1992-1995 Mitsubishi Fuso FH Series Truck Service Manual – PDF DOWNLOAD
DESCRIPTION:
1992-1995 Mitsubishi Fuso FH Series Truck Service Manual – PDF DOWNLOAD
FOREWORD:
- This Service Manual contains maintenance and repair procedures for the benefit of all those who are involved in the maintenance and repair of Mitsubishi Fuso Truck FH Series.
- Reading this manual carefully will help you to providing correct, efficient and fast maintenance. Please note, however, that due to continued vehicle improvements, the specifications and values supplied here for your use when providing maintenance may change without notice.
TABLE OF CONTENTS:
1992-1995 Mitsubishi Fuso FH Series Truck Service Manual – PDF DOWNLOAD
92-95 FH Service Manual 1
Manual Layout 2
Group 00 – General 4
Group 00 – General (Supplement) 5
Group 00 – General (’95 Minor Change) 22
Group 00 – General (’94 Minor Change) 30
Group 00 – General (’93 Minor Change) 36
Group 00 – General 42
Table of Contents 43
1 External Views 44
2 Major Specifications 49
3 Power Train Table 52
4 Equipment Model Notation 52
5 Performance Curves 53
51 Operation Performance Curves 53
52 Engine Performance Curves 53
6 Servicing Precautions 53
7 Standard Bolts and Nuts Tightening Torque Table 60
8 Towing Precautions 61
9 Chassis and Engine Numbers 62
10 Vehicle Identification Number 62
Group 01 – Maintenance Schedule 64
Table of Contents 65
1 How to Read the Maintenance Schedule Tables 66
2 Maintenance Schedule Tables 67
3 Maintenance Operations 73
31 Replacement of the Engine Oil Filter Element 73
32 Replacement of the Fuel Filter Element 73
33 Inspection of Air Dryer 74
34 Cleaning of the Fuel Feed Pump Gauze Filter 74
35 Bleeding Air from the Fuel Line 74
36 Water Separator Condensation Drain 75
37 Adjusting V-Belt Tension 75
38 Cleaning and Replacement of the Air Cleaner Element 76
39 Inspecting the Clutch Pedal <Vehicles with Manual Transmission> 77
310 The Tires 78
3101 Air Pressure 78
3102 Removing Tires 78
3103 Tire Mounting 79
3104 Checking the Wheel Nuts for Looseness 81
3105 Tire Rotation 81
311 Adjusting the Clearance of the Wheel Brake Shoe 82
312 Adjusting the Clearance of the Parking Brake Shoe 83
313 The Battery 83
314 Fuses 85
4 Lubrication 89
41 Engine Oil 90
42 Gear Oil for Manual Transmission 91
43 Automatic Transmission Fluid and Oil Filters for Automatic Transmission 92
44 Rear Axle Gear Oil 95
45 Power Steering Fluid 96
46 Brake Fluid 100
461 Brake Fluid Tank 100
462 Clutch Fluid Tank 103
47 Greasing the Various Areas of the Chassis 106
Group 11 – Engine 107
Table of Contents 108
1 Troubleshooting 110
2 Engine Removal and Installation (Manual Transmission Vehicles) 113
21 Service Standards 113
211 Tightening Torque Table 113
22 Removal of Engine and Transmission 113
221 Preparation for Removal 113
222 Removal of Harness 114
223 Removal of Air Compressor Hoses, Actuator and Tube Assembly 116
224 Removal of Parts Around the Engine 116
225 Removal of Engine Parts 117
226 Removal of Transmission Parts 119
227 Removal of Transmission 121
228 Removing the Engine from the Vehicle 121
23 Installation of the Engine and Transmission 122
231 Installation of Engine 122
232 Installation of Transmission 123
233 Installation of Transmission Parts 123
234 Installation of Engine Parts 125
235 Installation of Parts Around the Engine 126
236 Installation of Air Compressor Hoses, Actuator and Tube Assembly 127
237 Installation of Harness 128
24 Adjustment After Installation 129
241 Preparation for Adjustment 129
242 Adjustment 131
3 Engine Removal and Installation (Automatic Transmission Vehicles) 132
31 Service Standards 132
311 Tightening Torque Table 132
32 Removal of Engine and Transmission 132
321 Preparation for Removal 132
322 Removal of Harness 133
323 Removal of Air Compressor Hose 134
324 Removal of Parts Around the Engine 135
325 Removal of Engine Parts 136
326 Removal of Transmission Parts 138
327 Removal of Transmission 140
328 Removing the Engine from the Vehicle 140
33 Installation of the Engine and Transmission 141
331 Installation of the Engine 141
332 Installation of Transmission 142
333 Installation of Transmission Parts 143
334 Installation of Engine Parts 144
335 Installation of Parts Around the Engine 145
336 Installation of Air Compressor Hose 146
337 Installation of Harnesses 146
34 Adjustment After Installation 148
341 Preparation for Adjustment 148
342 Adjustment 150
4 Engine Assembly 151
41 Specifications 151
42 Service Standards 151
421 Service Standards Table 151
422 Tightening Torque Table 152
423 Special Tools Table 152
43 Inspection and Adjustment of Valve Clearance 154
44 Measurement of Compression Pressure 155
45 Inspection of Oil Pressure 157
46 Inspection and Adjustment of Fuel Injection Start Timing 157
47 Bleeding the Fuel System 158
48 Inspection and Adjustment of V-Belt Tension 159
49 Measurement of Turbocharger Boost Pressure 160
5 Cylinder Head and Valve Mechanism 163
51 Service Standards 163
511 Service Standards Table 163
512 Tightening Torque Table 163
513 Special Tools Table 164
52 General Description 166
521 Cylinder Head 166
522 Valve Mechanism 166
53 Removal 167
54 Disassembly 169
541 Rocker and Bracket Assembly 169
542 Cylinder Head Assembly 169
55 Inspection 171
56 Reassembly 179
561 Cylinder Head Assembly 179
562 Rocker and Bracket Assembly 181
57 Installation 182
6 Flywheel and Flywheel Housing (Manual Transmission Vehicles) 185
61 Service Standards 185
611 Service Standards Table 185
612 Tightening Torque Table 185
613 Special Tools Table 185
614 Sealant Table 185
62 General Description 186
63 Disassembly 186
64 Inspection 187
65 Reassembly 189
7 Flywheel and Flywheel Housing (Automatic Transmission Vehicles) 194
71 Service Standards 194
711 Tightening Torque Table 194
712 Special Tools Table 194
713 Sealant Table 194
72 General Description 195
73 Disassembly 195
74 Inspection 196
75 Reassembly 197
8 Timing Gear and Camshaft 201
81 Service Standards 201
811 Service Standards Table 201
812 Tightening Torque Table 201
813 Lubricant Table 201
814 Sealant Table 201
815 Special Tools Table 202
82 General Description 203
83 Disassembly 204
84 Inspection 207
85 Reassembly 211
9 Crankcase and Main Moving Parts 214
91 Service Standards 214
911 Service Standards Table 214
912 Tightening Torque Table 215
913 Sealant Table 215
914 Special Tools Table 215
92 General Description 216
921 Crankshaft 216
922 Connecting Rod 217
923 Piston 217
93 Disassembly 218
94 Inspection 222
95 Reassembly 233
Group 12 – Lubrication 240
Table of Contents 241
1 Troubleshooting 242
2 Lubrication System 242
21 Specifications 242
22 General Description 243
221 System Outline 243
222 Lubrication of Main Moving Parts 244
223 Camshaft Lubrication 244
224 Valve Mechanism Lubrication 244
225 Timing Gear Lubrication 245
226 Turbocharger Lubrication 245
227 Injection Pump Assembly Lubrication 246
228 Air Compressor Lubrication 246
23 Oil Pressure Check 246
3 Oil Pan and Oil Strainer 247
31 Service Standards 247
311 Tightening Torque Table 247
312 Sealant Table 247
32 General Description 247
33 Removal 247
34 Installation 248
35 Post-Installation Inspection 250
4 Oil Pump 251
41 Service Standards 251
411 Service Standards Table 251
42 General Description 251
43 Removal 251
44 Disassembly and Inspection 252
45 Reassembly 255
46 Installation 256
5 Oil Cooler and Oil Filter 257
51 Service Standards 257
511 Service Standards Table 257
512 Tightening Torque Table 257
513 Special Tools Table 257
52 General Description 258
53 Removal 259
54 Disassembly and Inspection 260
55 Reassembly 261
56 Installation 262
Group 13 – Fuel and Engine Control 264
Table of Contents 265
1 Troubleshooting 266
2 Fuel System 268
21 General Description 268
22 Removal and Installation of the Fuel Hoses 269
3 Prestroke Control Type Injection Pump System 270
31 Specifications 270
32 Service Standards 270
321 Service Standards Table 270
322 Tightening Torque Table 271
323 Special Tools Table 271
33 General Description 272
331 Prestroke Control Type Injection Pump System 272
332 Control Unit 275
333 Sensors 276
334 Injection Pump Proper 277
335 Governor 279
336 Feed Pump 284
337 Coupling 285
34 Service Procedure 285
341 Inspection of System 288
342 Removal of Injection Pump Assembly 309
343 Installation of Injection Pump Assembly 311
344 Adjustments After Installation of Injection Pump 314
345 Bleeding Air from the Fuel System 314
346 Adjustment of Fuel Injection Timing 314
347 Adjustment of No-Load Minimum and Maximum Speeds 315
348 Operation Check of the Engine Stop Cable 315
4 Injection Nozzles 316
41 Specifications 316
42 Service Standards 316
421 Service Standards Table 316
422 Tightening Torque Table 316
43 General Description 317
44 Removal 317
45 Disassembly 317
46 Inspection and Cleaning 319
47 Reassembly 320
48 Test and Adjustment 322
49 Installation 323
5 Fuel Filter 324
51 Specifications 324
52 Service Standards 324
521 Tightening Torque Table 324
522 Special Tools Table 324
53 General Description 325
54 Removal and Inspection 325
55 Installation 325
6 Water Separator 327
61 Specifications 327
62 Service Standards 327
63 General Description 327
64 Removal 327
65 Disassembly and Inspection 328
66 Reassembly 328
67 Installation 329
68 Draining Water 329
7 Fuel Tank 330
71 Specifications 330
72 Service Standards 330
73 General Description 330
74 Removal 330
75 Inspection 332
76 Installation 332
8 Engine Control System 334
81 Specifications 334
82 Service Standards 335
83 General Description 336
84 Removal 337
841 Disconnecting the Accelerator Control Cable and Engine Stop Cable 337
842 Removal of the Throttle Cable 340
843 Removal of the Accelerator Pedal and Accelerator Lever Assembly 342
85 Inspection 343
86 Installation 343
861 Installation of Accelerator Lever Assembly and Accelerator Pedal 344
862 Installation of Throttle Cable 345
863 Installation of Accelerator Control Cable and Engine Stop Cable 347
87 Adjustment After Installation 351
871 Adjustment of the Accelerator Pedal Stopper 351
872 Operation Check of the Engine Stop Cable 352
873 Adjustment of the Accelerator Switch (Exhaust Brake Microswitch) 352
Group 14 – Cooling 354
Table of Contents 355
1 Troubleshooting 356
2 Cooling System 357
21 Specifications 357
22 General Description 357
23 Removal 358
231 Preparation for Removal 358
232 Radiator and Reservoir Tank Removal 358
233 Cooling Fan and Auto-Cool Fan Coupling Removal 360
234 Water Pump Removal 361
235 Thermostat Removal 361
24 Installation 362
241 Thermostat Installation 362
242 Water Pump Installation 363
243 Cooling Fan and Auto-Cool Fan Coupling Installation 364
244 Radiator and Reservoir Tank Installation 364
245 Operations After Installation 366
3 Cooling Fan and Auto-Cool Fan Coupling 367
31 General Description 367
311 Cooling Fan 367
312 Auto-Cool Fan Coupling 367
32 Auto-Cool Fan Coupling Inspection 369
4 Thermostat 370
41 Service Standards 370
411 Service Standards Table 370
42 General Description 370
43 Inspection 370
5 Radiator 371
51 Service Standards 371
52 General Description 371
521 Radiator 371
522 Pressure Cap 371
523 Radiator Shroud 372
524 Reservoir Tank 372
53 Inspection and Cleaning 372
531 Radiator Cleaning 372
532 Radiator Inspection 373
533 Pressure Cap Inspection 373
534 Radiator (Cooling System) Cleaning 374
535 Gas Leak Test 376
536 Cooling System Air Bleeding 377
Group 15 – Intake and Exhaust 378
Table of Contents 379
1 Troubleshooting 380
2 Intake System 381
21 Specifications 381
22 Service Standards 381
221 Service Standards Table 381
222 Tightening Torque Table 381
23 General Description 381
24 Removal 383
25 Air Cleaner Disassembly, Cleaning and Reassembly 384
251 Disassembly 384
252 Cleaning 385
253 Reassembly 386
26 Installation 386
27 Intake System Inspection 388
3 Exhaust System 389
31 Service Standards 389
32 General Description 389
33 Removal 390
34 Inspection 391
35 Installation 392
36 Exhaust System Inspection 395
4 Turbocharger 396
41 Specifications 396
42 Service Standards 396
421 Service Standards Table 396
422 Tightening Torque Table 396
423 Lubricant Table 397
43 General Description 397
44 Removal 398
45 Disassembly 401
46 Cleaning and Inspection 406
461 Cleaning 406
462 Inspection 407
47 Reassembly 409
48 Installation 416
49 Post-Installation Inspection 418
5 Intercooler 419
51 Specifications 419
52 Service Standards 419
53 Outline 419
54 Removal 419
55 Cleaning and Inspection 420
56 Installation 420
6 Intake Shutter Valve System <Vehicles with Manual Transmission> 421
61 Specifications 421
62 Service Standards 421
621 Service Standards Table 421
622 Tightening Torque Table 421
63 General Description 422
64 Removal 423
65 Inspection 424
66 Installation 424
Group 16 – Engine Electrical 426
Table of Contents 427
1 Troubleshooting 428
2 Electrical System 430
21 Specifications 430
22 General Description 431
221 Starting System 433
222 Charging System 438
3 Starter 439
31 Service Standards 439
311 Service Standards Table 439
312 Lubricant 439
32 General Description 440
33 Removal 441
34 Disassembly 443
35 Inspection 446
36 Reassembly 454
37 Testing 459
38 Installation 461
4 Alternator 462
41 Service Standards 462
411 Service Standards Table 462
412 Tightening Torque Table 462
413 Lubricant Table 462
42 General Description 463
43 Removal 466
44 Disassembly 467
45 Inspection 470
46 Reassembly 474
47 Testing 477
471 Handling Precautions 477
472 Performance Testing 478
473 Regulator Inspection 479
48 Installation 480
5 Glow System 482
51 Service Standards 482
511 Service Standards 482
512 Tightening Torque Table 482
513 Special Tools Table 482
52 General Description 483
53 Removal 485
54 Inspection 486
541 Glow Plug Inspection 486
542 Glow Relay Inspection 486
543 Glow Controller Inspection 487
55 Installation 488
Group 21 – Clutch 490
Table of Contents 491
1 Troubleshooting 492
2 Clutch Proper 495
21 Specifications 495
22 Service Standards 495
221 Service Standards Table 495
222 Tightening Torque Table 495
223 Special Tools Table 496
23 General Description 497
24 Removal 498
241 Operation Before Removal 498
242 Removal of Clutch Proper 499
25 Disassembly 500
26 Inspection 501
27 Reassembly 506
28 Installation 508
29 Post-Installation Adjustment 509
210 Lubrication of Drive Pinion Splines 509
3 Clutch Control 511
31 Specifications 511
32 Service Standards 511
321 Service Standards Table 511
322 Tightening Torque Table 512
323 Sealant Table 512
324 Special Tools Table 513
33 General Description 514
34 Clutch Hose and Piping 515
341 Removal 515
342 Inspection 519
343 Installation 520
344 Post-Installation Work 523
35 Clutch Pedal Assembly 524
351 Removal 524
352 Disassembly 526
353 Inspection 527
354 Reassembly 528
355 Installation 530
356 Post-Installation Adjustment 531
36 Clutch Master Cylinder 531
361 Removal 531
362 Disassembly 532
363 Inspection 533
364 Reassembly 533
365 Installation 534
366 Post-Installation Adjustment 534
37 Clutch Power Cylinder 535
371 Removal 535
372 Disassembly 536
373 Inspection 537
374 Reassembly 538
375 Installation 539
376 Post-Installation Adjustment 540
38 Clutch Housing Assembly 540
381 Removal 540
382 Disassembly 542
383 Reassembly 543
384 Installation 545
385 Post-Installation Adjustment 545
39 Fluid Change in the Clutch System 546
310 Bleeding the Clutch System 547
311 Clutch Pedal Inspection and Adjustment 548
312 Clutch Adjustment 549
Group 22 – Manual Transmission 552
Table of Contents 553
1 Troubleshooting 554
2 Removing and Installing 556
21 Service Standards 556
211 Tightening Torque Table 556
22 Preliminary Operations 556
23 Removal 557
24 Installation 558
3 Transmission Assembly 561
31 Specifications 561
32 Service Standards 561
321 Service Standards Table 561
322 Tightening Torque Table 561
323 Special Tools Table 562
324 Sealant Table 565
33 General Description 565
34 Removal 570
341 Clutch Housing Assembly 570
342 Gear Shift, Upper and Lower 570
343 Rear Cover and Parking Brake 570
344 Transmission 570
35 Installation 574
351 Transmission 574
352 Rear Cover 577
353 Gear Shift, Upper and Lower 577
354 Clutch Housing Assembly 577
4 Main Shaft Assembly 578
41 Service Standards 578
411 Service Standards Table 578
412 Tightening Torque Table 578
413 Special Tools Table 579
42 Preliminary Inspection 580
43 Disassembly 581
44 Inspection 585
45 Reassembly 588
5 Counter Shaft Assembly 593
51 Service Standards 593
511 Sealant Table 593
52 Special Tools Table 593
53 Disassembly 593
54 Reassembly 594
6 Reverse Gear 595
61 Service Standards 595
611 Service Standards Table 595
612 Tightening Torque Table 595
613 Special Tools Table 595
62 Disassembly and Inspection 596
63 Reassembly 597
7 Gear Shift, Lower 598
71 Service Standards 598
711 Service Standards Table 598
712 Tightening Torque Table 598
713 Sealant Table 598
72 General Description 599
73 Disassembly 600
74 Inspection 602
75 Reassembly 603
8 Gear Shift, Upper 605
81 Service Standards 605
811 Service Standards Table 605
812 Tightening Torque Table 605
813 Sealant Table 605
82 Disassembly 606
83 Inspection 608
84 Reassembly 608
9 Rear Cover 611
91 Service Standards 611
911 Service Standards Table 611
912 Tightening Torque Table 611
913 Special Tools Table 611
914 Sealant Table 611
92 Disassembly 612
93 Inspection 614
94 Reassembly 614
10 Transmission Control 617
101 Specifications 617
102 Service Standards 617
1021 Service Standards Table 617
1022 Tightening Torque Table 617
103 General Description 618
104 Preliminary Operations 618
105 Removal 618
106 Inspection, Repair and Replacement 620
107 Installation 621
108 Control Cable 623
1081 Shift Cable 623
1082 Select Cable 624
1083 Inspection 624
109 Set Board Assembly 625
1091 Disassembly and Reassembly 625
Group 23 – Automatic Transmission 626
Table of Contents 627
1 Troubleshooting 628
2 Removing and Installing 630
21 Specifications 630
22 Service Standards 630
221 Tightening Torque Table 630
222 Special Tools Table 630
23 Removal 631
24 Installation 633
3 Oil Seal and Speedometer Worm 636
31 Service Standards 636
311 Service Standards Table 636
312 Tightening Torque Table 636
313 Special Tools Table 636
32 Removal and Installation 637
33 Replacement of Front Oil Seal 638
34 Replacement of Rear Oil Seal 638
35 Replacement of Speedometer Worm 638
4 Automatic Transmission Control System 639
41 Service Standards 639
411 Service Standards Table 639
412 Tightening Torque Table 640
413 Sealant Table 640
42 General Description 641
43 Removal and Installation 643
44 Inspection After Installation 646
45 Oil Cooler 646
46 Fluid Pipe and Oil Temperature Sensor 647
47 Replacement of Fluid and Oil Filter 648
Group 25 – Propeller Shaft 651
Table of Contents 652
1 Troubleshooting 653
2 Propeller Shaft 654
21 Specifications 654
22 Service Standards 654
221 Service Standards Table 654
222 Tightening Torque Table 654
223 Special Tools Table 655
23 General Description 656
24 Removal 657
25 Disassembly 659
26 Inspection 662
27 Reassembly 666
28 Installation 670
Group 26 – Front Axle 672
Table of Contents 673
1 Troubleshooting 674
2 Front Axle Assembly 675
21 Specifications 675
22 Service Standards 675
221 Tightening Torque Table 675
23 General Description 676
24 Removal 676
25 Installation 677
26 Post-Installation Adjustment 677
3 Wheel Hub and Brake Drum 682
31 Service Standards 682
311 Service Standards Table 682
312 Tightening Torque Table 682
313 Sealant Table 682
314 Special Tools Table 683
32 Disassembly 685
33 Inspection 688
34 Reassembly 690
4 Front Axle and Knuckle 695
41 Service Standards 695
411 Service Standards Table 695
412 Tightening Torque Table 695
413 Special Tools Table 695
42 Removal 696
43 Disassembly 697
44 Inspection 699
45 Reassembly 702
46 Installation 705
Group 27 – Rear Axle 706
Table of Contents 707
1 Troubleshooting 708
2 Rear Axle Assembly 710
21 Specifications 710
22 Service Standards 710
221 Service Standards Table 710
222 Tightening Torque Table 711
223 Special Tools Table 711
23 General Description 712
24 Removal 713
25 Inspection 714
26 Installation 715
3 Wheel Hub and Brake Drums 717
31 Service Standards 717
311 Service Standards Table 717
312 Tightening Torque Table 717
313 Special Tools Table 717
32 Disassembly 720
33 Inspection 723
34 Reassembly 726
4 Reduction and Differential 733
41 Service Standards 733
411 Service Standards Table 733
412 Tightening Torque Table 733
413 Lubricant Table 734
414 Special Tools Table 734
42 Removal 737
43 Pre-Disassembly Inspection 738
44 Disassembly 740
45 Inspection 744
46 Reassembly 749
47 Installation 758
Group 31 – Wheels and Tires 760
Table of Contents 761
1 Troubleshooting 762
2 Wheel and Tire 763
21 Specifications 763
22 Service Standards 763
221 Service Standards Table 763
222 Tightening Torque Table 763
23 General Description 764
24 Removal 764
241 Preparation for Removal 764
242 Removing Front Tires 765
243 Removing Rear Tires 766
25 Removal of Tire 766
26 Inspection 768
27 Installation of Tire 769
28 Inspection and Adjustment After Installation 770
29 Installation 771
Group 33 – Front Suspension 773
Table of Contents 774
1 Troubleshooting 775
2 Front Suspension Assembly 776
21 Service Standards 776
211 Service Standards Table 776
212 Tightening Torque Table 776
213 Special Tools Table 777
22 General Description 778
23 Removal 778
24 Inspection 781
25 Installation 782
3 Leaf Springs 787
31 Specifications 787
32 Service Standards 787
33 General Description 787
34 Pre-Disassembly Inspection 787
35 Disassembly 787
36 Inspection 788
37 Reassembly 788
4 Shock Absorbers 790
41 Specifications 790
42 General Description 790
43 Disassembly 790
44 Inspection 790
5 Stabilizer 791
51 General Description 791
52 Pre-Disassembly Inspection 791
53 Disassembly 791
54 Inspection 791
55 Reassembly 792
Group 34 – Rear Suspension 793
Table of Contents 794
1 Troubleshooting 795
2 Rear Suspension Assembly 796
21 Service Standards 796
211 Service Standards Table 796
212 Tightening Torque Table 796
213 Special Tools Table 796
22 General Description 797
23 Removal 797
24 Inspection 800
25 Installation 801
3 Leaf Springs 805
31 Specifications 805
32 General Description 805
33 Pre-Disassembly Inspection 805
34 Disassembly 805
35 Inspection 806
36 Reassembly 806
4 Shock Absorbers 808
41 Specifications 808
42 General Description 808
43 Disassembly 808
44 Inspection 808
5 Stabilizer 809
51 General Description 809
52 Pre-Disassembly Inspection 809
53 Disassembly 809
54 Inspection 809
55 Reassembly 810
Group 35 – Brake 811
Table of Contents 812
1 Troubleshooting 814
2 Brake System 818
21 Specifications 818
22 Service Standards 818
221 Tightening Torque Table 818
222 Special Tools Table 818
23 General Description 819
24 Bleeding the Brake Fluid Lines 820
25 Changing the Brake Fluid 821
3 Brake Piping and Brake Fluid Tank 822
31 Service Standards 822
311 Tightening Torque Table 822
32 General Description 823
33 Inspection Before Removal 827
34 Removing the Brake Fluid 828
35 Removal 828
36 Disassembly 833
37 Inspection 834
38 Reassembly 835
39 Installation 836
4 Air Tank 842
41 Specifications 842
42 Service Standards 842
421 Service Standards Table 842
422 Tightening Torque Table 842
423 Sealant Table 842
43 General Description 843
44 Drain Cock 843
441 Air Leak Test 843
442 Functional Inspection 843
443 Removal 844
444 Installation 844
45 Safety Valve 844
451 Air Leak Test 844
452 Functional Inspection 845
453 Removal 846
454 Installation 847
46 Air Tank 847
461 Air Leak Test 847
462 Removal 848
463 Installation 851
5 Air Compressor 856
51 Specifications 856
52 Service Standards 856
521 Service Standards Table 856
522 Tightening Torque Table 857
523 Special Tools Table 857
53 General Description 858
54 Removal 859
55 Disassembly 861
56 Inspection 865
57 Reassembly 868
58 Installation 874
6 Brake Pedal Assembly 877
61 Service Standards 877
611 Service Standards Table 877
612 Tightening Torque Table 877
62 Removal 877
63 Disassembly 880
64 Inspection 882
65 Reassembly 883
66 Installation 884
67 Adjusting the Pedal Height 887
7 Dual Brake Valve 888
71 Specifications 888
72 Service Standards 888
721 Service Standards Table 888
722 Tightening Torque Table 889
723 Sealant Table 889
73 General Description 889
74 Removal 895
75 Disassembly 896
76 Inspection 902
77 Reassembly 904
78 Installation 911
8 Brake Booster (Air-Master) 914
81 Specifications 914
82 Service Standards 914
821 Service Standards Table 914
822 Tightening Torque Table 915
823 Sealant Table 915
83 General Description 916
84 Removal 919
85 Disassembly 923
86 Inspection 929
87 Reassembly 930
88 Installation 937
89 Inspection After Installation 943
9 Air Dryer 944
91 Specifications 944
92 Service Standards 944
921 Service Standards Table 944
922 Tightening Torque Table 944
923 Sealant Table 944
93 General Description 945
94 Maintenance and Inspection 946
941 Maintenance and Inspection 946
942 Inspection and Replacement of Desiccant 946
943 Inspection After Replacement 949
95 Removal 950
96 Disassembly 952
97 Reassembly 956
98 Inspection After Reassembly 960
99 Installation 960
910 Inspection After Installation 964
10 Air Pressure Governor 965
101 Specifications 965
102 Service Standards 965
1021 Service Standards Table 965
1022 Tightening Torque Table 965
1023 Sealant Table 965
103 General Description 966
104 Functional Inspection 967
105 Adjustment 968
106 Removal 969
107 Disassembly 971
108 Reassembly 973
109 Installation 976
11 Check Valve 979
111 Service Standards 979
1111 Service Standards Table 979
1112 Tightening Torque Table 979
1113 Sealant Table 979
112 General Description 979
113 Removal 980
114 Disassembly 980
115 Inspection 981
116 Reassembly 981
117 Installation 982
12 Switch 984
121 Specifications 984
122 Service Standards 984
1221 Tightening Torque Table 984
1222 Sealant Table 984
123 Stop Lamp Switch 984
1231 Removal 984
1232 Inspection 984
1233 Installation 985
124 Low Air Pressure Switch 985
1241 Removal 985
1242 Inspection 986
1243 Installation 986
13 Front Drum Brake 987
131 Specifications 987
132 Service Standards 987
1321 Service Standards Table 987
1322 Tightening Torque Table 988
1323 Special Tools Table 988
133 General Description 989
134 Removal 989
135 Disassembly 990
136 Inspection 992
137 Reassembly 996
138 Wheel Cylinder 999
1381 Disassembly 999
1382 Inspection1000
1383 Reassembly1001
139 Installation1002
1310 Adjusting Holder Pin1004
1311 Adjusting Shoe Clearance1004
14 Rear Drum Brake1006
141 Specifications1006
142 Service Standards1006
1421 Service Standards Table1006
1422 Tightening Torque Table1006
1423 Special Tools Table1007
143 General Description1007
144 Removal1007
145 Disassembly1008
146 Inspection1010
147 Reassembly1014
148 Wheel Cylinder1017
1481 Disassembly1017
1482 Inspection1018
1483 Reassembly1019
149 Installation1021
1410 Adjusting Holder Pin1022
1411 Adjusting Shoe Clearance1022
15 Exhaust Brake System1024
151 Specifications1024
152 Service Standards1024
1521 Service Standards Table1024
1522 Tightening Torque Table1025
1523 Sealant Table1025
153 General Description1026
154 Removal1028
155 Disassembly1031
1551 Exhaust Brake Unit1031
156 Inspection1033
157 Reassembly1035
158 Installation1038
159 Operation Test After Installing1041
1510 Control Cylinder1041
15101 Disassembly1041
15102 Inspection1042
15103 Reassembly1042
15104 Inspection After Assembly1043
1511 Supply Valve1044
15111 Disassembly1044
15112 Reassembly1044
15113 Airtightness Test After Reassembling1045
15114 Operation Test After Reassembling1045
Group 36 – Parking Brake1046
Table of Contents1047
1 Troubleshooting1048
2 Parking Brake Control1049
21 Specifications1049
22 Service Standards1049
221 Service Standards Table1049
222 Tightening Torque Table1049
23 General Description1050
24 Removal1051
241 Preliminary Operation1051
242 Parking Brake Cable1051
243 Parking Brake Lever Assembly1052
25 Disassembly and Inspection1053
251 Disassembly1053
252 Inspection1054
26 Reassembly1055
27 Installation1056
271 Parking Brake Lever Assembly1056
272 Parking Brake Cable1057
28 Post-Installation Adjustment1058
3 Parking Brake Drum and Shoes1060
31 Specifications1060
32 Service Standards1060
321 Service Standards Table1060
322 Tightening Torque Table1061
323 Special Tools Table1061
33 General Description1062
34 Removal1063
341 Preliminary Operation1063
342 Removal1063
35 Disassembly and Inspection1065
351 Disassembly1065
352 Inspection1068
36 Reassembly1070
37 Installation1073
Group 37 – Steering1076
Table of Contents1077
1 Troubleshooting1078
2 Power Steering System1084
21 Service Standards1084
211 Service Standards Table1084
212 Tightening Torque Table1084
22 General Description1085
23 Replacement of Power Steering Fluid1086
24 Performance Verification Tests1090
25 Overall Checks on Power Steering1094
3 Steering Wheel and Shaft1097
31 Specifications1097
32 Service Standards1097
321 Tightening Torque Table1097
33 General1098
34 Removal1098
35 Disassembly1103
36 Reassembly1106
37 Installation1110
38 Inspection After Installation1115
4 Steering Linkage1116
41 Service Standards1116
411 Service Standards Table1116
412 Tightening Torque Table1116
413 Special Tools Table1116
42 General Description1117
43 Drag Link1118
431 Removal1118
432 Disassembly1118
433 Inspection and Reassembly1118
434 Installation1119
44 Tie Rod1120
441 Removal1120
442 Disassembly1120
443 Inspection and Reassembly1121
444 Installation1123
45 Post-Installation Inspection and Adjustment1123
5 Power Steering Booster1124
51 Specifications1124
52 Service Standards1124
521 Service Standards Table1124
522 Tightening Torque Table1125
523 Sealant Table1125
524 Special Tools Table1126
53 General Description1127
531 Construction1127
532 Operation1128
54 Removal1130
55 Disassembly1132
56 Inspection1137
57 Reassembly1139
58 Installation1145
59 Post-Installation Work1146
6 Power Steering Oil Pump1147
61 Specifications1147
62 Service Standards1147
621 Service Standards Table1147
622 Tightening Torque Table1148
623 Special Tools Table1148
63 General Description1149
64 Removal1153
65 Disassembly1154
66 Inspection1156
67 Reassembly 1159
68 Installation1161
69 Post-Installation Inspection and Adjustment1161
Group 41 – Frame1162
Table of Contents1163
1 Frame Assembly1164
11 Specifications1164
12 General Description1164
13 Inspection and Repair1165
131 Frame1165
132 Rivets1167
14 Frame Shape1169
Group 42 – Cab1173
Table of Contents1174
1 Troubleshooting1175
2 Cab Proper1177
21 Specifications1177
22 Service Standards1177
23 General Description1178
24 Tilting the Cab1178
25 Removal1180
251 Operation Before Removal1180
252 Operation in the Cab1182
253 Operation at the Cab Front1185
254 Operation with the Cab Tilted1188
255 Hoisting the Cab1191
26 Installation1192
261 Installing the Cab1192
262 Operation with the Cab Tilted1194
263 Operation from Front of the Cab1198
264 Operation in the Cab1201
265 Post-Installation Operation1203
3 Cab Mounting1205
31 Specifications1205
32 Service Standards1205
33 General Description1206
331 Cab Mounting1206
332 Cab Hinge1206
333 Cab Stay1207
334 Cab Tilt Link1207
34 Cab Tilt Link1208
341 Removal1208
342 Installation1210
343 Inspection and Adjustment After Installation1212
35 Rear Cab Mounting1213
351 Removal1213
352 Installation1216
353 Post-Installation Inspection and Adjustment1219
36 Cab Hinge1220
361 Removal1220
362 Installation1223
363 Post-Installation Operation1226
4 Front Windshield Glass and Rear Window Glass1227
41 Specifications1227
42 Service Standards1227
43 Removal1227
431 Operation Before Removal1227
432 Removal1227
44 Installation1228
441 Installation Operation1228
442 Post-Installation Operation1230
5 Door Assembly1231
51 Specifications1231
52 Service Standards1231
53 General Description1232
54 Removal1233
541 Removing the Door Trim1233
542 Removing the Front Door Window Regulator1234
543 Removing the Front Door Locking System1237
544 Removing the Outside Mirror Stay Assembly1238
545 Removing the Front Door Panel Assembly1238
55 Installation1241
551 Installing the Front Door Panel Assembly1241
552 Installing the Outside Mirror Stay Assembly1243
553 Installing the Front Door Locking System1244
554 Inspection and Adjustment After Installation of the Front Door Locking System1245
555 Installing the Front Door Window Regulator1246
556 Installing the Door Trims1249
6 Seats, Seat Belts and Floor Mat1250
61 Specifications1250
62 Service Standards1250
63 Removal1251
631 Removing the Seats1252
632 Removing the Seat Belts1253
633 Removing the Floor Mats1254
64 Installation1255
641 Installing the Floor Mats1256
642 Installing the Seat Belts1256
643 Installing the Seats1258
7 Trim1260
71 Specifications1260
72 Removal1260
73 Installation1263
8 Instrument Panel1266
81 Service Standards1266
82 Removal1267
83 Installation1279
84 Post-Installation Operation1291
9 Wiper and Washer1292
91 Service Standards1292
92 Removal1292
93 Installation1295
94 Post-Installation Inspection1298
10 Cab and Associated Parts1299
101 Service Standards1299
102 Removal1299
103 Installation1305
104 Post-Installation Inspection1311
11 Silencer and Enclosure1312
111 Removal1312
112 Installation1313
Group 54 – Chassis Electrical1315
Table of Contents1316
1 Troubleshooting1317
2 Chassis Electrical1322
21 Specifications1322
22 General Description1322
23 Wiring Harness1323
24 Centralized Ground Connections1325
3 Battery1326
31 Specifications1326
32 Service Standards1326
33 General Description1326
34 Removal1327
35 Inspection1328
36 Installation1329
4 Fuses and Relays1330
41 Specifications1330
42 Service Standards1331
43 General Description1332
44 Removal and Installation1333
45 Inspection1334
451 Fuses1334
452 Relays1334
5 Fusible Link1338
51 Specifications1338
52 General Description1338
53 Removal and Inspection1338
54 Installation1339
6 Starter Switch and Cold Start Switch1340
61 Specifications1340
62 General Description1340
63 Removal and Installation1341
64 Inspection1341
7 Steering Column Switches1342
71 Specifications1342
72 General Description1342
73 Inspection1343
8 Lighting System1344
81 Specifications1344
82 Service Standards1344
83 General Description1345
831 Lamps and Switches1345
832 Circuit Description1348
84 Removal1359
85 Inspection1361
86 Installation1363
87 Inspection and Adjustment After Installation1365
9 Meters and Gauges1367
91 Specifications1367
92 Service Standards1368
93 General Description1369
94 Removal1373
95 Inspection1377
96 Installation1381
97 Inspection After Installation1385
10 Indicator and Warning Lamp System1387
101 Specifications1387
102 Service Standards1387
103 General Description1388
1031 Function of Each Lamp1388
1032 Operation of Each Lamp1390
104 Removal and Installation1395
105 Inspection1396
11 Exhaust Brake System (Vehicles with Manual Transmission)1401
111 Specifications1401
112 Service Standards1401
113 General Description1402
114 Removal and Installation1404
115 Inspection1405
116 Inspection After Installation1406
12 Wiper and Washer System1407
121 Specifications1407
122 Service Standards1407
123 General Description1408
1231 Wiper System1408
1232 Washer System1411
124 Removal and Installation1411
125 Inspection and Cleaning1412
126 Inspection and Adjustment After Installation1414
13 Substarter System1416
131 General Description1416
132 Removal and Installation1417
133 Inspection1417
14 Horn1418
141 Specifications1418
142 General Description1418
143 Removal and Installation1419
144 Inspection1419
145 Inspection After Installation1419
15 Radio (Option), Cassette Stereo (Option), Speakers, and Antenna1420
151 Specifications1420
152 General Description1421
153 Removal and Installation1422
154 Inspection and Adjustment1423
16 Cigarette Lighter1425
161 Specifications1425
162 Service Standards1425
163 General Description1425
164 Removal and Installation1426
165 Inspection1426
166 Inspection After Installation1427
Group 55A – Air Conditioner1428
Group 55A (9402) – Air Conditioner1429
Table of Contents1430
1 Specifications1431
2 Outlines of Refrigeration System1432
21 Air System1432
22 Refrigerating Cycle1432
23 Electrical System1433
3 Construction1434
31 Engine Compartment1434
32 Cab1434
33 Control System1435
34 Compressor and Magnetic Clutch1438
341 Compressor1438
342 Check Valve1439
343 Magnetic Clutch1439
35 Condenser1439
36 Receiver Drier1439
37 Cooling Unit1440
38 Expansion Valve1440
39 High Pressure Switch1441
310 Power Relay1441
311 A/C Switch1441
312 Thermo Sensor1441
4 Troubleshooting1442
41 General Precautions1442
42 Trouble, Cause and Remedy1443
43 Inspection Procedures1445
431 A/C Switch1445
432 High Pressure Switch1445
433 Thermo Sensor1446
434 Magnetic Clutch1446
435 Refrigerant Charge1446
436 Receiver Drier Assembly1447
437 Belt Tension1447
438 Expansion Valve1447
439 Compressor1448
4310 Air Inclusion in Refrigerant Circuit1448
4311 Moisture Inclusion in Refrigerant Circuit1448
5 Removal and Installation1449
51 Precaution for Removal and Installation1449
52 Removal1449
521 Inside the Engine Compartment1449
522 Inside the Cab1450
53 Installation1453
6 Treatment After Installation1454
61 Check and Adjustment1454
62 Refrigerant Charge1454
621 Installation of Charge Equipment1454
622 Refrigerant Charge and Leak Check1455
623 Removal of Charge Equipment1455
63 Gas Charge1456
64 Checking the Refrigerant Level1456
65 Performance Test1457
651 Preparation1457
652 Stationary Performance Test1457
7 Cooling Unit1458
71 Components1458
72 Cautions in Disassembling1459
73 Disassembling1459
8 Maintenance1460
9 Compressor1461
91 Disassembling the Clutch1461
92 Reassembly the Clutch1462
93 Disassembling the Shaft Seal1463
94 Reassembly the Shaft Seal1464
95 Special Tool Figure1466
Group 55A (9106) – Air Conditioner1469
Table of Contents1470
1 Specifications1471
2 Outlines of Refrigeration System1472
21 Air System1472
22 Refrigerating Cycle1472
23 Electrical System1473
3 Construction1474
31 Engine Compartment1474
32 Cab1474
33 Control System1475
34 Compressor and Magnetic Clutch1478
341 Compressor1478
342 Check Valve1479
343 Magnetic Clutch1479
35 Condenser1479
36 Receiver Drier1479
37 Cooling Unit1480
38 Expansion Valve1480
39 High Pressure Switch1481
310 Power Relay1481
311 A/C Switch1481
312 Thermo Sensor1481
4 Troubleshooting1482
41 General Precautions1482
42 Trouble, Cause and Remedy1483
43 Inspection Procedures1485
431 A/C Switch1485
432 High Pressure Switch1485
433 Thermo Sensor1486
434 Magnetic Clutch1486
435 Refrigerant Charge1486
436 Receiver Drier Assembly1487
437 Belt Tension1487
438 Expansion Valve1487
439 Compressor1488
4310 Air Inclusion in Refrigerant Circuit1488
4311 Moisture Inclusion in Refrigerant Circuit1488
5 Removal and Installation1489
51 Precaution for Removal and Installation1489
52 Removal1489
521 Inside the Engine Compartment1489
522 Inside the Cab1490
53 Installation1493
6 Treatment After Installation1494
61 Check and Adjustment1494
62 Refrigerant Charge and Leak Check1494
621 Installation of Charge Equipment1494
622 Refrigerant Charge and Leak Check1495
623 Removal of Charge Equipment1495
63 Gas Charge1496
64 Checking the Refrigerant Level1496
65 Performance Test1497
651 Preparation1497
652 Stationary Performance Test1497
7 Cooling Unit1498
71 Components1498
72 Cautions in Disassembling1499
73 Disassembling1499
8 Maintenance1500
9 Compressor1501
91 Disassembling the Clutch1501
92 Reassembly the Clutch1502
93 Disassembling the Shaft Seal1503
94 Reassembly the Shaft Seal1504
95 Special Tool Figure1506
Group 55B – Heater1509
Table of Contents1510
1 Troubleshooting1511
2 Heater and Ventilation1512
21 Specifications1512
22 Service Standards1512
23 General Descriptions1513
24 Wiring Diagram1516
25 Pre-Removal Inspection1517
251 Blower Switch Inspection1517
252 Mode Control Lever Inspection1518
253 Temperature Control Lever Inspection1520
254 Air Selector Lever Inspection1521
255 Side Ventilator Inspection1522
26 Removal1523
27 Installation1528
28 Post-Installation Adjustments1532
3 Heater Plumbing1534
31 Removal1534
32 Inspection1535
33 Installation1535
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