Mitsubishi FGC15N to FGC33N Chassis and Mast Service Manual 99719-7C150 Vol. 1

Mitsubishi FGC15N to FGC33N Chassis and Mast Service Manual 99719-7C150 Vol. 1 - Image 2

Mitsubishi FGC15N to FGC33N Chassis and Mast Service Manual 99719-7C150 Vol. 1 - Image 3

Mitsubishi FGC15N to FGC33N Chassis and Mast Service Manual 99719-7C150 Vol. 1 - Image 4

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Mitsubishi FGC15N to FGC33N Chassis and Mast Service Manual 99719-7C150 Vol. 1

$50.00

Type Of Manual: Service Manual
Manual ID: 99719-7C150 Vol. 1
Number of Pages: 239
Size: 22.8MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- FGC15N, FGC18N, FGC20CN, FGC20N, FGC20N-HO, FGC25N, FGC25N-HO, FGC28N, FGC30N, FGC33N

1. FOREWORD
1.1. Safety
1.2. Symbols and Abbreviations
1.3. Units
1.3.1. Chapter 1 GENERAL INFORMATION
1.3.2. Chapter 2 COOLING SYSTEM
1.3.3. Chapter 3 ELECTRICAL SYSTEM
1.3.4. Chapter 4 CONTROLLER
1.3.5. Chapter 5 POWER TRAIN
1.3.6. Chapter 6 POWERSHIFT TRANSMISSION
1.3.7. Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
1.3.8. Chapter 8 REAR AXLE
1.3.9. Chapter 9 BRAKE SYSTEM
1.3.10. Chapter 10 STEERING SYSTEM
1.3.11. Chapter 11 HYDRAULIC SYSTEM
1.3.12. Chapter 12 MAST AND FORKS
1.3.13. Chapter 13 SERVICE DATA
1.3.14. Chapter 14 APPENDIX
2. TABLE OF CONTENTS
3. Chapter 1 GENERAL INFORMATION
3.1. Model View
3.2. Truck Models Covered
3.3. Serial Number Locations
3.4. Dimensions
3.5. Technical Data
4. Chapter 2 COOLING SYSTEM
4.1. Specification
4.2. Structure
4.3. Removing Fan Belt
4.3.1. Preparation
4.3.2. Removal Sequence
4.3.3. Suggestions for Removal
4.4. Installing Fan Belt
4.5. Inspecting and Adjusting Cooling System
4.5.1. Inspecting Fan Belt
4.5.2. Adjusting Fan Belt Tension
4.5.3. Connecting Radiator Hoses
4.5.4. Coolant
4.5.5. Radiator Cap
5. Chapter 3 ELECTRICAL SYSTEM
5.1. Electrical Components and Wiring Outline
5.1.1. Ton Class
5.1.2. , 3 Ton Classes
5.2. Console Box
5.2.1. Console Box Outline
5.2.2. Disassembling Console Box
5.2.3. Assembling Console Box
5.3. Meter Panel
5.3.1. Disassembling Meter Panel
5.3.2. Assembling Meter Panel
5.3.3. Bulb Replacement
5.4. Main Electrical Components
5.4.1. Meter Panel
5.4.2. Key Switch (Anti-Restart Switch)
5.4.3. Light Switch and Turn Signal Switch
5.4.4. Direction (FNR) Switch
5.4.5. Select Switch
5.4.6. Horn
5.4.7. Tank Unit
5.4.8. Brake Oil Sensor
5.4.9. Stop Light Switch
5.4.10. Thermoswitch (Engine Coolant Temperature)
5.4.11. Thermoswitch (T/C Oil)
5.4.12. Speed Sensor (Pulse Generator)
5.4.13. Parking Brake Switch
5.4.14. Relay Box
5.4.15. Fuse Box
5.4.16. List of Lights
5.5. Battery and Maintenance
5.5.1. State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
5.5.2. Specific Gravity Reading and State of Charge
5.5.3. Precautions for Battery Charging
5.6. Wire Color
5.6.1. List of Wire Color Codes
5.7. Troubleshooting
5.7.1. Starter System
5.7.2. Gauges
5.7.3. Lighting System
5.7.4. Alarm Unit
5.7.5. Battery
5.7.6. Horn Testing Procedures
5.8. Fuel Pressure Sensor Harness
5.8.1. Wire Harness
5.8.2. Converting the Year 2005/2006 Chassis Harness to 2004 Chassis Harness
5.8.3. Year 2005/2006 RELATIVE Fuel Pressure Sensor
5.8.4. Terminal Positions
5.8.5. Change the Wire Positions
5.8.6. Fuel Pressure Sensor Connector Kit P/N 91A04-06960
5.8.7. Change Pins
5.9. Wiring Harness Service Parts
5.9.1. Pick Tool Part
5.9.2. ETC Connector Assembly Part No. SE000218
5.9.3. ETC Pin Terminal W/ 6 Lead Part No. SE000219
5.9.4. Ignition Coil Connector Part No. 91A04-06590
5.9.5. Water Temp Sensor Connector Part No. 91A04-06410
5.9.6. Alternator Connector Part No. 91A04-06420
5.9.7. Air Flow Meter Connector Part No. 91A04-06580
5.9.8. LP Injector Driver Connector Part No. 05110-81230
5.9.9. Fuel Pressure Jumper Harness Part No. 91820-03200
5.9.10. Gasoline Injector Connector Part No. 91820-01840
5.9.11. Fuel Pressure Connector Part No. 91820-01850
5.9.12. Fuel Pressure Connector Part No. 91A04-06960
5.9.13. GSE Connector
5.9.14. Throttle Position Sensor
5.9.15. Soldering Procedure
5.9.16. Pin Removal Procedure
5.9.17. Pin Removal Procedure
5.10. Electrical Wiring Diagram
6. Chapter 4 CONTROLLER
6.1. Outline
6.2. Main Functions of Controllers
6.2.1. Meter Panel
6.2.2. VCM (Vehicle Control Module)
6.2.3. ECM (Engine Control Module)
6.2.4. GSE Connector
6.3. Service Tool
6.3.1. Service Tool Menus
6.3.2. Toolbox
6.3.3. Mot File Download Process
6.3.4. Check Main C Relay Circuit with Diagnostics Program
6.3.5. Programming Travel Speed
6.4. Mast Interlock System
6.4.1. Mast Interlock Function
6.4.2. Checking Procedure of Mast Interlock System
6.4.3. Active Test Inspection Procedure
6.5. Driving Interlock System
6.5.1. Controller Function
6.5.2. Checking the Operation of Driving Interlock Function
6.5.3. Active Test Inspection Procedure
6.6. Seat Belt Warning Light
6.6.1. Seat Belt Warning Light
6.6.2. Checking the Operation of Seat Belt Warning Light
6.7. Parking Brake Warning Buzzer and Light
6.7.1. Operation of Parking Brake Warning Buzzer and Light
6.7.2. Parking Brake Warning Buzzer
6.7.3. Checking the Operation of Parking Brake Warning Buzzer/Light with Key in OFF Position
6.8. Harness Codes
6.9. Controller Output Details
6.9.1. VCM (Vehicle Control Module)
6.9.2. Seat Switch
6.9.3. Parking Brake Switch
6.9.4. Direction Lever Switch
6.9.5. Vehicle Speed Sensor
6.9.6. T/M Solenoid
6.9.7. Unload Solenoid
6.9.8. Lift Lock Solenoid
6.9.9. Warning Buzzer
6.9.10. Warning Buzzer Relay
6.9.11. Warning Buzzer Circuit
6.9.12. Meter Panel
6.10. Truck Status Display and Troubleshooting
6.10.1. Truck Status Display
6.10.2. Diagnosis Table (F Code)
6.10.3. LED Blink Pattern
6.10.4. Probable Warning Cause on Diagnostic Code and Troubleshooting
6.11. Common Diagnostic Codes
6.11.1. F85(T/M Forward Travel Solenoid Warning) and F87 (T/M Backward Travel Solenoid Warning) Displayed
6.11.2. E-23 (Throttle Sensor Warning)
6.11.3. E-24 (Accelerator Sensor Warning)
6.11.4. E-27 (POS Sensor Warning)
6.11.5. E-30 (ECCS C/U System Warning)
6.11.6. E-31 (Throttle Control Warning)
6.11.7. E-35 (LPG Fuel Injection Disconnection Warning)
6.11.8. E-38 (LPG Vaporizer Diagnostic Result Warning)
6.11.9. E-42 (Gas Air-Fuel Ratio Malfunction) and E-43 (LPG Air-Fuel Ratio MalFunction)
7. Chapter 5 POWER TRAIN
7.1. Removing and Installing Engine and Transmission Assembly
7.1.1. Removal Sequence of Overhead Guard, Covers, and Air Cleaner
7.1.2. Suggestions for Removal of Overhead Guard, Cover, and Air Cleaner
7.1.3. Removal Sequence of Controls
7.1.4. Suggestion for Removal of Controls
7.1.5. Installation Sequence of Overhead Guard, Covers, Air Cleaner, and Controls
7.1.6. Preparation for Removing LPG System (Dual Fuel Gasoline and LPG Model)
7.1.7. Removal Sequence of LPG System (Dual Fuel Gasoline and LPG Model)
7.1.8. Preparation for Removal of Cooling, Exhaust and Hydraulic Systems
7.1.9. Removal Sequence of Cooling, Exhaust and Hydraulic Systems
7.1.10. Suggestion for Removal of Cooling, Exhaust and Hydraulic Systems
7.1.11. Installation Sequence of Cooling, Exhaust and Hydraulic Systems
7.1.12. Removal Sequence of Front Wheel and Front Axle Shaft
7.1.13. Preparation for Removal of Engine and Transmission Assembly
7.1.14. Removal Sequence of Engine and Transmission Assembly
7.1.15. Suggestions for Removal of Engine and Transmission Assembly
7.1.16. Suggestions for Installation of Engine and Transmission Assembly
8. Chapter 6 POWERSHIFT TRANSMISSION
8.1. Structure
8.1.1. Transmission
8.1.2. Torque Converter Components
8.1.3. Control Valve
8.1.4. Schematic Diagram of Powershift Transmission Hydraulic System
8.2. Removing Transmission
8.2.1. Suggestions for Removal
8.3. Installing Transmission
8.3.1. Suggestions for Installation
8.4. Disassembling Control Valve
8.4.1. Disassembly Sequence
8.5. Inspection and Repair After Disassembling Control Valve
8.6. Assembling Control Valve
8.6.1. Assembly Sequence
8.6.2. Suggestions for Assembly
8.7. Disassembling Input Shaft Assembly
8.7.1. Disassembly Sequence
8.7.2. Suggestions for Disassembly
8.8. Inspection and Repair After Disassembling Input Shaft Assembly
8.9. Disassembling Oil Pump Assembly
8.9.1. Disassembly Sequence
8.9.2. Suggestion for Disassembly
8.10. Inspection and Repair After Disassembling Oil Pump Assembly
8.11. Assembling Oil Pump
8.12. Inspection and Adjustment
8.12.1. Oil Pressure Measurement
8.12.2. Adjusting Brake (Inching) Pedal
8.12.3. Adjusting Inching Cable
8.12.4. Increasing the Inching Pedal Return Spring Tension
8.13. Troubleshooting
8.14. Tightening Torque
8.15. Service Data
8.15.1. Control Valve
9. Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
9.1. Structure
9.2. Removing and Installing Front Wheels
9.2.1. Preparation
9.2.2. Removal
9.2.3. Installation
9.3. Removing Front Axle
9.3.1. Preparation
9.3.2. Removal
9.3.3. Suggestions for Removal
9.3.4. Installation
9.4. Disassembling and Assembling Front Axle
9.4.1. Disassembly
9.4.2. Suggestions for Disassembly
9.4.3. Inspection after Disassembly
9.4.4. Assembly
9.5. Removing and Installing Reduction Differential
9.5.1. Removal
9.5.2. Installation
9.6. Disassembling and Assembling Reduction Differential
9.6.1. Disassembly (1, 2 Ton Classes)
9.6.2. Disassembly (3 Ton Class)
9.7. Disassembling and Assembling Reduction Differential
9.7.1. Disassembly
9.7.2. Inspection After Disassembling Reduction Differential
9.7.3. Assembly
9.7.4. Adjustment
9.8. Troubleshooting
9.9. Service Data
10. Chapter 8 REAR AXLE
10.1. Structure
10.1.1. Main Components of Rear Axle
10.1.2. Specifications for Wheel Alignment and Steering Angle
10.1.3. Main Components of Wheel Hub
10.1.4. Main Components of King Pin
10.1.5. Main Components of Tie Rod
10.1.6. Main Components of Steering Cylinder
10.2. Removing Rear Wheels
10.3. Installing Rear Wheels
10.4. Removing Rear Wheels and Rear Axle Assembly
10.4.1. Removal Sequence
10.4.2. Suggestions for Removal
10.5. Installing Rear Wheels
10.6. Disassembling Wheel Hub
10.6.1. Disassembly Sequence
10.6.2. Suggestions for Disassembly
10.7. Inspection and Repair After Disassembly
10.8. Assembling Wheel Hub
10.8.1. Adjusting Procedure of Wheel Hub Assembly
10.9. Disassembling Knuckle (King Pin)
10.9.1. Preparation
10.9.2. Suggestion for Disassembly
10.10. Inspection and Repair After Disassembling Knuckle (King Pin)
10.11. Assembling Knuckle (King Pin)
10.12. Removing Steering Cylinder
10.12.1. Preparation
10.12.2. Suggestions for Removal
10.12.3. Disassembly Sequence
10.12.4. Suggestions for Disassembly
10.13. Inspection and Repair After Disassembling Steering Cylinder
10.14. Assembling Steering Cylinder
10.15. Disassembling and Assembling Tie Rod
10.15.1. Disassembly Sequence
10.16. Assembling Tie Rod
10.17. Troubleshooting
10.18. Service Data
11. Chapter 9 BRAKE SYSTEM
11.1. Structure of Brake System
11.2. Structure of Wheel Brakes
11.2.1. Ton Class
11.2.2. , 3 Ton Class
11.3. Disassembling Master Cylinder
11.3.1. Disassembly Sequence
11.4. Inspection and Repair After Disassembling Master Cylinder
11.5. Assembling Master Cylinder
11.5.1. Suggestions for Assembly
11.6. Disassembling Wheel Brakes
11.6.1. Preparation
11.6.2. Disassembly Sequence
11.6.3. Suggestions for Disassembly
11.7. Inspection After Disassembling Wheel Brakes
11.8. Assembling Wheel Brakes
11.8.1. Assembly Sequence (1 Ton Class)
11.8.2. Assembly Sequence (2, 3 Ton Classes)
11.8.3. Suggestions for Assembly
11.9. Assembling Wheel Cylinder
11.9.1. Assembly Sequence
11.10. Inspection and Repair After Disassembling Wheel Cylinder
11.11. Assembling Wheel Cylinder
11.12. Inspecting and Adjusting Brake System
11.12.1. Automatic Adjuster Test
11.12.2. Manual Adjustment
11.12.3. Parking Brake Cable Adjustment
11.12.4. Brake Pedal Adjustment
11.12.5. Bleeding Brake Oil Lines
11.12.6. Braking Performance Test
11.12.7. Parking Brake Lever
11.13. Troubleshooting
11.13.1. Service Brake
11.13.2. Parking Brake
11.14. Service Data
11.14.1. Master Cylinder
11.14.2. Wheel Brakes
12. Chapter 10 STEERING SYSTEM
12.1. Structure and Function
12.1.1. General
12.1.2. Steering Valve
12.1.3. Steering Column
12.2. Disassembling and Assembling Pipes and Hoses
12.2.1. Suggestions for Disassembly and Assembly
12.3. Disassembling Steering Wheel and Steering Valve
12.3.1. Disassembly Sequence
12.3.2. Suggestions for Disassembly
12.3.3. Installing Steering Wheel and Steering Valve
12.4. Installation
12.4.1. Inspection After Installation
12.5. Removing Steering Valve
12.6. Installing Steering Valve
12.7. Disassembling Tilt Lock Lever
12.8. Assembling Tilt Lock Lever
12.9. Disassembling Steering Valve
12.9.1. Disassembly Sequence
12.9.2. Suggestions for Disassembly
12.10. Inspection After Disassembly
12.11. Assembling Steering Valve

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