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FOR INTERNAL USE ONLY

Truck Technology:

The Facts You Need (I)

Engine

Introduction

Understanding and remembering everything about the

mechanisms used in specially equipped or specialpurpose trucks and various other kinds of trucks is not
easy. However, most truck users are knowledgeable
about such vehicles. So its essential for salespeople
who deal directly with such users to have a basic
understanding of the way trucks move, the basic
structures of trucks, and other aspects of these
vehicles.
Having a basic knowledge of trucks is vital for
communication with customers. And further increasing
your knowledge will enable you to give customers
appropriate advice.
As a first step, well look at the basics of engines and
chassis. This text describing the engine is the first of
the truck basics series consisting of part 1 Engine
and part 2 Chassis.

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:

The Facts You Need (I) Engine

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.

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

Contents
Basics
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
1 What is an engine? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. How does an engine produce power? . . . . . . . . . . . . . . . . 12
2. Why is up-down motion turned into rotation?. . . . . . . . . . . 13
2 Diesel engines and gasoline engines:
Whats 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
3 How is an engine made up? . . . . . . . . . . . . . . . . . . . . . . . 20
4 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. Whats the governor? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. The common-rail system:
a means of realizing optimal combustion. . . . . . . . . . . . . . 29
5 Does an engine breathe? . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Can an engine work as a brake? . . . . . . . . . . . . . . . . . . . 31
7 Why is engine oil necessary? . . . . . . . . . . . . . . . . . . . . . . 32
8 How is an engine cooled? . . . . . . . . . . . . . . . . . . . . . . . . . 34
9 Does an engine generate electricity? . . . . . . . . . . . . . . . . 36

10 Future trucks and buses will reflect priorities

on the environment and safety. . . . . . . . . . . . . . . . . . . . . . 37

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.

Basics

What truck types does Mits

Mitsubishi Fuso truck types
Mitsubishi Fuso trucks exist in various types with
different 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)

ubishi Fuso make?

Fighter
(medium-duty truck)

Fighter

Fighter NX

Super Great
(heavy-duty truck)

Trucks like these are

used all over Japan.

How do trucks and

2 passenger cars differ?

Basics

Differences between a truck and a passenger car

As its name indicates, a passenger car is designed to carry people; most of the
space 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 to
create space for cargo or for special equipment such as a crane or cement
mixer. The engine of a passenger car is located under the hood. The engine of a
truck is located under the cab.

Passenger car
window

Headlamps

Rear bumper

Front bumper

Truck

Windsh
Side mirror

Front panel

Headlamps

Front bumper
ear bumper
Step

 NOTE

Basics

The names of truck parts

Lets learn the correct names of truck parts.

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

[Front of truck]
Side window
Wiper

Guard frame

Side mirror
Door
Body (cargo bed)

Mirror stay
Door handle

Gate

Front garnish

Turn-signal lamp
Headlamp

Foglamp

Radiator grille
Front fender

Front bumper
Cornering lamp

[Rear of truck]

Rear fender

Step

Rear window
Guard frame

Combination lamp

Fender garnish

Turn-signal lamp

Step garnish

Battery

Rear bumper

Air conditioner; AM/FM radio

with digital clock

Tachometer
(engine speed indicator)

Speedometer

Meter panel
Tilt- and telescopeadjustable steering
wheel

Air conditioner vent

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

Storage box
Left-hand multi-use
lever switch
(for wipers, hazard
warning lamps,
and exhaust brake)
Instrument-panel-mounted shift lever

Door pocket

Center console and center tray

Drivers seat

Door armrest
Seatbelt

Headrest

Assistant drivers seat

Instrument panel
(front panel positioned across front of cab)

Center console
and center tray

Armrest

Basics

How does a truck move?

A trucks driveline

Lets 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 truck
move are collectively called the driveline.

Steering whe
The steering whe
Turning the steeri
in which the front

Engine
The engine produces the power needed to make the truck m
The way the engine produces power and the way it transmit
the power are described in detail on later pages.

Driveshaft
Each 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 differential
to 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 different
s.

Wheels
The wheels are each fitted with a tire thats
ouching the ground.
The truck moves when the wheels are
urned by engine power.

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

ard

Basics

What engine types does

5 Mitsubishi Fuso have?

Mitsubishi Fuso engine types

Engine types are indicated with reference to the layout of the cylinders and with
reference to the number of cylinders. An engine whose cylinders are arranged in a
straight line is called an inline engine, and one whose cylinders are arranged like a
letter V (as seen from the front) is called a V-type engine. Also, an engine that has
four cylinders is called a four-cylinder engine, one with eight cylinders is called an
eight-cylinder engine, and so on. In a V8 engine, eight cylinders are arranged in two
banks of four cylinders each. Mitsubishi Fuso has many types of engine. Examples
are shown below.

10M21 [V10 engine]

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

6M60 (T1) [inline six-cylinder engine with turbocharger

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

4M50 (T3) [inline six-cylinder engine with turbocharger

and intercooler]

For information on turbochargers and

intercoolers, refer to pages 23 and 24.

10

What is an engine?

Vehicles are propelled by engine power.

A vehicles engine produces the
power that propels the vehicle. In a
sense, it forms the heart of the
vehicle.

Power and torque

Power
Power is the rate at which work is done by an engine. It
influences the vehicles maximum speed. A commonly
used 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 of
75kg by one meter in one second. Typically, an engines
power is expressed with respect to the engines speed.
For example, a certain engines maximum power might
be expressed as 210PS/2,900rpm, which means that
the engines highest possible power is 210PS and that
the engine delivers this power when running at a speed
of 2,900 revolutions per minute.

Torque
Torque is the rotational force produced by an engine. It
influences the vehicles hill-climbing ability and standing
start ability. A commonly used unit of engine torque is
kgfm, which indicates the number of kilograms of force
exerted by the crankshaft at a point one meter from the
center of the crankshaft. Typically, an engines torque is
expressed with respect to the engines speed. For
example, a certain engines maximum torque might be
expressed as 180kgfm/1,200rpm, which means that the
engines highest possible torque is 180kgfm and that
the engine delivers this torque when running at a speed
of 1,200 revolutions per minute.

<Engine performance curves: power and torque at a glance>

The power and torque of a vehicles engine are shown in a graph
in the vehicles catalog. This graph enables the engines
performance to be ascertained at a glance.
<kW/PS (power) equivalents>

(2

<Nm/kgfm (torque) equivalents>

Nm
412
686
785
1177
1275
1393
1520
1618
1k =
0.1019kgfm

kgfm
42
70
80
120
130
142
155
165
180

(1) Power curve (points of maximum power plotted)

(2) Torque curve (points of maximum torque plotted)

kW
69
92
103
114
118
132
154
165
177
184
199
235
243
257
272
279
294
302
316
353
382
405
1kW =

PS
94
125
140
155
160
180
210
225
240
250
270
320
330
350
370
380
400
410
430
480
520
550
=1ps

m
1Nm

11

How does an engine

1 produce power?

An engine produces power by making fuel explode.

Engines use burning fuel (typically gasoline or diesel fuel) to produce power. But
simply making the fuel burn would not create much power. To produce large amounts
of power, engines use a special arrangement and process. To see how power is
produced, lets look at a four-stroke-cycle gasoline engine.
<Gasoline engine>

1) Intake stroke
On the intake stroke, the piston
is moving downward and the
intake valve is open. A mixture of
air and vaporized fuel is drawn
into the cylinder.

2) Compression stroke
As the piston moves upward
following closure of the intake
valve, the air-fuel mixture in the
cylinder is compressed.

3) Power stroke
When the piston reaches the top
of its travel on the compression
stroke and the air-fuel mixture is
maximally compressed, the
spark plug produces a spark that
causes the air-fuel mixture to
explode. The force produced by
the explosion pushes the piston
downward. The engine thus
produces power.

4) Exhaust stroke
As the piston reaches the bottom
of its stroke, the exhaust valve
opens. As the piston then moves
upward on the exhaust stroke, it
forces the burned gases out of
the cylinder through the exhaust
port.

What does four-stroke-cycle mean?

A four-stroke-cycle engine is one that completes a power-producing cycle in four
vertical piston strokes (the intake stroke, the compression stroke, the power
stroke, and the exhaust stroke). The term four-stroke-cycle is an abbreviation of
four-stroke, one-cycle.

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

12

Why is up-down motion

2 turned into rotation?

The pistons reciprocating motion can be converted into rotational motion.

The pistons in an engine move up and down, so their motion cant be used to turn the wheels unless it is
converted into rotational motion. The conversion is done by connecting rods and a crankshaft, which are
attached to the bottom of the pistons. The action of the connecting rods and crankshaft is analogous to the
way a bicycle is pedaled. As the riders knees move up and down, the pedals go around in a circular manner.
The connecting rods attached to an engines piston correspond to the bicycle riders lower legs. As the
pistons move up and down, they drive the crankshaft round.

Piston

ee
orresponds to engine piston.)

Connecting rod

Lower leg
(Corresponds to
engine connecting rod.)

Crankshaft

Pedal
Corresponds to crankshaft.)

What is engine speed?

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

13

Diesel engines and gasoline

Whats the difference?

How diesel engines and gasoline engines differ

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

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

1) Intake stroke

2) Compression stroke

3) Power stroke

4) Exhaust stroke

<Gasoline engines and diesel engines: a comparison>

Item

Gasoline engine

Diesel engine

Compression ratio

Low

High

Compression pressure

Low

High

Air-fuel mixture

Created by mixture of fuel vapor with

air prior to compression

Created by spraying of fuel into

air after compression of air

Ignition method

Electric spark

Self-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%

14

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 combustion
stroke. The required explosion then occurs because of self-ignition.

1) Intake stroke
As the piston moves downward,
the intake valve opens, causing
air to rush into the cylinder.

2) Compression stroke
As the piston moves upward, the
air in the cylinder is compressed.

3) Power stroke
When the piston reaches the top
of its stroke and the air is
maximally compressed, an
injection nozzle sprays highly
pressurized diesel fuel into the
air. The temperature of the air
(500700C) brings about selfignition of the fuel, resulting in an
explosion and expansion.

4) Exhaust stroke
The exhaust valve opens, and
the upward movement of the
piston expels the gases that are
in the cylinder.

<The merits and demerits of a diesel engine>

Demerits

Merits

Causes noise and

vibration.
Costly to produce.
Heavy.

Recent designs are

quieter and cause less
vibration.
Does not need much daily
maintenance.
Diesel fuel is cheap.
Fuel consumption is low.

What is an engines
compression ratio?
The compression ratio is the ratio of the combined
volume of portions A and B (the total intake
volume) and the volume of just portion A (after the
air charge or air-fuel mixture charge has been
compressed to occupy just portion A). A
compression ratio of 10 means that the total intake
amount of air or mixture gets compressed to 1/10
of its original volume.
Piston stroke

Compression ratio
= A+B
A

The diesel engine was invented by Dr. Rudolf

Diesel, a German engineer, and is named after
him.

15

Are diesel engines

1 economical?
Attributes of diesel engines

Salesman:
A diesel engine is definitely cheaper.
Customer
Yes, the running costs are cheaper than for a gasoline engine.
But isnt the initial cost higher?

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

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

Flash point

Ignition point

Diesel fuel

50 to 70C

Approx. 250C

Gasoline

-40 to 20C

Approx. 300C

Diesel engines are simple to maintain.

Partly because a diesel engine has no ignition system, diesel engines are
structurally simpler than gasoline engines. Also, diesel engines are made to be
sturdy since they must withstand high compression ratios. Consequently, diesel
engines are easy to maintain. Easy maintenance is one of the most important
advantages of diesel engines.

16

Are diesel engines becoming

2 more advanced? (1)

The problem of exhaust emissions from diesel engines

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 unburned
HCs)). The production of these substances is influenced by the way air and fuel are mixed and by the
combustion temperature. Notably, NOx (the result of bonding between oxygen (O2) and nitrogen (N2)) is
created in large quantities if the combustion temperature is high. (The higher the combustion temperature, the
greater the quantities of NOx.) To limit NOx creation, the combustion temperature must be made sufficiently
low. However, making the combustion temperature low detracts from fuel economy and exacerbates
production 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 measures
include developing new fuel injection pumps that optimize the mixing of air and fuel and employing
intercoolers, turbochargers, exhaust gas recirculation (EGR) systems, and other systems that help to realize
combustion at optimal temperatures.
Intercoolers and turbochargers are generally seen as devices for increasing engine power, but they are also
effective against exhaust emissions. The environmental benefits are significant.

Injection pump
Effectively supplies fuel to the engine in accordance with the engine speed.
(See page 26.)

Turbocharger
Increases the density of the engines intake air, thereby enhancing
combustion efficiency. (See page 23.)

Intercooler
Cools air emerging from the turbocharger (necessary because the
turbocharger makes the air very hot), thereby making the combustion
temperature low. (See page 24.)

Cooled EGR system
An EGR system reduces the NOx content of the exhaust gases by directing
exhaust emissions into the intake side of the engine. NOx is produced when
the combustion temperature of the air-fuel mixture is high, so large amounts
of inert, already-burned gases are introduced into the intake flow by means
of the EGR system to slow the combustion and thus reduce the combustion
temperature. In a cooled EGR system, a cooler reduces the temperature of
the recirculated exhaust gases to further lower the combustion temperature
for an even bigger reduction in NOx emissions.

Positive crankcase ventilation (PCV) system
A PCV system removes blowby gases (harmful gases that have leaked into
the engines crankcase through the gaps between the pistons and cylinders)
and directs them into the combustion chambers, where they are burned. It
thus prevents blowby gases from being released into the atmosphere.

EGR valve
EGR cooler

Ex

Diesel particulate filter (DPF)

A DPF is a filter that removes PM from exhaust gases. The term DPF is a registered
trademark of Mitsubishi Fuso. The type of DPF used by Mitsubishi Fuso is actually a
combination of a wire-mesh DPF and an oxidizing catalyst. The oxidizing catalyst reduces
PM by converting unburned substances into water and carbon dioxide (CO2). PM that still
remains is captured by the filter, so hardly any PM is emitted.

17

Are diesel engines becoming

2 more advanced? (2)
Types of diesel engine

When a diesel engine starts, the resulting sharp increase in

pressure inside it can cause significant vibration and noise. Also,
any inaccuracy in the fuel injection timing can make the ignition
erratic, resulting in diesel knock, which causes noise and vibration.
Diesel engines have various features designed to overcome these
problems.

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

Types of diesel engine

Diesel engines have been developed with various types of combustion chamber in pursuit
of complete combustion. Currently, most diesel engines are of the single-chamber type.

18

Are diesel engines becoming

2 more advanced? (3)

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

Combustion
chamber
Cylinder

Merits

tion nozzle

Simple structure; few faults

High compression ratio; high thermal efficiency; also low fuel
consumption
Good startability

Demerits

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

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 because

of their fuel economy and high power.

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

Injection
nozzle
Main combustion
chamber

Swirl
chamber

Merits

Glow plug
(heater pl

High combustion speeds permit high engine speeds, making the

engine suitable for high-speed driving.
Low pressure from the fuel injection pump is sufficient, so the nozzles
can be simple.
Fuel mixes well with air, so there is little diesel knock. Operation is
quiet, and exhaust emissions are low.

Demerits

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

Structurally complex
Fuel economy is poorer than with direct injection.

Main combustion
chamber

Precombustion
chamber

Glow plug
(heater plug)

Merits

Injection nozzle

Low pressure from the fuel injection pump is sufficient, so the nozzles
can be simple.
Fuel mixes well with air, so there is little diesel knock. Operation is
quiet, and exhaust emissions are low.

Demerits

Precombustion-chamber type
In 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 combustion
there. Then, it undergoes complete combustion in the main combustion chamber.

Structurally complex
Fuel economy is poorer than with direct injection.

19

How is an engine made up?

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

What is an engines displacement?

An engines size is expressed as a number of cc. This number is as
follows:

the cross-sectional area of one piston (the bore) x

the stroke x the number of cylinders
For example, the displacement of a four-cylinder engine with a piston
diameter of 104mm and a piston stroke of 105mm is as follows:

52 x 52 x x 105 x 4 = 3,567cc

20

Bore

What are valves?

An engine has intake valves and exhaust
valves, which open and close in
accordance with the engines operation.
Opening and closing of the valves are
effected by the movement of a camshaft. If
the camshaft is located beside the
crankshaft and only the valves are
positioned above the cylinders, the engine
is called an overhead-valve (OHV) type. If
the valves and camshaft are located
above the cylinders, the engine is called
an overhead-cam (OHC) type.

Cylinder liner: (with piston inside)

Cylinder
Piston

Crankcase
(cylinder block)

w
wheel

21

Conne
ecting rod

What items are attached

to an engine?

Accessories essential for engine operation

A turbocharger, an intercooler, an injection pump (all mentioned earlier in The
problem of exhaust emissions from diesel engines), a governor, and other
accessories are attached to a diesel engine to enhance its operation.

Turbocharger

Intake system

Injection pump

Intercooler

Exhaust system

Turbocharger

22

Turbocharger

The turbocharger boosts the engines performance.

The benefit of turbocharging
As 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 its
cylinders, so it can inject more fuel for more powerful explosions, hence the
greater power. But space and weight considerations mean there are limits to
how big an engine can be.
Turbocharging, or forced induction, is a technique that was devised to overcome
this problem. With forced induction, the engines supply air is compressed (the
compression increases the airs density) and forced into the cylinders. More air
can thus be drawn into the cylinders at once, so more fuel can be injected and
burned for more powerful explosions without an increase in engine size. In other
words, its possible to obtain a benefit equivalent to that of a larger engine
without actually using a larger engine.

The operating principle of a turbocharger
In a turbocharger, the force of the engines exhaust
gases is used to turn a turbine wheel. A compressor
wheel is connected to the turbine wheel and turns
with it. The compressor wheel compresses air and
forces it into the engines cylinders.
By compressing the engines intake air, the
turbocharger yields benefits including higher engine
power and better fuel economy.

Exhaust

Turbine wheel

<Shown below are top viewing of the engines.>

Turbocha

ithout
gine w
An en charger is
o
a turb naturally
a
called d engine.
te
aspira

Naturally aspirated engine

Turbocharged engine

23

Intercooler

An intercooler is essential with a turbocharger.

The role of an intercooler
When air is compressed, it becomes hot. And when air becomes hot, it
becomes less dense. So although an engines turbocharger compresses air to
increase its density, the accompanying heat would, without an appropriate
countermeasure, limit the benefit of the turbocharger. An intercooler is the
necessary countermeasure. By cooling the compressed air that emerges from
the turbocharger, it increases the airs density, thereby enhancing the benefit of
the turbocharger. The intercooler boosts engine power, promotes fuel economy,
and helps to limit exhaust emissions at the same time.

Intercooler

The temperature of the compressed air emerging from a turbocharger is about

150C. An intercooler reduces the temperature to about 50C.

24

Where does fuel come

3 from?
The basic fuel supply path
Lets take a look at an engines fuel supply system. Diesel fuel in the fuel tank is
drawn up through a suction hose (fuel pipe) by the action of a feed pump. After
passing through a fuel filter, the fuel is fed to an injection pump and is then
sprayed by injection nozzles at the correct timing during the engines power
strokes. Fuel that is not used by the injection pump returns through a return
hose to the fuel tank.
Injection nozz

Fuel tank
Feed pump

Injection pump

Fuel filter
Feed pump

Injection pump
Injection nozzles

Suction hose

Feed pump
The feed pump feeds fuel from the fuel tank to the
injection pump. It is controlled so that the fuel
pressure does not become abnormal. Also, it
permits air to be bled out of the fuel system. (See
What is air bleeding? on the right.)

What is air bleeding?

If a vehicle runs out of fuel, air can enter
the fuel system. Even if fuel is then put in
the fuel tank, the engine will not start.
In this situation, air bleeding must be
performed. (See the figure on the left.) One
must loosen the air bleeding plug on the
fuel filter then release the priming pump on
the feed pump and move it up and down in
a pumping action. This action expels air,
together with fuel, from the fuel system
through the air bleeding plug. When air
bubbles stop emerging with the fuel, air
bleeding is complete.
One must then tighten the air bleeding plug
and push down the priming pump to its
stowed position.

Fuel filter
The fuel filter removes dirt and moisture from the
fuel so that clean fuel reaches the engine. It is
fitted with an air bleeding plug.
Air bleeding plug

25

How is fuel injected?

The role of injection

Lets look at the injection pump, which plays a particularly important role in the
fuel system. The injection pump pressurizes the fuel that is to be injected into
the combustion chambers, and it injects the fuel in optimal quantities and with
optimal timing uniformly among the cylinders.

General view of injection pump
<Inline type>
The injection pump supplies fuel to the engine
using a method like that of a syringe. (See the
figure below.) There are two types of injection
pump: the inline type, which contains an individual
syringe for each of the cylinders, and the distributor
type, which uses one syringe to supply fuel to all of
the cylinders.

mp

The inline type is used on most trucks. The

distributor type is used on certain diesel engines
for light-duty trucks.

Governor

Injection nozzle

In addition to the pump-proper, the injection pump

incorporates a governor that stabilizes and controls
the engine speed, a timer that regulates the timing
of fuel injection, and a feed pump that draws fuel
from the fuel tank and supplies the injection pump
with the fuel under pressure.

Structure of injection pump

The injection pump feeds fuel to the cylinders
under pressure by means of a camshaft that turns
together with the engines crankshaft.
Located inside the injection pump are plungers that
pressurize fuel before delivery to injection nozzles;
the camshaft that applies up-down movements to
the plungers as the engines crankshaft turns; and
a control rack that controls the amount of fuel each
plunger pressurizes and delivers to the
corresponding injection nozzle (see page 27).
These components form together a very precise
mechanism for properly controlling fuel injection.

Injection
pump

26

How is the amount of

5 injected fuel regulated?

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, through
its in-out port, the amount of fuel to be injected into the engines cylinder in one
go and pushes out this fuel to an injection nozzle.
A control rack that moves together with the accelerator pedal adjusts the
amount of fuel, thereby adjusting the engine speed.

Fuel
Plun
n-out

Plunger operating principle

The plunger has an oblique groove (called a lead) in its side. The lead is
connected to a passage that runs down the center of the plunger, making it
possible to alter the amount of fuel that the plunger pumps out.

Fuel intake

Fuel feed

End of fuel feed

el in-out port

Lead

As the plunger moves downward, fuel is

drawn into the plunger barrel through the
fuel in-out port.

As the plunger moves upward, the fuel inout port is closed off. The fuel feed
begins at the moment when the fuel inout port is closed off.

As the plunger rises further and the

plunger lead meets the fuel in-out port,
the fuel remaining in the plunger barrel
starts flowing back through the passage
in the center of the barrel and out through
the fuel in-out port. The fuel feed thus
ends.

Why is the plunger turned?

Plunger

As you can see from the figures above, the amount of fuel injected in
one go is metered by the distance from the point at which the top of
the plunger closes the fuel in-out port in the plunger barrel to the point
at which the plunger lead meets the fuel in-out port in the plunger
barrel. (This distance is called the effective stroke.) Since the lead is
oblique rather than vertical, rotating the plunger changes the effective
stroke 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 in
accordance with movement of the accelerator pedal and governor.

27

Control
rack

Plunger
barrel
Fuel in-out
port

Plunger

Whats the governor?

The 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 from
exceeding 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 supply
the engine with the required amount of fuel for the current engine speed. The governor can be mechanical or
electronic.

Mechanical governor
A mechanical governor uses the centrifugal force of flyweights to make control.
When the engine speed rises, the injection pumps camshaft, which turns together with the engines
crankshaft, also speeds up. At this time, the flyweights, which are attached to one end of the camshaft, are
pulled outward under their centrifugal force. Using the lever principle, the outward movement of the flyweights
causes the control lever to move in the direction of fuel reduction. When the engine is idling, the flyweights do
not move outward but keep the engine speed stable.
<Governor operating principle>
Control rack
Fuel
Increase

Re

Cam

Flyweight

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

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. The
timer does this job. It uses the centrifugal force and resulting inward and outward motion of flyweights (these
are attached to the camshaft) to adjust the injection timing of the injection pump.

28

The common-rail system: a means

7 of realizing optimal combustion

The common-rail fuel injection system

To realize optimal combustion with minimum nitrogen oxides (NOx) and
particulate matter (PM) emissions, Mitsubishi Fuso uses a computer-controlled
common-rail fuel injection system. In the common-rail fuel injection system, fuel
that has been raised to an ultra-high pressure by the supply pump is fed into a
storage chamber (called a common rail) that is located above the injectors. By
injecting highly pressurized fuel from the common rail, the system promotes
atomization of the injected fuel and thus enables optimal mixing of the fuel with
air 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 only
prevents incomplete combustion and suppresses NOx and PM generation; it
also realizes ideal combustion over the entire range of engine speeds. The
vehicles fuel economy, power performance, and driveability all benefit from the
common-rail fuel injection system.
Common-rail fuel injection system

Supply pump

Fuel filter

How does the common-rail system

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

29

Large fuel droplets

Baked

PM (or soot) created

Combustion on surface only

Small fuel droplets

PM creation greatly
suppressed
Near-complete combustion

Does an engine
breathe?

The intake system and exhaust system

As youve learned, an engine needs air to operate. Lets see how air flows into
an engine (intake) and how gases after combustion leave it (exhaust).

Exhaust

Intake system
The intake air duct is a snorkel type that positions
the intake opening as high as possible (where the
air is clean) and prevents water on the road
surface from entering the engines intake air. The
snorkel-type intake air duct stands behind the
cab. Air entering the air duct contains dirt and
dust, which would damage the engine if they
entered it, so an air cleaner removes such foreign
matter. The cleaned air flows through the intake
manifold, which distributes it to the engines
cylinders.

Exhaust system
Gases resulting from combustion in the engine
are collected in the exhaust manifold then flow
through the exhaust pipe and into the muffler.
The gases emerging from the engines cylinders
are extremely hot and highly pressurized. If they
were simply released to the atmosphere, they
would rapidly expand, creating a loud noise. The
muffler prevents this problem by allowing the
gases to expand little by little and by cooling
them before they emerge into the atmosphere.

30

Can an engine work as a

brake?

The brakes that stop a vehicle

A vehicles brakes can be broadly classified as follows: the service brakes, which
are applied by pressure on the brake pedal while the vehicle is moving, and the
parking brake (also called the handbrake), which is used to keep the vehicle
stationary. (Detailed information on brakes is given in the Chassis Section.)
Braking functions are also provided by the engine in the form of engine braking
and, 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 speed
drops and the vehicle slows down because of engine braking. The effect of
engine braking is stronger in lower gears than in higher gears. On a long
downward slope, a low gear should be selected to obtain powerful engine
braking.

Exhaust brake
An exhaust brake is a device that uses exhaust gases to increase the
effectiveness of engine braking. This device uses a valve in the exhaust
pipe to restrict the flow of exhaust gases, thereby increasing the engines
resistance to motion. An exhaust brake on a heavy-duty diesel vehicle
can yield 1.52.5 times the speed reduction that is possible with just
engine braking.
To prevent brake ineffectiveness resulting from brake fade, which is caused
by overheating and failure of the service brakes, and vapor locking, which is
caused by boiling of the brake fluid in the service brake hydraulic circuit, the
service brakes should be used together with engine braking and the exhaust
brake.

ake

t br

us
xha

The Mitsubishi Fuso Powertard brake

Mitsubishi Fuso vehicles are also available

with a device called a Powertard brake. The
Powertard brake boosts the effectiveness of
engine braking by making full use of the
engines resistance to motion during the
compression stroke. The overall
effectiveness is 34 times that of ordinary
engine braking.

Hardworking exhaust
gases
As youve seen, the exhaust gases not only
enhance the engines effectiveness by
powering the turbocharger; theyre also
used to create a braking function.

31

Why is engine oil necessary?

Lubricating oil: the lifeblood of the engine
The pistons, cylinders, crankshaft, cams, and other parts of an engine rub
against each other during operation. Lubricating oil is needed to make their
operation smooth.
<Great friction occurs inside engines.>
Friction occurs when objects rub against each other. To minimize the friction that
occurs in an engine, lubricating oil is used to create an oil film on the rubbing
surfaces of metal parts. With the metal parts sliding against the oil rather than
rubbing against each other, wear on the metal parts is minimized.

The engine oil flow in the lubrication system

Oil stored in the oil pan is circulated through the engine by an oil pump. Oil that has become hot and dirty is
cooled by an oil cooler then cleaned by an oil filter, after which it is again fed through the engine for
lubrication.

er

Oi
Oil pan

Oil cooler
Oil filter

Hardworking engine oil

The oil in an engine not only has a lubricating effect on the engines components; it also has a
cooling effect that cools the engine, a sealing effect that prevents leakage of gases through the
gaps between the pistons and cylinders, and a cleaning effect that carries dirt away from the
engine inner surfaces.

32


Types of engine oil

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

SAE viscosity
ratingnt

Application

Viscosity

SAE5W

Cold regions

Low

SAE10W
SAE20W

Winter

SAE20
SAE30

General use

SAE40

Summer

SAE50

Extremely hot regions

High

SAE: Society of Automotive Engineers

W: Winter grade (oil for winter and cold regions)
Multigrade oil, which has a wide viscosity range that
accommodates a wide range of temperatures, is also available.

<Performance classifications>
The stronger the oil film created by a type of oil, the better the oil performs. Oil performance is classified in
accordance with the results of tests. With any engine, it is important to use oil whose performance
classification 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 is
specified for Mitsubishi Fuso engines.
API service categories for diesel engine oil
Category (JIS)

API: American Petroleum Institute

Mitsubishi Fuso genuine oil

Properties of Mitsubishi Fuso

genuine oil

CA
CB
CC

Fuso Engine Oil CC

Contains a good balance of additives.

CD

Fuso Engine Oil S-3

Used for a wide range of applications

including trucks, construction machinery,
and ships.

CE
Fuso Engine Oil Super CF-4
CF-4
Fuso Engine Oil DH-2

33

High-performance oil containing

advanced additives
Intended for DPF-equipped vehicles.
Cuts ash accumulation and adhesion
in the DPF.

How is an engine cooled?

A hot engine is cooled using coolant.

An engine tends to become extremely hot because of the combustion that takes place inside it. To give
adequate performance, however, it must be kept at the optimal temperature, meaning that it must be cooled.
The engines cooling system does this job.
Reservoir tank
Cooling fan

Radiator

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

Radiator
The radiator consists of many pipes. Coolant that
has become hot while circulating through the
engine flows through the pipes in the radiator,
and its heat is carried away by air that flows
between the pipes.

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

34


Water pump
An impeller in the water pump is turned by the
crankshaft via a V-belt. As it turns, the coolant is
pressurized and circulates through the engine.

Oil cooler
If the engines lubricating oil became too hot, it
would become less effective. The oil cooler
prevents this problem by using the engines
coolant to cool the oil.
Oil

Co

Oil

nt

The oil cooler serves not only to cool the oil; on

cold days, it also serves to warm the oil.

<The engine must not be cooled too match.>

As you have learned, an engine needs to be cooled because the combustion that
occurs on the combustion strokes release a lot of heat. But an engine cannot give
its best performance if it is cooled too much. The best coolant temperature for
engine operation is considered to be 80C.

Thermostat
The thermostat prevents the coolant from
becoming too hot or too cold. It works as a kind of
valve. When the temperature of coolant that has
returned from the cylinder head is higher than the
predetermined temperature, the thermostat
causes it to flow into the radiator, where it is
cooled. When the temperature of coolant that has
returned from the cylinder head is below the
predetermined temperature, the thermostat
causes it to flow to the water pump, not into the
radiator.

Cooling fan
When the engine is idling or the vehicle is being
driven very slowly, there is no natural airflow
through the radiator. At such times, the cooling
fan is used to blow air through the radiator for
cooling purposes. The type of cooling fan used
on current vehicles is an auto cooling fan, which
does not run when the coolant temperature is
low.

To radiato

T
r head

Water pump

35

Does an engine
generate electricity?

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

Its no exaggeration to say that every vehicle today
depends on electronic control. The necessary
electricity is supplied by an alternator (a kind of
generator) and a battery (a device that can store
electricity). While the engine is running, the alternator
supplies the needed electricity to the vehicles
electrical systems. When the alternator alone cannot
supply enough electricity, the battery makes up the
shortfall.

Alternator

Starting system
Electricity for starting the engine comes from the
battery.
The starting system, which starts the engine,
consists of a starter motor, a starter switch, and the
battery. When the starter switch is turned ON, the
starter motors gear springs out and meshes with a
gear on the engines flywheel. The starter motor then
turns the flywheel to start the engine. When the
starter switch is turned OFF, the gear on the starter
motor is retracted.

36

10

Future trucks and buses will reflect

priorities on the environment and safety.

CNG, LPG, and electricity will realize clean running.

<CNG vehicles are environment-friendly owing to 2030% lower
emissions.>
On a CNG vehicle, compressed natural gas (CNG) is stored in tanks. CNG from
the tanks has its pressure reduced by a regulator and is then supplied to the
engines cylinders together with air in appropriate quantities in accordance with
sensor indications corresponding to the engines operating condition. The gases
remaining after combustion are treated by a three-way catalyzer, resulting in
relatively clean emissions.
Special equipment on a CNG
cargo truck

Ai t

CNG tank

Battery and resonator

<LPG realizes ultra-low exhaust emissions.>

Mitsubishi Fuso has developed engines such as the 4D34 LPG engine, which is based on a largedisplacement diesel engine and offers superior power performance and lower exhaust emissions. Using LPG
technology, 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 exhaust
emissions, low fuel consumption, and barrier-free
operation. The Mitsubishi Fuso Aerostar Non-Step
HEV Bus is a response to these demands (HEV is
acronym of hybrid electric vehicle). It has a seriestype electric hybrid drive system that realizes low
noise and low impact on environment. Further, it has
an optimal component layout and super-single rear
tires for greatly improved comfort.

Goals of development

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

Realize low exhaust emissions and fuel consumption by
means of constant-speed engine operation and brakingenergy regeneration.

Realize easy driving by means of electric motor propulsion
that requires no transmission.

Realize superior interior freedom of movement through
employment of wide single tires that allow superior aisle
width between the rear wheels.

(1) Electronic controller

(2) Inverter
(3) Diesel engine
(4) Generator
(5) Propulsion motor
(6) Accessory drive motor
(7) Lithium-ion battery
(8) Fuel tank

37

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

This brings us to the end of the

engine section. I hope it wasn't
too difficult, and I hope you're
now more confident about dealing
with customers. Next, we'll move
on to the chassis section.

Your name

Well done!

T-No. 03 - '05

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