Mitsubishi Fuso FE.FG.FH.FK.FM Series 2002-2004 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi Fuso FE.FG.FH.FK.FM Series 2002-2004, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi Fuso FE.FG.FH.FK.FM Series 2002-2004 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
FE.FG.FH.FK.FM Series 2002-2004 Fuso Service Manual (TWME0103&TWME0202&TWSE0101).pdf
PRODUCT DETAILS:
Total Pages: 4,655 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
'02-'04 S/M...1
FE-FG...0
Forward...2
How to Read this Manual...3
Index...4
How This Manual Is Structured...5
Terms...18
Group 00 - General...19
Index...20
Model Coding System...21
Power Train Table...22
Chassis No. & Engine No./Power Train Label...23
Vehicle Identification No...24
Precautions for Maintenance Operation...25
Table of Standard Tightening Torques...37
Connector Configuration Chart...41
Group 01 - Maintenance Schedule...83
Index...84
How To Read the Maintenance Schedule Tables...85
Maintenance Schedule Tables...87
Maintenance Operations...89
Lubrication Tables...111
Lubrication...113
Group 11A - Engine 4M5...131
Index...132
Specifications...133
Structure & Operation...135
Troubleshooting...145
On-Vehicle Inspection & Adjustment...147
Removal & Installation of Engine...151
Rocker Cover, Rocker Assemblies & Camshafts...155
Cylinder Head & Valve Mechanism...169
Front Case...183
Timing Gears & Balance Shafts...187
Pistons, Connecting Rods & Cylinder Liners...195
Flywheel...207
Crankshaft & Crankcase...211
Balance Shaft Bushings...0
Group 11B - Engine 4D3...224
Index...225
Specifications...226
Structure & Operation...227
Troubleshooting...230
Inspection & Adjustment Mounted in Vehicle...231
Removal & Installation of Engine...236
Cylinder Head & Valve Mechanism...240
Timing Gear...254
Camshaft...258
Piston, Connecting Rods & Cylinder Sleeve...264
Flywheel Without Flywheel Power Take-Off...278
Flywheel With Flywheel Power Take-Off...282
Crankshaft & Crankcase...290
Group 12A - Lubrication 4M5...297
Index...298
Specifications...299
Structure & Operation...301
Troubleshooting...310
On-Vehicle Inspection & Adjustment...311
Oil Pan, Oil Strainer & Oil Jet...315
Oil Pump...317
Oil Filter...321
Oil Cooler...323
Group 12B - Lubrication 4D3...326
Index...327
Specifications...328
Structure & Operation...329
Troubleshooting...336
Inspection & Adjustment Mounted in Vehicle...337
Oil Pan, Oil Strainer & Oil Jet...340
Oil Pump...342
Oil Cooler & Oil Filter...346
Group 13A - Fuel & Engine Control 4M5...348
Index...349
Specifications...350
Structure & Operation...351
On-Vehicle Inspection & Adjustment...354
Engine Control...358
Fuel Tank...362
Fuel Filter...363
Injection Pump...364
Injection Nozzle...368
Group 13B - Fuel & Engine Control 4D3...377
Index...378
Specifications...379
Structure & Operation...380
Troubleshooting...385
On-Vehicle Inspection & Adjustment...387
Engine Control...391
Fuel Tank...397
Fuel Filter...398
Water Separator...399
Injection Pump...401
Injection Nozzle...405
Group 13EA - Electronically Controlled Fuel System 4M5...409
Index...410
Specifications...411
Structure & Operation...412
Troubleshooting...423
Inspection of Electrical Equipment...445
Locations of Parts...453
Electrical Wiring Diagram...457
Group 13EB - Electronically Controlled Fuel System 4D3...458
Index...459
Structure & Operation...460
Troubleshooting...478
Inspection of Electrical Equipment...489
Locations of Parts...497
Electrical Wiring Diagram...498
Group 14A - Cooling 4M5...499
Index...500
Specifications/Structure & Operation...501
Troubleshooting...503
On-Vehicle Inspection & Adjustment...505
Radiator...509
Cooling Fan, V-Ribbed Belt, V-Belt & Water Pump...517
Water Hose & Pipe...521
Thermostat...523
Group 14B - Cooling 4D3...525
Index...526
Specifications/Structure & Operations...527
Troubleshooting...529
Inspection & Adjustment Mounted In Vehicle...531
Radiator...535
Cooling Fan & V-Belt...537
Water Pump...541
Thermostat...543
Group 15A - Intake & Exhaust 4M5...546
Index...547
Specifications/Structure & Operation...548
Troubleshooting...550
On-Vehicle Inspection & Adjustment...551
Air Duct & Air Cleaner Except Crew Cab...554
Air Duct & Air Cleaner Crew Cab...558
Turbocharger...561
Intercooler...566
Intake Manifold...568
Exhaust Manifold...570
Exhaust Pipe & Muffler...572
Group 15B - Intake & Exhaust 4D3...574
Index...575
Specifications/Structure & Operation...576
Troubleshooting...579
Inspection & Adjustment Mounted In Vehicle...580
Air Duct & Air Cleaner...582
Turbocharger...586
Intercooler...592
Intake Manifold...594
Exhaust Manifold...596
Exhaust Pipe & Muffler...598
Group 21 - Clutch...600
Index...601
Specifications/Structure & Operation...602
Troubleshooting...605
Inspection & Adjustment Mounted In Vehicle...606
Clutch Pedal...610
Clutch Master Cylinder...612
Clutch Power Cylinder...614
Work Before Removal & Installation of Clutch Body...616
Clutch Body...618
Clutch Control...622
Group 22 - Manual Transmission...623
Index...624
Specifications/Structure & Operations...625
Troubleshooting...628
Work Before Removal & Installation of Transmission Assembly...630
Removal & Installation of Transmission Assembly...631
Gear Shifter Upper...633
Rear Cover & Reverse Idler Gear...639
Transmission Body...643
Drive Pinion Assembly...651
Mainshaft Assembly...653
Countershaft Assembly...659
Transmission Control...663
Group 23 - Automatic Transmission...676
Index...677
Specifications...678
Structure & Operation...679
Troubleshooting Procedures...716
On-Vehicle Inspection & Adjustment...728
Removal & Installation of Automatic Transmission Assembly...736
Oil Cooler...742
Automatic Transmission Control...746
Replacement of Automatic Transmission Parts...756
Inspection & Adjustment of Other Devices...762
Location of Parts...764
Electrical Wiring Diagram...765
Group 24 - Transfer...767
Index...768
Specifications/Structure & Operation...769
Troubleshooting...771
Removal & Installation of Transfer Assembly...773
Front Drive...777
Idler Gear & Rear Drive...783
Transfer Control...789
Group 25 - Propeller Shaft...797
Index...798
Specifications...799
Structure & Operation...800
Troubleshooting...801
Removal & Installation of Propeller Shaft Transmission, Transfer To Rear Axle...803
Removal & Installation of Propeller Shaft Front Axle To Transfer...804
Rear Propeller Shaft P2 : FG639...805
Rear Propeller Shaft P2 : FG649...809
Rear Propeller Shaft P3...813
Front Propeller Shaft...817
Balancing Propeller Shaft...821
Group 26A - Front Axle...823
Index...824
Specifications/Structure & Operation...825
Inspection & Adjustment Mounted In Vehicle...827
Work Before Removal & Installation of Front Axle...831
Wheel Hub & Rotor...833
Front Axle, Knuckle & Kingpin...842
Group 26B - Front Axle...849
Index...850
Specifications/Structure & Operation...851
Troubleshooting...855
On-Vehicle Inspection & Adjustment...857
Work Before Removal & Installation of Front Axle...863
Wheel Hub & Brake Drum...865
Knuckle & Drive Shaft...875
Axle Housing...881
Reduction & Differential...883
Group 27 - Rear Axle...896
Index...897
Specifications...898
Structure & Operation...899
Troubleshooting...903
Work Before Removal & Installation of Rear Axle...905
Wheel Hub & Brake Drum FE639, FG...906
Wheel Hub & Rotor FE640, FE649...916
Axle Housing...926
Reduction & Differential...930
Muliplate Limited Slip Differential Assembly...944
FEFG group 27 '04 minor changes.pdf...0
Group 27 - Rear Axle...950
Index...951
Specifications...952
Structure and Operation...953
Troubleshooting...957
Work Before Removal and Installation of Rear Axle...959
Wheel Hub and Brake Drum FE639, FG...960
Wheel Hub and Rotor FE640, FE649...970
Axle Housing...980
Reduction and Differential...984
Multiplate Limited Slip Differential Assembly...998
Group 31 - Wheel & Tire...1004
Index...1005
Specifications/Troubleshooting...1006
Wheel & Tire...1007
Group 33 - Front Suspension...1011
Index...1012
Structure & Operation...1013
Troubleshooting...1014
Work Before Removal & Installation of Front Suspension...1015
Removal & Installation of Leaf Spring Assembly FE...1017
Removal & Installation of Leaf Spring Assembly FG...1019
Leaf Spring Assembly FE...1023
Leaf Spring Assembly FG...1025
Shock Absorber FE...1027
Shock Absorber FG...1028
Stabilizer FE...1029
Group 34 - Rear Suspension...1031
Index...1032
Structure & Operation...1033
Troubleshooting...1034
Work Before Removal & Installation of Rear Suspension...1035
Removal & Installation of Leaf Spring Assembly FE...1037
Removal & Installation of Leaf Spring Assembly FG...1041
Leaf Spring Assembly...1045
Shock Absorber...1048
Stabilizer FE...1049
Group 35A - Brake...1051
Index...1052
Specifications...1053
Structure & Operation...1054
Troubleshooting...1075
On-Vehicle Inspection & Adjustment...1081
Brake Master Cylinder...1097
Brake Pedal & Brake Booster (Master VAC)...1099
Front Wheel Brake FE639 (Except FE639 6 : Disc Brake...1101
Front Wheel Brake FE639 6, FE640 : Disc Brake...1105
Front Wheel Brake Drum Brake...1109
Rear Wheel Brake Drum Brake...1115
Rear Wheel Brake Disc Brake...1123
Vacuum Pump...1127
Exhaust Brake System...1129
Group 35E - Anti-Lock Brake System (ABS)...1133
Index...1134
Specifications/Structure & Operation...1135
On-Vehicle Inspection & Adjustment...1148
Troubleshooting...1152
Electric Circuit & Part Installation Locations...1158
Group 36 - Parking Brake...1160
Index...1161
Specifications/Structure & Operation...1162
Troubleshooting...1163
Inspection & Adjustment Mounted In Vehicle...1164
Parking Brake Control...1166
Parking Brake Assembly...1168
Backing Plate & Shoe Assembly...1170
Group 37 - Steering...1172
Index...1173
Specifications...1174
Structure & Operation...1175
Troubleshooting...1180
On-Vehicle Inspection & Adjustment...1183
Steering System...1186
Steering Column Subassembly...1192
Power Steering Booster FE...1196
Power Steering Booster FG...1202
Power Steering Oil Pump...1208
Power Steering Oil Tank...1212
Power Steering Fluid Line...1213
Drag Link...1214
Tie Rod Assembly...1216
FEFG group 37 - '04 minor changes.pdf...0
Group 37 - Steering...1218
Index...1219
Specifications...1220
Structure and Operation...1221
Troubleshooting...1226
On-Vehicle Inspection and Adjustment...1229
Steering System...1232
Steering Column Subassembly...1238
Power Steering Booster...1242
Power Steering Oil Pump...1248
Power Steering Oil Tank...1252
Power Steering Fluid Line...1253
Drag Link...1254
Tie Rod Assembly...1256
Group 41 - Frame...1258
Index...1259
Specifications/Structure & Operation/Inspection & Repair of Frames...1260
Inspection & Repair of Frames...1262
Group 42 - Cab...1265
Index...1266
Specifications...1267
Structure & Operation...1268
Troubleshooting...1277
Inspection & Adjustment Mounted In Vehicle...1282
Removal & Installation of Cab Tilt Cab...1286
Removal & Installation of Cab Fixed Cab...1293
Front Cab Mounting...1301
Rear Cab Mounting...1305
Cab Tilt Link...1307
Door...1310
Front Door...1311
Rear Door Crew Cab...1316
Cab Exterior Fitting...1319
Mirror...1323
Wiper & Washer...1325
Cab Interior Fitting...1329
Instrument Panel...1331
Window Glass...1335
Group 54 - Electrical...1337
Index...1338
How To Read This Group...1341
0-General...1345
Specifications...1346
Structure & Operation...1350
Troubleshooting...1370
1-Power, Charge & Ground Circuit...1378
110-Power Circuit...1379
115-Reserve Power Circuit...1388
125-Battery Charging Circuit...1389
130-Ground...1391
2-Starting & Preheating Circuit...1397
210-Engine Starting Circuit...1398
220-Engine Preheating Circuit...1400
225-Engine Warm-Up Circuit...1401
3-Lighting Circuit...1403
310-Headlamp Circuit...1404
313-Daytime Running Light Circuit...1406
320-Tail, Clearance & License Plate Lamp Circuit...1408
325-Stop Lamp Circuit...1409
330-Turn Signal & Hazard Lamp Circuit...1410
340-Backup Lamp Circuit...1411
345-Cab Lamp Circuit...1413
348-Illumination Lamp Circuit...1414
349-Marker & Identification Lamp Circuit...1415
352-Van Body Dome Light Circuit...1416
4-Meter Circuit...1417
401-Meter Cluster Internal Circuit...1418
410-Tachometer Circuit...1420
412-Speed Sensor Circuit...1422
420-Fuel Gauge Circuit...1423
425-Water Temperature Gauge Circuit...1424
5-Indicator & Warning Lamp Circuit...1425
510-Parking Brake Indicator Circuit...1426
515-Brake Warning Circuit...1427
535-Engine Oil Level & Oil Pressure Warning Circuit...1428
537-Overheating Warning Circuit...1429
540-Brake PadWarning Circuit...1430
550-Cab Tilt Warning Circuit...1431
566-Fuel Filter Warning Circuit...1432
6-Cab Side Electrical Circuit...1433
610-Cigarette Lighter Circuit...1434
612-Audio Circuit...1435
614-Wiper & Washer Circuit...1436
616-Horn Circuit...1437
618-Heater Circuit...1438
622-Power Window & Auto Door Lock Circuit...1439
629-Mirror Heater Circuit...1440
7-Chassis Side Electrical Circuit...1441
710-Exhaust Brake Circuit...1442
8-Engine & Transmission Side Electrical Circuit...1445
810-Four-Wheel Drive Circuit...1446
850-Transmission Power Take-Off Circuit...1447
9-Others Circuit...1448
910-Multipurpose Timing Control Unit Circuit...1449
10-Parts Installation Position...1451
A-Switch...1452
B-Relay & Electronic Control Unit...1454
C-Fuse, Meter, Sensor & Motor...1456
D-Heater & Air-Conditioner...1458
E-Door...1460
F-Roof...1461
J-Joint of Main Harness Connectors...1462
R-Engine...1464
S-Transmission...1466
T-Switch & Sensor...1467
U-Battery, Fuse & Connector...1468
V-Magnetic Valve, Motor & Actuator...1468
W-Buzzer & Lamp...1468
11-Inspection of Parts...1469
001 to 179 Switch...1470
180 to 249 Switch...1476
250 to 349 Sensor...1479
350 to 409 Control Unit...1481
410 to 509 Motor...1482
510 to 559 Actuator...1484
560 to 609 Magnetic Valve...1485
610 to 649 Buzzer & Horn...1486
650 to 699 Lamp...1487
750 to 859 Other...1488
860 Battery...1490
870 to 889 Fuse...1494
890 Meter Cluster...1498
12-Starter & Alternator...1501
930 Starter 4D3...1502
930 Starter 4M5...1516
940 Alternator 4D3...1530
940 Alternator 4M5...1536
950 Inspection of Alternator...1542
951 Inspection of Regulator...1543
13-On-Vehicle Inspection & Adjustment...1544
955 Inspection of Preheating System...1545
960 Headlamp Aiming...1547
965 Inspection of Brake Fluid Level Switch...1549
Group 55A - Air-conditioner...1550
Forward & Table of Contents...1551
Specifications...1552
Outlines of Refrigeration System...1553
Construction...1555
Troubleshooting...1562
Removal & Installation...1569
Treatment After Installation...1572
Maintenance...1578
Cooling Unit Assembly...1579
Compressor & Clutch Assembly...1581
Group 55B - Heater...1584
Index...1585
Specifications...1586
Structure & Operation...1587
Troubleshooting...1593
Heater Hose...1594
Heater Control...1596
Air Duct...1599
Heater Unit & Blower Assembly...1600
FH...0
FORWORD/GRP INDEX...1601
HOW TO READ THIS MANUAL...1602
INDEX...1603
HOW THIS MANUAL IS STRUCTURED...1604
TERMS...1617
GROUP 00 - GENERAL...1618
INDEX...1619
MODEL CODING SYSTEM...1620
POWER TRAIN TABLE...1621
CHASSIS NUMBER & ENGINE NUMBER/POWER TRAIN TABLE...1622
VEHICLE IDENTIFICATION NUMBER...1623
PRECAUTIONS FOR MAINTENANCE OPERATION...1624
TABLE OF STANDARD TIGHTENING TORQUES...1636
CONNECTOR CONFIGURATION CHART...1640
GROUP 01 - MAINTENANCE SCHEDULE...1686
INDEX...1687
HOW TO READ THE MAINTENANCE SCHEDULE TABLES...1688
MAINTENANCE SCHEDULE TABLES...1689
MAINTENANCE OPERATIONS...1694
LUBRICATION TABLES...1717
LUBRICATION...1718
GROUP 11A - ENGINE 4M5...1740
INDEX...1741
SPECIFICATIONS...1742
STRUCTURE AND OPERATION...1744
TROUBLESHOOTING...1754
ON-VEHICLE INSPECTION & ADJUSTMENT...1756
REMOVAL & INSTALLATION OF ENGINE...1760
ROCKER COVER, ROCKER ASSEMBLIES & CAMSHAFTS...1764
CYLINDER HEAD & VALVE MECHANISM...1778
FRONT CASE...1792
FRONT CASE...1794
TIMING GEARS AND BALANCE SHAFTS...1796
PISTONS, CONNECTING RODS & CYLINDER LINERS...1804
FLYWHEEL...1816
CRANKSHAFT & CRANKCASE...1820
BALANCE SHAFT BUSHINGS...1828
GROUP 11B - ENGINE 6D3...1833
INDEX...1834
SPECIFICATIONS...1835
STRUCTURE & OPERATION...1836
TROUBLESHOOTING...1839
ON-VEHICLE INSPECTION & ADJUSTMENT...1840
REMOVAL & INSTALLATION OF ENGINE...1843
CYLINDER HEAD & VALVE MECHANISM...1845
TIMING GEAR...1859
CAMSHAFT...1863
PISTON, CONNECTING ROD & CYLINDER SLEEVE...1869
FLYWHEEL...1883
CRANKSHAFT & CRANKCASE...1887
GROUP 12A - LUBRICATION 4M5...1894
INDEX...1895
SPECIFICATIONS...1896
STRUCTURE & OPERATION...1898
TROUBLESHOOTING...1907
ON-VEHICLE INSPECTION & ADJUSTMENT...1908
OIL PAN, OIL STRAINER & OIL JET...1912
OIL PUMP...1914
OIL FILTER...1918
OIL COOLER...1920
GROUP 12B - LUBRICATION 6D3...1923
INDEX...1924
SPECIFICATIONS...1925
STRUCTURE & OPERATION...1926
TROUBLESHOOTING...1934
ON-VEHICLE INSPECTION & ADJUSTMENT...1935
OIL PAN, OIL STRAINER & OIL JET...1939
OIL PUMP...1941
OIL COOLER & OIL FILTER...1945
GROUP 13A - FUEL & ENGINE CONTROL 4M5...1947
INDEX...1948
SPECIFICATIONS...1949
STRUCTURE & OPERATION...1950
ON-VEHICL INSPECTION & ADJUSTMENT...1953
ENGINE CONTROL...1957
FUEL TANK...1961
FUEL FILTER...1962
INJECTION PUMP...1963
INJECTION NOZZLE...1967
GROUP 13B - FUEL & ENGINE CONTROL 6D3...1976
INDEX...1977
SPECIFICATIONS...1978
STRUCTURE & OPERATION...1979
TROUBLESHOOTING...1986
ON-VEHICLE INSPECTION & ADJUSTMENT...1988
ENGINE CONTROL...1992
FUEL TANK...1997
FUEL FILTER...1998
WATER SEPARATOR...1999
INJECTION PUMP...2000
INJECTION PUMP DRIVE CASE...2006
INJECTION NOZZLE...2010
GROUP 13EA - ELECTRONICALLY CONTROLLED FUEL SYSTEM 4M5...2014
INDEX...2015
SPECIFICATIONS...2016
STRUCTURE & OPERATION...2017
TROUBLESHOOTING...2028
INSPECTION OF ELECTRICAL EQUIPMENT...2050
LOCATION OF PARTS...2058
ELECTRICAL WIRING DIAGRAM...2062
GROUP 13EB - ELECTRONICALLY CONTROLLED FUEL SYSTEM 6D3...2063
INDEX...2064
STRUCTURE & OPERATION...2065
TROUBLESHOOTING...2083
INSPECTION OF ELECTRICAL EQUIPMENT...2095
LOCATION OF PARTS...2103
ELECTRICAL WIRING DIAGRAM...2104
GROUP 14A - COOLING 4M5...2105
INDEX...2106
SPECIFICATIONS/STRUCTURE & OPERATION...2107
TROUBLESHOOTING...2109
ON-VEHICLE INSPECTION & ADJUSTMENT...2111
RADIATOR & FAN SHROUD...2115
RADIATOR...2117
COOLING FAN, V-RIBBED BELT, V-BELT & WATER PUMP...2125
WATER HOSE & PIPE...2129
THERMOSTAT...2130
GROUP 14B - COOLING 6D3...2131
INDEX...2132
SPECIFICATIONS/STRUCTURE & OPERATION...2133
TROUBLESHOOTING...2137
ON-VEHICLE INSPECTION & ADJUSTMENT...2139
RADIATOR & FAN SHROUD...2143
SURGE TANK...2151
COOLING FAN & V-BELT...2153
WATER PUMP...2156
THERMOSTAT...2157
GROUP 15A - INTAKE & EXHAUST 4M5...2159
INDEX...2160
SPECIFICATIONS/STRUCTURE & OPERATION...2161
TROUBLESHOOTING...2164
ON-VEHICLE INSPECTION & ADJUSTMENT...2165
AIR DUCT & AIR CLEANER...2167
TURBOCHARGER...2171
INTERCOOLER...2176
INTAKE MANIFOLD...2177
EXHAUST MANIFOLD...2179
EXHAUST PIPE & MUFFLER...2181
GROUP 15B - INTAKE & EXHAUST 6D3...2183
INDEX...2184
SPECIFICATIONS/STRUCTURE & OPERATION...2185
TROUBLESHOOTING...2188
ON-VEHICLE INSPECTION & ADJUSTMENT...2189
AIR DUCT & AIR CLEANER...2191
TURBOCHARGER...2195
INTERCOOLER...2200
INTAKE MANIFOLD...2201
EXHAUST MANIFOLD...2202
EXHAUST PIPE & MUFFLER...2203
GROUP 21 - CLUTCH...2205
INDEX...2206
SPECIFICATIONS/STRUCTURE & OPERATION...2207
TROUBLESHOOTING...2210
ON-VEHICLE INSPECTION & ADJUSTMENT...2211
CLUTCH PEDAL...2215
CLUTCH MASTER CYLINDER...2219
CLUTCH POWER CYLINDER...2221
WORK BEFORE REMOVAL & INSTALLATION OF CLUTCH BODY...2223
CLUTCH BODY...2225
CLUTCH CONTROL...2235
GROUP 22 - MANUAL TRANSMISSION...2237
INDEX...2238
SPECIFICATIONS...2239
STRUCTURE & OPERATION...2240
TROUBLESHOOTING...2246
WORK BEFORE REMOVAL & INSTALLATION OF TRANSMISSION ASSEMBLY...2247
REMOVAL & INSTALLATION OF TRANSMISSION ASSEMBLY...2249
GEAR SHIFTER UPPER & INTERLOCK PLATE...2252
EXTENSION HOUSING, REAR COVER & PARKING BRAKE ASSEMBLY...2257
6TH GEAR S6 AND REVERSE IDLER GEAR...2261
TRANSMISSION BODY...2269
DRIVE PINION ASSEMBLY...2283
MAINSHAFT ASSEMBLY...2285
COUNTERSHAFT ASSEMBLY...2293
TRANSMISSION CONTROL...2297
PULLER & INSTALLER KIT...2302
GROUP 23A - AUTOMATIC TRANSMISSION FH210...2303
INDEX...2304
SPECIFICATIONS...2305
STRUCTURE & OPERATION...2306
TROUBLESHOOTING PROCEDURES...2343
TROUBLESHOOTING...2345
ON-VEHICLE INSPECTION & ADJUSTMENT...2355
REMOVAL & INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY...2363
OIL COOLER...2369
AUTOMATIC TRANSMISSION CONTROL...2371
REPLACEMENT OF AUTOMATIC TRANSMISSION PARTS...2381
INSPECTION & ADJUSTMENT OF OTHER DEVICES...2387
LOCATION OF PARTS...2388
ELECTRICAL WIRING DIAGRAM...2389
GROUP 23B - AUTOMATIC TRANSMISSION FH211...2390
INDEX...2391
SPECIFICATIONS...2392
STRUCTURE & OPERATION...2393
TROUBLESHOOTING...2396
ON-VEHICLE INSPECTION & ADJUSTMENT...2398
WORK BEFORE REMOVAL & INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMLBY...2401
REMOVAL & INSTALLATION OF AUTOMATIC TRANSMISSION ASSEMBLY...2402
OIL SEAL & SPEEDOMETER WORM...2406
OIL PAN & OIL FILTER...2409
AUTOMATIC TRANSMISSION CONTROL...2410
OIL COOLER...2415
OIL FILTER...2416
GROUP 25 - PROPELLER SHAFT...2418
INDEX...2419
SPECIFICATIONS/STRUCTURE & OPERATION...2420
TROUBLESHOOTING...2421
REMOVAL & INSTALLATION OF PROPELLER SHAFT...2422
REAR PROPELLER SHAFT...2424
FRONT PROPELLER SHAFT...2428
BALANCING PROPELLER SHAFT...2432
GROUP 26 - FRONT AXLE...2433
INDEX...2434
SPECIFICATIONS/STRUCTURE & OPERATION...2435
ON-VEHICLE INSPECTION & ADJUSTMENT...2437
WORK BEFORE REMOVAL & INSTALLATION OF FRONT AXLE...2442
WHEEL HUB & BRAKE DRUM...2443
FRONT AXLE, KNUCKLE & KINGPIN...2455
GROUP 27 - REAR AXLE...2461
INDEX...2462
SPECIFICATIONS/STRUCTURE & OPERATION...2463
TROUBLESHOOTING...2465
WORK BEFORE REMOVAL & INSTALLATION OF REAR AXLE...2467
WHEEL HUB & BRAKE DRUM...2469
AXLE HOUSING...2483
REDUCTION & DIFFERENTIAL...2487
GROUP 31 - WHEEL & TIRE...2505
INDEX...2506
SPECIFICATIONS/TROUBLESHOOTING...2507
WHEEL & TIRE...2508
GROUP 33 - FRONT SUSPENSION...2513
INDEX...2514
STRUCTURE & OPERATION...2515
TROUBLESHOOTING...2516
WORK BEFORE REMOVAL & INSTALLATION OF FRONT SUSPENSION...2517
REMOVAL & INSTALLATION OF LEAF SPRING ASSEMBLY FH210...2519
REMOVAL & INSTALLATION OF LEAF SPRING ASSEMBLY FH211...2523
LEAF SPRING ASSEMBLY...2527
SHOCK ABSORBER...2529
STABILIZER...2530
GROUP 34 - REAR SUSPENSION...2531
INDEX...2532
STRUCTURE & OPERATION...2533
TROUBLESHOOTING...2534
WORK BEFORE REMOVAL & INSTALLATION OF REAR SUSPENSION...2535
REMOVAL & INSTALLATION OF LEAF SPRING ASSEMBLY...2537
LEAF SPRING ASSEMBLY...2543
GROUP 35A - BRAKE...2545
INDEX...2546
SPECIFICATIONS...2547
STRUCTURE & OPERATION...2549
TROUBLESHOOTING...2567
ON-VEHICLE INSPECTION & ADJUSTMENT...2573
BRAKE MASTER CYLINDER...2583
BRAKE PEDAL & BRAKE BOOSTER (HYDRAULIC BOOSTER)...2585
BRAKE BOOSTER (HYDRAULIC BOOSTER)...2587
FRONT WHEEL BRAKE...2589
REAR WHEEL BRAKE...2597
VACUUM PUMP FH210...2605
VACUUM PUMP FH211...2606
EXHAUST BRAKE SYSTEM...2607
GROUP 35E - ANTI-LOCK BRAKE SYSTEM (ABS)...2614
INDEX...2615
SPECIFICATIONS/STRUCTURE & OPERATION...2616
ON-VEHICLE INSPECTION & ADJUSTMENT...2629
TROUBLESHOOTING...2634
ELECTRICAL CIRCUIT AND PART INSTALLATION LOCATIONS...2640
GROUP 36A - PARKING BRAKE FH210...2643
INDEX...2644
SPECIFICATIONS/STRUCTURE & OPERATION...2645
TROUBLESHOOTING...2647
ON-VEHICLE INSPECTION & ADJUSTMENT...2648
PARKING BRAKE CONTROL...2649
PARKING BRAKE ASSEMBLY...2651
BACKING PLATE & SHOE ASSEMBLY...2653
GROUP 36B - PARKING BRAKE FH211...2655
INDEX...2656
SPECIFICATIONS/STRUCTURE & OPERATION...2657
TROUBLESHOOTING...2659
ON-VEHICLE INSPECTION & ADJUSTMENT...2660
PARKING BRAKE CONTROL...2661
PARKING BRAKE ASSEMBLY...2663
SUPPORT PLATE & SHOE ASSEMBLY ø203.2mm {8 in} Drum...2667
SUPPORT PLATE & SHOE ASSEMBLY ø254mm {10 in} Drum...2669
GROUP 37 - STEERING...2671
INDEX...2672
SPECIFICATIONS...2673
STRUCTURE & OPERATION...2674
TROUBLESHOOTING...2681
ON-VEHICLE INSPECTION & ADJUSTMENT...2684
STEERING SYSTEM...2687
STEERING COLUMN SUBASSEMBLY...2693
POWER STEERING BOOSTER...2697
POWER STEERING OIL PUMP KAYABA...2709
POWER STEERING OIL PUMP Unisia JKC Steering Systems...2713
POWER STEERING OIL TANK...2717
POWER STEERING FLUID LINE...2719
DRAG LINK...2721
TIE ROD ASSEMBLY...2723
GROUP 41 - FRAME...2725
INDEX...2726
SPECIFICATIONS...2727
STRUCTURE & OPERATION...2727
INSPECTION & REPAIR OF FRAMES...2727
GROUP 42 - CAB...2732
INDEX...2733
SPECIFICATIONS...2734
STRUCTURE & OPERATION...2735
TROUBLESHOOTING...2746
ON-VEHICLE INSPECTION & ADJUSTMENT...2751
REMOVAL & INSTALLATION OF CAB...2754
FRONT CAB MOUNTING...2762
REAR CAB MOUNTING...2764
CAB TILT LINK...2766
DOOR...2769
CAB EXTERIOR FITTING...2774
MIRROR...2778
WIPER & WASHER...2780
CAB INTERIOR FITTING...2783
INSTRUMENT PANEL...2785
WINDOW GLASS...2788
GROUP 54 - ELECTRICAL...2790
TABLE OF CONTENTS...2791
HOW TO READ THIS GROUP...2794
0-GENERAL...2798
SPECIFICATIONS...2799
STRUCTURE & OPERATION...2803
TROUBLESHOOTING...2829
1-POWER, CHARGE & GROUND CIRCUIT...2837
110-POWER CIRCUIT...2838
115-RESERVE POWER CIRCUIT...2847
125-BATTERY CHARGING CIRCUIT...2848
130-GROUND...2850
2-STARTING & PREHEATING CIRCUIT...2865
210-ENGINE STARTING CIRCUIT...2866
220-ENGINE PREHEATING CIRCUIT...2869
3-LIGHTING CIRCUIT...2872
310-HEADLAMP CIRCUIT...2873
313-DAYTIME RUNNING LIGHT CIRCUIT...2875
320-TAIL, CLEARANCE & LICENSE PLATE LAMP CIRCUIT...2877
325-STOP LAMP CIRCUIT...2878
330-TURN SIGNAL & HAZARD LAMP CIRCUIT...2879
340-BACKUP LAMP CIRCUIT...2880
345-CAB LAMP CIRCUIT...2882
348-ILLUMINATION LAMP CIRCUIT...2883
349-MARKER & IDENTIFICATION LAMP CIRCUIT...2884
352-VAN BODY DOME LIGHT CIRCUIT...2885
4-METER CIRCUIT...2887
401-METER CLUSTER INTERNAL CIRCUIT...2888
410-TACHOMETER CIRCUIT...2892
412-SPEEDOMETER CIRCUIT...2894
420-FUEL GAUGE CIRCUIT...2896
425-WATER TEMPERATURE GAUGE CIRCUIT...2897
5-INDICATOR & WARNING LAMP CIRCUIT...2898
510-PARKING BRAKE INDICATOR CIRCUIT...2899
515-BRAKE WARNING CIRCUIT...2901
530-WATER LEVEL WARNING CIRCUIT...2902
535-ENGINE OIL LEVEL & PRESSURE WARNING CIRCUIT...2903
536-ENGINE OIL PRESSURE WARNING CIRCUIT...2904
537-OVERHEATING WARNING CIRCUIT...2906
547-ATF TEMPERATURE WARNING CIRCUIT...2907
549-POWER STEERING FLUID LEVEL WARNING CIRCUIT...2908
550-CAB TILT WARNING CIRCUIT...2909
566-FUEL FILTER WARNING CIRCUIT...2910
6-CAB SIDE ELECTRICAL CIRCUIT...2911
610-CIGARETTE LIGHTER CIRCUIT...2912
612-AUDIO CIRCUIT...2913
614-WIPER & WASHER CIRCUIT...2914
616-HORN CIRCUIT...2915
618-HEATER CIRCUIT...2916
622-POWER WINDOW & AUTO DOOR LOCK CIRCUIT...2917
629-MIRROR HEATER CIRCUIT...2918
7-CHASSIS SIDE ELECTRICAL CIRCUIT...2920
710-EXHAUST BRAKE CIRCUIT...2921
8-ENGINE & TRANSMISSION SIDE ELECTRICAL CIRCUIT...2923
850-TRANSMISSION POWER TAKE-OFF CIRCUIT...2924
9-OTHERS CIRCUIT...2926
910-MULTIPURPOSE TIMING CONTROL UNIT CIRCUIT...2927
10-PARTS INSTALLATION POSITION...2931
A - SWITCH...2932
B - RELAY & ELECTRONIC CONTROL UNIT...2934
C - FUSE, METER, SENSOR & MOTOR...2936
D - HEATER...2938
E - DOOR...2939
F - ROOF...2940
J - JOINT OF MAIN HARNESS CONNECTORS...2942
R - ENGINE...2944
S - TRANSMISSION...2946
T - SWITCH & SENSOR...2948
U - BATTERY, FUSE & CONNECTOR...2949
V - MAGNETIC VALVE, MOTOR...2949
W - HORN & BUZZER...2949
11-INSPECTION OF PARTS...2950
001 to 179 SWITCH...2951
180 to 249 RELAY...2958
250 to 349 SENSOR...2961
350 to 409 CONTROL UNIT...2964
410 to 509 MOTOR...2967
510 to 559 ACTUATOR...2968
560 to 609 MAGNETIC VALVE...2969
610 to 649 BUZZER & HORN...2970
650 to 699 LAMP...2971
750 to 859 OTHER...2972
860 BATTERY...2974
870 to 889 FUSE...2977
890 METER CLUSTER...2981
12-STARTER & ALTERNATOR...2985
930 STARTER...2986
940 ALTERNATOR...3014
950 INSPECTION OF ALTERNATOR...3030
951 INSPECTION OF REGULATOR...3031
13-ON-VEHICLE INSPECTION & ADJUSTMENT...3032
955 INSPECTION OF PREHEATING SYSTEM...3033
960 HEADLAMP AIMING...3035
965 INSPECTION OF BRAKE FLUID LEVEL SWITCH...3037
966 INSPECTION OF POWER STEERING FLUID LEVEL SENSOR...3038
GROUP 55A - AIR-CONDITIONER...3039
6D34...3039
FORWORD...3040
TABLE OF CONTENTS...3040
SPECIFICATIONS...3041
OUTLINES OF REFRIGERATION SYSTEM...3042
CONSTRUCTION...3044
TROUBLESHOOTING...3052
REMOVAL & INSTALLATION...3059
TREATMENT AFTER INSTALLATION...3062
MAINTENANCE...3068
COOLING UNIT ASSEMBLY...3069
COMPRESSOR & CLUTCH ASSEMBLY...3071
4M50...3074
FOREWORD...3075
TABLE OF CONTENTS...3075
SPECIFICATIONS...3076
OUTLINES OF REFRIGERATION SYSTEM...3077
CONSTRUCTION...3079
TROUBLESHOOTING...3087
REMOVAL & INSTALLATION...3094
TREATMENT AFTER INSTALLATION...3097
MAINTENANCE...3103
COOLING UNIT ASSEMBLY...3104
COMPRESSOR & CLUTCH ASSEMBLY...3106
GROUP 55B - HEATER...3109
INDEX...3110
SPECIFICATIONS...3111
STRUCTURE & OPERATION...3112
TROUBLESHOOTING...3118
HEATER HOSE...3119
HEATER CONTROL...3121
AIR DUCT...3124
HEATER UNIT & BLOWER ASSEMBLY...3125
FK-FM...0
Forward...3126
How To Read This Manual...3127
Index...3128
How This Manual Is Structured...3129
Terms...3142
Group 00 - General...3143
Index...3144
Model Coding System...3145
Power Train Table...3146
Chassis Number & Engine Number...3147
Power Train Label...3147
Vehicle Identification Number...3148
Precautions For Maintenance Operation...3149
Table of Standard Tightening Torques...3161
Connector Configuration Chart...3165
Group 01 - Maintenance Schedule...3207
Index...3208
How to Read The Maintenance Schedule Tables...3209
Maintenance Schedule Tables...3210
Maintenance Operations...3214
Lubrication Tables...3233
Lubrication...3234
Group 11 - Engine...3254
Index...3255
Specifications...3256
Structure & Operation...3257
Untitled...3262
Troubleshooting...3262
On-Vehicle Inspection & Adjustment...3263
Removal & Installation of Engine...3266
Cylinder Head & Valve Mechanism...3268
Piston, Connecting Rod & Cylinder Sleeve...3282
Flywheel Power Take-Off...3296
Flywheel...3300
Timing Gear...3306
Camshaft...3310
Crankshaft & Crankcase...3316
Group 12 - Lubrication...3325
Index...3326
Specifications...3327
Structure & Operation...3328
Troubleshooting...3335
On-Vehicle Inspection & Adjustment...3336
Oil Pan & Oil Jet...3339
Oil Pump & Oil Strainer...3341
Oil Filter...3343
Oil Cooler...3345
Regulator Valve...3347
Group 13 - Fuel & Engine Control...3348
Index...3349
Specifications...3350
Structure & Operation...3352
Troubleshooting...3378
Reading & Erasing Diagnosis Codes...3382
Service Procedures Using Multi-Use Tester II...3388
Inspection Based On Diagnosis Code...3390
On-Vehicle Inspection & Adjustment...3394
Engine Control...3397
Fuel Tank...3402
Fuel Filter...3403
Water Separator...3404
Injection Pump...3406
Injection Nozzle...3410
Inspection of Other Devices...3414
Electric Circuit & Part Installation Locations...3425
Group 14 - Cooling...3427
Index...3428
Specifications...3429
Structure & Operation...3430
Troubleshooting...3434
On-Vehicle Inspection & Adjustment...3435
Radiator & Fan Shroud...3439
Cooling Fan & V-Belt...3443
Water Pump...3447
Thermostat...3449
Group 15 - Intake & Exhaust...3451
Index...3452
Specifications/Structure & Operation...3453
Troubleshooting...3457
On-Vehicle Inspection & Adjustment...3459
Air Duct & Air Cleaner...3461
Turbocharger...3463
Intercooler...3475
Intake Manifold...3477
Exhaust Manifold...3479
Exhaust Pipe & Muffler...3481
Group 21 - Clutch...3483
Index...3484
Specifications/Structure & Operation...3485
Troubleshooting...3490
On-Vehicle Inspection & Adjustment...3491
Clutch Pedal C6 (M060S6), C7 (M070S6)...3499
Clutch Pedal C7 (M8S2x5)...3503
Clutch Master Cylinder...3507
Clutch Power Cylinder C6 (M060S6), C7 (M070S6)...3509
Clutch Booster C7 (M8S2x5)...3511
Work Before Removal & Installation of Clutch Body...3517
Clutch Body C6...3519
Clutch Body C7...3529
Clutch Control...3539
Group 22A - Manual Transmission M080S6, M070S6...3541
Index...3542
Specifications/Structure & Operation...3543
Troubleshooting...3552
Work Before Removal & Installation of Transmission Assembly...3553
Removal & Installation of Transmission Assembly...3555
Gear Shifter Upper & Interlock Plate...3559
Power Shift Assembly...3565
Extension Housing, Rear Cover & Parking Brake Assembly...3571
6th Gear Over-Drive (O/D) & Reverse Idler Gear Over-Drive (O/D)...3575
Reverse Gear & Reverse Idler Gear Direct-Drive (D/D)...3583
Transmission Body...3589
Drive Pinion Assembly...3605
Mainshaft Assembly Over-Drive (O/D)...3607
Mainshaft Assembly Direct-Drive (D/D)...3615
Countershaft Assembly...3625
Transmission Control...3629
Puller & Installer Kit...3633
Group 22B - Manual Transmission M8S2x5...3634
Index...3635
Specifications...3636
Structure & Operation...3637
Troubleshooting...3646
Work Before Removal & Installation of Transmission Assembly...3648
Removal & Installation of Transmission Assembly...3650
Gear Shifter Upper...3654
Power Shift Assembly...3658
Gear Shifter Lower...3664
Rear Cover...3668
Splitter...3672
Splitter Upper Assembly...3678
Power Cylinder...3679
Transmission Body...3680
Mainshaft Assembly...3688
Countershaft Assembly...3696
Transmission Control...3698
Splitter Control...3702
Group 23A - Automatic Transmission FK617, FM617...3705
Index...3706
Specifications...3707
Structure & Operation...3708
Troubleshooting...3711
On-Vehicle Inspection & Adjustment...3713
Work Before Removal & Installation of Automatic Transmission Assembly...3716
Removal & Installation of Automatic Transmission Assembly...3717
Oil Seal & Speedometer Worm...3721
Oil Pan & Oil Filter...3724
Automatic Transmission Control...3725
Oil Cooler...3731
Oil Filter...3733
Group 23B - Automatic Transmission FM657...3734
Index...3735
Specifications...3736
Structure & Operation...3738
Troubleshooting...3741
On-Vehicle Inspection & Adjustment...3746
Oil Cooler...3754
Electric Circuit & Part Installation Locations...3756
Group 25 - Propeller Shaft...3758
Index...3759
Specifications/Structure & Operation...3760
Troubleshooting...3761
Removal & Installation of Propeller Shaft...3764
Rear Propeller Shaft P4...3766
Rear Propeller Shaft P8...3770
Rear Propeller Shaft P10...3774
Front Propeller Shaft P4...3778
Front Propeller Shaft P8...3782
Front Propeller Shaft P10...3788
Balancing Propeller Shaft...3793
Group 26 - Front Axle...3795
Index...3796
Specifications/Structure & Operation...3797
On-Vehicle Inspection & Adjustment...3803
Work Before Removal & Installation of Front Axle...3808
Wheel Hub & Brake Drum FK...3809
Wheel Hub & Brake Drum FM (Air-Over Hydraulic Brake)...3821
Wheel Hub & Brake Drum FM (Full-Air Brake)...3833
Front Axle, Knuckle & Kingpin FK...3857
Front Axle, Knuckle & Kingpin FM (Air-Over Hydraulic Brake)...3863
Group 27 - Rear Axle...3877
Index...3878
Specifications...3879
Structure & Operation...3880
Troubleshooting...3883
Work Before Removal & Installation of Rear Axle...3885
Wheel Hub & Brake Drum FK...3887
Wheel Hub & Brake Drum FM...3901
Axle Housing...3917
Reduction & Differential...3921
Group 31 - Wheel & Tire...3941
Index...3942
Specifications/Troubleshooting...3943
Wheel & Tire...3944
Group 33 - Front Suspension...3949
Index...3950
Structure & Operation...3951
Troubleshooting...3952
Work Before Removal & Installation of Front Suspension...3953
Removal & Installation of Leaf Spring Assembly...3955
Leaf Spring Assembly...3959
Shock Absorber...3961
Group 34 - Rear Suspension...3962
Index...3963
Structure & Operation...3964
Troubleshooting...3965
Work Before Removal & Installation of Rear Suspension...3966
Removal & Installation of Leaf Spring Assembly...3968
Leaf Spring Assembly...3974
Group 35A - Brake Air Over Hydraulic Brake...3976
Index...3977
Specifications...3978
Structure & Operation...3980
Troubleshooting...4006
On-Vehicle Inspection & Adjustment...4010
Handling of Connector & Nylon Tube Piping...4018
Brake Pedal...4020
Dual Brake Valve...4022
Brake Booster (Airmaster)...4030
Front Wheel Brake...4036
Rear Wheel Brake...4046
Air Compressor...4056
Air Dryer...4064
Air Pressure Governor...4068
Fluid Tank...4070
Check Valve/Safety Valve...4071
Supply Valve...4072
Exhaust Brake System...4074
Group 35B - Brake Full Air Brake...4078
Index...4079
Specifications...4080
Structure & Operation...4082
Troubleshooting...4109
On-Vehicle Inspection & Adjustment...4113
Handling of Connector & Nylon Tube Piping...4117
Brake Pedal...4118
Dual Brake Valve...4120
Relay Valve...4128
Quick Release Valve...4130
Front Wheel Brake Manual Transmission...4132
Front Wheel Brake Automatic Transmission...4142
Rear Wheel Brake Manual Transmission...4152
Rear Wheel Brake Automatic Transmission...4166
Expander Assembly...4176
Air Compressor...4182
Air Dryer...4190
Air Pressure Governor...4194
Check Valve/Safety Valve...4196
Supply Valve...4197
Exhaust Brake System...4198
Group 35E - Anti-Lock Brake System (ABS)...4202
Index...4203
Specifications/Structure & Operation...4204
On-Vehicle Inspection & Adjustment...4218
Troubleshooting...4223
Electrical Circuit & Part Installation Locations...4238
Group 36A - Parking Brake Center Parking Brake...4240
Index...4241
Specifications/Structure & Operation...4242
Troubleshooting...4244
On-Vehicle Inspection & Adjustment...4245
Parking Brake Control...4246
Parking Brake Assembly...4248
Support Plate & Shoe Assembly...4252
Group 36B - Parking Brake Wheel Parking Brake...4254
Index...4255
Structure & Operation...4256
Troubleshooting...4261
Parking Brake Control Valve...4262
Spring Brake Valve...4264
Double Check Valve...4267
Group 37 - Steering...4268
Index...4269
Specifications...4270
Structure & Operation...4271
Troubleshooting...4278
On-Vehicle Inspection & Adjustment...4281
Steering System...4284
Linkage & Bracket...4288
Power Steering Booster...4290
Power Steering Oil Pump...4302
Power Steering Oil Tank...4306
Power Steering Fluid Line...4307
Drag Link...4308
Tie Rod Assembly...4310
Group 41 - Frame...4313
Index...4314
Specifications/Structure & Operation/Inspection & Repair of Frames...4315
Group 42 - Cab...4320
Index...4321
Specifications...4322
Structure & Operation...4324
Troubleshooting...4340
On-Vehicle Inspection & Adjustment...4346
Removal & Installation of Cab...4350
Front Cab Mounting...4358
Rear Cab Mounting...4361
Cab Tilt Link...4362
Door...4366
Cab Exterior Fitting...4372
Mirror...4378
Wiper & Washer...4380
Cab Interior Fitting...4384
Instrument Panel...4390
Window Glass...4394
Group 54 - Electrical...4398
Index...4399
How To Read This Group...4402
0 General...4406
Specifications...4407
Structure & Operation...4411
Troubleshooting...4427
1 Power, Charge & Ground Circuit...4435
110-Power Circuit...4436
115-Reserve Power Circuit...4445
125-Battery Charging Circuit...4446
130-Ground...4447
2 Starting & Preheating Circuit...4462
210-Engine Starting Circuit...4463
220-Engine Preheating Circuit...4464
3-Lighting Circuit...4467
310-Headlamp Circuit...4468
313-Daytime Running Light Circuit...4470
320-Tail, Clearance & License Plate Lamp Circuit...4472
325-Stop Lamp Circuit...4473
330-Turn Signal & Hazard Lamp Circuit...4474
340-Backup Lamp Circuit...4475
345-Cab Lamp Circuit...4476
348-Illumination Lamp Circuit...4477
349-Marker & Identification Lamp Circuit...4478
325-Van Body Dome Light Circuit...4479
4 Meter Circuit...4480
401-Meter Cluster Internal Circuit...4481
410-Tachometer Circuit...4483
412-Speedometer Circuit...4484
420-Fuel Gauge Circuit...4486
425-Water Temperature Gauge Circuit...4487
5 Indicator & Warning Lamp Circuit...4488
510-Parking Brake Indicator Circuit...4489
515-Brake Warning Circuit...4491
530-Water Level Warning Circuit...4493
536-Engine Oil Pressure Warning Circuit...4494
537-Overheating Warning Circuit...4495
547-ATF Temperature Warning Circuit...4496
548-Transmission High/Low Indicator Circuit...4497
550-Cab Tilt Warning Circuit...4498
6 Cab Side Electrical Circuit...4499
610-Cigarette Lighter Circuit...4500
612-Audio Circuit...4501
614-Wiper & Washer Circuit...4502
616-Horn Circuit...4503
618-Heater Circuit...4504
622-Power Window & Auto Door Lock Circuit...4505
629-Mirror Heater Circuit...4506
7 Chassis Side Electrical Circuit...4507
710-Exhaust Brake Circuit...4508
718-Air Dryer Circuit...4510
8 Engine & Transmission Side Electrical Circuit...4511
850-Transmission Power Take-Off Circuit...4512
9 Others Circuit...4513
910-Multipurpose Timing Control Unit Circuit...4514
10 Parts Installation Position...4516
A-Switch...4517
B-Relay & Electronic Control Unit...4519
C-Fuse, Meter, Sensor, Buzzer & Motor...4521
D-Heater...4523
E-Door & Mirror...4524
F-Roof...4525
G-Cab...4527
J-Joint of Main Harness Connectors...4529
R-Engine...4531
S-Transmission...4533
T-Switch & Sensor...4535
U-Battery, Fuse & Connector...4537
V-Magnetic Valve, Motor & Actuator...4538
W-Buzzer...4538
11 Instpection of Parts...4539
001 to 179-Switch...4540
180 to 249-Relay...4548
250 to 349-Sensor...4551
350 to 409-Control Unit...4554
410 to 509-Motor...4555
510 to 559-Actuator...4557
560 to 609-Magnetic Valve...4558
610 to 649-Buzzer & Horn...4559
650 to 699-Lamp...4560
750 to 859-Other...4561
860-Battery...4563
870 to 889-Fuse...4566
890-Meter Cluster...4570
12 Starter & Alternator...4574
930-Starter...4575
940-Alternator...4589
950-Inspection of Alternator...4596
951-Inspection of Regulator...4597
13 On-Vehicle Inspection & Adjustment...4598
955-Inspection of Preheating System...4599
960-Headlamp Aiming...4601
965-Inspection of Brake Fluid Level Switch...4603
Group 55A - Air Conditioner...4604
Forward & Table of Contents...4605
Specifications...4606
Outlines of Refrigeration System...4607
Construction...4609
Troubleshooting...4616
Removal & Installation...4623
Treatment After Installation...4626
Maintenance...4632
Cooling Unit Assembly...4633
Compressor & Clutch Assembly...4635
Group 55B - Heater...4638
Index...4639
Specifications/Structure & Operation...4640
Troubleshooting...4646
Heater Hose...4648
Heater Control...4650
Air Duct...4653
Heater Unit & Blower...4654
Air Outlet Ventilation...4655
Mitsubishi Fuso FE.FG.FH.FK.FM Series 2002-2004 Repair Service Manual
