2008 Fuso FE FG BODY BUILDERS DRAWINGS & SUPPORTING DATA - PDF

BODY BUILDER’S DRAWINGS AND SUPPORTING DATA

LIT. No. LTE07001-A SEP. 2007

INTRODUCTION This book has been designed to provide information for body and equipment manufacturers who mount their products on MITSUBISHI-FUSO FE chassis.

We believe that all the detailed information which is essential for that purpose is contained in this book, but if you require any additional data or information, please contact:

MITSUBISHI FUSO TRUCK OF AMERICA, INC. 2015 Center Square Road, Logan Township, NJ 08085 (Phone : (856) 467-4500)

The specifications and descriptions contined in this book are based on the latest product information at the time of publication, but since the design of MITSUBISHI-FUSO truck is continuously being improved, we must reserve the right to discontinue or change at any time without prior notice.

COMPLIANCE WITH FEDERAL MOTOR VEHICLE SAFETY STANDARDS The federal government has established Federal Motor Vehicle Safety Standards (FMVSS) for various categories of motor vehicles and motor vehicle equipment under the provisions of the National Traffic and Motor Vehicle Safety Act of 1966. The Act imposes important legal responsibilities on manufacturers, dealers, body builders and others engaged in the marketing of motor vehicles and motor vehicle equipment.

Vehicles manufactured by Mitsubishi FUSO Truck & Bus Corporation (MFTBC) for the subsequent installation of commercial bodies are classified as incomplete vehicles. These vehicles fully comply with certain applicable Motor Vehicle Safety Standards, and partially (or do not) comply with others.

They cannot be certified fully because certain components which are required for certification are not furnished. Under present federal regulations, vehicles completed from these units are required to meet all applicable standards in effect on the date of manufacture of the incomplete vehicle, the date of final completion, or date between those two dates, as determined by their final configuration.

MFTBC incomplete vehicles carry in the glove box a document, as shown on the next page, that provides the vehicle types (truck) into which they may appropriately be completed, and the degree to which the incomplete vehicles comply with each of the standards in effect on the date of its manufacture. The completing manufacturer must certify compliance with all applicable standards, but may rely on MFTBC certification for those standards so indicated in the instructions for completing the vehicle document, provided that the instructions for completing the vehicle are followed. Questions may be directed to the Engineering or Service Department of MFTBC. Alterations, modifications, or additions to the vehicle which affect compliance with FMVSS are not covered by MFTBC certification and are the responsibility of the completing manufacturer. Likewise the completing manufacturer must assume responsibility for compliance with changes in federal requirements that occur after the manufacture of the incomplete vehicle by MFTBC, if he elects to certify compliance as of a later date.

INCOMPLETE VEHICLE DOCUMENT

DO NOT REMOVE THIS DOCUMENT MUST REMAIN WITH THIS VEHICLE UNTIL IT IS CERTIFIED AS A COMPLETE VEHICLE

List of FMVSS and CMVSS applicable to MFTBC trucks with GVWR of more than 10,000 lbs. manufactured after Jan. 1, 2007 is shown below.

Title

FMVSS/CMVSS NO. 101

Controls and Displays

102

Transmission Shift Lever Sequence, Starter Interlock and Transmission Braking Effect

103

Windshield Defrosting and Defogging Systems

104

Windshield Wiping and Washing Systems

105

Hydraulic Brake Systems

106

Brake Hoses

108

Lamps, Reflective Devices and Associated Equipment

111

Rearview Mirrors

115

Vehicle Identification Number (CMVSS ONLY)

116

Motor Vehicle Brake Fluids

119

New Pneumatic Tires for Vehicles other than Passenger Cars

120

Tire Selection and Rims for Motor Vehicles other than Passenger Cars

124

Accelerator Control Systems

205

Glazing Materials

206

Door Locks and Door Retention Components

207

Seating Systems

208

Occupant Crash Protection

209

Seat Belt Assemblies

210

Seat Belt Assembly Anchorages

302

Flammability of Interior Materials

1100

Vehicle Emissions (CMVSS only)

1106

Noise Emission (CMVSS only)

In addition to the Incomplete Vehicle Document, a Safety conformance Label as shown to the right is affixed to all the vehicles when shipped from the factory. This label contains all the FMVSS numbers applicable not only to chassis-cabs but also to completed vehicles if they are completed in accordance with the Incomplete Vehicle Document.

This label is affixed to the door latch post of the left-hand side door.

DO NOT COVER OVER WITH ANY OTHER LABEL.

NOISE REGULATIONS The U.S. Environmental Protection Agency (EPA) has established noise emission standards applicable to medium and heavy trucks in excess of 10,000 lbs. GVWR manufactured after January 1, 1988 (40 CFR §205.52), requiring that they must conform to an 80 dB (A) maximum noise level when tested pursuant to EPA’s test procedures.

MFTBC trucks are built in conformance with EPA Noise Emission Standards. Modified or altered vehicles may increase in noise emissions; compliance with applicable noise standards are the responsibility of the subsequent stage manufacturer.

A sample of Noise Emission Conformity Label is shown below. This label is affixed to all the vehicles when shipped from the factory.

DO NOT COVER OVER WITH ANY OTHER LABEL.

This label is affixed to the left-hand side door panel.

PART I

GENERAL PRINCIPLES OF BODY AND EQUIPMENT MOUNTING

TABLE OF CONTENTS 1. CLEARANCE BETWEEN THE MOUNTED BODY AND CHASSIS COMPONENTS ............................... I-1-1 1.1

Cab back ........................................................................................................................................... I-1-1

1.2

Around engine .................................................................................................................................... I-1-3

1.3

Around transmission .......................................................................................................................... I-1-3

1.4

Above transmission ........................................................................................................................... I-1-4

1.5

Below transmission ........................................................................................................................... I-1-4

1.6

Behind transmission .......................................................................................................................... I-1-4

1.7

Front propeller shaft .......................................................................................................................... I-1-4

1.8

Rear propeller shaft ........................................................................................................................... I-1-4

1.9

Front axle, Rear axle, Steering linkage ............................................................................................. I-1-4

1.10 Brake hose (connected to the front and rear wheels) ....................................................................... I-1-5 1.11 Fuel hose and other hoses ................................................................................................................ I-1-5 1.12 Exhaust system ................................................................................................................................. I-1-5 1.13 Rear spring ........................................................................................................................................ I-1-6 2. MOUNTING THE BODY FOR EASY INSPECTION, REMOVAL AND INSTALLATION OF CHASSIS COMPONENTS ........................................................................................ I-2-1 2.1

Battery ............................................................................................................................................... I-2-1

2.2

Fuel tank ............................................................................................................................................ I-2-1

2.3

Rear fuel tank .................................................................................................................................... I-2-2

2.4

Rear spring ........................................................................................................................................ I-2-4

3. CAUTION IN MODIFYING CHASSIS FRAMES ........................................................................................ I-3-1 3.1

Drilling frames (General) ................................................................................................................... I-3-1

3.2

Drilling side rails ................................................................................................................................ I-3-1

3.3

Drilling crossmembers ....................................................................................................................... I-3-3

3.4

Welding to frame ............................................................................................................................... I-3-4

3.5

Extension of rear overhang ............................................................................................................... I-3-5

3.6

Shortening or extending the frame within the wheelbase ................................................................. I-3-7

3.7

Reinforcement on side rail ................................................................................................................. I-3-7

3.8

Mounting equipment on the side rail ................................................................................................. I-3-9

3.9

Others ................................................................................................................................................ I-3-9

4. CAUTIONS IN MOUNTING A REAR BODY .............................................................................................. I-4-1 4.1

General cautions ............................................................................................................................... I-4-1

4.2

Sub-frame .......................................................................................................................................... I-4-1

4.3

Attaching with U-bolts ........................................................................................................................ I-4-4

4.4

Mounting bracket ............................................................................................................................... I-4-5

4.5

Mounting of rear body (FG only) ....................................................................................................... I-4-6

4.6

Attaching of the rear combination lamps ........................................................................................... I-4-7

5. INSTALLING REAR FENDER AND MUD GUARD .................................................................................... I-5-1 5.1

Installing rear fender .......................................................................................................................... I-5-1

5.2

Rear fender mud flap ......................................................................................................................... I-5-1

6. ELECTRICAL WIRING ............................................................................................................................... I-6-1 6.1

Additional wiring ................................................................................................................................ I-6-1

6.2

Power source for electrical equipment of the body ........................................................................... I-6-3

6.3

Installing switch and relay for specially equipped body ..................................................................... I-6-6

7. REAR COMBINATION AND LICENSE PLATE LAMPS ............................................................................ I-7-1 7.1

Rear combination lamps .................................................................................................................... I-7-1

7.2

License plate lamp ............................................................................................................................ I-7-1

8. BRAKE LINES ............................................................................................................................................ I-8-1 8.1

Chassis tubing form and dimension specifications ........................................................................... I-8-1

8.2

Making additional tubes ..................................................................................................................... I-8-2

8.3

Running additional lines .................................................................................................................... I-8-3

9. EXHAUST SYSTEM ................................................................................................................................... I-9-1 9.1

Modifying the exhaust system ........................................................................................................... I-9-1

9.2

Clearance between exhaust system and other components ............................................................ I-9-1

10. FUEL TANK ................................................................................................................................................ I-10-1 10.1 Moving the fuel tank .......................................................................................................................... I-10-1 10.2 Fuel tubes .......................................................................................................................................... I-10-1 10.3 Others ................................................................................................................................................ I-10-2 11. PAINTING ................................................................................................................................................... I-11-1 11.1 Parts not to be painted ...................................................................................................................... I-11-1 11.2 Paint spot remover ............................................................................................................................ I-11-1 11.3 Cautions on drying after painting ....................................................................................................... I-11-1 11.4 Main external rubber and plastic parts .............................................................................................. I-11-2 12. A/T OIL COOLER ....................................................................................................................................... I-12-1 12.1 Moving the A/T oil cooler ................................................................................................................... I-12-1

Be sure to allow a minimum clearance of 50 mm (1.97 in.) from any point of the tilt path of the cab when tilting to avoid interference with any body over the cab.

FE

Fig. 1.1

FE.FG I-1-1 Return to Table of Contents

FG

Fig. 1.2

FE.FG I-1-2 Return to Table of Contents

25 mm (0.98 in.) in circumference Fig. 1.3

25 mm (0.98 in.) in circumference

Fig. 1.4

FE.FG I-1-3 Return to Table of Contents

Fig. 1.5

FE.FG I-1-4 Return to Table of Contents

FE.FG I-1-5 Return to Table of Contents

Fig. 1.7

FE.FG I-1-6 Return to Table of Contents

FE.FG I-2-1 Return to Table of Contents

Location

2.3 Rear fuel tank

Cautions (Continued)

Be cautious while installing the rear fuel tank piping. Do not let it interfere with the body.

Do not allow foreign materials to enter the fuel tank and related parts.

Install all fuel hoses so that there is no slack, or broken parts and make sure that the hose is free to accept fuel. If hose is too long, may be required to be shortened.

The temporary rubber cap on the fuel tank filler frame pass through must be removed. Clip part number MH021308 must be reused.

When inserting fuel filler hose MK517156, make sure that the hose is completely against the seat (spool) of the filler pipe. Install in accordance with the illustration printed below. Make sure there is no interference with the breather hose.

Remove the two tie wraps that temporarily hold the breather hose in the shipping position.

Insert more than 20 mm (0.79 in.) of the breather hose MK517155 to the filler end pipe and retain it suing clamp # MH021302.

Position the breather hose using clamps MH020946 to points indicated in the illustration below. Secure breather hose to the filler pipe using tie wraps #ME292602 in two places. Refer to Fig. 2.3, Fig. 2.4 and indicated in PART II Section 12.2 “FE Series (Rear fuel tank)”.

The fuel filler end must be attached to the rear body structure. The rear body structure must be strong enough to support the weight of all components. The filler pipe must not be allowed to project beyond the side of the body.

The fuel filler pipe MUST be located at least 169 mm (6.65 in.) above the height of the upper truck frame flange. This will allow satisfactory fill speed.

Attach the fuel cap tether. See PART II Section 12.2 “FE Series (Rear fuel tank)”.

The air vent valve inclination must be approximately 25 degrees to vertical.

Attach caution label MK518283 where it will be easy to see.

Inspect the system and insure that all attaching hardware is secure. Make sure there are no leaks or restrictions.

FE.FG I-2-2 Return to Table of Contents

Cautions (Continued)

Location

2.3 Rear fuel tank (Continued)

Part Screw of Clip Filler end

Tightening torque 3.9 ± 1.0 {2.9 ± 0.7} [N·m {ft.lbs}] 8 - 12 {5.9 - 8.8} [N·m {ft.lbs}]

Remarks With tether of filler cap

FE.FG I-2-3 Return to Table of Contents

FE.FG I-2-4 Return to Table of Contents

blow torch to drill holes.

FE.FG I-3-1 Return to Table of Contents

A FE83D FE84D (except FE84DHW) FE85D FE84DHW FG84

30 mm (1.18 in.)

20 mm (0.79 in.)

No bolt holes in the upper and lower flange

FE.FG I-3-2 Return to Table of Contents

FE.FG I-3-3 Return to Table of Contents

on to the flange of the side rails. Welding on the lower of the side rail.

for temporarily adhesion.

Fig. 1.5

FE.FG I-3-4 Return to Table of Contents

Fig. 3.9

FE.FG I-3-5 Return to Table of Contents

Butt-weld the additional material and the side rail continuously, and

while welding the reinforcement to the lower face of the

FE.FG I-3-6 Return to Table of Contents

because it produces a gap with the side rail flange.

FE.FG I-3-7 Return to Table of Contents

FE.FG I-3-8 Return to Table of Contents

Holder panel

FE.FG I-3-9 Return to Table of Contents

Modifying any part related to the axle, steering, brake or propeller shaft.

Modifying brake hoses or vacuum lines. (Use MFTBC replacement parts only.)

and exhaust pipes.

FE.FG I-4-1 Return to Table of Contents

(2) Fig. 4.2

Fig. 4.2

Fig. 4.2 Fig. 4.3

Fig. 4.3

FE.FG I-4-2 Return to Table of Contents

Fig. 4.2

Fig. 4.3,

Fig. 4.4

be rolled smoothly

Fig. 4.4

FE.FG I-4-3 Return to Table of Contents

Allow sufficient clearance for the U-bolts to be tightened to the sub-frames or main bolsters.

Don’t contact the pipes, hoses, wires and harness. sub-frame or main

Fig. 4.5

Fig. 4.6

FE.FG I-4-4 Return to Table of Contents

Fig. 4.7

FE.FG I-4-5 Return to Table of Contents

use:

Fig. 4.8

concentrated stress on the chassis frame

Fig. 4.9

FE.FG I-4-6 Return to Table of Contents

4.6 Attaching of the rear combination lamps

Fig. 4.10

since, because this bolt tightens the cross

This bracket temporary tightens the lamp assembly in 2 places.

Use a more sophisticated one for permanent installation.

Fig. 4.11

FE.FG I-4-7 Return to Table of Contents

as open as possible to compensate for bad operating conditions. The stan-

Section 11.

FE.FG I-5-1 Return to Table of Contents

FE.FG I-5-2 Return to Table of Contents

cable wiring due to the transfer of the battery, be sure not to make any extension

FE.FG I-6-1 Return to Table of Contents

10 (0.39) or more 20 (0.79) or more

FE.FG I-6-2 Return to Table of Contents

Bonding or clamps should only be used for extra support.

7 8

FE.FG I-6-3 Return to Table of Contents

Front van body interior lamp connector

Rear van body interior lamp connector

FE.FG I-6-4 Return to Table of Contents

G-W

15A

FE.FG I-6-5 Return to Table of Contents

Location

6.3 Installing switch and relay for specially equipped body

Cautions (Continued)

Description

Toggle switch

Mitsubishi P/N MK541358, laterally arranged switch (without lighting circuit) MK541359, longitudinally arranged switch (without lighting circuit)

Permissible current

Connector (Harness side)

Circuit diagram Circuit diagram

2.0A or less

Connector type AK10A (MH056885) 2.0A or less

Terminals − (Normally open end): 20A or less Relay

MK420480 Terminals − (Normally closed end): 10A or less

Connector type EQ5A (MH059820)

Terminal Terminal

: Power supply : Ground

Notes: 1. Be sure to add the relay to the circuit before the switch for specially equipped body and avoid applying the load current to the switch since the switch can carry less permissible current (2.0A).

2. The permissible current for the relay is as shown in the above table. Do not connect any loads which exceed the standard value.

3. Typical connection diagram Cab harness *

Chassis harness Load

Mitsubishi genuine relay

Mitsubishi genuine switch

Marked with * : Points from which the current is taken off.

- - - - : Added wiring

FE.FG I-6-6 Return to Table of Contents

Fuse Capacity Chart High-current fuse (1P) Main load Alternator (terminal B) High-current fuse box Fuse No. Main load FH1 Fuse box (S1, A1 to A5, M1 to M12) FH2 Fuse box (B1 to B12) FH3 Fuse box (B13 to B16) FH7 ABS motor FH8 ABS solenoid FH12 Hydraulic booster B25 Tail lamp B27 Horn B28 Air-conditioner B29 Condenser fan B30 Blower fan B33 Van body dome light B34 ATF cooler fan B36 Engine electronic drive unit BATT1 Alternator BATT2 Glow

Capacity 120A

Capacity 60A 60A 40A 40A 40A 60A 15A 10A 10A 25A 30A 10A 20A 20A 120A 60A

ABS: Anti-lock brake system ATF: Automatic transmission fluid

FE.FG I-6-7 Return to Table of Contents

Fuse box Fuse No. A1 A2 A4 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 M1 M2 M3 M4 M5 M6 M8 M9 M10 M11 S1

Cigar lighter Audio Opt (ACC) Stop lamp Meter Turn signal lamp Opt (B) Audio Cab lamp Power window (driver) Power window (assistant) Engine electronic control unit MVCU Mirror heater Automatic transmission Tester Headlamp (HI) Headlamp (LH/LO) Headlamp (RH/LO) Backup lamp Meter Wiper Opt (M) Relay control Automatic transmission Exhaust brake Engine electronic control unit MVCU ABS Starter

Diagnosis fuse Fuse No. A/T ABS ABS MVCU MVCU Engine ECU

Diagnosis Diagnosis Memory clear Diagnosis Memory clear Diagnosis

Main load

Capacity 15A 10A 10A 15A 10A 15A 10A 10A 10A 30A 30A 20A 10A 20A 10A 15A 20A 20A 20A 10A 10A 15A 10A 10A 10A 10A 5A 10A 10A 10A

Main load

Capacity 5A 5A 10A 5A 10A 5A

ABS: Anti-lock brake system A/T: Automatic transmission ECU: Electronic control unit MVCU: Multifunction vehicle control unit

FE.FG I-6-8 Return to Table of Contents

MFTBC equipment, but don’t use the original bracket which holds the lamps.

7.2 License plate lamp

plate lamp and license plate, and then perform the installation.

FE.FG I-7-1 Return to Table of Contents

the components due to brake safety. Tubing, joints, and brake components should be protected with covers during mounting work to prevent them from dents, damages, welding sparks, and heat and routing changes of tubing necessary for

conforms to the following specifications.

FE.FG I-8-1 Return to Table of Contents

Using brake tubes of the same material as the tubes connected to the chassis

Fig. 8.1.

and the connecting surface joint, resulting in

MFTBC

Fig. 8.2

FE.FG I-8-2 Return to Table of Contents

Crossed

FE.FG I-8-3 Return to Table of Contents

FE.FG I-8-4 Return to Table of Contents

When it is necessary to protect brake lines against possible damage as Fabricate a protective panel in which will not be deformed by flying objects

FE.FG I-8-5 Return to Table of Contents

Location

Procedure

9.1 Modifying the exhaust system

Do not make any adjustments or modifications to the exhaust system at all costs.

Making any adjustments or modifications to the exhaust system may cause malfunctions to the OBD/EMD system.

9.2 Clearance between exhaust system and other components

Mount the rear body so that it conforms with the following requirements to ensure fire prevention and vehicle safety.

(1) Maintain the clearances shown below when mounting the rear body. Install heat insulators if it is impossible to maintain these clearances.

Components Minimum clearance mm (in.)

80 (3.15) Air pipe 80 (3.15) Air tank 150 (5.91) Battery 100 (3.94) Brake booster 100 (3.94) Brake tube 150 (5.91) Cable 150 (5.91) Electric harness 150 (5.91) Fuel tank 200 (7.87) Fuel tube 50 (1.97) Mud guard 100 (3.94) Oil pan 100 (3.94) Oil pipe 50 (1.97) Propeller shaft, Differential 100 (3.94) Rear body floor 30 (1.18) Shock absorber 20 (0.79) Spring, Axle 20 (0.79) Sub frame, Crossmember 100 (3.94) Tire 80 (3.15) Vacuum tank Be extra cautious 150 (5.91) Plasticresonance materials and may cause the decline of engine output. when handling the piping.

150 (5.91) Rubber materials (2) The clearances between the muffler and or exhaust pipes and the rear body should correspond to the specifications described in Section 1 “CLEARANCE BETWEEN THE MOUNTED BODY AND CHASSIS COMPONENTS”.

FE.FG I-9-1 Return to Table of Contents

Avoid unnecessary moving of the fuel tank. If it is necessary to do so, follow the

Fig. 10.1

9.5 (0.37)

80-6500 (3.15-225.9)

FE.FG I-10-1 Return to Table of Contents

FE.FG I-10-2 Return to Table of Contents

Do not paint the following parts.

Plastic parts .... Front grill, Front cover, Front cover, side, Washer nozzle, Step, Fender, Head lamp lens, Battery cover, Air intake ducts, etc.

11.2 may crack in plastic components.

11.3

FE.FG I-11-1 Return to Table of Contents

FE.FG I-11-2 Return to Table of Contents

FE.FG I-11-3

Return to Table of Contents

MAIN EXTERNAL RUBBER AND PLASTIC PARTS <FE>

Fig. 11.1

FE.FG I-11-4

Return to Table of Contents

MAIN EXTERNAL RUBBER AND PLASTIC PARTS (CREW CAB) <FE>

Fig. 11.2

FE.FG I-11-5

Return to Table of Contents

MAIN EXTERNAL RUBBER AND PLASTIC PARTS <FG>

Fig. 11.3

FE83D FE84D (except FE84DHW) FE85D

FE84DHW

Fig. 12.1

(3) (4)

Never extend the A/T oil cooler lines.

After the body mounted, check the cooling operation.

FE.FG I-12-1 Return to Table of Contents

BODY BUILDER’S DRAWINGS AND SUPPORTING DATA

LIT. No. LTE07001-A SEP. 2007

INTRODUCTION This book has been designed to provide information for body and equipment manufacturers who mount their products on MITSUBISHI-FUSO FE chassis.

We believe that all the detailed information which is essential for that purpose is contained in this book, but if you require any additional data or information, please contact:

MITSUBISHI FUSO TRUCK OF AMERICA, INC. 2015 Center Square Road, Logan Township, NJ 08085 (Phone : (856) 467-4500)

The specifications and descriptions contined in this book are based on the latest product information at the time of publication, but since the design of MITSUBISHI-FUSO truck is continuously being improved, we must reserve the right to discontinue or change at any time without prior notice.

COMPLIANCE WITH FEDERAL MOTOR VEHICLE SAFETY STANDARDS The federal government has established Federal Motor Vehicle Safety Standards (FMVSS) for various categories of motor vehicles and motor vehicle equipment under the provisions of the National Traffic and Motor Vehicle Safety Act of 1966. The Act imposes important legal responsibilities on manufacturers, dealers, body builders and others engaged in the marketing of motor vehicles and motor vehicle equipment.

Vehicles manufactured by Mitsubishi FUSO Truck & Bus Corporation (MFTBC) for the subsequent installation of commercial bodies are classified as incomplete vehicles. These vehicles fully comply with certain applicable Motor Vehicle Safety Standards, and partially (or do not) comply with others.

They cannot be certified fully because certain components which are required for certification are not furnished. Under present federal regulations, vehicles completed from these units are required to meet all applicable standards in effect on the date of manufacture of the incomplete vehicle, the date of final completion, or date between those two dates, as determined by their final configuration.

MFTBC incomplete vehicles carry in the glove box a document, as shown on the next page, that provides the vehicle types (truck) into which they may appropriately be completed, and the degree to which the incomplete vehicles comply with each of the standards in effect on the date of its manufacture. The completing manufacturer must certify compliance with all applicable standards, but may rely on MFTBC certification for those standards so indicated in the instructions for completing the vehicle document, provided that the instructions for completing the vehicle are followed. Questions may be directed to the Engineering or Service Department of MFTBC. Alterations, modifications, or additions to the vehicle which affect compliance with FMVSS are not covered by MFTBC certification and are the responsibility of the completing manufacturer. Likewise the completing manufacturer must assume responsibility for compliance with changes in federal requirements that occur after the manufacture of the incomplete vehicle by MFTBC, if he elects to certify compliance as of a later date.

INCOMPLETE VEHICLE DOCUMENT

DO NOT REMOVE THIS DOCUMENT MUST REMAIN WITH THIS VEHICLE UNTIL IT IS CERTIFIED AS A COMPLETE VEHICLE

List of FMVSS and CMVSS applicable to MFTBC trucks with GVWR of more than 10,000 lbs. manufactured after Jan. 1, 2007 is shown below.

FMVSS/CMVSS NO.

Title

101

Controls and Displays

102

Transmission Shift Lever Sequence, Starter Interlock and Transmission Braking Effect

103

Windshield Defrosting and Defogging Systems

104

Windshield Wiping and Washing Systems

105

Hydraulic Brake Systems

106

Brake Hoses

108

Lamps, Reflective Devices and Associated Equipment

111

Rearview Mirrors

115

Vehicle Identification Number (CMVSS ONLY)

116

Motor Vehicle Brake Fluids

119

New Pneumatic Tires for Vehicles other than Passenger Cars

120

Tire Selection and Rims for Motor Vehicles other than Passenger Cars

124

Accelerator Control Systems

205

Glazing Materials

206

Door Locks and Door Retention Components

207

Seating Systems

208

Occupant Crash Protection

209

Seat Belt Assemblies

210

Seat Belt Assembly Anchorages

302

Flammability of Interior Materials

1100

Vehicle Emissions (CMVSS only)

1106

Noise Emission (CMVSS only)

In addition to the Incomplete Vehicle Document, a Safety conformance Label as shown to the right is affixed to all the vehicles when shipped from the factory. This label contains all the FMVSS numbers applicable not only to chassis-cabs but also to completed vehicles if they are completed in accordance with the Incomplete Vehicle Document.

This label is affixed to the door latch post of the left-hand side door.

DO NOT COVER OVER WITH ANY OTHER LABEL.

NOISE REGULATIONS The U.S. Environmental Protection Agency (EPA) has established noise emission standards applicable to medium and heavy trucks in excess of 10,000 lbs. GVWR manufactured after January 1, 1988 (40 CFR §205.52), requiring that they must conform to an 80 dB (A) maximum noise level when tested pursuant to EPA’s test procedures.

MFTBC trucks are built in conformance with EPA Noise Emission Standards. Modified or altered vehicles may increase in noise emissions; compliance with applicable noise standards are the responsibility of the subsequent stage manufacturer.

A sample of Noise Emission Conformity Label is shown below. This label is affixed to all the vehicles when shipped from the factory.

DO NOT COVER OVER WITH ANY OTHER LABEL.

This label is affixed to the left-hand side door panel.

PART II

DRAWINGS AND TECHNICAL DATA

TABLE OF CONTENTS 1. LINE-UP CHART ....................................................................................................................................... II-1-1

2. TYPICAL BODY LENGTH ......................................................................................................................... II-2-1

3. CHASSIS CAB DRAWING ........................................................................................................................ II-3-1 3.1

Chassis cab drawing ........................................................................................................................ II-3-1

3.1.1

FE8!DDZ (automatic transmission) ........................................................................................... II-3-1

3.1.2

FE85DDZ (manual transmission) ................................................................................................ II-3-2

3.1.3

FE8!DEZ (automatic transmission) ........................................................................................... II-3-3

3.1.4

FE85DEZ (manual transmission) ................................................................................................ II-3-4

3.1.5

FE8!DGZ (automatic transmission) ........................................................................................... II-3-5

3.1.6

FE85DGZ (manual transmission) ................................................................................................ II-3-6

3.1.7

FE84DHW (automatic transmission) ........................................................................................... II-3-7

3.1.8

FE8!DJZ (automatic transmission) ............................................................................................ II-3-8

3.1.9

FE85DJZ (manual transmission) ................................................................................................. II-3-9

3.1.10 FE85DKZ (automatic transmission) ............................................................................................ II-3-10 3.1.11 FE85DKZ (manual transmission) ................................................................................................ II-3-11 3.1.12 FG84DF6 (manual transmission) ................................................................................................ II-3-12 3.2

Cab front and rear view .................................................................................................................... II-3-13

4. CHASSIS FRAME ASSEMBLY ................................................................................................................. II-4-1 4.1

FE8!DDZ ........................................................................................................................................ II-4-1

4.2

FE8!DEZ ......................................................................................................................................... II-4-2

4.3

FE8!DGZ ........................................................................................................................................ II-4-3

4.4

FE8!DJZ ......................................................................................................................................... II-4-4

4.5

FE85DKZ .......................................................................................................................................... II-4-5

4.6

FE84DHW ........................................................................................................................................ II-4-6

4.7

FG84DF6 .......................................................................................................................................... II-4-7

5. CROSSMEMBER REAR VIEW ................................................................................................................. II-5-1 5.1

FE Series (Except FE84DHW) ......................................................................................................... II-5-1

5.2

FE84DHW ........................................................................................................................................ II-5-2

5.3

FG Series ......................................................................................................................................... II-5-3

6. FRAME SECTION MODULUS DIAGRAMS .............................................................................................. II-6-1 6.1

FE8!DDZ ........................................................................................................................................ II-6-1

6.2

FE8!DEZ ......................................................................................................................................... II-6-2

6.3

FE8!DGZ ........................................................................................................................................ II-6-3

6.4

FE8!DJZ ......................................................................................................................................... II-6-4

6.5

FE85DKZ .......................................................................................................................................... II-6-5

6.6

FE84DHW ........................................................................................................................................ II-6-6

6.7

FG84DF6 .......................................................................................................................................... II-6-7

7. FRAME HEIGHT ........................................................................................................................................ II-7-1 7.1

Tire radius ......................................................................................................................................... II-7-1

7.2

Front and rear springs ...................................................................................................................... II-7-2

7.2.1

FE83 ............................................................................................................................................ II-7-2

7.2.2

FE84 (Except FE84DHW) .......................................................................................................... II-7-3

7.2.3

FE84DHW ................................................................................................................................... II-7-4

7.2.4

FE85 ............................................................................................................................................ II-7-5

7.2.5

FG84 ........................................................................................................................................... II-7-6

7.3

Vehicle’s sprung weight .................................................................................................................... II-7-7

8. TIRE AND DISC WHEEL .......................................................................................................................... II-8-1

9. FRONT AXLE ............................................................................................................................................ II-9-1

10. REAR AXLE ............................................................................................................................................... II-10-1

11. REAR AXLE BOUNCE HEIGHT ............................................................................................................... II-11-1

12. FUEL TANK ............................................................................................................................................... II-12-1 12.1 FE Series .......................................................................................................................................... II-12-1 12.2 FE Series (Rear fuel tank) ................................................................................................................ II-12-3 12.3 FE Series (Spare fuel tank) .............................................................................................................. II-12-4 12.4 FG Series ......................................................................................................................................... II-12-5 13. BATTERY BOX .......................................................................................................................................... II-13-1

14. LICENSE PLATE LAMP ............................................................................................................................ II-14-1

15. REAR COMBINATION LAMP ................................................................................................................... II-15-1

16. BRAKES PIPING DIAGRAM ..................................................................................................................... II-16-1 16.1 FE83D, FE84D ................................................................................................................................. II-16-1 16.2 FE85D .............................................................................................................................................. II-16-2 16.3 FG84DF6 .......................................................................................................................................... II-16-3 17. PROPELLER SHAFT ................................................................................................................................ II-17-1

18. EXHAUST SYSTEM .................................................................................................................................. II-18-1 18.1 FE8!DDZ ........................................................................................................................................ II-18-1 18.2 FE8!DEZ ......................................................................................................................................... II-18-2 18.3 FE8!DGZ ........................................................................................................................................ II-18-3 18.4 FE8!DJZ, FE85DKZ ....................................................................................................................... II-18-4 18.5 FE84DHW ........................................................................................................................................ II-18-5 18.6 FG84DF6 .......................................................................................................................................... II-18-6 19. ELECTRIC CIRCUIT DIAGRAM ............................................................................................................... II-19-1 19.1 POWER, CHARGE AND GROUND CIRCUIT ................................................................................. II-19-1 POWER CIRCUIT ............................................................................................................... II-19-1 RESERVE POWER CIRCUIT ............................................................................................. II-19-13 BATTERY CHARGING CIRCUIT ........................................................................................ II-19-14 GROUND ............................................................................................................................. II-19-15 19.2 STARTING CIRCUIT ........................................................................................................................ II-19-32 ENGINE STARTING CIRCUIT ............................................................................................ II-19-32 ENGINE PREHEATING CIRCUIT ....................................................................................... II-19-34 19.3 LIGHTING CIRCUIT ......................................................................................................................... II-19-36 HEADLAMP CIRCUIT ......................................................................................................... II-19-36 DAYTIME RUNNING LIGHT CIRCUIT ............................................................................... II-19-37 TAIL, CLEARANCE AND LICENSE PLATE LAMPS CIRCUIT .......................................... II-19-39 STOP LAMP CIRCUIT ........................................................................................................ II-19-40 TURN SIGNAL AND HAZARD LAMP CIRCUIT ................................................................. II-19-42 BACKUP LAMP CIRCUIT ................................................................................................... II-19-43 CAB LAMP CIRCUIT ........................................................................................................... II-19-45 ILLUMINATION LAMP CIRCUIT ......................................................................................... II-19-46 IDENTIFICATION LAMP AND SIDE MARKER LAMP CIRCUIT ........................................ II-19-47 VAN BODY DOME LIGHT CIRCUIT ................................................................................... II-19-48 19.4 METER CLUSTER ........................................................................................................................... II-19-49 METER CLUSTER INTERNAL CIRCUIT ........................................................................... II-19-49 TACHOMETER CIRCUIT .................................................................................................... II-19-51 SPEEDOMETER CIRCUIT ................................................................................................. II-19-52 FUEL GAUGE CIRCUIT ...................................................................................................... II-19-53 WATER TEMPERATURE GAUGE CIRCUIT ..................................................................... II-19-54

19.5 INDICATOR AND WARNING LAMP CIRCUIT ................................................................................ II-19-55 PARKING BRAKE INDICATOR CIRCUIT .......................................................................... II-19-55 BRAKE WARNING CIRCUIT .............................................................................................. II-19-56 ENGINE OIL LEVEL WARNING CIRCUIT ......................................................................... II-19-58 ENGINE OIL PRESSURE WARNING CIRCUIT ................................................................. II-19-59 OVERHEATING WARNING CIRCUIT ................................................................................ II-19-60 BRAKE PAD WARNING CIRCUIT ...................................................................................... II-19-61 CAB TILT WARNING CIRCUIT ........................................................................................... II-19-62 FUEL FILTER WARNING CIRCUIT .................................................................................... II-19-63 19.6 CAB SIDE ELECTRICAL CIRCUIT .................................................................................................. II-19-64 CIGARETTE LIGHTER CIRCUIT ........................................................................................ II-19-64 AUDIO CIRCUIT .................................................................................................................. II-19-65 WIPER AND WASHER CIRCUIT ........................................................................................ II-19-66 HORN CIRCUIT .................................................................................................................. II-19-67 AIR-CONDITIONER CIRCUIT ............................................................................................ II-19-68 POWER WINDOW AND CENTRAL DOOR LOCK CIRCUIT ............................................. II-19-70 MIRROR HEATER CIRCUIT ............................................................................................... II-19-71 19.7 CHASSIS SIDE ELECTRICAL CIRCUIT ......................................................................................... II-19-72 EXHAUST BRAKE CIRCUIT ............................................................................................... II-19-72 19.8 ENGINE AND TRANSMISSION SIDE ELECTRICAL CIRCUIT ...................................................... II-19-74 TRANSMISSION POWER TAKE-OFF CIRCUIT ................................................................ II-19-74 19.9 OTHER CIRCUIT ............................................................................................................................. II-19-75 JOINT CONNECTOR (J/C) ................................................................................................. II-19-75 DIAGNOSIS SWITCH AND MEMORY CLEAR SWITCH ................................................... II-19-79 COMMONRAIL SYSTEM CIRCUIT ................................................................................................. II-19-80 AUTOCRUISE SYSTEM CIRCUIT .................................................................................................. II-19-87 AUTOMATIC TRANSMISSION CIRCUIT ........................................................................................ II-19-89 ANTI-LOCK BRAKE SYSTEM CIRCUIT ......................................................................................... II-19-93

1. LINE-UP CHART BASIC COMPORNENTS MODEL SERIES

VEHICLE MODEL

ENGINE

TRANSMISSION

TIRES

FE83DDZSLSUH FE83D

FE83DEZSLSUH

4M50T-8AT8

M036A6 (AISIN)

FE83DGZSLSUH FE84DDZSLSUH

LT215/85R16

FE84DEZSLSUH FE84D

FE84DGZSLSUH

4M50T-6AT8

M036A6 (AISIN)

FE84DJZSLSUH FE84DHWSLSUH FE85DDZSLSUG FE85DEZSLSUG M036S6

FE85DGZSLSUG FE85DJZSLSUG FE85DKZSLSUG FE85D

4M50T-6AT8

215/75R17.5

FE85DDZSLSUH FE85DEZSLSUH M036A6 (AISIN)

FE85DGZSLSUH FE85DJZSLSUH FE85DKZSLSUH FG84D

FG84DF6SLSUJ

4M50T-6AT7

M036S5

LT235/85R16

WHEEL BASE 2,910 (114.6) 3,410 (134.3) 3,870 (152.4) 2,910 (114.6) 3,410 (134.3) 3,870 (152.4) 4,470 (176.0) 4,200 (165.4) 2,910 (114.6) 3,410 (134.3) 3,870 (152.4) 4,470 (176.0) 4,810 (189.4) 2,910 (114.6) 3,410 (134.3) 3,870 (152.4) 4,470 (176.0) 4,810 (189.4) 3,510 (138.2)

BASIC DIMENSIONS mm (in.)

OVERALL OVERALL OVERALL WIDTH HEIGHT LENGTH (approx.) (approx.)

5,771 (227.2) 6,271 2,270 (246.9) (89.4) 6,731 (265.0) 2,130 5,771 (83.9) (227.2) 6,271 2,290 (246.9) (90.2) 6,731 (265.0) 7,331 (288.6) 6,460 2,030 2,275 (254.3) (79.9) (89.6) 5,771 (227.2) 6,271 (246.9) 6,731 (265.0) 7,331 (288.6) 7,671 2,126 2,285 (302.0) (83.7) (90.0) 5,771 (227.2) 6,271 (246.9) 6,731 (265.0) 7,331 (288.6) 7,671 (302.0) 5,713 2,060 2,510 (224.9) (81.1) (98.8)

CURB WEIGHT kg (lbs.)

CAB TO REAR AXLE (ACTUAL) 2,385 (93.9) 2,885 (113.6) 3,345 (131.7) 2,385 (93.9) 2,885 (113.6) 3,345 (131.7) 3,945 (155.3) 2,675 (105.3) 2,385 (93.9) 2,885 (113.6) 3,345 (131.7) 3,945 (155.3) 4,285 (168.7) 2,385 (93.9) 2,885 (113.6) 3,345 (131.7) 3,945 (155.3) 4,285 (168.7) 2,970 (116.9)

FRONT

REAR

TOTAL

1,810 (3,990) 1,850 (4,080) 1,880 (4,145) 1,820 (4,010) 1,860 (4,100) 1,880 (4,145) 1,895 (4,180) 1,980 (4,365) 1,825 (4,025) 1,860 (4,100) 1,885 (4,155) 1,890 (4,170) 1,910 (4,210) 1,860 (4,100) 1,900 (4,190) 1,920 (4,235) 1,930 (4,255) 1,945 (4,290) 1,940 (4,280)

865 (1,910) 845 (1,865) 845 (1,865) 900 (1,985) 875 (1,930) 885 (1,950) 900 (1,985) 940 (2,070) 955 (2,105) 940 (2,070) 945 (2,085) 965 (2,130) 960 (2,115) 965 (2,130) 945 (2,085) 955 (2,105) 970 (2,140) 965 (2,130) 795 (1,755)

2,675 (5,900) 2,695 (5,945) 2,725 (6,010) 2,720 (5,995) 2,735 (6,030) 2,765 (6,095) 2,795 (6,165) 2,920 (6,435) 2,780 (6,130) 2,800 (6,170) 2,830 (6,240) 2,855 (6,300) 2,870 (6,325) 2,825 (6,230) 2,845 (6,275) 2,875 (6,340) 2,900 (6,395) 2,910 (6,420) 2,735 (6,035)

RATING kg (lbs.)

FRONT

REAR

TOTAL

5,670 (12,500)

2,430 (5,360)

4,480 (9,880) 6,575 (14,500)

2,900 (6,395)

5,760 (12,700)

8,160 (17,995)

2,600 (5,730)

4,300 (9,480)

6,375 (14,050)

FE.FG II-1-1 Return to Table of Contents

2. TYPICAL BODY LENGTH

1. MFTA suggests the X-marked body length of each model because of stability, commerciality and reliability.

2. Rear body dimensions shall not exceed 96” wide (outside) and 96” from top of frame to top of body without prior approval from MFTA Applications Group.

Vehicle Model D E FE83D FE84D FE85D

G J K

FE84D

HW

FG84D

F

WB 114.6 (2,910) 134.3 (3,410) 152.4 (3,870) 176 (4,470) 189.4 (4,810) 165.4 (4,200) 138.2 (3,510)

CA 93.9 (2,385) 113.6 (2,885) 131.7 (3,345) 155.3 (3,945) 168.7 (4,285) 105.3 (2,675) 116.9 (2,970)

Dimensions, Inch (mm) UCA CB CE 86 7.9 158.5 (2,185) (200) (4,025) 105.7 7.9 178.1 (2,685) (200) (4,525) 123.8 7.9 196.3 (3,145) (200) (4,985) 147.4 7.9 219.9 (3,745) (200) (5,585) 160.8 7.9 233.3 (4,085) (200) (5,925) 103.4 1.9 147.8 (2,626) (49) (3,753) 108.5 8.5 158.0 (2,755) (215) (4,013)

OAL 227.2 (5,771) 246.9 (6,271) 265 (6,731) 288.6 (7,331) 302 (7,671) 254.3 (6,460) 224.9 (5,713)

Body Length (ft) HG 12 14 16 18 20 22 24.0 X (610) 24.0 X X (610) 24.0 X X (610) 24.0 X X (610) 24.0 X X (610) 26.6 X1 X1 (675) 28.3 X1 X1 (720) X1: NOT APPLICABLE TO REAR FUEL TANK

Variations to this chart require prior approval from MFTA Applications Group.

NOTES: (1) Selection of the correct model and wheelbase is dependent on many factors. This chart can serve only as a quick reference guide. It does not preclude the necessity of performing a complete weight distribution analysis, particularly when equipment such as lift gates, reefers or others are required.

(2) MFTA assumes no liability whatsoever for any damage(s) to person(s) or property caused by utilization of this chart.

Selection of the correct model and wheelbase is solely the responsibility of the selling dealers and final stage manufacturer.

(3) All weight distribution calculations herein are based on water level loading and a cab-to-body clearance on above table.

(4) When selection of the correct model and wheelbase is made, carefully follow the requirements below; (a) Individual GAWR’s and GVWR’s must not be exceeded. (b) It is advisable that front axle loading ratio be 33% of total vehicle weight or more for vehicle stability. (c) The length of the rear overhang must comply with state and local regulations, if any.

(5) The center of gravity of the completed vehicle with a full load should not exceed 60” above ground level and must be located horizontally between the centerlines of the front and rear axles.

FE.FG II-2-1 Return to Table of Contents

3. CHASSIS CAB DRAWING 3.1 Chassis cab drawing 3.1.1 FE8!DDZ (automatic transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-1 Return to Table of Contents

3.1.2 FE85DDZ (manual transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-2 Return to Table of Contents

3.1.3 FE8!DEZ (automatic transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-3 Return to Table of Contents

3.1.4 FE85DEZ (manual transmission)

UNIT : mm (in.)

SCALE : 1/30

FE.FG II-3-4 Return to Table of Contents

3.1.5 FE8!DGZ (automatic transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-5 Return to Table of Contents

3.1.6 FE85DGZ (manual transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-6 Return to Table of Contents

3.1.7 FE84DHW (automatic transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-7 Return to Table of Contents

3.1.8 FE8!DJZ (automatic transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-8 Return to Table of Contents

3.1.9 FE85DJZ (manual transmission)

UNIT : mm (in.)

SCALE : 1/30

FE.FG II-3-9 Return to Table of Contents

3.1.10 FE85DKZ (automatic transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-10 Return to Table of Contents

3.1.11 FE85DKZ (manual transmission)

UNIT : mm (in.)

SCALE : 1/30

FE.FG II-3-11 Return to Table of Contents

3.1.12 FG84DF6 (manual transmission)

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-3-12 Return to Table of Contents

3.2 Cab front and rear view CAB FRONT AND REAR VIEWS (FE)

CAB FRONT AND REAR VIEWS (FG)

CAB REAR VIEWS (FE8W)

FE.FG II-3-13 Return to Table of Contents

4. CHASSIS FRAME ASSEMBLY 4.1 FE8!DDZ

UNIT : mm (in.)

SCALE : 1/30

FE.FG II-4-1 Return to Table of Contents

4.2 FE8!DEZ

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-4-2 Return to Table of Contents

4.3 FE8!DGZ

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-4-3 Return to Table of Contents

4.4 FE8!DJZ

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-4-4 Return to Table of Contents

4.5 FE85DKZ

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-4-5 Return to Table of Contents

4.6 FE84DHW

UNIT : mm (in.)

SCALE : 1/30 FE.FG II-4-6 Return to Table of Contents

4.7 FG84DF6

UNIT : mm (in.)

SCALE : 1/30

FE.FG II-4-7 Return to Table of Contents

5. CROSSMEMBER REAR VIEW 5.1 FE Series (Except FE84DHW)

FE.FG II-5-1 Return to Table of Contents

5.2 FE84DHW

FE.FG II-5-2 Return to Table of Contents

5.3 FG Series

FE.FG II-5-3 Return to Table of Contents

FE.FG II-6-1

Return to Table of Contents

6. FRAME SECTION MODULUS DIAGRAMS 6.1 FE8!DDZ

6.2 FE8!DEZ

FE.FG II-6-2 Return to Table of Contents

6.3 FE8!DGZ

FE.FG II-6-3 Return to Table of Contents

6.4 FE8!DJZ

FE.FG II-6-4 Return to Table of Contents

6.5 FE85DKZ

FE.FG II-6-5 Return to Table of Contents

6.6 FE84DHW

FE.FG II-6-6 Return to Table of Contents

6.7 FG84DF6

FE.FG II-6-7 Return to Table of Contents

7. FRAME HEIGHT 7.1 Tire radius (Ground to top of Frame at Front & Rear Axle center) Calculating the formulas Hf = hf + Rf (Frame height, Front) Hr = hr + Rr (Frame height, Rear) hf

: Distance from top to front wheel center (see section 9 : Front and Rear springs)

hr

: Distance from top to rear wheel center (see section 9 : Front and Rear springs)

Rf, Rr : Tire radius (See following Tire chart following.)

FE.FG II-7-1 Return to Table of Contents

FE.FG II-7-2

Return to Table of Contents

(FRONT)

7.2 Front and rear springs 7.2.1 FE83 (REAR)

FE.FG II-7-3

Return to Table of Contents

(FRONT)

7.2.2 FE84 (Except FE84DHW) (REAR)

(REAR) (FRONT)

7.2.3 FE84DHW

FE.FG II-7-4 Return to Table of Contents

(FRONT)

(REAR)

7.2.4 FE85

FE.FG II-7-5 Return to Table of Contents

(REAR) (REAR) (FRONT)

7.2.5 FG84

FE.FG II-7-6 Return to Table of Contents

7.3 Vehicle’s sprung weight VEHICLE MODEL FE83DDZSLSUH FE84DDZSLSUH FE83DEZSLSUH FE84DEZSLSUH FE83DGZSLSUH FE84DGZSLSUH FE84DHWSLSUH FE84DJZSLSUH FE85DDZSLSUG FE85DEZSLSUG FE85DGZSLSUG FE85DJZSLSUG FE85DKZSLSUG FE85DDZSLSUH FE85DEZSLSUH FE85DGZSLSUH FE85DJZSLSUH FE85DKZSLSUH FG84DF6SLSUJ

FRONT 1510 (3,330) 1550 (3,415) 1575 (3,470) 1670 (3,680) 1580 (3,485) 1480 (3,265) 1520 (3,350) 1540 (3,395) 1550 (3,415) 1565 (3,450) 1515 (3,340) 1550 (3,415) 1575 (3,470) 1590 (3,505) 1600 (3,525) 1535 (3,385)

SPRUNG WEIGHT kg (Ibs) REAR 340 (750) 315 (685) 320 (710) 405 (895) 340 (750) 325 (715) 300 (660) 310 (685) 330 (730) 325 (720) 335 (740) 315 (695) 320 (710) 335 (740) 335 (740) 300 (660)

TOTAL 1850 (4,080) 1865 (4,100) 1895 (4,180) 2075 (4,575) 1920 (4,235) 1805 (3,980) 1820 (4,010) 1850 (4,080) 1880 (4,145) 1890 (4,170) 1850 (4,080) 1865 (4,110) 1895 (4,180) 1925 (4,245) 1935 (4,265) 1835 (4,045)

FE.FG II-7-7 Return to Table of Contents

FE.FG II-8-1

Return to Table of Contents

17.5X6.00

16X6K

FG84

16X6K

FE85

FE84

FE83

MODEL

VEHICLE

WHEEL SIZE

LT235/85R16

FG84

DISC WHEEL

215/75R17.5

LT215/85R16

TIRE SIZE

FE85

FE84

FE83

MODEL

VEHICLE

TIRE

6

5

HOLES

BOLT

10

12

10

RATING

PLY

222.25 (8.75)

208 (8.2)

mm (in.)

DIAMETER

CIRCUIT

BOLT

E

F

E

RANGE

LOAD

8. TIRE AND DISC WHEEL

6

in.

135 (5.3)

127 (5.0)

mm (in.)

9 (0.4)

OF DISC

1 PIECE

RIM TYPE

2760 (6084)

3200 (7055)

2430 (5360)

kg (lbs.)

SINGLE

FRONT

5040 (11112)

6200 (13669)

4480 (9880)

kg (lbs.)

DUAL

REAR

LOAD CAPACITY PER AXLE

(DROP CENTER)

230 (9.1)

212 (8.3)

THICKNESS

812 (32.0)

767 (30.2)

216 (8.5)

mm (in.)

mm (in.)

772 (30.4)

WIDTH

DIAMETER

SECTION

TIRE DIMENSION OVERALL

OFFSET

WIDTH

RIM

550 (80)

690 (100)

550 (80)

kPa (psi)

PRESSURE

INFLATION

MAXIMUM

9. FRONT AXLE FE

FG

FRONT AXLE

VEHICLE

CAPACITY

TIRE SIZE

FT

SC

FH

mm (in.)

mm (in.)

mm (in.)

1665 (65.55)

807 (31.77)

177 (6.97)

MODEL

MODEL

FE83

F200T

2400 (5290)

FE84

F300T

2500 (5510)

FG84

F200TW

2600 (5730)

LT235/85R16 (16x6K)

1650 (65.00)

807 (31.77)

156.5 (6.16)

FE85

F350T

2900 (6390)

215/75R17.5 (17.5x6.00)

1665 (65.55)

807 (31.77)

177 (6.97)

kg (lbs.)

LT215/85R16 (16x6K)

DEFINITIONS FT : Front tread SC : Spring to spring distance FH : Distance between the center line of tire and the bottom of front axle FC : Front axle clearance Minimum clearance between the front axle and the ground-line TIRE LOADED RADIUS : See section 7: FRAME HEIGHT “Tire radius” (PAGE II-7-1) Formula for calculating front axle clearance FC = Tire loaded Radius - FH

FE.FG II-9-1 Return to Table of Contents

10. REAR AXLE

VEHICLE MODEL

REAR AXLE MODEL

CAPACITY kg (lbs.)

FE83 R033T

FE84

TIRE SIZE

4500 (9920)

LT215/85R16

R035T

5760 (12700)

FG84

R033T

4300 (9480)

SC

RH

DS

mm (in.)

mm (in.)

mm (in.)

mm (in.)

1660 (65.35)

990 (38.98)

1560 (61.42)

900 (35.43)

1660 (65.35)

990 (38.98)

1560 (61.42)

900 (35.43)

(16x6K)

FE84W FE85

RT

215/75R17.5 (17.5x6.00) LT235/85R16 (16x6K)

254 (10.00) 182.5 (7.19)

270 (10.63)

DEFINITIONS RT : Rear tread SC : Spring to spring distance RH : Distance between the center line of tire and the bottom of rear axle DS : Dual tire spacing DW : Minimum distance between the inner surface of rear tires MW : Overall width of vehicle RC : Rear axle clearance Minimum clearance between the rear axle and the ground-line TIRE SECTION WIDTH : See section 8: “TIRE AND DISC WHEEL” (PAGE II-8-1) TIRE LOADED RADIUS : See section 7: FRAME HEIGHT “Tire radius” (PAGE II-7-1) Formula for calculating rear axle clearance DW = RT - DS - TIRE SECTION WIDTH MW = RT + DS + TIRE SECTION WIDTH RC = TIRE LOADED RADIUS - RH FE.FG II-10-1 Return to Table of Contents

11. REAR AXLE BOUNCE HEIGHT

MODEL

TIRE SIZE

FE83

R

A

(1)

B

(2)

(3)

C

mm (in.)

mm (in.)

mm (in.)

mm (in.)

LT215/85R16

396.5 (15.61)

180 (7.09)

105 (4.13)

645 (25.39)

Except FE84DHW

LT215/85R16

396.5 (15.61)

180 (7.09)

105 (4.13)

650 (25.59)

FE84DHW

LT215/85R16

396.5 (15.61)

137 (5.39)

159 (6.26)

645 (25.39)

FE85

LT215/75R17.5

393.5 (15.49)

180 (7.09)

105 (4.13)

648 (25.51)

FG84

LT235/85R16

414 (16.30)

115 (4.53)

170 (6.69)

669 (26.30)

D mm (in.)

365 (14.37)

NOTES: (1)

“A” indicates the distance between the top of rear axle and the upper face of frame in extreme bump position.

(2)

“B” indicates the distance between the top of tire and the upper face of frame in bump position.

(3)

“C” indicates the distance between the side wall of tire and the web face frame.

FE.FG II-11-1 Return to Table of Contents

12. FUEL TANK 12.1 FE Series <Except FE84DHW>

UNIT : mm FE.FG II-12-1 Return to Table of Contents

<FE84DHW>

UNIT : mm FE.FG II-12-2 Return to Table of Contents

12.2 FE Series (Rear fuel tank)

UNIT : mm FE.FG II-12-3 Return to Table of Contents

12.3 FE Series (Spare fuel tank)

FE8 DJZ

FE8 DGZ FE8 DKZ

UNIT : mm FE.FG II-12-4 Return to Table of Contents

12.4 FG Series

UNIT : mm FE.FG II-12-5 Return to Table of Contents

UNIT : mm (in.)

13. BATTERY BOX

FE.FG II-13-1 Return to Table of Contents

FE.FG II-14-1

Return to Table of Contents

FE84DHW FG84D

14. LICENSE PLATE LAMP

FE8***Z

15. REAR COMBINATION LAMP

FE.FG II-15-1 Return to Table of Contents

FE.FG II-16-1

Return to Table of Contents

16. BRAKES PIPING DIAGRAM 16.1 FE83D, FE84D

16.2 FE85D

FE.FG II-16-2 Return to Table of Contents

16.3 FG84DF6

FE.FG II-16-3 Return to Table of Contents

17. PROPELLER SHAFT FE Series

FG Series

UNIT : mm FE.FG II-17-1 Return to Table of Contents

MODEL SERIES

FE85D

VEHICLE MODEL (T/M MODEL)

ENG CTR TO JOINT (mm) l0

-

FE85DEZ (T/M M036S6)

678

FE85DGZ (T/M M036S6)

792

FE85D

998

h0

h1

1164

-

986

302

1126

748

253

h2

JOINT ANGLE (Degree) h3*

a0

a1

-

0.4

900

568

a2*

a3*

b

1.0

0.1

2.0

2.8

-2.1

1.6

3.5

-3.1

4.1

-4.5

3.1

-4.4

1.1

0.0

2.2

345

988

2.0

262

301

2.7

-2.1

1.6

1.5

0.5

305

1057 -

0.7

347 1164

-

324

319

1153

-

324

0.5

-

FE83DGZ (T/M M036A6)

888

1128

318

0.8

3.4

-3.1

1.4

FE84DDZ (T/M M036A6)

-

1057

-

-

1.1

0.0

2.2

FE84DEZ (T/M M036A6)

568

2.7

-2.1

1.6

3.4

-3.1

1.4

FE84DGZ (T/M M036A6)

-

988

900

888

305

347

278

-

813

1166

FE84DHW (T/M M036A6)

1108

-

1258

FE85DDZ (T/M M036A6)

-

FE85DEZ (T/M M036A6)

568 900

-

888

229

1057

-

988

301

1128

262

FE85DKZ (T/M M036A6)

678

-

0.6

0.9

4.1

-4.5

1.5

2.0

-

2.5

1.1

1.3

1.1

0.0

2.2

2.7

-2.1

1.6

3.4

-3.1

1.4

4.1

-4.5

-

0.5 324

345 1021

514

535

-

479

-

0.8 0.6

305

1153 888

279

347 1166

-

0.8

318

813 638

0.5 324

318

638

FG84DF6 (T/M M036S5)

-

1128

FE84DJZ (T/M M036A6)

FE85DGZ (T/M M036A6)

301 262

FE85DJZ (T/M M036A6)

FG84D

-

l3*

813

FE83DDZ (T/M M036A6) FE83DEZ (T/M M036A6)

l2

JOINT POINT (mm)

-

FE85DKZ (T/M M036S6)

FE84D

l1

FE85DDZ (T/M M036S6)

FE85DJZ (T/M M036S6)

FE83D

PROPELLER SHAFT TRUE LENGTH (mm)

2.8

0.9

1.5 1.8

3.1

-4.4

-

4.8

0.3

-0.9

NOTE: *-marked is at the upper bounce limit (at the full-stroke).

FE.FG II-17-2 Return to Table of Contents

18. EXHAUST SYSTEM 18.1 FE8 DDZ

FE.FG II-18-1 Return to Table of Contents

18.2 FE8 DEZ

FE.FG II-18-2 Return to Table of Contents

18.3 FE8 DGZ

FE.FG II-18-3 Return to Table of Contents

18.4 FE8 DJZ, FE85DKZ

FE.FG II-18-4 Return to Table of Contents

18.5 FE84DHW

FE.FG II-18-5 Return to Table of Contents

18.6 FG84DF6

FE.FG II-18-6 Return to Table of Contents

19. ELECTRIC CIRCUIT DIAGRAM 19.1 POWER, CHARGE AND GROUND CIRCUIT POWER CIRCUIT

FE.FG II-19-1 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-2 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-3 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-4 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-5 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-6 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-7 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-8 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-9 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-10 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-11 Return to Table of Contents

POWER CIRCUIT

FE.FG II-19-12 Return to Table of Contents

RESERVE POWER CIRCUIT

FE.FG II-19-13 Return to Table of Contents

BATTERY CHARGING CIRCUIT

FE.FG II-19-14 Return to Table of Contents

GROUND

FE.FG II-19-15 Return to Table of Contents

GROUND Location [1] [2] [3] ECU:

MVE3

Wire diameter-wire color B

GCE5

B

EA10

5-B

– (GCE5)

1.25-B

Cab ground

– (MVE3)

1.25-B

Cab ground

Circuit No.

Destination MVCU case ground Engine ECU case ground Frame ground

Remarks – – – Engine ECU case ground MVCU case ground

Electronic control unit

MVCU: Multifunction vehicle control unit

FE.FG II-19-16 Return to Table of Contents

GROUND

FE.FG II-19-17 Return to Table of Contents

GROUND Location

Circuit No.

[5] [6] [8]

HNE1 – – EA11 EA12 ASE1 ASE2 BWE2 EA01 EA03A EA04 EA07 GCE1 GCE3 EA08 GCE2 EA02 EA03B EA10 EA14

[9] [10] [11] (1) [11] (2) [11] (3) [11] (4) [11] (5) [12]

Wire diameter-wire color 1.25-B 15-B 85 2-B 1.25-B 3-B 3-B 3-B 1.25-B 3-B B 0.85-B 2-B 2-B 0.85-B 2-B 1.25-B 3-B 5-B 1.25-B

Destination Horn bracket Battery Engine JOINT1 JOINT2 Hydraulic unit Hydraulic unit Center panel harness Joint connector (J/C-M1) JOINT (EA03) Meter cluster Joint connector (J/C-1) Engine electronic control unit Engine electronic control unit Joint connector (J/C-1) Engine electronic control unit Joint connector (J/C-M1) JOINT (EA03) Cab ground Rear chassis harness

Remarks – Battery ground Engine ground – – – – – – – – – – – – – – – – –

FE.FG II-19-18 Return to Table of Contents

GROUND

FE.FG II-19-19 Return to Table of Contents

GROUND

FE.FG II-19-20 Return to Table of Contents

GROUND

FE.FG II-19-21 Return to Table of Contents

GROUND

FE.FG II-19-22 Return to Table of Contents

GROUND

FE.FG II-19-23 Return to Table of Contents

GROUND

FE.FG II-19-24 Return to Table of Contents

GROUND

FE.FG II-19-25 Return to Table of Contents

GROUND

FE.FG II-19-26 Return to Table of Contents

GROUND

FE.FG II-19-27 Return to Table of Contents

GROUND

FE.FG II-19-28 Return to Table of Contents

GROUND

FE.FG II-19-29 Return to Table of Contents

GROUND

FE.FG II-19-30 Return to Table of Contents

GROUND

FE.FG II-19-31 Return to Table of Contents

19.2 STARTING CIRCUIT ENGINE STARTING CIRCUIT

FE.FG II-19-32 Return to Table of Contents

ENGINE STARTING CIRCUIT

FE.FG II-19-33 Return to Table of Contents

ENGINE PREHEATING CIRCUIT

FE.FG II-19-34 Return to Table of Contents

ENGINE PREHEATING CIRCUIT

FE.FG II-19-35 Return to Table of Contents

19.3 LIGHTING CIRCUIT HEADLAMP CIRCUIT

FE.FG II-19-36 Return to Table of Contents

DAYTIME RUNNING LIGHT CIRCUIT

FE.FG II-19-37 Return to Table of Contents

DAYTIME RUNNING LIGHT CIRCUIT

FE.FG II-19-38 Return to Table of Contents

TAIL, CLEARANCE AND LICENSE PLATE LAMPS CIRCUIT

FE.FG II-19-39 Return to Table of Contents

STOP LAMP CIRCUIT

FE.FG II-19-40 Return to Table of Contents

STOP LAMP CIRCUIT

FE.FG II-19-41 Return to Table of Contents

TURN SIGNAL AND HAZARD LAMP CIRCUIT

FE.FG II-19-42 Return to Table of Contents

BACKUP LAMP CIRCUIT

FE.FG II-19-43 Return to Table of Contents

BACKUP LAMP CIRCUIT

FE.FG II-19-44 Return to Table of Contents

CAB LAMP CIRCUIT

FE.FG II-19-45 Return to Table of Contents

ILLUMINATION LAMP CIRCUIT

FE.FG II-19-46 Return to Table of Contents

IDENTIFICATION LAMP AND SIDE MARKER LAMP CIRCUIT

FE.FG II-19-47 Return to Table of Contents

VAN BODY DOME LIGHT CIRCUIT

FE.FG II-19-48 Return to Table of Contents

19.4 METER CLUSTER METER CLUSTER INTERNAL CIRCUIT

FE.FG II-19-49 Return to Table of Contents

METER CLUSTER INTERNAL CIRCUIT

FE.FG II-19-50 Return to Table of Contents

TACHOMETER CIRCUIT

FE.FG II-19-51 Return to Table of Contents

SPEEDOMETER CIRCUIT

FE.FG II-19-52 Return to Table of Contents

FUEL GAUGE CIRCUIT

FE.FG II-19-53 Return to Table of Contents

WATER TEMPERATURE GAUGE CIRCUIT

FE.FG II-19-54 Return to Table of Contents

19.5 INDICATOR AND WARNING LAMP CIRCUIT PARKING BRAKE INDICATOR CIRCUIT

FE.FG II-19-55 Return to Table of Contents

BRAKE WARNING CIRCUIT

FE.FG II-19-56 Return to Table of Contents

BRAKE WARNING CIRCUIT

FE.FG II-19-57 Return to Table of Contents

ENGINE OIL LEVEL WARNING CIRCUIT

FE.FG II-19-58 Return to Table of Contents

ENGINE OIL PRESSURE WARNING CIRCUIT

FE.FG II-19-59 Return to Table of Contents

OVERHEATING WARNING CIRCUIT

FE.FG II-19-60 Return to Table of Contents

BRAKE PAD WARNING CIRCUIT

FE.FG II-19-61 Return to Table of Contents

CAB TILT WARNING CIRCUIT

FE.FG II-19-62 Return to Table of Contents

FUEL FILTER WARNING CIRCUIT

FE.FG II-19-63 Return to Table of Contents

19.6 CAB SIDE ELECTRICAL CIRCUIT CIGARETTE LIGHTER CIRCUIT

FE.FG II-19-64 Return to Table of Contents

AUDIO CIRCUIT

FE.FG II-19-65 Return to Table of Contents

WIPER AND WASHER CIRCUIT

FE.FG II-19-66 Return to Table of Contents

HORN CIRCUIT

FE.FG II-19-67 Return to Table of Contents

AIR-CONDITIONER CIRCUIT

FE.FG II-19-68 Return to Table of Contents

AIR-CONDITIONER CIRCUIT

FE.FG II-19-69 Return to Table of Contents

POWER WINDOW AND CENTRAL DOOR LOCK CIRCUIT

FE.FG II-19-70 Return to Table of Contents

MIRROR HEATER CIRCUIT

FE.FG II-19-71 Return to Table of Contents

19.7 CHASSIS SIDE ELECTRICAL CIRCUIT EXHAUST BRAKE CIRCUIT

FE.FG II-19-72 Return to Table of Contents

EXHAUST BRAKE CIRCUIT

FE.FG II-19-73 Return to Table of Contents

19.8 ENGINE AND TRANSMISSION SIDE ELECTRICAL CIRCUIT TRANSMISSION POWER TAKE-OFF CIRCUIT

FE.FG II-19-74 Return to Table of Contents

19.9 OTHER CIRCUIT JOINT CONNECTOR (J/C)

FE.FG II-19-75 Return to Table of Contents

JOINT CONNECTOR (J/C)

FE.FG II-19-76 Return to Table of Contents

JOINT CONNECTOR (J/C)

FE.FG II-19-77 Return to Table of Contents

JOINT CONNECTOR (J/C)

FE.FG II-19-78 Return to Table of Contents

DIAGNOSIS SWITCH AND MEMORY CLEAR SWITCH

FE.FG II-19-79 Return to Table of Contents

COMMONRAIL SYSTEM CIRCUIT

FE.FG II-19-80 Return to Table of Contents

COMMONRAIL SYSTEM CIRCUIT

FE.FG II-19-81 Return to Table of Contents

COMMONRAIL SYSTEM CIRCUIT

FE.FG II-19-82 Return to Table of Contents

COMMONRAIL SYSTEM CIRCUIT

FE.FG II-19-83 Return to Table of Contents

COMMONRAIL SYSTEM CIRCUIT

FE.FG II-19-84 Return to Table of Contents

COMMONRAIL SYSTEM CIRCUIT

FE.FG II-19-85 Return to Table of Contents

COMMONRAIL SYSTEM CIRCUIT

FE.FG II-19-86 Return to Table of Contents

AUTOCRUISE SYSTEM CIRCUIT

FE.FG II-19-87 Return to Table of Contents

AUTOCRUISE SYSTEM CIRCUIT

FE.FG II-19-88 Return to Table of Contents

AUTOMATIC TRANSMISSION CIRCUIT

FE.FG II-19-89 Return to Table of Contents

AUTOMATIC TRANSMISSION CIRCUIT

FE.FG II-19-90 Return to Table of Contents

AUTOMATIC TRANSMISSION CIRCUIT

FE.FG II-19-91 Return to Table of Contents

AUTOMATIC TRANSMISSION CIRCUIT

FE.FG II-19-92 Return to Table of Contents

ANTI-LOCK BRAKE SYSTEM CIRCUIT

FE.FG II-19-93 Return to Table of Contents

ANTI-LOCK BRAKE SYSTEM CIRCUIT

FE.FG II-19-94 Return to Table of Contents

BODY BUILDER’S DRAWINGS AND SUPPORTING DATA

SEP. 2007