FK.FM For South Africa Pub.No.THME0408, DECEMBER 2004 Shop Manual electrical an FuUSOFK.FM electrical For South Africa Shop Manual FOREWORD This Shop Manual is published for the information and ‘guidance of personnel responsible for maintenance of Mi- tsubishi FK, FM series truck, and includes procedures for adjustment and maintenance services. ‘We eamestly 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 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. DECEMBER 2004 Applicable models FK, FM, GROUP INDEX HOW TO READ THIS MANUAL GENERAL POWER, CHARGE AND GROUND. CIRCUIT... STARTING CIRCUIT. LIGHTING CIRCUIT... METER CIRCUIT. INDICATOR AND WARNING LAMP CIRCUIT... CAB SIDE ELECTRICAL CIRCUIT CHASSIS SIDE ELECTRICAL CIRCUIT OTHER CIRCUIT. PARTS INSTALLATION POSITIONS INSPECTION OF PARTS. STARTER AND ALTERNATOR sees EZ ON-VEHICLE INSPECTION AND ADJUSTMENT. CONNECTOR CONFIGURATION CHART (©2004 Mitsubishi Fuso Truck & Bus Corporation Printed in JapanCONTENTS HOW TO READ THIS MANUAL HOW TO READ THIS MANUAL 2 54-00 GENERAL PRECAUTIONS FOR MAINTENANCE OPERATION SPECIFICATIONS ... STRUCTURE AND OPERATION 1. Starter. 2. Alternator... 3. Headlamps 4, MUTIC (Multipurpose Timing Control Unit)... : ‘TROUBLESHOOTING. 54-01 POWER, CHARGE AND GROUND CIRCUIT HIGH-CURRENT FUSE BOX RELAY AND FUSE BOX... ELAY AND FUSE BOX CIRCUIT... POWER CIRCUIT. . (GID RESERVE POWER CIRCUIT... SATTERY CHARGING CIRCUIT... ROUND 54-01-2 54-01-4 54-02 STARTING CIRCUIT (QD ENGINE STARTING CIRCUIT....... 5402-2 (QD ENGINE STOPPING CIRCUIT....... 54-02-3 54-03 LIGHTING CIRCUIT (GD HEADLAMP CIRCUIT .. 54-03-2 (2D TAIL, CLEARANCE AND LICENSE PLATE LAMPS CIRCUIT «0.0. 54-03-3, ® STOP LAMP CIRCUIT. 54-03-4 GD TURN SIGNAL AND HAZARD LAMP CIRCUIT 5403-6 GD BACKUP LAMP CIRCUIT 5403-8 ZB CAB AND SPOT LAMP CIRCUIT. 54.03-9 GD ILLUMINATION LAMP CIRCUIT. 54-03-10 END-OUTLINE MARKER LAMP CIRCUIT. 54-03-11 54-04 METER CIRCUIT METER CLUSTER INTERNAL CIRCUIT. 54-04-2 (GD TACHOMETER CIRCUIT... 5404-4 (G&D SPEEDOMETER CIRCUIT. 5404-5 FUEL GAUGE CIRCUIT. 54-04-6 (G5 WATER TEMPERATURE GAUGE CIRCUIT. 5404-7 54-05 INDICATOR AND WARNING LAMP CIRCUIT CHD PARKING BRAKE INDICATOR CIRCUIT. 54-05-2 CH® BRAKE WARNING CIRCUIT........ 54-05-3 (GD AIR FILTER INDICATOR CIRCUIT. 54-05-5 WATER LEVEL AND OVERHEATING WARNING CIRCUIT... 54-05-6 (@® ENGINE OIL PRESSURE WARNING CIRCUIT... 54-05-7 ENGINE OIL FILTER WARNING CIRCUIT. 54-05-8 CD TRANSMISSION HIGH/LOW INDICATOR CIRCUIT. 54-05-9 SD CAB TILT WARNING CIRCUIT... 54-05-1054-06 CAB SIDE ELECTRICAL CIRCUIT CIGARETTE LIGHTER CIRCUIT... 54-06-2 WIPER AND WASHER CIRCUIT... 54-06-3 HORN CIRCUIT HEATER CIRCUIT 54-06-4 54-06-6 54-07 CHASSIS SIDE ELECTRICAL CIRCUIT XHAUST BRAKE CIRCUI 54-07-2 54-09 OTHER CIRCUIT |UTIC (MULTIPURPOSE TIMING CONTROL UNIT) CIRCUIT 54-09-2 54-10 PARTS INSTALLATION POSITIONS Cab side [A] SWITCH 54-10-2 B] RELAY AND ELECTRONIC CONTROL UNIT. 54-10-4 FUSE, METER, BUZZER AND = MOTOR. 54-10-5 DJHEATER.. 54-10-6 F]ROo} 54-10-7 G]caB. 54-10-8 J] JOINT OF MAIN HARNESS CONNECTORS .. Engine and transmission ENGINE TRANSMISSION .. Chassis side SWITCH AND SENSOR... FUSE AND CONNECTOR... MAGNETIC VALVE BUZZER .. 54-11 INSPECTION OF PARTS #001 to #179 SWITCH.. 54-11-2 #180 to #249 RELAY, 54-11-7 #250 to #349 SENSOR. #350 to #409 CONTROL UNIT. #410 to #509 MOTO! #560 to #609 MAGNETIC VALVE.. #610 to #649 BUZZER #650 to #699 LAMP. #750 to #859 OTHER #860 BATTERY #890 METER CLUSTET 54-12 STARTER AND ALTERNATOR #930 STARTER #940 ALTERNATOR. 54-12-2 54-12-46 54-13 ON-VEHICLE INSPECTION AND ADJUSTMENT #950 INSPECTION OF ALTERNATOR.. 54-13-2 #951 INSPECTION OF REGULATOR... 54-13-3 #960 HEADLAMP AIMING.. 54-13-4 54-14 CONNECTOR CONFIGURATION CHART CONNECTOR CONFIGURATION CHART. 54-14-2HOW TO READ THIS MANUALHOW TO READ THIS MANUAL HOW TO READ CIRCUITS (ELECTRICAL) 1.2 [Key number Indicates part installation location. 1.1 [Index number Reference numbers All the parts installation locations for electrical circuits, are listed in Gr54-10. | 1.3| Part name 425.) WATER TEWPERATURE GAUGE C1RCUIT 01” #890 sate crate Br Wires that have both base and tracer colors are indicated by two letters. RY (Yellow tracer on Red bate) G (ease color) GL (Blue tracer on Groen base) L tracer color) s0680e| 1.9 Code number: #001 to #999 + Code numbers are reference numbers to find individual parts inspection procedures. The inspection procedure for a part can be found using its code number shown in a circuit diagram. 4.40Grounding point: [1] to [99] + Locations where wires are grounded to the vehicle. All of the grounding points are listed in CISD. 4.11 Harness connection ‘+ The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity.HOW TO READ THIS MANUAL Wire color Wie calor Base olor + acer Blac Baw Bac Biacw 8 Back faw Hay BEM oe wlecered Bo SM Tm, Bi Brown! Brown! Brown! Brown! Brown! ea Brown BWV “white | 8°8 black [BY yellow |B red |S “green Green! Green! Green! Green! Green! Green! iS Green |GW “white |OR red |CY yellow [C8 back [St blue |S orange Gr Grylot Sv ler Stay Bue! She ry Buel Buel E eee | white [LR Bluelred | LY yellow: I black |LO orange re green lun ght Tare Light ght tg sh Jug green’ |tgy green’ [igh green’ igw green! gl red yellow black white © orange for N82! Jon OraRwR! Jog Orange! Pink Pink! Pink) Pind i all ic black |P& green i blue [PY white Pa Purple Real Real Real Rear Real c Red |RW white [RB black |RY—yelow [RE green [RL_Rediblue |RO orange 3 Seybhe Vieley Viele Vout vy wot vy Nek vw YSleY vee volured [va Vek Wy wane [wre WRT yyy WEY |, WRT veg We | vey WaT red back ble ren orange Yelowi Yelow! Yalow Yellow Yellow Yalow a red |¥8 black |¥S green he blue [YW white [YO orange 7 Yellow Yellow! Yellow! ye pink Wy violetUnits ‘+ Tightening torques and other parameters are given in SI* units with metric units added in brackets {}. Values in engine specifications, performance curves, and other items taken from official approval documents are given only in metric units. *Sk: Le Systéme International d’Uni Example: 390 N:m (40 kgm) Metric u Slunit Unit Sl onit (metic unit) Conversion factor Force NikoA 9.80665 N (1 Kath Moment of fore Nem tkafmp 9.80665 Nm (1 kof my Positive pressure kPa {katie} {98,0665 kPa {1 kgflom?} Presur | sm reseure kPa (mmHg) 0.133822 KPa (1 mmHg} Pa {mmH0) 9.80665 Pa (1 mmHz0} ‘Volume cam? {Ly am? {1 Uy Power RPS) 0.7355 KW {1 PS) Heat quantity Tikal) 4186.05 5 (1 kcal Heat fow W tkcalhy 1.16279 W {f Kean} ‘Angle : = Temperature °c = Electric current A = Votage Vv = Resistance a = Electric power w =HOW TO READ THIS MANUAL ‘This manual consists of the following parts: ‘+ Specifications + Structure and Operation + Troubleshooting = Circuits ‘+ Electrical and Electronic parts Location ‘+ Inspection of Electrical and Electronic parts + Onwehidle Inspection and Adjustment On-vehicle Inspection and Adjustment ‘+ Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de- scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedure + Procedures for servicing components and parts off the vehicle are described centering on key points in their re- moval, installation, disassembly, reassembly, inspection, etc. Inspection ‘+ Check items subject to acceptance or otherwise on the basis of service standards are all given. ‘+ Some routine visual checks and cleaning of some reused parts are not described but must be always included in actual service work. Caution ‘+ This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: DANGER A. —————— Precautions that should be taken in handling potentially dangerous substances such as battery fui and coolant adctves. WARNING A, —————— Precautionary instructions, which, if not observed, could result in serious injury or death, CAUTION A, —————— Precautionary instructions, which, ifnot observed, could result in damage to or de- struction of equipment or parts. NOTE ‘Suggestions or supplementary information for more efficient use of equipment or a better understanding, Terms and Units + Front and rear ‘The forward running direction of the vet the front and the reversing direction is the rear. Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right. Standard value + Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear- ance between two parts when assembled, and the standard value for an assembly part, as the case may be. Limit ‘+ When the value of a part exceeds this, itis no longer serviceable in respect of performance and strength and must be replaced or repaired,Tightening torque Values are directly specified for out-of-standard tightening torques for bolts and nuts. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Val. ues for standard tightening torques are based on thread size and material.) ‘When the item is to be tightened in a "wet" state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque