---===SME_1009_00006_0001.djvu===--- Pub.No.00EMT0003, AUGUST 2010 Shop Manual electrical For South Africa (EURO 2) ---===SME_1009_00006_0001.djvu===--- Pub.No.00EMT0003, AUGUST 2010 Shop Manual electrical For South Africa (EURO 2) ---===SME_1009_00006_0002.djvu===--- ---===SME_1009_00006_0003.djvu===--- Pub.No.00EMT0003, AUGUST 2010 ---===SME_1009_00006_0004.djvu===--- GROUP INDEX FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso FK.FM.FN series trucks, and includes procedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage. For more details, please consult your nearest authorized Mitsubishi Fuso dealer or distributors. Kindly note that the specifications and maintenance ser- vice figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. AUGUST 2010 Applicable models FK.FM.FN ©2010 Mitsubishi Fuso Truck & Bus Corporation GENERAL ................................................ SPECIFICATIONS .................................... STRUCTURE AND OPERATION............. TROUBLESHOOTING ............................. POWER, CHARGE AND GROUND CIRCUIT ................................................... ENGINE STARTING AND STOPPING CIRCUIT................................ LIGHTING CIRCUIT ................................. METER CIRCUIT...................................... INDICATOR AND WARNING LAMP CIRCUIT ........................................ CAB SIDE ELECTRICAL CIRCUIT ......... CHASSIS SIDE ELECTRICAL CIRCUIT ................................................... OTHER CIRCUIT...................................... ELECTRICAL EQUIPMENT INSTALLATION POSITIONS ................... INSPECTION OF ELECTRICAL EQUIPMENT ............................................ STARTER AND ALTERNATOR ............... ON-VEHICLE INSPECTION AND ADJUSTMENT ......................................... CONNECTOR CONFIGURATION CHART ..................................................... ---===SME_1009_00006_0005.djvu===--- This Shop Manual contains the information classified into the following groups. If any system or equipment has two or more variations with significantly different construction, the variations are handled as different groups. These groups are identified by different alphabets preceded by the same number. 1. ENGINE volume 2. CHASSIS volume 3. ELECTRICAL volume Group No. Group subject 11 ENGINE 12 LUBRICATION 13 FUEL AND ENGINE CONTROL 14 COOLING 15 INTAKE AND EXHAUST Group No. Group subject 21 CLUTCH 22A MANUAL TRANSMISSION <M060S6, M070S6> 22B MANUAL TRANSMISSION <M060S9 (EATON FS-8209)> 25 PROPELLER SHAFT 26A FRONT AXLE <FK61> 26B FRONT AXLE <FK62, FM, FN> 27 REAR AXLE 31 WHEEL, TIRE 33 FRONT SUSPENSION 34A REAR SUSPENSION <LEAF (SHACKLE LINK TYPE)> 34B REAR SUSPENSION <LEAF (TRUNNION TYPE)> 35A BRAKE <AIR OVER HYDRAULIC BRAKE> 35B BRAKE <FULL AIR BRAKE> 35EA ANTI-LOCK BRAKE SYSTEM (ABS) <AIR OVER HYDRAULIC BRAKE> 35EB ANTI-LOCK BRAKE SYSTEM (ABS) <FULL AIR BRAKE> 36 PARKING BRAKE 37 STEERING 41 BUMPER, FRAME 42 CAB MOUNTING, TILT 43 DOOR 51 EXTERIOR 52 INTERIOR 55 HEATER Group No. Group subject 54 ELECTRICAL ---===SME_1009_00006_0006.djvu===--- CONTENTS 54-00A GENERAL VEHICLE MODEL CODING SYSTEM............................................... 54-00A-2 EQUIPMENT TYPE CODING SYSTEM................................................ 54-00A-3 POWER TRAIN TABLE ........................ 54-00A-5 HOW TO READ THIS MANUAL .......... 54-00A-6 1. Illustrated Parts Breakdown and Service Procedures .......................... 54-00A-8 2. How to Use Diagnosis Codes <Electronic Control System> ........... 54-00A-10 3. How to Read Circuits....................... 54-00A-11 CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE........... 54-00A-14 PRECAUTIONS FOR MAINTENANCE OPERATION ...................................... 54-00A-15 JACKING UP THE VEHICLE............. 54-00A-25 DIAGNOSIS CODES 1. Diagnosis Codes ........................... 54-00A-28 2. Reading and Erasing the Diagnosis Code ............................. 54-00A-29 TABLE OF STANDARD TIGHTENING TORQUES .......................................... 54-00A-36 54-00B SPECIFICATIONS SPECIFICATIONS ............................... 54-00B-2 54-00C STRUCTURE AND OPERATION 1. Starter....................................................... 54-00C-2 2. Alternator ................................................. 54-00C-3 3. Lighting .................................................... 54-00C-6 4. Meter Cluster ........................................... 54-00C-8 5. MUTIC (Multipurpose Timing Control Unit) ...................................................... 54-00C-18 6. Engine Electronic Control Unit (Starter Continuous Energizing Preventing Function) .......................... 54-00C-22 54-00D TROUBLESHOOTING TROUBLESHOOTING ......................... 54-00D-2 54-01 POWER, CHARGE AND GROUND CIRCUIT HIGH-CURRENT FUSE BOX ................. 54-01-2 RELAY AND FUSE BOX ........................ 54-01-4 RELAY AND FUSE BOX CIRCUIT......................................... 54-01-6 POWER CIRCUIT .......................... 54-01-8 RESERVE POWER CIRCUIT....... 54-01-20 BATTERY CHARGING CIRCUIT....................................... 54-01-21 GROUND ..................................... 54-01-22 54-02 ENGINE STARTING AND STOPPING CIRCUIT ENGINE STARTING CIRCUIT ...... 54-02-2 ENGINE STOPPING CIRCUIT ................................................ (See Gr13.) 54-03 LIGHTING CIRCUIT HEADLAMP CIRCUIT ................... 54-03-2 TAIL, POSITION AND LICENSE PLATE LAMPS CIRCUIT ............. 54-03-3 STOP LAMP CIRCUIT................... 54-03-4 TURN SIGNAL AND HAZARD LAMP CIRCUIT ............................. 54-03-6 BACKUP LAMP CIRCUIT ............. 54-03-8 CAB LAMP CIRCUIT................... 54-03-10 ILLUMINATION LAMP CIRCUIT....................................... 54-03-12 104 110 115 125 130 210 215 310 320 325 330 340 345 348 ---===SME_1009_00006_0007.djvu===--- 54-04 METER CIRCUIT METER CLUSTER INTERNAL CIRCUIT......................................... 54-04-2 TACHOMETER CIRCUIT .............. 54-04-3 SPEEDOMETER CIRCUIT ............ 54-04-4 FUEL GAUGE CIRCUIT ................ 54-04-5 WATER TEMPERATURE GAUGE CIRCUIT......................................... 54-04-6 AIR GAUGE CIRCUIT .................... 54-04-7 54-05 INDICATOR AND WARNING LAMP CIRCUIT PARKING BRAKE INDICATOR CIRCUIT......................................... 54-05-2 BRAKE WARNING CIRCUIT ........ 54-05-4 AIR CLEANER ELEMENT WARNING CIRCUIT ...................... 54-05-6 WATER LEVEL AND OVERHEATING WARNING CIRCUIT ...................... 54-05-7 ENGINE OIL LEVEL WARNING CIRCUIT......................................... 54-05-8 ENGINE OIL PRESSURE WARNING CIRCUIT ...................... 54-05-9 ENGINE OIL FILTER WARNING CIRCUIT....................................... 54-05-10 TRANSMISSION HIGH/LOW INDICATOR CIRCUIT.................. 54-05-11 CAB TILT WARNING CIRCUIT... 54-05-12 FUEL FILTER WARNING CIRCUIT........................................ 54-05-13 54-06 CAB SIDE ELECTRICAL CIRCUIT CIGARETTE LIGHTER CIRCUIT .. 54-06-2 WIPER AND WASHER CIRCUIT .. 54-06-3 HORN CIRCUIT ............................. 54-06-4 HEATER CIRCUIT ......................... 54-06-5 POWER TILT CIRCUIT.................. 54-06-6 54-07 CHASSIS SIDE ELECTRICAL CIRCUIT EXHAUST BRAKE CIRCUIT......... 54-07-2 54-09 OTHER CIRCUIT JOINT CONNECTOR (J/C) ........... 54-09-2 COMMON RAIL SYSTEM ELECTRIC CIRCUIT DIAGRAM......................... (See Gr13.) ANTI-LOCK BRAKE SYSTEM CIRCUIT DIAGRAM........................ (See Gr35E.) 54-10 ELECTRICAL EQUIP- MENT INSTALLATION POSITIONS Cab side SWITCH AND SENSOR.................... 54-10-2 RELAY, ELECTRONIC CONTROL UNIT AND FUSE ............ 54-10-6 METER, BUZZER AND MOTOR ........................................... 54-10-10 HEATER ......................................... 54-10-12 DOOR .............................................. 54-10-13 ROOF .............................................. 54-10-14 CAB ................................................. 54-10-15 POWER TILT................................... 54-10-16 JOINTS OF MAIN HARNESS CONNECTORS ............................... 54-10-18 Engine and transmission ENGINE ........................................... 54-10-22 TRANSMISSION ............................. 54-10-23 Chassis side SWITCH AND SENSOR.................. 54-10-24 FUSE ............................................... 54-10-27 MAGNETIC VALVE AND BUZZER .......................................... 54-10-28 JOINTS OF HARNESS CONNECTORS ............................... 54-10-29 OTHERS .......................................... 54-10-30 401 410 412 420 425 436 510 515 520 530 535 536 538 548 550 566 610 614 616 618 650 710 905 A B C D E F G H J R S T U V W X ---===SME_1009_00006_0008.djvu===--- 54-11 INSPECTION OF ELEC- TRICAL EQUIPMENT #001 to #179 SWITCH ............................ 54-11-2 #180 to #249 RELAY .............................. 54-11-7 #250 to #349 SENSOR ........................... 54-11-8 #350 to #409 CONTROL UNIT ............. 54-11-10 #410 to #509 MOTOR ........................... 54-11-11 #560 to #609 MAGNETIC VALVE ........ 54-11-12 #610 to #649 BUZZER, HORN ............. 54-11-13 #650 to #699 LAMP .............................. 54-11-14 #750 to #859 OTHER............................ 54-11-15 #860 BATTERY..................................... 54-11-18 #890 METER ......................................... 54-11-21 54-12 STARTER AND ALTERNATOR #930 STARTER....................................... 54-12-2 #940 ALTERNATOR ............................. 54-12-16 54-13 ON-VEHICLE INSPECTION AND ADJUSTMENT #950 INSPECTION OF ALTERNATOR .. 54-13-2 #951 INSPECTION OF REGULATOR .... 54-13-3 #956 INSPECTION OF STARTER CONTINUOUS ENERGIZING PREVENTING FUNCTION ............ 54-13-4 #960 HEADLAMP AIMING ..................... 54-13-6 54-14 CONNECTOR CONFIGURATION CHART CONNECTOR CONFIGURATION CHART .................................................... 54-14-2 ---===SME_1009_00006_0009.djvu===---