Mitsubishi Fuso FE, FG, FK & FM Series Trucks Workshop Repair Service Manual

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This workshop service repair manual PDF download for the FE, FG, FK & FM Series Mitsubishi Fuso Trucks has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

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.

APPLICABLE MODELS :

FE83DDZSLSUA
FE83DEZSLSUA
FE83DGZSLSUA
FE83DDZSLSUB
FE83DEZSLSUB
FE83DGZSLSUB
FE84DDZSLSUA
FE84DEZSLSUA
FE84DGZSLSUA
FE84DHZSLSUA
FE84DDZSLSUB
FE84DEZSLSUB
FE84DGZSLSUB
FE84DHZSLSUB
FE84DHWSLSUB
FE85DDZSLSUC
FE85DEZSLSUC
FE85DGZSLSUC
FE85DHZSLSUC
FE85DJZSLSUC
FE85DDZSLSUB
FE85DEZSLSUB
FE85DGZSLSUB
FE85DHZSLSUB
FE85DJZSLSUB
FG84DC6SLSUA
FG84DE6SLSUA
FK61FH1LSUA
FK61FJ1LSUA
FK61FK1LSUA
FK61FL1LSUA
FK61FJ1LSUB
FK61FK1LSUB
FK61FL1LSUB
FM61FF1LSUA
FM61FJ1LSUA
FM61FL1LSUA
FM61FM1LSUA
FM61FP1LSUA
FM64FM1LSUA
FM64FP1LSUA
FM61FJ1LSUB
FM61FL1LSUB
FM61FM1LSUB
FM61FP1LSUB
FM64FM1LSUB
FM64FP1LSUB
FM65FJ1LSUA
FM65FL1LSUA
FM65FM1LSUA
FM65FP1LSUA
FM65FJ1LSUB
FM65FL1LSUB
FM65FM1LSUB
FM65FP1LSUB
FM65FF2LSUC
FM65FJ2LSUC
FM65FL2LSUC
FM65FM2LSUC
FM65FP2LSUC

TABLE OF CONTENTS :

2005 FE/FG Service Manual
Group 00 – General
Group 01 – Maintenance Schedule
Group 11 – Engine
Group 12 – Lubrication
Group 13 – Fuel and Engine Control
Group 14 – Cooling
Group 15 – Intake and Exhaust
Group 17 – Emission Control
Group 21 – Clutch
Group 22 – Manual Transmission
Group 23 – Automatic Transmission
Group 24 – Transfer
Group 25 – Propeller Shaft
Group 26 – Front Axle
Group 27 – Rear Axle
Group 31 – Wheel and Tire
Group 33 – Front Suspension
Group 34 – Rear Suspension
Group 35 – Brake
Group 36 – Parking Brake
Group 37 – Steering
Group 41 – Frame
Group 42 – Cab
Group 43 – Door
Group 51 – Exterior
Group 52 – Interior
Group 54 – Electrical
Group 55 – A/C & Heater

2005 FK/FM Service Manual
Group 00 – General
Group 01 – Maintenance Schedule
Group 11 – Engine
Group 12 – Lubrication
Group 13 – Fuel and Engine Control
Group 14 – Cooling
Group 15 – Intake and Exhaust
Group 17 – Emission Control
Group 21 – Clutch
Group 22 – Manual Transmission
Group 23 – Automatic Transmission
Group 25 – Propeller Shaft
Group 26 – Front Axle
Group 27 – Rear Axle
Group 31 – Wheel and Tire
Group 33 – Front Suspension
Group 34 – Rear Suspension
Group 35 – Brake
Group 36 – Parking Brake
Group 37 – Steering
Group 41 – Frame
Group 42 – Cab
Group 54 – Electrical
Group 55 – A/C & Heater

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : TWSE0405-00 & TWME0404-00
Total Pages : 3164

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2005 Service Manual
2005 FE/FG Service Manual
Group 00 – General
Table of Contents
Equipment Type Codes List
Power Train Table
How to Read this Manual
Chassis Number, Engine Number, Power Train Label
Vehicle Identification Number
Precautions for Maintenance Operation
Jacking Up the Vehicle
Diagnosis Codes
1. Connecting Multi-Use Tester
2. Accessing/Erasing Diagnosis Codes <Common Rail, Exhaust Gas Recirculation, Pre-heater
3. Accessing/Erasing Diagnosis Codes <Automatic Transmission
4. Accessing/Erasing Diagnosis Codes <Anti-lock Brake System
Table of Standard Tightening Torques
Group 01 – Maintenance Schedule
Table of Contents
How to Read the Maintenance Schedule Tables
Maintenance Schedule Tables
Maintenance Operations
Lubrication Tables
Lubrication
Group 11 – Engine
Table of Contents
Specifications
Structure and Operation
1. Exploded View
2. Cylinder Head, Cylinder Head Gasket, Camshaft, and Camshaft Frame
3. Valve Mechanism
4. Connecting Rod
5. Piston
6. Timing Gears
7. Flywheel
8. Balance Shafts
9. Crankcase and Main Bearings
10. Oil Seals
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Measuring Compression Pressure
2. Inspection and Adjustment of Valve Clearance
Engine Removal and Installation
<Tilt Cab
<Fixed Cab
Rocker Cover
Rockers and Camshafts
Cylinder Head and Valve Mechanism
Pistons, Connecting Rod and Cylinder Liners
Flywheel
Front Case
Timing Gears and Balance Shafts
Crankshaft and Crankcase
Balance Shaft Bushings
Group 12 – Lubrication
Table of Contents
Specifications
Structure and Operation
1. Lubrication System
2. Oil Pump
3. Oil Cooler
4. Oil Filter
5. Lubrication of Engine Components
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Oil Filter Replacement
2. Engine Oil Replacement
3. Oil Pressure Measurement
Oil Pan, Oil Strainer and Oil Jets
Oil Pump
Oil Filter
Oil Cooler
Group 13 – Fuel and Engine Control
Group 13A – Fuel and Engine Control
Table of Contents
Specifications
Structure and Operation
1. Fuel System (Flow of Fuel)
2. Engine Control
3. Fuel Filter
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Inspecting and Adjusting No-load Minimum and Maximum Speeds
2. Air-bleeding of Fuel System
3. Fuel Filter Replacement
Fuel Tank
Fuel Filter
Engine Control
Common Rail
Supply Pump
Injector
Group 13E – Electronically Controlled Fuel System
Table of Contents
Specifications
Structure and Operation
1. Overview
2. Electronic Control System
3. Electronic Control Unit Connection Diagram
Troubleshooting
1. Inspection Procedure
2. Cautions to Observe when Performing Inspections
3. Inspection Based on Diagnosis Codes
4. Multi-Use Tester Service Data
5. Actuator Tests Performed Using Multi-Use Tester
6. Inspections Performed at Electronic Control Unit Connectors
Inspection of Electrical Equipment
Installed Locations of Parts
Electric Circuit Diagram
Group 14 – Cooling
Table of Contents
Specifications
Structure and Operation
1. Cooling System (Flow of Coolant)
2. Thermostat
3. Water Pump
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Coolant Replacement and Cleaning of Cooling System
2. Air Bleeding of Cooling System
3. Air/Gas Leakage Test
Disconnection and Connection of Hoses and Pipes
Radiator
Cooling Fan, V-Belt and Water Pump
Tension Pulley
Thermostat
Pressure Cap and Water Outlet Case
Group 15 – Intake and Exhaust
Table of Contents
Specifications
Structure and Operation
1. Air Cleaner
2. Turbocharger
3. Muffler
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Measurement of Turbocharger Boost Pressure
Air Duct and Air Cleaner <Except Crew Cab
Air Duct and Air Cleaner <Crew Cab
Turbocharger
Intercooler
Intake Manifold
Exhaust Manifold
Exhaust Pipe
Muffler
Group 17 – Emission Control
Table of Contents
Structure and Operation
1. Exhaust Gas Recirculation System
2. Crankcase Emission Control System
Exhaust Gas Recirculation System
1. Inspection Procedure
2. Cautions to Observe when Performing Inspections
3. Inspections Based on Diagnosis Codes
4. Multi-Use Tester Service Data
5. Actuator Tests Performed Using Multi-Use Tester
6. Inspections Performed at Electronic Control Unit Connectors
7. Inspection of Electrical Equipment
8. Installed Locations of Parts
9. Electric Circuit Diagram
Exhaust Gas Recirculation Valve, Pipe and Cooler
Crankcase Emission Control System
Group 21 – Clutch
Table of Contents
Specifications
Structure and Operation
1. Clutch Control
2. Clutch Master Cylinder
3. Clutch Proper and Clutch Direct Power Cylinder
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Replacement of Brake Fluid (Clutch System)
2. Air Bleeding of Brake Fluid (Clutch System)
3. Inspection of Clutch Disk Wear Limit
Clutch Pedal
Clutch Master Cylinder
Clutch Proper
Clutch Control
Group 22 – Manual Transmission
Table of Contents
Specifications
Structure and Operation
1. Transmission
2. Synchromesh Mechanism
3. Interlock Mechanism
4. Speedometer Gear Bushing
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Inspection and Replacement of Transmission Oil
Removal and Installation of Transmission Assembly
Gear Shifter Upper
Rear Cover <S5 and Parking Brake
Extension Housing <S6 and Parking Brake
Reverse Idler Gear
6th Gear <S6
Transmission Body
Drive Pinion
Mainshaft
Countershaft
Transmission Control
Bearing Puller and Installer
Group 23 – Automatic Transmission
Table of Contents
Specifications
Structure and Operation
1. Overview
2. Electronic Control System
3. Electronic Control Unit Connection Diagram
Troubleshooting
1. Inspection Procedure
2. Cautions to Observe When Performing Inspections
3. Inspections Based on Diagnosis Codes
4. Multi-Use Tester Service Data
5. Inspections Performed at Electronic Control Unit Connectors
6. Likely Causes of Symptoms
On-Vehicle Inspection and Adjustment
1. Stall Test
2. Time Lag Test
3. Line Pressure Test
4. Road Test
5. Inspection of ATF
6. Replacement of ATF
7. Dealer Adjust
Removal and Installation of Automatic Transmission
Automatic Transmission Control
Oil Cooler
<Models Except Crew Cab
<Crew Cab
Replacement of Parts of Automatic Transmission Main Body
Inspection of Electrical Equipment
Installed Locations of Parts
Electric Circuit Diagram
Group 24 – Transfer
Table of Contents
Specifications
Structure and Operation
1. Transfer
2. Speedometer Gear Bushing
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Inspection and Replacement of Transfer Oil
Removal and Installation of Transmission (with Transfer)
Removal and Installation of Transfer
Front Drive
Rear Drive
Transfer
Transfer Control
Group 25 – Propeller Shaft
Table of Contents
Specifications
Structure and Operation
1. Configuration of Propeller Shaft Connection
2. Propeller Shaft <without Center Bearing
3. Propeller Shaft <with Center Bearing
Troubleshooting
Removal and Installation of Propeller Shaft <Between T/M (or T/F) and Rear Axle
Removal and Installation of Propeller Shaft <Between Front Axle and T/F
Propeller Shaft <P2
Propeller Shaft <P3
Group 26 – Front Axle
Group 26A – Front Axle <FE
Table of Contents
Specifications
Structure and Operation
1. Wheel Hub and Rotor
2. Knuckle and Kingpin, Front Axle
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Inspection and Adjustment of Wheel Alignment
2. Inspection and Adjustment of Steering Angle
3. Inspection of Side Slip
4. Inspection of Play in Tie Rod End Ball Joint
Wheel Hub and Rotor
Knuckle and Kingpin, Front Axle
Tie Rod
Group 26B – Front Axle <FG
Table of Contents
Specifications
Structure and Operation
1. Wheel Hub and Brake Drum
2. Free Wheel Hub
3. Drive Shaft and Steering Knuckle, Axle Housing
4. Reduction and Differential
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Inspection and Adjustment of Wheel Alignment
2. Inspection and Adjustment of Steering Angle
3. Inspection of Side Slip
4. Inspection of Play at Tie Rod End Ball Joint
5. Inspection and Replacement of Axle Oil
Wheel Hub and Brake Drum
Drive Shaft and Steering Knuckle
Tie Rod
Axle Housing
Reduction and Differential
Group 27 – Rear Axle
Table of Contents
Specifications
Structure and Operation
1. Wheel Hub and Rotor
2. Wheel Hub and Brake Drum
3. Reduction and Differential
4. Limited Slip Differential
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Inspection and Replacement of Axle Oil
Wheel Hub and Rotor
Wheel Hub and Brake Drum
Axle Housing
Reduction and Differential
Group 31 – Wheel and Tire
Table of Contents
Specifications
Troubleshooting
Wheel and Tire
Group 33 – Front Suspension
Table of Contents
Structure and Operation
1. Front Suspension Elements
Troubleshooting
Stabilizer <FE
Shock Absorber <FE
Shock Absorber <FG
Leaf Spring <FE
Leaf Spring <FG
Group 34 – Rear Suspension
Table of Contents
Structure and Operation
1. Rear Suspension Elements
Troubleshooting
Shock Absorber
Leaf Spring
Stabilizer
Group 35 – Brake
Group 35A – Brake
Table of Contents
Specifications
Structure and Operation
1. Brake System
2. Vacuum Pump
3. Vacuum Booster and Brake Master Cylinder
4. Hydraulic Booster and Brake Master Cylinder
5. Flow Priority Valve
6. Front Disc Brake
7. Front Drum Brake
8. Rear Disc Brake
9. Rear Drum Brake
10. Exhaust Brake System
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Replacement of Brake Fluid
2. Air Bleeding of Brake System
3. Inspection and Adjustment of Brake Pedal Free Play
4. Inspection and Adjustment of Brake Pedal Depressed Height from Floor
5. Inspection of Brake Pedal Full Stroke and Adjustment of Installed Height of Brake Pedal
6. Inspection and Replacement of Disc Brake Pad
7. Measurement of Disc Brake Drag Torque
8. Inspection of Drum Brake Lining Thickness
9. Initial Setting of Clearance between Brake Drum and Shoe
10. Inspection of Check Valve in Vacuum Line Hose
11. Inspection of Vacuum Pump
12. Inspection of Vacuum Booster
13. Inspection of Hydraulic Booster
Vacuum Pump
Brake Master Cylinder <with Vacuum Booster
Brake Master Cylinder <with Hydraulic Booster
Brake Pedal & Vacuum Booster, Hydraulic Booster
Front Disc Brake <235 mm {9.25 in.} Disc
Front Disc Brake <252 mm {9.92 in.} Disc
Front Drum Brake
Rear Disc Brake <235 mm {9.25 in.} Disc
Rear Disc Brake <252 mm {9.92 in.} Disc
Rear Drum Brake
Exhaust Brake System
Group 35E – Anti-lock Brake System (ABS)
Table of Contents
Specifications
Structure and Operation
1. Overview
2. Electronic Control System
3. Electronic Control Unit Schematic Diagram
Troubleshooting
1. Diagnosis Procedure
2. Precautions when Carrying Out Diagnosis
3. Diagnosis Based on Diagnosis Codes
4. Multi-Use Tester Service Data
5. Actuator Test Using Multi-Use Tester
6. Inspection at Hydraulic Unit (Electronic Control Unit) Connector
On-Vehicle Inspection and Adjustment
1. Functional Check
2. Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope
3. Inspection of Hydraulic Unit (Electronic Control Unit) Operation
4. Inspection after Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)
Hydraulic Unit Connector Coupling and Uncoupling
Inspection of Electrical Components
Components Location
Electrical Wiring Diagram
Group 36 – Parking Brake
Table of Contents
Specifications
Structure and Operation
1. Components and Parts
2. Parking Brake Lever
3. Parking Brake
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Inspection and Adjustment of Parking Brake Shoe Clearance
2. Inspection and Adjustment of Parking Brake Lever
Parking Brake Control
Parking Brake
<FE (Manual Transmission)
<FE (Automatic Transmission)
<FG
Group 37 – Steering
Table of Contents
Specifications
Structure and Operation
1. Steering System
2. Oil Flow
3. Power Steering Gear (Backlash Compensation Mechanism)
4. Power Steering Oil Pump <Kayaba Industry Product
5. Power Steering Oil Pump <Unisia JKC Product
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Change of Power Steering Fluid
2. Bleeding of Power Steering System
3. Performance Verification Test of Power Steering System
4. Steering Wheel Play
5. Steering Column Looseness
6. Drag Link Ball Joint Backlash
Steering Column
Power Steering Gear and Drag Link
Power Steering Oil Pump <Kayaba Industry Product
Power Steering Oil Pump <Unisia JKC Product
Power Steering Oil Tank
Group 41 – Frame
Table of Contents
Specifications
Structure and Operation
Frame
Group 42 – Cab
Table of Contents
Specifications
Structure and Operation
1. Front Cab Mounting
2. Rear Cab Mounting <Except Crew Cab
3. Center and Rear Cab Mountings <Crew Cab
4. Cab Tilt Link <Except Crew Cab
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Adjustment of Cab Tilt System <Except Crew Cab
Removal and Installation of Cab
<Except Crew Cab
<Crew Cab
Front Cab Mounting
<Except Crew Cab
<Crew Cab
Rear Cab Mounting <Except Crew Cab
Center and Rear Cab Mountings <Crew Cab
Cab Tilt Link <Except Crew Cab
Cab Stay <Except Crew Cab
Group 43 – Door
Table of Contents
Specifications
Structure and Operation
1. Front Door Lock System
2. Rear Door Lock System <Crew Cab
3. Front Door Glass Opening and Closing Mechanism
4. Rear Door Glass Opening and Closing Mechanism <Crew Cab
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Adjustment of Front Door Alignment
2. Adjustment of Rear Door Alignment <Crew Cab
Front Door
Rear Door <Crew Cab
Group 51 – Exterior
Table of Contents
Structure and Operation
1. Wiper and Washer System
Troubleshooting
Mirror
Wiper and Washer
Front Cover
Front Grille, Front Corner Panel and Headlamp
Fender
Step
Garnish <Crew Cab
Wheel House
Window Glass
Group 52 – Interior
Table of Contents
Seat
<Driver
<Passenger
<Rear
Seat Belt
Instrument Panel
Trim and Scuff Plate
<Except Crew Cab
<Crew Cab
Head Lining
<Except Crew Cab
<Crew Cab
Group 54 – Electrical
Table of Contents
How to Read this Group
54-00 – General
Precautions for Maintenance Operation
Specifications
Structure and Operation
1. Starter
2. Alternator
3. Headlamps
4. Meter Cluster
5. Daytime Running Light System
6. Wiper Control
7. Starter Continuous Energizing Preventing Function and Preheating Function
Troubleshooting
54-01 – Power, Charge and Ground Circuit
High-Current Fuse Box
Fuse Box
110 – Power Circuit
115 – Reserve Power Circuit
125 – Battery Charging Circuit
130 – Ground
54-02 – Starting Circuit
210 – Engine Starting Circuit
220 – Engine Preheating Circuit
54-03 – Lighting Circuit
310 – Headlamp Circuit
313 – Daytime Running Light Circuit
320 – Tail, Clearance and License Plate Lamps Circuit
325 – Stop Lamp Circuit
330 – Turn Signal and Hazard Lamp Circuit
340 – Backup Lamp Circuit
345 – Cab Lamp Circuit
348 – Illumination Lamp Circuit
349 – Identification Lamp and Side Marker Lamp Circuit
352 – Van Body Dome Light Circuit
54-04 – Meter Circuit
401 – Meter Cluster Internal Circuit
412 – Speedometer Circuit
420 – Fuel Gauge Circuit
425 – Water Temperature Gauge Circuit
54-05 – Indicator and Warning Lamp Circuit
510 – Parking Brake Indicator Circuit
515 – Brake Warning Circuit
535 – Engine Oil Level Warning Circuit
536 – Engine Oil Pressure Warning Circuit
537 – Overheating Warning Circuit
540 – Brake Pad Warning Circuit
550 – Cab Tilt Warning Circuit
566 – Fuel Filter Warning Circuit
54-06 – Cab Side Electrical Circuit
610 – Cigarette Lighter Circuit
612 – Audio Circuit
614 – Wiper and Washer Circuit
616 – Horn Circuit
620 – Air-Conditioner Circuit
622 – Power Window and Auto Door Lock Circuit
629 – Mirror Heater Circuit
54-07 – Chassis Side Electrical Circuit
710 – Exhaust Brake Circuit
54-08 – Engine and Transmission Side Electrical Circuit
810 – Four-Wheel Drive Circuit <FG
850 – Transmission Power Take-Off Circuit
54-09 – Other Circuit
905 – Joint Connector (J/C)
907 – Diagnosis Switch, Memory Clear Switch
54-10 – Parts Installation Positions
A – Switch
B – Relay and Electronic Control Unit
C – Fuse, Meter, Sensor, Buzzer, Motor and Actuator
D – Air-Conditioner <Option
E – Door
F – Roof
J – Joint of Main Harness Connectors
R – Engine
S – Transmission
T – Switch and Sensor
U – Fuse and Connector
V – Magnetic Valve and Motor
W – Buzzer and Connector
54-11 – Inspection of Parts
#001 to #179 – Switch
#180 to #249 – Relay
#250 to #349 – Sensor
#350 to #409 – Control Unit
#410 to #509 – Motor
#510 to #539 – Actuator
#560 to #609 – Magnetic Valve
#610 to #649 – Buzzer, Horn
#650 to #699 – Lamp
#750 to #859 – Other
#860 – Battery
54-12 – Starter adn Alternator
#930 – Starter
#940 – Alternator
54-13 – On-Vehicle Inspection and Adjustment
#950 – Inspection of Alternator
#951 – Inspection of Regulator
#955 – Inspection of Preheating System
#956 – Inspection of Starter Continuous Energizing Preventing Function
#960 – Headlamp Aiming
54-14 – Connector Configuration Chart
Connector Configuration Chart
Group 55 – A/C & Heater
Group 55A – Air-Conditioner
Table of Contents
Specifications
Structure and Operation
1. Air-Conditioner System
2. Engine Room
3. Cabin Room
4. Compressor
5. Magnetic Clutch
6. Check Valve
7. Side Condensor Assembly
8. Relief Valve
9. Receiver Assembly
10. Evaporator Assembly
11. Expansion Valve
12. Dual Pressure Switch
13. Power Relay
14. Air-Conditioner Switch
15. Thermostat
16. Control System
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Recovery of Refrigerant
2. Inspection and Adjustment of V-Belt
3. Inspection of Magnetic Clutch
4. Recharging the System with Refrigerant
5. Checking Refrigerant Charge Level
6. Adding Refrigerant
7. Inspection of Receiver Assembly
8. Inspection of Dual Pressure Switch
Connecting Air-Conditioner Piping
Compressor
Condenser, Receiver
Cooling Unit
Air-Conditioner Circuit
Group 55B – Heater
Table of Contents
Specifications
Structure and Operation
1. Heater
2. Air Duct
3. Heater Control
Troubleshooting
Heater Control
Air Duct
Heater Unit, Blower
2005 FK/FM Service Manual
Group 00 – General
Table of Contents
Model Coding System
Power Train Table
Chassis Number and Engine Number
Power Train Label
Vehicle Identification Number
Precautions for Maintenance Operation
Diagnosis Codes
1. Connecting Multi-Use Tester
2. Accessing/Erasing Diagnosis Codes <Common Rail, Exhaust gas recirculation, Pre-heater
3. Accessing/Erasing Diagnosis Codes <Auto Cruise
4. Accessing/Erasing Diagnosis Codes <Anti-lock Brake System
Table of Standard Tightening Torques
Connector Configuration Chart
Group 01 – Maintenance Schedule
Table of Contents
How to Read the Maintenance Schedule Tables
Maintenance Schedule Tables
Maintenance Operations
Lubrication Tables
Lubrication
Group 11 – Engine
Table of Contents
Specifications
Structure and Operation
1. Engine Proper
2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket
3. Valve Mechanism
4. Connecting Rods
5. Pistons
6. Timing Gears
7. Flywheel
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Measuring Compression Pressure
2. Inspecting and Adjusting Valve Clearance
Engine Removal and Installation
Rocker Cover, Rocker and Bracket Assembly, Camshaft
Cylinder Head, Valve Mechanism
Pistons, Connecting Rods and Cylinder Liners
Flywheel
<Manual Transmission
<Automatic Transmission
Timing Gears
Crankshaft and Crankcase
Group 12 – Lubrication
Table of Contents
Specifications
Structure and Operation
1. Lubrication System
2. Oil Pump
3. Oil Filter
4. Oil Cooler
5. Engine Oil Pressure Switch and Regulator Valve
6. Lubrication of Related Parts
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Oil Filter Replacement
2. Engine Oil Replacement
3. Oil Pressure Measurement
Oil Pan and Oil Jet
Oil Pump and Oil Strainer
Oil Filter
Oil Cooler
Regulator Valve
Group 13 – Fuel and Engine Control
Group 13A – Fuel and Engine Control
Table of Contents
Specifications
Structure and Operation
1. Fuel System
2. Engine Control
3. Fuel Filter
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Checking No-load Minimum and Maximum Speeds
2. Air Bleeding of Fuel System
3. Replacement of Fuel Filter
Engine Control
Fuel Tank
Fuel Filter
Common Rail Assembly
Supply Pump
Injector, Fuel Temperature Sensor
Group 13E – Electronically Controlled Fuel System
Table of Contents
<Common Rail System
Specifications
Structure and Operation
1. Overview
2. Electronic Control System
3. Electronic Control Unit Connection Diagram
Troubleshooting
1. Inspection Procedure
2. Cautions to Observe When Performing Inspections
3. Inspections Based on Diagnosis Codes
4. Multi-Use Tester Service Data
5. Actuator Tests Performed Using Multi-Use Tester
6. Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit
7. Inspections Performed at Electronic Control Unit Connectors
Inspection of Electrical Equipment
Installed Locations of Parts
Electric Circuit Diagram
<Auto Cruise System
Structure and Operation
1. General Description
2. Electronic Control System
3. Electronic Control Unit Connection Diagram
Troubleshooting
1. Inspection Procedure
2. Cautions to Observe When Performing Inspections
3. Inspection Based on Diagnosis Codes
4. Multi-Use Tester Service Data
5. Actuator Tests Performed using Multi-Use Tester
6. Inspections Performed at Electronic Control Unit Connectors
Inspection of Electrical Equipment
Installed Locations of Parts
Electric Circuit Diagram
Group 14 – Cooling
Table of Contents
Specifications
Structure and Operation
1. Cooling System (Coolant Flow)
2. Water Pump
3. Thermostat
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Replacing Coolant and Cleaning Cooling System
2. Air Bleeding of Cooling System
3. Gas Leak Testing
Radiator and Fan Shroud
Cooling Fan and V-Belt
Water Pump
Thermostat
Group 15 – Intake and Exhaust
Table of Contents
Specifications
Structure and Operation
1. Air Cleaner
2. Turbocharger Assembly
Troubleshooting
On-Vehicle Inspection and Adjustment
Measurement of Turbocharger Boost Pressure
Air Duct
Air Cleaner
Turbocharger
Intercooler
Intake Manifold
Exhaust Manifold
Exhaust Pipe and Muffler
Group 17 – Emission Control
Table of Contents
Structure and Operation
1. Exhaust Gas Recirculation System
2. Crankcase Emission Control System
On-Vehicle Inspection and Adjustment
1. Replacement of PCV Valve Element
Exhaust Gas Recirculation System
1. Inspection Procedure
2. Cautions to Observe when Performing Inspections
3. Inspections Based on Diagnosis Codes
4. Multi-Use Tester Service Data
5. Actuator Tests Performed Using Multi-Use Tester
6. Inspection of Electrical Equipment
Installed Locations of Parts
Electric Circuit Diagram
Exhaust Gas Recirculation Valve, Exhaust Gas Recirculation Solenoid Valve, Exhaust Gas Recirculation Pipe, Exhaust Gas Recirculation Cooler
Crankcase Emission Control System
Group 21 – Clutch
Table of Contents
Specifications
Structure and Operation
Troubleshooting
On-Vehicle Inspection and Adjustment
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding <Clutch Power Cylinder
Clutch Fluid (Brake Fluid) Replacement and Air Bleeding <Clutch Booster
Inspection of Function <Clutch Booster
Clutch Pedal Free Play <Clutch Power Cylinder
Clutch Pedal Free Play <Clutch Booster
Clutch Pedal <M060S6, M070S6
Clutch Pedal <Eaton FS-8209
Clutch Master Cylinder
Clutch Power Cylinder <M060S6, M070S6
Clutch Booster <Eaton FS-8209
Work Before Removal and Installation of Clutch Body
Clutch Body
Clutch Control <M060S6, M070S6
Clutch Control <Eaton FS-8209
Group 22 – Manual Transmission
Group 22A – Manual Transmission <M060S6, M070S6
Table of Contents
Specifications
Structure and Operation
Troubleshooting
Work Before Removal and Installation of Transmission Assembly
Removal and Installation of Transmission Assembly
Gear Shifter Upper and Interlock Plate
Power Shift Assembly
Extension Housing and Parking Brake Assembly
6th Gear and Reverse Idler Gear <M060
Reverse Gear and Reverse Idler Gear <M070
Transmission Body
Drive Pinion Assembly
Mainshaft Assembly <Over-Drive (M060)
Mainshaft Assembly <Direct-Drive (M070)
Countershaft Assembly
Transmission Control
Puller and Installer Kit
Group 22B – Manual Transmission <M060S9 (Eaton FS-8209)
Table of Contents
Specifications
Removal and Installation of Transmission Assembly
Transmission Control
High-Low Control
Group 23 – Automatic Transmission
Group 23A – Automatic Transmission <M065A5 (Allison LCT1000, LCT2400)
Table of Contents
Specifications
Structure and Operation
1. Outline
2. Electronic Control System
3. Electronic Control Unit Connection Diagram
Troubleshooting
1. Failure by Equipment
2. Measures for Transitory Failure
On-Vehicle Inspection and Adjustment
1. Stall Test
2. Line Pressure Test
3. Inspection of Automatic Transmission Fluid
4. Replacement of Automatic Transmission Fluid
5. Replacement of Oil Filter
Preparatory Work for Removal and Installation of Automatic Transmission Assembly
Removal and Installation of Automatic Transmission Assembly
Parking Brake Assembly
Oil Pan, Suction Filter and Level Gauge
Automatic Transmission Control
Oil Cooler
Inspection of Electrical Equipment
Installed Locations of Parts
Electric Circuit Diagram
Group 23B – Automatic Transmission <M100A6 (Allison MD3060P)
Table of Contents
Specifications
Structure and Operation
1. Automatic Transmission Assembly
2. Automatic Transmission Control System
3. Oil Cooler System
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Stall Test
2. Line Pressure Test
3. Inspection of Automatic Transmission Fluid
4. Replacement of Automatic Transmission Fluid
5. Level Check of Automatic Transmission Fluid
6. Replacement of Oil Filter
Oil Cooler
Installed Locations of Parts
Electric Circuit Diagram
Group 25 – Propeller Shaft
Table of Contents
Specifications
Structure and Operation
Troubleshooting
Removal and Installation of Propeller Shaft
Rear Propeller Shaft
<P8
<P10, P12
Front Propeller Shaft
<P8
<P10, P12
Balancing Propeller Shaft
Group 26 – Front Axle
Table of Contents
Specifications
Structure and Operation
On-Vehicle Inspection and Adjustment
Adjustment of Wheel Alignment
Adjustment of Steering Angle
Measurement of Side Slip
Work Before Removal and Installation of Front Axle
Wheel Hub and Brake Drum
<FK
<FM (Air-Over Hydraulic Brake)
<FM (Full-Air Brake)
Front Axle, Knuckle and Kingpin
<FK
<FM (Air-Over Hydraulic Brake)
<FM (Full-Air Brake)
Group 27 – Rear Axle
Table of Contents
Specifications
Structure and Operation
Troubleshooting
Work Before Removal and Installation of Rear Axle
Wheel Hub and Brake Drum
<FK
<FM
Axle Housing
Reduction and Differential <D050H, D8H
Reduction and Differential <D10H
Group 31 – Wheel and Tire
Table of Contents
Specifications
Troubleshooting
Wheel and Tire
Group 33 – Front Suspension
Table of Contents
Structure and Operation
Troubleshooting
Work Before Removal and Installation of Front Suspension
Removal and Installation of Leaf Spring Assembly
Leaf Spring Assembly
Shock Absorber
Group 34 – Rear Suspension
Group 34A – Rear Suspension <LEAF
Table of Contents
Structure and Operation
Troubleshooting
Work Before Removal and Installation of Rear Suspension
Removal and Installation of Leaf Spring Assembly
Leaf Spring Assembly
Group 34B – Rear Suspension <AIR
Table of Contents
Specifications
Structure and Operation
1. Air Suspension
2. Air Suspension System
3. Leveling Valve
Troubleshooting
On-Vehicle Inspection and Adjustment
Adjustment of Air Spring Height
Work Before Removal and After Installation of Rear Suspension
Shock Absorber
Removal and Installation of Leaf Spring Assembly and Air Spring
Leaf Spring Assembly
Air Spring
Leveling Valve
Group 35 – Brake
Group 35A – Brake <Air Over Hydraulic Brake
Table of Contents
Specifications
Structure and Operation
Troubleshooting
On-Vehicle Inspection and Adjustment
Replacement of Brake Fluid
Air Bleeding of Brake System
Inspection and Adjustment of Brake Pedal Free Play
Thickness Inspection and Replacement of Brake Lining
Inspection of Brake Shoe Clearance
Inspection and Maintenance of Air Dryer
Inspection and Adjustment of Air Dryer’s Air Pressure Governor
Handling of Connector and Nylon Tube Piping
Air Compressor
Air Dryer
Brake Pedal
Dual Brake Valve
Brake Booster (Airmaster)
Front Wheel Brake
<320 mm {12.6 in.} Drum Brake
<400 mm {15.7 in.} Drum Brake
Rear Wheel Brake
<320 mm {12.6 in.} Drum Brake
<400 mm {15.7 in.} Drum Brake
Fluid Tank
Check Valve
Safety Valve
Supply Valve
Exhaust Brake System
Group 35B – Brake <Full Air Brake
Table of Contents
Specifications
Structure and Operation
Troubleshooting
On-Vehicle Inspection and Adjustment
Inspection and Adjustment of Brake Pedal Free Play
Thickness Inspection and Replacement of Brake Lining
Handling of Connector and Nylon Tube Piping
Air Compressor
Air Dryer
Brake Pedal
Dual Brake Valve
Relay Valve
Quick Release Valve
Front Wheel Brake
Rear Wheel Brake
Expander Assembly
Check Valve
Safety Valve
Supply Valve
Exhaust Brake System
Group 35E – Anti-Lock Brake System (ABS)
Table of Contents
Specifications
Structure and Operation
On-Vehicle Inspection and Adjustment
Periodic Inspection Procedures
Adjustment of Wheel Speed Sensor Clearance <Air-Over Hydraulic Brake
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope
Troubleshooting
Inspection Procedures
Inspection Flowchart
Diagnosis Code Chart
Service Data Chart
Actuator Drive Chart
Locations of Parts
Electrical Wiring Diagram
Group 36 – Parking Brake
Group 36A – Parking Brake <Center Parking Brake
Table of Contents
Specifications
Structure and Operation
Troubleshooting
On-Vehicle Inspection and Adjustment
Adjustment of Parking Brake Shoe Clearance and Lever Stroke
Parking Brake Control
Parking Brake Assembly
Support Plate and Shoe Assembly
Group 36B – Parking Brake <Wheel Parking Brake
Table of Contents
Structure and Operation
Troubleshooting
Parking Brake Control Valve
Spring Brake Valve
Double Check Valve
Group 37 – Steering
Table of Contents
Specifications
Structure and Operation
Troubleshooting
On-Vehicle Inspection and Adjustment
Change of Power Steering Fluid
Bleeding of Power Steering System
Steering Wheel Play
Performance Verification Test of Power Steering System
Steering System
Linkage and Bracket
Power Steering Booster
Power Steering Oil Pump
<FK, FM61, FM64
<FM65
Power Steering Oil Tank
Drag Link
Tie Rod Assembly
Group 41 – Frame
Table of Contents
Specifications
Structure and Operation
Inspection and Repair of Frames
Group 42 – Cab
Table of Contents
Specifications
Structure and Operation
Troubleshooting
On-Vehicle Inspection and Adjustment
Adjustment of Door Fitting
Removal and Installation of Cab
Front Cab Mounting
Rear Cab Mounting
Cab Stay
Cab Tilt Link
Door
Mirror
Seat
<Driver
<Passenger
Seat Belt
Wiper and Washer
Instrument Panel
Scuff Plate and Trim
Headlining
Front Panel
Radiator Grille and Corner Panel
Step
Fender
Mud Guard
Window Glass
Group 54 – Electrical
Table of Contents
How to Read This Group
0 – General
Specifications
Structure and Operation
1. Starter
2. Alternator
3. Lamp
4. Daytime Running Light (DRL) System
5. MUTIC (Multipurpose Timing Control Unit)
6. Engine Electronic Control Unit
Troubleshooting
1. Fault Diagnosis Function
2. Power and Charging
3. Engine Starting, Preheating and Stopping
4. Lighting
5. Meter
6. Cigarette Lighter and Audio
7. Accessory Noise Generation Source
8. Horn
1 – Power, Charge and Ground Circuit
104 – Relay and Fuse Box Circuit
110 – Power Circuit
111 – Electronic Control Unit Power Circuit
115 – Reserve Power Circuit
125 – Battery Charging Circuit
130 – Ground
2 – Starting and Preheating Circuit
210 – Engine Starting Circuit
220 – Engine Preheating Circuit
3 – Lighting Circuit
310 – Headlamp Circuit
313 – Daytime Running Light Circuit
320 – Tail, Clearance and License Plate Lamp Circuit
325 – Stop Lamp Circuit
330 – Turn Signal and Hazard Lamp Circuit
340 – Backup Lamp Circuit
345 – Cab Lamp Circuit
348 – Illumination Lamp Circuit
349 – Marker and Identification Lamp Circuit
352 – Van Body Dome Light Circuit
4 – Meter Circuit
401 – Meter Cluster Internal Circuit
410 – Tachometer Circuit
412 – Speedometer Circuit
420 – Fuel Gauge Circuit
425 – Water Temperature Gauge Circuit
5 – Indicator and Warning Lamp Circuit
510 – Parking Brake Indicator Circuit
515 – Brake Warning Circuit
530 – Water Level Warning Circuit
535 – Engine Oil Level Warning Circuit
536 – Engine Oil Pressure Warning Circuit
537 – Overheating Warning Circuit
548 – Transmission High/Low Indicator Circuit
550 – Cab Tilt Warning Circuit
566 – Fuel Filter Warning Circuit
6 – Cab Side Electrical Circuit
610 – Cigarette Lighter Circuit
612 – Audio Circuit
614 – Wiper and Washer Circuit
616 – Horn Circuit
620 – Air-Conditioner Circuit
622 – Power Window and Auto Door Lock Circuit
629 – Mirror Heater Circuit
7 – Chassis Side Electrical Circuit
710 – Exhaust Brake Circuit
718 – Air Dryer Circuit
722 – Air Suspension Circuit
8 – Engine and Transmission Side Electrical Circuit
850 – Transmission Power Take-Off Circuit
9 – Others Circuit
910 – Multipurpose Timing Control Unit Circuit
10 – Parts Installation Position
A – Switch
B – Relay and Electronic Control Unit
C – Fuse, Meter, Sensor, Buzzer and Motor
D – Heater
E – Door and Mirror
F – Roof
G – Cab
J – Joint of Main Harness Connectors
R – Engine
S – Transmission
T – Switch and Sensor
U – Fuse and Connector
V – Magnetic Valve
W – Buzzer
11 – Inspection of Parts
#001 to #179 – Switch
#180 to #249 – Relay
#250 to #349 – Sensor
#350 to #409 – Control Unit
#410 to #509 – Motor
#510 to #559 – Actuator
#560 to #609 – Magnetic Valve
#610 to #649 – Buzzer and Horn
#650 to #699 – Lamp
#750 to #859 – Other
#860 – Battery
#870 to #889 – Fuse
#890 – Meter Cluster
12 – Starter and Alternator
#930 – Starter
#940 – Alternator
#950 – Inspection of Alternator
#951 – Inspection of Regulator
13 – On-Vehicle Inspection and Adjustment
#955 – Inspection of Preheating System
#960 – Adjustment of Headlamp Aiming
#965 – Inspection of Brake Fluid Level Switch
Group 55 – A/C & Heater
Group 55A – Air-Conditioner
Table of Contents
Specifications
Structure and Operation
1. Air System
2. Refrigerating Circuit
3. Engine Room
4. Cabin Room
5. Compressor
6. Magnetic Clutch
7. Check Valve
8. Side Condenser Assembly
9. Relief Valve
10. Receiver Assembly
11. Cooling Unit Assembly
12. Expansion Valve
13. Dual Pressure Switch
14. Power Relay
15. Air-Conditioner Switch
16. Thermostat
17. Control System
Troubleshooting
On-Vehicle Inspection and Adjustment
1. Recovery of Refrigerant
2. Inspection and Adjustment of V-Belt
3. Inspection of Magnetic Clutch
4. Charging System with Refrigerant
5. Inspection of Refrigerant
6. Replenishment of Refrigerant
7. Inspection of Receiver Assembly
Connection of Air-Conditioner Piping
Compressor and Tension Pulley
Side Condenser Assembly and Receiver Assembly
Cooling Unit
Air-Conditioner Circuit
Group 55B – Heater
Table of Contents
Specifications
Structure and Operation
Troubleshooting
Heater Hose
Heater Control
Air Duct
Heater Unit and Blower
Air Outlet Ventilation

 

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Mitsubishi Fuso FE, FG, FK & FM Series Trucks Workshop Repair Service Manual.pdf

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