Mitsubishi Fuso Canter Fe Fg 4m5 4d3 Shop Manual 2002 2004

GROUP INDEX HOW TO READ THIS MANUAL GENERAL ............................................. 00 MAINTENANCE SCHEDULE ............... 01 ENGINE

SERVICE MANUAL 2002 Model 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 contined vehicle improvements that are made throughout the model years. Should you encounter any discrepancy in the information provided, please do not hesitate to contact your nearest Mitsubishi Fuso Dealer or Mitsubishi Fuso Truck of America, Inc. April 2001

< 4M5 > ................................................... 11A < 4D3 > .................................................... 11B

LUBRICATION

< 4M5 > ................................................... 12A < 4D3 > .................................................... 12B

FUEL AND ENGINE CONTROL

< 4M5 > ................................................... 13A < 4D3 > .................................................... 13B

ELECTRONICALLY CONTROLLED FUEL SYSTEM

< 4M5 > ................................................... 13EA < 4D3 > .................................................... 13EB

COOLING

< 4M5 > ................................................... 14A < 4D3 > .................................................... 14B

INTAKE AND EXHAUST

< 4M5 > ................................................... 15A < 4D3 > .................................................... 15B

CLUTCH ............................................... 21 MANUAL TRANSMISSION .................. 22 AUTOMATIC TRANSMISSION ............ 23 TRANSFER ........................................... 24

HOME

PROPELLER SHAFT ........................... 25 FRONT AXLE

< FE > ...................................................... 26A < FG > ..................................................... 26B

REAR AXLE ......................................... 27 WHEEL AND TIRE ............................... 31 FRONT SUSPENSION ......................... 33 REAR SUSPENSION ........................... 34 BRAKE ................................................. 35A ANTI-LOCK BRAKE SYSTEM ............. 35E PARKING BRAKE ................................ 36 STEERING ............................................ 37 FRAME ................................................. 41 CAB ...................................................... 42 ELECTRICAL ....................................... 54 AIR-CONDITIONER .............................. 55A HEATER ............................................... 55B

How to Read this Manual

' 98 Minor Change

Pub No. TWSE0101-H

INDEX HOW THIS MANUAL IS STRUCTURED ................................................. 2 TERMS ................................................................................................... 15

HOW THIS MANUAL IS STRUCTURED

I'm here to explain how to use this manual. To get the most out of your manual, follow along carefully and read all the notes given by my assistant.

We're here to help you.

23929

Group 21

This manual is divided into groups, with one group for each main area of the vehicle.

By way of example, let's look at Group 21, which covers the clutch.

Group 27

Group 31

23915

Each group is divided into five parts, as shown below.

Specifications

23916

Specifications, oil quantities, and other information pertaining to system components.

INDEX Structure and Operation Information on the structure and operation of the overall system and its components.

SPECIFICATIONS ..........................................................

STRUCTURE AND OPERATION ...................................

TROUBLESHOOTING ...................................................

ON-VEHICLE INSPECTION AND ADJUSTMENT

Troubleshooting An item-by-item guide to fault symptoms and their probable causes.

1. Clutch Fluid Replacement and Air Bleeding ...................

2. Inspection of Clutch Booster Functionality .....................

3. Clutch Pedal Play ...............................................................

CLUTCH PEDAL ............................................................

CLUTCH MASTER CYLINDER ......................................

On-Vehicle Inspection and Adjustment Instructions for on-vehicle inspection and adjustment operations.

CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER ......................................................................

CLUTCH POWER CYLINDER ........................................

CLUTCH-PROPER ........................................................

CLUTCH HOUSING .......................................................

CLUTCH DISC WEAR INDICATOR SWITCH .................

Service Instructions (See the next and subsequent pages.)

The service instructions are the most important parts of this manual. Starting on the next page, you'll learn more about them.

23917

2

HOW THIS MANUAL IS STRUCTURED Service procedures

1 Now, let's take a detailed look at the service instructions.

Please follow along carefully.

INDEX SPECIFICATIONS .................................................

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Clutch Fluid Replacement and Air Bleeding ........

2. Inspection of Clutch Booster Functionality .........

3. Clutch Pedal Play ...................................................

CLUTCH PEDAL ...................................................

CLUTCH MASTER CYLINDER .............................

CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER .............................................................

CLUTCH POWER CYLINDER ..............................

CLUTCH-PROPER ................................................

CLUTCH HOUSING ..............................................

23918

2 The service instructions consist of the parts shown below. Starting on page 7, these parts are described in detail in order of the circled numbers.

20244

Group number Name of system or assembly

1 Exploded view

This shows the system or assembly in its disassembled form.

Key numbers

List of part names

This appears on each right-hand page.

4 Lubricants, fluids and/or sealants

This table shows the required brands and quantities of oils, greases and/or sealants.

2 Service

5 Special tools

3 Tightening

6 Service

standards

torques

procedure

26310

3

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

HOW THIS MANUAL IS STRUCTURED 3 Look at the exploded view first; it gives an overview of the system or assembly.

26311

4

2 6

I see... First I look at the exploded view, then I look at parts to .

2 6

All other information is given in parts to .

23921

5

2 6

Basically, you should find the information you need from parts to as you perform the service procedure.

20245 26312

But how should I find the information I need?

I'll show you on the next page.

23922

4

HOW THIS MANUAL IS STRUCTURED 6 Find the information you need using the key numbers.

For example, let's assume you're assembling the clutch and need the tightening torque for the bolt .

1

To find the tightening torque, just look up key number 1 in the “Tightening torques” table.

5.9 {4.3, 0.6}

45204

I see... The key numbers for the exploded view match the key numbers on other parts of the page.

20252

To help you find information quickly: Tightening torques are marked with Ê .

Lubricants, fluids and sealants are marked with -.

And every key number that appears in the service procedure is enclosed with a square.

26314

5

HOW THIS MANUAL IS STRUCTURED 1

Exploded view

1

CLUTCH-PROPER <C5> Pressure Plate-and-Lever Assembly

Ù

Explanatory notes for the exploded view are given below. Explanatory notes for the parts list are given on the facing page.

● Pre-disassembly operations Õ P21 - 44

12 11 7-

-

6

8

P

8 3 2 1 Ê -

5

• Disassembly sequence 1 Bolt 2 Lock plate 3 Support nut 4 Pressure spring 5 Pressure spring cap 6 Return spring 7 Release lever plate 8 Clutch cover 9 Release lever pin 10 Support lever pin 11 Support lever 12 Release lever 13 Bushing 14 Pressure plate P Positioning pin Ù : Non-reusable part NOTE Do not remove the bushing 13 unless it is defective.

● Assembly sequence Reverse the order of disassembly.

Repair kit : Clutch release Lever kit

23925

● Post-assembly Inspection and adjustment Õ P21 - 44

This mark indicates a part that cannot be reused.

Pressure Plate-and-Lever Assembly Ù

This mark indicates that lubricant or sealant must be applied to the part.

12 11 7-

-

The key number enclosed with a square indicates that the part is mentioned in the service procedure.

23926

6

8

This mark indicates that a tightening torque is specified for the part.

P

5

3 2 1 Ê -

P : Indicates positioning 23927

pin.

So parts without Ê marks don't have specified tightening torques ?

No, they don't. But every bolt and nut must be tightened to a standard torque. A Ê mark shows either that the part must be tightened to a torque other than the standard torque or that the standard torque cannot be determined from the part's shape or markings.

Standard tightening torques are explained at the bottom of the next page.

23928

6

HOW THIS MANUAL IS STRUCTURED 2 ● Pre-disassembly operations Õ P21 - 44

The key numbers are given here.

● Disassembly sequence 1 Bolt 2 Lock plate 3 Support nut 4 Pressure spring 5 Pressure spring cap 6 Return spring 7 Release lever plate 8 Clutch cover 9 Release lever pin 10 Support lever pin 11 Support lever 12 Release lever 13 Bushing 14 Pressure plate Ù : Non-reusable part

The key numbers show the disassembly sequence.

This shows that certain operations must be performed before disassembly.

The names of parts are given here.

Links to reference information are given as follows: • Õ P21 - 44 Refer to the indicated page of the same group.

• ^ Gr 42 Refer to the indicated group in another manual.

NOTE Do not remove bushing 13 unless it is faulty. ● Assembly sequence Follow the disassembly sequence in reverse.

Repair kit : Clutch Release Lever kit ● Post-assembly inspection and adjustment Õ P21 - 44

This shows that certain operations must be performed after assembly.

The name of the specified repair kit (if any) is given here.

The assembly sequence is given here. Assembly is usually performed in the opposite order to disassembly. If the assembly sequence is otherwise specified, it is given in terms of key numbers like this: ● Assembly sequence 14→12→10→13→11.....

Now let's look at standard tightening torques. Normally, bolts and nuts have numbers or markings to show their material strength.

Tightening torques for bolts and nuts with such numbers and markings are shown in the Table of Standard Tightening Torques that appears in group 00.

INDEX ENGINE NUMBER AND NUMBER PLATE ...................................................

+

PRECAUTIONS FOR MAINTENANCE OPERATIONS .......................................

TABLE OF STANDARD TIGHTENING TORQUES ......................

23930

7

HOW THIS MANUAL IS STRUCTURED 2

Service standards Service standards

Unit : mm {in.} Maintenance item

Location

4

Installed load (Installed length 49.1 {1.93})

Pressure spring

Squareness 7 10, 13

Release lever plate height Clearance between release lever pin and bushing

Pressure plate

Limit

885 N {200 lbf, 90.2 kgf}

750 N {170 lbf,76.7 kgf}

Replace

2.9 {0.11} or less

5.0 {0.20} Relative difference 0.5 {0.020} maximum

Replace

0.4 {0.016}

Replace

53.8±0.7 {2.12±0.028} [10 {0.39}] 0.02 to 0.11 {0.00079 to 0.0043}

Thickness 14

Standard value (Basic diameter in [ ])

Flatness Strap bolt hole I.D.

Adjust

23.6±0.1 {0.93±0.0039}

21 {0.83}

Replace

0.05 {0.0020} or less

0.2 {0.0079}

Correct or replace

10.5 {0.41}

Replace

10.2 to 10.25 {0.40 to 0.40}

Number(s) in this column match the key number(s) on the exploded view

3

Remedy

1.

Tightening torques Ê Tightening torque Location 1

Unit : N·m {ft.lbs, kgf.m}

Parts to be tightened Bolt (Lock plate mounting)

1

Number(s) in this column match the key number(s) on the exploded view .

Tightening torque

Remarks

5.9 to 7.8 {4.3 to 5.8, 0.6 to 0.8}

—

If oil or grease must be applied to threads before tightening, the word "Wet" appears in this column.

Remarks Wet

4

Lubricants, fluids and/or sealants

- Lubricant Location 3 7, 12

Points of application

Quantity

Threads and spherical surface of support nut

Anti-seizure compound

As required

Sliding surfaces of release lever plate and release lever

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

11, 12

Sliding surfaces of support lever and release lever

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

11, 14

Sliding surfaces of support lever and pressure plate

Molybdenum disulfide grease [NLGI No.2 (Li soap)]

As required

1

Number(s) in this column match the key number(s) on the exploded view .

8

Specified lubricant

The specified types/brand are shown here.

HOW THIS MANUAL IS STRUCTURED 5

Special tools 0 Special tools

Unit : mm {in.}

Location

8

Tool name and shape

Part No.

Clutch Installer

MH061051

Application

Removal and installation of clutch cover

01277

1

Number(s) in this column match the key number(s) on the exploded view .

For any special tool that is not a Mitsubishi genuine part, no illustration is shown; only the part number is given, as shown below.

0 Special tools Location

Tool name and shape

Part No.

Application

21

Insertion Tool

*910-24461

Installation of O-ring

32

Retainer

*910-24590

Retention of primary piston

* BOSCH BRAKING SYSTEMS Co. Ltd. product number

6

Service procedure

1

1

Number(s) is this column match the key number(s) exploded view .

The service procedure gives instructions in order of key numbers.

6

Installation of pressure spring If the pressure plate 17 has been reqround, insert between the pressure plate and pressure spring 6 an adjusting washer A whose thickness matches that of the ground off material.

6 A

Regrind amount Less than 1 mm {0.039 in.}

17

16

01280

Not required

1 mm {0.039 in.} (or more) to less than 2 mm {0.079 in.}

1.2 mm {0.047 in.} x 1

2 mm {0.079 in.} (or more) to less than 3 mm {0.12 in.}

1.2 mm {0.047 in.} x 2 or 2.3 mm {0.091 in.} x 1

GL

17

Thickness and number of washer(s)

Clearance between release lever pin and bushing If the measurement exceeds the specified limit, replace the

11

defective part(s).

NOTE Perform this check with the bushing 16 press-fitted into the pressure plate 17.

01282

9

HOW THIS MANUAL IS STRUCTURED 2 Service procedures contain a variety of symbols and other indications. Let's look at some examples.

Key number 23931

2

Installation of oil seal Apply grease to the lip A of the oil seal 2.

• Using the 0 Oil Seal Installer ‚ fit the oil seal 2 into the front bearing retainer 3. Make sure the oil seal is aligned as illustrated.

[Example 1: Special tools]

•

0 2

3

A

Name of special tool

00299

Every special tool is indicated by a 0 symbol.

The text of the service procedure also includes the special tool's name. To see the part number and shape of a special tool, find the tool's key number and name in the “Special tools” table .

5

23932 26315

If more than one special tool is used, the symbols are supplemented by letters (for example, 1, 2 and 3) to enable crossreferencing between the exploded view and service procedure.

20277

1

1 2

6

3

3 4 5

2 6

10

20

17152

Removal and installation of clutch cover

[Removal] • Compress the pressure spring 8 using the 3 Clutch Installer, then remove the 1 Stopper Bolt, 2 Washer, strap bolt 1, washer 2, bolt 3, lock plate 4 and support nut 5.

• Gradually loosen the 3 Clutch Installer until the pressure spring 8 is ineffective, then remove the clutch cover 6.

HOW THIS MANUAL IS STRUCTURED 3

[Example 2: Identification or mating marks] Any mark on an actual part is given in quotation marks “ ” in the service procedure.

F

“L”

5

Installation of torsion bar

Fit the torsion bar 10 such that the "L" identification mark is on the side of the anchor lever 5.

CAUTION! Make sure the torsion bar 10 aligned as specified. If the torsion bar is installed the wrong way around, the torsion direction will be reversed, resulting in damage.

10 05471

I see... The mark in the service procedure is actually visible on the part.

26304

4

[Example 3 : Alignment of parts]

1

All illustrations show the correct alignment/direction of parts relative to each other.

Provided the alignment/direction is shown clearly in the exploded view , no further explanation is given in the text of the service procedure.

15

K

49

Installation of oil seal

Fit the oil seal 15 into the body 49, making sure it is aligned as illustrated.

0 10933

That's all from us. We hope these notes will help you get the most of this manual.

Bye!

23934

11

HOW THIS MANUAL IS STRUCTURED HOW TO READ CIRCUITS (GROUP 54) 1 Index number 3 Code number 2 Key number 4 Part name

425

WATER TEMPERATURE GAUGE CIRCUIT

C04 871

C01 890

Fuse box

Meter cluster

110 401 F20

Water temperature gauge AU16C 4

5

J04

LY WT01

B EA03

Y BC20

Y BC20

13

5 Connector type

Meter 12

LY WT01

B EA03

12 Wire connection

BT20A 1

9

Y BC20

Cab

J08

6

LgR <FE6>

11 Grounding point

6

Installation area of 7 harness on the vehicle

MU04

130

U01

Circuit number Color of wire 10 Cross section of conductor

To multipurpose timing control unit

910

EA02 3-B

14

Number of terminal at connector

Cab

BT20A 12

Chassis

U06

6

Circuits for other 8 specification for other model or type Chassis

AA6A 5

Engine <FG> LgR MU04 <FG> LY WT01

2

AS2A

Water temperature sensor <FE>

MU04 LgR<FG>

MU04 0.85-LgR <FE>

MU04

2

WT01 0.85-LY <FE>

WT01 LY <FG>

1

WT01

AS2A

R01 262

1

Water temperature sensor <FG> 1

2

3

4

5

6

Female connector

3

2

1

6

5

4

R01 262

Male connector

42076

9

Examples of terminal connector numbering

P 43351

12

HOW THIS MANUAL IS STRUCTURED 1 Index number: 110 Each circuit has its own Index number respectively and has three digits ( 110 ).

How to read index number • By proper using of the index number, it is possible to locate right place immediately since the circuit drawing of this manual book are classified as function by function. (including “Power Circuit” 110 and “Ground Circuit” 130 .)

• How to check the location of circuit drawing in each part The circuit drawing which can not be diagramed in one page due to its complicated structure (such as meter cluster and electronic control unit etc.), has its remarked index number to be connected to other circuit drawing. ( 401 , 910 , etc.)

2 Key number: A01~ Key number is the number to indicate the installation position of the parts, and is shown by A01 ~ Z. The details of the installation position are described in GROUP 10 .

3 Code number: 001 ~ Code number is the number to indicate the one portion of the parts to be checked and has three digits ( 001 ).

The details of the parts to be checked are described in GROUP 1 1 .

4 Part name 5 Connector type Connectors are shown by without mentioning Male or Female and in the box it is described model of connector, number of terminals and its classification, etc.

Table of connectors is described in GROUP 1 4.

6 Number of terminal at connector Terminal numbers of connector are shown by figures in the box.

Model

7 Installation area of harness on the vehicle The location and boundary of the harnesses in the vehicle are shown in the each circuit drawing and it may help to check mounting position of connectors.

Number of terminals Classification

9

BT20A 1 12

Number of terminal at connector

8 Circuits for other specification for other model or type

P 43460

9 Examples of terminal connector numbering As it is shown, for female connectors, with placing the lock upward then starting to put numbers from the upper left. And when it is male connector, put numbers from the upper right, also with placing the lock upward.

10 Circuit number, color of wire, and cross section of conductor are shown in circuit drawings.

WT01 0.85 LY Color of wire Õ P14 Circuit numbers

Cross section of conductor (Unit : mm2 )

Except for 0.5mm2, Wire thickness is described in the circuit drawing. The reason why only wire thickness, 0.5 mm2 is not described in the drawings is 0.5mm2 is so common and so that the circuit drawing can be seen more easily.

(Examples) 0.5mm2: Y 0.85mm2: 0.85 — LY 3mm2: 3 — B 11 Grounding point The actual locations of grounding points on the vehicle are shown. Refer to

130 for detailed information.

12 Wire connection When the wires are connected into one point of the harnesses, the circuit drawing shows “Arrow mark”.

CAUTION !

Be careful that direction of the arrow does not show the direction of the electric current flow.

13

HOW THIS MANUAL IS STRUCTURED ● Wire Colors Example: WB means a wire whose ground color is white and whose stripe is black.

W (Wire ground color) B (Stripe)

07384

Wire ground color

Wire ground color + Stripe

W

White

WR

White red

WB

White black

WL

White blue

B

Black

BW

Black white

BY

Black yellow

BR

Black red

R

Red

RW

Red white

RB

Red black

RY

Red yellow

RG

Red green RL

Y

Yellow

YR

Yellow red

YB

Yellow black

YG

Yellow green

YL

Yellow blue YW

Yellow white

GR

Green red

GY

Green yellow

GB

Green black GL

Green blue

Blue black LO

Blue orange

G

Green

GW

Green white

Br

Brown

BrW

Brown white

L Lg

Blue

LW

Yellow green

O

Orange

P

Pink

LgR

PB

Blue white Yellow green red

LR

Blue red

LgY

Yellow green yellow

LY LgB

WG

Blue yellow Yellow green black

LB LgW

White green

Red blue

Yellow green white

Pink black

● Shield Wire A shield wire is clearly identified as follows: Example

Shield

Sheath Shield Core (conductor and insulation)

● Twist wire Twist wires are made by twisting the core of wires by the constant pitch.

Example:

Shown in circuit drawing

14

P 43533

07385

TERMS The terms in this manual are defined as follows. ● This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information:

DANGER–

Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives.

WARNING–

Precautionary instructions, which, if not observed, could result in serious injury or death.

CAUTION–

Precautionary instructions, which, if not observed, could result in damage to or destruction of equipment or parts.

NOTE

Suggestions or supplementary information for more efficient use of equipment or a better understanding.

● Front and rear The terms “front” is the fan side and “rear” the flywheels side of the engine. ● Left and right The terms “right” and “left” shall be used to indicate the side as viewed from the flywheel side of the engine. ● Terms of service standards (1) Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be.

The figure in [ ] is the basic diameter.

(2) Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. ● Tightening torque Appropriate tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened.

Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.

When the item is to be tightened in a “wet” state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque.

15

Group 00 General Table of Contents BACK

' 98 Minor Change HOME

Pub No. TWSE0101-00

INDEX MODEL CODING SYSTEM ............................................................ 00- 2 POWER TRAIN TABLE .................................................................. 00- 3 CHASSIS NUMBER AND ENGINE NUMBER ............................... 00- 4 POWER TRAIN LABEL .................................................................. 00- 4 VEHICLE IDENTIFICATION NUMBER .......................................... 00- 5 PRECAUTIONS FOR MAINTENANCE OPERATION .................... 00- 6 TABLE OF STANDARD TIGHTENING TORQUES ....................... 00- 18 CONNECTOR CONFIGURATION CHART .................................... 00- 22

MODEL CODING SYSTEM Equipment Model Equipment name Engine

Model description 4

D

3

4

Code description

T

5 4 3 2 1 4

M

5

0

T

5 4 3 2 1 Clutch

C

4

W

1 2 3 4 5

No. of cylinders (4 : Four cylinders) Stands for diesel engine Series number Version number With turbocharger

30 Disk outer diameter Facing material (W : Woven) Loading capacity of major type (tonnage) Stands for clutch

Transmission

M

035

S

5 No. of forward speeds Meshing (S : Synchromesh A : Automatic) Loading capacity of major type (tonnage) Stands for transmission

Propeller shaft

P

3 Loading capacity of major type (tonnage) Stands for propeller shaft

Reduction and differential

D

033

H Teeth shape (H : hypiod gear) Loading capacity of major type (tonnage) Stands for reduction and differential

00-2

POWER TRAIN TABLE

00 Final reduction and gear ratio

Engine model

Clutch model

Transmission model

Propeller shaft

4D34T3 145 HP/2900 rpm 275 ft.lbs/1600 rpm (SAE, Gross)

C4W30

M035S5 5.380/0.722

P3

R033T

D033H 5.714

Torque converter

M035A4 3.018/0.703

C4W30

M035S5 5.380/0.722

P3

R033T

D033H 5.714

Torque converter

M035A4 3.018/0.703

4M50T2 175 HP/2700 rpm 347 ft.lbs/1800 rpm (SAE, Gross)

Torque converter

M035A4 3.018/0.703

P3

R033T

D033H 5.285

FE649 G.V.W. 6375 kg {14050 lb}

4D34T3 145 HP/2900 rpm 275 ft.lbs/1600 rpm (SAE, Gross)

Torque converter

M035A4 3.018/0.703

P3

R033T

D033H 5.714

FE649 G.V.W. 6575 kg {14500 lb}

4D34T3 145 HP/2900 rpm 275 ft.lbs/1600 rpm (SAE, Gross)

C4W30

M035S5 5.380/0.722

P3

R033T

D033H 5.714

FG639 G.V.W. 5445 kg {12000 lb}

4D34T3 145 HP/2900 rpm 275 (253:*b) ft.lbs/1600 rpm (SAE, Gross)

Torque converter

M035A4+TF3 3.018/0.765

P2 (Front) P3 (Rear)

R033T

D1H modified 5.714 (Front) D033H 5.714 (Rear)

4D34T3 145 HP/2900 rpm 275 (253:*a) ft.lbs/1600 rpm (SAE, Gross)

C4W30

M035S5+TF3 5.380/0.722

P2 (Front) P3 (Rear)

R033T

D1H modified 5.714 (Front) D033H 5.714 (Rear)

Model

FE639 G.V.W. 5445 kg {12000 lb}

FE639 G.V.W. 6125 kg {13500 lb}

FE640 G.V.W. 6575 kg {14500 lb}

FG649 G.V.W. 6375 kg {14050 lb}

4D34T3 145 HP/2900 rpm 275 ft.lbs/1600 rpm (SAE, Gross)

Rear axle model

*a: Torque cut when 1st/reverse is selected *b: Torque cut when 4WD/Low is selected

00-3

CHASSIS NUMBER AND ENGINE NUMBER/POWER TRAIN LABEL CHASSIS NUMBER AND ENGINE NUMBER The serial numbers for chassis and engines are assigned to the respective vehicles and engines in manufacturing sequence: every vehicle and engine has its own numbers. These numbers are required for registration and incidental inspection of the vehicle. Please do not fail to mention these numbers to the dealers when ordering spare parts.

Chassis number Chassis number 1 is punch-marked on the frame by the left-side front wheel.

Example : FE639C-❚❚❚❚❚❚

1

Vehicle model

Chassis number

02251

Engine number Engine number 2 is punch-marked on the left side of the crankcase.

< 4D3 >

Example : 4D34-❚❚❚❚❚❚ 2

Engine number Engine model

02252

< 4M5 > 2

P29747

POWER TRAIN LABEL Power train label 1 located in the position illustrated indicates the vehicle model, chassis number and information relevant to the vehicle's power train components.

1

00-4

02650

VEHICLE IDENTIFICATION NUMBER

00

VEHICLE IDENTIFICATION NUMBER The vehicle identification number is punch-marked on the plate, which is attached in the position as illustrated.

The vehicle identification number consists of a 17-digit set of alphanumeric characters. Each digit represents the following specifications.

< Except crew cab >

< Crew cab > 45910

J W 6 A A C 1 H ■ 2 L■ ■ ■ ■ ■ ■

1 2 345 678 9 FG 1 2 3 4 5 6 7 8 9 F G H

Country Make Vehicle type Gross vehicle weight/Brake system Line

Series (Wheelbase)

Cab chassis type Engine Check digit Model year Plant

H

J: W: 6: 7: A: B: A: B: G: H: K: L: C: E: F: H: 1: 3: H: S:

Japan Mitsubishi Fuso Incomplete Vehicle Truck 10001 to 14000 lbs/Hydraulic 14001 to 16000 lbs/Hydraulic FE639 FE649 FG639 FE640 FE640■W FG649 2.6 to 2.98 m {8.53 to 9.48 ft.} 3.2 to 3.49 m {10.49 to 11.44 ft.} 3.5 to 3.79 m {11.48 to 12.43 ft.} 4.1 to 4.39 m {13.45 to 14.40 ft.} Chassis cab Mixer 3.907 l Diesel turbocharged and charge air cooled 4.899 l Diesel turbocharged and charge air cooled

2: K: L: M:

2002 Kawasaki-1 Kawasaki-2 Kawasaki-3

Plant sequential number

00-5

PRECAUTIONS FOR MAINTENANCE OPERATION DANGER – This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

In order to determine the condition of the vehicle adequately, keep records of the accumulated mileage, operating condition, what the customer’s complaint is, and other information that may be necessary. Prepare steps to be taken to perform efficient maintenance procedures.

Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the procedure specified by this manual.

06473

Perform maintenance work on level ground.

Prepare the following.

• To prevent the seats, upholstery, floor and bodywork from being spoiled or scratched, cover with workshop sheet cover(s).

00008

• Prepare general and special tools necessary for the maintenance work.

WARNING– Do not attempt to use tools other than special tools where use of special tools is specified in this manual. This will avoid injury or damage.

00009

When jacking up the vehicle to work under the vehicle, carry out the following preparatory work: • Chock the wheels on both sides.

• Jack up the vehicle using a garage jack.

• Support the frame on rigid jack stands.

WARNING–

14192

00-6

• Chock the wheels securely so the vehicle does not move.

• Do not remove the chocks until the entire operation is completed.

• Supporting a vehicle on a garage jack only is extremely dangerous, so always support the frame on rigid jack stands.

• Leave the garage jack and rigid jack stands in place until the entire operation is completed. Never remove them during the operation.

00 When tilting the cab, be sure to insert the safety pin into the cab stay so that the cab stay remains locked and is not released when the cab is tilted.

14193

Pay special attention to safety when removing or installing heavy items such as engines, transmissions and axles.

When lifting up heavy items using cables, pay special attention to the following points: • Check the mass of the item to be lifted and use a cable capable of lifting that mass.

14194

• If you do not have the specified lifting hanger, secure the item using cable taking the point-of-balance of the item into consideration.

14195

• You must work in a position where you will not be injured even if the cable comes undone and the lifted item falls.

14196

00-7

PRECAUTIONS FOR MAINTENANCE OPERATION Be particularly careful not to work in shoes that have oily soles and are slippery. When working as a team of two or more, arrange signals in advance and keep confirming safety. Be careful not to accidentally bump switches or levers.

00012

Check for oil leakage before cleaning the area having the fault otherwise you might miss detecting the leakage.

00013

Prepare replacement part(s) beforehand.

00014

Replace oil seals, packing, O-rings and other rubber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts.

00015

On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.

00016

00-8

00 Put alignment marks on part combinations before disassembly and arrange the disassembled parts neatly. This will help avoid mismating of the parts later.

Put the alignment marks, punch marks, etc. where performance and appearance will not be affected.

Cover the area left open after removal of parts to keep it free from dust.

CAUTION–

00017

• Take care to avoid mixing up numerous parts, similar parts, left and right, etc.

• Keep new parts for replacement and original (removed) parts separate.

Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly.

Use only the specified oil, grease, etc. for lubricant, remove the excess immediately after application with a clean rag, etc.

CAUTION– When the specified lubricant, fluid and sealant is not available, you may use an equivalent.

00018

Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers.

00019

Before carrying out maintenance work on the electric system, disconnect the negative terminal from the batteries to prevent them from shortcircuiting.

CAUTION– Be sure to turn starter and lighting switches, etc. off before disconnecting or connecting battery terminals, because the semiconductors can become damaged.

14184

00-9

PRECAUTIONS FOR MAINTENANCE OPERATION Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. Do not attempt to remove the cover from, or apply paint to, the electronic control unit.

00021

Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type connector, first push toward arrow mark. To reconnect a lock-type connector, press the separated parts until they click together.

00022

When washing the vehicle, cover the electric system parts and instruments with waterproof material beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately.

00023

14184

00-10

When using an electric welder, such electronic parts that are directly connected to the batteries might be damaged due to the flow of current from the welder that flows through the negative circuit. Parts that have switches might be subject to the same danger if the switches are left on.

Therefore, do not fail to observe the following.

A : Welder B : Connect the negative terminal of the welder as near as possible to the area that is to be welded.

C : Disconnect the negative cable at the batteries. ^ Gr 54 130

00 â&#x20AC;˘ Disconnect the negative terminals of batteries. â&#x20AC;˘ Disconnect connections between the cab harness wires and the chassis harness wires.

06863

To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from 0 volt. Do not apply voltage higher than the specified value.

In particular, pay close attention to the electronic control unit and sensors, since they are not always fed by battery voltage.

14185

When using testers or the like for continuity tests, be careful not to allow test probes to touch the wrong terminals.

00027

00-11

PRECAUTIONS FOR MAINTENANCE OPERATION Measurement procedures using connectors

C

B

• Test with connectors engaged (continuity through circuit obtained)

B A

B

Connect the test harness and connector A between these parts 02587

< Waterproof connector > Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector.

Never insert the test probe from the harness side of the waterproof connection, or waterproof performance might be diminished causing corrosion of the connector.

< Non-waterproof connector > Insert test probe C from the harness side of the connector. Where control units, etc. have connectors that are too small to accept the test probe, do not force the test probe into them.

C

02588

• Test with connectors disengaged Using female pins Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.

02589

Using male pins Touch the pins directly using test probes.

CAUTION– Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit.

02590

00-12

00 Connector inspection procedures â&#x20AC;˘ Visual inspection Check for loose connection and poor engagement.

02591

Check if harnesses are broken by pulling gently around the terminals.

02592

Check for a decrease in contact pressure between the male and female terminals.

02593

Check for poor contact caused by connector pins having fallen out, rusted terminals or foreign particles. â&#x20AC;˘ Connector pin fall out inspection Damaged connector pin stoppers can cause poor engagement of the terminals (male and female pins) even if the connector body is secured, and might cause some pins to fall out. Check if the pins have fallen out from the connector by pulling each harness wire gently.

02594

00-13

PRECAUTIONS FOR MAINTENANCE OPERATION Inspection procedures for blown out fuses

A +

_

_

+

0Ω

The major causes of a short circuit are as follows: • Harness stuck under the vehicle mounted body.

• Harness sheath damaged by friction or heat.

• Water in connectors or circuits.

• Mistakes (accidental short circuits) A : Battery B : Fuse C : Loaded switch D : Load E : Short circuit

B

C

Remove fuse B and measure resistance between the loaded side of the fuse and ground.

Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0 Ω, a short has occurred between the switch and the loaded point. A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present.

E

D

02596

Precautions for handling alternator When servicing alternators, pay attention to the following : • Do not connect the alternator with battery polarities reversed.

If the alternator is connected with reversed polarities, a large current flow from the battery to the alternator occurs, and the diode or regulator might be damaged.

04746

• While the engine is running, do not remove the battery terminals. If the battery terminals are removed at that time, a surge voltage is generated and the diode or regulator might be weakened.

04747

• Do not use a high-voltage tester such as a megger for inspection.

If a high-voltage tester is used, the diode or regulator might be destroyed.

02371

00-14

00 â&#x20AC;˘ Do not splash water over the alternator.

If water is directly splashed over the alternator, individual components will be short-circuited and might be destroyed.

05165

â&#x20AC;˘ Do not short-circuit terminal B and terminal L while running the alternator.

If the terminals are short-circuited while the alternator is running, the diode trio might be destroyed.

04749

â&#x20AC;˘ Disconnect the battery terminals before quick-charging the battery.

Quick-charging without disconnecting the battery terminals might damage the diode or regulator.

05166

00-15

PRECAUTIONS FOR MAINTENANCE OPERATION Measures for temporary faults

02597

Temporary faults often occur under certain conditions. So identifying those conditions helps to find possible causes. To find the conditions under which temporary faults occurred, you need to reproduce the faults after interviewing customers in detail about actual driving conditions, weather, frequency of occurence and fault phenomena.

Then determine if the faults were caused by vibration, temperature or other possible elements depending on the actual conditions identified.

If vibration is suspected as a possible cause, inspect individual connectors as follows to check if the fault will occur: • Shake the connector gently in all four directions of the arrows as illustrated.

• Shake the wiring harness gently in all four directions of the arrows as illustrated.

• Wiggle each sensor or piece of equipment by hand.

• Gently shake the wiring harnesses near movable parts such as suspensions.

02598

02599

00-16

The inspection subjects include possible causes related to the diagnosis code outputs and faults, as well as the connectors and other parts in the inspection procedure.

00

MEMO

00-17

TABLE OF STANDARD TIGHTENING TORQUES • Use specified bolts and nuts and tighten them at specified torques according to the following table, unless otherwise specified.

• Threads and contact seats shall be dry.

• Where there is difference in strength classification between the nut and bolt (or stud bolt), the torque specified for the bolt shall apply.

Hex-head Bolt and Stud Bolt Strength classification

Unit : N·m {ft.lbs, kgf·m}

4T

8T

7T

Representation Diameter symbol

(Stud)

(Stud)

(Stud)

M5

2 to 3 {1.4 to 2.2, 0.2 to 0.3}

—

4 to 6 {2.9 to 4.3, 0.4 to 0.6}

—

5 to 7 {3.6 to 5.1, 0.5 to 0.7}

—

M6

4 to 6 {2.9 to 4.3, 0.4 to 0.6}

—

7 to 11 {5.1 to 8.0, 0.7 to 1.1}

—

8 to 12 {5.8 to 8.7, 0.8 to 1.2}

—

M8

9 to 14 {6.5 to 10.0, 0.9 to 1.4}

—

17 to 26 {12 to 19, 1.7 to 2.6}

—

20 to 29 {14 to 22, 2.0 to 3.0}

—

M 10

19 to 28 {14 to 20, 1.9 to 2.8}

18 to 26 36 to 52 33 to 49 45 to 60 {13 to 20,1.8 to 2.7} {25 to 40, 3.5 to 5.5} {25 to 36, 3.5 to 5.0} {33 to 43, 4.5 to 6.0}

41 to 59 {31 to 50, 4.3 to 6.9}

M 12

35 to 50 31 to 46 70 to 95 65 to 85 {25 to 36, 3.4 to 5.0} {22 to 34, 3.1 to 4.7} {51 to 69, 7.0 to 9.5} {47 to 61, 6.5 to 8.5}

M 14

60 to 85 {43 to 61, 6.0 to 8.5}

55 to 75 120 to 160 {40 to 54, 5.5 to 7.5} {87 to 115, 12 to 16}

M 16

90 to 130 {69 to 94, 9.5 to 13}

90 to 120 180 to 240 160 to 220 200 to 270 190 to 260 {65 to 87, 9.0 to 12} {130 to 175, 18 to 24} {115 to 160, 16 to 22} {145 to 195, 20 to 27} {135 to 190, 19 to 26}

85 to 110 {61 to 80, 8.5 to 11}

75 to 100 {54 to 72, 7.5 to 10}

110 to 140 130 to 180 120 to 160 {80 to 100, 11 to 14} {94 to 130, 13 to 18} {87 to 120, 12 to 17}

M 18

140 to 190 120 to 160 260 to 340 220 to 290 290 to 390 260 to 340 {100 to 135, 14 to 19} {87 to 115, 12 to 16} {180 to 255, 25 to 35} {160 to 215, 22 to 30} {215 to 290, 30 to 40} {190 to 255, 26 to 35}

M 20

190 to 260 170 to 230 350 to 470 320 to 420 410 to 550 370 to 490 {135 to 190, 19 to 26} {120 to 165, 17 to 23} {260 to 345, 36 to 48} {230 to 310, 32 to 43} {295 to 405, 41 to 56} {265 to 360, 37 to 50}

M 22

260 to 340 230 to 300 470 to 640 430 to 570 550 to 740 490 to 670 {190 to 255, 26 to 35} {165 to 225, 23 to 31} {345 to 470, 48 to 65} {310 to 420, 43 to 58} {405 to 540, 56 to 75} {360 to 490, 50 to 68}

M 24

340 to 450 290 to 390 630 to 840 540 to 730 730 to 980 630 to 840 {255 to 330, 34 to 46} {210 to 290, 29 to 40} {455 to 620, 63 to 86} {395 to 535, 55 to 74} {535 to 725, 74 to 100} {460 to 620, 64 to 86}

Hex-head Flange Bolt Strength classification

Unit : N·m {ft.lbs, kgf·m}

4T

8T

7T

Representation Diameter symbol

M6

4 to 6 {2.9 to 4.3, 0.4 to 0.6}

—

8 to 12 {5.8 to 8.7, 0.8 to 1.2}

—

9 to 14 {6.5 to 10, 0.9 to 1.4}

—

M8

10 to 15 {7.0 to 11, 1.0 to 1.5}

—

19 to 28 {14 to 20, 1.9 to 2.8}

—

22 to 32 {16 to 24, 2.2 to 3.3}

—

M 10

21 to 30 20 to 28 39 to 58 {15 to 22, 2.1 to 3.1} {14 to 21, 1.9 to 2.9} {28 to 43, 3.9 to 6.0}

37 to 53 50 to 65 45 to 65 {26 to 39, 3.6 to 5.4} {36 to 47, 5.0 to 6.5} {33 to 47, 4.5 to 6.5}

M 12

38 to 54 35 to 51 80 to 110 {27 to 40, 3.8 to 5.5} {25 to 38, 3.4 to 5.2} {58 to 80, 8.0 to 11}

70 to 95 {51 to 69, 7.0 to 9.5}

00-18

90 to 120 {65 to 87, 9.0 to 12}

85 to 110 {61 to 80, 8.5 to 11}

00 Hex-head Nut Strength classification

Unit : N·m {ft.lbs, kgf·m}

4T

6T

Representation

Diameter symbol

Standard screw

Coarse screw

M5

2 to 3 {1.4 to 2.2, 0.2 to 0.3}

—

4 to 6 {2.9 to 4.3, 0.4 to 0.6}

—

M6

4 to 6 {2.9 to 4.3, 0.4 to 0.6}

—

7 to 11 {5.1 to 8.0, 0.7 to 1.1}

—

M8

9 to 14 {6.5 to 10, 0.9 to 1.4}

—

17 to 26 {12 to 19, 1.7 to 2.6}

—

M 10

19 to 28 {14 to 20, 1.9 to 2.8}

18 to 26 {13 to 20, 1.8 to 2.7}

36 to 52 {25 to 40, 3.5 to 5.5}

33 to 49 {25 to 36, 3.5 to 5.0}

M 12

35 to 50 {25 to 36, 3.4 to 5.0}

31 to 46 {22 to 34, 3.1 to 4.7}

70 to 95 {51 to 69, 7.0 to 9.5}

65 to 85 {47 to 61, 6.5 to 8.5}

M 14

60 to 85 {43 to 61, 6.0 to 8.5}

55 to 75 {40 to 54, 5.5 to 7.5}

120 to 160 {87 to 115, 12 to 16}

110 to 140 {80 to 100, 11 to 14}

M 16

90 to 130 {69 to 94, 9.5 to 13}

90 to 120 {65 to 87, 9.0 to 12}

180 to 240 {130 to 175, 18 to 24}

160 to 220 {115 to 160, 16 to 22}

M 18

140 to 190 {100 to 135, 14 to 19}

20 to 160 {87 to 115, 12 to 16}

260 to 340 {180 to 255, 25 to 35}

220 to 290 {160 to 215, 22 to 30}

M 20

190 to 260 {135 to 190, 19 to 26}

170 to 230 {120 to 165, 17 to 23}

350 to 470 {260 to 345, 36 to 48}

320 to 420 {230 to 310, 32 to 43}

M 22

260 to 340 230 to 300 {190 to 255, 26 to 35} {165 to 225, 23 to 31}

470 to 640 {345 to 470, 48 to 65}

430 to 570 {310 to 420, 43 to 58}

M 24

340 to 450 290 to 390 {255 to 330, 34 to 46} {210 to 290, 29 to 40}

630 to 840 {455 to 620, 63 to 86}

540 to 730 {395 to 535, 55 to 74}

Standard screw

Coarse screw

Hex-head Flange Nut Unit : N·m {ft.lbs, kgf·m} Strength classification

4T

Representation

Diameter symbol

Standard screw

Coarse screw

M6

4 to 6 {2.9 to 4.3, 0.4 to 0.6}

—

M8

10 to 15 {7.0 to 11, 1.0 to 1.5}

—

M 10

21 to 30 {15 to 22, 2.1 to 3.1}

20 to 28 {14 to 21, 1.9 to 2.9}

M 12

38 to 54 35 to 51 {27 to 40, 3.8 to 5.5} {25 to 38, 3.4 to 5.2}

00-19

TABLE OF STANDARD TIGHTENING TORQUES Tightening torque for flair nut for general purpose Pipe diameter Tightening torque

ø4.76 mm {0.19 in.} ø6.35 mm {0.25 in.} 17 {12, 1.7}

Unit : N·m {ft.lbs, kgf·m}

ø8 mm {0.31 in.}

ø10 mm {0.39 in.}

ø12 mm {0.47 in.}

ø15 mm {0.59 in.}

39 {29, 4.0}

59 {43, 6.0}

88 {65, 9.0}

98 {72, 10.0}

25 {19, 2.6}

Tightening torque for air piping nylon tube for general purpose {DIN type} Unit : N·m {ft.lbs, kgf·m}   

+5.9  +4.3 +0.6 20 2.0 14 – 0  – 0, –0

12×1.5 mm {0.47×0.059 in.}

  

Tightening torque

10×1.25 mm {0.39×0.049 in.}

+9.8  +7.2 +1.0  36 49 5.0 –0 – 0  – 0,

29

+9.8  +7.2 +1.0  22 3.0 –0 – 0  – 0,

  

6×1 mm {0.24×0.039 in.}

15×1.5 mm {0.59×0.059 in.} +4.9  +7.2 +0.5  40 54 5.5 – 0  – 0, –0

  

Standard diameter

Tightening torque for air piping nylon tube for general purpose {SAE type} Unit : N·m {ft.lbs, kgf·m} +3.9 +2.9 +0.4 13– 0 9.4– 0, 1.3– 0

  

00-20

1/2 in.   

Tightening torque



3/8 in. +4.9 +3.6 +0.5 29 – 0 22– 0, 3.0– 0 

5/8 in.   

1/4 in.

+4.9 +3.6 +0.5 49– 0  36– 0, 5.0– 0 

  

Standard diameter

+4.9  +3.6 +0.5 64– 0  47– 0, 6.5– 0

00

MEMO

00-21

CONNECTOR CONFIGURATION CHART Model (Number shows number of pins)

AA

AA 1 A

AA 2 A

AA 2 B

AA 3 A

AA 3 B

AA 4 A

AA 4 B

AA 6 A

00-22

Connection

00 Model (Number shows number of pins)

AA

Connection

AA 6 B

AA 8 A

AA10A

AA12A

AB

AB 2 A

AB 3 A

AB 4 A

AB 6 A

AC

AC 1 A

00-23

CONNECTOR CONFIGURATION CHART Model (Number shows number of pins)

AC

AC 2 A

AC 3 A

AC 4 A

AD

AD 1 A

AD 2 A

AE

AE 2 A

AE 3 A

AE 5 A

AE 7 A

00-24

Connection

00 Model (Number shows number of pins)

AE

Connection

AE 9 A

AE11A

AE13A

AE15A

AE16A (White, Gray, Black)

AE16B (Green)

AE16C (Blue)

AE17A

AG

AG16A

00-25

CONNECTOR CONFIGURATION CHART Model (Number shows number of pins)

AG

AG20A

AH

AH10A

AH12A

AH18A

AH18B

00-26

Connection

00 Model (Number shows number of pins)

AH

AH24A

AJ

AJ 2 A

Connection

AJ 4 A

AJ 8 A

AJ10A

AJ12A

00-27

CONNECTOR CONFIGURATION CHART Model (Number shows number of pins)

AJ

00-28

AJ16A

Connection

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL