Mitsubishi Fuso FE.FG.FK.FM Series Repair Service Manual 1996-2001
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi Fuso FE.FG.FK.FM Series 1996-2001, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi Fuso FE.FG.FK.FM Series 1996-2001 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.
Mitsubishi Fuso FE.FG.FK.FM Series 1996-2001 Service Manual (TWME9502&TWME9503&TWSE9501).pdf
PRODUCT DETAILS:
Total Pages: 5,067 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
1996-2001 Service Manual...1
96-01 FE/FG Service Manual...2
Group 00 - General...3
2001 Model Year Changes...4
Foreword/Group Index...5
2001 Model Changes...6
Group 00 - General...18
Power Train Table...19
Vehicle Identification Number...20
Engine Number...20
Precautions for Maintenance Operation...21
Group 01 - Maintenance Schedule...22
How to Read the Maintenance Schedule Tables...23
Maintenance Schedule Tables...24
Maintenance Operations...25
Lubrication...35
Group 11 - Engine '4D34T3'...37
Flywheel...38
Flywheel Power Take-Off...42
Group 23 - Automatic Transmission...45
Structure and Operation...46
Troubleshooting...50
Group 24 - Transfer 'FG'...57
Structure and Operation...58
Removal and Installation of Transfer Assembly...60
Front Drive...64
Idler Gear and Rear Drive...70
Group 54 - Electrical...76
101 Battery...78
104 Fuse...81
110 Power Circuit...82
125 Battery Charging Circuit...84
130 Ground...86
Specifications '4M5'...87
Structure and Operation '4M5'...88
201 Starter '4M5'...89
210 Engine Starting Circuit '4M5 Automatic Transmission'...102
225 Engine Warming Up Circuit '4M5'...106
410 Tachometer Circuit '4M5'...108
604 Relay and Control Unit...110
629 Mirror Heater Circuit...112
710 Exhaust Brake Circuit '4M5 Automatic Transmission'...114
801 Engine Electrics '4M5'...116
810 Four-Wheel Drive Circuit 'FG'...120
910 Multipurpose Timing Control Unit Circuit '4M5'...122
2000 Model Year Changes...123
Foreword/Group Index...124
2000 Model Changes...125
Group 00 - General...133
Power Train Table...134
Vehicle Identification Number...134
Group 26B - Front Axle 'FG'...135
Structure and Operation...136
On-Vehicle Inspection and Adjustment...138
Wheel Hub and Brake Drum...142
Group 42 - Cab...149
Structure and Operation...150
Troubleshooting...152
Door...154
Group 54 - Electrical...159
Specifications...161
Structure and Operation...161
104 Fuse...162
106 Alternator...164
110 Power Circuit...170
210 Engine Starting Circuit...172
313 Daytime Running Light Circuit...176
401 Meter Cluster...180
622 Power Window and Auto Door Lock Circuit...182
710 Exhaust Brake Circuit...186
1999 Model Year Changes...190
Foreword/Group Index...191
1999 Model Changes...192
Group 00 - General...200
Power Train Table...201
Vehicle Identification Number...201
Connector Configuration Chart...202
Group 37 - Steering...203
Steering System...204
Group 54 - Electrical...210
125 Battery Charging Circuit...212
210 Engine Starting Circuit...214
225 Engine Warming Up Circuit...218
340 Backup Lamp Circuit 'Automatic Transmission'...220
604 Relay and Control Unit...222
710 Exhaust Brake Circuit...224
1998 Model Year Changes...232
Foreword...233
1998 Model Changes...234
Power Train Table...242
Vehicle Identification Number...242
Structure and Operation...244
Multiplate Limited Slip Differential Assembly 'D033H'...246
1997 Model Year Changes...252
Foreword...253
1997 Model Changes...254
212 Sub-Starter Circuit...255
Group 00 - General...259
Table of Contents...260
Model Coding System...261
Power Train Table...262
Chassis Number and Engine Number...262
Power Train Label...263
Vehicle Identification Number...263
Precautions for Maintenance Operation...265
Table of Standard Tightening Torques...277
Connector Configuration Chart...281
Group 01 - Maintenance Schedule...302
Group 01 - '98 Minor Change - Maintenance Schedule...303
Table of Contents...304
How To Read the Maintenance Schedule Tables...305
Maintenance Schedule Tables...306
Maintenance Operations...308
Replacement of Oil Filter...308
Replacement of Fuel Filter...309
Draining of Water Separator Condensation...310
Cleaning of Fuel Feed Pump Gauze Filter...310
Bleeding of Air from Fuel Line...311
Adjustment of V-Belt Tension...312
Cleaning and Replacement of Air Cleaner Element...314
Inspection of Clutch Pedal Free Play...315
Tire...316
Inspection of Brake Lining Thickness 'Drum Brake Only'...321
Battery...321
Fuse...324
Lubrication...327
Engine Oil...329
Manual Transmission Gear Oil...331
Automatic Transmission Fluid...333
Transfer Gear Oil 'FG Model Only'...335
Front Axle Gear Oil 'FG Model Only' and Rear Axle Gear Oil...336
Power Steering Fluid...337
Brake Fluid...339
Greasing Various Areas of Chassis...343
Group 01 - Maintenance Schedule...345
Table of Contents...346
How To Read the Maintenance Schedule Tables...347
Maintenance Schedule Tables...348
Maintenance Operations...350
Replacement of Oil Filter...350
Replacement of Fuel Filter...351
Draining of Water Separator Condensation...352
Cleaning of Fuel Feed Pump Gauze Filter...352
Bleeding of Air from Fuel Line...353
Adjustment of V-Belt Tension...354
Cleaning and Replacement of Air Cleaner Element...356
Inspection of Clutch Pedal Free Play...357
Tire...358
Inspection of Brake Lining Thickness 'Rear Drum Brake'...363
Battery...363
Fuse...366
Lubrication...369
Engine Oil...370
Manual Transmission Gear Oil...372
Automatic Transmission Fluid...373
Rear Axle Gear Oil...375
Power Steering Fluid...376
Brake Fluid...378
Greasing Various Areas of Chassis...381
Group 10 - Removal and Installation of Engine...383
Group 10 - '98 Minor Change - Removal and Installation of Engine...384
Table of Contents...385
Removal and Installation of Engine...386
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses...386
Removal and Installation of Transmission Related Parts...388
Removal and Installation of Engine Related Parts...390
Removal and Installation of Engine...392
'FE'...392
'FG'...394
Group 10 - Removal and Installation of Engine...396
Table of Contents...397
Removal and Installation of Engine...398
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses...398
Removal and Installation of Transmission Related Parts...400
Removal and Installation of Engine Related Parts...402
Removal and Installation of Engine...404
Group 11 - Engine...406
Group 11A - '01 Minor Change - Engine '4M50T2'...407
Table of Contents...408
Specifications...409
Structure and Operation...411
Troubleshooting...421
On-Vehicle Inspection and Adjustment...423
Rocker Cover, Rocker Assemblies, and Camshafts...427
Cylinder Head and Valve Mechanism...441
Front Case...455
Timing Gears and Balance Shafts...459
Pistons, Connecting Rods and Cylinder Liners...467
Flywheel...479
Crankshaft and Crankcase...483
Balance Shaft Bushings...491
Group 11 - Engine...496
Table of Contents...497
Specifications...498
Structure and Operation...499
Troubleshooting...502
Inspection and Adjustment Mounted in Vehicle...503
Inspection of Engine Compression...503
Inspection and Adjustment of Valve Clearance...505
Cylinder Head and Valve Mechanism...508
Timing Gear...522
Camshaft...526
Piston, Connecting Rod and Cylinder Sleeve...532
Flywheel...546
Crankshaft and Crankcase...550
Group 12 - Lubrication...557
Group 12A - '01 Minor Change - Lubrication '4M50T2'...558
Table of Contents...559
Specifications...560
Structure and Operation...562
Troubleshooting...572
On-Vehicle Inspection and Adjustment...574
Oil Filter Replacement...574
Engine Oil Replacement...575
Oil Pressure Measurement...576
Oil Pan, Oil Strainer and Oil Jet...578
Oil Pump...580
Oil Filter...584
Oil Cooler...586
Group 12 - Lubrication...589
Table of Contents...590
Specifications...591
Structure and Operation...592
Troubleshooting...601
Inspection and Adjustment Mounted in Vehicle...602
Replacement of Oil Filter...602
Replacement of Engine Oil...603
Measurement of Oil Pressure...604
Oil Pan, Oil Strainer and Oil Jet...605
Oil Pump...607
Oil Cooler and Oil Filter...611
Group 13 - Fuel and Engine Control...613
Group 13A - '01 Minor Change - Fuel and Engine Control '4M50T2'...614
Table of Contents...615
Specifications...616
Structure and Operation...617
Fuel System (Fuel flow)...617
Engine Control...618
Fuel Filter...619
On-Vehicle Inspection and Adjustment...620
Checking Minimum and Maximum No-Load Speeds...620
Bleeding Air from Fuel System...621
Replacing Fuel Filter...621
Engine Control...624
Fuel Tank...627
Fuel Filter...628
Injection Pump...630
Injection Nozzle...634
Group 13E - '01 Minor Change - Fuel and Engine Control '4M50T2'...643
Table of Contents...644
Specifications...645
Structure and Operation...646
General...646
Electronic Control System...648
Pin Configuration of Engine Control Unit...652
Troubleshooting...657
Inspection Procedures...657
Connection of Multi-Use Tester II...659
Reading and Erasing Diagnostic Trouble Codes...660
Diagnostic Trouble Codes and Check Items...662
Service Data of Multi-Use Tester II...671
Actuator Test by Multi-Use Tester II...673
Checks at Connector of Control Unit...675
Checks On Intermittent Troubles...678
Inspection of Electrical Equipment...679
Locations of Parts...687
Group 13 - '99 Minor Change - Fuel and Engine Control...692
Table of Contents...693
Specifications...694
Structure and Operation...696
Troubleshooting...724
Reading and Erasing Diagnosis Codes...728
Service Procedures Using M.U.T.-II...734
Inspection Based on Diagnosis Code...736
On-Vehicle Inspection and Adjustment...740
Checking and Adjusting Injection Timing...740
Bleeding Air from Fuel System...743
Cleaning Gauze Filter...743
Replacing Fuel Filter...744
Engine Control...745
Fuel Tank...750
Fuel Filter...751
Water Separator...752
Injection Pump...754
Injection Nozzle...758
Inspection of Other Devices...762
Electric Circuit and Part Installation Locations...772
Group 13 - Fuel and Engine Control...774
Table of Contents...775
Specifications...776
Structure and Operation...778
Troubleshooting...798
Inspection and Adjustment Mounted in Vehicle...802
Inspection and Adjustment of Fuel Injection Timing...802
Inspection and Adjustment of No-Load Minimum and Maximum Revolution...805
Inspection and Adjustment of Idling Actuator 'with Cab Cooler'...806
Pre-Stroke Control Injection Pump System...808
Troubleshooting Procedure...808
Electric Circuit and Position of Parts Installation...814
Inspection by Individual Diagnosis Code...816
Inspection of Temporary Faults...834
Engine Control...836
Fuel Tank...841
Water Separator...842
Fuel Filter...844
Injection Pump...846
Injection Nozzle...850
Group 14 - Cooling...854
Group 14A - '01 Minor Change - Cooling '4M50T2'...855
Table of Contents...856
Specifications...857
Structure and Operation...857
Troubleshooting...859
On-Vehicle Inspection and Adjustment...861
Replacing Coolant and Cleaning Cooling System...861
Air Bleeding of Cooling System...863
Gas Leak Testing...863
Radiator...865
Cooling Fan, V-Ribbed Belt and Water Pump...873
Water Hose & Pipe...879
Thermostat...881
Group 14 - Cooling...883
Table of Contents...884
Specifications...885
Structure and Operation...885
Troubleshooting...889
Inspection and Adjustment Mounted in Vehicle...891
Replacing Coolant and Cleaning Cooling System...891
Air Bleeding of Cooling System...893
Gas Leakage Test...893
Radiator...895
Cooling Fan and V-Belt...897
Water Pump...901
Thermostat...903
Group 15 - Intake and Exhaust...906
Group 15A - '01 Minor Change - Intake and Exhaust '4M50T2'...907
Table of Contents...908
Specifications...909
Structure and Operation...909
Air Cleaner...909
Turbocharger Assembly...910
Troubleshooting...911
On-Vehicle Inspection and Adjustment...912
Measurement of Turbocharger Boost Pressure...912
Air Duct and Air Cleaner...915
Turbocharger...918
Intercooler...923
Intake Manifold...925
Exhaust Manifold...927
Exhaust Pipe and Muffler...928
Group 15 - Intake and Exhaust...929
Table of Contents...930
Specifications...931
Structure and Operation...931
Troubleshooting...934
Inspection and Adjustment Mounted in Vehicle...935
Measurement of Turbo Boost Pressure...935
Air Duct and Air Cleaner...937
Turbocharger...941
Intercooler...947
Intake Manifold...949
Exhaust Manifold...951
Exhaust Pipe and Muffler...953
Group 21 - Clutch...955
Table of Contents...956
Specifications...957
Structure and Operation...957
Troubleshooting...960
Inspection and Adjustment Mounted in Vehicle...961
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding...961
Clutch Pedal Free Play...963
Clutch Pedal...965
Clutch Master Cylinder...967
Clutch Power Cylinder...969
Work Before Removal and Installation of Clutch Body...971
Clutch Body...973
Clutch Control...977
Group 22 - Manual Transmission...978
Table of Contents...979
Specifications...980
Structure and Operation...980
Troubleshooting...983
Work Before Removal and Installation of Transmission Assembly...985
Removal and Installation of Transmission Assembly...986
Gear Shifter Upper...988
Rear Cover and Reverse Idler Gear...994
Transmission Body...998
Drive Pinion Assembly...1006
Mainshaft Assembly...1008
Countershaft Assembly 'Non-Backlash Mechanism'...1014
Transmission Control...1018
Group 23 - Automatic Transmission...1029
Group 23 - '99 Minor Change - Automatic Transmission...1030
Table of Contents...1031
Specifications...1032
Structure and Operation...1034
Troubleshooting Procedures...1070
Troubleshooting...1072
On-Vehicle Inspection and Adjustment...1082
Stall Test...1082
Time Lag Test...1083
Line Pressure Test...1084
Road Test...1086
Inspection of Automatic Transmission Fluid (ATF)...1088
Changing Automatic Transmission Fluid (ATF)...1089
Removal and Installation of Automatic Transmission Assembly...1090
Oil Cooler...1095
Automatic Transmission Control...1098
Replacement of Automatic Transmission Parts...1108
Inspection and Adjustment of Other Devices...1114
Group 23 - Automatic Transmission...1120
Table of Contents...1121
Specifications...1122
Structure and Operation...1123
Troubleshooting Procedure...1170
Electric Circuit and Parts Installation Position...1181
Inspection by Individual Diagnosis Code...1183
Inspection by Symptom...1210
Inspection of Temporary Fault...1225
Inspection Using the Check Box (Harness Checker)...1226
Inspection and Adjustment Mounted in Vehicle...1230
Stall Test...1230
Line Pressure Test...1231
Road Test...1233
Inspection of Automatic Transmission Fluid...1235
Replacement of Automatic Transmission Fluid...1236
Work Before Removal and Installation of Automatic Transmission Assembly...1238
Removal and Installation of Automatic Transmission Assembly...1239
Oil Cooler...1244
Automatic Transmission Control...1248
Replacement of Relative Parts of Automatic Transmission Body...1260
Group 24 - Transfer...1265
Group 24 - '98 Minor Change - Transfer 'FG'...1265
Table of Contents...1266
Specifications...1267
Structure and Operation...1267
Troubleshooting...1269
Removal and Installation of Transfer Assembly...1271
Front Drive...1275
Idler Gear and Rear Drive...1281
Transfer Control...1287
Group 25 - Propeller Shaft...1295
Group 25 - '98 Minor Change - Propeller Shaft...1296
Table of Contents...1297
Specifications...1298
Structure and Operation...1298
Troubleshooting...1299
Removal and Installation of Propeller Shaft...1300
Rear Propeller Shaft...1302
Balancing Propeller Shaft...1306
Group 25 - Propeller Shaft...1307
Table of Contents...1308
Specifications...1309
Structure and Operation...1309
Troubleshooting...1310
Removal and Installation of Propeller Shaft...1311
Rear Propeller Shaft...1313
Front Propeller Shaft...1317
Balancing Propeller Shaft...1321
Group 26 - Front Axle...1322
Group 26 - Front Axle...1323
Table of Contents...1324
Specifications...1325
Structure and Operation...1325
Inspection and Adjustment Mounted in Vehicle...1327
Adjustment of Wheel Alignment...1327
Adjustment of Steering Angle...1330
Measurement of Side Slip...1330
Work Before Removal and Installation of Front Axle...1331
Wheel Hub and Rotor...1333
Front Axle, Knuckle and Kingpin...1339
Group 26B - '98 Minor Change - Front Axle...1346
Table of Contents...1347
Specifications...1348
Structure and Operation...1348
Troubleshooting...1351
On-Vehicle Inspection and Adjustment...1353
Adjustment of Wheel Alignment...1353
Adjustment of Steering Angle...1356
Measurement of Side Slip...1357
Work Before Removal and Installation of Front Axle...1358
Wheel Hub and Brake Drum...1360
Knuckle and Drive Shaft...1368
Axle Housing...1374
Reduction and Differential...1376
Group 27 - Rear Axle...1389
Table of Contents...1390
Specifications...1391
Structure and Operation...1392
Troubleshooting...1394
Work Before Removal and Installation of Rear Axle...1396
Wheel Hub and Brake Drum 'FE639'...1397
Wheel Hub and Rotor 'FE649'...1405
Axle Housing...1413
Reduction and Differential...1417
Group 31 - Wheel and Tire...1431
Table of Contents...1432
Specifications...1433
Troubleshooting...1433
Wheel and Tire...1434
Group 33 - Front Suspension...1438
Group 33 - '98 Minor Change - Front Suspension...1439
Table of Contents...1440
Structure and Operation...1441
Troubleshooting...1442
Work Before Removal and Installation of Front Suspension...1443
Removal and Installation of Leaf Spring Assembly...1445
'FE'...1445
'FG'...1447
Leaf Spring Assembly...1451
'FE'...1451
'FG'...1453
Shock Absorber...1455
'FE'...1455
'FG'...1456
Stabilizer 'FE'...1457
Group 33 - Front Suspension...1459
Table of Contents...1460
Structure and Operation...1461
Troubleshooting...1462
Work Before Removal and Installation of Front Suspension...1463
Removal and Installation of Leaf Spring Assembly...1465
Leaf Spring Assembly...1467
Shock Absorber...1469
Stabilizer...1471
Group 34 - Rear Suspension...1473
Group 34 - '98 Minor Change - Rear Suspension...1474
Table of Contents...1475
Structure and Operation...1476
Troubleshooting...1477
Work Before Removal and Installation of Rear Suspension...1478
Removal and Installation of Leaf Spring Assembly...1480
'FE'...1480
'FG'...1484
Leaf Spring Assembly...1488
Shock Absorber...1491
Stabilizer 'FE'...1492
Group 34 - Rear Suspension...1494
Table of Contents...1495
Structure and Operation...1496
Troubleshooting...1497
Work Before Removal and Installation of Rear Suspension...1498
Removal and Installation of Leaf Spring Assembly...1500
Leaf Spring Assembly...1504
Shock Absorber...1507
Stabilizer...1508
Group 35 - Brake...1510
Group 35A - '00 Minor Change - Anti-Lock Brake System (ABS)...1511
Table of Contents...1512
Specifications...1513
Structure and Operation...1513
On-Vehicle Inspection and Adjustment...1520
Periodic Inspection Procedures...1520
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope...1521
Hydraulic Unit Operation Check...1522
Troubleshooting...1524
Troubleshooting Procedures...1524
Diagnosis Code Indication...1525
Diagnosis Code Chart...1528
Actuator Drive Chart...1528
Service Data...1529
Wheel Speed Sensor and Rotor...1531
'Front Axle: Disc Brake'...1531
'Front Axle: Drum Brake'...1535
'Rear Axle: Disc Brake'...1541
'Rear Axle: Drum Brake'...1547
Electric Circuit and Part Installation Locations...1553
Group 35 - '98 Minor Change - Brake...1555
Table of Contents...1556
Specifications...1557
Structure and Operation...1558
Troubleshooting...1587
On-Vehicle Inspection and Adjustment...1593
Replacement of Brake Fluid...1593
Air Bleeding of Brake System...1595
Inspection and Adjustment of Brake Pedal Free Play...1597
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel...1597
Inspection and Replacement of Disc Brake Pad...1598
Drum Brake Lining Thickness Inspection and Replacement...1601
Inspection of Brake Shoe Clearance...1601
Inspection of Brake Booster (Master Vac)...1602
Inspection of Bypass Valve...1607
Brake Master Cylinder...1609
Brake Pedal and Brake Booster (Master Vac)...1611
Front Wheel Brake...1613
'FE639: Disc Brake'...1613
'FE649: Disc Brake'...1617
'FG639: Drum Brake'...1621
Rear Wheel Brake...1627
'FE639, FG639: Drum Brake'...1627
'FE649: Disc Brake'...1635
Vacuum Pump...1639
Load Sensing Valve...1640
Exhaust Brake System...1641
Group 35 - Brake...1647
Table of Contents...1648
Specifications...1649
Structure and Operation...1650
Troubleshooting...1673
Inspection and Adjustment Mounted in Vehicle...1679
Replacement of Brake Fluid...1679
Air Bleeding of Brake System...1681
Inspection and Adjustment of Brake Pedal Free Play...1683
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel...1683
Inspection and Replacement of Disc Brake Pad...1684
Drum Brake Lining Thickness Inspection and Replacement...1687
Inspection of Brake Shoe Clearance...1687
Inspection of Brake Booster (Master Vac)...1688
Inspection of Bypass Valve...1693
Brake Master Cylinder...1695
Brake Pedal and Brake Booster (Master Vac)...1697
Front Wheel Brake...1699
'FE639: Disc Brake'...1699
'FE649: Disc Brake'...1703
Rear Wheel Brake...1707
'FE639: Drum Brake'...1707
'FE649: Disc Brake'...1715
Vacuum Pump...1719
Load Sensing Valve...1721
Exhaust Brake System...1723
Group 36 - Parking Brake...1729
Table of Contents...1730
Specifications...1731
Structure and Operation...1731
Troubleshooting...1733
Inspection and Adjustment Mounted in Vehicle...1734
Adjustment of Parking Brake Shoe Clearance and Ratchet Bar Pulling Stroke...1734
Parking Brake Control...1735
Parking Brake Assembly...1737
Backing Plate and Shoe Assembly...1739
Group 37 - Steering...1741
Group 37 - '98 Minor Change - Steering...1742
Table of Contents...1743
Specifications...1744
Structure and Operation...1745
Troubleshooting...1750
On-Vehicle Inspection and Adjustment...1753
Change of Power Steering Fluid...1753
Bleeding of Power Steering System...1754
Steering Wheel Play...1754
Performance Verification Test of Power Steering System...1755
Steering System...1756
Steering Column Subassembly...1762
Power Steering Booster...1766
'FE'...1766
'FG'...1772
Power Steering Oil Pump...1778
Power Steering Oil Tank...1782
Power Steering Fluid Line...1783
Drag Link...1784
Tie Rod Assembly...1786
Group 37 - Steering...1788
Table of Contents...1789
Specifications...1790
Structure and Operation...1791
Troubleshooting...1796
Inspection and Adjustment Mounted in Vehicle...1799
Change of Power Steering Fluid...1799
Bleeding of Power Steering System...1800
Steering Wheel Play...1800
Performance Verification Test of Power Steering System...1801
Steering System...1802
Steering Column Subassembly...1806
Power Steering Booster...1810
Power Steering Oil Pump...1816
Power Steering Oil Tank...1820
Power Steering Fluid Line...1821
Drag Link...1822
Tie Rod Assembly...1824
Group 41 - Frame...1826
Table of Contents...1827
Specifications...1828
Structure and Operation...1828
Inspection and Repair of Frames...1828
Group 42 - Cab...1833
Table of Contents...1834
Specifications...1835
Structure and Operation...1836
Troubleshooting...1846
Inspection and Adjustment Mounted in Vehicle...1850
Adjustment of Cab Tilt...1850
Adjustment of Door Fitting...1851
Removal and Installation of Cab...1853
Front Cab Mounting...1861
Rear Cab Mounting...1863
Cab Tilt Link...1865
Door...1868
Cab Exterior Fitting...1873
Mirror...1877
Wiper and Washer...1879
Cab Interior Fitting...1882
Instrument Panel...1884
Window Glass...1887
Group 54 - Electrical...1889
Group 54 - '98 Minor Change - Electrical...1890
Table of Contents...1891
Specifications 'Alternator'...1892
Structure and Operation 'Alternator'...1893
Troubleshooting...1895
100-On-Vehicle Inspection and Adjustment...1896
106-Alternator...1898
401-Meter Cluster...1906
810-Four-Wheel Drive Circuit...1908
Group 54 - Electrical...1910
Table of Contents...1911
Connector Configuration Chart...1913
1-Power, Charging and Ground...1933
Specifications...1934
Structure and Operation...1935
Troubleshooting...1938
100-Inspection and Adjustment Mounted in Vehicle...1940
Inspection of Alternator...1940
Inspection of Regulator...1941
101-Battery...1942
104-Fuse...1946
106-Alternator...1948
110-Power Circuit...1954
115-Reserve Power Circuit...1964
125-Battery Charging Circuit...1966
130-Ground...1968
2-Starting, Preheating and Stopping Engine...1973
Specifications...1974
Structure and Operation...1975
Troubleshooting...1982
200-Inspection and Adjustment Mounted in Vehicle...1984
Inspection of Engine Preheating System...1984
201-Starter...1985
210-Engine Starting Circuit...1998
'Manual Transmission'...1998
'Automatic Transmission'...2002
212-Sub-Starter Circuit...2006
'Manual Transmission'...2006
'Automatic Transmission'...2008
215-Engine Stopping Circuit...2010
220-Engine Preheating Circuit...2014
225-Engine Warming Up Circuit...2018
3-Lighting...2020
Specifications...2021
Structure and Operation...2023
Troubleshooting...2025
300-Inspection and Adjustment Mounted in Vehicle...2027
Headlamp Aiming...2027
310-Headlamp Circuit...2029
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuits...2031
325-Stop Lamp Circuit...2033
330-Turn Signal Lamp and Hazard Lamp Circuits...2035
340-Backup Lamp Circuit...2037
'Manual Transmission'...2037
'Automatic Transmission'...2041
345-Cab Lamp Circuit...2045
348-Illumination Lamp Circuit...2049
349-Marker Lamp and Identification Lamp Circuits...2051
352-Van Body Dome Light Circuit...2053
4-Meter...2055
Specifications...2056
Troubleshooting...2057
401-Meter Cluster...2058
410-Tachometer Circuit...2064
420-Fuel Gauge Circuit...2066
425-Water Temperature Gauge Circuit...2070
5-Indicator and Warning...2072
Troubleshooting...2073
500-Inspection and Adjustment Mounted in Vehicle...2076
Inspection of Brake Fluid Level Switch...2076
510-Parking Brake Indicator Circuit...2077
515-Brake Warning Circuit...2079
535-Engine Oil Level and Oil Pressure Warning Circuit...2083
537-Overheating Warning Circuit...2085
540-Brake Pad Warning Circuit...2087
550-Cab Tilt Warning Circuit...2091
6-Cab Side Electrics...2093
Specifications...2094
Troubleshooting...2094
601-Switch...2096
604-Relay and Control Unit...2100
606-Warning Buzzer...2103
610-Cigarette Lighter Circuit...2104
612-Audio Circuit...2106
614-Wiper and Washer Circuit...2108
616-Horn Circuit...2112
618-Heater Circuit...2114
7-Chassis Electrics...2117
701-Magnetic Valve...2118
710-Exhaust Brake Circuit...2120
'Manual Transmission'...2120
'Automatic Transmission'...2124
8-Engine and Transmission Electrics...2127
801-Engine Electrics...2128
802-Transmission Electrics...2132
9-Others...2134
Structure and Operation...2135
910-Multipurpose Timing Control Unit Circuit...2141
Group 55 - Air Conditioner and Heater...2143
Group 55A - Air-Conditioner...2144
Foreword/Table of Contents...2145
Specifications...2146
Outlines of Refrigeration System...2147
Construction...2149
Troubleshooting...2156
Removal and Installation...2163
Treatment After Installation...2166
Maintenance...2172
Cooling Unit Assembly...2173
Compressor & Clutch Assembly...2175
Group 55B - Heater...2178
Table of Contents...2179
Specifications...2180
Structure and Operation...2181
Troubleshooting...2187
Heater Hose...2188
Heater Control...2190
Air Duct...2193
Heater Unit and Blower Assembly...2194
96-01 FH Service Manual...2195
How to Read this Manual...2198
Table of Contents...2199
How This Manual is Compiled...2200
General Explanation of This Manual...2201
Terms and Units...2211
Group 00 - General...2212
2001 Model Year Changes...2213
Foreword/Group Index...2214
2001 Model Changes...2215
Group 00 - General...2217
Power Train Table...2218
Vehicle Identification Number...2218
Precautions for Maintenance Operation...2219
Group 01 - Maintenance Schedule...2220
Maintenance Operations...2221
Battery...2221
Fuse...2225
Group 14 - Cooling...2227
Radiator, Fan Shroud...2228
Group 54 - Electrical...2234
101-Battery...2237
104-Fuse...2240
629-Mirror Heater Circuit...2241
2000 Model Year Changes...2243
Foreword/Group Index...2244
2000 Model Changes...2245
Group 00 - General...2250
Power Train Table...2251
Vehicle Identification Number...2251
Group 42 - Cab...2252
Structure & Operation...2253
Troubleshooting...2255
Door...2257
Group 54 - Electrical...2262
Specifications...2264
Structure and Operation...2264
104-Fuse...2265
106-Alternator...2267
110-Power Circuit...2273
115-Reserve Power Circuit...2275
210-Engine Starting Circuit...2277
'Manual Transmission...2277
'Automatic Transmission'...2279
313-Daytime Running Light Circuit...2281
401-Meter Cluster...2285
622-Power Window and Auto Door Lock Circuit...2287
710-Exhaust Brake Circuit 'Manual Transmission'...2291
1999 Model Year Changes...2294
Foreword/Group Index...2295
1999 Model Changes...2296
Group 00 - General...2305
Power Train Table...2306
Vehicle Identification Number...2306
Connector Configuration Chart...2307
Group 37 - Steering...2308
Steering System...2309
Group 54 - Electrical...2315
210-Engine Starting Circuit...2317
345-Cab Lamp Circuit...2321
510-Parking Brake Indicator Circuit...2323
515-Brake Warning Circuit...2325
536-Engine Oil Pressure Warning Circuit...2327
710-Exhaust Brake Circuit 'Manual Transmission'...2329
1998 Model Year Changes...2333
Table of Contents...2334
Foreword...2335
1998 Model Changes...2336
Vehicle Identification Number: '98 Model...2345
Injection Pump Drive Case...2346
1997 Model Year Changes...2350
Table of Contents...2351
Foreword...2352
1997 Model Changes...2353
Cab Interior Fitting...2355
220-Engine Preheating and Cold Start Circuit...2357
'Manual Transmission'...2357
'Automatic Transmission'...2359
Group 00 - General...2361
Table of Contents...2362
Model Coding System...2363
Power Train Table...2364
Chassis Number and Engine Number...2364
Power Train Label...2365
Vehicle Identification Number...2365
Precautions For Maintenance Operation...2367
Table of Standard Tightening Torques...2379
Connector Configuration Chart...2383
Group 01 - Maintenance Schedule...2404
Group 01 - '98 Minor Change - Maintenance Schedule...2405
Table of Contents...2406
How to Read the Maintenance Schedule Tables...2407
Maintenance Schedule Tables...2408
Maintenance Operations...2412
Replacement of Oil Filter...2412
Replacement of Fuel Filter...2413
Draining of Water Separator Condensation...2414
Cleaning of Fuel Feed Pump Gauze Filter...2414
Bleeding of Air from Fuel Line...2415
Adjustment of V-Belt Tension...2416
Cleaning and Replacement of Air Cleaner Element...2418
Inspection of Clutch Pedal Free Play...2419
Tire...2419
Inspection of Brake Pedal Free Play...2425
Inspection of Clearance between Brake Pedal and Floor Panel...2425
Inspection of Brake Lining Thickness...2426
Battery...2426
Fuse...2429
Lubrication...2431
Engine Oil...2432
Clutch Fluid (Brake Fluid)...2434
Manual Transmission Gear Oil...2436
Automatic Transmission Fluid and Oil Filter...2437
Rear Axle Gear Oil...2440
Power Steering Fluid...2441
Brake Fluid...2443
Greasing Various Areas of Chassis...2447
Group 01 - Maintenance Schedule...2449
Table of Contents...2450
How to Read the Maintenance Schedule Tables...2451
Maintenance Schedule Tables...2452
Maintenance Operations...2456
Replacement of Oil Filter...2456
Replacement of Fuel Filter...2457
Draining of Water Separator Condensation...2458
Cleaning of Fuel Feed Pump Gauze Filter...2458
Bleeding of Air from Fuel Line...2459
Adjustment of V-Belt Tension...2460
Cleaning and Replacement of Air Cleaner Element...2462
Inspection of Clutch Pedal Free Play...2463
Tire...2463
Inspection of Brake Lining Thickness...2469
Battery...2469
Fuse...2473
Lubrication...2475
Engine Oil...2476
Clutch Fluid (Brake Fluid)...2478
Manual Transmission Gear Oil...2480
Automatic Transmission Fluid and Oil Filter...2481
Rear Axle Gear Oil...2484
Power Steering Fluid...2485
Brake Fluid...2487
Greasing Various Areas of Chassis...2491
Group 10 - Removal and Installation of Engine...2493
Table of Contents...2494
Removal and Installation of Engine...2495
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses...2495
Removal and Installation of Engine Related Parts...2497
Removal and Installation of Engine...2499
Group 11 - Engine...2501
Table of Contents...2502
Specifications...2503
Structure and Operation...2504
Troubleshooting...2507
Inspection and Adjustment Mounted in Vehicle...2508
Inspection of Engine Compression...2508
Inspection and Adjustment of Valve Clearance...2510
Cylinder Head and Valve Mechanism...2511
Timing Gear...2525
Camshaft...2529
Piston, Connecting Rod and Cylinder Sleeve...2535
Flywheel...2549
Crankshaft and Crankcase...2553
Group 12 - Lubrication...2560
Table of Contents...2561
Specifications...2562
Structure and Operation...2563
Troubleshooting...2571
Inspection and Adjustment Mounted in Vehicle...2572
Replacement of Oil Filter...2572
Replacement of Engine Oil...2573
Measurement of Oil Pressure...2574
Oil Pan, Oil Strainer and Oil Jet...2576
Oil Pump...2578
Oil Cooler and Oil Filter...2582
Group 13 - Fuel and Engine Control...2584
Group 13 - '99 Minor Change - Fuel and Engine Control...2585
Table of Contents...2586
Specifications...2587
Structure and Operation...2589
Troubleshooting...2619
Reading and Erasing Diagnosis Codes...2623
Service Procedures Using MUT-II...2629
Inspection Based on Diagnosis Code...2631
On-Vehicle Inspection and Adjustment...2635
Checking and Adjusting Injection Timing...2635
Bleeding Air from Fuel System...2636
Cleaning Gauze Filter...2636
Replacing Fuel Filter...2637
Engine Control...2638
Fuel Tank...2643
Fuel Filter...2644
Water Separator...2645
Injection Pump...2647
Injection Pump Drive Case...2653
Injection Nozzle...2657
Inspection of Other Devices...2661
Electric Circuit and Part Installation Locations...2671
Group 13 - Fuel and Engine Control...2673
Table of Contents...2674
Specifications...2675
Structure and Operation...2677
Troubleshooting...2697
Inspection and Adjustment Mounted in Vehicle...2701
Inspection and Adjustment of Fuel Injection Timing...2701
Inspection and Adjustment of No-Load Minimum and Maximum Revolution...2702
Pre-Stroke Control Injection Pump System...2703
Troubleshooting Procedure...2703
Electric Circuit and Position of Parts Installation...2709
Inspection by Individual Diagnosis Code...2711
Inspection of Temporary Faults...2729
Engine Control...2731
Fuel Tank...2736
Water Separator...2737
Fuel Filter...2739
Injection Pump...2741
Injection Nozzle...2747
Group 14 - Cooling...2751
Table of Contents...2752
Specifications...2753
Structure and Operation...2753
Troubleshooting...2757
Inspection and Adjustment Mounted in Vehicle...2759
Replacing Coolant and Cleaning Cooling System...2759
Air Bleeding of Cooling System...2761
Gas Leakage Test...2761
Radiator and Fan Shroud...2763
Surge Tank...2767
Cooling Fan and V-Belt...2769
Water Pump...2772
Thermostat...2773
Group 15 - Intake and Exhaust...2775
Table of Contents...2776
Specifications...2777
Structure and Operation...2777
Troubleshooting...2780
Inspection and Adjustment Mounted in Vehicle...2781
Measurement of Turbo Boost Pressure...2781
Air Duct and Air Cleaner...2783
Turbocharger...2787
Intercooler...2792
Intake Manifold...2793
Exhaust Manifold...2794
Exhaust Pipe and Muffler...2795
Group 21 - Clutch...2797
Table of Contents...2798
Specifications...2799
Structure and Operation...2799
Troubleshooting...2802
Inspection and Adjustment Mounted in Vehicle...2803
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding...2803
Clutch Pedal Free Play...2805
Clutch Pedal...2807
Clutch Master Cylinder...2811
Clutch Power Cylinder...2813
Work Before Removal and Installation of Clutch Body...2815
Clutch Body...2817
Clutch Control...2827
Group 22 - Manual Transmission...2829
Group 22 - '00 Minor Change - Manual Transmission 'M050S5, S6'...2830
Table of Contents...2831
Specifications...2832
Structure and Operation...2833
Troubleshooting...2839
Work Before Removal and Installation of Transmission Assembly...2840
Removal and Installation of Transmission Assembly...2842
Gear Shifter Upper and Interlock Plate...2845
Extension Housing, Rear Cover and Parking Brake Assembly...2850
6th Gear 'S6' and Reverse Idler Gear...2854
Transmission Body...2862
Drive Pinion Assembly...2876
Mainshaft Assembly...2878
Countershaft Assembly...2886
Transmission Control...2890
Group 22 - Manual Transmission...2895
Table of Contents...2896
Specifications...2897
Structure and Operation...2898
Troubleshooting...2905
Work Before Removal & Installation of Transmission Assembly...2906
Removal and Installation of Transmission Assembly...2907
Gear Shifter Upper and Interlock Plate...2911
Rear Cover and Parking Brake Assembly...2917
Reverse Idler Gear...2921
Transmission Body...2923
Drive Pinion Assembly...2935
Mainshaft Assembly...2937
Countershaft Assembly...2945
Transmission Control...2949
Puller and Installer Kit...2954
Group 23 - Automatic Transmission...2955
Table of Contents...2956
Specifications...2957
Structure and Operation...2958
Troubleshooting...2961
Inspection and Adjustment Mounted In Vehicle...2963
Work Before Removal & Installation of Automatic Transmission Assembly...2966
Removal and Installation of Automatic Transmission Assembly...2967
Oil Seal and Speedometer Worm...2971
Oil Pan and Oil Filter...2974
Automatic Transmission Control...2975
Oil Cooler...2981
Oil Filter...2983
Group 25 - Propeller Shaft...2985
Table of Contents...2986
Specifications...2987
Structure and Operation...2987
Troubleshooting...2988
Removal and Installation of Propeller Shaft...2989
Rear Propeller Shaft...2991
Front Propeller Shaft...2995
Balancing Propeller Shaft...2999
Group 26 - Front Axle...3000
Table of Contents...3001
Specifications...3002
Structure and Operation...3002
Inspection and Adjustment Mounted In Vehicle...3004
Adjustment of Wheel Alignment...3004
Adjustment of Steering Angle...3008
Measurement of Side Slip...3008
Work Before Removal & Installation of Front Axle...3009
Wheel Hub and Brake Drum...3010
Front Axle, Knuckle and Kingpin...3018
Group 27 - Rear Axle...3024
Table of Contents...3025
Specifications...3026
Structure and Operation...3026
Troubleshooting...3028
Work Before Removal and Installation of Rear Axle...3030
Wheel Hub and Brake Drum...3032
Axle Housing...3042
Reduction and Differential...3046
Group 31 - Wheel and Tire...3064
Table of Contents...3065
Specifications...3066
Troubleshooting...3066
Wheel and Tire...3067
Group 33 - Front Suspension...3072
Table of Contents...3073
Structure and Operation...3074
Troubleshooting...3075
Work Before Removal & Installation of Front Suspension...3076
Removal and Installation of Leaf Spring Assembly...3078
Leaf Spring Assembly...3084
Shock Absorber...3086
Stabilizer...3087
Group 34 - Rear Suspension...3088
Table of Contents...3089
Structure and Operation...3090
Troubleshooting...3091
Work Before Removal & Installation of Rear Suspension...3092
Removal and Installation of Leaf Spring Assembly...3094
Leaf Spring Assembly...3098
Shock Absorber...3100
Stabilizer...3101
Group 35 - Brake...3102
Group 35A - '00 Minor Change - Anti-Lock Brake System (ABS)...3103
Table of Contents...3104
Specifications...3105
Structure and Operation...3105
On-Vehicle Inspection and Adjustment...3112
Periodic Inspection Procedures...3112
Adjustment of Wheel Speed Sensor Clearance...3113
Inspection of Wheel Speed Sensor Signal Waveform using Oscilloscope...3114
Hydraulic Unit Operation Check...3115
Troubleshooting...3117
Troubleshooting Procedures...3117
Diagnosis Code Indication...3118
Diagnosis Code Chart...3121
Actuator Drive Chart...3122
Service Data...3122
Wheel Speed Sensor and Rotor...3123
'Front Axle'...3123
'Rear Axle'...3129
Electric Circuit and Part Installation Locations...3137
Group 35 - '98 Minor Change - Brake...3139
Table of Contents...3140
Specifications...3141
Structure and Operation...3143
Troubleshooting...3161
On-Vehicle Inspection and Adjustment...3167
Replacement of Brake Fluid...3167
Air Bleeding of Brake System...3169
Inspection and Adjustment of Brake Pedal Free Play...3171
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel...3171
Thickness Inspection and Replacement of Brake Lining...3172
Inspection of Brake Shoe Clearance...3172
Inspection of Brake Booster (Hydraulic Booster)...3173
Brake Master Cylinder...3175
Brake Pedal and Brake Booster (Hydraulic Booster)...3177
Brake Booster (Hydraulic Booster)...3179
Front Wheel Brake...3181
Rear Wheel Brake...3189
Vacuum Pump...3197
Exhaust Brake System...3199
Group 35 - Brake...3206
Table of Contents...3207
Specifications...3208
Structure and Operation...3210
Troubleshooting...3232
Inspection and Adjustment Mounted In Vehicle...3236
Replacement of Brake Fluid...3236
Air Bleeding of Brake System...3238
Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel...3240
Thickness Inspection and Replacement of Brake Lining...3241
Inspection of Brake Shoe Clearance...3241
Inspection and Maintenance of Air Dryer...3242
Handling of Connectors...3243
Brake Pedal...3244
Dual Brake Valve...3248
Brake Booster (Airmaster)...3255
Front Wheel Brake...3262
Rear Wheel Brake...3270
Air Compressor...3278
Air Dryer...3286
Air Pressure Governor...3290
Fluid Tank...3292
Check Valve...3293
Safety Valve...3293
Supply Valve...3294
Exhaust Brake System...3296
Group 36 - Parking Brake...3303
Table of Contents...3304
Specifications...3305
Structure and Operation...3305
Troubleshooting...3307
Inspection and Adjustment Mounted In Vehicle...3308
Adjustment of Parking Brake Shoe Clearance and Lever Stroke...3308
Parking Brake Control...3309
Parking Brake Assembly...3311
Support Plate and Shoe Assembly...3315
' ø203.2 mm {8 in.} Drum '...3315
' ø254 mm {10 in.} Drum '...3317
Group 37 - Steering...3319
Group 37 - '98 Minor Change - Steering...3320
Table of Contents...3321
Specifications...3322
Structure and Operation...3323
Troubleshooting...3329
On-Vehicle Inspection and Adjustment...3332
Change of Power Steering Fluid...3332
Bleeding of Power Steering System...3332
Steering Wheel Play...3333
Performance Verification Test of Power Steering System...3334
Steering System...3336
Steering Column Subassembly...3342
Power Steering Booster...3346
Power Steering Oil Pump...3358
Power Steering Oil Tank...3362
Power Steering Fluid Line...3364
Drag Link...3366
Tie Rod Assembly...3368
Group 37 - Steering...3370
Table of Contents...3371
Specifications...3372
Structure and Operation...3373
Troubleshooting...3378
Inspection and Adjustment Mounted In Vehicle...3381
Change of Power Steering Fluid...3381
Bleeding of Power Steering System...3381
Steering Wheel Play...3382
Performance Verification Test of Power Steering System...3383
Steering System...3384
Steering Column Subassembly...3388
Power Steering Booster...3392
Power Steering Oil Pump...3404
Power Steering Oil Tank...3408
Power Steering Fluid Line...3409
Drag Link...3410
Tie Rod Assembly...3412
Group 41 - Frame...3414
Table of Contents...3415
Specifications...3416
Structure and Operation...3416
Inspection and Repair of Frames...3416
Group 42 - Cab...3421
Table of Contents...3422
Specifications...3423
Structure and Operation...3424
Troubleshooting...3434
Inspection and Adjustment Mounted In Vehicle...3438
Adjustment of Cab Tilt...3438
Adjustment of Door Fitting...3439
Removal and Installation of Cab...3441
Front Cab Mounting...3449
Rear Cab Mounting...3451
Cab Tilt Link...3453
Door...3456
Cab Exterior Fitting...3461
Mirror...3465
Wiper and Washer...3467
Cab Interior Fitting...3470
Instrument Panel...3472
Window Glass...3475
Group 54 - Electrical...3477
Group 54 - '98 Minor Change - Electrical...3478
Table of Contents...3479
1-Power, Charging and Ground...3481
Specifications...3482
Structure and Operation...3482
Troubleshooting...3483
100-On-Vehicle Inspection and Adjustment...3484
Inspection of Alternator...3484
Inspection of Regulator...3485
104-Fuse...3486
106-Alternator...3488
110-Power Circuit...3494
115-Reserve Power Circuit...3502
125-Battery Charging Circuit...3504
130-Ground...3506
2-Starting, Preheating and Stopping Engine...3514
210-Engine Starting Circuit 'Manual Transmission'...3515
220-Engine Preheating Circuit 'Manual Transmission'...3517
3-Lighting...3519
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuit...3520
325-Stop Lamp Circuit...3522
352-Van Body Dome Light Circuit...3524
4-Meter...3526
401-Meter Cluster...3527
5-Indicator and Warning...3533
Troubleshooting...3534
500-On-Vehicle Inspection and Adjustment...3538
Inspection of Brake Fluid Level Switch...3538
Inspection of Power Steering Fluid Level Sensor...3539
510-Parking Brake Indicator Circuit...3540
515-Brake Warning Circuit...3542
530-Water Level Warning Circuit...3546
536-Engine Oil Pressure Warning Circuit...3548
537-Overheating Warning Circuit...3550
547-Automatic Transmission Fluid Temperature Warning Circuit...3552
549-Power Steering Fluid Level Warning Circuit...3554
6-Cab Side Electrics...3558
Specifications...3559
Troubleshooting...3560
616-Horn Circuit...3561
7-Chassis Electrics...3563
701-Magnetic Valve 'Manual Transmission'...3564
710-Exhaust Brake Circuit 'Manual Transmission'...3566
8-Engine and Transmission Electrics...3568
801-Engine Electrics...3569
802-Transmission Electrics 'Manual Transmission'...3573
'Manual Transmission'...3573
'Automatic Transmission'...3575
850-Transmission Power Take-Off Circuit 'Option'...3577
9-Others...3579
905-Joint Connector...3580
Group 54 - Electrical...3582
Table of Contents...3583
Connector Configuration Chart...3585
1-Power, Charging and Ground...3605
Specifications...3606
Structure and Operation...3607
Troubleshooting...3610
100-Inspection and Adjustment Mounted in Vehicle...3612
Inspection of Alternator...3612
Inspection of Regulator...3613
101-Battery...3614
104-Fuse...3618
106-Alternator...3620
110-Power Circuit...3626
125-Battery Charging Circuit...3634
130-Ground...3636
2-Starting, Preheating and Stopping Engine...3644
Specifications...3645
Structure and Operation...3646
Troubleshooting...3655
200-Inspection and Adjustment Mounted in Vehicle...3657
Inspection of Engine Preheating System...3657
201-Starter...3658
210-Engine Starting Circuit...3671
'Manual Transmission'...3671
'Automatic Transmission'...3675
212-Sub-Starter Circuit 'Manual Transmission'...3679
'Manual Transmission'...3679
'Automatic Transmission'...3681
215-Engine Stopping Circuit...3683
220-Engine Preheating and Cold Start Circuit 'Manual Transmission'...3687
'Manual Transmission'...3687
'Automatic Transmission'...3691
3-Lighting...3694
Specifications...3695
Structure and Operation...3697
Troubleshooting...3699
300-Inspection and Adjustment Mounted in Vehicle...3701
Headlamp Aiming...3701
310-Headlamp Circuit...3703
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuits...3705
325-Stop Lamp Circuit...3707
330-Turn Signal Lamp and Hazard Lamp Circuits...3711
340-Backup Lamp Circuit...3713
345-Cab Lamp Circuit...3717
348-Illumination Lamp Circuit...3721
349-Marker Lamp and Identification Lamp Circuits...3723
352-Van Body Dome Light Circuit...3725
4-Meter...3727
Specifications...3728
Troubleshooting...3729
401-Meter Cluster...3730
410-Speedometer and Tachometer Circuits...3736
420-Fuel Gauge Circuit...3738
425-Water Temperature Gauge Circuit...3742
5-Indicator and Warning...3744
Troubleshooting...3745
500-Inspection and Adjustment Mounted in Vehicle...3748
Inspection of Brake Fluid Level Switch...3748
510-Parking Brake Indicator Circuit...3749
515-Brake Warning Circuit...3751
530-Water Level Warning Circuit...3755
536-Engine Oil Pressure Warning Circuit...3759
537-Overheating Warning Circuit...3761
547-Automatic Transmission Fluid Teperature Warning Circuit...3763
550-Cab Tilt Warning Circuit...3767
6-Cab Side Electrics...3769
Specifications...3770
Troubleshooting...3770
601-Switch...3772
604-Relay and Control Unit...3776
606-Warning Buzzer...3779
610-Cigarette Lighter Circuit...3780
612-Audio Circuit...3782
614-Wiper and Washer Circuit...3784
616-Horn Circuit...3788
618-Heater Circuit...3790
7-Chassis Electrics...3793
701-Magnetic Valve...3794
710-Exhaust Brake Circuit 'Manual Transmission'...3796
718-Air Dryer Circuit...3800
8-Engine and Transmission Electrics...3802
801-Engine Electrics...3803
802-Transmission Electrics 'Manual Transmission'...3807
'Manual Transmission'...3807
'Automatic Transmission'...3809
850-Transmission Power Take-Off Circuit 'Option'...3811
9-Others...3813
Structure and Operation...3814
905-Joint Connector...3818
910-Multipurpose Timing Control Unit Circuit...3820
Group 55 - Air Conditioner and Heater...3822
Group 55A - Air-conditioner...3823
Foreword/Table of Contents...3824
1. Specifications...3825
2. Outlines of Refrigeration System...3826
3. Construction...3828
4. Troubleshooting...3835
5. Removal and Installation...3842
6. Treatment After Installation...3845
7. Maintenance...3851
8. Cooling Unit Assembly...3852
9. Compressor & Clutch Assembly...3854
Group 55B - Heater...3857
Table of Contents...3858
Specifications...3859
Structure and Operation...3860
Troubleshooting...3866
Heater Hose...3867
Heater Control...3869
Air Duct...3872
Heater Unit and Blower Assembly...3873
96-01 FK/FM Service Manual...3874
How to Read this Manual...3875
Table of Contents...3876
How This Manual Is Compiled...3877
General Explanation of This Manual...3878
Terms and Units...3888
Group 00 - General...3889
FKFM 2001 Model Year Changes...3890
Foreword/Group Index...3891
2001 Model Changes...3892
00 - General...3896
Power Train Table...3897
Vehicle Identification Number...3898
Precautions for Maintenance Operation...3899
01 - Maintenance Schedule...3900
Maintenance Operations...3901
Battery...3901
Fuse...3905
11 - Engine...3907
Structure and Operation...3908
Flywheel Power Take-Off...3910
Timing Gears...3914
Crankshaft and Crankcase...3918
35A - Brake (Air Over Hydraulic Brake)...3927
Specifications...3928
Structure and Operation...3929
Air Dryer...3930
54 - Electrical...3933
101-Battery...3936
104-Fuse...3939
629-Mirror Heater Circuit...3940
850-Transmission Power Take-Off Circuit...3942
FKFM 2000 Model Year Changes...3945
Foreword/Group Index...3946
2000 Model Changes...3947
00 - General...3954
Power Train Table...3955
Vehicle Identification Number...3956
35C - Anti-Lock Brake System (ABS)...3957
Wheel Speed Sensor and Rotor 'Rear Axle'...3958
42 - Cab...3964
Structure and Operation...3965
Troubleshooting...3969
Door...3971
54 - Electrical...3976
Specifications...3978
Structure and Operation...3978
104-Fuse...3980
106-Alternator...3981
115-Reserve Power Circuit...3989
313-Daytime Running Light Circuit...3991
401-Meter Cluster...3995
622-Power Window and Auto Door Lock Circuit...3997
FKFM 1999 Model Changes...4001
Foreword/Group Index...4002
1999 Model Changes...4003
00 - General...4013
Power Train Table...4014
Vehicle Identification Number...4015
Connector Configuration Chart...4016
35A - Brake (Air Over Hydraulic Brake)...4018
Specifications...4019
Brake Booster (Airmaster)...4021
37 - Steering...4027
Steering System...4028
54 - Electrical...4032
210-Engine Starting Circuit...4035
410-Speedometer Circuit...4039
515-Brake Warning Circuit 'Air Over Hydraulic Brake'...4043
710-Exhaust Brake Circuit 'Manual Transmission'...4047
FKFM 1998 Model Changes...4051
Foreword...4052
1998 Model Changes...4053
Vehicle Identificatin Number...4057
Power Shift Assembly...4059
54 - Electrical...4064
Specifications...4065
Structure and Operation...4066
201-Starter...4067
FKFM 1997 Model Changes...4078
Foreword...4079
1997 Model Changes...4080
Power Train Table...4081
Flywheel and Timing Gear...4082
21 - Clutch...4084
Specifications...4085
Structure and Operation...4086
Troubleshooting...4087
Clutch Body 'C6 (AR 350)'...4088
Specifications...4092
Wheel and Tire...4093
220-Engine Preheating & Cold Start Circuit 'Manual Transmission'...4094
220-Engine Preheating & Cold Start Circuit 'Automatic Transmission'...4096
Group 00 - General...4098
Table of Contents...4099
Model Coding System...4100
Power Train Table...4101
Chassis Number & Engine Number...4102
Power Train Label...4102
Vehicle Identification Number...4103
Precautions for Maintenance Operation...4104
Table of Standard Tightening Torques...4116
Connector Configuration Chart...4120
Group 01 - Maintenance Schedule...4141
Table of Contents...4142
How To Read The Maintenance Schedule Tables...4143
Maintenance Schedule Tables...4144
Maintenance Operations...4148
Replacement of Oil Filter...4148
Replacement of Fuel Filter...4149
Draining of Water Separator Condensation...4150
Cleaning of Fuel Feed Pump Gauze Filter...4150
Bleeding of Air from Fuel Line...4151
Adjustment of V-Belt Tension...4152
Cleaning and Replacement of Air Cleaner Element...4154
Inspection of Clutch Pedal Free Play...4155
Tire...4156
Inspection of Brake Lining Thickness...4162
Battery...4162
Fuse...4165
Lubrication...4167
Engine Oil...4168
Clutch Fluid (Brake Fluid)...4170
Manual Transmission Gear Oil...4172
Automatic Transmission Fluid and Oil Filter...4173
Rear Axle Gear Oil...4176
Power Steering Fluid...4177
Brake Fluid...4179
Greasing Various Areas of Chassis...4183
Group 10 - Removal and Installation of Engine...4185
Table of Contents...4186
Removal and Installation of Engine...4187
Charge and Discharge of Engine Coolant, Removal and Installation of Hoses...4187
Removal and Installation of Engine Related Parts...4189
Removal and Installation of Engine...4191
Group 11 - Engine...4193
Table of Contents...4194
Specifications...4195
Structure and Operation...4196
Troubleshooting...4200
Inspection and Adjustment Mounted In Vehicle...4201
Inspection of Engine Compression...4201
Inspection and Adjustment of Valve Clearance...4203
Cylinder Head and Valve Mechanism...4205
Piston, Connecting Rod and Cylinder Sleeve...4219
Flywheel and Timing Gear...4233
Camshaft...4243
Crankshaft and Crankcase...4249
Group 12 - Lubrication...4256
Table of Contents...4257
Specifications...4258
Structure and Operation...4259
Troubleshooting...4266
Inspection and Adjustment Mounted In Vehicle...4267
Replacement of Oil Filter...4267
Replacement of Engine Oil...4268
Measurement of Oil Pressure...4269
Oil Pan and Oil Jet...4270
Oil Pump and Oil Strainer...4272
Oil Filter...4274
Oil Cooler...4276
Regulator Valve...4278
Group 13 - Fuel and Engine Control...4279
Group 13 - Fuel and Engine Control '99 Minor Change...4280
Table of Contents...4281
Specifications...4282
Structure and Operation...4284
Troubleshooting...4316
Reading and Erasing Diagnosis Codes...4320
Service Procedures Using MUT-II...4326
Inspection Based On Diagnosis Code...4328
On-Vehicle Inspection and Adjustment...4332
Checking and Adjusting Injection Timing...4332
Bleeding Air from Fuel System...4333
Cleaning Gauze Filter...4333
Replacing Fuel Filter...4334
Engine Control...4335
Fuel Tank...4340
Fuel Filter...4341
Water Separator...4342
Injection Pump...4344
Injection Nozzle...4348
Inspection of Other Devices...4352
Electrical Circuit and Part Installation Locations...4362
Group 13 - Fuel and Engine Control...4364
Table of Contents...4365
Specifications...4366
Structure and Operation...4368
Troubleshooting...4388
Inspection and Adjustment Mounted In Vehicle...4392
Inspection and Adjustment of Fuel Injection Timing...4392
Inspection and Adjustment of No-load Minimum and Maximum Revolution...4393
Pre-Stroke Control Injection Pump System...4394
Troubleshooting Procedure...4394
Electric Circuit and Position of Parts Installation...4400
Inspection by Individual Diagnosis Code...4402
Inspection of Temporary Faults...4420
Engine Control...4422
Fuel Tank...4426
Water Separator...4427
Fuel Filter...4428
Injection Pump...4430
Injection Nozzle...4434
Group 14 - Cooling...4438
Table of Contents...4439
Specifications...4440
Structure and Operation...4441
Troubleshooting...4445
Inspection and Adjustment Mounted In Vehicle...4446
Replacing Coolant and Cleaning Cooling System...4446
Air Bleeding of Cooling System...4448
Gas Leakage Test...4448
Radiator and Fan Shroud...4450
Cooling Fan and V-Belt...4454
Water Pump...4458
Thermostat...4462
Group 15 - Intake and Exhaust...4464
Table of Contents...4465
Specifications...4466
Structure and Operation...4466
Troubleshooting...4470
Inspection and Adjustment Mounted In Vehicle...4472
Measurement of Turbo Boost Pressure...4472
Air Duct and Air Cleaner...4474
Turbocharger...4476
Intercooler...4488
Intake Manifold...4490
Exhaust Manifold...4492
Exhaust Pipe and Muffler...4494
Group 21 - Clutch...4496
Table of Contents...4497
Specifications...4498
Structure and Operation...4498
Troubleshooting...4503
Inspection and Adjustment Mounted In Vehicle...4504
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding 'Clutch Power Cylinder'...4504
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding 'Clutch Booster'...4506
Inspection of Function 'Clutch Booster'...4508
Clutch Pedal Free Play 'Clutch Power Cylinder'...4509
Clutch Pedal Free Play 'Clutch Booster'...4510
Clutch Pedal 'C6, C7 (M070S6)'...4512
Clutch Pedal 'C7 (M8S2x5)'...4516
Clutch Master Cylinder...4520
Clutch Power Cylinder 'C6, C7 (M070S6)'...4522
Clutch Booster 'C7 (M8S2x5)'...4524
Work Before Removal and Installation of Clutch Body...4530
Clutch Body 'C6'...4532
Clutch Body 'C7'...4542
Clutch Control...4552
Group 22 - Manual Transmission...4554
Group 22A - Manual Transmission 'M060S5, S6, M070S6' TWME9620...4555
Table of Contents...4556
Specifications...4557
Structure and Operation...4557
Troubleshooting...4566
Work Before Removal and Installation of Transmission Assembly...4567
Removal and Installation of Transmission Assembly...4569
Gear Shifter Upper and Interlock Plate...4573
Power Shift Assembly...4579
Extension Housing, Rear Cover and Parking Brake Assembly...4585
6th Gear 'S6 Over-Drive(O/D)' & Reverse Idler Gear 'S5, S6 Over-Drive(O/D)'...4589
Reverse Gear and Reverse Idler Gear 'S6 Direct-Drive(D/D)'...4597
Transmission Body...4603
Drive Pinion Assembly...4619
Mainshaft Assembly 'S5, S6 Over-Drive (O/D)'...4621
Mainshaft Assembly 'S6 Direct-Drive (D/D)'...4629
Countershaft Assembly...4639
Transmission Control...4643
Puller and Installer Kit...4647
Group 22A - Manual Transmission 'M060S5, S6, M070S6' TWME9503-22A...4648
Table of Contents...4649
Specifications...4650
Structure and Operation...4650
Troubleshooting...4659
Work Before Removal and Installation of Transmission Assembly...4660
Removal and Installation of Transmission Assembly...4662
Gear Shifter Upper and Interlock Plate...4666
Power Shift Assembly...4672
Extension Housing, Rear Cover and Parking Brake Assembly...4678
Reverse Idler Gear ' S5 '...4682
Reverse Gear and Reverse Idler Gear ' S6 '...4684
Transmission Body...4690
Drive Pinion Assembly...4704
Mainshaft Assembly...4706
'S5'...4706
'S6'...4714
Countershaft Assembly...4724
Transmission Control...4728
Puller and Installer Kit...4732
Group 22B - Manual Transmission ' M8S2x5 '...4733
Table of Contents...4734
Specifications...4735
Structure and Operation...4736
Troubleshooting...4745
Work Before Removal and Installation of Transmission Assembly...4747
Removal and Installation of Transmission Assembly...4749
Gear Shifter Upper...4753
Power Shift Assembly...4757
Gear Shifter Lower...4763
Rear Cover...4767
Splitter...4771
Splitter Upper Assembly...4777
Power Cylinder...4778
Transmission Body...4779
Mainshaft Assembly...4787
Counter Shaft Assembly...4795
Transmission Control...4797
Splitter Control...4801
Group 23 - Automatic Transmission...4804
Group 23 - Automatic Transmission 2001 Model Year Change...4805
Foreword / Index...4806
Model Changes (For FM657 with Automatic Transmission)...4807
Group 00 General - Table of Contents...4810
Power Train Table...4811
Group 23 Automatic Transmission - Table of Contents...4812
Specifications...4813
Structure and Operation...4815
1. Automatic Transmission Assembly...4815
2. Automatic Transmission Control System...4816
3. Oil Cooler System...4817
Troubleshooting...4818
On-Vehicle Inspection and Adjustment...4823
1. Stall Test...4823
2. Line Pressure Test...4824
3. Inspection of Automatic Transmission Fluid...4826
4. Replacement of Automatic Transmission Fluid...4827
5. Level Check of Automatic Transmission Fluid...4829
6. Replacement of Oil Filter...4830
Oil Cooler...4831
Electrical Wiring Diagram...4833
Group 35B Brake (Full Air-Wedge Type-Brake) - Table of Contents...4834
Specifications...4835
Structure and Operation...4837
Troubleshooting...4842
Inspection and Adjustment On Vehicle...4843
Thickness Inspection and Replacement of Brake Lining...4843
Front Wheel Brake...4845
Rear Wheel Brake...4855
Expander Assembly...4865
Group 54 Electrical - Table of Contents...4871
410-Speedometer Circuit...4874
604-Relay and Control Unit...4876
710-Exhaust Brake Circuit...4880
802-Transmission Electrics...4883
Group 23 - Automatic Transmission...4884
Table of Contents...4885
Specifications...4886
Structure and Operation...4887
Troubleshooting...4890
Inspection and Adjustment Mounted In Vehicle...4892
Work Before Removal & Installation of Automatic Transmission Assembly...4895
Removal and Installation of Automatic Transmission Assembly...4896
Oil Seal and Speedometer Worm...4900
Oil Pan and Oil Filter...4903
Automatic Transmission Control...4904
Oil Cooler...4912
Oil Filter...4914
Group 25 - Propeller Shaft...4915
Table of Contents...4916
Specifications...4917
Structure and Operation...4917
Troubleshooting...4918
Removal and Installation of Propeller Shaft...4919
Rear Propeller Shaft...4921
'P4'...4921
'P8'...4925
'P10'...4929
Front Propeller Shaft...4933
'P4'...4933
'P8'...4937
'P10'...4943
Balancing Propeller Shaft...4948
Group 26 - Front Axle...4950
Table of Contents...4951
Specifications...4952
Structure and Operation...4952
Inspection and Adjustment Mounted In Vehicle...4956
Adjustment of Wheel Alignment...4956
Adjustment of Steering Angle...4960
Measurement of Side Slip...4960
Work Before Removal and Installation of Front Axle...4961
Wheel Hub and Brake Drum...4962
Front Axle, Knuckle and Kingpin 'FK'...4972
Front Axle, Knuckle and Kingpin 'FM'...4978
Group 27 - Rear Axle...4985
Table of Contents...4986
Specifications...4987
Structure and Operation...4988
Troubleshooting...4991
Work Before Removal and Installation of Rear Axle...4993
Wheel Hub and Brake Drum...4995
Axle Housing...5007
Reduction and Differential...5011
Group 31 - Wheel and Tire...5031
Table of Contents...5032
Specifications...5033
Troubleshooting...5033
Wheel and Tire...5034
Group 33 - Front Suspension...5039
Table of Contents...5040
Structure and Operation...5041
Troubleshooting...5042
Work Before Removal and Installation of Front Suspension...5043
Removal and Installation of Leaf Spring Assembly...5045
Leaf Spring Assembly...5049
Shock Absorber...5051
Group 34 - Rear Suspension...5052
Table of Contents...5053
Structure and Operation...5054
Troubleshooting...5055
Work Before Removal and Installation of Rear Suspension...5056
Removal and Installation of Leaf Spring Assembly...5058
Leaf Spring Assembly...5064
Group 35 - Brake...5066
Group 35C - Anti-Lock Brake System (ABS) '99 Minor Change...5067
Table of Contents...5068
Specifications...5069
Structure and Operation...5069
On-Vehicle Inspection and Adjustment...5087
Periodic Inspection Procedures...5087
Adjustment of Wheel Speed Sensor Clearance...5089
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope...5091
Troubleshooting...5092
Troubleshooting Procedures...5092
Troubleshooting Flowchart...5093
Tester...5095
Procedure of Inspection Using MUT-II...5097
Procedure of Inspection Using Diagnosis Switch...5103
Wheel Speed Sensor and Rotor...5107
'Front Axle'...5107
'Rear Axle'...5125
Control Valve...5146
Electric Circuit and Part Installation Locations...5147
Group 35A - Brake 'Air Over Hydraulic Brake'...5149
Table of Contents...5150
Specifications...5151
Structure and Operation...5153
Troubleshooting...5181
Inspection and Adjustment Mounted In Vehicle...5183
Replacement of Brake Fluid...5183
Air Bleeding of Brake System...5185
Inspection and Adjustment of Brake Pedal Free Play...5187
Thickness Inspection and Replacement of Brake Lining...5188
Inspection of Brake Shoe Clearance...5188
Inspection and Maintenance of Air Dryer...5189
Handling of Connector...5191
Brake Pedal...5193
Dual Brake Valve...5195
Brake Booster (Airmaster)...5202
Front Wheel Brake...5209
Rear Wheel Brake...5219
Air Compressor...5229
Air Dryer...5237
Air Pressure Governor...5241
Fluid Tank...5243
Check Valve / Safety Valve...5244
Supply Valve...5245
Exhaust Brake System...5247
Group 35B - Brake 'Full Air Brake'...5251
Table of Contents...5252
Specifications...5253
Structure and Operation...5254
Troubleshooting...5275
Inspection and Adjustment Mounted In Vehicle...5279
Inspection and Adjustment of Brake Pedal Free Play...5279
Thickness Inspection and Replacement of Brake Lining...5279
Inspection of Automatic Slack Adjuster Function...5280
Inspection and Maintenance of Air Dryer...5282
Handling of Connector...5283
Brake Pedal...5285
Dual Brake Valve...5287
Relay Valve...5295
Quick Release Valve...5297
Front Wheel Brake...5299
Rear Wheel Brake...5311
Air Compressor...5325
Air Dryer...5333
Air Pressure Governor...5337
Check Valve / Safety Valve...5339
Supply Valve...5341
Exhaust Brake System...5343
Group 36 - Parking Brake...5347
Group 36A - Parking Brake 'Center Parking Brake'...5348
Table of Contents...5349
Specifications...5350
Structure and Operation...5350
Troubleshooting...5352
Inspection and Adjustment Mounted In Vehicle...5353
Adjustment of Parking Brake Shoe Clearance and Lever Stroke...5353
Parking Brake Control...5354
Parking Brake Assembly...5356
Support Plate and Shoe Assembly...5360
Group 36B - Parking Brake 'Wheel Parking Brake'...5362
Table of Contents...5363
Structure and Operation...5364
Troubleshooting...5369
Parking Brake Control Valve...5370
Spring Brake Valve...5372
Double Check Valve...5375
Group 37 - Steering...5376
Table of Contents...5377
Specifications...5378
Structure and Operation...5379
Troubleshooting...5386
Inspection and Adjustment Mounted In Vehicle...5389
Change of Power Steering Fluid...5389
Bleeding of Power Steering System...5389
Steering Wheel Play...5390
Performance Verification Test of Power Steering System...5391
Steering System...5392
Linkage and Bracket...5396
Power Steering Booster...5398
Power Steering Oil Pump...5410
Power Steering Oil Tank...5414
Power Steering Fluid Line...5415
Drag Link...5416
Tie Rod Assembly...5418
Group 41 - Frame...5421
Table of Contents...5422
Specifications...5423
Structure and Operation...5423
Inspection and Repair of Frames...5423
Group 42 - Cab...5428
Table of Contents...5429
Specifications...5430
Structure and Operation...5432
Troubleshooting...5445
Inspection and Adjustment Mounted In Vehicle...5450
Adjustment of Cab Tilt...5450
Adjustment of Cab Tilt Lock Switch...5451
Adjustment of Door Fitting...5452
Removal and Installation of Cab...5454
Front Cab Mounting...5462
Rear Cab Mounting...5465
Cab Tilt Link...5466
Door...5470
Cab Exterior Fitting...5476
Mirror...5482
Wiper and Washer...5484
Cab Interior Fitting...5488
Instrument Panel...5494
Window Glass...5498
Group 54 - Electrical...5501
Table of Contents...5502
Connector Configuration Chart...5504
1-Power, Charging and Ground...5524
Specifications...5525
Structure and Operation...5526
Troubleshooting...5530
100-Inspection and Adjustment Mounted In Vehicle...5531
Inspection of Alternator...5531
Inspection of Regulator...5532
101-Battery...5533
104-Fuse...5537
106-Alternator...5539
110-Power Circuit...5545
115-Reserve Power Circuit...5555
125-Battery Charging Circuit...5557
130-Ground...5559
2-Starting, Preheating and Stopping Engine...5567
Specifications...5568
Structure and Operation...5570
Troubleshooting...5582
200-Inspection and Adjustment Mounted In Vehicle...5584
Inspection of Engine Preheating System...5584
201-Starter...5585
210-Engine Starting Circuit...5596
212-Sub-Starter Circuit...5600
215-Engine Stopping Circuit...5604
220-Engine Preheating and Cold Start Circuit...5608
'Manual Transmission'...5608
'Automatic Transmission'...5612
3-Lighting...5615
Specifications...5616
Structure and Operation...5618
Troubleshooting...5620
300-Inspection and Adjustment Mounted In Vehicle...5622
Headlamp Aiming...5622
310-Headlamp Circuit...5624
320-Tail Lamp, Clearance Lamp and License Plate Lamp Circuits...5626
325-Stop Lamp Circuit...5628
330-Turn Signal Lamp and Hazard Lamp Circuits...5632
340-Backup Lamp Circuit...5634
345-Cab Lamp Circuit...5638
348-Illumination Lamp Circuit...5642
349-Marker Lamp and Identification Lamp Circuits...5644
352-Van Body Dome Light Circuit...5646
4-Meter...5648
Specifications...5649
Troubleshooting...5650
401-Meter Cluster...5651
410-Speedometer and Tachometer Circuits...5657
420-Fuel Gauge Circuit...5659
425-Water Temperature Gauge Circuit...5663
5-Indicator and Warning...5665
Troubleshooting...5666
500-Inspection and Adjustment Mounted In Vehicle...5671
Inspection of Brake Fluid Level Switch 'Air Over Hydraulic Brake'...5671
510-Parking Brake Indicator Circuit...5672
'Center Parking Brake'...5672
'Wheel Parking Brake'...5674
515-Brake Warning Circuit...5678
530-Water Level Warning Circuit...5682
536-Engine Oil Pressure Warning Circuit...5686
537-Overheating Warning Circuit...5688
547-Automatic Transmission Fluid Temperature Warning Circuit...5690
548-Transmission High/Low Indicator Circuit '10-speed transmission'...5694
550-Cab Tilt Warning Circuit...5696
6-Cab Side Electrics...5698
Specifications...5699
Troubleshooting...5699
601-Switch...5701
604-Relay and Control Unit...5705
606-Warning Buzzer...5708
610-Cigarette Lighter Circuit...5709
612-Audio Circuit...5711
614-Wiper and Washer Circuit...5713
616-Horn Circuit...5717
618-Heater Circuit...5719
7-Chassis Electrics...5722
701-Magnetic Valve...5723
710-Exhaust Brake Circuit 'Manual Transmission'...5725
718-Air Dryer Circuit...5729
8-Engine and Transmission Electrics...5732
801-Engine Electrics...5733
802-Transmission Electrics...5737
'Manual Transmission (5-Speed, 6-Speed Transmission)'...5737
'Manual Transmission (10-speed Transmission)'...5739
'Automatic Transmission'...5741
850-Transmission Power Take-Off Circuit 'Option'...5743
9-Others...5745
Structure and Operation...5746
910-Multipurpose Timing Control Unit Circuit...5750
Group 55 - Air Conditioner and Heater...5752
Group 55A - Air-Conditioner...5753
Foreword/Table of Contents...5754
Specifications...5755
Outlines of Refrigeration System...5756
Construction...5758
Troubleshooting...5765
Removal and Installation...5772
Treatment After Installation...5775
Maintenance...5781
Cooling Unit Assembly...5782
Compressor & Clutch Assembly...5784
Group 55B - Heater...5787
Table of Contents...5788
Specifications...5789
Structure and Operation...5789
Troubleshooting...5795
Heater Hose...5797
Heater Control...5799
Air Duct...5802
Heater Unit and Blower...5803
Air Outlet Ventilation...5804
Mitsubishi Fuso FE.FG.FK.FM Series Repair Service Manual 1996-2001
