Mitsubishi FG15N-35CN, FD20N-35N Chassis and Mast Service Manual 99719-M9140 Vol 1

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mitsubishi fg15n 35cn fd20n 35n chassis and mast service manual 99719 m9140 vol 1 2

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Mitsubishi FG15N-35CN, FD20N-35N Chassis and Mast Service Manual 99719-M9140 Vol 1

$50.00

Type Of Manual: Service Manual
Manual ID: 99719-M9140 Vol 1
Number of Pages: 631
Size: 36.7MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- FG15N, FG18N, FG20CN, FG20N, FG25N, FG28N, FG30N, FG33N, FG35CN, FD20N, FD25N, FD28N, FD30N, FD33N, FD35N

1. M9140_VOL1_FG15N_SERVICE_2014-07E1_MIT_50949
2. M9140_VOL2_FG15N_SERVICE_2014-07E1_MIT_50950
3. M9140_VOL3_FG15N_SERVICE_2014-07E1_MIT_50951
3.1. FOREWORD
3.1.1. Safety
3.1.2. Symbols and Abbreviations
3.1.3. Units
3.2. TABLE OF CONTENTS
3.3. Chapter 1 GENERAL INFORMATION
3.3.1. Model View
3.3.2. Truck Models Covered
3.3.3. Serial Number Locations
3.3.4. Dimensions
3.3.5. Technical Data
3.4. Chapter 2 COOLING SYSTEM
3.4.1. Specification
3.4.2. Structure
3.4.3. Removing Fan Belt
3.4.3.1. Preparation
3.4.3.2. Removal Sequence
3.4.3.3. Suggestions for Removal
3.4.4. Installing Fan Belt
3.4.5. Inspecting and Adjusting Cooling System
3.4.5.1. Inspecting Fan Belt
3.4.5.2. Adjusting Fan Belt Tension
3.4.5.3. Connecting Radiator Hoses
3.4.5.4. Coolant
3.4.5.5. Radiator Cap
3.5. Chapter 3 ELECTRICAL SYSTEM
3.5.1. Electrical Components and Wiring Outline
3.5.1.1. Locations of Electrical Components
3.5.2. Console Box
3.5.2.1. Console Box Outline
3.5.2.2. Disassembling Console Box
3.5.2.3. Assembling Console Box
3.5.3. Meter Panel
3.5.3.1. Disassembling Meter Panel
3.5.3.2. Assembling Meter Panel
3.5.3.3. Bulb Replacement
3.5.4. Main Electrical Components
3.5.4.1. Meter Panel
3.5.4.2. Key Switch
3.5.4.3. Key Switch (Anti-Restart Switch)
3.5.4.4. Light Switch and Turn Signal Switch
3.5.4.5. Direction (FNR) Switch
3.5.4.6. Select Switch
3.5.4.7. Horn
3.5.4.8. Tank Unit
3.5.4.9. Brake Oil Sensor
3.5.4.10. Stop Light Switch
3.5.4.11. Thermoswitch (Engine Coolant Temperature)
3.5.4.12. Thermoswitch (T/C Oil)
3.5.4.13. Speed Sensor (Pulse Generator)
3.5.4.14. Parking Brake Switch
3.5.4.15. Relay Box
3.5.4.16. Fuse Box
3.5.4.17. QGS Controller (Diesel Model)
3.5.4.18. Rear Combination Light
3.5.4.19. Rear Combination Harness
3.5.4.20. List of Lights
3.5.5. Battery and Maintenance
3.5.5.1. State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
3.5.5.2. Specific Gravity Reading and State of Charge
3.5.5.3. Precautions for Battery Charging
3.5.6. Wire Color
3.5.6.1. List of Wire Color Codes
3.5.7. Troubleshooting
3.5.7.1. Starter System
3.5.7.2. Gauges
3.5.7.3. Lighting System
3.5.7.4. Alarm Unit
3.5.7.5. Battery
3.5.7.6. Horn Testing Procedures
3.5.8. Fuel Pressure Sensor Harness
3.5.8.1. Wire Harness
3.5.8.2. Converting the Year 2005/2006 Chassis Harness to 2004 Chassis Harness
3.5.8.3. Year 2005/2006 RELATIVE Fuel Pressure Sensor
3.5.8.4. Terminal Positions
3.5.8.5. Change the Wire Positions
3.5.8.6. Fuel Pressure Sensor Connector Kit P/N 91A04-06960
3.5.8.7. Change Pins
3.5.9. Wiring Harness Service Parts
3.5.9.1. Pick Tool Part
3.5.9.2. ETC Connector Assembly Part No. SE000218
3.5.9.3. ETC Pin Terminal W/ 6 Lead Part No. SE000219
3.5.9.4. Ignition Coil Connector Part No. 91A04-06590
3.5.9.5. Water Temp Sensor Connector Part No. 91A04-06410
3.5.9.6. Alternator Connector Part No. 91A04-06420
3.5.9.7. Air Flow Meter Connector Part No. 91A04-06580
3.5.9.8. LP Injector Driver Connector Part No. 05110-81230
3.5.9.9. Fuel Pressure Jumper Harness Part No. 91820-03200
3.5.9.10. Gasoline Injector Connector Part No. 91820-01840
3.5.9.11. Fuel Pressure Connector Part No. 91820-01850
3.5.9.12. Fuel Pressure Connector Part No. 91A04-06960
3.5.9.13. GSE Connector
3.5.9.14. Throttle Position Sensor
3.5.9.15. Soldering Procedure
3.5.9.16. Pin Removal Procedure
3.5.9.17. Pin Removal Procedure
3.5.10. Electrical Wiring Diagram
3.6. Chapter 4 CONTROLLER
3.6.1. Outline
3.6.2. Main Functions of Controllers
3.6.2.1. Meter Panel
3.6.2.2. VCM (Vehicle Control Module)
3.6.2.3. ECM (Engine Control Module)
3.6.2.4. GSE Connector
3.6.3. Service Tool
3.6.3.1. Service Tool Menus
3.6.3.2. Toolbox
3.6.3.3. Mot File Download Process
3.6.3.4. Check Main C Relay Circuit with Diagnostics Program
3.6.3.5. Programming Travel Speed
3.6.4. Mast Interlock System
3.6.4.1. Mast Interlock Function
3.6.4.2. Checking Procedure of Mast Interlock System
3.6.4.3. Active Test Inspection Procedure
3.6.5. Driving Interlock System
3.6.5.1. Controller Function
3.6.5.2. Checking the Operation of Driving Interlock Function
3.6.5.3. Active Test Inspection Procedure
3.6.6. Seat Belt Warning Light
3.6.6.1. Operation of Seat Belt Warning Light
3.6.6.2. Checking the Operation of Seat Belt Warning Light
3.6.7. Parking Brake Warning Buzzer and Light
3.6.7.1. Operation of Parking Brake Warning Buzzer and Light
3.6.7.2. Parking Brake Warning Buzzer
3.6.7.3. Checking the Operation of Parking Brake Warning Buzzer/Light with Key in OFF Position
3.6.8. Harness Codes
3.6.9. Controller Output Details
3.6.9.1. VCM (Vehicle Control Module)
3.6.9.2. Seat Switch
3.6.9.3. Parking Brake Switch
3.6.9.4. Direction Lever Switch
3.6.9.5. Vehicle Speed Sensor
3.6.9.6. T/M Solenoid
3.6.9.7. Unload Solenoid
3.6.9.8. Lift Lock Solenoid
3.6.9.9. Warning Buzzer
3.6.9.10. Warning Buzzer Relay
3.6.9.11. Warning Buzzer Circuit
3.6.9.12. Meter Panel
3.6.10. Truck Status Display and Troubleshooting
3.6.10.1. Truck Status Display
3.6.10.2. Diagnosis Table (F Code)
3.6.10.3. LED Blink Pattern
3.6.10.4. Diagnostic Codes and Troubleshooting
3.6.11. Common Diagnostic Codes
3.6.11.1. F85(T/M Forward Travel Solenoid Warning) and F87 (T/M Backward Travel Solenoid Warning) Displayed
3.6.11.2. E-23 (Throttle Sensor Warning)
3.6.11.3. E-24 (Accelerator Sensor Warning)
3.6.11.4. E-27 (POS Sensor Warning)
3.6.11.5. E-30 (ECCS C/U System Warning)
3.6.11.6. E-31 (Throttle Control Warning)
3.6.11.7. E-35 (LPG Fuel Injection Disconnection Warning)
3.6.11.8. E-38 (LPG Vaporizer Diagnostic Result Warning)
3.6.11.9. E-42 (Gas Air-Fuel Ratio Malfunction) and E-43 (LPG Air-Fuel Ratio MalFunction)
3.7. Chapter 5 POWER TRAIN
3.7.1. Removing and Installing Engine and Transmission Assembly (For Gasoline engine Trucks)
3.7.1.1. Removal Sequence of Overhead Guard, Covers, and Air Cleaner
3.7.1.2. Suggestions for Removal of Overhead Guard, Cover, and Air Cleaner
3.7.1.3. Removal Sequence of Controls
3.7.1.4. Suggestion for Removal of Controls
3.7.1.5. Installation Sequence of Overhead Guard, Covers, Air Cleaner, and Controls
3.7.1.6. Preparation for Removal of LPG System (Dual Fuel Gasoline and LPG Model)
3.7.1.7. Removal Sequence of LPG System (Dual Fuel Gasoline and LPG Model)
3.7.1.8. Installation Sequence of LPG System (Dual Fuel Gasoline and LPG Model)
3.7.1.9. Preparation for Removal of Radiator and Pipes
3.7.1.10. Removal Sequence of Radiator and Pipes
3.7.1.11. Suggestion for Removal of Radiator and Pipes
3.7.1.12. Installation Sequence of Radiator and Pipes
3.7.1.13. Preparation for Removal of Engine and Transmission Assembly
3.7.1.14. Removal Sequence of Engine and Transmission Assembly
3.7.1.15. Suggestions for Removal of Engine and Transmission Assembly
3.7.1.16. Installation Sequence of Engine and Transmission Assembly
3.7.1.17. Suggestions for Installation of Engine and Transmission Assembly
3.7.1.18. Removing and Installing of Engine and Transmission Assembly (For Diesel Engine Trucks)
3.7.1.19. Removal Sequence of Overhead Guard, Covers, and Air Cleaner
3.7.1.20. Suggestions for Removal of Overhead Guard, Covers, and Air Cleaner
3.7.1.21. Removal Sequence of Controls
3.7.1.22. Suggestions for Removal and Installation
3.7.1.23. Preparation for Removal of Radiator and Pipes
3.7.1.24. Removal Sequence of Radiator and Pipes
3.7.1.25. Suggestion for Removal of Radiator and Pipes
3.7.1.26. Installation Sequence of Radiator and Pipes
3.7.1.27. Preparation for Removal of Engine and Transmission Assembly
3.7.1.28. Removal Sequence of Engine and Transmission Assembly
3.7.1.29. Suggestions for Removal of Engine and Transmission Assembly
3.7.1.30. Installation of Engine and Transmission Assembly
3.7.1.31. Suggestion for Installation of Engine and Transmission Assembly (Those Not Shared with Gasoline Engine Trucks)
3.8. Chapter 6 POWERSHIFT TRANSMISSION
3.8.1. Structure
3.8.1.1. External View of Torque Converter Transmission
3.8.1.2. External View of Control Valve
3.8.1.3. Transmission Components
3.8.1.4. Torque Converter Components
3.8.1.5. Torque Converter Drive Control Components
3.8.1.6. Schematic Diagram of Powershift Transmission Hydraulic System
3.8.2. Removing Transmission
3.8.2.1. Suggestions for Removal
3.8.3. Installing Transmission
3.8.3.1. Suggestions for Installation
3.8.4. Disassembling Torque Converter Transmission
3.8.4.1. Preparation
3.8.4.2. Removing Transmission Accessories
3.8.4.3. Removing Oil Pump
3.8.4.4. Removing Transmission Housing
3.8.4.5. Removing Input Shaft, Idler Shaft and Output Gear
3.8.4.6. Disassembling Transmission Housing
3.8.4.7. Disassembling Torque Converter Housing
3.8.4.8. Disassembling Idler Shaft
3.8.4.9. Disassembling Output Gear
3.8.4.10. Disassembling Forward Side Input Shaft Gear Assembly
3.8.4.11. Disassembling Reverse Side Input Shaft Gear
3.8.4.12. Disassembling Oil Pump
3.8.5. Assembling Torque Converter Transmission
3.8.5.1. Assembling Transmission Housing
3.8.5.2. Assembling Idler Shaft Assembly
3.8.5.3. Assembling Output Gear Assembly
3.8.5.4. Inspecting Input Shaft Gear Assembly
3.8.5.5. Assembling Forward Side Input Shaft Gear Assembly
3.8.5.6. Assembling Reverse Side Input Shaft Gear Assembly
3.8.5.7. Assembling and Installing Oil Pump Assembly
3.8.5.8. Assembling Torque Converter Housing
3.8.5.9. Installing Transmission Housing
3.8.5.10. Installing Servo Case Assembly
3.8.5.11. Installing Transmission Accessories
3.8.6. Disassembling Control Valve
3.8.6.1. Removing Control Valve Accessories
3.8.6.2. Removing Valve Body Plate
3.8.6.3. Removing Plugs
3.8.6.4. Removing Strainer
3.8.6.5. Disassembling Regulator Valve Section
3.8.6.6. Disassembling Accumulator Valve Section
3.8.6.7. Disassembling Inching Valve Section
3.8.6.8. Removing Oil Seal and Plug
3.8.7. Assembling Control Valve
3.8.7.1. Assembly Sequence of Control Valve
3.8.7.2. Suggestions for Assembly
3.8.7.3. Washing and Inspecting
3.8.7.4. Installing Valve Plug and Oil Seal
3.8.7.5. Assembling Inching Valve Section
3.8.7.6. Assembling Accumulator Valve Section
3.8.7.7. Assembling Regulator Valve Section
3.8.7.8. Installing Strainer
3.8.7.9. Installing Plug
3.8.7.10. Installing Valve Body Plate and Breather Cover
3.8.7.11. Assembling Control Valve Accessories
3.8.8. Inspection and Adjustment
3.8.8.1. Oil Pressure Measurement
3.8.8.2. Adjusting Brake (Inching) Pedal
3.8.8.3. Adjusting Inching Cable
3.8.8.4. Increasing the Inching Pedal Return Spring Tension
3.8.9. Troubleshooting
3.8.10. Service Data
3.8.10.1. Pump Boss
3.8.10.2. Pilot Boss
3.8.10.3. Oil Pump
3.8.10.4. Flexible Plate
3.8.10.5. Clutches
3.8.10.6. Input Shaft
3.9. Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
3.9.1. Structure
3.9.1.1. Ton Class
3.9.1.2. Ton Class
3.9.1.3. Ton Class
3.9.2. Removing Front Wheels
3.9.2.1. Preparation
3.9.2.2. Removal
3.9.2.3. Suggestion for Removal
3.9.3. Installing Front Wheels
3.9.4. Removing Front Axle and Reduction Differential
3.9.4.1. Preparation
3.9.4.2. Removal Sequence
3.9.4.3. Suggestions for Removal
3.9.5. Installing Front Axle
3.9.6. Disassembling Front Axle
3.9.6.1. Disassembly Sequence
3.9.6.2. Suggestions for Disassembly
3.9.7. Inspection and Repair After Disassembling Front Axle
3.9.8. Assembling Front Axle
3.9.9. Disassembling Reduction Differential
3.9.9.1. Disassembly Sequence
3.9.9.2. Suggestions for Disassembly
3.9.10. Inspection and Repair After Disassembling Reduction Differential
3.9.11. Assembling Reduction Differential
3.9.11.1. Assembly Sequence
3.9.11.2. Suggestions for Assembly
3.9.11.3. Adjustment
3.9.12. Troubleshooting
3.9.13. Service Data
3.9.13.1. Hub and Wheels
3.9.13.2. Reduction Differential
3.10. Chapter 8 REAR AXLE
3.10.1. Structure
3.10.1.1. Main Components of Rear Axle
3.10.1.2. Specifications for Wheel Alignment and Steering Angle
3.10.1.3. Main Components of Wheel Hub
3.10.1.4. Main Components of King Pin
3.10.1.5. Main Components of Tie Rod
3.10.1.6. Main Components of Steering Cylinder
3.10.2. Removing Rear Wheels
3.10.3. Installing Rear Wheels
3.10.4. Removing Rear Wheels and Rear Axle Assembly
3.10.4.1. Removal Sequence
3.10.4.2. Suggestions for Removal
3.10.5. Installing Rear Wheels
3.10.6. Disassembling Wheel Hub
3.10.6.1. Disassembly Sequence
3.10.6.2. Suggestions for Disassembly
3.10.7. Inspection and Repair After Disassembly

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