Mitsubishi Fuso FE.FG.FK.FM Series Repair Service Manual 2005

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Price: US$ 35.00

Complete service repair manual with Electrical Wiring Diagrams for 2005 Mitsubishi Fuso FE.FG.FK.FM Series , with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

official 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 2005 Service Manual (TWME0404&TWSE0405).pdf

PRODUCT DETAILS:
Total Pages: 3,143 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
2005 Service Manual....1
  2005 FE/FG Service Manual....2
    Group 00 - General....3
      Table of Contents....4
      Equipment Type Codes List....5
      Power Train Table....6
      How to Read this Manual....7
      Chassis Number, Engine Number, Power Train Label....13
      Vehicle Identification Number....14
      Precautions for Maintenance Operation....15
      Jacking Up the Vehicle....27
      Diagnosis Codes....29
        1. Connecting Multi-Use Tester....29
        2. Accessing/Erasing Diagnosis Codes 'Common Rail, Exhaust Gas Recirculation, Pre-heater'....33
        3. Accessing/Erasing Diagnosis Codes 'Automatic Transmission'....35
        4. Accessing/Erasing Diagnosis Codes 'Anti-lock Brake System'....37
      Table of Standard Tightening Torques....39
    Group 01 - Maintenance Schedule....42
      Table of Contents....43
      How to Read the Maintenance Schedule Tables....44
      Maintenance Schedule Tables....46
      Maintenance Operations....50
      Lubrication Tables....56
      Lubrication....58
    Group 11 - Engine....62
      Table of Contents....63
      Specifications....64
      Structure and Operation....65
        1. Exploded View....65
        2. Cylinder Head, Cylinder Head Gasket, Camshaft, and Camshaft Frame....66
        3. Valve Mechanism....67
        4. Connecting Rod....68
        5. Piston....68
        6. Timing Gears....69
        7. Flywheel....69
        8. Balance Shafts....70
        9. Crankcase and Main Bearings....71
        10. Oil Seals....73
      Troubleshooting....74
      On-Vehicle Inspection and Adjustment....76
        1. Measuring Compression Pressure....76
        2. Inspection and Adjustment of Valve Clearance....78
      Engine Removal and Installation....80
        'Tilt Cab'....80
        'Fixed Cab'....88
      Rocker Cover....90
      Rockers and Camshafts....92
      Cylinder Head and Valve Mechanism....104
      Pistons, Connecting Rod and Cylinder Liners....118
      Flywheel....132
      Front Case....136
      Timing Gears and Balance Shafts....138
      Crankshaft and Crankcase....146
      Balance Shaft Bushings....154
    Group 12 - Lubrication....159
      Table of Contents....160
      Specifications....161
      Structure and Operation....162
        1. Lubrication System....162
        2. Oil Pump....163
        3. Oil Cooler....164
        4. Oil Filter....165
        5. Lubrication of Engine Components....166
      Troubleshooting....169
      On-Vehicle Inspection and Adjustment....171
        1. Oil Filter Replacement....171
        2. Engine Oil Replacement....175
        3. Oil Pressure Measurement....177
      Oil Pan, Oil Strainer and Oil Jets....179
      Oil Pump....181
      Oil Filter....185
      Oil Cooler....189
    Group 13 - Fuel and Engine Control....191
      Group 13A - Fuel and Engine Control....192
        Table of Contents....193
        Specifications....194
        Structure and Operation....195
          1. Fuel System (Flow of Fuel)....195
          2. Engine Control....196
          3. Fuel Filter....197
        Troubleshooting....198
        On-Vehicle Inspection and Adjustment....200
          1. Inspecting and Adjusting No-load Minimum and Maximum Speeds....200
          2. Air-bleeding of Fuel System....201
          3. Fuel Filter Replacement....202
        Fuel Tank....204
        Fuel Filter....206
        Engine Control....208
        Common Rail....211
        Supply Pump....212
        Injector....214
      Group 13E - Electronically Controlled Fuel System....216
        Table of Contents....217
        Specifications....218
        Structure and Operation....219
          1. Overview....219
          2. Electronic Control System....228
          3. Electronic Control Unit Connection Diagram....234
        Troubleshooting....236
          1. Inspection Procedure....236
          2. Cautions to Observe when Performing Inspections....237
          3. Inspection Based on Diagnosis Codes....238
          4. Multi-Use Tester Service Data....252
          5. Actuator Tests Performed Using Multi-Use Tester....254
          6. Inspections Performed at Electronic Control Unit Connectors....256
        Inspection of Electrical Equipment....259
        Installed Locations of Parts....266
        Electric Circuit Diagram....272
    Group 14 - Cooling....278
      Table of Contents....279
      Specifications....280
      Structure and Operation....282
        1. Cooling System (Flow of Coolant)....282
        2. Thermostat....283
        3. Water Pump....283
      Troubleshooting....284
      On-Vehicle Inspection and Adjustment....286
        1. Coolant Replacement and Cleaning of Cooling System....286
        2. Air Bleeding of Cooling System....288
        3. Air/Gas Leakage Test....288
      Disconnection and Connection of Hoses and Pipes....290
      Radiator....294
      Cooling Fan, V-Belt and Water Pump....302
      Tension Pulley....305
      Thermostat....306
      Pressure Cap and Water Outlet Case....308
    Group 15 - Intake and Exhaust....310
      Table of Contents....311
      Specifications....312
      Structure and Operation....312
        1. Air Cleaner....312
        2. Turbocharger....313
        3. Muffler....314
      Troubleshooting....315
      On-Vehicle Inspection and Adjustment....316
        1. Measurement of Turbocharger Boost Pressure....316
      Air Duct and Air Cleaner 'Except Crew Cab'....318
      Air Duct and Air Cleaner 'Crew Cab'....322
      Turbocharger....326
      Intercooler....332
      Intake Manifold....334
      Exhaust Manifold....335
      Exhaust Pipe....336
      Muffler....338
    Group 17 - Emission Control....339
      Table of Contents....340
      Structure and Operation....341
        1. Exhaust Gas Recirculation System....341
        2. Crankcase Emission Control System....346
      Exhaust Gas Recirculation System....347
        1. Inspection Procedure....347
        2. Cautions to Observe when Performing Inspections....348
        3. Inspections Based on Diagnosis Codes....349
        4. Multi-Use Tester Service Data....351
        5. Actuator Tests Performed Using Multi-Use Tester....351
        6. Inspections Performed at Electronic Control Unit Connectors....352
        7. Inspection of Electrical Equipment....353
        8. Installed Locations of Parts....354
        9. Electric Circuit Diagram....359
      Exhaust Gas Recirculation Valve, Pipe and Cooler....363
      Crankcase Emission Control System....365
    Group 21 - Clutch....367
      Table of Contents....368
      Specifications....369
      Structure and Operation....370
        1. Clutch Control....370
        2. Clutch Master Cylinder....371
        3. Clutch Proper and Clutch Direct Power Cylinder....373
      Troubleshooting....375
      On-Vehicle Inspection and Adjustment....377
        1. Replacement of Brake Fluid (Clutch System)....377
        2. Air Bleeding of Brake Fluid (Clutch System)....379
        3. Inspection of Clutch Disk Wear Limit....381
      Clutch Pedal....383
      Clutch Master Cylinder....387
      Clutch Proper....389
      Clutch Control....393
    Group 22 - Manual Transmission....398
      Table of Contents....399
      Specifications....400
      Structure and Operation....402
        1. Transmission....402
        2. Synchromesh Mechanism....404
        3. Interlock Mechanism....407
        4. Speedometer Gear Bushing....407
      Troubleshooting....408
      On-Vehicle Inspection and Adjustment....410
        1. Inspection and Replacement of Transmission Oil....410
      Removal and Installation of Transmission Assembly....412
      Gear Shifter Upper....414
      Rear Cover 'S5' and Parking Brake....420
      Extension Housing 'S6' and Parking Brake....424
      Reverse Idler Gear....428
      6th Gear 'S6'....432
      Transmission Body....438
      Drive Pinion....454
      Mainshaft....456
      Countershaft....466
      Transmission Control....468
      Bearing Puller and Installer....473
    Group 23 - Automatic Transmission....474
      Table of Contents....475
      Specifications....476
      Structure and Operation....477
        1. Overview....477
        2. Electronic Control System....488
        3. Electronic Control Unit Connection Diagram....494
      Troubleshooting....496
        1. Inspection Procedure....496
        2. Cautions to Observe When Performing Inspections....497
        3. Inspections Based on Diagnosis Codes....498
        4. Multi-Use Tester Service Data....507
        5. Inspections Performed at Electronic Control Unit Connectors....510
        6. Likely Causes of Symptoms....513
      On-Vehicle Inspection and Adjustment....518
        1. Stall Test....518
        2. Time Lag Test....519
        3. Line Pressure Test....520
        4. Road Test....522
        5. Inspection of ATF....523
        6. Replacement of ATF....524
        7. Dealer Adjust....526
      Removal and Installation of Automatic Transmission....530
      Automatic Transmission Control....538
      Oil Cooler....546
        'Models Except Crew Cab'....546
        'Crew Cab'....548
      Replacement of Parts of Automatic Transmission Main Body....550
      Inspection of Electrical Equipment....554
      Installed Locations of Parts....558
      Electric Circuit Diagram....562
    Group 24 - Transfer....568
      Table of Contents....569
      Specifications....570
      Structure and Operation....571
        1. Transfer....571
        2. Speedometer Gear Bushing....572
      Troubleshooting....573
      On-Vehicle Inspection and Adjustment....574
        1. Inspection and Replacement of Transfer Oil....574
      Removal and Installation of Transmission (with Transfer)....576
      Removal and Installation of Transfer....578
      Front Drive....580
      Rear Drive....584
      Transfer....590
      Transfer Control....598
    Group 25 - Propeller Shaft....602
      Table of Contents....603
      Specifications....604
      Structure and Operation....604
        1. Configuration of Propeller Shaft Connection....604
        2. Propeller Shaft 'without Center Bearing'....605
        3. Propeller Shaft 'with Center Bearing'....606
      Troubleshooting....607
      Removal and Installation of Propeller Shaft 'Between T/M (or T/F) and Rear Axle....608
      Removal and Installation of Propeller Shaft 'Between Front Axle and T/F'....612
      Propeller Shaft 'P2'....614
      Propeller Shaft 'P3'....620
    Group 26 - Front Axle....630
      Group 26A - Front Axle 'FE'....631
        Table of Contents....632
        Specifications....633
        Structure and Operation....634
          1. Wheel Hub and Rotor....634
          2. Knuckle and Kingpin, Front Axle....635
        Troubleshooting....636
        On-Vehicle Inspection and Adjustment....637
          1. Inspection and Adjustment of Wheel Alignment....637
          2. Inspection and Adjustment of Steering Angle....641
          3. Inspection of Side Slip....642
          4. Inspection of Play in Tie Rod End Ball Joint....642
        Wheel Hub and Rotor....643
        Knuckle and Kingpin, Front Axle....651
        Tie Rod....659
      Group 26B - Front Axle 'FG'....661
        Table of Contents....662
        Specifications....663
        Structure and Operation....663
          1. Wheel Hub and Brake Drum....663
          2. Free Wheel Hub....664
          3. Drive Shaft and Steering Knuckle, Axle Housing....665
          4. Reduction and Differential....666
        Troubleshooting....667
        On-Vehicle Inspection and Adjustment....671
          1. Inspection and Adjustment of Wheel Alignment....671
          2. Inspection and Adjustment of Steering Angle....675
          3. Inspection of Side Slip....675
          4. Inspection of Play at Tie Rod End Ball Joint....676
          5. Inspection and Replacement of Axle Oil....676
        Wheel Hub and Brake Drum....679
        Drive Shaft and Steering Knuckle....689
        Tie Rod....695
        Axle Housing....697
        Reduction and Differential....699
    Group 27 - Rear Axle....714
      Table of Contents....715
      Specifications....716
      Structure and Operation....717
        1. Wheel Hub and Rotor....717
        2. Wheel Hub and Brake Drum....718
        3. Reduction and Differential....719
        4. Limited Slip Differential....720
      Troubleshooting....722
      On-Vehicle Inspection and Adjustment....724
        1. Inspection and Replacement of Axle Oil....724
      Wheel Hub and Rotor....726
      Wheel Hub and Brake Drum....736
      Axle Housing....746
      Reduction and Differential....750
    Group 31 - Wheel and Tire....777
      Table of Contents....778
      Specifications....779
      Troubleshooting....780
      Wheel and Tire....781
    Group 33 - Front Suspension....786
      Table of Contents....787
      Structure and Operation....788
        1. Front Suspension Elements....788
      Troubleshooting....789
      Stabilizer 'FE'....790
      Shock Absorber 'FE'....792
      Shock Absorber 'FG'....794
      Leaf Spring 'FE'....796
      Leaf Spring 'FG'....800
    Group 34 - Rear Suspension....804
      Table of Contents....805
      Structure and Operation....806
        1. Rear Suspension Elements....806
      Troubleshooting....807
      Shock Absorber....808
      Leaf Spring....810
      Stabilizer....828
    Group 35 - Brake....831
      Group 35A - Brake....832
        Table of Contents....833
        Specifications....834
        Structure and Operation....836
          1. Brake System....836
          2. Vacuum Pump....839
          3. Vacuum Booster and Brake Master Cylinder....840
          4. Hydraulic Booster and Brake Master Cylinder....846
          5. Flow Priority Valve....852
          6. Front Disc Brake....853
          7. Front Drum Brake....854
          8. Rear Disc Brake....857
          9. Rear Drum Brake....858
          10. Exhaust Brake System....859
        Troubleshooting....862
        On-Vehicle Inspection and Adjustment....866
          1. Replacement of Brake Fluid....866
          2. Air Bleeding of Brake System....868
          3. Inspection and Adjustment of Brake Pedal Free Play....872
          4. Inspection and Adjustment of Brake Pedal Depressed Height from Floor....872
          5. Inspection of Brake Pedal Full Stroke and Adjustment of Installed Height of Brake Pedal....873
          6. Inspection and Replacement of Disc Brake Pad....874
          7. Measurement of Disc Brake Drag Torque....877
          8. Inspection of Drum Brake Lining Thickness....877
          9. Initial Setting of Clearance between Brake Drum and Shoe....878
          10. Inspection of Check Valve in Vacuum Line Hose....879
          11. Inspection of Vacuum Pump....879
          12. Inspection of Vacuum Booster....880
          13. Inspection of Hydraulic Booster....887
        Vacuum Pump....890
        Brake Master Cylinder 'with Vacuum Booster'....892
        Brake Master Cylinder 'with Hydraulic Booster'....896
        Brake Pedal & Vacuum Booster, Hydraulic Booster....898
        Front Disc Brake '235 mm {9.25 in.} Disc'....900
        Front Disc Brake '252 mm {9.92 in.} Disc'....904
        Front Drum Brake....908
        Rear Disc Brake '235 mm {9.25 in.} Disc'....914
        Rear Disc Brake '252 mm {9.92 in.} Disc'....916
        Rear Drum Brake....918
        Exhaust Brake System....924
      Group 35E - Anti-lock Brake System (ABS)....926
        Table of Contents....927
        Specifications....928
        Structure and Operation....930
          1. Overview....930
          2. Electronic Control System....940
          3. Electronic Control Unit Schematic Diagram....944
        Troubleshooting....946
          1. Diagnosis Procedure....946
          2. Precautions when Carrying Out Diagnosis....947
          3. Diagnosis Based on Diagnosis Codes....948
          4. Multi-Use Tester Service Data....954
          5. Actuator Test Using Multi-Use Tester....956
          6. Inspection at Hydraulic Unit (Electronic Control Unit) Connector....957
        On-Vehicle Inspection and Adjustment....960
          1. Functional Check....960
          2. Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope....961
          3. Inspection of Hydraulic Unit (Electronic Control Unit) Operation....962
          4. Inspection after Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)....963
        Hydraulic Unit Connector Coupling and Uncoupling....964
        Inspection of Electrical Components....966
        Components Location....970
        Electrical Wiring Diagram....974
    Group 36 - Parking Brake....976
      Table of Contents....977
      Specifications....978
      Structure and Operation....979
        1. Components and Parts....979
        2. Parking Brake Lever....979
        3. Parking Brake....980
      Troubleshooting....981
      On-Vehicle Inspection and Adjustment....982
        1. Inspection and Adjustment of Parking Brake Shoe Clearance....982
        2. Inspection and Adjustment of Parking Brake Lever....983
      Parking Brake Control....986
      Parking Brake....990
        'FE (Manual Transmission)'....990
        'FE (Automatic Transmission)'....992
        'FG'....994
    Group 37 - Steering....996
      Table of Contents....997
      Specifications....998
      Structure and Operation....1000
        1. Steering System....1000
        2. Oil Flow....1000
        3. Power Steering Gear (Backlash Compensation Mechanism)....1001
        4. Power Steering Oil Pump 'Kayaba Industry Product'....1002
        5. Power Steering Oil Pump 'Unisia JKC Product'....1004
      Troubleshooting....1006
      On-Vehicle Inspection and Adjustment....1008
        1. Change of Power Steering Fluid....1008
        2. Bleeding of Power Steering System....1009
        3. Performance Verification Test of Power Steering System....1010
        4. Steering Wheel Play....1011
        5. Steering Column Looseness....1011
        6. Drag Link Ball Joint Backlash....1011
      Steering Column....1012
      Power Steering Gear and Drag Link....1022
      Power Steering Oil Pump 'Kayaba Industry Product'....1044
      Power Steering Oil Pump 'Unisia JKC Product'....1048
      Power Steering Oil Tank....1052
    Group 41 - Frame....1054
      Table of Contents....1055
      Specifications....1056
      Structure and Operation....1057
      Frame....1058
    Group 42 - Cab....1062
      Table of Contents....1063
      Specifications....1064
      Structure and Operation....1065
        1. Front Cab Mounting....1065
        2. Rear Cab Mounting 'Except Crew Cab'....1066
        3. Center and Rear Cab Mountings 'Crew Cab'....1066
        4. Cab Tilt Link 'Except Crew Cab'....1067
      Troubleshooting....1068
      On-Vehicle Inspection and Adjustment....1070
        1. Adjustment of Cab Tilt System 'Except Crew Cab'....1070
      Removal and Installation of Cab....1072
        'Except Crew Cab'....1072
        'Crew Cab'....1076
      Front Cab Mounting....1080
        'Except Crew Cab'....1080
        'Crew Cab'....1082
      Rear Cab Mounting 'Except Crew Cab'....1084
      Center and Rear Cab Mountings 'Crew Cab'....1085
      Cab Tilt Link 'Except Crew Cab'....1086
      Cab Stay 'Except Crew Cab'....1088
    Group 43 - Door....1089
      Table of Contents....1090
      Specifications....1091
      Structure and Operation....1092
        1. Front Door Lock System....1092
        2. Rear Door Lock System 'Crew Cab'....1092
        3. Front Door Glass Opening and Closing Mechanism....1093
        4. Rear Door Glass Opening and Closing Mechanism 'Crew Cab'....1095
      Troubleshooting....1097
      On-Vehicle Inspection and Adjustment....1099
        1. Adjustment of Front Door Alignment....1099
        2. Adjustment of Rear Door Alignment 'Crew Cab'....1102
      Front Door....1105
      Rear Door 'Crew Cab'....1113
    Group 51 - Exterior....1119
      Table of Contents....1120
      Structure and Operation....1121
        1. Wiper and Washer System....1121
      Troubleshooting....1122
      Mirror....1123
      Wiper and Washer....1125
      Front Cover....1127
      Front Grille, Front Corner Panel and Headlamp....1129
      Fender....1133
      Step....1135
      Garnish 'Crew Cab'....1137
      Wheel House....1138
      Window Glass....1139
    Group 52 - Interior....1142
      Table of Contents....1143
      Seat....1144
        'Driver'....1144
        'Passenger'....1146
        'Rear'....1148
      Seat Belt....1150
      Instrument Panel....1156
      Trim and Scuff Plate....1176
        'Except Crew Cab'....1176
        'Crew Cab'....1180
      Head Lining....1182
        'Except Crew Cab'....1182
        'Crew Cab'....1184
    Group 54 - Electrical....1186
      Table of Contents....1187
      How to Read this Group....1190
      54-00 - General....1194
        Precautions for Maintenance Operation....1195
        Specifications....1205
        Structure and Operation....1208
          1. Starter....1208
          2. Alternator....1209
          3. Headlamps....1212
          4. Meter Cluster....1213
          5. Daytime Running Light System....1221
          6. Wiper Control....1223
          7. Starter Continuous Energizing Preventing Function and Preheating Function....1225
        Troubleshooting....1229
      54-01 - Power, Charge and Ground Circuit....1236
        High-Current Fuse Box....1237
        Fuse Box....1239
        110 - Power Circuit....1241
        115 - Reserve Power Circuit....1251
        125 - Battery Charging Circuit....1252
        130 - Ground....1253
      54-02 - Starting Circuit....1268
        210 - Engine Starting Circuit....1269
        220 - Engine Preheating Circuit....1271
      54-03 - Lighting Circuit....1272
        310 - Headlamp Circuit....1273
        313 - Daytime Running Light Circuit....1275
        320 - Tail, Clearance and License Plate Lamps Circuit....1277
        325 - Stop Lamp Circuit....1278
        330 - Turn Signal and Hazard Lamp Circuit....1279
        340 - Backup Lamp Circuit....1281
        345 - Cab Lamp Circuit....1283
        348 - Illumination Lamp Circuit....1285
        349 - Identification Lamp and Side Marker Lamp Circuit....1286
        352 - Van Body Dome Light Circuit....1287
      54-04 - Meter Circuit....1288
        401 - Meter Cluster Internal Circuit....1289
        412 - Speedometer Circuit....1290
        420 - Fuel Gauge Circuit....1291
        425 - Water Temperature Gauge Circuit....1292
      54-05 - Indicator and Warning Lamp Circuit....1293
        510 - Parking Brake Indicator Circuit....1294
        515 - Brake Warning Circuit....1296
        535 - Engine Oil Level Warning Circuit....1298
        536 - Engine Oil Pressure Warning Circuit....1299
        537 - Overheating Warning Circuit....1300
        540 - Brake Pad Warning Circuit....1301
        550 - Cab Tilt Warning Circuit....1302
        566 - Fuel Filter Warning Circuit....1303
      54-06 - Cab Side Electrical Circuit....1304
        610 - Cigarette Lighter Circuit....1305
        612 - Audio Circuit....1306
        614 - Wiper and Washer Circuit....1307
        616 - Horn Circuit....1308
        620 - Air-Conditioner Circuit....1309
        622 - Power Window and Auto Door Lock Circuit....1311
        629 - Mirror Heater Circuit....1312
      54-07 - Chassis Side Electrical Circuit....1313
        710 - Exhaust Brake Circuit....1314
      54-08 - Engine and Transmission Side Electrical Circuit....1316
        810 - Four-Wheel Drive Circuit 'FG'....1317
        850 - Transmission Power Take-Off Circuit....1318
      54-09 - Other Circuit....1319
        905 - Joint Connector (J/C)....1320
        907 - Diagnosis Switch, Memory Clear Switch....1325
      54-10 - Parts Installation Positions....1326
        A - Switch....1327
        B - Relay and Electronic Control Unit....1330
        C - Fuse, Meter, Sensor, Buzzer, Motor and Actuator....1331
        D - Air-Conditioner 'Option'....1332
        E - Door....1333
        F - Roof....1334
        J - Joint of Main Harness Connectors....1335
        R - Engine....1337
        S - Transmission....1338
        T - Switch and Sensor....1341
        U - Fuse and Connector....1342
        V - Magnetic Valve and Motor....1344
        W - Buzzer and Connector....1344
      54-11 - Inspection of Parts....1345
        #001 to #179 - Switch....1346
        #180 to #249 - Relay....1352
        #250 to #349 - Sensor....1354
        #350 to #409 - Control Unit....1355
        #410 to #509 - Motor....1356
        #510 to #539 - Actuator....1357
        #560 to #609 - Magnetic Valve....1358
        #610 to #649 - Buzzer, Horn....1359
        #650 to #699 - Lamp....1361
        #750 to #859 - Other....1362
        #860 - Battery....1364
      54-12 - Starter adn Alternator....1367
        #930 - Starter....1368
        #940 - Alternator....1382
      54-13 - On-Vehicle Inspection and Adjustment....1390
        #950 - Inspection of Alternator....1391
        #951 - Inspection of Regulator....1392
        #955 - Inspection of Preheating System....1393
        #956 - Inspection of Starter Continuous Energizing Preventing Function....1397
        #960 - Headlamp Aiming....1401
      54-14 - Connector Configuration Chart....1403
        Connector Configuration Chart....1404
    Group 55 - A/C & Heater....1472
      Group 55A - Air-Conditioner....1473
        Table of Contents....1474
        Specifications....1475
        Structure and Operation....1477
          1. Air-Conditioner System....1477
          2. Engine Room....1478
          3. Cabin Room....1479
          4. Compressor....1480
          5. Magnetic Clutch....1481
          6. Check Valve....1481
          7. Side Condensor Assembly....1482
          8. Relief Valve....1482
          9. Receiver Assembly....1483
          10. Evaporator Assembly....1483
          11. Expansion Valve....1484
          12. Dual Pressure Switch....1484
          13. Power Relay....1485
          14. Air-Conditioner Switch....1485
          15. Thermostat....1485
          16. Control System....1487
        Troubleshooting....1489
        On-Vehicle Inspection and Adjustment....1491
          1. Recovery of Refrigerant....1491
          2. Inspection and Adjustment of V-Belt....1491
          3. Inspection of Magnetic Clutch....1492
          4. Recharging the System with Refrigerant....1493
          5. Checking Refrigerant Charge Level....1495
          6. Adding Refrigerant....1496
          7. Inspection of Receiver Assembly....1497
          8. Inspection of Dual Pressure Switch....1497
        Connecting Air-Conditioner Piping....1498
        Compressor....1499
        Condenser, Receiver....1501
        Cooling Unit....1503
        Air-Conditioner Circuit....1505
      Group 55B - Heater....1506
        Table of Contents....1507
        Specifications....1508
        Structure and Operation....1510
          1. Heater....1510
          2. Air Duct....1511
          3. Heater Control....1512
        Troubleshooting....1516
        Heater Control....1518
        Air Duct....1522
        Heater Unit, Blower....1524
  2005 FK/FM Service Manual....1526
    Group 00 - General....1527
      Table of Contents....1528
      Model Coding System....1529
      Power Train Table....1531
      Chassis Number and Engine Number....1533
      Power Train Label....1533
      Vehicle Identification Number....1534
      Precautions for Maintenance Operation....1535
      Diagnosis Codes....1547
        1. Connecting Multi-Use Tester....1547
        2. Accessing/Erasing Diagnosis Codes 'Common Rail, Exhaust gas recirculation, Pre-heater'....1551
        3. Accessing/Erasing Diagnosis Codes 'Auto Cruise'....1553
        4. Accessing/Erasing Diagnosis Codes 'Anti-lock Brake System'....1555
      Table of Standard Tightening Torques....1557
      Connector Configuration Chart....1561
    Group 01 - Maintenance Schedule....1629
      Table of Contents....1630
      How to Read the Maintenance Schedule Tables....1631
      Maintenance Schedule Tables....1632
      Maintenance Operations....1638
      Lubrication Tables....1644
      Lubrication....1645
    Group 11 - Engine....1648
      Table of Contents....1649
      Specifications....1650
      Structure and Operation....1651
        1. Engine Proper....1651
        2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket....1652
        3. Valve Mechanism....1653
        4. Connecting Rods....1653
        5. Pistons....1654
        6. Timing Gears....1654
        7. Flywheel....1656
      Troubleshooting....1657
      On-Vehicle Inspection and Adjustment....1658
        1. Measuring Compression Pressure....1658
        2. Inspecting and Adjusting Valve Clearance....1662
      Engine Removal and Installation....1666
      Rocker Cover, Rocker and Bracket Assembly, Camshaft....1668
      Cylinder Head, Valve Mechanism....1678
      Pistons, Connecting Rods and Cylinder Liners....1696
      Flywheel....1710
        'Manual Transmission'....1710
        'Automatic Transmission'....1716
      Timing Gears....1720
      Crankshaft and Crankcase....1726
    Group 12 - Lubrication....1735
      Table of Contents....1736
      Specifications....1737
      Structure and Operation....1738
        1. Lubrication System....1738
        2. Oil Pump....1739
        3. Oil Filter....1739
        4. Oil Cooler....1740
        5. Engine Oil Pressure Switch and Regulator Valve....1740
        6. Lubrication of Related Parts....1741
      Troubleshooting....1744
      On-Vehicle Inspection and Adjustment....1745
        1. Oil Filter Replacement....1745
        2. Engine Oil Replacement....1747
        3. Oil Pressure Measurement....1748
      Oil Pan and Oil Jet....1749
      Oil Pump and Oil Strainer....1751
      Oil Filter....1754
      Oil Cooler....1755
      Regulator Valve....1757
    Group 13 - Fuel and Engine Control....1758
      Group 13A - Fuel and Engine Control....1759
        Table of Contents....1760
        Specifications....1761
        Structure and Operation....1762
          1. Fuel System....1762
          2. Engine Control....1763
          3. Fuel Filter....1764
        Troubleshooting....1765
        On-Vehicle Inspection and Adjustment....1767
          1. Checking No-load Minimum and Maximum Speeds....1767
          2. Air Bleeding of Fuel System....1768
          3. Replacement of Fuel Filter....1769
        Engine Control....1771
        Fuel Tank....1774
        Fuel Filter....1775
        Common Rail Assembly....1777
        Supply Pump....1779
        Injector, Fuel Temperature Sensor....1783
      Group 13E - Electronically Controlled Fuel System....1785
        Table of Contents....1786
        'Common Rail System'....1787
          Specifications....1787
          Structure and Operation....1789
            1. Overview....1789
            2. Electronic Control System....1797
            3. Electronic Control Unit Connection Diagram....1803
          Troubleshooting....1805
            1. Inspection Procedure....1805
            2. Cautions to Observe When Performing Inspections....1806
            3. Inspections Based on Diagnosis Codes....1807
            4. Multi-Use Tester Service Data....1824
            5. Actuator Tests Performed Using Multi-Use Tester....1827
            6. Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit....1829
            7. Inspections Performed at Electronic Control Unit Connectors....1830
          Inspection of Electrical Equipment....1833
          Installed Locations of Parts....1841
          Electric Circuit Diagram....1847
        'Auto Cruise System'....1855
          Structure and Operation....1855
            1. General Description....1855
            2. Electronic Control System....1855
            3. Electronic Control Unit Connection Diagram....1859
          Troubleshooting....1861
            1. Inspection Procedure....1861
            2. Cautions to Observe When Performing Inspections....1862
            3. Inspection Based on Diagnosis Codes....1863
            4. Multi-Use Tester Service Data....1866
            5. Actuator Tests Performed using Multi-Use Tester....1867
            6. Inspections Performed at Electronic Control Unit Connectors....1868
          Inspection of Electrical Equipment....1869
          Installed Locations of Parts....1871
          Electric Circuit Diagram....1877
    Group 14 - Cooling....1878
      Table of Contents....1879
      Specifications....1880
      Structure and Operation....1880
        1. Cooling System (Coolant Flow)....1880
        2. Water Pump....1881
        3. Thermostat....1881
      Troubleshooting....1882
      On-Vehicle Inspection and Adjustment....1884
        1. Replacing Coolant and Cleaning Cooling System....1884
        2. Air Bleeding of Cooling System....1886
        3. Gas Leak Testing....1886
      Radiator and Fan Shroud....1888
      Cooling Fan and V-Belt....1896
      Water Pump....1900
      Thermostat....1908
    Group 15 - Intake and Exhaust....1910
      Table of Contents....1911
      Specifications....1912
      Structure and Operation....1913
        1. Air Cleaner....1913
        2. Turbocharger Assembly....1913
      Troubleshooting....1915
      On-Vehicle Inspection and Adjustment....1916
        Measurement of Turbocharger Boost Pressure....1916
      Air Duct....1918
      Air Cleaner....1920
      Turbocharger....1922
      Intercooler....1927
      Intake Manifold....1928
      Exhaust Manifold....1929
      Exhaust Pipe and Muffler....1930
    Group 17 - Emission Control....1932
      Table of Contents....1933
      Structure and Operation....1934
        1. Exhaust Gas Recirculation System....1934
        2. Crankcase Emission Control System....1938
      On-Vehicle Inspection and Adjustment....1939
        1. Replacement of PCV Valve Element....1939
      Exhaust Gas Recirculation System....1940
        1. Inspection Procedure....1940
        2. Cautions to Observe when Performing Inspections....1941
        3. Inspections Based on Diagnosis Codes....1942
        4. Multi-Use Tester Service Data....1944
        5. Actuator Tests Performed Using Multi-Use Tester....1944
        6. Inspection of Electrical Equipment....1944
      Installed Locations of Parts....1946
      Electric Circuit Diagram....1952
      Exhaust Gas Recirculation Valve, Exhaust Gas Recirculation Solenoid Valve, Exhaust Gas Recirculation Pipe, Exhaust Gas Recirculation Cooler....1956
      Crankcase Emission Control System....1960
    Group 21 - Clutch....1962
      Table of Contents....1963
      Specifications....1964
      Structure and Operation....1964
      Troubleshooting....1969
      On-Vehicle Inspection and Adjustment....1970
        Clutch Fluid (Brake Fluid) Replacement and Air Bleeding 'Clutch Power Cylinder'....1970
        Clutch Fluid (Brake Fluid) Replacement and Air Bleeding 'Clutch Booster'....1972
        Inspection of Function 'Clutch Booster'....1974
        Clutch Pedal Free Play 'Clutch Power Cylinder'....1975
        Clutch Pedal Free Play 'Clutch Booster'....1976
      Clutch Pedal 'M060S6, M070S6'....1978
      Clutch Pedal 'Eaton FS-8209'....1982
      Clutch Master Cylinder....1986
      Clutch Power Cylinder 'M060S6, M070S6'....1988
      Clutch Booster 'Eaton FS-8209'....1990
      Work Before Removal and Installation of Clutch Body....1998
      Clutch Body....2000
      Clutch Control 'M060S6, M070S6'....2016
      Clutch Control 'Eaton FS-8209'....2018
    Group 22 - Manual Transmission....2020
      Group 22A - Manual Transmission 'M060S6, M070S6'....2021
        Table of Contents....2022
        Specifications....2023
        Structure and Operation....2023
        Troubleshooting....2032
        Work Before Removal and Installation of Transmission Assembly....2033
        Removal and Installation of Transmission Assembly....2035
        Gear Shifter Upper and Interlock Plate....2038
        Power Shift Assembly....2043
        Extension Housing and Parking Brake Assembly....2049
        6th Gear and Reverse Idler Gear 'M060'....2053
        Reverse Gear and Reverse Idler Gear 'M070'....2061
        Transmission Body....2067
        Drive Pinion Assembly....2083
        Mainshaft Assembly 'Over-Drive (M060)'....2085
        Mainshaft Assembly 'Direct-Drive (M070)'....2093
        Countershaft Assembly....2105
        Transmission Control....2109
        Puller and Installer Kit....2113
      Group 22B - Manual Transmission 'M060S9 (Eaton FS-8209)'....2114
        Table of Contents....2115
        Specifications....2116
        Removal and Installation of Transmission Assembly....2118
        Transmission Control....2122
        High-Low Control....2126
    Group 23 - Automatic Transmission....2129
      Group 23A - Automatic Transmission 'M065A5 (Allison LCT1000, LCT2400)'....2130
        Table of Contents....2131
        Specifications....2132
        Structure and Operation....2136
          1. Outline....2136
          2. Electronic Control System....2140
          3. Electronic Control Unit Connection Diagram....2144
        Troubleshooting....2146
          1. Failure by Equipment....2146
          2. Measures for Transitory Failure....2152
        On-Vehicle Inspection and Adjustment....2154
          1. Stall Test....2154
          2. Line Pressure Test....2155
          3. Inspection of Automatic Transmission Fluid....2156
          4. Replacement of Automatic Transmission Fluid....2157
          5. Replacement of Oil Filter....2158
        Preparatory Work for Removal and Installation of Automatic Transmission Assembly....2159
        Removal and Installation of Automatic Transmission Assembly....2160
        Parking Brake Assembly....2162
        Oil Pan, Suction Filter and Level Gauge....2164
        Automatic Transmission Control....2166
        Oil Cooler....2174
        Inspection of Electrical Equipment....2176
        Installed Locations of Parts....2180
        Electric Circuit Diagram....2184
      Group 23B - Automatic Transmission 'M100A6 (Allison MD3060P)'....2188
        Table of Contents....2189
        Specifications....2190
        Structure and Operation....2192
          1. Automatic Transmission Assembly....2192
          2. Automatic Transmission Control System....2193
          3. Oil Cooler System....2194
        Troubleshooting....2195
        On-Vehicle Inspection and Adjustment....2200
          1. Stall Test....2200
          2. Line Pressure Test....2201
          3. Inspection of Automatic Transmission Fluid....2203
          4. Replacement of Automatic Transmission Fluid....2204
          5. Level Check of Automatic Transmission Fluid....2206
          6. Replacement of Oil Filter....2207
        Oil Cooler....2208
        Installed Locations of Parts....2210
        Electric Circuit Diagram....2214
    Group 25 - Propeller Shaft....2216
      Table of Contents....2217
      Specifications....2218
      Structure and Operation....2218
      Troubleshooting....2220
      Removal and Installation of Propeller Shaft....2222
      Rear Propeller Shaft....2224
        'P8'....2224
        'P10, P12'....2228
      Front Propeller Shaft....2232
        'P8'....2232
        'P10, P12'....2238
      Balancing Propeller Shaft....2243
    Group 26 - Front Axle....2245
      Table of Contents....2246
      Specifications....2247
      Structure and Operation....2247
      On-Vehicle Inspection and Adjustment....2253
        Adjustment of Wheel Alignment....2253
        Adjustment of Steering Angle....2257
        Measurement of Side Slip....2257
      Work Before Removal and Installation of Front Axle....2258
      Wheel Hub and Brake Drum....2259
        'FK'....2259
        'FM (Air-Over Hydraulic Brake)'....2273
        'FM (Full-Air Brake)'....2287
      Front Axle, Knuckle and Kingpin....2301
        'FK'....2301
        'FM (Air-Over Hydraulic Brake)'....2307
        'FM (Full-Air Brake)'....2315
    Group 27 - Rear Axle....2321
      Table of Contents....2322
      Specifications....2323
      Structure and Operation....2324
      Troubleshooting....2327
      Work Before Removal and Installation of Rear Axle....2329
      Wheel Hub and Brake Drum....2331
        'FK'....2331
        'FM'....2345
      Axle Housing....2361
      Reduction and Differential 'D050H, D8H'....2365
      Reduction and Differential 'D10H'....2385
    Group 31 - Wheel and Tire....2405
      Table of Contents....2406
      Specifications....2407
      Troubleshooting....2407
      Wheel and Tire....2408
    Group 33 - Front Suspension....2413
      Table of Contents....2414
      Structure and Operation....2415
      Troubleshooting....2416
      Work Before Removal and Installation of Front Suspension....2417
      Removal and Installation of Leaf Spring Assembly....2419
      Leaf Spring Assembly....2423
      Shock Absorber....2425
    Group 34 - Rear Suspension....2426
      Group 34A - Rear Suspension 'LEAF'....2427
        Table of Contents....2428
        Structure and Operation....2429
        Troubleshooting....2430
        Work Before Removal and Installation of Rear Suspension....2431
        Removal and Installation of Leaf Spring Assembly....2433
        Leaf Spring Assembly....2439
      Group 34B - Rear Suspension 'AIR'....2441
        Table of Contents....2442
        Specifications....2443
        Structure and Operation....2444
          1. Air Suspension....2444
          2. Air Suspension System....2445
          3. Leveling Valve....2447
        Troubleshooting....2449
        On-Vehicle Inspection and Adjustment....2450
          Adjustment of Air Spring Height....2450
        Work Before Removal and After Installation of Rear Suspension....2451
        Shock Absorber....2453
        Removal and Installation of Leaf Spring Assembly and Air Spring....2455
        Leaf Spring Assembly....2459
        Air Spring....2461
        Leveling Valve....2463
    Group 35 - Brake....2466
      Group 35A - Brake 'Air Over Hydraulic Brake'....2467
        Table of Contents....2468
        Specifications....2469
        Structure and Operation....2471
        Troubleshooting....2490
        On-Vehicle Inspection and Adjustment....2494
          Replacement of Brake Fluid....2494
          Air Bleeding of Brake System....2496
          Inspection and Adjustment of Brake Pedal Free Play....2498
          Thickness Inspection and Replacement of Brake Lining....2499
          Inspection of Brake Shoe Clearance....2499
          Inspection and Maintenance of Air Dryer....2499
          Inspection and Adjustment of Air Dryer's Air Pressure Governor....2501
        Handling of Connector and Nylon Tube Piping....2503
        Air Compressor....2505
        Air Dryer....2511
        Brake Pedal....2515
        Dual Brake Valve....2517
        Brake Booster (Airmaster)....2525
        Front Wheel Brake....2531
          '320 mm {12.6 in.} Drum Brake'....2531
          '400 mm {15.7 in.} Drum Brake'....2539
        Rear Wheel Brake....2549
          '320 mm {12.6 in.} Drum Brake'....2549
          '400 mm {15.7 in.} Drum Brake'....2557
        Fluid Tank....2567
        Check Valve....2568
        Safety Valve....2568
        Supply Valve....2569
        Exhaust Brake System....2571
      Group 35B - Brake 'Full Air Brake'....2574
        Table of Contents....2575
        Specifications....2576
        Structure and Operation....2578
        Troubleshooting....2595
        On-Vehicle Inspection and Adjustment....2599
          Inspection and Adjustment of Brake Pedal Free Play....2599
          Thickness Inspection and Replacement of Brake Lining....2599
        Handling of Connector and Nylon Tube Piping....2604
        Air Compressor....2606
        Air Dryer....2612
        Brake Pedal....2616
        Dual Brake Valve....2618
        Relay Valve....2626
        Quick Release Valve....2628
        Front Wheel Brake....2630
        Rear Wheel Brake....2640
        Expander Assembly....2650
        Check Valve....2656
        Safety Valve....2656
        Supply Valve....2657
        Exhaust Brake System....2658
      Group 35E - Anti-Lock Brake System (ABS)....2661
        Table of Contents....2662
        Specifications....2663
        Structure and Operation....2663
        On-Vehicle Inspection and Adjustment....2677
          Periodic Inspection Procedures....2677
          Adjustment of Wheel Speed Sensor Clearance 'Air-Over Hydraulic Brake'....2679
          Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope....2680
        Troubleshooting....2681
          Inspection Procedures....2681
          Inspection Flowchart....2682
          Diagnosis Code Chart....2683
          Service Data Chart....2685
          Actuator Drive Chart....2686
        Locations of Parts....2687
        Electrical Wiring Diagram....2691
    Group 36 - Parking Brake....2694
      Group 36A - Parking Brake 'Center Parking Brake'....2695
        Table of Contents....2696
        Specifications....2697
        Structure and Operation....2697
        Troubleshooting....2699
        On-Vehicle Inspection and Adjustment....2700
          Adjustment of Parking Brake Shoe Clearance and Lever Stroke....2700
        Parking Brake Control....2701
        Parking Brake Assembly....2703
        Support Plate and Shoe Assembly....2707
      Group 36B - Parking Brake 'Wheel Parking Brake'....2709
        Table of Contents....2710
        Structure and Operation....2711
        Troubleshooting....2716
        Parking Brake Control Valve....2717
        Spring Brake Valve....2719
        Double Check Valve....2722
    Group 37 - Steering....2723
      Table of Contents....2724
      Specifications....2725
      Structure and Operation....2726
      Troubleshooting....2735
      On-Vehicle Inspection and Adjustment....2738
        Change of Power Steering Fluid....2738
        Bleeding of Power Steering System....2738
        Steering Wheel Play....2739
        Performance Verification Test of Power Steering System....2740
      Steering System....2741
      Linkage and Bracket....2747
      Power Steering Booster....2749
      Power Steering Oil Pump....2763
        'FK, FM61, FM64'....2763
        'FM65'....2769
      Power Steering Oil Tank....2774
      Drag Link....2775
      Tie Rod Assembly....2777
    Group 41 - Frame....2780
      Table of Contents....2781
      Specifications....2782
      Structure and Operation....2782
      Inspection and Repair of Frames....2782
    Group 42 - Cab....2787
      Table of Contents....2788
      Specifications....2789
      Structure and Operation....2791
      Troubleshooting....2801
      On-Vehicle Inspection and Adjustment....2807
        Adjustment of Door Fitting....2807
      Removal and Installation of Cab....2809
      Front Cab Mounting....2815
      Rear Cab Mounting....2818
      Cab Stay....2819
      Cab Tilt Link....2821
      Door....2823
      Mirror....2829
      Seat....2831
        'Driver'....2831
        'Passenger'....2837
      Seat Belt....2839
      Wiper and Washer....2841
      Instrument Panel....2847
      Scuff Plate and Trim....2851
      Headlining....2853
      Front Panel....2857
      Radiator Grille and Corner Panel....2859
      Step....2861
      Fender....2863
      Mud Guard....2865
      Window Glass....2867
    Group 54 - Electrical....2870
      Table of Contents....2871
      How to Read This Group....2874
      0 - General....2878
        Specifications....2879
        Structure and Operation....2883
          1. Starter....2883
          2. Alternator....2885
          3. Lamp....2888
          4. Daytime Running Light (DRL) System....2889
          5. MUTIC (Multipurpose Timing Control Unit)....2891
          6. Engine Electronic Control Unit....2895
        Troubleshooting....2902
          1. Fault Diagnosis Function....2902
          2. Power and Charging....2913
          3. Engine Starting, Preheating and Stopping....2914
          4. Lighting....2915
          5. Meter....2918
          6. Cigarette Lighter and Audio....2919
          7. Accessory Noise Generation Source....2919
          8. Horn....2920
      1 - Power, Charge and Ground Circuit....2921
        104 - Relay and Fuse Box Circuit....2922
        110 - Power Circuit....2923
        111 - Electronic Control Unit Power Circuit....2933
        115 - Reserve Power Circuit....2934
        125 - Battery Charging Circuit....2935
        130 - Ground....2936
      2 - Starting and Preheating Circuit....2956
        210 - Engine Starting Circuit....2957
        220 - Engine Preheating Circuit....2959
      3 - Lighting Circuit....2961
        310 - Headlamp Circuit....2962
        313 - Daytime Running Light Circuit....2964
        320 - Tail, Clearance and License Plate Lamp Circuit....2966
        325 - Stop Lamp Circuit....2967
        330 - Turn Signal and Hazard Lamp Circuit....2968
        340 - Backup Lamp Circuit....2969
        345 - Cab Lamp Circuit....2972
        348 - Illumination Lamp Circuit....2973
        349 - Marker and Identification Lamp Circuit....2974
        352 - Van Body Dome Light Circuit....2975
      4 - Meter Circuit....2976
        401 - Meter Cluster Internal Circuit....2977
        410 - Tachometer Circuit....2979
        412 - Speedometer Circuit....2980
        420 - Fuel Gauge Circuit....2983
        425 - Water Temperature Gauge Circuit....2984
      5 - Indicator and Warning Lamp Circuit....2985
        510 - Parking Brake Indicator Circuit....2986
        515 - Brake Warning Circuit....2988
        530 - Water Level Warning Circuit....2990
        535 - Engine Oil Level Warning Circuit....2991
        536 - Engine Oil Pressure Warning Circuit....2992
        537 - Overheating Warning Circuit....2993
        548 - Transmission High/Low Indicator Circuit....2994
        550 - Cab Tilt Warning Circuit....2995
        566 - Fuel Filter Warning Circuit....2996
      6 - Cab Side Electrical Circuit....2997
        610 - Cigarette Lighter Circuit....2998
        612 - Audio Circuit....2999
        614 - Wiper and Washer Circuit....3000
        616 - Horn Circuit....3001
        620 - Air-Conditioner Circuit....3002
        622 - Power Window and Auto Door Lock Circuit....3003
        629 - Mirror Heater Circuit....3004
      7 - Chassis Side Electrical Circuit....3005
        710 - Exhaust Brake Circuit....3006
        718 - Air Dryer Circuit....3009
        722 - Air Suspension Circuit....3010
      8 - Engine and Transmission Side Electrical Circuit....3012
        850 - Transmission Power Take-Off Circuit....3013
      9 - Others Circuit....3014
        910 - Multipurpose Timing Control Unit Circuit....3015
      10 - Parts Installation Position....3016
        A - Switch....3017
        B - Relay and Electronic Control Unit....3019
        C - Fuse, Meter, Sensor, Buzzer and Motor....3021
        D - Heater....3023
        E - Door and Mirror....3024
        F - Roof....3025
        G - Cab....3027
        J - Joint of Main Harness Connectors....3029
        R - Engine....3031
        S - Transmission....3033
        T - Switch and Sensor....3035
        U - Fuse and Connector....3039
        V - Magnetic Valve....3041
        W - Buzzer....3041
      11 - Inspection of Parts....3043
        #001 to #179 - Switch....3044
        #180 to #249 - Relay....3053
        #250 to #349 - Sensor....3056
        #350 to #409 - Control Unit....3059
        #410 to #509 - Motor....3060
        #510 to #559 - Actuator....3061
        #560 to #609 - Magnetic Valve....3062
        #610 to #649 - Buzzer and Horn....3063
        #650 to #699 - Lamp....3064
        #750 to #859 - Other....3065
        #860 - Battery....3067
        #870 to #889 - Fuse....3070
        #890 - Meter Cluster....3074
      12 - Starter and Alternator....3078
        #930 - Starter....3079
        #940 - Alternator....3093
        #950 - Inspection of Alternator....3100
        #951 - Inspection of Regulator....3101
      13 - On-Vehicle Inspection and Adjustment....3102
        #955 - Inspection of Preheating System....3103
        #960 - Adjustment of Headlamp Aiming....3105
        #965 - Inspection of Brake Fluid Level Switch....3107
    Group 55 - A/C & Heater....3108
      Group 55A - Air-Conditioner....3109
        Table of Contents....3110
        Specifications....3111
        Structure and Operation....3112
          1. Air System....3112
          2. Refrigerating Circuit....3113
          3. Engine Room....3114
          4. Cabin Room....3115
          5. Compressor....3116
          6. Magnetic Clutch....3117
          7. Check Valve....3117
          8. Side Condenser Assembly....3118
          9. Relief Valve....3118
          10. Receiver Assembly....3119
          11. Cooling Unit Assembly....3119
          12. Expansion Valve....3120
          13. Dual Pressure Switch....3120
          14. Power Relay....3121
          15. Air-Conditioner Switch....3121
          16. Thermostat....3121
          17. Control System....3123
        Troubleshooting....3125
        On-Vehicle Inspection and Adjustment....3127
          1. Recovery of Refrigerant....3127
          2. Inspection and Adjustment of V-Belt....3127
          3. Inspection of Magnetic Clutch....3128
          4. Charging System with Refrigerant....3129
          5. Inspection of Refrigerant....3131
          6. Replenishment of Refrigerant....3132
          7. Inspection of Receiver Assembly....3133
        Connection of Air-Conditioner Piping....3134
        Compressor and Tension Pulley....3135
        Side Condenser Assembly and Receiver Assembly....3139
        Cooling Unit....3141
        Air-Conditioner Circuit....3145
      Group 55B - Heater....3147
        Table of Contents....3148
        Specifications....3149
        Structure and Operation....3150
        Troubleshooting....3155
        Heater Hose....3157
        Heater Control....3159
        Air Duct....3162
        Heater Unit and Blower....3163
        Air Outlet Ventilation....3164

Mitsubishi Fuso FE.FG.FK.FM Series Repair Service Manual 2005

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