more advanced? (3) . . . . . . 19

�How is an engine made up? . . . . . . . . . . . . . . . . . . . . . . . 20

�What items are attached to an engine? . . . . . . . . . . . . . . 22

1. Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Where does fuel come from?. . . . . . . . . . . . . . . . . . . . . . . 25

4. How is fuel injected? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5. How is the amount of injected fuel regulated?. . . . . . . . . . 27

6. What’s the governor? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7. The common-rail system:

a means of realizing optimal combustion. . . . . . . . . . . . . . 29

�Does an engine breathe?. . . . . . . . . . . . . . . . . . . . . . . . . . 30

�Can an engine work as a brake? . . . . . . . . . . . . . . . . . . . 31

�Why is engine oil necessary? . . . . . . . . . . . . . . . . . . . . . . 32

�How is an engine cooled? . . . . . . . . . . . . . . . . . . . . . . . . . 34

�Does an engine generate electricity? . . . . . . . . . . . . . . . . 36

�Future trucks and buses will reflect priorities on the environment and safety. . . . . . . . . . . . . . . . . . . . . . 37

INDEX

Truck Technology:

The Facts You Need (I) – Engine –

1

2

34

5678910

2

1 What truck types does Mits

Mitsubishi Fuso truck types

Mitsubishi Fuso trucks exist in various types withdifferent cargo capacities as follows:��Canter (light-duty truck)��Fighter (medium-duty truck)��Super Great (heavy-duty truck)

�� Canter (light-duty truck)

�� Canter (light-duty truck)

Basics

3

ubishi Fuso make?

�� Fighter (medium-duty truck)

�� Super Great(heavy-duty truck)

Fighter

Fighter NX

Trucks like these are used all over Japan.

4

2How do trucks andpassenger cars differ?

Differences between a truck and a passenger carAs its name indicates, a passenger car is designed to carry people; most of thespace inside a passenger car is used as a cabin for occupants.On a truck, the cab is made as small as possible and is located at the front tocreate space for cargo or for special equipment such as a crane or cementmixer. The engine of a passenger car is located under the hood. The engine of atruck is located under the cab.

Headlamps

Front bumper

window

Rear bumper

Windsh

Side mirror

Front panel

Headlamps

Front bumper

Step

ear bumper

Passenger car

Truck

Basics

– NOTE –

6

3 The names of truck parts

Let’s learn the correct names of truck parts.

Wiper

Side mirror

Mirror stayBody (cargo bed)

Front garnish

Guard frame

Side window

Door

Door handleGate

Turn-signal lamp

Foglamp

Headlamp

Radiator grille

Front bumper

Cornering lampStep

Front fenderRear fender

Rear window

Guard frame

Fender garnish

Turn-signal lamp

Step garnish

Battery

Combination lamp

Rear bumper

[Front of truck]

[Rear of truck]

Before you learn about trucks in detail, let’s look at the names of truck parts.

Basics

7

Air conditioner; AM/FM radio with digital clock

Tachometer (engine speed indicator)

SpeedometerMeter panel

Tilt- and telescope-adjustable steering wheel

Right-hand multi-use lever switch (for turn signals and lights)

Left-hand multi-use lever switch (for wipers, hazard warning lamps, and exhaust brake)

Center console and center trayInstrument-panel-mounted shift lever

Storage box

Air conditioner vent

Door pocketDoor armrest

SeatbeltDriver’s seat

Headrest

Assistant driver’s seat

ArmrestCenter consoleand center tray

Instrument panel(front panel positioned across front of cab)

8

4 How does a truck move?

A truck’s drivelineLet’s look at the parts of a truck that are needed to make the truck move. As you can see from the illustration,a truck moves by making the wheels turn using power from the engine. The parts used to make the truckmove are collectively called the driveline.

Basics

Steering wheThe steering wheTurning the steeriin which the front

EngineThe engine produces the power needed to make the truck mThe way the engine produces power and the way it transmitthe power are described in detail on later pages.

9

DriveshaftEach rear wheel is linked to the differential by a driveshaft. Power that has been transmitted by the propeller shaft to the differential is transmitted from the differentialto the wheels by the driveshafts. Differential

fferential enables the truck to be driven hly on curves by automatically allowing er and outer wheels to turn at differents.

eller shaftpeller shaft is a rotating shaft that transmits om the transmission toward the rear wheels.

ard

WheelsThe wheels are each fitted with a tire that’s ouching the ground. The truck moves when the wheels areurned by engine power.

10

Engine types are indicated with reference to the layout of the cylinders and withreference to the number of cylinders. An engine whose cylinders are arranged in astraight line is called an inline engine, and one whose cylinders are arranged like aletter ‘V’ (as seen from the front) is called a V-type engine. Also, an engine that hasfour cylinders is called a four-cylinder engine, one with eight cylinders is called aneight-cylinder engine, and so on. In a V8 engine, eight cylinders are arranged in twobanks of four cylinders each. Mitsubishi Fuso has many types of engine. Examplesare shown below.

➾ For information on turbochargers andintercoolers, refer to pages 23 and 24.

Mitsubishi Fuso engine types

10M21 [V10 engine]

6M70 (T4) [inline six-cylinder engine with turbochargerand intercooler]

8M22 (T1) [V8 engine with turbocharger and intercooler]

6M60 (T1) [inline six-cylinder engine with turbochargerand intercooler]

4M50 (T3) [inline six-cylinder engine with turbochargerand intercooler]

5What engine types doesMitsubishi Fuso have?Basics

11

What is an engine?1Vehicles are propelled by engine power.

A vehicle’s engine produces thepower that propels the vehicle. In asense, it forms the heart of thevehicle.

�� PowerPower is the rate at which work is done by an engine. Itinfluences the vehicle’s maximum speed. A commonlyused unit of engine power is ‘PS’, which stands for‘PferdeStarke’, the German translation of ‘horsepower’.Power of 1PS is the power needed to raise a weight of75kg by one meter in one second. Typically, an engine’spower is expressed with respect to the engine’s speed.For example, a certain engine’s maximum power mightbe expressed as 210PS/2,900rpm, which means thatthe engine’s highest possible power is 210PS and thatthe engine delivers this power when running at a speedof 2,900 revolutions per minute.

�� TorqueTorque is the rotational force produced by an engine. Itinfluences the vehicle’s hill-climbing ability and standingstart ability. A commonly used unit of engine torque is‘kgf·m’, which indicates the number of kilograms of forceexerted by the crankshaft at a point one meter from thecenter of the crankshaft. Typically, an engine’s torque isexpressed with respect to the engine’s speed. Forexample, a certain engine’s maximum torque might beexpressed as 180kgf·m/1,200rpm, which means that theengine’s highest possible torque is 180kgf·m and thatthe engine delivers this torque when running at a speedof 1,200 revolutions per minute.

<Engine performance curves: power and torque at a glance>The power and torque of a vehicle’s engine are shown in a graphin the vehicle’s catalog. This graph enables the engine’sperformance to be ascertained at a glance.

(1) Power curve (points of maximum power plotted)(2) Torque curve (points of maximum torque plotted)

<kW/PS (power) equivalents>

Power and torque

412686785

11771275139315201618

N·m427080

120130142155165180

kgf·m

1k · = ·m0.1019kgf·m 1N·m

(26992

103114118132154165177184199235243257272279294302316353382405

kW94

125140155160180210225240250270320330350370380400410430480520550

PS

1kW ==1ps

<N·m/kgf·m (torque) equivalents>

12

1How does an engineproduce power?1

Engines use burning fuel (typically gasoline or diesel fuel) to produce power. Butsimply making the fuel burn would not create much power. To produce large amountsof power, engines use a special arrangement and process. To see how power isproduced, let’s look at a four-stroke-cycle gasoline engine.

Two-stroke-cycle engines exist in addition to four-stroke-cycleengines. However, four-stroke-cycle engines are used in alltrucks for reasons including regulations on exhaust emissions.

1) Intake strokeOn the intake stroke, the pistonis moving downward and theintake valve is open. A mixture ofair and vaporized fuel is drawninto the cylinder.

2) Compression strokeAs the piston moves upwardfollowing closure of the intakevalve, the air-fuel mixture in thecylinder is compressed.

3) Power strokeWhen the piston reaches the topof its travel on the compressionstroke and the air-fuel mixture ismaximally compressed, thespark plug produces a spark thatcauses the air-fuel mixture toexplode. The force produced bythe explosion pushes the pistondownward. The engine thusproduces power.

What does ‘four-stroke-cycle’ mean?A four-stroke-cycle engine is one that completes a power-producing cycle in fourvertical piston strokes (the intake stroke, the compression stroke, the powerstroke, and the exhaust stroke). The term ‘four-stroke-cycle’ is an abbreviation of‘four-stroke, one-cycle.

4) Exhaust strokeAs the piston reaches the bottomof its stroke, the exhaust valveopens. As the piston then movesupward on the exhaust stroke, itforces the burned gases out ofthe cylinder through the exhaustport.

Two-stroke-cycle engines

An engine produces power by making fuel explode.

<Gasoline engine>

13

2Why is up-down motionturned into rotation?1

The pistons in an engine move up and down, so their motion can’t be used to turn the wheels unless it isconverted into rotational motion. The conversion is done by connecting rods and a crankshaft, which areattached to the bottom of the pistons. The action of the connecting rods and crankshaft is analogous to theway a bicycle is pedaled. As the rider’s knees move up and down, the pedals go around in a circular manner.The connecting rods attached to an engine’s piston correspond to the bicycle rider’s lower legs. As thepistons move up and down, they drive the crankshaft round.

Piston

Connecting rod

Crankshaft

eeorresponds to engine piston.)

Lower leg (Corresponds to engine connecting rod.)

PedalCorresponds to crankshaft.)

The piston’s reciprocating motion can be converted into rotational motion.

When people talk about the speed of an engine, they’re referring to thespeed of rotation of the crankshaft. For example, an engine speed of 3,000rpm means thatthe crankshaft turns 3,000 times in a period of one minute. This speed equates to 50 turnsof the crankshaft per second. In other words, the pistons are moving up and down 50 timesper second. Because so much activity takes place in an engine, a high level of mechanicalprecision is demanded.

What is engine speed?

14

Diesel engines and gasoline What’s the difference?

How diesel engines and gasoline engines differEngines can be classified into two main kinds: gasoline engines, which use gasoline asfuel, and diesel engines, which use diesel fuel as fuel. A gasoline engine and a dieselengine are both four-stroke-cycle engines. However, the principles behind their intake,compression, and power strokes are different.

2

1) Intake stroke

<Gasoline engines and diesel engines: a comparison>

Item Gasoline engine Diesel engine

Compression ratio Low High

Compression pressure Low High

Air-fuel mixtureCreated by mixture of fuel vapor with Created by spraying of fuel into

air prior to compression air after compression of air

Ignition method Electric sparkSelf-ignition by means of heat

resulting from compression

Fuel supply device Carburetor or fuel injectors Injection pump

Fuel Gasoline Diesel fuel

Thermal efficiency 23 to 28% 29 to 38%

2) Compression stroke 3) Power stroke 4) Exhaust stroke

Gasoline engine

A gasoline engine draws in a mixture of gasoline and air on the intake stroke and compresses the mixture onthe compression stroke. Then on the power stroke, it uses a spark from a spark plug to cause thecompressed mixture to explode.

15

engines:

Diesel engine

A diesel engine draws in only air (no fuel) on the intake stroke. Diesel fuel is injected into the compressed air on the combustionstroke. The required explosion then occurs because of self-ignition.

1) Intake strokeAs the piston moves downward,the intake valve opens, causingair to rush into the cylinder.

2) Compression strokeAs the piston moves upward, theair in the cylinder is compressed.

3) Power strokeWhen the piston reaches the topof its stroke and the air ismaximally compressed, aninjection nozzle sprays highlypressurized diesel fuel into theair. The temperature of the air(500–700°C) brings about self-ignition of the fuel, resulting in anexplosion and expansion.

4) Exhaust strokeThe exhaust valve opens, andthe upward movement of thepiston expels the gases that arein the cylinder.

<The merits and demerits of a diesel engine>

Demerits Merits

The compression ratio is the ratio of the combinedvolume of portions A and B (the total intakevolume) and the volume of just portion A (after theair charge or air-fuel mixture charge has beencompressed to occupy just portion A). Acompression ratio of 10 means that the total intakeamount of air or mixture gets compressed to 1/10of its original volume.

What is an engine’scompression ratio?

The diesel engine was invented by Dr. RudolfDiesel, a German engineer, and is named afterhim.

• Causes noise andvibration.

• Costly to produce.• Heavy.

• Recent designs arequieter and cause lessvibration.

• Does not need much dailymaintenance.

• Diesel fuel is cheap.• Fuel consumption is low.

Piston stroke

Compression ratio

= A + BA

16

1Are diesel engineseconomical?2

Salesman:A diesel engine is definitely cheaper.CustomerYes, the running costs are cheaper than for a gasoline engine.But isn’t the initial cost higher?

Attributes of diesel engines

Running costs:These are the costs of running an engine from day to day.Initial cost: This is the cost of buying an engine.

Diesel engines not only use cheaper fuel; they’re very efficient, too.

The fuel used by diesel engines is much cheaper than gasoline; the more a diesel engineis used, the greater the saving becomes.Diesel fuel has a higher flash point than gasoline (it does not readily catch fire when thetemperature is low), so ignition is not achieved using spark plugs. Rather, ignition isachieved by means of self-ignition, which takes advantage of the fact that diesel fuel has alow ignition point (can undergo self-ignition even when the temperature is relatively low). Adiesel engine has a higher compression ratio than a gasoline engine because the heatgenerated by compression is used to cause the self-ignition.The high compression ratio simultaneously means that expansion during combustion isgreat. Consequently, a diesel engine has high thermal efficiency, which translates intohigh power and low fuel consumption.

Flash point:This is the lowest temperature at which fuel catches firewhen brought close to fire.Ignition point:This is the lowest temperature at which fuelspontaneously ignites as a result of its own heat.

Diesel engines are simple to maintain.Partly because a diesel engine has no ignition system, diesel engines arestructurally simpler than gasoline engines. Also, diesel engines are made to besturdy since they must withstand high compression ratios. Consequently, dieselengines are easy to maintain. Easy maintenance is one of the most importantadvantages of diesel engines.

Flash point Ignition point

Diesel fuel 50 to 70°C Approx. 250°C

Gasoline -40 to 20°C Approx. 300°C

?

17

2Are diesel engines becomingmore advanced? (1)2

The main harmful substances in the exhaust emissions of a diesel engine are carbon monoxide (CO),hydrocarbons (HCs), nitrogen oxides (NOx), and particulate matter (PM (mainly black smoke and unburnedHCs)). The production of these substances is influenced by the way air and fuel are mixed and by thecombustion temperature. Notably, NOx (the result of bonding between oxygen (O2) and nitrogen (N2)) iscreated in large quantities if the combustion temperature is high. (The higher the combustion temperature, thegreater the quantities of NOx.) To limit NOx creation, the combustion temperature must be made sufficientlylow. However, making the combustion temperature low detracts from fuel economy and exacerbatesproduction of black smoke. The tradeoff is a difficult problem.

<Measures to limit exhaust emissions>Mitsubishi Fuso takes various measures to make exhaust emissions as clean as possible. These measuresinclude developing new fuel injection pumps that optimize the mixing of air and fuel and employingintercoolers, turbochargers, exhaust gas recirculation (EGR) systems, and other systems that help to realizecombustion at optimal temperatures.Intercoolers and turbochargers are generally seen as devices for increasing engine power, but they are alsoeffective against exhaust emissions. The environmental benefits are significant.

�� Injection pumpEffectively supplies fuel to the engine in accordance with the engine speed.(See page 26.)�� TurbochargerIncreases the density of the engine’s intake air, thereby enhancingcombustion efficiency. (See page 23.)�� IntercoolerCools air emerging from the turbocharger (necessary because theturbocharger makes the air very hot), thereby making the combustiontemperature low. (See page 24.)�� Cooled EGR systemAn EGR system reduces the NOx content of the exhaust gases by directingexhaust emissions into the intake side of the engine. NOx is produced whenthe combustion temperature of the air-fuel mixture is high, so large amountsof inert, already-burned gases are introduced into the intake flow by meansof the EGR system to slow the combustion and thus reduce the combustiontemperature. In a cooled EGR system, a cooler reduces the temperature ofthe recirculated exhaust gases to further lower the combustion temperaturefor an even bigger reduction in NOx emissions.�� Positive crankcase ventilation (PCV) systemA PCV system removes blowby gases (harmful gases that have leaked intothe engine’s crankcase through the gaps between the pistons and cylinders)and directs them into the combustion chambers, where they are burned. Itthus prevents blowby gases from being released into the atmosphere.

The problem of exhaust emissions from diesel engines

Diesel particulate filter (DPF)A DPF is a filter that removes PM from exhaust gases. The term ‘DPF’ is a registeredtrademark of Mitsubishi Fuso. The type of DPF used by Mitsubishi Fuso is actually acombination of a wire-mesh DPF and an oxidizing catalyst. The oxidizing catalyst reducesPM by converting unburned substances into water and carbon dioxide (CO2). PM that stillremains is captured by the filter, so hardly any PM is emitted.

EGR coolerEGR valve

Ex

18

2Are diesel engines becomingmore advanced? (2)2

When a diesel engine starts, the resulting sharp increase inpressure inside it can cause significant vibration and noise. Also,any inaccuracy in the fuel injection timing can make the ignitionerratic, resulting in diesel knock, which causes noise and vibration.Diesel engines have various features designed to overcome theseproblems.

Types of diesel engine

Diesel knockWhen the combustion pressure in a cylinder rises abnormally, it can create a shock wave that severelyvibrates the engine, resulting in a knocking noise. Measures to prevent diesel knock include improvementsin fuel ignitability, the shapes of combustion chambers, and injection systems.

�� Types of diesel engineDiesel engines have been developed with various types of combustion chamber in pursuitof complete combustion. Currently, most diesel engines are of the single-chamber type.

19

2Are diesel engines becomingmore advanced? (3)2

Single-chamber type

With this type, each cylinder has a single combustion chamber.

�� Direct injectionThe cylinder head has a flat surface, and the piston has an indentation in its crown; together the flat surface and indentationform a combustion chamber. On the compression stroke, a swirling motion is created in the air as the air is compressed. Theinjection nozzle has five or six holes, through which it sprays fuel into the swirling air in a radial pattern, thereby causing the fuelto mix well with the air such that self-ignition readily takes place.

Dem

erit

sM

erit

s • Simple structure; few faults• High compression ratio; high thermal efficiency; also low fuel

consumption• Good startability

• Injection pump and nozzles must have high performance to spray fuel

directly into highly pressurized combustion chambers and are thus

costly.

• Sensitive to changes in fuel and operating conditions.

Direct-injection diesel engines are widely used in trucks becauseof their fuel economy and high power.

tion nozzle

Combustion chamber

Cylinder

Dual-chamber type

Each cylinder has one main combustion chamber and one auxiliary chamber. This arrangement is effective at cutting dieselknock. However, the total volume of the combustion chambers is large, meaning that heat easily escapes; a glow plug isessential.

�� Swirl-chamber typeThis arrangement includes an auxiliary chamber (called a swirl chamber) whose shape promotes swirling action; combustiontakes place in two stages. On the compression stroke, fuel is injected into swirling air flowing from the main combustionchamber into the swirl chamber. The fuel thus mixes well with the air. Combustion smoothly propagates from the swirl chamberto the main combustion chamber.

Dem

erit

sM

erit

s

• High combustion speeds permit high engine speeds, making theengine suitable for high-speed driving.

• Low pressure from the fuel injection pump is sufficient, so the nozzlescan be simple.

• Fuel mixes well with air, so there is little diesel knock. Operation isquiet, and exhaust emissions are low.

• Structurally complex

• Fuel economy is poorer than with direct injection.

Glow plug(heater pl

Injectionnozzle

Main combustionchamber

Swirl chamber

�� Precombustion-chamber typeIn this arrangement, there is an auxiliary chamber (called a precombustion chamber) in addition to a main combustion chamber.Combustion takes place in two stages: Fuel is injected into the precombustion chamber and undergoes partial combustionthere. Then, it undergoes complete combustion in the main combustion chamber.

Dem

erit

sM

erit

s • Low pressure from the fuel injection pump is sufficient, so the nozzlescan be simple.

• Fuel mixes well with air, so there is little diesel knock. Operation isquiet, and exhaust emissions are low.

• Structurally complex

• Fuel economy is poorer than with direct injection.

Injection nozzle

Main combustionchamber Precombustion

chamber

Glow plug(heater plug)

20

How is an engine made up?3The structure of the main body of an engine

The main body of an engine consists of the cylinder head, the crankcase (thiscontains the pistons and crankshaft), the oil pan, and other parts.

Bore

What is an engine’s displacement?An engine’s size is expressed as a number of cc. This number is asfollows:the cross-sectional area of one piston (the bore) x the stroke x the number of cylindersFor example, the displacement of a four-cylinder engine with a pistondiameter of 104mm and a piston stroke of 105mm is as follows:52 x 52 x π x 105 x 4 = 3,567cc

Cylinder liner: (with piston inside)

Cylinder

Crankcase(cylinder block)

Piston

wheelw ecting rodConne

C

21

An engine has intake valves and exhaustvalves, which open and close inaccordance with the engine’s operation.Opening and closing of the valves areeffected by the movement of a camshaft. Ifthe camshaft is located beside thecrankshaft and only the valves arepositioned above the cylinders, the engineis called an overhead-valve (OHV) type. Ifthe valves and camshaft are locatedabove the cylinders, the engine is calledan overhead-cam (OHC) type.

What are valves?

22

What items are attachedto an engine?

Accessories essential for engine operationA turbocharger, an intercooler, an injection pump (all mentioned earlier in ‘Theproblem of exhaust emissions from diesel engines’), a governor, and otheraccessories are attached to a diesel engine to enhance its operation.

Turbocharger

Intake system

Intercooler

Injection pump

I k

Exhaust system

Turbocharger

4

23

1 Turbocharger4

�� The benefit of turbochargingAs you can imagine, a big engine (one with a big overall displacement)produces more power than small one. A big engine can draw more air into itscylinders, so it can inject more fuel for more powerful explosions, hence thegreater power. But space and weight considerations mean there are limits tohow big an engine can be.Turbocharging, or forced induction, is a technique that was devised to overcomethis problem. With forced induction, the engine’s supply air is compressed (thecompression increases the air’s density) and forced into the cylinders. More aircan thus be drawn into the cylinders at once, so more fuel can be injected andburned for more powerful explosions without an increase in engine size. In otherwords, it’s possible to obtain a benefit equivalent to that of a larger enginewithout actually using a larger engine.

�� The operating principle of a turbochargerIn a turbocharger, the force of the engine’s exhaustgases is used to turn a turbine wheel. A compressorwheel is connected to the turbine wheel and turnswith it. The compressor wheel compresses air andforces it into the engine’s cylinders.By compressing the engine’s intake air, theturbocharger yields benefits including higher enginepower and better fuel economy.

Exhaust

Turbine wheel

<Shown below are top viewing of the engines.>

Turbocha

Turbocharged engine Naturally aspirated engine

The turbocharger boosts the engine’s performance.

An engine without

a turbocharger is

called a naturally

aspirated engine.

24

2 Intercooler4

�� The role of an intercoolerWhen air is compressed, it becomes hot. And when air becomes hot, itbecomes less dense. So although an engine’s turbocharger compresses air toincrease its density, the accompanying heat would, without an appropriatecountermeasure, limit the benefit of the turbocharger. An intercooler is thenecessary countermeasure. By cooling the compressed air that emerges fromthe turbocharger, it increases the air’s density, thereby enhancing the benefit ofthe turbocharger. The intercooler boosts engine power, promotes fuel economy,and helps to limit exhaust emissions at the same time.

The temperature of the compressed air emerging from a turbocharger is about150°C. An intercooler reduces the temperature to about 50°C.

Intercooler

An intercooler is essential with a turbocharger.

25

3Where does fuel comefrom?4

The basic fuel supply pathLet’s take a look at an engine’s fuel supply system. Diesel fuel in the fuel tank isdrawn up through a suction hose (fuel pipe) by the action of a feed pump. Afterpassing through a fuel filter, the fuel is fed to an injection pump and is thensprayed by injection nozzles at the correct timing during the engine’s powerstrokes. Fuel that is not used by the injection pump returns through a returnhose to the fuel tank.

Injection nozz

Injection pump

Feed pump

Suction hoseInjection nozzles

Injection pump

Fuel filter

Feed pump

Fuel tank

�� Feed pumpThe feed pump feeds fuel from the fuel tank to theinjection pump. It is controlled so that the fuelpressure does not become abnormal. Also, itpermits air to be bled out of the fuel system. (See“What is air bleeding?” on the right.)

�� Fuel filterThe fuel filter removes dirt and moisture from thefuel so that clean fuel reaches the engine. It isfitted with an air bleeding plug.

If a vehicle runs out of fuel, air can enterthe fuel system. Even if fuel is then put inthe fuel tank, the engine will not start.In this situation, air bleeding must beperformed. (See the figure on the left.) Onemust loosen the air bleeding plug on thefuel filter then release the priming pump onthe feed pump and move it up and down ina pumping action. This action expels air,together with fuel, from the fuel systemthrough the air bleeding plug. When airbubbles stop emerging with the fuel, airbleeding is complete.One must then tighten the air bleeding plugand push down the priming pump to itsstowed position.

What is air bleeding?

Air bleeding plug

26

4 How is fuel injected?4The role of injection

Let’s look at the injection pump, which plays a particularly important role in thefuel system. The injection pump pressurizes the fuel that is to be injected intothe combustion chambers, and it injects the fuel in optimal quantities and withoptimal timing uniformly among the cylinders.

In addition to the pump-proper, the injection pumpincorporates a governor that stabilizes and controlsthe engine speed, a timer that regulates the timingof fuel injection, and a feed pump that draws fuelfrom the fuel tank and supplies the injection pumpwith the fuel under pressure.

The injection pump supplies fuel to the engineusing a method like that of a syringe. (See thefigure below.) There are two types of injectionpump: the inline type, which contains an individualsyringe for each of the cylinders, and the distributortype, which uses one syringe to supply fuel to all ofthe cylinders.

�� General view of injection pump<Inline type>

mp

T

Governor

�� Structure of injection pumpThe injection pump feeds fuel to the cylindersunder pressure by means of a camshaft that turnstogether with the engine’s crankshaft.Located inside the injection pump are plungers thatpressurize fuel before delivery to injection nozzles;the camshaft that applies up-down movements tothe plungers as the engine’s crankshaft turns; anda control rack that controls the amount of fuel eachplunger pressurizes and delivers to thecorresponding injection nozzle (see page 27).These components form together a very precisemechanism for properly controlling fuel injection.

Injection nozzle

Injectionpump

The inline type is used on most trucks. Thedistributor type is used on certain diesel enginesfor light-duty trucks.

27

5How is the amount ofinjected fuel regulated?4

A device for precise fuel injection�� The plunger mechanism: the heart of the injection pump

<How the plunger pressurizes fuel while metering it?>The plunger is moved up and down by a cam. As it moves, it draws in, throughits in-out port, the amount of fuel to be injected into the engine’s cylinder in onego and pushes out this fuel to an injection nozzle.A control rack that moves together with the accelerator pedal adjusts theamount of fuel, thereby adjusting the engine speed.

�� Plunger operating principleThe plunger has an oblique groove (called a lead) in its side. The lead isconnected to a passage that runs down the center of the plunger, making itpossible to alter the amount of fuel that the plunger pumps out.

As the plunger moves downward, fuel isdrawn into the plunger barrel through thefuel in-out port.

As the plunger moves upward, the fuel in-out port is closed off. The fuel feedbegins at the moment when the fuel in-out port is closed off.

As the plunger rises further and theplunger lead meets the fuel in-out port,the fuel remaining in the plunger barrelstarts flowing back through the passagein the center of the barrel and out throughthe fuel in-out port. The fuel feed thusends.

�� Fuel intake �� Fuel feed �� End of fuel feed

Fuel

n-out

Plun

el in-out port

Lead

As you can see from the figures above, the amount of fuel injected inone go is metered by the distance from the point at which the top ofthe plunger closes the fuel in-out port in the plunger barrel to the pointat which the plunger lead meets the fuel in-out port in the plungerbarrel. (This distance is called the effective stroke.) Since the lead isoblique rather than vertical, rotating the plunger changes the effectivestroke and thus changes the amount of fuel that is injected in one go.Rotating the plunger is the job of the control rack, which moves inaccordance with movement of the accelerator pedal and governor.

Why is the plunger turned?Plunger barrel

Fuel in-out port

Plunger

Control rack

Plunger

28

6 What’s the governor?4The governor: a device that automatically controls the fuel injection amount to stabilize the engine speed

The governor continuously operates to stabilize the engine speed as necessary under a variety of conditions.For example, it keeps the engine speed stable while the engine is idling and prevents the engine speed fromexceeding the permitted limit when the accelerator pedal is pressed strongly.

<Types of governor>The governor controls the plungers in the injection pump by moving the control rack as necessary to supplythe engine with the required amount of fuel for the current engine speed. The governor can be mechanical orelectronic.

�� Mechanical governorA mechanical governor uses the centrifugal force of flyweights to make control.When the engine speed rises, the injection pump’s camshaft, which turns together with the engine’scrankshaft, also speeds up. At this time, the flyweights, which are attached to one end of the camshaft, arepulled outward under their centrifugal force. Using the lever principle, the outward movement of the flyweightscauses the control lever to move in the direction of fuel reduction. When the engine is idling, the flyweights donot move outward but keep the engine speed stable.

<Governor operating principle>

�� Electronic governorAn electronic governor is an advanced electronic control device. In an electronic governor, a computerreceives signals indicating not only the engine speed but also the engine loading, coolant temperature, andother factors. The computer processes the signals to determine the optimal fuel injection amount.

Control rack

FuelIncrease Re

Cam

Flyweight

The timer: a device that automatically controls the fuel injection timing

The engine speed continuously changes, so it is essential to adjust the fuel injection timing accordingly. Thetimer does this job. It uses the centrifugal force and resulting inward and outward motion of flyweights (theseare attached to the camshaft) to adjust the injection timing of the injection pump.

29

7The common-rail system: a meansof realizing optimal combustion4

To realize optimal combustion with minimum nitrogen oxides (NOx) andparticulate matter (PM) emissions, Mitsubishi Fuso uses a computer-controlledcommon-rail fuel injection system. In the common-rail fuel injection system, fuelthat has been raised to an ultra-high pressure by the supply pump is fed into astorage chamber (called a common rail) that is located above the injectors. Byinjecting highly pressurized fuel from the common rail, the system promotesatomization of the injected fuel and thus enables optimal mixing of the fuel withair in the cylinders.Also, the system allows precise control over the number of injections per cycle,the timing of injections, and the amounts of fuel injected. It thus not onlyprevents incomplete combustion and suppresses NOx and PM generation; italso realizes ideal combustion over the entire range of engine speeds. Thevehicle’s fuel economy, power performance, and driveability all benefit from thecommon-rail fuel injection system.

Common-rail fuel injection system

Supply pump

Fuel filter

The common-rail fuel injection system

With a conventional engine, the fuel pressure is relatively low,meaning that the droplets of fuel injected into the cylinderscannot be made very small. Consequently, the surfaces of fueldroplets coming into direct contact with air burn well but thecenters do not. Further, the centers are exposed to the hightemperature of the burning surfaces and are thus baked,resulting in soot. Unburned fuel and lubricating oil stick to thesoot particles, resulting in PM.With the common-rail system, by contrast, the high pressure offuel injected into the cylinders means that the fuel droplets arerelatively small. The small fuel droplets permit completecombustion and thus limit the creation of soot.

How does the common-rail systemcut PM generation?

Large fuel dropletsBaked

PM (or soot) created

Combustion on surface only

Small fuel droplets

Near-complete combustion

PM creation greatlysuppressed

30

Does an enginebreathe?

The intake system and exhaust systemAs you’ve learned, an engine needs air to operate. Let’s see how air flows intoan engine (intake) and how gases after combustion leave it (exhaust).

Exhaust

5

�� Intake systemThe intake air duct is a snorkel type that positionsthe intake opening as high as possible (where theair is clean) and prevents water on the roadsurface from entering the engine’s intake air. Thesnorkel-type intake air duct stands behind thecab. Air entering the air duct contains dirt anddust, which would damage the engine if theyentered it, so an air cleaner removes such foreignmatter. The cleaned air flows through the intakemanifold, which distributes it to the engine’scylinders.

�� Exhaust systemGases resulting from combustion in the engineare collected in the exhaust manifold then flowthrough the exhaust pipe and into the muffler.The gases emerging from the engine’s cylindersare extremely hot and highly pressurized. If theywere simply released to the atmosphere, theywould rapidly expand, creating a loud noise. Themuffler prevents this problem by allowing thegases to expand little by little and by coolingthem before they emerge into the atmosphere.

31

Can an engine work as abrake?6

The brakes that stop a vehicleA vehicle’s brakes can be broadly classified as follows: the service brakes, whichare applied by pressure on the brake pedal while the vehicle is moving, and theparking brake (also called the handbrake), which is used to keep the vehiclestationary. (Detailed information on brakes is given in the Chassis Section.)Braking functions are also provided by the engine in the form of engine brakingand, with a truck or bus, by an exhaust brake, which works using exhaust gases.

�� Can the engine work as a brake?If the accelerator pedal is released while the vehicle is moving, the engine speeddrops and the vehicle slows down because of ‘engine braking’. The effect ofengine braking is stronger in lower gears than in higher gears. On a longdownward slope, a low gear should be selected to obtain powerful enginebraking.

�� Exhaust brakeAn exhaust brake is a device that uses exhaust gases to increase theeffectiveness of engine braking. This device uses a valve in the exhaustpipe to restrict the flow of exhaust gases, thereby increasing the engine’sresistance to motion. An exhaust brake on a heavy-duty diesel vehiclecan yield 1.5–2.5 times the speed reduction that is possible with justengine braking.

Exhaust brake

To prevent brake ineffectiveness resulting from brake fade, which is causedby overheating and failure of the service brakes, and vapor locking, which iscaused by boiling of the brake fluid in the service brake hydraulic circuit, theservice brakes should be used together with engine braking and the exhaustbrake.

The Mitsubishi Fuso Powertard brake

Mitsubishi Fuso vehicles are also availablewith a device called a Powertard brake. ThePowertard brake boosts the effectiveness ofengine braking by making full use of theengine’s resistance to motion during thecompression stroke. The overalleffectiveness is 3–4 times that of ordinaryengine braking.

As you’ve seen, the exhaust gases not onlyenhance the engine’s effectiveness bypowering the turbocharger; they’re alsoused to create a braking function.

Hardworking exhaustgases

32

Why is engine oil necessary?7Lubricating oil: the lifeblood of the engine

The pistons, cylinders, crankshaft, cams, and other parts of an engine rubagainst each other during operation. Lubricating oil is needed to make theiroperation smooth.

<Great friction occurs inside engines.>Friction occurs when objects rub against each other. To minimize the friction thatoccurs in an engine, lubricating oil is used to create an oil film on the rubbingsurfaces of metal parts. With the metal parts sliding against the oil rather thanrubbing against each other, wear on the metal parts is minimized.

�� The engine oil flow in the lubrication systemOil stored in the oil pan is circulated through the engine by an oil pump. Oil that has become hot and dirty iscooled by an oil cooler then cleaned by an oil filter, after which it is again fed through the engine forlubrication.

er

Oi

Oil cooler

Oil filter

Oil pan

Hardworking engine oilThe oil in an engine not only has a lubricating effect on the engine’s components; it also has acooling effect that cools the engine, a sealing effect that prevents leakage of gases through thegaps between the pistons and cylinders, and a cleaning effect that carries dirt away from theengine inner surfaces.

SAE viscosity Application

ratingnt

SAE5W Cold regions

SAE10W

SAE20W Winter

SAE20

SAE30 General use

SAE40 Summer

SAE50 Extremely hot regions

Category (JIS) Mitsubishi Fuso genuine oilProperties of Mitsubishi Fuso

genuine oil

CA

CB

CC Fuso Engine Oil CC Contains a good balance of additives.

Used for a wide range of applications CD Fuso Engine Oil S-3 including trucks, construction machinery,

and ships.

CE

Fuso Engine Oil Super CF-4High-performance oil containing advanced additives

CF-4 Intended for DPF-equipped vehicles. Fuso Engine Oil DH-2 Cuts ash accumulation and adhesion

in the DPF.

33

�� Types of engine oil<Viscosity categories>To prevent engine oil from becoming too thin at high temperatures or too thick at low temperatures, types ofengine oil are categorized by viscosity to suit the temperatures at which they are to be used.

<Performance classifications>The stronger the oil film created by a type of oil, the better the oil performs. Oil performance is classified inaccordance with the results of tests. With any engine, it is important to use oil whose performanceclassification suits the characteristics of the engine. Oil performance classifications are as follows: CC → CD→CE →CF-4. Use of engine oil with classifications of CC (CD for turbocharged engines) and higher isspecified for Mitsubishi Fuso engines.

API service categories for diesel engine oil

Multigrade oil, which has a wide viscosity range thataccommodates a wide range of temperatures, is also available.

SAE: Society of Automotive EngineersW: Winter grade (oil for winter and cold regions)

API: American Petroleum Institute

Viscosity

Low

High

34

How is an engine cooled?8

An engine tends to become extremely hot because of the combustion that takes place inside it. To giveadequate performance, however, it must be kept at the optimal temperature, meaning that it must be cooled.The engine’s cooling system does this job.

Cooling fan

Reservoir tank

Radiator

A hot engine is cooled using coolant.

There are two possible ways to cool an engine: water cooling (using liquid coolant) and air cooling (using air). Air cooling is lesseffective than water cooling, and it necessitates a thin-walled cylinder block, which exacerbates engine noise. It is used only onmotorcycles and limited number of cars.

Never open a radiator cap while the radiator is hot. Hot, highly pressurized coolantcould spray out and scald you.

�� RadiatorThe radiator consists of many pipes. Coolant thathas become hot while circulating through theengine flows through the pipes in the radiator,and its heat is carried away by air that flowsbetween the pipes.

35

�� Water pumpAn impeller in the water pump is turned by thecrankshaft via a V-belt. As it turns, the coolant ispressurized and circulates through the engine.

<The engine must not be cooled too match.>As you have learned, an engine needs to be cooled because the combustion thatoccurs on the combustion strokes release a lot of heat. But an engine cannot giveits best performance if it is cooled too much. The best coolant temperature forengine operation is considered to be 80°C.

�� Oil coolerIf the engine’s lubricating oil became too hot, itwould become less effective. The oil coolerprevents this problem by using the engine’scoolant to cool the oil.

Co nt

Oil Oil

�� ThermostatThe thermostat prevents the coolant frombecoming too hot or too cold. It works as a kind ofvalve. When the temperature of coolant that hasreturned from the cylinder head is higher than thepredetermined temperature, the thermostatcauses it to flow into the radiator, where it iscooled. When the temperature of coolant that hasreturned from the cylinder head is below thepredetermined temperature, the thermostatcauses it to flow to the water pump, not into theradiator.

�� Cooling fanWhen the engine is idling or the vehicle is beingdriven very slowly, there is no natural airflowthrough the radiator. At such times, the coolingfan is used to blow air through the radiator forcooling purposes. The type of cooling fan usedon current vehicles is an auto cooling fan, whichdoes not run when the coolant temperature islow.

To radiato

T

Water pump

r head

The oil cooler serves not only to cool the oil; oncold days, it also serves to warm the oil.

36

Does an enginegenerate electricity?9

It’s no exaggeration to say that every vehicle todaydepends on electronic control. The necessaryelectricity is supplied by an alternator (a kind ofgenerator) and a battery (a device that can storeelectricity). While the engine is running, the alternatorsupplies the needed electricity to the vehicle’selectrical systems. When the alternator alone cannotsupply enough electricity, the battery makes up theshortfall.

Alternator

The battery alone is used for startup. Power is generated thereafter.

�� Starting systemElectricity for starting the engine comes from thebattery.The starting system, which starts the engine,consists of a starter motor, a starter switch, and thebattery. When the starter switch is turned ON, thestarter motor’s gear springs out and meshes with agear on the engine’s flywheel. The starter motor thenturns the flywheel to start the engine. When thestarter switch is turned OFF, the gear on the startermotor is retracted.

37

Future trucks and buses will reflectpriorities on the environment and safety.10

<CNG vehicles are environment-friendly owing to 20–30% loweremissions.>On a CNG vehicle, compressed natural gas (CNG) is stored in tanks. CNG fromthe tanks has its pressure reduced by a regulator and is then supplied to theengine’s cylinders together with air in appropriate quantities in accordance withsensor indications corresponding to the engine’s operating condition. The gasesremaining after combustion are treated by a three-way catalyzer, resulting inrelatively clean emissions.

<LPG realizes ultra-low exhaust emissions.>Mitsubishi Fuso has developed engines such as the 4D34 LPG engine, which is based on a large-displacement diesel engine and offers superior power performance and lower exhaust emissions. Using LPGtechnology, Mitsubishi Fuso is seeking new possibilities for environmental compatibility and fuel economy.

<A proposal for a new kind of city bus.>City buses must meet demands for low exhaustemissions, low fuel consumption, and barrier-freeoperation. The Mitsubishi Fuso Aerostar Non-StepHEV Bus is a response to these demands (HEV isacronym of ‘hybrid electric vehicle’). It has a series-type electric hybrid drive system that realizes lownoise and low impact on environment. Further, it hasan optimal component layout and super-single reartires for greatly improved comfort.

�� Increase adoption of low-pollution vehicles that havediesel engines and thus require no new infrastructure.

�� Realize low exhaust emissions and fuel consumption bymeans of constant-speed engine operation and braking-energy regeneration.

�� Realize easy driving by means of electric motor propulsionthat requires no transmission.

�� Realize superior interior freedom of movement throughemployment of wide single tires that allow superior aislewidth between the rear wheels.

�� Goals of development

Ai t k CNG tank

Battery and resonator g

CNG, LPG, and electricity will realize clean running.

Special equipment on a CNGcargo truck

(1) Electronic controller

(2) Inverter

(3) Diesel engine

(4) Generator

(5) Propulsion motor

(6) Accessory drive motor

(7) Lithium-ion battery

(8) Fuel tank

AABS.................................................................[C] 25

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

This index covers part I ‘Engine’ and part II ‘Chassis’.[E] denotes the items appearing in the engine sectionand [C] denotes those appearing in the chassis section.

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

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

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

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

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

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

EEGR cooler......................................................[E] 17

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

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

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

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

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

Engine’s displacement.....................................[E] 20

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

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

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

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

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

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

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

Flange joint........................................................[C] 3

Flash point.......................................................[E] 16

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

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

Flywheel PTO..................................................[C] 13

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

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

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

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

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

GGasoline engine ..............................................[E] 14

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

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

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

HHalogen headlamps ........................................[C] 32

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

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

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

Horsepower .....................................................[E] 11

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

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

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

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

IIgnition point ....................................................[E] 16

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

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

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

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

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

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

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

Intake manifold ................................................[E] 30

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

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

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

KKnuckle arm ....................................................[C] 16

LLead ................................................................[E] 27

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

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

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

Lock brake.......................................................[C] 24

Lockup.............................................................[C] 25

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

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

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

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

MMain combustion chamber ..............................[E] 19

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

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

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

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

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

NNaturally aspirated engine...............................[E] 23

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

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

OOHC engine.....................................................[E] 21

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

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

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

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

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

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

PPad .................................................................[C] 23

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

RRack gear........................................................[C] 17

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

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

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

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

Retarder ..........................................................[C] 24

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

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

SSAE .................................................................[E] 33

Sector shaft .....................................................[C] 17

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

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

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

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

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

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

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

Stabilizer .........................................................[C] 28

Starter motor ...................................................[E] 36

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

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

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

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

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

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

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

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

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

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

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

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

TTandem master cylinder ..................................[C] 20

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

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

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

VValve................................................................[E] 21

Vapor locking...................................................[E] 31

Vehicle-speed-sensitive power steering ..........[C] 18

Viscosity categories (Engine oil) .....................[E] 33

V-type ..............................................................[E] 10

WWater cooling...................................................[E] 34

Water jacket....................................................[E] 34

Water pump.....................................................[E] 35

Web joints .........................................................[C] 3

Wedge-type.....................................................[C] 20

Worm shaft......................................................[C] 17

This brings us to the end of the engine section. I hope it wasn'ttoo difficult, and I hope you're

now more confident about dealingwith customers. Next, we'll move

on to the chassis section.

Well done!

Your name

T-No. 03 - '05 www.mitsubishi-fuso.com