Mitsubishi Fuso Truck FE FG FK FM Series Service Manual 2005 2006 2007 – PDF DOWNLOAD
DESCRIPTION:
Mitsubishi Fuso Truck FE FG FK FM Series Service Manual 2005 2006 2007 – PDF DOWNLOAD
FOREWORD:
This Service Manual contains maintenance and repair methods for the Mitsubishi Fuso Truck FE. FG Series. Read this manual carefully as an aid in providing correct, efficient maintenance. Please note that the information and specifications contained within this manual may change without notice. This is due to product modifications and continued vehicle improvements that are made throughout the model years. Should you encounter any discrepancy in the information provided
TABLE OF CONTENTS:
Mitsubishi Fuso Truck FE FG FK FM Series Service Manual 2005 2006 2007 – PDF DOWNLOAD
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 {925 in} Disc> 900
Front Disc Brake <252 mm {992 in} Disc> 904
Front Drum Brake 908
Rear Disc Brake <235 mm {925 in} Disc> 914
Rear Disc Brake <252 mm {992 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 Operation1000
1 Steering System1000
2 Oil Flow1000
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
Troubleshooting1006
On-Vehicle Inspection and Adjustment1008
1 Change of Power Steering Fluid1008
2 Bleeding of Power Steering System1009
3 Performance Verification Test of Power Steering System1010
4 Steering Wheel Play1011
5 Steering Column Looseness1011
6 Drag Link Ball Joint Backlash1011
Steering Column1012
Power Steering Gear and Drag Link1022
Power Steering Oil Pump <Kayaba Industry Product>1044
Power Steering Oil Pump <Unisia JKC Product>1048
Power Steering Oil Tank1052
Group 41 – Frame1054
Table of Contents1055
Specifications1056
Structure and Operation1057
Frame1058
Group 42 – Cab1062
Table of Contents1063
Specifications1064
Structure and Operation1065
1 Front Cab Mounting1065
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
Troubleshooting1068
On-Vehicle Inspection and Adjustment1070
1 Adjustment of Cab Tilt System <Except Crew Cab>1070
Removal and Installation of Cab1072
<Except Crew Cab>1072
<Crew Cab>1076
Front Cab Mounting1080
<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 – Door1089
Table of Contents1090
Specifications1091
Structure and Operation1092
1 Front Door Lock System1092
2 Rear Door Lock System <Crew Cab>1092
3 Front Door Glass Opening and Closing Mechanism1093
4 Rear Door Glass Opening and Closing Mechanism <Crew Cab>1095
Troubleshooting1097
On-Vehicle Inspection and Adjustment1099
1 Adjustment of Front Door Alignment1099
2 Adjustment of Rear Door Alignment <Crew Cab>1102
Front Door1105
Rear Door <Crew Cab>1113
Group 51 – Exterior1119
Table of Contents1120
Structure and Operation1121
1 Wiper and Washer System1121
Troubleshooting1122
Mirror1123
Wiper and Washer1125
Front Cover1127
Front Grille, Front Corner Panel and Headlamp1129
Fender1133
Step1135
Garnish <Crew Cab>1137
Wheel House1138
Window Glass1139
Group 52 – Interior1142
Table of Contents1143
Seat1144
<Driver>1144
<Passenger>1146
<Rear>1148
Seat Belt1150
Instrument Panel1156
Trim and Scuff Plate1176
<Except Crew Cab>1176
<Crew Cab>1180
Head Lining1182
<Except Crew Cab>1182
<Crew Cab>1184
Group 54 – Electrical1186
Table of Contents1187
How to Read this Group1190
54-00 – General1194
Precautions for Maintenance Operation1195
Specifications1205
Structure and Operation1208
1 Starter1208
2 Alternator1209
3 Headlamps1212
4 Meter Cluster1213
5 Daytime Running Light System1221
6 Wiper Control1223
7 Starter Continuous Energizing Preventing Function and Preheating Function1225
Troubleshooting1229
54-01 – Power, Charge and Ground Circuit1236
High-Current Fuse Box1237
Fuse Box1239
110 – Power Circuit1241
115 – Reserve Power Circuit1251
125 – Battery Charging Circuit1252
130 – Ground1253
54-02 – Starting Circuit1268
210 – Engine Starting Circuit1269
220 – Engine Preheating Circuit1271
54-03 – Lighting Circuit1272
310 – Headlamp Circuit1273
313 – Daytime Running Light Circuit1275
320 – Tail, Clearance and License Plate Lamps Circuit1277
325 – Stop Lamp Circuit1278
330 – Turn Signal and Hazard Lamp Circuit1279
340 – Backup Lamp Circuit1281
345 – Cab Lamp Circuit1283
348 – Illumination Lamp Circuit1285
349 – Identification Lamp and Side Marker Lamp Circuit1286
352 – Van Body Dome Light Circuit1287
54-04 – Meter Circuit1288
401 – Meter Cluster Internal Circuit1289
412 – Speedometer Circuit1290
420 – Fuel Gauge Circuit1291
425 – Water Temperature Gauge Circuit1292
54-05 – Indicator and Warning Lamp Circuit1293
510 – Parking Brake Indicator Circuit1294
515 – Brake Warning Circuit1296
535 – Engine Oil Level Warning Circuit1298
536 – Engine Oil Pressure Warning Circuit1299
537 – Overheating Warning Circuit1300
540 – Brake Pad Warning Circuit1301
550 – Cab Tilt Warning Circuit1302
566 – Fuel Filter Warning Circuit1303
54-06 – Cab Side Electrical Circuit1304
610 – Cigarette Lighter Circuit1305
612 – Audio Circuit1306
614 – Wiper and Washer Circuit1307
616 – Horn Circuit1308
620 – Air-Conditioner Circuit1309
622 – Power Window and Auto Door Lock Circuit1311
629 – Mirror Heater Circuit1312
54-07 – Chassis Side Electrical Circuit1313
710 – Exhaust Brake Circuit1314
54-08 – Engine and Transmission Side Electrical Circuit1316
810 – Four-Wheel Drive Circuit <FG>1317
850 – Transmission Power Take-Off Circuit1318
54-09 – Other Circuit1319
905 – Joint Connector (J/C)1320
907 – Diagnosis Switch, Memory Clear Switch1325
54-10 – Parts Installation Positions1326
A – Switch1327
B – Relay and Electronic Control Unit1330
C – Fuse, Meter, Sensor, Buzzer, Motor and Actuator1331
D – Air-Conditioner <Option>1332
E – Door1333
F – Roof1334
J – Joint of Main Harness Connectors1335
R – Engine1337
S – Transmission1338
T – Switch and Sensor1341
U – Fuse and Connector1342
V – Magnetic Valve and Motor1344
W – Buzzer and Connector1344
54-11 – Inspection of Parts1345
#001 to #179 – Switch1346
#180 to #249 – Relay1352
#250 to #349 – Sensor1354
#350 to #409 – Control Unit1355
#410 to #509 – Motor1356
#510 to #539 – Actuator1357
#560 to #609 – Magnetic Valve1358
#610 to #649 – Buzzer, Horn1359
#650 to #699 – Lamp1361
#750 to #859 – Other1362
#860 – Battery1364
54-12 – Starter adn Alternator1367
#930 – Starter1368
#940 – Alternator1382
54-13 – On-Vehicle Inspection and Adjustment1390
#950 – Inspection of Alternator1391
#951 – Inspection of Regulator1392
#955 – Inspection of Preheating System1393
#956 – Inspection of Starter Continuous Energizing Preventing Function1397
#960 – Headlamp Aiming1401
54-14 – Connector Configuration Chart1403
Connector Configuration Chart1404
Group 55 – A/C & Heater1472
Group 55A – Air-Conditioner1473
Table of Contents1474
Specifications1475
Structure and Operation1477
1 Air-Conditioner System1477
2 Engine Room1478
3 Cabin Room1479
4 Compressor1480
5 Magnetic Clutch1481
6 Check Valve1481
7 Side Condensor Assembly1482
8 Relief Valve1482
9 Receiver Assembly1483
10 Evaporator Assembly1483
11 Expansion Valve1484
12 Dual Pressure Switch1484
13 Power Relay1485
14 Air-Conditioner Switch1485
15 Thermostat1485
16 Control System1487
Troubleshooting1489
On-Vehicle Inspection and Adjustment1491
1 Recovery of Refrigerant1491
2 Inspection and Adjustment of V-Belt1491
3 Inspection of Magnetic Clutch1492
4 Recharging the System with Refrigerant1493
5 Checking Refrigerant Charge Level1495
6 Adding Refrigerant1496
7 Inspection of Receiver Assembly1497
8 Inspection of Dual Pressure Switch1497
Connecting Air-Conditioner Piping1498
Compressor1499
Condenser, Receiver1501
Cooling Unit1503
Air-Conditioner Circuit1505
Group 55B – Heater1506
Table of Contents1507
Specifications1508
Structure and Operation1510
1 Heater1510
2 Air Duct1511
3 Heater Control1512
Troubleshooting1516
Heater Control1518
Air Duct1522
Heater Unit, Blower1524
2005 FK/FM Service Manual1526
Group 00 – General1527
Table of Contents1528
Model Coding System1529
Power Train Table1531
Chassis Number and Engine Number1533
Power Train Label1533
Vehicle Identification Number1534
Precautions for Maintenance Operation1535
Diagnosis Codes1547
1 Connecting Multi-Use Tester1547
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 Torques1557
Connector Configuration Chart1561
Group 01 – Maintenance Schedule1629
Table of Contents1630
How to Read the Maintenance Schedule Tables1631
Maintenance Schedule Tables1632
Maintenance Operations1638
Lubrication Tables1644
Lubrication1645
Group 11 – Engine1648
Table of Contents1649
Specifications1650
Structure and Operation1651
1 Engine Proper1651
2 Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket1652
3 Valve Mechanism1653
4 Connecting Rods1653
5 Pistons1654
6 Timing Gears1654
7 Flywheel1656
Troubleshooting1657
On-Vehicle Inspection and Adjustment1658
1 Measuring Compression Pressure1658
2 Inspecting and Adjusting Valve Clearance1662
Engine Removal and Installation1666
Rocker Cover, Rocker and Bracket Assembly, Camshaft1668
Cylinder Head, Valve Mechanism1678
Pistons, Connecting Rods and Cylinder Liners1696
Flywheel1710
<Manual Transmission>1710
<Automatic Transmission>1716
Timing Gears1720
Crankshaft and Crankcase1726
Group 12 – Lubrication1735
Table of Contents1736
Specifications1737
Structure and Operation1738
1 Lubrication System1738
2 Oil Pump1739
3 Oil Filter1739
4 Oil Cooler1740
5 Engine Oil Pressure Switch and Regulator Valve1740
6 Lubrication of Related Parts1741
Troubleshooting1744
On-Vehicle Inspection and Adjustment1745
1 Oil Filter Replacement1745
2 Engine Oil Replacement1747
3 Oil Pressure Measurement1748
Oil Pan and Oil Jet1749
Oil Pump and Oil Strainer1751
Oil Filter1754
Oil Cooler1755
Regulator Valve1757
Group 13 – Fuel and Engine Control1758
Group 13A – Fuel and Engine Control1759
Table of Contents1760
Specifications1761
Structure and Operation1762
1 Fuel System1762
2 Engine Control1763
3 Fuel Filter1764
Troubleshooting1765
On-Vehicle Inspection and Adjustment1767
1 Checking No-load Minimum and Maximum Speeds1767
2 Air Bleeding of Fuel System1768
3 Replacement of Fuel Filter1769
Engine Control1771
Fuel Tank1774
Fuel Filter1775
Common Rail Assembly1777
Supply Pump1779
Injector, Fuel Temperature Sensor1783
Group 13E – Electronically Controlled Fuel System1785
Table of Contents1786
<Common Rail System>1787
Specifications1787
Structure and Operation1789
1 Overview1789
2 Electronic Control System1797
3 Electronic Control Unit Connection Diagram1803
Troubleshooting1805
1 Inspection Procedure1805
2 Cautions to Observe When Performing Inspections1806
3 Inspections Based on Diagnosis Codes1807
4 Multi-Use Tester Service Data1824
5 Actuator Tests Performed Using Multi-Use Tester1827
6 Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit1829
7 Inspections Performed at Electronic Control Unit Connectors1830
Inspection of Electrical Equipment1833
Installed Locations of Parts1841
Electric Circuit Diagram1847
<Auto Cruise System>1855
Structure and Operation1855
1 General Description1855
2 Electronic Control System1855
3 Electronic Control Unit Connection Diagram1859
Troubleshooting1861
1 Inspection Procedure1861
2 Cautions to Observe When Performing Inspections1862
3 Inspection Based on Diagnosis Codes1863
4 Multi-Use Tester Service Data1866
5 Actuator Tests Performed using Multi-Use Tester1867
6 Inspections Performed at Electronic Control Unit Connectors1868
Inspection of Electrical Equipment1869
Installed Locations of Parts1871
Electric Circuit Diagram1877
Group 14 – Cooling1878
Table of Contents1879
Specifications1880
Structure and Operation1880
1 Cooling System (Coolant Flow)1880
2 Water Pump1881
3 Thermostat1881
Troubleshooting1882
On-Vehicle Inspection and Adjustment1884
1 Replacing Coolant and Cleaning Cooling System1884
2 Air Bleeding of Cooling System1886
3 Gas Leak Testing1886
Radiator and Fan Shroud1888
Cooling Fan and V-Belt1896
Water Pump1900
Thermostat1908
Group 15 – Intake and Exhaust1910
Table of Contents1911
Specifications1912
Structure and Operation1913
1 Air Cleaner1913
2 Turbocharger Assembly1913
Troubleshooting1915
On-Vehicle Inspection and Adjustment1916
Measurement of Turbocharger Boost Pressure1916
Air Duct1918
Air Cleaner1920
Turbocharger1922
Intercooler1927
Intake Manifold1928
Exhaust Manifold1929
Exhaust Pipe and Muffler1930
Group 17 – Emission Control1932
Table of Contents1933
Structure and Operation1934
1 Exhaust Gas Recirculation System1934
2 Crankcase Emission Control System1938
On-Vehicle Inspection and Adjustment1939
1 Replacement of PCV Valve Element1939
Exhaust Gas Recirculation System1940
1 Inspection Procedure1940
2 Cautions to Observe when Performing Inspections1941
3 Inspections Based on Diagnosis Codes1942
4 Multi-Use Tester Service Data1944
5 Actuator Tests Performed Using Multi-Use Tester1944
6 Inspection of Electrical Equipment1944
Installed Locations of Parts1946
Electric Circuit Diagram1952
Exhaust Gas Recirculation Valve, Exhaust Gas Recirculation Solenoid Valve, Exhaust Gas Recirculation Pipe, Exhaust Gas Recirculation Cooler1956
Crankcase Emission Control System1960
Group 21 – Clutch1962
Table of Contents1963
Specifications1964
Structure and Operation1964
Troubleshooting1969
On-Vehicle Inspection and Adjustment1970
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 Cylinder1986
Clutch Power Cylinder <M060S6, M070S6>1988
Clutch Booster <Eaton FS-8209>1990
Work Before Removal and Installation of Clutch Body1998
Clutch Body2000
Clutch Control <M060S6, M070S6>2016
Clutch Control <Eaton FS-8209>2018
Group 22 – Manual Transmission2020
Group 22A – Manual Transmission <M060S6, M070S6>2021
Table of Contents2022
Specifications2023
Structure and Operation2023
Troubleshooting2032
Work Before Removal and Installation of Transmission Assembly2033
Removal and Installation of Transmission Assembly2035
Gear Shifter Upper and Interlock Plate2038
Power Shift Assembly2043
Extension Housing and Parking Brake Assembly2049
6th Gear and Reverse Idler Gear <M060>2053
Reverse Gear and Reverse Idler Gear <M070>2061
Transmission Body2067
Drive Pinion Assembly2083
Mainshaft Assembly <Over-Drive (M060)>2085
Mainshaft Assembly <Direct-Drive (M070)>2093
Countershaft Assembly2105
Transmission Control2109
Puller and Installer Kit2113
Group 22B – Manual Transmission <M060S9 (Eaton FS-8209)>2114
Table of Contents2115
Specifications2116
Removal and Installation of Transmission Assembly2118
Transmission Control2122
High-Low Control2126
Group 23 – Automatic Transmission2129
Group 23A – Automatic Transmission <M065A5 (Allison LCT1000, LCT2400)>2130
Table of Contents2131
Specifications2132
Structure and Operation2136
1 Outline2136
2 Electronic Control System2140
3 Electronic Control Unit Connection Diagram2144
Troubleshooting2146
1 Failure by Equipment2146
2 Measures for Transitory Failure2152
On-Vehicle Inspection and Adjustment2154
1 Stall Test2154
2 Line Pressure Test2155
3 Inspection of Automatic Transmission Fluid2156
4 Replacement of Automatic Transmission Fluid2157
5 Replacement of Oil Filter2158
Preparatory Work for Removal and Installation of Automatic Transmission Assembly2159
Removal and Installation of Automatic Transmission Assembly2160
Parking Brake Assembly2162
Oil Pan, Suction Filter and Level Gauge2164
Automatic Transmission Control2166
Oil Cooler2174
Inspection of Electrical Equipment2176
Installed Locations of Parts2180
Electric Circuit Diagram2184
Group 23B – Automatic Transmission <M100A6 (Allison MD3060P)>2188
Table of Contents2189
Specifications2190
Structure and Operation2192
1 Automatic Transmission Assembly2192
2 Automatic Transmission Control System2193
3 Oil Cooler System2194
Troubleshooting2195
On-Vehicle Inspection and Adjustment2200
1 Stall Test2200
2 Line Pressure Test2201
3 Inspection of Automatic Transmission Fluid2203
4 Replacement of Automatic Transmission Fluid2204
5 Level Check of Automatic Transmission Fluid2206
6 Replacement of Oil Filter2207
Oil Cooler2208
Installed Locations of Parts2210
Electric Circuit Diagram2214
Group 25 – Propeller Shaft2216
Table of Contents2217
Specifications2218
Structure and Operation2218
Troubleshooting2220
Removal and Installation of Propeller Shaft2222
Rear Propeller Shaft2224
<P8>2224
<P10, P12>2228
Front Propeller Shaft2232
<P8>2232
<P10, P12>2238
Balancing Propeller Shaft2243
Group 26 – Front Axle2245
Table of Contents2246
Specifications2247
Structure and Operation2247
On-Vehicle Inspection and Adjustment2253
Adjustment of Wheel Alignment2253
Adjustment of Steering Angle2257
Measurement of Side Slip2257
Work Before Removal and Installation of Front Axle2258
Wheel Hub and Brake Drum2259
<FK>2259
<FM (Air-Over Hydraulic Brake)>2273
<FM (Full-Air Brake)>2287
Front Axle, Knuckle and Kingpin2301
<FK>2301
<FM (Air-Over Hydraulic Brake)>2307
<FM (Full-Air Brake)>2315
Group 27 – Rear Axle2321
Table of Contents2322
Specifications2323
Structure and Operation2324
Troubleshooting2327
Work Before Removal and Installation of Rear Axle2329
Wheel Hub and Brake Drum2331
<FK>2331
<FM>2345
Axle Housing2361
Reduction and Differential <D050H, D8H>2365
Reduction and Differential <D10H>2385
Group 31 – Wheel and Tire2405
Table of Contents2406
Specifications2407
Troubleshooting2407
Wheel and Tire2408
Group 33 – Front Suspension2413
Table of Contents2414
Structure and Operation2415
Troubleshooting2416
Work Before Removal and Installation of Front Suspension2417
Removal and Installation of Leaf Spring Assembly2419
Leaf Spring Assembly2423
Shock Absorber2425
Group 34 – Rear Suspension2426
Group 34A – Rear Suspension <LEAF>2427
Table of Contents2428
Structure and Operation2429
Troubleshooting2430
Work Before Removal and Installation of Rear Suspension2431
Removal and Installation of Leaf Spring Assembly2433
Leaf Spring Assembly2439
Group 34B – Rear Suspension <AIR>2441
Table of Contents2442
Specifications2443
Structure and Operation2444
1 Air Suspension2444
2 Air Suspension System2445
3 Leveling Valve2447
Troubleshooting2449
On-Vehicle Inspection and Adjustment2450
Adjustment of Air Spring Height2450
Work Before Removal and After Installation of Rear Suspension2451
Shock Absorber2453
Removal and Installation of Leaf Spring Assembly and Air Spring2455
Leaf Spring Assembly2459
Air Spring2461
Leveling Valve2463
Group 35 – Brake2466
Group 35A – Brake <Air Over Hydraulic Brake>2467
Table of Contents2468
Specifications2469
Structure and Operation2471
Troubleshooting2490
On-Vehicle Inspection and Adjustment2494
Replacement of Brake Fluid2494
Air Bleeding of Brake System2496
Inspection and Adjustment of Brake Pedal Free Play2498
Thickness Inspection and Replacement of Brake Lining2499
Inspection of Brake Shoe Clearance2499
Inspection and Maintenance of Air Dryer2499
Inspection and Adjustment of Air Dryer’s Air Pressure Governor2501
Handling of Connector and Nylon Tube Piping2503
Air Compressor2505
Air Dryer2511
Brake Pedal2515
Dual Brake Valve2517
Brake Booster (Airmaster)2525
Front Wheel Brake2531
<320 mm {126 in} Drum Brake>2531
<400 mm {157 in} Drum Brake>2539
Rear Wheel Brake2549
<320 mm {126 in} Drum Brake>2549
<400 mm {157 in} Drum Brake>2557
Fluid Tank2567
Check Valve2568
Safety Valve2568
Supply Valve2569
Exhaust Brake System2571
Group 35B – Brake <Full Air Brake>2574
Table of Contents2575
Specifications2576
Structure and Operation2578
Troubleshooting2595
On-Vehicle Inspection and Adjustment2599
Inspection and Adjustment of Brake Pedal Free Play2599
Thickness Inspection and Replacement of Brake Lining2599
Handling of Connector and Nylon Tube Piping2604
Air Compressor2606
Air Dryer2612
Brake Pedal2616
Dual Brake Valve2618
Relay Valve2626
Quick Release Valve2628
Front Wheel Brake2630
Rear Wheel Brake2640
Expander Assembly2650
Check Valve2656
Safety Valve2656
Supply Valve2657
Exhaust Brake System2658
Group 35E – Anti-Lock Brake System (ABS)2661
Table of Contents2662
Specifications2663
Structure and Operation2663
On-Vehicle Inspection and Adjustment2677
Periodic Inspection Procedures2677
Adjustment of Wheel Speed Sensor Clearance <Air-Over Hydraulic Brake>2679
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope2680
Troubleshooting2681
Inspection Procedures2681
Inspection Flowchart2682
Diagnosis Code Chart2683
Service Data Chart2685
Actuator Drive Chart2686
Locations of Parts2687
Electrical Wiring Diagram2691
Group 36 – Parking Brake2694
Group 36A – Parking Brake <Center Parking Brake>2695
Table of Contents2696
Specifications2697
Structure and Operation2697
Troubleshooting2699
On-Vehicle Inspection and Adjustment2700
Adjustment of Parking Brake Shoe Clearance and Lever Stroke2700
Parking Brake Control2701
Parking Brake Assembly2703
Support Plate and Shoe Assembly2707
Group 36B – Parking Brake <Wheel Parking Brake>2709
Table of Contents2710
Structure and Operation2711
Troubleshooting2716
Parking Brake Control Valve2717
Spring Brake Valve2719
Double Check Valve2722
Group 37 – Steering2723
Table of Contents2724
Specifications2725
Structure and Operation2726
Troubleshooting2735
On-Vehicle Inspection and Adjustment2738
Change of Power Steering Fluid2738
Bleeding of Power Steering System2738
Steering Wheel Play2739
Performance Verification Test of Power Steering System2740
Steering System2741
Linkage and Bracket2747
Power Steering Booster2749
Power Steering Oil Pump2763
<FK, FM61, FM64>2763
<FM65>2769
Power Steering Oil Tank2774
Drag Link2775
Tie Rod Assembly2777
Group 41 – Frame2780
Table of Contents2781
Specifications2782
Structure and Operation2782
Inspection and Repair of Frames2782
Group 42 – Cab2787
Table of Contents2788
Specifications2789
Structure and Operation2791
Troubleshooting2801
On-Vehicle Inspection and Adjustment2807
Adjustment of Door Fitting2807
Removal and Installation of Cab2809
Front Cab Mounting2815
Rear Cab Mounting2818
Cab Stay2819
Cab Tilt Link2821
Door2823
Mirror2829
Seat2831
<Driver>2831
<Passenger>2837
Seat Belt2839
Wiper and Washer2841
Instrument Panel2847
Scuff Plate and Trim2851
Headlining2853
Front Panel2857
Radiator Grille and Corner Panel2859
Step2861
Fender2863
Mud Guard2865
Window Glass2867
Group 54 – Electrical2870
Table of Contents2871
How to Read This Group2874
0 – General2878
Specifications2879
Structure and Operation2883
1 Starter2883
2 Alternator2885
3 Lamp2888
4 Daytime Running Light (DRL) System2889
5 MUTIC (Multipurpose Timing Control Unit)2891
6 Engine Electronic Control Unit2895
Troubleshooting2902
1 Fault Diagnosis Function2902
2 Power and Charging2913
3 Engine Starting, Preheating and Stopping2914
4 Lighting2915
5 Meter2918
6 Cigarette Lighter and Audio2919
7 Accessory Noise Generation Source2919
8 Horn2920
1 – Power, Charge and Ground Circuit2921
104 – Relay and Fuse Box Circuit2922
110 – Power Circuit2923
111 – Electronic Control Unit Power Circuit2933
115 – Reserve Power Circuit2934
125 – Battery Charging Circuit2935
130 – Ground2936
2 – Starting and Preheating Circuit2956
210 – Engine Starting Circuit2957
220 – Engine Preheating Circuit2959
3 – Lighting Circuit2961
310 – Headlamp Circuit2962
313 – Daytime Running Light Circuit2964
320 – Tail, Clearance and License Plate Lamp Circuit2966
325 – Stop Lamp Circuit2967
330 – Turn Signal and Hazard Lamp Circuit2968
340 – Backup Lamp Circuit2969
345 – Cab Lamp Circuit2972
348 – Illumination Lamp Circuit2973
349 – Marker and Identification Lamp Circuit2974
352 – Van Body Dome Light Circuit2975
4 – Meter Circuit2976
401 – Meter Cluster Internal Circuit2977
410 – Tachometer Circuit2979
412 – Speedometer Circuit2980
420 – Fuel Gauge Circuit2983
425 – Water Temperature Gauge Circuit2984
5 – Indicator and Warning Lamp Circuit2985
510 – Parking Brake Indicator Circuit2986
515 – Brake Warning Circuit2988
530 – Water Level Warning Circuit2990
535 – Engine Oil Level Warning Circuit2991
536 – Engine Oil Pressure Warning Circuit2992
537 – Overheating Warning Circuit2993
548 – Transmission High/Low Indicator Circuit2994
550 – Cab Tilt Warning Circuit2995
566 – Fuel Filter Warning Circuit2996
6 – Cab Side Electrical Circuit2997
610 – Cigarette Lighter Circuit2998
612 – Audio Circuit2999
614 – Wiper and Washer Circuit3000
616 – Horn Circuit3001
620 – Air-Conditioner Circuit3002
622 – Power Window and Auto Door Lock Circuit3003
629 – Mirror Heater Circuit3004
7 – Chassis Side Electrical Circuit3005
710 – Exhaust Brake Circuit3006
718 – Air Dryer Circuit3009
722 – Air Suspension Circuit3010
8 – Engine and Transmission Side Electrical Circuit3012
850 – Transmission Power Take-Off Circuit3013
9 – Others Circuit3014
910 – Multipurpose Timing Control Unit Circuit3015
10 – Parts Installation Position3016
A – Switch3017
B – Relay and Electronic Control Unit3019
C – Fuse, Meter, Sensor, Buzzer and Motor3021
D – Heater3023
E – Door and Mirror3024
F – Roof3025
G – Cab3027
J – Joint of Main Harness Connectors3029
R – Engine3031
S – Transmission3033
T – Switch and Sensor3035
U – Fuse and Connector3039
V – Magnetic Valve3041
W – Buzzer3041
11 – Inspection of Parts3043
#001 to #179 – Switch3044
#180 to #249 – Relay3053
#250 to #349 – Sensor3056
#350 to #409 – Control Unit3059
#410 to #509 – Motor3060
#510 to #559 – Actuator3061
#560 to #609 – Magnetic Valve3062
#610 to #649 – Buzzer and Horn3063
#650 to #699 – Lamp3064
#750 to #859 – Other3065
#860 – Battery3067
#870 to #889 – Fuse3070
#890 – Meter Cluster3074
12 – Starter and Alternator3078
#930 – Starter3079
#940 – Alternator3093
#950 – Inspection of Alternator3100
#951 – Inspection of Regulator3101
13 – On-Vehicle Inspection and Adjustment3102
#955 – Inspection of Preheating System3103
#960 – Adjustment of Headlamp Aiming3105
#965 – Inspection of Brake Fluid Level Switch3107
Group 55 – A/C & Heater3108
Group 55A – Air-Conditioner3109
Table of Contents3110
Specifications3111
Structure and Operation3112
1 Air System3112
2 Refrigerating Circuit3113
3 Engine Room3114
4 Cabin Room3115
5 Compressor3116
6 Magnetic Clutch3117
7 Check Valve3117
8 Side Condenser Assembly3118
9 Relief Valve3118
10 Receiver Assembly3119
11 Cooling Unit Assembly3119
12 Expansion Valve3120
13 Dual Pressure Switch3120
14 Power Relay3121
15 Air-Conditioner Switch3121
16 Thermostat3121
17 Control System3123
Troubleshooting3125
On-Vehicle Inspection and Adjustment3127
1 Recovery of Refrigerant3127
2 Inspection and Adjustment of V-Belt3127
3 Inspection of Magnetic Clutch3128
4 Charging System with Refrigerant3129
5 Inspection of Refrigerant3131
6 Replenishment of Refrigerant3132
7 Inspection of Receiver Assembly3133
Connection of Air-Conditioner Piping3134
Compressor and Tension Pulley3135
Side Condenser Assembly and Receiver Assembly3139
Cooling Unit3141
Air-Conditioner Circuit3145
Group 55B – Heater3147
Table of Contents3148
Specifications3149
Structure and Operation3150
Troubleshooting3155
Heater Hose3157
Heater Control3159
Air Duct3162
Heater Unit and Blower3163
Air Outlet Ventilation3164
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