Isuzu F & G Series 96-02

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F & G SERIES Workshop Manual

(1996 – 2002)
Publication No. for
Complete Set
Section (O Mark shows the content
Application Component Publication No. MY Remarks
No. of each complete set)
F*R F*S FV* G** LT
0 General Information MGGEN-WE-0001 O O O O O 00-02
0 General Information MGGEN-WE-681 O O O O O 96-99
2 Frame and Cab MGFRM-WE-9601 O O O O - 96-02
3 Steering, Suspension, Tires and Wheels MGSTG-WE-9601 O O O O O 96-02
3 Suspension, (Hendricson Air Suspension) MGHAS-WE-0001 - - O - - 00-02 Australia only
4 Propeller Shaft and Axle MGPRO-WE-681 O O O O O 96-02
4 Mentor Axle MGMEA-WE-0001 - - O O - 00-02
4 Rockwell Axle MGROA-WE-661 - - O O - 96-99 Australia
5 Brakes (Air Over Hydraulic) MGBRA-WE-0011 O O - - - 00-02
Brakes (Air Over Hydraulic) Parking and
5 MGBRA-WE-681 O O - - - 96-99
Exhaust Brake
5 Brakes (Full Air) MGBRF-WE-0001 O - O O O 00-02
5 Brakes (Full Air) Exhaust Brake MGBRF-WE-681 - - O O O 96-99
5 Mentor Brakes MGMEB-WE-0001 - - O O - 00-02 Australia
5 Rockwell Brakes MGROB-WE-661 - - O O - 96-99
6 Engine (6HE1TC) MG6HE-WE-0001 - - O O - 00-02 Australia/HK
6 Engine (6HH; 2 Valve) MG6HH-WE-681 O O O - O 96-02 Australia
6 Engine (6SD1 and 6SD1TC) MG6SD-WE-9601 O - O O - 96-02
7 Manual Transmission (MBJ) and Clutch MGTRJ-WE-681 O O - - - 96-02
7 Manual Transmission (MLD) and Clutch MGTRD-WE-681 O - O - O 96-02
7 Manual Transmission (MAL) and Clutch MGTRL-WE-661 O - O - - 96-02
7 Manual Transmission (EATON FS8203) MGFS8-WE-661 - - O O - 96-99 Australia only
7 Manual Transmission (Fuller RT7608LL) MGRT7-WE-661 - - O - - 96-02 Australia
7 Automatic Transmission MGATM-WE-9601 O - O - - 96-02 Australia/HK
7 Transfer Case MGTRF-WE-661 - O - - - 96-02 Australia/Malaysia
8 Chassis Electrical MGCEL-WE-0111 O O O O O 01-02
8 Chassis Electrical MGCEL-WE-681 O O O O O 96-00
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NOTICE
Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations,
it is recommended that you carefully read and thoroughly understand the information contained in Section
OA under the headings "GENERAL REPAIR INSTRUCTIONS" and "HOW TO USE THIS MANUAL".
All material contained in this Manual is based on the latest product information available at the time of
publication. All rights are reserved to make changes at any time without prior notice.
Applicable Model: All F&G-series vehicles
This manual is applicable to 2000 year model and later vehicle.
General Information (MGGEN-WE-0001)

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION NO. CONTENTS
OA General Information
OB Maintenance and Lubrication
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NOTICE
Before using this Workshop Manual to assist you in performing vehicle service and maintenance
operations, it is recommended that you carefully read and thoroughly understand the information
contained in Section OA under the headings "GENERAL REPAIR INSTRUCTIONS" and "HOW TO
USE THIS MANUAL".
All material contained in this Manual is based on latest product information available at the time of
Applicable Model: All F&G-series vehicles This manual is applicable to 1996 year model and later
vehicles.
General Information (MGGEN-WE-681)

OA General Information
OB Maintenance and Lubrication
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NOTICE
Frame and Cab (MGFRM-WE-9601)

00 Service Information
2A Frame
2B Cab
2C Pintle Hook
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NOTICE

x For the disassembly, reassembly, and inspection of air suspension
used in FVD / GVD / FVY, refer to the Air Suspension Workshop Manual.
x For the disassembly, reassembly, and inspection of MERITOR made

axle used in FVR / FVD / FVZ / PVY / GVR / GVD, refer to the MERITOR
axle Workshop Manual.
Steering, Suspension, Tires and Wheels (MGSTG-WE-9601)

3A —
3B1 Power Steering
3B2 —
3B3 Steering Linkage
3B4 Steering Column
3C Front Suspension
3D Rear Suspension
3E Wheels and Tires
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NOTICE
Applicable Model: FVD 32, FVD 23, GVD 23, FVY 23

Suspension, (Hendricson Air Suspension) (MGHAS-WE-0001)
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HA/HAS SUSPENSION
U Bolt Locknut Torque Procedure
PARTS LIST
HAS230 & 400
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NOTICE
USE THIS MANUAL".
Applicable Model: All F&G-series vehicles.
This manual is applicable to 1996 year model and later vehicles.
Propeller Shaft and Axle (MGPRO-WE-681)

4A Propeller Shaft
4B Rear Axle
4C Front Axle
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NOTICE
Before using this Workshop Manual to assist you in performing vehicle

service and maintenance operations, it is recommended that you carefully
read and thoroughly understand the information contained in Section 0A
under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO
USE THIS MANUAL”.
All material contained in this Manual is based on the latest product

information available at the time of publication.
All rights reserved to make changes at any time without prior notice.
Applicable Model: FVR, FVD, FVZ, FVY, GVR, GVD
This manual is applicable to 2000 year model and later vehicles

Except those sold in the United States of America and Canada.
Mentor Axle (MGMEA-WE-0001)
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MERITOR
FRONT NON-DRIVE
STEERING AXLES
MERITOR
TIE ROD AND
CROSS TUBE
ASSEMBLY
MERITOR
SINGLE REDUCTION
DIFFERENTIAL CARRIERS
MERITOR
TANDEM AXLE
FORWARD REAR
DRIVE UNIT
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MERITOR
FRONT NON-DRIVE
STEERING AXLES
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MERITOR
TIE ROD AND CROSS
TUBE ASSEMBLY
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TANDEM AXLE FORWARD
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NOTICE
Rockwell Axle (MGPRO-WE-681)
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NOTICE
it is recommended that you carefully read and thoroughly understand the information contained in Section 0A
under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
publication.
All rights are reserved to make changes at any time without prior notice.
Applicable Model
F-series
FRR32 FSR32 FTR32 FSS33
FRR33 FSR33 FTR33 FTS33
Brakes (Air Over Hydraulic) (MGBRA-WE-0011)


5A Hydraulic Brakes
5B –
5C Parking Brakes
5D Air Compressor and Governor
5E Exhaust Brake
5F –
5G HSA
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SERVICE INFORMATION 00-1
SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Troubleshooting .............................................................................................................. 00- 2
Brake System .............................................................................................................. 00- 2
Brake Lining ................................................................................................................ 00- 9
Brake Drum ................................................................................................................ 00- 10
Air Booster .................................................................................................................. 00- 11
Air Dryer ...................................................................................................................... 00- 12
Parking Brakes ............................................................................................................ 00- 13
Air Compressor and Governor .................................................................................. 00- 14
Exhaust Brake ............................................................................................................ 00- 15
Main Data and Specifications ........................................................................................ 00- 17
Service Standard ............................................................................................................ 00- 21
Servicing .......................................................................................................................... 00- 25
Fixing Torque .................................................................................................................. 00- 36
Special Tools.................................................................................................................... 00- 47
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00-2 SERVICE INFORMATION
TROUBLESHOOTING
Brake System
PROBLEM POSSIBLE CAUSE CORRECTION
No Brakes 1. No air pressure. 1. Check for leaks, broken lines, broken
compressor, defective governor, etc.
Repair or replace as necessary.
2. Restricted tubing or hose. 2. Replace defective parts.
3. Defective application valve. 3. Repair or replace.
4. Ice in the system. 4. Thaw and drain the system.
5. Brakes out of adjustment. 5. Adjust.
6. Defective supply line. 6. Replace the check valve.
7. Governor not working. 7. Check governor operation.
8. Air compressor not working. 8. Repair or replace.
Insufficient Brakes 1. Low air line pressure. 1. Check for leaks, etc. and repair.
Check governor cut-out pressure-
adjustment, then check safety valve
for correct “pop-off” pressure.
2. Pedal improperly adjusted. 2. Adjust.
3. Worn linings or drums. 3. Replace as necessary.
4. Plugged, crimped, or restricted lines. 4. Repair or replace.
Slow Brake 1. Low air line pressure. 1. Check for leaks, etc. and repair.
Application Check governor cut-out pressure-
adjustment, then check safety valve
for correct “pop-off” pressure.
2. Pedal binding. 2. Lubricate pivot pin, clean and check
for foreign objects.
3. Wheel cylinder piston sticking. 3. Repair the wheel cylinder.
4. Restriction in the lines. 4. Remove the restriction or replace the
line.
5. Leaking, or malfunctioning, application 5. Repair or replace.
valve or quick release valve.
6. Worn linings or drums. 6. Replace as necessary.
7. Brake shoes binding. 7. Free up the anchor pin, replace or
lubricate as necessary.
8. Air booster leaking. 8. Repair the booster.
Uneven Braking 1. Defective application valve. 1. Repair or replace.
(Front or Rear Brakes 2. Defective quick release valve. 2. Repair or replace.
Not Working)
3. Front or rear system check valve 3. Replace.
stuck open.
4. Defective air booster. 4. Repair or replace.
5. Ice in the air lines. 5. Thaw. Drain the air system.
6. Damaged air lines. 6. Check for air leaks and damaged,
bent, or kinked air lines.
7. Damaged hydraulic lines. 7. Repair or replace.
8. No brake fluid at the booster. 8. Check for plugged, kinked, or
damaged hose to the reservoir.
Brake Pedal Travel Application valve. Repair or replace.
Decreasing
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Brake System (Cont.)

Brake Fade 1. Incorrect lining. 1. Replace with recommended lining.
2. Poor lining contact. 2. Grind the lining to the proper radius;
adjust.
3. Thin drum. 3. Replace the drum.
4. Dragging brakes. 4. Adjust.
5. All conditions listed under “PULLS 5. All corrections listed under “PULLS
TO ONE SIDE.” TO ONE SIDE.”
6. Low air pressure. 6. Check for air leaks.
7. Quick release defective. 7. Replace the quick release valve.
All Brakes Drag When 1. Pedal does not return to stop. 1. Lubricate the pedal linkage, adjust
Adjustment Is Known the pedal.
to Be Correct 2. Improper fluid. 2. Replace rubber parts and fill with the
recommended brake fluid.
3. Use of incorrect rubber parts. 3. Install the proper parts.
One Wheel Drags 1. Weak or broken shoe return spring. 1. Replace the return spring.
2. Brake shoe to drum clearance too 2. Adjust to specification.
small.
3. Loose wheel bearings. 3. Adjust or replace the wheel bearings.
4. Wheel cylinder piston cups swollen 4. Rebuild the cylinders. Flush the
and distorted or piston stuck. hydraulic system and fill with
recommended fluid.
5. Pistons sticking in the wheel cylinder. 5. Clean or replace the pistons;clean the
cylinder bore.
6. Drum out-of-round. 6. Machine the drum.
7. Restricted brake line or hose. 7. Check for soft hoses or damaged
lines. Replace as necessary.
8. Distorted shoe. 8. Replace.
9. Defective lining. 9. Replace with the recommended
lining.
10. Loose or bent mounting plate. 10. Tighten the fasteners, replace the
plate.
Dragging Brakes 1. Booster check valve sticking. 1. Clean or replace the check valve.
2. Improper fluid. 2. Flush the hydraulic system and fill
with recommended brake fluid, and
replace rubber components.
3. Brake pedal adjustment incorrect. 3. Adjust the pedal.
4. Incorrect shoe return spring. 4. Replace the shoe return spring.
5. Brake pedal linkage interference or 5. Free the linkage and lubricate.
binding.
6. Incorrect lining. 6. Replace the linings.
7. All condition listed under “ONE 7. All corrections under “ONE WHEEL
WHEEL DRAGS.” DRAGS.”
8. Application valve. 8. Repair or replace.
9. Frozen anchor pins. 9. Free the anchor pins and shoes.
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Light Pedal Pressure 1 . Brake adjustment not correct. 1. Adjust the brakes.
- Brakes too Severe 2. Loose mounting plate on the front 2. Tighten the plates.
(Grabby Brakes) axle.
3. A small amount of grease or fluid on 3. Replace the linings.
the lining.
4. Incorrect lining. 4. Install factory specified linings.
5. Wheel bearing loose. 5. Adjust the wheel bearings.
6. Lining loose on the shoe. 6. Replace the lining or the shoe and
lining.
7. Excessive dust and dirt in the drum. 7. Clean and sand the drums and
linings.
8. Out-of-round drum. 8. Turn the drums in pairs or replace.
9. Anchor pins frozen. 9. Free the pins and shoes.
10. Defective application valve. 10. Repair or replace.
11. Defective quick release valve. 11. Replace.
Low Pedal or Pedal 1. Excessive clearance between the 1. Adjust the brakes.
Goes to Floor linings and drum.
2. Pedal stop not adjusted, or missing. 2. Adjust or install the pedal stop.
3. Weak brake hose. 3. Replace with new hose.
4. Leaking wheel cylinder. 4. Clean and rebuild.
5. Leaking booster cylinder. 5. Clean and rebuild.
6. Air in the hydraulic system. 6. Bleed the hydraulic system.
7. Improper brake fluid (Low boiling 7. Flush the system and refill with
point.). recommended brake fluid.
8. Low fluid level. 8. Fill the reservoir with brake fluid;
check for leaks and bleed system.
9. Bent of distorted brake shoes. 9. Replace axle sets.
10. Low air pressure. 10. Check for air leaks and repair. Check
governor cut-out.
11. Leaks at hydraulic line connections. 11. Check for hydraulic leaks and repair.
Slow Brake Release 1. Foot pedal binding. 1. Lubricate the pivot pin, clean-check
for foreign objects.
2. Restriction in the line. 2. Remove the restriction or replace
line.
3. Weak shoe return spring. 3. Replace the spring.
4. Leaking or malfunctioning application 4. Repair or replace.
valve or quick release valve.
Poor or Loss of Assist 1. Low brake fluid level. 1. Fill the reservoir to the proper level.
Bleed the system.
2. Air in the hydraulic system. 2. Locate the source of the air leak and
repair. Bleed the system.
3. Weak brake hose. 3. Replace.
4. Air booster internal wear or damage. 4. Repair the air booster.
5. Low air pressure. 5. Check for the source of leakage. Repair.
6. Defective quick release valve. 6. Replace.
BACK FORWARD
TO MODEL INDEX

Poor or Loss of Assist 7. Sticking check valve. 7. Replace.
(Cont.) 8. No brake fluid at the booster. 8. Check for plugged, kinked, or
damaged hose to the reservoir.
Pulls to One Side 1. Grease or fluid soaked lining. 1. Replace axle sets.
2. Loose wheel bearings, loose (or 2. Adjust the wheel bearing, tighten (or
distorted) mounting plate on the rear replace) the mounting plate to the
or front axle or loose spring bolts. axle and tighten the spring bolts.
3. Linings not of the recommended 3. Install recommended linings. Install
kind. the shoes correctly.
4. Tires not properly or evenly inflated 4. Inflate the tires to recommended
or unequal wear of tread. Different pressures. Rearrange the tires so
tread non-skid design. that a pair of non-skid tread surfaces
of similar design and equal wear will
be installed on the front wheels, and
another pair with like tread will be
installed on the rear wheels.
5. Water, mud, etc., in the brakes. 5. Remove any foreign material from all
of the brake parts and inside of the
drums. Lubricate the anchor pins.
6. Wheel cylinder sticking. 6. Repair or replace the wheel cylinder.
7. Weak or broken shoe return springs. 7. Check the spring; replace distorted,
open coiled, or cracked spring.
8. Out-of-round drums or different sized 8. Refinish or replace the drums in axle
drums on the same axle. pairs.
9. Brake dragging. 9. Check for loose lining. Adjust.
(Refer to “DRAGGING BRAKES”
previously.)
10. Weak chassis spring, loose U-bolts, 10. Replace the spring, tighten the U-
loose steering gear, etc. bolts, adjust the steering gear, etc.
11. Loose steering. 11. Repair and adjust.
12. Unequal camber. 12. Adjust to “Specifications.”
13. Restricted brake line or hose. 13. Check for soft hose or damaged lines.
Replace as necessary.
14. Wheel cylinder size different on 14. Replace with the correct cylinders.
opposite ends.
15. Loose kingpin. 15. Replace the kingpins or bushing.
16. Distorted, damaged, or scored drum. 16. Refinish the drums in axle pairs.
Replace if necessary.
17. Front end alignment. 17. Align the front end.
18. Excessively worn linings. 18. Replace in axle sets.
19. Mixed size linings. 19. Use standard or oversize linings in a
brake.
20. Water/wet linings. 20. Apply the brakes a few times while
moving at a slow speed to dry the
linings.
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TO MODEL INDEX

One Wheel Locks 1. Gummy lining. 1. Replace in axle sets.
2. Tire tread slick. 2. Match up tire treads from side to
side.
3. Brake adjustment not correct. 3. Adjust the brakes.
4. Restricted brake line or hoses. 4. Check for soft hoses or damaged
lines. Replace as necessary.
5. Incorrect lining. 5. Replace. Linings must be the same
on the axle.
6. Grease or fluid soaked lining. 6. Replace in axle sets.
7. Foreign material in the brakes. 7. Remove the material and lubricate
the anchor pins.
8. Mixed size linings. 8. Use all standard or oversize linings.
Air Pressure Above 1. Defective air gage. 1. Replace.
Normal 2. Governor out of adjustment or 2. Adjust or replace.
defective.
3. Restricted line between compressor 3. Clear the line or replace.
governor and supply (wet) reservoir.
4. Compressor unloader inoperative. 4. Repair or replace.
5. Safety valve defective. 5. Replace.
Quick Loss of Pressure 1. Leaking lines or connections. 1. Repair or replace.
When Engine Is 2. Leaking compressor governor. 2. Repair or replace.
Stopped
3. Leaking check valve. 3. Replace.
(Brakes Not Applied)
4. Leaking air system valves. 4. Repair or replace.
5. Open or leaking reservoir drain cock. 5. Replace.
6. Leaking low air pressure switch. 6. Tighten or replace.
Quick Loss of Pressure 1. Leaking compressor governor. 1. Repair or replace.
When Engine Is 2. Leaking air system valves. 2. Repair or replace.
Stopped
3. Leaking lines or connections. 3. Repair or replace.
(Brakes Fully Applied)
4. Leaking hoses or connections. 4. Tighten the connections or replace
the hose.
5. Leaking air booster. 5. Repair or replace.
Safety Valve 1. Safety valve defective. 1. Replace.
“Blows Off” 2. Pressure in the system above 2. Also see chart on “Air Pressure
normal. Above Normal” previously.
3. Governor out of adjustment. 3. Adjust.
Slow Pressure Build 1. Air leaks. 1. Find the source of the air leaks.
up in Reservoirs Repair.
2. Faulty air compressor. 2. Repair.
3. Drain cock stuck open (or leaking). 3. Replace.
4. Faulty governor. 4. Check operation. Repair or replace.
5. Clogged supply line to the reservoir. 5. Clean or replace.
6. Application valve leaking. 6. Repair or replace.
7. Low air pressure switch leaking. 7. Tighten or replace.
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TO MODEL INDEX

Wet Weather: Brakes 1. Linings too sensitive to water. 1. Replace in axle sets.
Grab or Won’t Hold 2. Dirty brakes. 2. Clean out.
3. Bent mounting plate opening. 3. Replace.
4. Scored drums. 4. Machine in pairs. Replace if
necessary.
Brakes Squeak 1. Mounting plate bent or shoes twisted. 1. Replace damage parts.
2. Metallic particles or dust imbedded 2. Replace the linings in axle sets.
in the lining.
3. Lining rivets loose or lining not held 3. Replace the rivets and/or tighten the
tightly against the shoe at the ends. lining by reriveting.
4. Drums distorted, tapered, or not 4. Machine or replace drums.
square.
5. Incorrect lining. 5. Replace the linings in axle sets.
6. Mixed size lining. 6. Use all standard or oversize linings
in a brake.
7. Weak or broken return spring. 7. Replace the return spring.
8. Loose wheel bearings. 8. Tighten to the proper setting.
9. Loose mounting plate, anchor, drum, 9. Tighten.
wheel cylinder.
10. Linings located wrong on the shoes. 10. Install the lining correctly.
11. Linings worn out. 11. Reline the brakes.
12. Linings glazed. 12. Replace.
13. Cracked or threaded drums. 13. Replace in axle pairs.
Brakes Chatter 1. Incorrect lining at drum clearance. 1. Adjust to specification.

2. Loose mounting plate. 2. Tighten securely.
3. Grease, fluid, road dust on the lining. 3. Clean or reline.
4. Weak or broken return spring. 4. Replace the return spring.
5. Loose wheel bearings. 5. Readjust.
6. Drums out-of-round. 6. Machine the drums in axle sets.
7. Cocked or distorted shoes. 7. Straighten or replace.
8. Distorted, tapered, or barrel-shaped 8. Machine drums in pairs. Replace if
drums. necessary.
9. Incorrect lining material. 9. Reline with correct linings.
10. Linings worn out. 10. Reline the brake.
11. Linings loose on the shoes. 11. Rerivet the linings to the shoes.
Replace distorted shoes.
12. Foreign material imbedded in the 12. Replace the linings in axle sets.
linings.
13. Cracked or threaded drums. 13. Replace in axle pairs.
14. Anchor pin/bushing worn. 14. Replace the anchor pin. Worn
bushing requires shoe replacement.
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TO MODEL INDEX

Shoe Click 1. Return springs weak. 1. Replace the spring.
2. Shoe bent. 2. Straighten or replace.
3. Anchor pin/bushing worn. 3. Replace the anchor pin.
Noise and Chatter 1. Bent, damaged or incorrect shoes. 1. Replace with the correct shoes and
Squealing, Clicking or lining. Always replace in axle sets.
Scraping Sound upon 2. Worn out lining. 2. Replace the shoes and lining in axle
Brake Application sets.
3. Foreign material imbedded in the 3. Replace the shoes and lining in axle
lining. sets.
4. Broken shoe return spring. 4. Replace the return spring.
5. Cracked or threaded drums (lathe 5. Replace the drums in axle sets.
marks.).
6. Frozen anchor pin. 6. Free up the anchor pin. Lubricate
the anchor pin and bushing.
7. Worn anchor pin and shoe bushing. 7. Replace the anchor pins and shoes.
Lubricate the anchor pin and
bushing.
8. Mixed size linings. 8. Use all standard or oversize linings
in a brake.
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TO MODEL INDEX
BRAKE LINING
Poor Contact at the 1. Bell-mouthed drum.
Center of Shoe 2. Distorted mounting plate.
3. Bent brake shoe. Repair or replace as required.
4. Worn anchor pin or bushing.
5. Loose wheel bearing.
6. Anchor pins frozen.
Unequal Wear on the 1. Brake linings not a balanced set.
Shoes in the Same 2. Sticking anchor pin.
Brake Repair or replace as required.
3. Worn anchor pin or bushings.
4. Stick wheel cylinder piston.
Material at the Center 1. Undersize linings.
of the Shoe 2. Oversize drum. Repair or replace as required.
Excessively Thin
Lining Tapered Across 1. Bell-mouthed drum.
the Width of Same 2. Bent shoe.
Brake Repair or replace as required.
3. Distorted mounting plate.
4. Worn bushings and anchor pins.
Lining Worn at 1. Bent mounting plate.
One End Repair or replace as required.
2. Worn pins or bushings.
Linings Glazed 1. Grease on lining.

2. Wrong type lining for service Repair or replace as required.
involved.
Rivets Torn Loose 1. Improper size rivet.
2. Improper setting of the rivet. Repair or replace as required.
3. Enlarged rivet holes in the shoe.
Unequal Wear- 1. Weak shoe return spring.
Opposite Brakes, 2. Obstructed hydraulic line.
of Same Axle
3. Stuck wheel cylinder piston. Repair or replace as required.
4. Frozen anchor pin.
5. Brake drum surface in poor condition.
Linings Scored 1. Scored drum.
2. Abrasive material between the lining Repair or replace as required.
and drum.
Cracks at Bolt Holes 1. Overtightened bolts.

or Rivet Holes 2. Wrong type rivets or bolts.
3. Rivets not properly set.
Repair or replace as required.
4. Dirt or rust on the shoe table.
5. Too thick of shim under the lining.
6. Wrong size lining.
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TO MODEL INDEX
BRAKE LINING (CONT.)

Elongation of the Bolt 1. Loose rivets or bolts. Repair or replace as required.
Holes or Rivet Holes 2. Wrong size rivets.
Wear on the Edge 1. Wrong width lining.

of the Lining 2. Holes improperly drilled.
4. Bent shoe.
Groove on the Edge 1. Lining too wide.
of the Lining Repair or replace as required.
2. Worn drum.
BRAKE DRUM
Brake Drum Heat 1. Out-of-round brake drum.
Checked in Spots 2. Eccentric mounting of the drum. Repair or replace as required.
Drum Uniformly 1. Improper friction materials.
Heat Checked 2. Overworked brake. Repair or replace as required.
3. Driver abuse.
Excessive Scoring 1. Improper friction materials.
of the Drum 2. Overworked brake.
3. Abrasive material between the lining
and drum. Repair or replace as required.
4. Soft drum.
5. Bent or warped shoe.
6. Worn anchor pin and bushing.
Excessive Drum 1. Driver abuse.
Cracks 2. Weak drum.
3. Wrong friction material.
4. Overworked brake.
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AIR BOOSTER
INSUFFICIENT BRAKING FORCE
Checkpoint Trouble Cause Countermeasure
Hydraulic piston cup

NG Replace the hydraulic
Brake pedal effective stroke damaged (Brake fluid
piston cup
leakage)
OK NG Cylinder cap loose (Brake

Retighten the cylinder cap
fluid leakage)
OK NG Cup gasket damaged

Replace the cup gasket
(Brake fluid leakage)
OK
Air leakage from between NG Piston plate rubber gasket Replace the piston plate
the piston plate and the
damaged rubber gasket
cylinder shell
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AIR DRYER
1. WATER IN VEHICLE RESERVOIRS
NG
Governor Faulty governor Replace governor
OK
NG
Desiccant Desiccant is contaminated Replace desiccant
OK
NG
Purge valve Air dryer not purging Refer to next section
2. AIR DRYER DOES NOT PURGE OR EXHAUST AIR
Broken, kinked, plugged, Test to determine air flows

NG through purge control line
Purge valve control line frozen or disconnected when compressor is
purge control line unloaded
OK
Test electrical circuit

NG Frozen Purge valve (Cold (heater, thermostat, wiring
Purge valve
weather operation only) and fuse), Replace parts as
necessary.
OK
NG Repair or replace purge

Purge valve Faulty Purge valve
valve
3. CONSTANT EXHAUST OF AIR AT PURGE VALVE
NG Repair or replace Purge

Purge valve Faulty Purge valve
valve
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PARKING BRAKES
INSUFFICIENT BRAKING FORCE
Clearance between the

Brake lining and drum NG Adjust the brake lining and
brake lining and the brake
clearance the brake drum clearance
drum excessive
OK
NG
Brake lining Brake lining worn out Replace the brake lining
OK
NG
Camshaft Camshaft worn out Replace the camshaft
OK
NG Adjust the control wire

Control wire Control wire stretched length or replace the
control wire
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TO MODEL INDEX
AIR COMPRESSOR AND GOVERNOR

Compressor Not 1. Damaged inlet valve plunger or 1. Replace the cylinder head assembly.
Unloading spring.
2. Intake cavity restrictions. 2. Remove the restriction; clean the
cavity.
3. Malfunctioning governor. 3. Remove the governor.
4. Unloader line or cavity to the 4. Remove the restriction.
governor restricted.
5. Unloader mechanism binding or 5. Replace the cylinder head assembly.
stuck.
Excessive Oil Flowing 1. Excessive wear. 1. Repair or replace.
Through Compressor 2. High inlet vacuum. 2. Clean or repair as necessary.
3. Small oil return line. 3. Install the proper line.
4. Excessive oil pressure. 4. Determine the cause of pressure and
repair.
5. Oil supply or return lines to 5. Determine the cause of condition
compressor flooded. and repair.
6. Damaged oil seal rings in crankcase 6. Replace the seals.
cover.
7. Piston ring not properly installed. 7. Install properly.
8. Back pressure from engine 8. Determine the cause of the pressure
crankcase. and repair.
Noisy Operation 1. Restriction in the cylinder head or 1. Remove the restriction or clean.
discharge line.
2. Worn or burned out bearings. 2. Replace.
3. Compressor not getting the proper 3. Clean and repair or replace
lubrication. malfunctioning parts.
4. Excessive wear. 4. Rebuild or replace.
Compressor Fails to 1. Restriction in the compressor 1. Remove the restriction and clean.
Maintain Sufficient cylinder head intake, discharge
Pressure cavities or in discharge line.
2. Leaking or broken discharge valves. 2. Replace the cylinder head assembly.
3. Excessive wear. 3. Rebuild or replace.
4. Inlet valve stuck open. 4. Replace the cylinder head assembly.
5. Worn inlet valves. 5. Replace the cylinder head assembly.
6. Excessive system leakage or usage. 6. Check and repair.
High or Low Pressure 1. Governor out of adjustment. 1. Replace the governor.
2. Governor leakage. 2. Replace the governor.
3. Compressor leakage. 3. Check the fittings, bolts, and mating
surfaces. Tighten or overhaul.
4. Unloader not functioning. 4. Replace the cylinder head assembly.
5. Defective governor. 5. Replace the governor.
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EXHAUST BRAKE
Exhaust Brake Does 1. Blown fuse. 1. Replace.
Not Operate 2. Improperly adjusted or faulty 2. Adjust or replace.
accelerator or clutch switches.
3. Poor connections or corroded 3. Clean or replace.
terminals at switches or control
valve.
4. Improperly adjusted or seized 4. Adjust or repair.
exhaust manifold valve.
5. Air or vacuum lines kinked, 5. Repair. In freezing weather keep air
restricted, or plugged with ice. tanks drained.
6. Seized relay crank. 6. Repair.
7. Broken or missing relay rod. 7. Repair.
8. Air cylinder, vacuum chamber or 8. Melt ice. Drain lines of water. Keep
magnetic valve jammed with ice. air tanks drained in freezing weather.
9. Faulty magnetic valve. 9. Replace.
10. Faulty air cylinder or vacuum 10. Replace.
chamber.
11. Broken wire in wiring harness. 11. Repair.
Exhaust Brake Slow 1. Tight exhaust manifold valve or relay 1. Free up and lubricate.
to Operate crank.
2. Improperly adjusted accelerator or 2. Adjust.
clutch switches.
Weak Braking Action 1. Improperly adjusted or tight exhaust 1. Free up and/or adjust. Lubricate as
manifold valve. needed.
2. Tight relay crank. 2. Free up and lubricate.
3. Air or vacuum lines kinked or 3. Repair. In freezing weather, keep air
partially plugged with ice. tanks drained.
4. Leaking fittings at air lines or vacuum 4. Tighten.
lines.
5. Leaky air cylinder or vacuum 5. Replace.
chamber.
Exhaust Brake Will 1. Seized relay crank or exhaust 1. Free up and lubricate.
Not Shut Off manifold valve.
2. Magnetic valve or air cylinder 2. Melt ice and drain lines. Keep
jammed with ice. air tanks drained in freezing
weather.
3. Short in wiring harness. 3. Repair.
4. Faulty control switch. 4. Replace.
Exhaust Brake “ON” 1. Improperly adjusted clutch or 1. Adjust.

Continuously When accelerator switches.
Control Switch Is 2. Switches improperly wired. 2. Check wiring against wiring diagram.
“ON” (Not Controlled Repair as needed.
by Clutch or
3. Short in wiring harness. 3. Repair.
Accelerator Switches)
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EXHAUST BRAKE (CONT.)

Engine Overheats or 1. Exhaust manifold valve stuck 1. Free up and lubricate or replace.
Loses Power partially closed.
2. Exhaust manifold valve adjusted so 2. Adjust.
that it is partially closed.
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MAIN DATA AND SPECIFICATIONS

Hydraulic Brakes
VEHICLE MODEL
ITEMS FRR FSR FSS FTS
SERVICE BRAKE
Type; Front 2 Leading (2L)
; Rear Dual 2 Leading (D2L)
Drum inside diameter mm (in)
; Front 320 (12.6) 400 (15.8)
; Rear 320 (12.6) 410 (16.1)
Lining dimension mm (in)
(Width × Thickness)
; Front 110 × 12 115 × 12
(4.3 × 0.5) (4.5 × 0.5)
; Rear 145 × 13 115 × 14.5 140 × 14.5
(5.7 × 0.5) (4.5 × 0.6) (5.5 × 0.6)
Pedal free play; LHD/RHD mm (in) 9-14(0.35-0.55)Reference/12-16(0.47-0.63) 10-14(0.39-0.55)
Lining clearance mm (in) 0.35 (0.014)
Wheel cylinder inside diameter
mm (in)
; Front 36.5 (1.44) 34.93 (1.38) 40.0 (1.57)
; Rear 40.0 (1.57) 44.0 (1.73) 38.1 (1.50) 47.5 (1.87)
Piston clearance mm (in) 0.15 (0.006)
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Hydraulic Brakes (Cont.)

VEHICLE MODEL FTS
ITEMS
FRR FSR FSS FTS
Australia
BRAKE CONTROL PARTS
AIRMASTER
Power cylinder diameter
× Stroke mm (in) 114.3 × 79 (4.50 × 3.11) 138 × 118 138 × 114
(5.43 × 4.65) (5.43 × 4.49)
Hydraulic cylinder diameter

× Stroke mm (in) 23.8 × 79 (0.94 × 3.11) 29.1 × 115 29.1 × 111
(1.15 × 4.53) (1.14 × 4.37)
Hydraulic cylinder operating

Volume cm3 (cu·in) Approx. 34 (2.1) Approx. 76 Approx. 74
(4.6) (4.5)
Approx. 74(4.5)
for Australia
Remaining pressure
kPa (kg / cm2 / psi) 78.5 – 107.9 (0.8 – 1.1 / 11.4 – 15.6)
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Hydraulic Brakes (Cont.)

VEHICLE MODEL
FSR*(RD2) FTR
ITEMS
SERVICE BRAKE
Type ; Front Leading and Trailing (L and T)
; Rear Leading and Trailing (L and T)
Drum inside diameter mm (in)

; Front 410 (16.1)
; Rear 410 (16.1)
Lining dimension mm (in)

(Width × Thickness)
; Front 140 × 16 (5.5 × 0.6) 140 × 16 (5.5 × 0.6)
; Rear 140 × 16 (5.5 × 0.6) 140 × 16 (5.5 × 0.6)
Pedal free play; LHD/RHD mm (in) 9 – 14 (0.35 – 0.55)(Reference) /10 – 14 (0.39 – 0.55)
Lining clearance mm (in) 0.30 (0.012)

Wheel cylinder inside diameter
mm (in)
; Front 50.8 (2.00)
; Rear 53.5 (2.11)
Piston clearance mm (in) 0.15 (0.006)
BRAKE CONTROL PARTS

AIRMASTER
Power cylinder diameter
× Stroke mm (in) 138 × 118 (5.43 × 4.65)
138 × 114 (5.43 × 4.49) for Australia
Hydraulic cylinder diameter
× Stroke mm (in) 29.1 × 115 (1.14 × 4.53)
29.1 × 111 (1.14 × 4.37) for Australia
Hydraulic cylinder operating
Volume cm3 (cu·in) Approx. 76 (4.6) for Australia
Approx. 74 (4.5) for Australia
Remaining pressure
kPa (kg / cm2 / psi) 78.5 – 107.9 (0.8 – 1.1 / 11.4 – 15.6)
*RD2 (Heavy duty package)

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Parking Brakes
TRANSMISSION MLD
MBJ
ITEMS MODEL Automatic transmission
Type Internal expanding, Duo Servo

Location At rear of transmission
Brake drum diameter mm (in) 216 (8.50) 254 (10.0)
Brake lining dimension
Width × Thickness mm (in) 50 (1.97) × 5.5 (0.22) 60 (2.36) × 5.5 (0.22)
Brake lever travel (notch)
Normal 2–5
Limit for use 15
Lining clearance mm (in) 0.25 (0.0098) 0.23 (0.0091)
Air Compressor
ENGINE MODEL
6H series standard 6H series (E1Q)*
ITEMS
Type Reciprocating
Cooling method Air Water
Bore × stroke mm (in) 70 × 40 (2.756 × 1.575) 85 × 60 (3.3465 × 2.3622)
Number of piston rings Compression: 2 / Oil: 1 or 2
Capacity lit / rev (in3 / rev) 0.155 (0.944) 0.34 (2.07)
Drive method Gear
Ratio To 1 0.5
Unloader valve operation
Governor pressure
kPa (kg / cm2 / psi) 686 – 785 (7 – 8 / 100 – 114)
*E1Q.....Heavy Duty Air Compressor
Exhaust Brake
Type Electric and air control butterfly valve
Location; exhaust brake valve Between exhaust manifold and pipe
ENGINE MODEL
6H Series
ITEMS
Exhaust brake valve inside diameter mm (in) 75 (2.953)
Exhaust brake valve operating angle degree 60
Control cylinder inside diameter mm (in) 30 (1.181)
Control cylinder effective stroke mm (in) 50 (1.969)
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SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT
WHEEL BRAKE ASSEMBLY

Brake Drum inside diameter mm (in) 320.0 (12.60) 322.0 (12.68)
400.0 (15.75) 404.0 (15.91)
410.0 (16.14) 414.0 (16.30)
Brake Drum Run-Out mm (in) – 0.2 (0.0079)
Clearance to Rivet Head mm (in) – 0.5 (0.0197)
Clearance between Wheel Cylinder and
Piston mm (in) – 0.25(0.0098)
Clearance between Anchor Pin Bushing
Inside Diameter and Anchor Pin Diameter
mm (in) 0.10 (0.0039) 0.25 (0.0098)
Clearance between Brake Shoe Flange
Edge and Back Plate mm (in)
For FRR (Front Brake) 0.55 – 0.90 –
(0.0217 – 0.0354)
For FSR, FSS, FTS (Front Brake) 0.50 – 1.20 –
(0.0197 – 0.0472)
For FRR, FSR, FSS, FTS (Rear Brake) 0.55 – 0.90 –
(0.0217 – 0.0354)
BRAKE VALVE
Clearance between Pedal Pin and Bushing
mm (in) 0.015 – 0.086 0.40
(0.0006 – 0.0034) (0.0157)
Clearance between Roller Pin and Roller
Bushing mm (in) 0.015 – 0.108 0.25
(0.0006 – 0.0043) (0.0098)
Clearance between Plunger and Bushing
mm (in) – 0.49 (0.0193)
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AIR BOOSTER
Clearance between Hydraulic Cylinder
and Piston mm (in) – 0.15 (0.0059)
PARKING BRAKE
Brake Drum Inside Diameter mm (in) 216 (8.50) 218 (8.58)
254 (10.0) 256 (10.08)
Brake Drum Run-Out mm (in) 0.05 (0.002) –
Clearance to Rivet Head mm (in) – 0.5 (0.0197)
AIR COMPRESSOR
Cylinder Bore Uneven Wear mm (in) – 0.1 (0.004)
Clearance between Cylinder Bore
and Piston mm (in)
Cylinder Bore Size
70 (2.756) 0.05 – 0.10 0.2
(0.0020 – 0.0039) (0.008)
85 (3.347) 0.07 – 0.12 0.2
(0.0028 – 0.0047) (0.008)
Clearance between Piston and Piston Pin
mm (in)
Cylinder Bore Size
70 (2.756) 0.006 – 0.022 0.1
(0.0002 – 0.0009) (0.004)
85 (3.347) 0.006 – 0.026 0.1
(0.0002 – 0.0010) (0.004)
Clearance between Piston Ring and Piston
Ring Groove mm (in)
Cylinder Bore 70 mm Type
Compression Ring 0.015 – 0.055 0.15
(0.0006 – 0.0021) (0.0060)
Oil Ring 0.02 – 0.05 0.15
(0.0007 – 0.0023) (0.0060)
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AIR COMPRESSOR
(0.0008 – 0.0020) (0.0060)
Oil Ring 0.03 – 0.07 0.15
(0.0012 – 0.0028) (0.0060)
Piston Ring Gap mm (in)
(0.0039 – 0.0098) (0.039)
Oil Ring 0.10 – 0.30 1.0
(0.0039 – 0.0120) (0.039)
(0.0060 – 0.0120) (0.039)
Oil Ring 0.15 – 0.35 1.0
(0.0060 – 0.0140) (0.039)
Clearance between Connecting Rod Small
End and Piston Pin mm (in)
Cylinder Bore 70 mm Type 0.006 – 0.022 0.1
(0.0002 – 0.0009) (0.004)
(0.0002 – 0.0010) (0.004)
Clearance between Connecting Rod Big
End and Crankpin mm (in)
(0.0013 – 0.0030) (0.0006)
(0.0013 – 0.0030) (0.0006)
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SERVICING
CONTENTS
PAGE
Service Brakes ................................................................................................................ 00- 26
Brake Pedal Free Play and Adjustment .................................................................... 00- 26
Cleaning of Exhaust Port .......................................................................................... 00- 26
Water Drain ................................................................................................................ 00- 26
Lining Wear and Clearance Adjustment .................................................................. 00- 27
Air Bleeding ................................................................................................................ 00- 28
Air Booster Wear Indicator Reset.............................................................................. 00- 29
Air Booster Assembly ................................................................................................ 00- 29

Air Dryer ...................................................................................................................... 00- 30
Load Sensing Proportioning Valve Adjustment ...................................................... 00- 31
Parking Brakes ................................................................................................................ 00- 32
Parking Brake Adjustment ........................................................................................ 00- 32
Wheel Parking Brake .................................................................................................. 00- 33
Exhaust Brake ................................................................................................................ 00- 34
Exhaust Brake Adjustment ........................................................................................ 00- 34
Fixing Torque .................................................................................................................. 00- 36
Special Tools.................................................................................................................... 00- 47
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SERVICE BRAKES
Brake Pedal Free Play and Adjustment
Brake Pedal (RHD)
Turn the adjusting screw all the way out, then turn it
in just enough, so that brake pedal free play (stroke of
pedal until a resistance is felt) is adjusted to the
specified play. Fully tighten the lock nut when a
correct adjustment is obtained.
Brake Pedal Free Play (RHD) mm (in)
Vehicle Model Free Play

FRR, FSR, FSS 12 – 16 (0.47 – 0.63)
FSR (RD2), FTR,
10 – 14 (0.39 – 0.55)
FTS
Brake Pedal Free Play (LHD) mm (in)
9 – 14 (0.35 – 0.55) (Reference)
Cleaning of Exhaust Port

Brake Valve
Water Drain
Air Tank
Keep drain valve opened until tank is drained
completely
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Lining Wear and Clearance Adjustment

Lining Wear
1. Check the brake lining edge for wear visually
through the inspection hole in the backing plate.
2. If the stepped portion on the lining edge worn, the
brake lining should be changed with a new one.
Lining Clearance Adjustment (2L and D2L)

1. Remove the rubber cap from the inspection hole
and turn the adjuster, so that the lining clearance
is set to “0”.
2. Turn the adjuster back as the following specified
notches. Install the rubber cap to the inspection
hole after adjustment.
Brake Lining Clearance mm (in)
Lining
Model Notches
clearance
Front and
FRR 7–9
rear 0.35
Front 7–9 (0.014)
FSR, FSS, FTS
Rear 5–6
3. Repeat steps 1 and 2 for the other adjuster, and

then at each wheel.
Lining Clearance Adjustment (L and T)

1. Remove the rubber cap from the inspection hole.
2. Insert the 0.3 mm feeler gauge to the inspection
hole.
3. Adjust the brake lining clearance by turning adjust
cam so that the feeler gauge moves with
difficulty. Install the rubber cap to the inspection
hole after adjustment.
Brake Lining Clearance mm (in)
Model Lining clearance
FSR (RD2), FTR 0.30 (0.012)
4. Repeat steps 1, 2 and 3 at the other cam, and

then at each wheel.
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Air Bleeding
Air Bleeding
• Perform bleeding operation with engine running,
to maintain air pressure. Make sure exhaust is
suitably ventilated.
• Bleed the hydraulic system with the fluid reservoir
filled to the specified level.
• Bleed the system starting with the air booster first
in the sequence shown in the figure.
front line
rear line
1. Fill the brake fluid reservoir with brake

fluid.Handle the brake fluid with reasonable care
to avoid spillage as it is damaging to paint.
NOTE:
Take care to prevent foreign matter from entry, when
replenishing or replacing brake fluid.
2. Connect a vinyl pipe to the bleeder screw on the

air booster and the other end of the pipe in a
transparent container.
3. Pump the brake pedal several times and hold it
depressed. Loosen the bleeder screw to release
brake fluid together with air bubbles. Tighten the
bleeder screw before pressure is released
completely.
4. Repeat the step in paragraph 3 above until the air
bubbles disappear completely. Securely tighten
the bleeder screw when the air bubbles disappear
completely.
Torque N•m (kg•m / lb•ft)
23 (2.3 / 17)
5. Repeat the steps to 4 above on the remaining

wheel cylinders. Bleed the system starting with
the farthest wheel from the air booster.
6. Fill the brake fluid reservoir to the specified level.
Pour brake fluid carefully so as not to produce air
bubbles.
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Air Booster Wear Indicator Reset

Wear Indicator
A/T LOW TR
OIL BRAKE
BRAKE
PTO P S /T ENGINE When the wear indicating light comes on, correct the
AIR O/RUN
brake shoe clearance or repair hydraulic oil leakage
from the line.
Check that the wear indicator light turns off when the
starter switch is turned to the “ON” position after
repairing.
Air Booster Assembly (Air Master)

1. Inspection for Air Leakage
Install airmaster on vehicle and increase air pressure
to approximately 59 kPa (6.0 kg / cm2) then check that
air is not leaking from the exhaust cover on the air
booster.
2. Inspection for Oil Leakage
With the brake pedal depressed, check to make certain
oil is not leaking through the joints in hydraulic
circuits. Keep the brake pedal party depressed and
check for variation in pedal feel as time passes.
3. Operating Test
Operate the brake pedal repeatedly and check
movement of airmaster push rod and listen for noise
indicating discharge of air from the exhaust cover to
be sure no time delay in operation is present.
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Air Dryer
1. Be sure to check the air drain every three(3)
months or every 20,000 km, whichever comes
first.
Inspect for moisture in the air system by opening
drain valve and checking for presence of water. In
areas where more than approximately a 16°C
(61°F) range of temperature is common, small
amounts of water can accumulate in the air brake
system due to condensation. The presence of
small amounts of water due to condensation is
normal and should not be considered as an
indication that the dryer is not performing
properly. The desiccant should be replaced when
it has been determined that the desiccant is
contaminated and does not have adequate water
adsorption capacity. Excessive oil in the air drain
indicates that the air compressor requires
attention.
2. Replace the desiccant, filters and gaskets once
every year or every 100,000 km, whichever comes
first.
3. Take care to ensure that the drain port is not
blocked or obstructed by foreign material.
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Load Sensing Proportioning Valve (L.S.P.V.)

Adjustment (for South Africa only)
1. Set the specific rear axle load as below.
Model Rear axle set load
FRR 16080N / 1640kg / 3620lb
FSR 19020N / 1940kg / 4280lb
FTR-F 21574N / 2200kg / 4851lb
FTR-M 24420N / 2490kg / 5490lb
2. Remove the link rod by loosening the lock nut and

adjust nut.
3. Reinstall the link rod and adjust the pulling down
length “L” with the adjust nut.
The pulling down length “L” is shown in the plate
on the valve body.
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PARKING BRAKES
Parking Brake Adjustment
Brake Shoe Clearance Adjustment
1. Move the lever from side to side 3 or 4 times to
properly center the brake shoes.
2. With a screw driver turn adjuster upward until the
brake drum drags.
3. Back off the adjuster as specified.
Transmission Clearance
model Notches mm (in)
0.25
MBJ 13 (0.0098)
MLD and 0.23
Automatic transmission 13
(0.0091)
Cam Shaft Lever

1. Loosen lock nut.
2. With rod or cable adjust to specification.
Parking Lever
(notch)
Vehicle model Standard Limit
F Series 2–5 15
When pulled with a force of 196 N (20 kgf, 44.1 lb.)
Cam Clearance
When connecting cable or link rod with cam shaft
lever, use adjust nut in order to make the clearance 0
mm (0 in) between cam and shoe, then lock adjust nut
with lock nut.
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Wheel Parking Brake

Release of Wheel Parking Brake for Emergency and
Restoration
In case of the emergency.
PA
RK
If the air pressure in the air tank is lowered, the
parking (spring) brake can not be released with the
IN
G
RE
LE
AS
E
brake valve.
In such instance, the spring brake can be released as
follows.
Release
Rotate the turn buckle of the push rod which connects
the wheel cylinder and power chamber to extend the
rod until the wheel rotates freely.
Restoration
1. Remove the pin from the jaw joint and detach the
push rod.
2. Fill the power chamber with air of the specified
pressure.
3. Pull the rod on the wheel cylinder side outward by
hand, rotate the turn buckle to shorten the push
rod to the proper length, attach the jaw joint and
insert the pin.
NOTE:
The wheel cylinder will be damaged if the air
chamber is filled before the push rod is detached.
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EXHAUST BRAKE
Exhaust Brake Adjustment
Brake Valve
Adjust it to the value specified below, using the
stopper bolt.
When valve is open:
Parallelness between butterfly valve and tube inner
surface: ± 2 degrees
When valve is completely closed, with lever

contacting with stopper clearances are following.
Clearance mm (in)
For 6HE1 Except 6HE1
The respective
0.3 – 0.5 0.2 – 0.4
clearances of the
(0.012 – 0.020) (0.008 – 0.016)
points A and B
The average clearance 0.3 – 0.4 0.2 – 0.3
of the points A and B (0.012 – 0.016) (0.008 – 0.012)
Accelerator Switch
Adjust the clearance “A” with adjust nut.
Clearance: A mm (in)
Standard 16 – 17 (0.63 – 0.67)
The accelerator switch is installed within the cab and

is interlocked with the accelerator pedal.
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Clutch Switch (Mechanical Type)

The clutch switch is installed on the upper part of the
clutch pedal.
Exhaust Brake Switch

Pull the lever type exhaust brake switch on the
steering column and check that the indicator lamp on
the instrument panel operates.
Wiring
A continuity should exist across the switch terminals
when both of the accelerator pedal and clutch pedal
are released, and continuity should not exist when
either of the pedals is depressed.
Accelerator switch should be checked after
completing idling adjustment.
Magnetic Valve
With a circuit tester check for open coil.
156MT003
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FIXING TORQUE
Front Wheel Brake N•m (kg•m / lb•ft)
-Two Leading Type-
For FRR
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N•m (kg•m / lb•ft)

-Two Leading Type-
For FSR, FSS and FTS
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-Leading and trailing Type-
For FSR(RD2), FTR
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Rear Wheel Brake N•m (kg•m / lb•ft)

-Dual Two Leading Type-
For FRR
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-Dual Two Leading Type-
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-Leading and Trailing Type-
For FSR(RD2), FTR
FTR (STD) 83 (8.5 / 61)

FTR *(RD2) 137 (14.0 / 101)
FTR *(B3A) 76 (7.8 / 56)
*(RD2): Heavy duty package

*(B3A): Wheel parking brake
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Brake Valve (RHD) N•m (kg•m / lb•in)
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Air Booster N•m (kg•m / lb•ft)

– NISSIN MADE –
FRR, FSS(EXCEPT AUSTRALIA) models
14(1.4/10)
10(1.0/7.2)
17(1.7/12)
14(1.4/10)
25(2.5/18)
333MY00008
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– JKC MADE –
10(1.0/7.2)
25(2.5/18)
10(1.0/7.2)
25(2.5/18)
25(2.5/18)
333MX00012
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Parking Brake Drum N•m (kg•m / lb•ft)
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Air Compressor N•m (kg•m / lb•ft)
29(3.0/22)
49(5.0/36)
(for 6H series 25(2.5/18)

engine standard 6H series engine 147(15.0/108)
type only)
6S series engine 255(26.0/188)
29(3.0/22)
(for 6S series engine)
*
6H series engine 23(2.3/17)
6S series engine 6(0.6/4.3)
15(1.5/11)
54498A
01/09/03 01
039M200004
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SPECIAL TOOLS
PART NO. SERVICE PARKING
ILLUSTRATION PART NAME
ISUZU BRAKE BRAKE
Brake shoe spring

9-8523-1554-0 ●
remover & installer kit
9-8522-1231-0
Brake shoe spring ●
(Included kit No.
installer
9-8523-1554-0)
Brake shoe spring Pliers

9-8522-0026-0 ●
(2 leading type only)
Brake shoe spring

1-8523-7002-0 remover (Leading/ ●
Trailing type only)
Brake shoe spring

1-8523-7013-0 remover & installer
●
(Leading/Trailing type
9-8523-1560-0 rear wheel only)
Anchor pin puller

9-8521-0095-0 (Leading/Trailing type ●
only)
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HYDRAULIC BRAKES 5A-1
SECTION 5A
HYDRAULIC BRAKES
CONTENTS
Page 1 of 3 PAGE
General Description ....................................................................................................... 5A- 4
Front Wheel Brake Assembly (Two Leading Type) ..................................................... 5A- 19
Disassembly ............................................................................................................... 5A- 19
Inspection and Repair ................................................................................................ 5A- 22
Reassembly ................................................................................................................ 5A- 26
Front Wheel Brake Assembly (Leading and Trailing Type) ........................................ 5A- 32
Disassembly ............................................................................................................... 5A- 32
Reassembly ................................................................................................................ 5A- 38
Rear Wheel Brake Assembly (Dual Two Leading Type) ............................................. 5A- 41
Disassembly ............................................................................................................... 5A- 41
Reassembly ................................................................................................................ 5A- 48
Rear Wheel Brake Assembly (Leading and Trailing Type) ......................................... 5A- 53
Disassembly ............................................................................................................... 5A- 53
Reassembly ................................................................................................................ 5A- 59
Brake Valve and Pedal (RHD model) ............................................................................ 5A- 62
Removal ....................................................................................................................... 5A- 62
Installation ................................................................................................................... 5A- 63
Brake Valve and Pedal (LHD model) ............................................................................. 5A- 64
Removal ....................................................................................................................... 5A- 65
Installation ................................................................................................................... 5A- 66

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5A-2 HYDRAULIC BRAKES
Page 2 of 3
Brake Valve (RHD model) .............................................................................................. 5A- 69
Disassembly ............................................................................................................... 5A- 69
Reassembly ................................................................................................................ 5A- 75
Brake Valve (LHD model) .............................................................................................. 5A- 79
Disassembly ............................................................................................................... 5A- 79
Reassembly ................................................................................................................ 5A- 83
Operation Test ........................................................................................................... 5A- 86
Air Booster ...................................................................................................................... 5A- 90
Removal ...................................................................................................................... 5A- 90
Installation .................................................................................................................. 5A- 91
Power Piston and Shell ................................................................................................. 5A- 92
Disassembly ............................................................................................................... 5A- 92
Reassembly ................................................................................................................ 5A- 94
Hydraulic Cylinder Assembly ........................................................................................ 5A- 96
Disassembly (JKC mode) .......................................................................................... 5A- 96
Disassembly (NISSIN made) ..................................................................................... 5A- 98
Inspection and Repair ................................................................................................ 5A-100
Reassembly (JKC made)............................................................................................ 5A-101
Reassembly (NISSIN made) ...................................................................................... 5A-103
Air Circuit Parts .............................................................................................................. 5A-105
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Page 3 of 3
Multi Protection Valve ................................................................................................... 5A-108
Performance Test ....................................................................................................... 5A-108
Air Dryer (DR-31 type) .................................................................................................... 5A-110
Disassembly ............................................................................................................... 5A-110
Reassembly ................................................................................................................ 5A-115
Air Dryer (DR-41 type) .................................................................................................... 5A-120
Disassembly ............................................................................................................... 5A-120
Reassembly ................................................................................................................ 5A-122
Operation Test ........................................................................................................... 5A-125
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GENERAL DESCRIPTION
Hydraulic Brake System
FRR (General)
11 10 11
RHD 9 9
15
7 7
16 5 4 6
13
PRIM 7
8
SEC
14
17 3
1
2
EXH BRK CYL 12
RHD/LHD
ACC LINE
11 11
FLEX HOSE
AIR PIPE (φ6.35) LHD

AIR PIPE (φ8)
AIR PIPE (φ10)
AIR PIPE (φ12)

16
AIR PIPE (φ15)
PRIM
OIL PIPE (φ6.35) 8
SEC
OIL PIPE (φ8) 17
RUBBER HOSE
NYLON TUBE (12X1.5)
NO PART NAME NO PART NAME

1 Air Compressor 15 Safety Valve
2 Air Charge Governor 16 Pressure Switch (Prim)
3 Air Dryer (Option) 17 Pressure Switch (Sec)
4 Air Reservoir-Supply (7l) 18
5 Air Reservoir-Service Brake; Prim (7l) 19
6 Air Reservoir-Service Brake; Sec(7l) 20
7 Check Valve 21
8 Dual Brake Valve 22
9 Servo Unit; Air Master 23
10 Oil Reservoir Tank 24
11 Wheel Cylinder 25
12 Magnetic Valve
13 Single Air Pressure Gauge
14 Low Pressure Switch (Air Reservoir)
370Mt007
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FRR (ADR Regulation)
13
15 15
25 25
12 12 14 19
16
22 24 22
22
5 4 6 7
9
21 25 25
PRIM
8 23 22 23 23 23
SEC
10
3
1
2
EXH BRK CYL 18
VSS 18 11
ACC LINE
17
20
RR WHEEL PARKING LINE (OPTION) 19
15 15
FLEX HOSE
AIR PIPE (φ6.35)

AIR PIPE (φ8)
AIR PIPE (φ10)
AIR PIPE (φ12)
AIR PIPE (φ15)
OIL PIPE (φ6.35)

OIL PIPE (φ8)
RUBBER HOSE
NYLON TUBE ( 8X1.0)

1 Air Compressor 15 Wheel Cylinder
2 Air Charge Governor 16 Air Valve
3 Air Dryer (Option) 17 Parking Brake Control Valve
4 Air Reservoir-Supply (7l) 18 Magnetic Valve
5 Air Reservoir-Service Brake; Prim (7l) 19 Spring Chamber
6 Air Reservoir-Service Brake; Sec(7l) 20 Pressure Switch (Spring Brake)
7 Air Reservoir-Spring Brake; (15l) 21 Dual Air Pressure Gauge
8 Dual Brake Valve 22 Check Valve
9 Pressure Switch (Prim) 23 Low Pressure Switch (Air Reservoir)
10 Pressure Switch (Sec) 24 Safety Valve
11 Quick Release Valve 25 Test Connector
12 Servo Unit; Air Master
13 Oil Reservoir Tank
14 Load Sensing Proportioning Valve
370MT008
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FRR (EC Regulation)

13
15 15
25 25
12 12 14
A C 19
22 24 16 22
25
B D
5 4 6 7
9
21 25 22
PRIM
8 23 22 23 23 25
SEC
10
1
2
EXH BRK CYL 11 18
ACC LINE
17
20 19
15 15
FLEX HOSE
AIR PIPE (φ6.35)

AIR PIPE (φ8)
CIRCUIT A , B , VALVE PRESSURE (OPEN) ; 600kPa
AIR PIPE (φ10) (SHUT) ;450kPa
AIR PIPE (φ12) CIRCUIT C , D , VALVE PRESSURE (OPEN) ; 550kPa
(SHUT) ;400kPa
AIR PIPE (φ15)
NO.16;VALVE PRESSURE
OIL PIPE (φ6.35)
OIL PIPE (φ8)
RUBBER HOSE
NYLON TUBE ( 8X1.0)

2 Air Charge Governor 16 Multi Circuit Protection Valve
3 17 Parking Brake Control Valve
4 Air Reservoir-Supply (7l) 18 Quick Release Valve
5 Air Reservoir-Service Brake; Prim (7l) 19 Spring Chamber
6 Air Reservoir-Service Brake; Sec(7l) 20 Pressure Switch (Spring Brake)
9 Pressure Switch (Prim) 23 Low Pressure Switch
11 Magnetic Valve 25 Test Connector
370mT009
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FRR (With Wheel Parking)
11 10 11
RHD 20
9 9
19
15 7
7 7
16 5 4 6 18
13
PRIM 7
8
SEC 14
17 14
3
1
2
EXH BRK CYL 12
RHD/LHD 23
ACC LINE
22
21
20
11 11
FLEX HOSE

AIR PIPE (φ8)
AIR PIPE (φ10)
AIR PIPE (φ12)

16
AIR PIPE (φ15) 13
PRIM
OIL PIPE (φ6.35) 8
SEC
OIL PIPE (φ8) 17
RUBBER HOSE
NYLON TUBE ( 8X1.0) NYLON TUBE (12X1.5)

1 Air Compressor 15 Safety Valve
2 Air Charge Governor 16 Pressure Switch (Prim)
3 Air Dryer (Option) 17 Pressure Switch (Sec)
4 Air Reservoir-Supply (7l) 18 Air Reservoir-Spring Brake; (15l)
5 Air Reservoir-Service Brake; Prim (7l) 19 Air Valve
6 Air Reservoir-Service Brake; Sec(7l) 20 Spring Chamber
7 Check Valve 21 Pressure Switch (Spring Brake)
8 Dual Brake Valve 22 Parking Brake Control Valve
9 Servo Unit; Air Master 23 Quick Release Valve
11 Wheel Cylinder 25
12 Magnetic Valve
13 Dual Air Pressure Gauge
14 Low Pressure Switch (Air Reservoir)
370Mt010
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FSR,FTR (General)
11
12 12
10 10
RHD
16 16
6 5
8 15 15
16
PRIM
7 4
SEC
9 15 19
3 16
1
2
EXH BRK CYL 13
RHD/LHD
ACC LINE
12 12
FLEX HOSE

AIR PIPE (φ8)
AIR PIPE (φ10)
AIR PIPE (φ12)

8
AIR PIPE (φ15)
PRIM
OIL PIPE (φ6.35) 7
SEC
OIL PIPE (φ8) 9
RUBBER HOSE
NYLON TUBE (12X1.5)

1 Air Compressor 15 Check Valve
2 Air Charge Governor 16 Low Pressure switch (Air Reservior)
3 Air Dryer (Option) 17
4 Air Reservoir-Supply (22.4l) 18
5 Air Reservoir-Service Brake; Prim (11.2l) 19 Safety Valve
6 Air Reservoir-Service Brake; Sec(11.2l) 20
7 Dual Brake Valve
8 Pressure Switch (Prim)
9 Pressure Switch (Sec)
10 Servo Unit; Air Master
12 Wheel Cylinder
13 Magnetic Valve
14
370MT003
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FSR (ADR Regulation)

11
13 13
23 23
10 10 12
19
22 22
23
18
6 5 23
18
8 21 21
20
PRIM 14
7 4
SEC
9 21 24
3 22
1
2 14
EXH BRK CYL 15 18
VSS 15
ACC LINE
16
17 19
13 13
FLEX HOSE
AIR PIPE (φ6.35)

AIR PIPE (φ8)
AIR PIPE (φ10)
AIR PIPE (φ12)
AIR PIPE (φ15)
OIL PIPE (φ6.35)

OIL PIPE (φ8)
RUBBER HOSE
NYLON TUBE ( 8X1.0)

1 Air Compressor 15 Magnetic Valve
2 Air Charge Governor 16 Parking Brake Control Valve
3 Air Dryer (Option) 17 Pressure Switch (Spring Brake)
4 Air Reservoir-Supply (22.4l) 18 Quick Release Valve
5 Air Reservoir-Service Brake; Prim (11.2l) 19 Spring Chamber
6 Air Reservoir-Service Brake; Sec(11.2l) 20 Dual Air Pressure Gauge
9 Pressure Switch (Sec) 23 Test Connector
10 Servo Unit; Air Master 24 Safety Valve
13 Wheel Cylinder
14 Air Valve
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FSR,FTR (EC Regulation)

13
15 15
24 24
12 12 14
19
23 23 24 23
24 24
6 5 7
10 A
21 22 22 C 22
PRIM 8
9 B
SEC D
11 4
22 25
1 18
2
EXH BRK CYL 20
ACC LINE
16
19
17
15 15
FLEX HOSE
AIR PIPE (φ6.35)

CIRCUIT A , B , VALVE PRESSURE (OPEN) ; 600kPa
AIR PIPE (φ8) (SHUT) ;450kPa
AIR PIPE (φ10) CIRCUIT C , D , VALVE PRESSURE (OPEN) ; 550kPa
(SHUT) ;400kPa
AIR PIPE (φ12)
NO.8;VALVE PRESSURE
AIR PIPE (φ15)
OIL PIPE (φ6.35)

OIL PIPE (φ8)
RUBBER HOSE
NYLON TUBE ( 8X1.0)

3 17 Pressure Switch (Spring Brake)
6 Air Reservoir-Service Brake; Sec(11.2l) 20 Magnetic Valve
8 Multi Circuit Protection Valve 22 Check Valve
9 Dual Brake Valve 23 Low Pressure Switch (Air Reservoir)
10 Pressure Switch (Prim) 24 Test Connector
370MT005
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FSR,FTR (With Wheel Parking)

11
12 12
10 10
RHD 23
16 16
6 5
8 15 15
16
PRIM
7 4 21
SEC
9 15
3 24
16
1
2
EXH BRK CYL 13 22
RHD/LHD
ACC LINE
19
23
20
12 12
FLEX HOSE

AIR PIPE (φ8)
AIR PIPE (φ10)
AIR PIPE (φ12)

8
16
AIR PIPE (φ15)
PRIM
OIL PIPE (φ6.35) 7
SEC
OIL PIPE (φ8) 9
RUBBER HOSE
NYLON TUBE ( 8X1.0) NYLON TUBE (12X1.5)

1 Air Compressor 15 Check Valve
2 Air Charge Governor 16 Low Pressure Switch (Air Reservoir)
3 Air Dryer (Option) 17
4 Air Reservoir-Supply (22.4l) 18
5 Air Reservoir-Service Brake; Prim (11.2l) 19 Parking Brake Control Valve
6 Air Reservoir-Service Brake; Sec(11.2l) 20 Pressure Switch (Spring Brake)
7 Dual Brake Valve 21 Air Valve
8 Pressure Switch (Prim) 22 Quick Release Valve
9 Pressure Switch (Sec) 23 Spring Chamber
12 Wheel Cylinder
13 Magnetic Valve
14
370MT006
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ｲﾗｽﾄ番号・追番 3 7 0 M T
FSS/FTS(ADR)
品名又は
配管図
FSS,FTS (ADR Regulation) 電装タイトル
11
13 13
23 23
10 10 12
19
22 22
23
18
6 5 23
18
8 21 21
20
PRIM 14
7 4
SEC
9 21 24
3 22
1
2 14
EXH BRK CYL 15 18
T/F HIGH 15
VSS 15
T/F ON-OFF 15 T/F LOW 15

ACC LINE
16
17 19
13 13
FLEX HOSE
AIR PIPE (φ6.35)

AIR PIPE (φ8)
AIR PIPE (φ10)
AIR PIPE (φ12)
AIR PIPE (φ15)
OIL PIPE (φ6.35)

OIL PIPE (φ8)
RUBBER HOSE

1 Air Compressor 15 Magnetic Valve
3 Air Dryer (Option) 17 Pressure Switch (Spring Brake)
6 Air Reservoir-Service Brake; Sec(11.2l) 20 Dual Air Pressure Gauge
9 Pressure Switch (Sec) 23 Test Connector
13 Wheel Cylinder
14 Air Valve
370MT018
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Wheel Brake
—Two Leading and Dual Two Leading Type—
Front Wheel Brakes Rear Wheel Brakes

The front wheel brakes are the two leading shoe type. The rear wheel brakes are the dual two leading shoe
This combination of two leading shoes provides type.
nearly equal braking force. This prevents an uneven The dual two leading shoe type brake eliminates the
load distribution on the wheel hub bearings. problem of weaker braking force on reverse stops
This type of brake is widely used on the front wheels common to two leading shoe type brakes while
of many vehicles. maintaining the many advantages of this type of
brake.
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—Leading and Trailing Type—
Both the front and the rear brakes are the leading and A single wheel cylinder provides stable brake action.
trailing type. If the leading and trailing brake shoes are correctly
This type of brake features a combination of leading adjusted, braking force will be the same whether the
and trailing brake shoes. It has very little servo action. vehicle is moving forward or backward.
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Brake Valve
RHD RHD LHD

(For SouthAfrica)
334MY00002
The dual brake valve is a single assembly which Secondary Valve

simultaneously controls the brake systems at both The secondary valve senses the pressure being
the front and the rear wheels of the vehicle. This delivered to the primary system and delivers a nearly
ensures vehicle safety at all times. equivalent air pressure to the secondary system relay
Depressing the brake pedal causes the dual brake valve.
valve to supply the appropriate air pressure to the air Should the primary control valve become inoperative
booster relay valve. due to primary system piping damage, the secondary
The dual brake valve consists of the primary and valve will continue to operate in response to the force
secondary control valves. Each of these valves has an applied to the brake pedal.
air supply port to supply air from the air tank and a
discharge port to deliver air to the air booster relay
valve.
Primary Valve
The primary valve controls the air pressure being
delivered to the primary system. The amount of air
pressure delivered is directly proportional to the
force applied to the brake pedal.
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Air Booster (Airmaster)
FRR, FSS (EXCEPT AUSTRALIA) models
From brake valve
To wheel cylinder
FSR, FTR, FTS, FSS (FOR AUSTRALIA) models
From brake valve
To wheel cylinder
333MY00006
The air booster is similar in structure and operating action. The air booster utilizes the difference between
principle to the hydromaster. The hydromaster, atmospheric pressure and compressed air delivered
however, reacts to the difference between a negative from the air compressor.
pressure and atmospheric pressure to provide servo
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Multi Protection Valve

Valve contruction and component parts
12 1
11 7
1 Body(A) 11 Dust Seal Rubber

17
2
2 Body(B) 12 Dust Cover
14
3 Piston Asm 13 Check Valve Asm
16
13 4 Valve Asm 14 O-ring

15
5 5 Valve 15 Valve Spring
4 18
6 Piston 16 M8 Nut
6 19
7 O-ring 17 Bolt
8 3
8 Main Spring 18 Spacer
9
10
13 4 3 9 Dust Seal Plate 19 Shim
10 Retaining Ring
Port Name and Piston No.
Secondary Side:B Primary Side:A

B A
Piston No.1
Piston No.3 Outlet Port 23 Outlet Port 21
B room A room
Inlet Port
Piston No.4 Outlet Port 24 Outlet Port 22 Piston No.2
B A
B-B A-A
333MY00006
The multi-protection valve is an integral part of the • Secondary-side multi-Protection valve outlet ports
automotive air brake circuit. The valve maintains (No. 23 and No. 24) discharge through auxiliary
normal circuit air pressure when other circuit lines to protect the wheelpark line, and other circuits.
components are damaged or fail.
• Primary-side multi-protection valve outlet ports
(No. 21 and No. 22) discharge to individual brake
circuits through the front and rear axle brake lines.
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Brake circuit and piston condition Open : ○ Close : ×

Piston Piston Piston Piston
No.1 No.2 No.3 No.4
Normal ○ ○ ○ ○
Primary side malfunction × × ○ ○

During air pressure replenishment following Port 22
primary side malfunction ○ × ○ ○
Secondary side malfunction
× × ○ ×
During air pressure replenishment following Port 24
secondary side malfunction ○ ○ ○ ×
Dual Air Pressure Gauge
The pointers show the air pressure of air tanks in the
front and rear brake system.
While driving the pressure gauge reading should be
5 0 within the range of 690 to 780 kPa (7 to 8 kg / cm2 / 100
to 114 psi).
For South Africa 740 to 830 kPa (7.5 to 8.5 kg / cm2 /
107 to 121 psi).
0 5
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FRONT WHEEL BRAKE ASSEMBLY

(Two Leading Type)
DISASSEMBLY
Two Leading Type
For FRR
Disassembly Steps
1. Cotter pin 9. Wheel cylinder assembly
2. Flange nut 10. Back plate
3. Brake shoe return spring 11. Adjusting screw
4. Brake shoe assembly 12. Piston assembly
5. Flexible hose 13. Boot
6. Forward brake pipe 14. Lock plate
7. Backward brake pipe 15. Bleeder screw
8. Connector
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Two Leading Type

Disassembly Steps
1. Shoe holder nut 9. Wheel cylinder assembly
2. Lock plate 10. Back plate
5. Flexible hose 13. Boot
6. Forward brake pipe 14. Lock plate
7. Backward brake pipe 15. Bleeder screw
8. Connector
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Disassembly Steps
1. Cotter Pin (FSR) or Shoe Holder Nut (FSR-B, FSS, FTS)
2. Flange Nut (FSR) or Lock Plate (FSR-B, FSS, FTS)
3. Brake Shoe Return Spring
Use the brake shoe spring pliers to remove the return
springs.
Brake Shoe Spring Pliers: 9-8522-0026-0
4. Brake Shoe Assembly

5. Flexible Hose
1. Place a tray beneath the flexible hose to receive
the brake fluid.
2. Remove the union nut (1).
3. Remove the joint nut (2) and the flexible hose (3).
NOTE:
Take care not to twist the piping and the flexible
hose.
6. Forward Brake Pipe

7. Backward Brake Pipe
8. Connector
9. Wheel Cylinder Assembly
Store all of the removed parts in a clean part tray.
10. Back Plate

11. Adjusting Screw
12. Piston Assembly
13. Boot
14. Lock Plate
15. Bleeder Screw
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INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
Brake Drum
Brake Drum Inside Diameter
Visually inspect the brake drum for excessive wear
and scoring.
If the brake drum is scored or worn, lathed to the
specified limit.
Use a vernier caliper to measure the brake drum
inside diameter.
If the brake drum inside diameter exceeds the
specified limit, it may be increased by 2 or 4 mm
(0.0787 or 0.1575 in).
Oversize brake linings are available as service parts.
Brake Drum Inside Diameter mm (in)
Standard Limit
320.0 (12.60) 322.0 (12.68)
Inside
400.0 (15.75) 404.0 (15.91)
diameter
410.0 (16.14) 414.0 (16.30)
Brake Drum Run-Out mm (in)

Limit 0.2 (0.0079)
Brake Lining
Brake Lining Thickness
Use a vernier caliper to measure the brake lining
thickness (rivet depth).
If the measured value is less than the specified limit,
the brake lining must be replaced.
Clearance to Rivet Head (Rivet Depth) mm (in)

Limit 0.5 (0.0197)
1 Rivet depth
2 Lining height
3 Rivet
4 Lining
5 Brake shoe
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Brake Lining Replacement

Brake Lining Removal
1. Remove the rivet caulking portions with a
hammer and chisel.
2. Remove the rivets with a hammer and punch.
3. Inspect the brake shoe for cracking.
Brake Lining Installation

1. Install the brake lining and the rivets to the brake
shoe.
2. Place the brake shoe assembly in the air hydraulic
riveter.
3. Use the air hydraulic riveter to set and caulk each
of the rivets.
4. Start riveting at the center of lining and work
towards the ends.
Brake Lining and Drum Contact

1. Apply chalk powder to the entire inside brake
drum surface.
2. Place the brake shoe assembly in the inside brake
drum.
3. Move the brake shoe assembly around the inside
brake drum.
Check for uniform contact between the brake
lining and the brake drum.
4. Correct any areas having poor contact with
sandpaper.
5. Repeat Steps 1 through 4 until the contact
between the brake lining and the brake drum is
perfect.
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Brake Shoe Return Spring

Use the spring balance to measure the return spring
tension.
Return Spring Specifications
Vehicle model Free length Set load/Set length

mm (in) N (kg / lb) / mm (in)
FRR Front 163.3 (6.43) 284(29.0/64)/179.1(7.05)

Rear 200.8 (7.91) 329(33.5/74)/218.0(8.58)
FSR Front 236.5 (9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8 (4.99) 500(51.0/112)/135.0(5.31)
FRR (Wheel park) Front 236.5 (9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8 (4.99) 500(51.0/112)/135.0(5.31)
FSS, FTS Front 236.5 (9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8 (4.99) 500(51.0/112)/135.0(5.31)
FTR Front 190.8 (7.51) 547(55.74/123)/212.0(8.35)
Rear 192.0 (7.56) 402(41.0/90)/212.0(8.35)
FTR (Wheel park) Front 190.8 (7.51) 547(55.74/123)/212.0(8.35)
Rear 200.7 (7.90) 243(24.8/55)/212.0(8.35)
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Wheel Cylinder
Piston. mm (in)
Wheel cylinder
Limit
diameter
34.93 (1.3752)
36.50 (1.4370)
Front 40.00 (1.5748)
47.50 (1.8700)
50.80 (2.0000)
38.10 (1.5000) 0.25 (0.0098)
44.00 (1.7323)
47.50 (1.8701)
Rear
50.80 (2.0000)
53.50 (2.1063)
55.56 (2.1874)
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REASSEMBLY
Two Leading Type
For FRR
Reassembly Steps
1. Piston assembly 9. Brake shoe return spring
2. Boot 10. Flange nut
3. Adjusting screw 11. Cotter pin
4. Lock plate 12. Connector
5. Bleeder screw 13. Backward brake pipe
6. Wheel cylinder assembly 14. Forward brake pipe
7. Back plate 15. Flexible hose
8. Brake shoe assembly
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Two Leading Type

Reassembly Steps
1. Piston assembly 9. Brake shoe return spring
2. Boot 10. Lock plate
3. Adjusting screw 11. Shoe holder nut
4. Lock plate 12. Connector
5. Bleeder screw 13. Backward brake pipe
6. Wheel cylinder assembly 14. Forward brake pipe
7. Back plate 15. Flexible hose
8. Brake shoe assembly
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Reassembly Steps
1. Piston Assembly
1. Apply a coat of clean brake fluid to the piston 1.
2. Apply a coat of rubber grease to the piston cups

2 and the cylinder inside wall.
Be sure to lubricate the entire cylinder bore with
the rubber grease 3.
3. Install the piston assembly to the cylinder.
2. Boot
3. Adjusting Screw
4. Lock Plate
5. Bleeder Screw
Tighten the wheel cylinder assembly bolts to the
specified torque.
Wheel Cylinder Assembly
Bolt Torque N•m (Kg•m / lb•ft)
FRR FSR, FSS, FTS
A 116 (11.8 / 85) 186 (19.0 / 137)
B 23 (2.3 / 17) 40 (4.1 / 30)
7. Back Plate
1. Apply a coat of molybdenum disulfide grease to
the back plate ridged portions 1 contacting the
brake shoe edge.
2. Tighten the back plate bolts to the specified

torque.
Back Plate Bolt Torque N•m (Kg•m / lb•ft)
127 (13.0 / 94)
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Apply a coat of molybdenum disulfide grease to the
wheel cylinder parts contacting the brake shoe 1.

Use the brake shoe spring pliers to install the brake
shoe return springs.
10. Flange Nut or Lock Plate

11. Cotter Pin or Holder Nut
flange nut seating faces 2 contacting the brake shoe.
1. Brake Shoe Assembly Installation (FSR)

1) Insert a 0.6 mm (0.0236 in) feeler gauge 1
between the brake shoe flange edge and the back
plate.
2) Check that the brake shoe assembly is resting
stably on the back plate ridged portions.
3) Temporarily tighten the flange nut 2.

4) Back off the flange nut to align the flange nut slot
with the holder pin hole 3.
5) Measure the clearance 4 between the brake shoe

flange edge and the back plate.
Brake Shoe Flange Edge
and Back Plate Clearance 4 mm (in)
0.55 – 0.90 (0.0217 – 0.0354)
6) Insert the cotter pin into the holder pin hole.

7) Bend back the split pin.
8) Remove the feeler gauge.
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2. Brake Shoe Assembly Installation (FSR, FSS, FTS)

1) Insert a 0.6 mm (0.0236 in) feeler gauge 1
plate.
2) Check that the brake shoe assembly 2 is resting
3) Adjust the clearance 3 between the brake shoe
flange edge and the back plate by turning the
holder pin 4 with a wrench.
Brake Shoe Flange Edge

and Back Plate Clearance mm (in)
0.50 – 1.20 (0.0197 – 0.0472)
4) Tighten the lock nut 5 to the specified torque.

Lock Nut Torque N•m (Kg•m / lb•ft)
76 (7.8 / 56)
5) Remove the feeler gauge.

6) Bend one tooth of the lock plate 6 over the back
plate holder.
Bend the tooth at the opposite side of the lock
plate over the lock nut.
12. Connector
Tighten the connector bolts to the specified torque.
Connector Bolt Torque N•m (Kg•m / lb•ft)
FSR 23 (2.3 / 17)
FSR, FSS, FTS 16 (1.6 / 12)
13. Backward Brake Pipe

14. Forward Brake Pipe
Tighten the backward and forward brake pipe flare
nuts to the specified torque.
Flare Nut Torque N•m (Kg•m / lb•ft)
16 (1.6 / 12)
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15. Flexible Hose

1. Install the flexible hose 1, the joint nut 2, and
the union nut 3.
2. Tighten the flexible hose to the specified torque.
Flexible Hose Torque N•m (Kg•m / lb•ft)
21 (2.1 / 15)
NOTE:
hose.
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FRONT WHEEL BRAKE ASSEMBLY

(Leading and Trailing Type)
DISASSEMBLY
Leading and Trailing Type
For FSR(RD2), FTR
Disassembly Steps
1. Brake shoe return spring and cover 8. Wheel cylinder cover
2. Lock plate 9. Anchor pin bracket
3. Anchor pin 10. Push rod
4. Brake shoe assembly 11. Boot
5. Brake drum cover 12. Piston assembly
6. Flexible hose 13. Return spring
7. Wheel cylinder assembly
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Disassembly Steps
1. Brake Shoe Return Spring and Cover

Remover: 1-8523-7002-0
NOTE:
That brake shoes fall apart as the return springs are
removed.
2. Lock Plate
3. Anchor Pin
The anchor pin can be removed easily by using a
anchor pin puller.
Anchor pin puller: 9-8521-0095-0

5. Brake Drum Cover
6. Flexible Hose
Disconnect the flexible hose assembly by loosening
the parts in sequence of union nut 1, joint nut 2 and
flexible hose 3 to prevent twisting and damaging
pipe and hose.
NOTE:
Position a tray to receive brake fluid flowing out
when nut 1 is removed.

8. Wheel Cylinder Cover
9. Anchor Pin Bracket
10. Push Rod
11. Boot
12. Piston Assembly
13. Return Spring
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during inspection.
Brake Drum
and scoring.
specified limit.
inside diameter.
(0.0787 or 0.1575 in).
Standard Limit
320.0 (12.60) 322.0 (12.68)
Inside
400.0 (15.75) 404.0 (15.91)
diameter
410.0 (16.14) 414.0 (16.30)

Limit 0.2 (0.0079)
Brake Lining
Limit 0.5 (0.0197)
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1 Rivet depth
2 Lining height
3 Rivet
4 Lining
5 Brake shoe

hammer and chisel.

shoe.
riveter.
of the rivets.
towards the ends.

drum surface.
drum.
brake drum.
sandpaper.
perfect.
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TO MODEL INDEX

Use the spring balance to measure the return spring
tension.
Free length Set load /Set length
Vehicle model
mm(in) N (kg / lb) / mm (in)
FRR Front 163.3(6.43) 284(29.0/64)/179.1(7.05)

Rear 200.8(7.91) 329(33.5/74)/218(8.58)
FSR Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FRR (Wheel park) Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FSS, FTS Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FTR Front 190.8(7.51) 547(55.74/123)/212.0(8.35)
Rear 192.0(7.56) 402(41.0/90)/212.0(8.35)
FTR (Wheel park) Front 190.8(7.51) 547(55.74/123)/212.0(8.35)
Rear 200.7(7.90) 243(24.8/55)/212.0(8.35)
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Wheel cylinder
Piston. mm (in)
Wheel cylinder
Limit
diameter
34.93 (1.3752)
36.50 (1.4370)
Front 40.00 (1.5748)
47.50 (1.8700)
50.80 (2.0000)
38.10 (1.5000) 0.25 (0.0098)
44.00 (1.7323)
47.50 (1.8701)
Rear
50.80 (2.0000)
53.50 (2.1063)
55.56 (2.1874)
Brake shoe
Clearance between Anchor Pin Bushing Inside
Diameter and Anchor Pin Diameter. mm (in)
Standard Limit
0.10 (0.0039) 0.25 (0.0098)
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REASSEMBLY
For FSR(RD2), FTR
Reassembly Steps
1. Return spring 8. Flexible hose
2. Piston assembly 9. Brake drum cover
3. Boot 10. Brake shoe assembly
4. Push rod 11. Anchor pin
5. Anchor pin bracket 12. Lock plate
6. Wheel cylinder cover 13. Brake shoe return spring and cover.
7. Wheel cylinder assembly
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Reassembly Steps
1. Return Spring
2. Piston Assembly
Before installing piston lubricate piston and cylinder
wall with brake fluid to prevent scratching piston cup.
3. Boot
4. Push Rod
Apply molybdenum disulfide grease to the threads of
upper and lower bolts before tightening.
Bolt Torque N•m (kg•m / lb•ft)
Upper side 181 (18.5 / 134)
Lower side 520 (53 / 383)

83 (8.5 / 61)
8. Flexible Hose
1. Install the flexible hose 1, the joint nut 2, and
the union nut 3.
2. Tighten the flexible hose to the specified torque.
Flexible Hose Torque N•m (kg•m / lb•ft)
21 (2.1 / 15)
NOTE:
hose.
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9. Brake Drum Cover

11. Anchor Pin
Apply molybdenum disulfide grease to the anchor
pin and the inside wall of the bushes.
12. Lock Plate

27 (2.8 / 20)
Bend the lock plate over the bolt after tightening.
13. Brake Shoe Return Spring and Cover

Installer: 9-8522-1231-0
(Included kit No.9-8523-1554-0)
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REAR WHEEL BRAKE ASSEMBLY

(Dual Two Leading Type)
DISASSEMBLY
Dual Two Leading Type
For FRR
Disassembly Steps
1. Cotter pin 8. Lock plate
2. Flange nut 9. Back plate
3. Brake shoe return spring 10. Lock plate
4. Brake shoe assembly 11. Adjusting screw
5. Brake pipe 12. Piston assembly
6. Wheel cylinder assembly 13. Boot
7. Wheel cylinder cover 14. Bleeder screw
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Disassembly Steps
1. Cotter pin 9. Back plate
2. Flange nut 10. Lock plate
5. Brake pipe 13. Boot
6. Wheel cylinder assembly 14. Bleeder screw
7. Wheel cylinder cover 15. Anchor piece
8. Lock plate
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Disassembly Steps
1. Cotter Pin
2. Flange Nut
3. Brake Shoe Return Spring (FRR)
Use the brake shoe spring pliers to remove the return
springs.
3. Brake Shoe Return Spring (FSR, FSS, FTS)

Use a screw driver to remove the return springs.

5. Brake Pipe

8. Lock Plate
9. Back Plate
10. Lock Plate
11. Adjusting Screw
12. Piston Assembly
13. Boot
14. Bleeder Screw
15. Anchor Piece (FSR, FSS, FTS)
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during inspection.
Brake Drum
and scoring.
specified limit.
inside diameter.
(0.0787 or 0.1575 in).
Standard Limit
320.0 (12.60) 322.0 (12.68)
Inside
400.0 (15.75) 404.0 (15.91)
diameter
410.0 (16.14) 414.0 (16.30)

Limit 0.2 (0.0079)
Brake Lining
Limit 0.5 (0.0197)
BACK FORWARD
TO MODEL INDEX
1 Rivet depth
2 Lining height
3 Rivet
4 Lining
5 Brake shoe

hammer and chisel.

shoe.
riveter.
of the rivets.
towards the ends.

drum surface.
drum.
brake drum.
sandpaper.
perfect.
BACK FORWARD
TO MODEL INDEX

Use the spring balanced to measure the return spring
tension.
Vehicle model Free length Set load /Set length

mm(in) N(kg / lb) / mm (in)
FRR Front 163.3(6.43) 284(29.0/64)/179.1(7.05)

Rear 200.8(7.91) 329(33.5/74)/218.0(8.58)
FSR-B Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FRR (Wheel park) Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FSS, FTS Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FTR Front 190.8(7.51) 547(55.74/123)/212.0(8.35)
Rear 192.0(7.56) 402(41.0/90)/212.0(8.35)
Rear 200.7(7.90) 243(24.8/55)/212.0(8.35)
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Wheel cylinder
Piston. mm (in)
Wheel cylinder
Limit
diameter
34.93 (1.3752)
36.50 (1.4370)
Front 40.00 (1.5748)
47.50 (1.8700)
50.80 (2.0000)
38.10 (1.5000) 0.25 (0.0098)
44.00 (1.7323)
47.50 (1.8701)
Rear
50.80 (2.0000)
53.50 (2.1063)
55.56 (2.1874)
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REASSEMBLY
For FRR
Reassembly Steps
1. Bleederscrew 9. Wheel cylinder cover
2. Boot 10. Wheel cylinder assembly
3. Piston assembly 11. Brake shoe assembly
4. Adjusting screw 12. Brake shoe return spring
5. No correspondent part 13. Flange nut
6. Lock plate 14. Cotter pin
7. Back plate 15. Brake pipe
8. Lock plate
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Reassembly Steps
1. Bleederscrew 9. Wheel cylinder cover
2. Boot 10. Wheel cylinder assembly
3. Piston assembly 11. Brake shoe assembly
4. Adjusting screw 12. Brake shoe return spring
5. Anchor piece 13. Flange nut
6. Lock plate 14. Cotter pin
7. Back plate 15. Brake pipe
8. Lock plate
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TO MODEL INDEX
Reassembly Steps
1. Bleeder Screw
2. Boot
3. Piston Assembly

2 and the cylinder bore.
Be sure that you apply the rubber grease to the
entire area of the cylinder bore 3.
4. Adjusting Screw
adjusting screw slit and threads.
5. Anchor Piece (FSR, FSS, FTS)

6. Lock Plate
7. Back Plate
the brake drum cover ridged portions 1
contacting the brake shoe flange edge.
2. Tighten the brake drum cover bolts to the
specified torque.
Brake Drum Cover Bolt Torque N•m (kg•m / lb•ft)
127 (13.0 / 94)
8. Lock Plate
Tighten the wheel cylinder assembly bolts to the
specified torque.
Wheel Cylinder Assembly
FRR 74 (7.5 / 54)
FSR, FSS, FTS 157 (16.0 / 116)
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wheel cylinder parts contacting the brake shoe 1.
12. Brake Shoe Return Spring (FRR)

12. Brake Shoe Return Spring (FSR, FSS, FTS)

Brake Shoe Spring Installer: 9-8522-1231-0
13. Flange Nut

14. Cotter Pin
flange nut seating faces 2 contacting the brake shoe.
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Brake Shoe Assembly Installation

1. Insert a 0.6 mm (0.0236 in) feeler gauge 1
plate.
2. Check that the brake shoe assembly is resting
3. Temporarily tighten the flange nut 2.
4. Back off the flange nut to align the flange nut slot
with the holder pin hole 3.
5. Measure the clearance 4 between the brake shoe

flange edge and the back plate.
Brake Shoe Flange Edge and
Back Plate Clearance 4 mm (in)
0.55 – 0.90 (0.0217 – 0.0354)
6. Insert the cotter pin into the holder pin.

7. Bend back the cotter pin.
8. Remove the feeler gauge.
15. Brake Pipe

Tighten the brake pipe flare nuts to the specified
torque.
Flare Nut Torque N•m (kg•m / lb•ft)
16 (1.6 / 12)
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REAR WHEEL BRAKE ASSEMBLY

(Leading and Trailing Type)
DISASSEMBLY
For FSR(RD2), FTR
Disassembly Steps
1. Brake shoe return spring: inner 8. Wheel cylinder cover
(except FTR standard model) 9. Wheel cylinder assembly
2. Brake shoe return spring: outer 10. Anchor pin bracket
3. Lock plate 11. Push rod
4. Anchor pin 12. Boot
6. Brake drum cover 14. Return spring
7. Brake pipe
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Disassembly Steps
1. Brake Shoe Return Spring: Inner

(Except FTR Standard Model)
Remover: 1-8523-7013-0
1. Install the arm into position from inboard side of
the shoes, then set it to the pin return spring.
2. Stretch the return spring by turning the handle,
then remove the inner pin from the shoe.
3. Release the handle and remove the return spring
and pin guide.
2. Brake Shoe Return Spring: Outer

Remover: 1-8523-7002-0
NOTE:
That brake shoes fall apart as the return spring is
removed.
3. Lock Plate
4. Anchor Pin
The anchor pin can be removed easily by using a
anchor pin puller.
Anchor Pin Puller: 9-8521-0095-0
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6. Brake Drum Cover
7. Brake Pipe
11. Push Rod
12. Boot
13. Piston Assembly
14. Return Spring
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during inspection.
Brake Drum
and scoring.
specified limit.
inside diameter.
(0.0787 or 0.1575 in).
Standard Limit
320.0 (12.60) 322.0 (12.68)
Inside
400.0 (15.75) 404.0 (15.91)
diameter
410.0 (16.14) 414.0 (16.30)

Limit 0.2 (0.0079)
Brake Lining
Limit 0.5 (0.0197)
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1 Rivet depth
2 Lining height
3 Rivet
4 Lining
5 Brake shoe

hammer and chisel.

shoe.
riveter.
of the rivets.
towards the ends.

drum surface.
drum.
brake drum.
sandpaper.
perfect.
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Use the spring balanced to measure the return spring
tension.
Vehicle model Free length Set load / Set length

mm (in) N (kg / lb) / mm (in)
FRR Front 163.3(6.43) 284(29.0/64)/179.1(7.05)

Rear 200.8(7.91) 329(33.5/74)/218.0(8.58)
FSR Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FSR (Wheel park) Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FSS, FTS Front 236.5(9.31) 412(42.0/93)/247.0(9.72)
Rear 126.8(4.99) 500(51.0/112)/135.0(5.31)
FTR Front 190.8(7.51) 547(55.74/123)/212.0(8.35)
Rear 192.0(7.56) 402(41.0/90)/212.0(8.35)
Rear 200.7(7.90) 243(24.8/55)/212.0(8.35)
Wheel Cylinder
Clearance between Wheel Cylinder and Piston.
mm (in)
Wheel cylinder
Limit
diameter
34.93 (1.3752)
36.50 (1.4370)
Front 40.00 (1.5748)
47.50 (1.8700)
50.80 (2.0000)
38.10 (1.5000) 0.25 (0.0098)
44.00 (1.7323)
47.50 (1.8701)
Rear
50.80 (2.0000)
53.50 (2.1063)
55.56 (2.1874)
Brake Shoe
Clearance between Anchor Pin Bushing Inside
Diameter and Anchor Pin Diameter.
mm (in)
Standard Limit
0.10 (0.0039) 0.25 (0.0098)
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REASSEMBLY
For FSR(RD2), FTR
Reassembly Steps
1. Return spring 8. Brake pipe
2. Piston assembly 9. Brake drum cover
3. Boot 10. Brake shoe assembly
4. Push rod 11. Anchor pin
5. Anchor pin bracket 12. Lock plate
6. Wheel cylinder assembly 13. Brake shoe return spring: inner
7. Wheel cylinder cover (except FTR standard model)
14. Brake shoe return spring: outer
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Reassembly Steps
1. Return Spring
2. Piston Assembly
Before installing piston, lubricate piston cup and
cylinder wall with brake fluid to prevent scratching
piston cup.
3. Boot
4. Push Rod
Anchor Pin Bracket Bolt Torque N•m (kg•m / lb•ft)
127 (13.0 / 94)
Then apply grease to the adjusting cam.

Wheel Cylinder Bolt Torque N•m (kg•m / lb•ft)
Model Torque
FTR (Standard) 83 (8.5 / 61)
FTR *(RD2) 137 (14.0 / 101)
FTR *(B3A) 76 (7.8 / 56)
*(RD2): Heavy duty package

*(B3A): Wheel parking brake

8. Brake Pipe
Flare Nut Torque N•m (kg•m / lb•ft)
Pipe diameter
Torque
mm (in)
4.76 (0.187) 16 (1.6 / 12)
9. Brake Drum Cover

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11. Anchor Pin

Apply molybdenum disulfide grease to the anchor
pins and the inside wall of the bushes.
12. Lock Plate

Lock Plate Bolt Torque N•m (kg•m / lb•ft)
27 (2.8 / 20)
Bend the lock over the bolt.
13. Brake Shoe Return Spring: Inner

(Except FTR Standard Model)
Installer: 1-8523-7003-0
1. Install the arm into position from inboard side of
the shoe, then set it the return spring pin guide.
2. Stretch the return spring by turning the handle,
then install the inner pin into the shoe.
3. Release the handle and install the return spring
and pin guide.
14. Brake Shoe Return Spring: Outer

Installer: 9-8522-1231-0
(Included kit No.9-8523-1554-0)
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BRAKE VALVE AND PEDAL (RHD MODEL)

REMOVAL
Removal Steps
1. Air Pipe
After tilting the cab, disconnect the four air pipes from
the brake valve at the pipe union nuts.
2. Stop Light Switch Harness
Disconnect the two stop light switch harnesses from
the brake valve at the terminals.
3. Accelerator Pedal
Before removing the accelerator
pedal, return the tilted cab to
the original position.
4. Brake Valve
Remove the brake valve together with the pedal and
plate by pulling upward.
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INSTALLATION
Installation Steps
1. Brake Valve
Apply a sealant to the pedal board seal and install it.
2. Accelerator Pedal
3. Stop Light Switch Harness
After tilting the cab, connect the two stop light switch
harnesses.
4. Air Pipe
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5A–64 HYDRAULIC BRAKES
BRAKE VALVE AND PEDAL (LHD MODEL)
1
4
310MT007
Removal Steps Installation Steps

1. Brake air pipe 4. Brake valve assembly
2. Center joint and lock nut 3. Brake pedal assembly
3. Brake pedal assembly 2. Center joint and lock nut
4. Brake valve assembly 1. Brake air pipe
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HYDRAULIC BRAKES 5A–65
REMOVAL
Removal Steps
1. Brake Air Pipe

After tilting the cab, disconnect brake air pipes from
the brake valve assembly.
377MT001
Center joint 2. Center Joint and Lock Nut

Lock nut
• Return the tilted cab to the original position.
Double nut
• Remove the pedal control rod cover.
Brake valve
• Disconnect the brake valve and pedal by loosening
the center joint and lock nut (combination B).
A
310MT004
3. Brake Pedal Assembly

4. Brake Valve Assembly
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INSTALLATION
Installation Steps
4. Brake Valve Assembly

After tilting the cab, install the brake valve assembly
to the bracket.
Brake Valve Bolt Torque N·m (kg·m / lb·ft)
40 (4.1 / 30)
3. Brake Pedal Assembly

• Return the tilted cab to the original position.
• Install the brake pedal assembly to the brake pedal
plate.
Brake Pedal Bolt Torque N·m (kg·m / lb·ft)
M6 bolt 8 (0.8 / 69 lb·in)
M8 bolt 19 (1.9 / 14)
2. Center Joint and Lock Nut

1) Fix the brake pedal in a state of being brought in
contact with the stopper on the return side.
310MT002
2) Pull up the push rod in the illustrated direction and

make sure there is free play.
If there is no play, replace with a new brake valve.
Brake Valve Push Rod Free Play mm (in)

0.1 – 0.8 (0.0039 – 0.0315)
Push rod
310MT003
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Center joint
3) Install the brake valve to the bracket. After
Lock nut installation of brake valve, pull up and tighten the
Double nut center joint and higher-walled side of double
Brake valve nut.(combination A).
4) Tighten the center joint and the lock nut
(combination B).
Brake Valve Bolt Torque N·m (kg·m / lb·ft)
B 40 (4.1 / 30)
A
310MT004
Center Joint Torque N·m (kg·m / lb·ft)

62 (6.3 / 46)
5) After installation of the brake valve, release the

brake pedal and check to see there is free play at
S
the pedal end (S).
NOTE:
Pedal end play (S) is between the brake pedal 's
contact with its return side stopper and the push
rod's contact with the brake valve plunger, not
including the stroke of 1.4 ± 0.3 mm (0.055 ± 0.012 in)
to the delivery of brake pressure.
310MT005
6) Check the pedal end play in accordance with the

table. If the check result is NG, brake valve must
be reinstalled.
Pedal End Play (S) mm (in)
S=0 NG
More than 10.5 (0.4134) NG
More than 0, 10.5 (0.4134) or less OK
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7) Measure the angle of the brake pedal from the

pedal board.
Floor (Pedal boad)
Brake Pedal Angle (θ) degree
θ
(10.5°)
42 ± 1.5
WL
1. Brake Air Pipe
310MT006
NOTE:
Make sure that there is no brake dragging.
Brake Pedal Free Play Measurement

After installation of brake valve and pedal, measure
the pedal free play.
If the brake valve and pedal were installed certainly as
above procedure, pedal free play could be obtained
properly.
Brake Pedal Free Play (Reference) mm (in)

9.0 – 14.0 (0.35 – 0.55)
310MT011
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BRAKE VALVE (RHD MODEL)

DISASSEMBLY
13
37
12 38
36
B 14 35 for South Africa
43 34 model only
32 32
44
33 33
46
45
47 31
48
50 27
49 28
30
52 29
3
5 26
53
51 25
4 8
54 22
B
23
21
7 18
6 19
24 20
11 1
10 41
17
2 42 16
9 15
39
40
334MY00004
Disassembly Steps
1. Cotter pin 22. Valve
2. Washer 23. Valve retainer
3. Pin 24. O-ring
4. Lock pin 25. Cover
5. Pedal 26. Screw
6. Cotter pin 27. Sleeve
7. Washer 28. Washer
8. Roller pin 29. Spring
9. Roller 30. Spring
10. Adjusting screw 31. Piston
11. Lock nut 32. O-ring
12. Plunger 33. O-ring
13. Boot 34. Spring
14. Plate 35. Snap ring
15. Snap ring 36. O-ring retainer
16. Exhaust cover 37. O-ring
17. Washer 38. O-ring
18. O-ring retainer 39. Spring
19. O-ring 40. Washer
20. O-ring 41. Valve
21. Spring 42. Valve retainer
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43. Snap ring 49. Piston

44. Spring 50. O-ring
45. Bolt 51. Spring
46. Spring seat 52. Bushing
48. Spring 54. Body
Disassembly Steps
1. Cotter Pin
2. Washer
3. Pin
4. Lock Pin
5. Pedal
Remove all parts up to the lock nut in Item 11 together
with the pedal.
6. Cotter Pin
7. Washer
8. Roller Pin
9. Roller
10. Adjusting Screw
11. Lock Nut
12. Plunger
13. Boot
14. Plate
15. Snap Ring
16. Exhaust Cover
17. Washer
18. O-ring Retainer
19. O-ring
20. O-ring
21. Spring
22. Valve
23. Valve Retainer
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24. O-ring
25. Cover
26. Screw
Passage for exhaust gas should not be scratched with
screw driver.
27. Sleeve
28. Washer
29. Spring
30. Spring
31. Piston
32. O-ring
33. O-ring
34. Spring
35. Snap Ring
36. O-ring Retainer
37. O-ring
38. O-ring
39. Spring
40. Washer
41. Valve
42. Valve Retainer
43. Snap Ring
44. Spring
45. Bolt
The bolt should be loosened with the seat spring
pushed downward.
46. Spring Seat

47. Spring
48. Spring
49. Piston
50. O-ring
51. Spring
52. Bushing
53. O-ring
54. Body
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Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are
found through inspection.
Plate
Check that the difference between the maximum and
minimum inside diameters of the pin hole is less than
0.1mm.
Check the bushing that its sliding surface is free from
damage and that the plunger slides smoothly.
Plunger
The plunger must slide smoothly through the hole in
the plate.
External stepped wear must be less than 0.1mm. The
roller contact surface must be free of serious wear.
Body
The O-ring contact surface and inlet valve seat surface
must be free of scars detrimental to airtightness.
For South Africa model only
334HY00006
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Piston
Must be free of scars which can damage the body.
Relay Piston
Must be free of scars which can damage the body.
For South Africa model only
334HY00005
Cover
Pedal
Clearance between Pin and Bushing mm (in)
Standard Limit
0.015 – 0.086 (0.0006 – 0.0034) 0.4 (0.0157)
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Clearance between Roller and Pin mm (in)

Standard Limit
0.015 – 0.108 (0.0006 – 0.0043) 0.25 (0.0098)
Clearance between Plunger and Bushing mm (in)

Limit 0.49 (0.0193)
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REASSEMBLY
42
17
B 43 18
19
41 20 for South Africa
21 model only
12
22 22
11
23 23
9
10
8 24
7
5 28
6 27
26
4 25
52
50 29
3
2 30
51 47
1 33
B
32
34
48
37
49 36
31 35
45
54
44 14
53 38
13
39
46 40
15
16
334MY00005
Reassembly Steps
1. Body 22. O-ring
3. O-ring 24. Piston
4. Bushing 25. Spring
5. O-ring 26. Spring
6. Piston 27. Washer
7. Spring 28. Sleeve
8. Spring 29. Screw
9. Spring seat 30. Cover
10. Bolt 31. O-ring
11. Spring 32. Valve retainer
12. Snap ring 33. Valve
13. Valve retainer 34. Spring
14. Valve 35. O-ring
16. Washer 37. O-ring retainer
17. O-ring 38. Washer
18. O-ring 39. Exhaust cover
19. O-ring retainer 40. Snap ring
20. Snap ring 41. Plate
21. Spring 42. Boot
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43. Plunger 49. Cotter pin

44. Adjusting screw 50. Pedal
45. Lock nut 51. Lock pin
46. Roller 52. Pin
47. Roller pin 53. Washer
48. Washer 54. Cotter pin
Reassembly Steps
1. Body
Apply Airmaster paste or lithium - base grease to the
O-ring sliding surface, and metal sliding surfaces.
2. Spring
3. O-ring
4. Bushing
5. O-ring
6. Piston
O-ring groove and metal sliding surfaces.
7. Spring
8. Spring
9. Spring Seat
10. Bolt
Tighten bolt to the specified torque.
Bolt Torque N•m (kg•m / lb•in)
7 (0.7 / 61)
11. Spring
12. Snap Ring
13. Valve Retainer
14. Valve
15. Spring
16. Washer
17. O-ring
18. O-ring
19. O-ring Retainer
20. Snap Ring

21. Spring
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22. O-ring
23. O-ring
24. Piston
25. Spring
26. Spring
27. Washer
28. Sleeve
29. Screw
• Tighten the sleeve to the specified torque.
Sleeve Torque N•m (kg•m / lb•in)

2 (0.2 / 17)
• Apply Airmaster paste or lithium - base grease to

the sleeve.
• Tighten screw to the specified torque.
Screw Torque N•m (kg•m / lb•in)

7 (0.7 / 61)
30. Cover
O-ring groove.
7 (0.7 / 61)
31. O-ring
32. Valve Retainer
33. Valve
34. Spring
35. O-ring
36. O-ring
37. O-ring Retainer
38. Washer
39. Exhaust Cover

40. Snap Ring
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41. Plate
16 (1.6 / 12)
42. Boot
43. Plunger
Apply MoS2 grease to the pedal pin, roller pin and
plunger. Particularly, seal 1 cc grease between the
boot and plunger.
44. Adjusting Screw

Assemble all the parts from Item 44 to 49 with the
pedal.
45. Lock Nut

46. Roller
47. Roller Pin
48. Washer
49. Cotter Pin
50. Pedal
51. Lock Pin
52. Pin
53. Washer
54. Cotter Pin
Adjustment of Brake Pedal Free Play

After reassembling the brake valve, adjust the pedal
free play by turning the adjusting screw.
Brake Pedal Free Play mm (in)

Vehicle Model Free Play
FRR, FSR, FSS 12 – 16 (0.47 – 0.63)
FSR (RD2), FTS
10 – 14 (0.39 – 0.55)
FTR
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BRAKE VALVE (LHD MODEL)

DISASSEMBLY
1
2
6 22
3 37
36
4 38
5 7
35
8 34
9 39
10 28 33
32
12 53
14 31 52
15 30 51
16 29 50
27
17 49
18 26 45 48
11 25
19 47
46
20
24 44
21 43
23 13 40 42
41
334MT006
Disassembly Steps
1. Nut 22. Upper piston spring
2. Nut 23. O-ring
3. Dust cover 24. Relay piston
4. Plate 25. O-ring
5. Horseshoe washer 26. Relay piston spring
6. Push rod 27. Snap ring
7. Plunger 28. Primary valve assembly
8. E-ring 29. Snap ring
9. Stem plate 30. Special washer
10. Stem spring 31. O-ring
11. Upper piston assembly 32. Retainer
12. Nut 33. Primary valve spring
13. Stem 34. Valve retainer
14. Spring washer 35. Primary valve
15. Washer 36. Bushing; upper body
16. Spring seat 37. O-ring
17. Main spring 38. Upper body
18. Spring seat 39. O-ring
19. Sub spring 40. Exhaust cover assembly
20. Upper piston 41. Screw
21. Sleeve 42. Retaining washer
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43. Exhaust seat 49. Retainer

44. Exhaust cover 50. Secondary valve assembly
45. Secondary valve assembly 51. Valve retainer
46. Snap ring 52. Secondary valve
47. Washer 53. Lower body
48. O-ring
Disassembly Steps
1. Nut
2. Nut
3. Dust Cover
4. Plate
5. Horseshoe Washer
6. Push Rod
7. Plunger
8. E-ring
Hold the lower side of the stem and the relay piston.
Push the stem plate down to remove the E-ring.
9. Stem Plate
10. Stem Spring
11. Upper Piston Assembly
12. Nut
Loosen the nut to disassemble the upper piston
assembly.
13. Stem
14. Spring Washer
15. Washer
16. Spring Seat
17. Main Spring
18. Spring Seat
19. Sub Spring
20. Upper Piston
21. Sleeve
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22. Upper Piston Spring

23. O-ring
24. Relay Piston
25. O-ring
26. Relay Piston Spring
27. Snap Ring
Remove the snap ring using a snap ring plier.
28. Primary Valve Assembly

29. Snap Ring
30. Special Washer
31. O-ring
32. Retainer
33. Primary Valve Spring
34. Valve Retainer
35. Primary Valve
36. Bushing; Upper Body
37. O-ring
38. Upper Body
39. O-ring
40. Exhaust Cover Assembly
41. Screw
42. Retaining Washer
43. Exhaust Seat
44. Exhaust Cover
45. Secondary Valve Assembly
46. Snap Ring
47. Washer
48. O-ring
49. Retainer
51. Valve Retainer
52. Secondary Valve
53. Lower Body
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Make necessary correction or parts replacement if excessive wear, damage or any other abnormal
conditions are found through inspection.
Visual Check
Inspect the following parts for excessive wear,
• O-rings damage or other abnormal conditions.
• Snap ring
• Lower valve
• Upper valve
• Springs
Brake Valve Push Rod Free Play Measurement

Pull up the push rod in the illustrated direction and
make sure there is free play.
If there is no play, replace with a new brake valve.
Brake Valve Push Rod Free Play mm (in)

Push rod 0.1 – 0.8 (0.0039 – 0.0315)
310MT003
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REASSEMBLY
53 52
48 32
49 17
18
50 16
51 47
19
46 20
45 15
44 26 21
22
41 1
40 23 2
39 24 3
38 25 4
27
37 5
36 28 9 6
42 29
35 7
8
33
30 10
34 11
43 31 14 12
13
334MT007
Reassembly Steps
1. Lower body 22. Retainer
2. Secondary valve 23. O-ring
3. Valve retainer 24. Special washer
4. Secondary valve spring 25. Snap ring
5. Retainer 26. Primary valve assembly
6. O-ring 27. Snap ring
7. Washer 28. Relay piston spring
8. Snap ring 29. O-ring
9. Secondary valve assembly 30. Relay piston
10. Exhaust cover 31. Stem
11. Exhaust seat 32. Upper piston spring
12. Retaining washer 33. Upper piston
13. Screw 34. Sleeve
14. Exhaust cover assembly 35. Sub spring
15. O-ring 36. Spring seat
16. Upper body 37. Main spring
17. O-ring 38. Spring seat
18. Bushing; upper body 39. Washer
19. Primary valve 40. Spring washer
20. Valve retainer 41. Nut
21. Primary valve spring 42. Upper piston assembly
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43. O-ring 49. Dust cover

44. Stem spring 50. Plate
45. Stem plate 51. Horseshoe washer
46. E-ring 52. Nut
47. Plunger 53. Nut
48. Push rod
Reassembly Steps
Preparation
Lubricate O-rings, O-ring grooves and piston bores
with lithium base grease before reassembling the
brake valve.
1. Lower Body
2. Secondary Valve
3. Valve Retainer
4. Secondary Valve Spring
5. Retainer
6. O-ring
Apply lithium grease to the O-ring and O-ring groove.
7. Washer
8. Snap Ring
10. Exhaust Cover
11. Exhaust Seat
12. Retaining Washer
13. Screw
15. O-ring
16. Upper Body
17. O-ring
18. Bushing; Upper Body
19. Primary Valve
20. Valve Retainer
21. Primary Valve Spring
22. Retainer
23. O-ring
24. Special Washer
25. Snap Ring
26. Primary Valve Assembly
27. Snap Ring
28. Relay Piston Spring
29. O-ring
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30. Relay Piston

31. Stem
32. Upper Piston Spring
33. Upper Piston
34. Sleeve
35. Sub Spring
36. Spring Seat
37. Main Spring
38. Spring Seat
39. Washer
40. Spring Washer
41. Nut
42. Upper Piston Assembly
43. O-ring
44. Stem Spring
45. Stem Plate
46. E-ring
47. Plunger
48. Push Rod
49. Dust Cover
50. Plate
51. Horseshoe Washer
52. Nut
10.5+20 mm 53. Nut
30mm
• Apply liquid gasket (Three Bond 1305B or
equivalent) to nut threads.
• Fix double nut as figure, and tighten them to the
specified torque.
Double Nut Torque N·m (kg·m / lb·ft)
62 (6.3 / 46)
334MT010
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OPERATION TEST
Simplified Test on Brake Valve
After overhauling the brake valve, a simplified test can
be conducted as follows if necessary. Before
conducting the test, have ready a brake valve mount,
goniometer, air gauges and foot pressure gauge.
1. Set the brake valve on the brake valve mount, and
fasten it with a vice.
2. Conduct an air leak test.
1) Supply compressed air of 686 – 785kPa (7 –
8kg/cm2) to the brake valve through its supply port,
and confirm that the compressed air does not leak
from the delivery port.
2) Mount the air gauges on the brake valve at its
primary and secondary delivery ports.
3) Step on the brake pedal to the half open and full
open adjusting positions, and make sure that the
delivery ports are free of the air leakage.
Check the joints, mounting seats, exhaust port, etc.
that they are also free of air leakage.
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3. Operate the brake valve, and check if the

characteristics line diagram is satisfied.
The secondary side is the same in performance as
the primary side except that the secondary side
has a slight lower delivery pressure — 3 kPa – 13
kPa (0.03 – 0.13 kg/cm2 / 0.43 – 1.85psi) lower than
on the primary side.
1) Slowly step down on the brake pedal (or push rod),
and measure the angle (or stroke) at which the
pressure begins to build up on the delivery port
side.
For RHD, use the pedal adjusting bolt for this
adjustment.
Pressure Rising Level and Angle (or Stroke)
FRR, FSR, FSS FSR*, FTR, FTS
Less Than 44 kPa Less Than 34 kPa
(0.45 kg/cm2 / 6.4psi) (0.35 kg/cm2 / 5.0psi)
Angle (RHD) 3.5° – 4.5° 3° – 4°
Stroke (LHD) 1.4±0.3mm (0.055±0.012in)
FSR*····FSR with Heavy Duty Package (RD2)
2)
RHD
Depress the brake pedal to an angle of 12° for FRR,
FSR and FSS or 8° for FSR (RD2), FTR, FTS, keep it
there, and check the delivery pressure on the
delivery port side.
Delivery Pressure at 12° (or 8°) kPa (kg/cm2 / psi)
Model Angle Pressure
FRR, FSR, FSS 12° 137 - 216 (1.4 - 2.2 / 20 - 31)
FSR(RD2), FTR,
8° 127 - 206 (1.3 - 2.1 / 18 - 30)
FTS
LHD
Depress the brake valve push rod to stroke of
4.3mm (0.17in) for FRR and FSR, or 3.8mm (0.15in)
forFSR (RD2), FTR, keep it there, and check the
delivery pressure on the delivery port side.
Delivery Pressure at 3.8mm (4.3mm) kPa (kg/cm2 / psi)
Model Stroke Pressure
FRR, FSR 4.3 (0.17) 142 - 221 (1.45 - 2.25 / 21 - 32)
FTR,
3.8 (0.15) 177 - 255 (1.80 - 2.60 / 26 - 37)
FSR(RD2)
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3) Depress the brake pedal (or push rod) further, and

check the angle (or stroke) at which the pressure
on the supply port side is equal to the pressure on
the delivery port side.
Angle or Stroke
Model Angle or Stroke
RHD 15.5° – 18.5°
FRR, FSR 5.5 – 6.6mm (0.22 – 0.26in)
LHD FSR(RD2),
5.8 – 6.9mm (0.23 – 0.27in)
FTR
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Brake Valve Characteristic Diagram (RHD)
For FRR, FSR, FSS

MPa (Supply Air Pressue 0.7MPa)
0.7
N
0.6
Delivery Port Pressure
(Primary)
0.5
Pedal Force
0.4 400
0.33 Pedal Force
0.3 300
233
0.2 200
0.18 130
0.1 100
85
0 0
37
0 2 4 6 8 10 12 14 16 18 20 22
4±0.5 12 15.5 16+2.5
-0.5
0.045 or less
Pedal Angle (Deg.)
For FSR (RD2), FTR, FTS
MPa (Supply Air Pressue 0.7MPa)
0.7
0.6
0.5 N
(Primary)
0.4
0.4 Pedal Force 400
Pedal Force
0.3 300
233
0.2 200
142
0.17
0.1 100
80
0 0
0 2 4 6 8 10 12 14 16 18 20 22 38
3.5 ±0.5 8 13 16 +2.5
-0.5
0.034 or less Pedal Angle (Deg.)
Brake Valve Characteristic Diagram (LHD)
For FRR, FSR For FSR (RD2), FTR
5.7+0.9
-0.2 6.0+0.9
-0.2
Delivery Port Pressure (Primary) kPa
Delivery Port Pressure (Primary) kPa
Full Stroke 8.9±0.8 Full Stroke 8.9±0.8

690 690
Delivery Port
590 Delivery Port 590 Pressure
Pressure 4.8
N
490 5.5 490

Plunger Force
Plunger Force
390 4.3 1960 390 3.8 1960

333±69
392±69
290 181±39 1470 290 216±39 1470
44 or less
34 or less
150-277N
200 150-277N Plunger 980 200 Plunger 980
Force Force
98 490 98 490
471±98N at 181kPa 530±98N at 216kPa
0 0 0 0
0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10
1.4±0.3 Plunger Stroke (mm) 1.4±0.3 Plunger Stroke (mm)
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AIR BOOSTER
REMOVAL
Removal Steps
1. Air pipe
2. Fluid pipe
3. Air booster
Removal Steps
1. Air Pipe
2. Fluid Pipe
After removal, plug open ends to prevent entrance of
foreign matter.
3. Air Booster
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INSTALLATION
Installation Steps
1. Air booster
2. Fluid pipe
3. Air pipe
Installation Steps
1. Air Booster
2. Fluid Pipe
3. Air Pipe
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POWER PISTON AND SHELL

DISASSEMBLY
333MY00004
Disassembly Steps
1. Hydraulic cylinder assembly 4. Power piston assembly
2. Cylinder shell 5. Return spring
3. Nut 6. O-ring
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Disassembly Steps
1. Hydraulic Cylinder Assembly
Apply a setting mark prior to disassembly.
2. Cylinder Shell
3. Nut
Special socket wrench
4. Power Piston Assembly

5. Return Spring
6. O-ring
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REASSEMBLY
333MY00005
Reassembly Steps
1. O-ring 5. Cylinder shell
2. Return spring 6. Hydraulic cylinder assembly
3. Power piston assembly
4. Nut
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Reassembly Steps
1. O-ring
2. Return Spring
3. Power Piston Assembly
Apply Airmaster paste or lithium-base grease to the
Gasket and cylinder shell.
(g)
JKC MADE NISSIN MADE
Gasket 10 5
Cylinder shell 20 10
4. Nut
Nut Torque N•m (kg•m / lb•ft)
25 (2.5 / 18)
When fastening nuts, keep the power piston steadily.

Otherwise O-ring may cut into the push rod screw.
5. Cylinder Shell
Apply Airmaster paste or lithium-base grease to the
entire inner faces.
Align the both setting marks when installing.
JKC MADE NISSIN MADE
Bolt size 8 mm – 14 (1.4 / 10)

Bolt size 10 mm 25 (2.5 / 18) –
6. Hydraulic Cylinder Assembly
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HYDRAULIC CYLINDER ASSEMBLY

DISASSEMBLY (JKC MADE)
1
2 4
6
7
333MW004
Disassembly Steps
1. Switch 4. End plate assembly
2. Residual pressure check valve 5. Push rod
assembly 6. Straight pin
3. Exhaust end cover assembly 7. Hydraulic piston assembly
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Disassembly Steps (JKC Made)

1. Switch
2. Residual Pressure Check Valve Assembly
Remove the retaining ring with a snap ring pliers.
3. Exhaust End Cover Assembly

4. End Plate Assembly
5. Push Rod
6. Straight Pin
7. Hydraulic Piston Assembly
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DISASSEMBLY (NISSIN MADE)
2 10
6
4
9
8
5
7
333MW014
Disassembly Steps
1. Switch 6. Straight pin
2. Residual pressure check valve 7. Hydraulic piston assembly
assembly 8. Sleeve
3. Exhaust cover assembly 9. Retainer assembly
4. Snap ring 10. Push rod
5. Stop pin
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Disassembly Steps (Nissin Made)

1. Switch
2. Residual Pressure Check Valve
Remove the retaining ring with a snap ring pliers.
4. Snap Ring
Remove the snap ring with a snap ring pliers.
5. Stop Pin
6. Straight Pin
8. Sleeve
9. Retainer Assembly
10. Push Rod
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during inspection.
Visual Check
Inspect the following parts for wear, damage or other
abnormal conditions.
Make sure not to use detergents on rubber parts of
the O-ring, oil seal, valve etc., as they may deteriorate.
Hydraulic cylinder
Clearance between Hydraulic Cylinder and
Piston mm (in)
Limit 0.15 (0.006)
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REASSEMBLY (JKC MADE)
7
6 4
2
1
333MW009
Reassembly Steps
1. Hydraulic piston assembly 5. Exhaust cover assembly
2. Straight pin 6. Residual pressure check valve assembly
3. Push rod 7. Switch
4. End plate assembly
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Reassembly Steps (JKC Made)
Power piston side

Piston cup A must be installed in the right direction.
333MW013
2. Straight Pin
3. Push Rod
4. End Plate Assembly
Power piston side
When install the end plate assembly to the push rod,
make sure not to attach it from the side of push rod
power piston.
Apply silicon grease on the end plate oil seal.
333MW012

Install the retaining ring with a snap ring pliers.
7. Switch
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REASSEMBLY (NISSIN MADE)
9 1
5
7
2
3
6
4
10
333MW015
Reassembly Steps
1. Push rod 6. Stop pin
2. Retainer assembly 7. Snap ring
3. Sleeve 8. Exhaust cover assembly
4. Hydraulic piston assembly 9. Residual pressure check valve assembly
5. Straight pin 10. Switch
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Reassembly Steps (NISSIN Made)
1. Push Rod
Install the snap ring with a snap ring pliers.
2. Retainer Assembly
Power piston side
When install the retainer assembly to the push rod,
make sure not to attach it from the side of push rod
power piston.
Apply silicon grease on the retainer oil seal.
3. Sleeve
333MW010
Power piston side

Piston cup A must be installed in the right direction.
5. Straight Pin
6. Stop Pin
A
333MW011
7. Snap Ring

Install the retaining ring with a snap ring pliers.
10. Switch
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AIR CIRCUIT PARTS

during inspection.
The following air circuit parts cannot be repaired or overhauled.
Faulty parts must be replaced with new ones.
Pressure Protection Valve (Air Valve)

Performance Test
Check that the valve is closed when the air pressure
on the supply port is zero.
Check that, when the air pressure on the supply port
has risen to anywhere between 461 and 500 kPa (4.7
and 5.1 kg / cm2), the valve opens and that the air runs
to the delivery port.
Check the valve body, pipe joints, and delivery port
that they are free of air leakage.
Double Check Valve

Check that, when the delivery port is closed and air is
supplied to either of the supply ports, the other supply
port is free of air leakage.
Check the valve body and pipe joints that they are free
of air leakage.
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Air Tank Safety Valve

Operating test
1. Connect the safety valve to a tester.
2. Increase the pressure of air within the tester by
operating the air compressor.
3. The pressure gauge needle will continue to
deflect and begin to dance at a point indicating
that the safety valve is being actuated.
Operating Pressure kPa (kg / cm2 / psi)
912 (9.3 / 132)
Air Check Valve

The valve, spring and stopper are built into the joint
bolt and cannot be disassembled for inspection or
correction.
The entire check valve assembly must be replaced if
air leakage is noticeable.
1. Pressure test
Apply compressed air of 0.3 kg / cm2 into the valve
from the “A” side and feel of air at the “B” side with
hand.
2. Leak test
Connect a pipe to the “A” side of the valve and
submerge the end of the pipe into kerosene.
Apply compressed air of 2.0 kg / cm2 into the valve
from the “B” side and check air leaks at the “A” side.
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Air Tank Drain Valve

Performance test
Check that, when the ring is pulled horizontally, water
and air can be smoothly discharged.
There must be no air leakage when the ring is
released.
Air Tank Automatic Drain Valve

(If so equipped)
Performance test
Check that water will be smoothly discharged when
the air pressure inside the air tank has lowered due to
the use of air devices.
There must be no air leakage other than when air is
discharged.
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MULTI PROTECTION VALVE

Port Name and Piston No.
Secondary Side:B Primary Side:A

B A
Piston No.1
Piston No.3 Outlet Port 23 Outlet Port 21
B room A room
Inlet Port
Piston No.4 Outlet Port 24 Outlet Port 22 Piston No.2
B A
B-B A-A
320MY00004
Performance test
1. Valve opening pressure
(1) Primary
Valve opening pressure shall be as follows :
charging speed. time Duration 3~7 sec.
Time for air pressure rising 295 → 490 (3 → 5/43
→ 71) kPa (kg / cm2 / psi) under the condition
opening air at outlet 21, 22 saturation pressure of
inlet.
(2) Secondary
Valve opening pressure shall be as follows :
charging speed. time Duration 8~22 sec.
Time for air pressure rising 295 → 490 (3 → 5/43
→ 71) kPa (kg / cm2 / psi) under the condition
pressure = 0 at outlet 23, outlet 24.
2. Valve closing pressure
Minimum pressure drop shall be as follows :
Pressure drop time : 3 sec MAX. Time for drop
pressure to air pressure drop as 590 → 295 (6 → 3/
43 → 22) kPa (kg / cm2 / psi) under the condition
pressure = 930 (9.5/135) kPa (kg / cm2 / psi) at
outlet 21, outlet 22, outlet 23, and outlet 24. outlet
vol is about 0.5L
kPa (kg / cm2 / psi)
Outlet port 21, 22 23, 24
Valve opening pressure 570 (5.8/82) 570 (5.8/82)
General Export
Valve closing pressure 440 (4.5/64) 440 (4.5/64)
Valve opening pressure 640 (6.5/92) 690 (7.0/100)
South Africa (DELTA MOTOR) or China
Valve closing pressure 510 (5.2/74) 560 (5.7/81)
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3. Air tightness
(1) By-pass check valve for primary line
No air leakage at the inlet 1, when applied air
pressure of 49 (0.5 / 7) kPa (kg / cm2 / psi) and 392
(4 / 57) kPa (kg / cm2 / psi) to the inlet 1 from the
outlet 21 and 22.
(2) Center check valve
No air leakage at the outlet 21 and 22, when
applied air pressure of 49 (0.5 / 7) kPa (kg / cm2 /
psi) and 930 (9.5 / 135) kPa (kg / cm2 / psi) to the
outlet 21 and 22 from the inspection port.
(3) Check Valve for secondary line
No air leakage at the inspection port. when
applied air pressure of 49 (0.5 / 7) kPa (kg / cm2 /
psi) and 930 (9.5 / 135) kPa (kg / cm2 / psi) to the
inspection port from the outlet 23 and 24.
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AIR DRYER (DR-31 TYPE)

DISASSEMBLY
Disassembly Steps
1. Thermostat 16. Sealing ring
2. Heater 17. Case guide
3. Purge chamber 18. Oil filter
4. O-ring 19. Filter gasket
5. Cover and check valve 20. Gasket ring
6. Body 21. Snap ring
7. Set spring 22. Valve body assembly
8. O-ring 23. Exhaust cover
9. Filter plate 24. O-ring
10. Case assembly 25. Bolt and washer
11. Filter 26. Piston
12. Desiccant 27. O-ring
13. Filter 28. Valve spring
14. Filter plate 29. Valve
15. Case 30. Valve body
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Disassembly Steps
1. Thermostat
2. Heater
3. Purge Chamber
1. Remove the four bolts on the purge chamber.
2. Clamp the air dryer in a vice with soft jow.
3. Remove the remaining bolts.
WARNING:
USE CARE IN REMOVING PURGE CHAMBER BOLTS
TO PREVENT BODILY INJURY BECAUSE THE PURGE
CHAMBER IS SPRING LOADED.
4. O-ring
5. Cover and Check Valve
6. Body
7. Set Spring
8. O-ring
9. Filter Plate
10. Case Assembly
11. Filter
12. Desiccant
13. Filter
14. Filter Plate
15. Case
16. Sealing Ring
17. Case Guide
18. Oil Filter
19. Filter Gasket
20. Gasket Ring
21. Snap Ring
22. Valve Body Assembly
1. Remove the snap ring.
2. Remove the valve body assembly.
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23. Exhaust Cover

24. O-ring
25. Bolt and Washer
26. Piston
1. Clamp a 10 mm hexagon wrench in a vice.
2. Set the piston on the hexagon wrench.
3. Use a open end wrench to remove the bolt. Take
care not to scratch the piston surface.
27. O-ring
28. Valve Spring
29. Valve
30. Valve Body
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during inspection.
Thermostat
1. Cool the thermostat to bellow 0˚C (32˚F). Using an
ohmmeter, check the continuity between the two
terminals. If no continuity exists, the thermostat
should be replaced.
2. Warm the thermostat to over 20˚C (68˚F). Using an
ohmmeter, check the continuity between the two
terminals. If continuity exists, the thermostat
should be replaced.
Heater
Make a continuity test between heater terminal and
body. If no continuity exists, the heat wire is broken
and the heater should be replaced.
Cover
Check the operation of the check valve.
Desiccant
If the desiccant is contaminated, it should be replaced.
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Piston
The valve body contact surface must be free from
damage.
Valve
Valve body seat surface must be free from damage.
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REASSEMBLY
Reassembly Steps
1. Body 16. O-ring
2. Gasket ring 17. Cover and check valve
3. Filter gasket 18. Purge chamber
4. Oil filter 19. Valve body
5. Case 20. O-ring
6. Filter plate 21. Piston
7. Filter 22. Valve spring
8. Desiccant 23. Valve
9. Filter 24. Bolt and washer
10. Case assembly 25. O-ring
11. Case guide 26. Exhaust cover
12. Sealing ring 27. Valve body assembly
13. O-ring 28. Snap ring
14. Filter plate 29. Heater
15. Set spring 30. Thermostat
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Reassembly Steps
1. Body
2. Gasket Ring
3. Filter Gasket
4. Oil Filter
1. Install the filter gasket to the Oil filter.
2. Install the Oil filter into the body.
5. Case
6. Filter Plate
7. Filter
The side of soft must be facing up.
8. Desiccant
1. Pour the entire package of desiccant material into
the case making sure none is lost.
2. While slowly turning the case, tap the side of the
case with a plastic mallet.
3. Install the filter, soft side down.
9. Filter
10. Case Assembly
1. Install the case assembly to the body.
2. Install the case guide between the body and the
case.
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11. Case Guide

12. Sealing Ring
1. Apply a coat of silicon grease to the sealing ring.
2. Install the sealing ring to the body.
13. O-ring
1. Apply a coat of silicon grease to the O-ring.
2. Install the O-ring to the groove in the body.
14. Filter Plate

15. Set Spring
16. O-ring
2. Install the O-ring to the cover.

18. Purge Chamber
1. Install the cover and the purge chamber to the
body.
2. Tighten the bolts to the specified torque.
Purge Chamber Bolts Torque N•m (kg•m / lb•in)
12 (1.2 / 104)
19. Valve Body

20. O-ring
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21. Piston
2. Install the O-ring to the piston.
22. Valve Spring

1. Apply a coat of silicon grease to the valve body
bore.
2. Install the valve spring to the valve. Take care not
to scratch the O-ring.
23. Valve
24. Bolt and Washer
1. Clamp a 10 mm hexagon wrench in a vise.
3. Tighten the bolt to the specified torque.
6 (0.6 / 52)
25. O-ring
2. Install the O-ring to the valve body.
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26. Exhaust Cover

1. Use a hammer to install the exhaust cover to the
valve body.
27. Valve Body Assembly

1. Apply a coat of silicon grease to the bore of the
body.
2. Install valve body assembly to the body. Take care
not to scratch the O-ring.
28. Snap Ring

29. Heater
30. Thermostat
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AIR DRYER (DR-41 TYPE)

DISASSEMBLY
Disassembly Steps
1. Thermostat 17. O-ring
2. Heater 18. O-ring
3. Purge chamber 19. Gasket ring
4. Case assembly 20. Body assembly
5. Cover and check valve 21. Stop ring
6. Set spring 22. Exhaust cover
7. Filter plate 23. Bolt and washer
8. Filter 24. Valve
9. Desiccant 25. Valve spring
10. Filter 26. Piston
11. Filter plate 27. O-ring
12. Screw and seal washer 28. Snap ring
13. Oil filter 29. Body
14. O-ring 30. Valve body
15. Case 31. O-ring
16. O-ring
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Disassembly Steps
1. Thermostat
2. Heater
3. Purge Chamber
4. Case Assembly
Press the cover with one hand, until the four screws
have been removed.
6. Set Spring
7. Filter Plate
8. Filter
9. Desiccant
10. Filter
11. Filter Plate
12. Screw and Seal Washer
13. Oil Filter
14. O-ring
15. Case
16. O-ring
17. O-ring
18. O-ring
19. Gasket Ring
20. Body Assembly
21. Stop Ring
22. Exhaust Cover
23. Bolt and Washer
3. Use a 8 mm socket wrench to remove the bolt.
Take care not to scratch the body surface to the
piston.
24. Valve
25. Valve Spring
26. Piston
27. O-ring
28. Snap Ring
29. Body
30. Valve Body
31. O-ring

during inspection.
See AIR DRYER (DR-31 TYPE) “INSPECTION AND REPAIR”, page 5A-113.
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REASSEMBLY
Reassembly Steps
1. O-ring 17. Case
2. Valve body 18. O-ring
3. Body 19. Oil filter
4. Snap ring 20. Screw and seal washer
5. O-ring 21. Filter plate
6. Piston 22. Filter
7. Valve spring 23. Desiccant
8. Valve 24. Filter
9. Bolt and washer 25. Filter plate
10. Exhaust cover 26. Set spring
11. Stop ring 27. Cover and check valve
12. Body assembly 28. Case assembly
13. Gasket ring 29. Purge chamber
14. O-ring 30. Heater
15. O-ring 31. Thermostat
16. O-ring
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Reassembly Steps
1. O-ring
2. Install the O-ring to the groove in the valve body.
2. Valve Body
1. Apply a coat of silicon grease to the bore of the
body.
2. Install valve body to the body. Take care not to
scratch the O-ring.
3. Body
4. Snap Ring
5. O-ring
6. Piston
2. Install the O-ring to the piston.
3. Apply a coat of silicon grease to the valve body
bore and the piston metal sliding surface.
4. Install the valve spring to the valve body. Take
care not to scratch the O-ring.
7. Valve Spring
8. Valve
9. Bolt and Washer
3. Tighten the bolt to the specified torque.
6 (0.6 / 52)
10. Exhaust Cover

1. Use a hammer to install the exhaust cover to the
valve body.
11. Stop Ring
12. Body Assembly
13. Gasket Ring
2. Install the O-ring to the body.
14. O-ring
15. O-ring
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OPERATION TEST
Operation Test
1. Check that the purge noise continues for
approximately three(3) seconds when governor
cut-out pressure is reached.
2. After the air compressor has switched from
unload to load state following fall of the air
pressure, the leak from the air dryer exhaust port
should be less than 20 cc in one minute. (A 15
mm (0.59 in.) soap bubble in 6 seconds is
permissible.)
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PARKING BRAKE 5C-1
SECTION 5C
PARKING BRAKE
CONTENTS
PAGE
General Description ........................................................................................................ 5C- 2
Parking Brake .................................................................................................................. 5C- 5
Disassembly ................................................................................................................ 5C- 5
Inspection and Repair ................................................................................................ 5C- 7
Reassembly ................................................................................................................ 5C- 8
Rear Wheel Parking Brake.............................................................................................. 5C- 11
Removal ...................................................................................................................... 5C- 11
Installation .................................................................................................................. 5C- 12
Spring Brake Chamber .................................................................................................. 5C- 14
Disassembly ................................................................................................................ 5C- 14
Reassembly ................................................................................................................ 5C- 16
Air Circuit Parts .............................................................................................................. 5C- 18
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5C-2 PARKING BRAKE
GENERAL DESCRIPTION
Parking Brake Lever
Parking Brake Assembly
The parking brake is a mechanically operated internal- The control cable is routed into the vehicle cab where
expanding type drum brake. It is mounted on the rear it is connected to the parking brake lever.
of the transmission case.
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PARKING BRAKE 5C-3
Rear Wheel Parking Brake
The rear wheel parking brake system is available as Parking brake operation is controlled by the parking
an option. brake control valve.
This type of parking brake applies braking force Exhausting the compressed air in the spring brake
through the rear wheel brake cylinders instead of the chamber, the spring force provides the braking force.
propeller shaft.
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5C-4 PARKING BRAKE
Quick Release Valve
The quick release valve is part of the optional rear control valve, spring force opens the exhaust port to
wheel parking brake system. release the air from the chamber into the atmosphere.
As compressed air is released from the parking brake
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PARKING BRAKE 5C-5
PARKING BRAKE
DISASSEMBLY
Disassembly Steps
1. Lock nut and adjusting nut 12. Lever
2. Bolt and nut 13. Washer
3. Cotter pin, washer and waved 14. Brake shoe and support plate
washer 15. Return spring
4. Cable 16. Anchor pin brace
5. Lever assembly 17. Camshaft
6. Nut (or bolt) 18. Brake shoe assembly
7. O-ring 19. Spring: adjuster
8. Drum with cover and flange 20. Adjusting screw
9. Flange 21. Brake shoe
10. Spring 22. Support plate
11. Nut, spring washer and bolt 23. Dust cover
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5C-6 PARKING BRAKE
Disassembly Steps
1. Lock Nut and Adjusting Nut
2. Bolt and Nut
3. Cotter Pin, Washer and Waved Washer
4. Cable
5. Lever Assembly
6. Nut (or bolt)
7. O-ring
8. Drum with Cover and Flange
9. Flange
10. Spring
11. Nut, Spring Washer and Bolt
12. Lever
13. Washer
14. Brake Shoe and Support Plate
15. Return Spring
Remover: 9-8523-1554-0
16. Anchor Pin Brace

17. Camshaft
19. Spring: adjuster
20. Adjusting Screw
21. Brake Shoe
22. Support Plate
23. Dust Cover
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PARKING BRAKE 5C-7

during inspection.
Visual check
Inspect the following parts for wear, corrosion, scuffs,
scratches, deterioration or other abnormal conditions.
Brake Drum
mm (in)
Trans
mission Standard Limit
model
Brake drum MBJ 216 (8.50) 218 (8.58)
size inside
diameter MLD, A/T 254 (10.0) 256 (10.08)
Uneven wear
and or score Run out 0.05 (0.002) or less
Return Spring
mm (in)
Transmission model MBJ MLD, A/T
Brake drum size 216 (8.50) 254 (10.0)
Free length 54.7 (2.154) 68 (2.677)
Set load N 152 181
(kg / lb) (15.5 / 34.18) (18.5 / 40.79)
Set length 58 (2.283) 75 (2.953)
Note: A/T...Automatic Transmission
Brake Lining
Clearance to Rivet Head mm (in)
Limit 0.5 (0.0197)
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5C-8 PARKING BRAKE
REASSEMBLY
Reassembly Steps
1. Dust cover 13. Bolt, spring washer and nut
2. Support plate 14. Spring
3. Brake shoe 15. Flange
4. Adjusting screw 16. Drum with cover and flange
5. Spring: adjuster 17. O-ring
6. Brake shoe assembly 18. Nut (or bolt)
7. Camshaft 19. Lever assembly
8. Anchor pin brace 20. Cable
9. Return spring 21. Waved washer, washer and cotter pin
10. Brake shoe and support plate 22. Bolt and nut
11. Washer 23. Adjusting nut and lock nut
12. Lever
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PARKING BRAKE 5C-9
Reassembly Steps
1. Dust Cover
2. Support Plate
123 (12.5 / 90)
3. Brake Shoe
4. Adjusting Screw
5. Spring: adjuster
7. Camshaft
8. Anchor Pin Brace
9. Spring
Spring installer: 9-8523-1554-0
10. Brake Shoe and Support Plate

11. Washer
12. Lever
13. Bolt, Spring Washer and Nut
14. Spring
15. Flange
16. Drum with Cover and Flange
17. O-ring
Discard the used O-ring and install a new one.
18. Nut (or Bolt)
Transmission model Torque
MBJ 588 (60 / 434)
MLD 785 (80 / 579)
Automatic 147 (15 / 108)
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5C-10 PARKING BRAKE
19. Lever Assembly

20. Cable
21. Waved Washer, Washer and Cotter Pin
22. Bolt and Nut
23. Adjusting Nut and Lock Nut
Adjust the parking brake after installation of the
parking brake assembly.
For “PARKING BRAKE ADJUSTMENT” refer to
SERVICING (page 00-32).
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PARKING BRAKE 5C-11
REAR WHEEL PARKING BRAKE

REMOVAL
Removal Steps
1. Pin and Cotter Pin
2. Air Pipe
3. Spring brake chamber
Removal Steps
2. Air Pipe
Before disconnecting the air pipe from the spring
brake chamber, release compressed air with the
parking brake control valve.
3. Spring Brake Chamber
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5C-12 PARKING BRAKE
INSTALLATION
Installation Steps
1. Spring brake chamber
2. Air pipe
3. Pin and cotter pin
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PARKING BRAKE 5C-13
Installation Steps
1. Spring Brake Chamber
Tighten the power chamber assembly bolts to the
specified torque.
Spring Brake Chamber Bolt Torque N•m (kg•m / lb•ft)
76 (7.8 / 56)
2. Air Pipe
1. Tighten the air pipe flare nut to the specified
torque.
Air Pipe Flare Nut Torque N•m (kg•m / lb•ft)
47 (4.8 / 35)
2. Detach the push rod.

3. Fill the spring brake chamber with air of the
specified pressure.
4. Pull the rod on the wheel cylinder side outward by
hand, rotate the turn buckle to shorten the
pushrod to the proper length, attach the jaw joint
and insert the pin.
NOTE:
The wheel cylinder will be damaged if the air
chamber is filled before the push rod is detached.
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5C-14 PARKING BRAKE
SPRING BRAKE CHAMBER

DISASSEMBLY
Disassembly Steps
1. Rod clevis 6. Upper cover assembly
2. Stud 7. Diaphragm
3. Rod turn-buckle 8. Rod assembly
4. Rod guard 9. Spring
5. Clamp ring 10. Lower cover assembly
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PARKING BRAKE 5C-15
Disassembly Steps
1. Rod Clevis
2. Stud
3. Rod Turn-buckle
4. Rod Guard
5. Clamp Ring
Before disassembly, apply setting mark to the upper
cover assembly, clamp ring and lower cover assembly
to ensure reassembly of them into original position.
Apply pressure onto the lower cover and upper cover
with a bench press to remove the clamp ring.
6. Upper Cover Assembly
Gradually release a bench press until spring is fully
stretched, then remove the upper cover assembly.
7. Diaphragm
8. Rod Assembly
9. Spring
10. Lower Cover Assembly

during inspection.
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5C-16 PARKING BRAKE
REASSEMBLY
Reassembly steps
1. Lower cover assembly 6. Clamp ring
2. Spring 7. Rod guard
3. Rod assembly 8. Rod turn-buckle
4. Diaphragm 9. Stud
5. Upper cover assembly 10. Rod clevis
Reassembly Steps
1. Lower Cover Assembly
2. Spring
3. Rod Assembly
4. Diaphragm
5. Upper Cover Assembly
Align setting mark on lower cover with that on upper
cover. Apply pressure gradually with a bench press.
6. Clamp Ring
19 (1.9 / 14)
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PARKING BRAKE 5C-17
7. Rod Guard
8. Rod Turn-buckle
9. Stud
10. Rod Clevis
Length of Push Rod mm (in)
Model L
FRR 282 (11.10)
FSR 273.5 (10.77)
FTR 309 (12.17)
FSS 273.5 (10.77)
FTS 333 (13.11)
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5C-18 PRAKING BRAKE
AIR CIRCUIT PARTS

during inspection.
The following air circuit parts cannot be repaired or overhauled.
Faulty parts must be replaced with new ones.
Parking Brake Control Valve

1. LEAKAGE TEST
1. With the valve handle in the fully applied
(parking) position, connect 785 kPa (8 kgf / cm2)
air supply to the inlet port. Check for exhaust port
leakage.
PA
RK
IN
G
RE
LE
AS
E
2. With the valve handle in the released position,

connect 785 kPa (8 kgf / cm2) air supply to the inlet
port. Check for exhaust port leakage.
A 15 mm (0.59 in.) soap bubble in 15 seconds is
permissible.
2. INSPECTION
1. Connect 686 kPa (7 kg / cm2) air supply to the inlet
port and a gauge to the delivery port.
2. Move the valve handle slowly to the applied
position. Inspect for the point where the pressure
gauge shows the first rise.
Quick Release Valve

PERFORMANCE TEST
The relationship between supply port pressure and
delivery port pressure is as shown at left. Check the
valve body, pipe joints, and exhaust port that they are
free of air leakage.
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AIR COMPRESSOR AND GOVERNOR 5D-1
SECTION 5D
AIR COMPRESSOR AND GOVERNOR
CONTENTS
PAGE
General Description ........................................................................................................ 5D- 2
Air Compressor .............................................................................................................. 5D- 3
Disassembly ................................................................................................................ 5D- 3
Inspection and Repair ................................................................................................ 5D- 9

Reassembly ................................................................................................................ 5D- 16
Air Governor .................................................................................................................... 5D- 23
Inspection and Repair ................................................................................................ 5D- 23
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5D-2 AIR COMPRESSOR AND GOVERNOR
GENERAL DESCRIPTION
Unloader
Unloader
Air outlet Air outlet
Air inlet
Air inlet
Inlet valve Delivery valve Inlet valve

Delivery valve
for 6HH1 engine (EURO-2 model) for 6HH1 engine (except EURO-2 model)
Air outlet
Unloader
Air inlet
Inlet valve
Delivery valve
039MY00001
The air compressor is directly mounted to the the air pressure is regulated by the air governor.
cylinder body rear left side. The compressor unloader is also regulated by the
The air compressor is a reciprocating type driven by governor.
the injection pump timing gear. The system acts to maintain constant air pressure
The air compressor delivers air to the air tank where resulting in improved fuel economy.
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AIR COMPRESSOR
DISASSEMBLY (6HH1 EURO-2 MODEL)
10
8
7
3 9
11
6
2
12
13
14 15
039MY001
Disassembly Steps
1. Nut 9. Piston
2. Injection pump timing gear 10. Piston ring
3. Unloader 11. Connecting rod assembly
4. Cylinder head 12. Bearing cover
5. Gasket 13. Crankshaft and bearing
6. Cylinder and O-ring 14. Oil seal
7. Snap ring 15. Crankcase
8. Piston pin
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Disassembly steps
1. Nut
2. Injection Pump Timing Gear
1. Clamp the injection pump timing gear in a vise.
Take care not to damage the timing gear.
2. Loosen the nut.
3. Use a remover to remove the injection pump
timing gear.
3. Unloader
4. Cylinder Head
5. Gasket
6. Cylinder and O-ring
7. Snap Ring
Use snap ring pliers to remove the snap ring.
8. Piston Pin
9. Piston
10. Piston Ring
Use a piston ring replacer to remove the piston ring.
11. Connecting Rod Assembly

1. Straighten the connecting rod nut lock plate tang.
2. Loosen the connecting rod nuts.
3. Remove the connecting rod.
NOTE:
Do not attempt to remove the connecting rod cap
bolts.
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12. Bearing Cover

13. Crankshaft and Bearing
1. Use a mallet to drive out the crankshaft end.
Take care not to damage the crankshaft .
2. Remove the crankshaft with the bearing cover
from the crankcase.
3. Remove the bearing cover from the crankshaft.
14. Oil Seal (for 6S series engine type)

15. Crankcase
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DISASSEMBLY (EXCEPT 6HH1 EURO-2 MODEL)
5
4
2 6
8
10
9
3
11
6HH1 9
11
6HE1-TC
039MY00003
Disassembly Steps
1. Unloader 6. Piston
2. Cylinder head assembly and gasket 7. Piston ring assembly
3. Cylinder body and O-ring and Oil 8. Bearing cover and O-ring
seal 9. Bearing
4. Snap ring 10. Connecting rod
5. Piston pin 11. Crankshaft and bearing
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Disassembly Steps
1. Unloader
2. Cylinder Head Assembly and Gasket
3. Cylinder Body and O-ring
Remove the four bolts which connect the cylinder with
the crank case.
Tap out the cylinder from the crank case with a
wooden hammer.
4. Snap Ring
5. Piston Pin
Remove the snap ring using a snap ring pliers.
6. Piston
7. Piston Ring Assembly
Remove the piston ring using a piston ring pliers.
8. Bearing Cover and O-ring and Oil Seal

9. Bearing
Remove the bearing using a bearing remover or gear
remover.
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10. Connecting Rod

Remove the bearing using a bench press.
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during inspection.
Cylinder Head
Cylinder Head
Check the cylinder head for cracking.
If the cylinder head is cracked, it must be replaced.
Inlet Valve (In The Cylinder Head)
Check the valve spring and the valve seat for
excessive wear or damage.
If the inlet valve is excessively worn or damaged, the
entire cylinder head must be replaced.
Delivery Valve (In The Cylinder Head)
Check the valve excessive wear or damage.
If the valve is excessively worn or damaged, the entire
cylinder head must be replaced.
Unloader
1. Remove the unloader valve and spring from the
body.
2. Check the unloader valve for excessive wear or
damage.
If the unloader valve is excessively worn or
damaged, it must be replaced.
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Cylinder
Cylinder Bore and Piston Clearance
Cylinder Bore Uneven Wear
1. Use a cylinder indicator to measure the cylinder
bore.
If the uneven wear exceeds the specified limit, the
cylinder must be replaced.
Cylinder Bore Uneven Wear mm (in)
Cylinder bore size Limit
70 (2.756)
0.1 (0.004)
85 (3.347)
Cylinder Bore (Reference) mm (in)

Cylinder bore size Standard
70 (2.756) 70.00 – 70.03 (2.756 – 2.757)
85 (3.347) 85.00 – 85.03 (3.346 – 3.348)
2. Use a micrometer to measure the piston outside

diameter.
Piston Outside Diameter (Reference) mm (in)

70 (2.756) 69.93 – 69.95 (2.753 – 2.754)
85 (3.347) 84.91 – 84.93 (3.343 – 3.344)
3. Calculate the cylinder bore and piston clearance.

Cylinder Bore and Piston Clearance mm (in)
Cylinder bore size Standard Limit

0.05 – 0.10
70 (2.756)
(0.0020 – 0.0039)
0.2 (0.008)
0.07 – 0.12
85 (3.347)
(0.0028 – 0.0047)
If the clearance exceeds the specified limit, the

cylinder and/or the piston must be replaced.
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Piston
Piston and Piston Pin Clearance
1. Use a cylinder indicator to measure the piston pin
bore.
Piston Pin Bore (Reference) mm (in)
16.006 – 16.017 (0.630 – 0.631)
2. Use a micrometer to measure the piston pin

diameter.
Piston Pin Diameter (Reference) mm (in)
Cylinder bore size Diameter
70 (2.756) 15.995 – 16.000 (0.6297 – 0.6299)
85 (3.347) 15.991 – 16.000 (0.6296 – 0.6299)
3. Calculate the piston and piston pin clearance.

Piston and Piston Pin Clearance mm (in)
0.006 – 0.022
70 (2.756)
(0.0002 – 0.0009)
0.1 (0.004)
0.006 – 0.026
85 (3.347)
(0.0002 – 0.0010)

piston and/or the piston pin must be replaced.
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Piston Ring and Piston Ring Groove Clearance

Use a feeler gauge to measure the clearance between
the piston ring and the piston ring groove at several
points around the piston.
Piston Ring and Piston Ring Groove
Clearance mm (in)
Cylinder bore 70mm type Standard Limit
Compression Ring 0.015 – 0.055

(0.0006 – 0.0021)
0.15
0.02 – 0.06 (0.0060)
Oil Ring
(0.0007 – 0.0023)
Piston Ring and Piston Ring Groove

Clearance mm (in)
Cylinder bore 85 mm type Standard Limit
Compression Ring 0.02 – 0.05

(0.0008 – 0.0020) 0.15
0.03 – 0.07 (0.0060)
Oil Ring
(0.0012 – 0.0028)
If the clearance exceeds the specified limit, the piston

ring must be replaced.
Piston Ring Gap

Use a feeler gauge to measure the piston ring gap.
Do not allow the piston ring to slant to one side or the
other. It must be perfectly horizontal.
Piston Ring Gap (Cylinder bore 70 mm type) mm (in)
Standard Limit
0.10 – 0.25
Compression Ring
(0.0039 – 0.0098)
1.0 (0.039)
Oil Ring 0.10 – 0.30
(0.0039 – 0.012 )
Piston Ring Gap (Cylinder bore 85 mm type) mm (in)

Standard Limit
0.15 – 0.30
Compression Ring
(0.006 – 0.012)
1.0 (0.039)
0.15 – 0.35
Oil Ring
(0.006 – 0.014)
If the measured value exceeds the specified limit, the

piston ring must be replaced.
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Connecting Rod
Connecting Rod Small End and Piston Pin clearance
1. Use a cylinder indicator to measure the
connecting rod small end inside diameter.
Connecting Rod Small End Inside Diameter
(Reference) mm (in)
Standard
16.006 – 16.017 (0.6300 – 0.6305)
2. Use a micrometer to measure the piston pin

diameter.
Piston Pin Diameter (Reference) mm (in)
Cylinder bore size Diameter

70 (2.756) 15.995 – 16.000 (0.6297 – 0.6299)
85 (3.347) 15.991 – 16.000 (0.6296 – 0.6299)
3. Calculate the connecting rod small end and piston

pin clearance.
Connecting Rod Small End and Piston Pin
Clearance mm (in)
0.006 – 0.022
70 (2.756)
(0.0002 – 0.0009)
0.1 (0.004)
0.006 – 0.026
85 (3.347)
(0.0002 – 0.0010)

connecting rod and/or the piston pin must be
replaced.
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Connecting Rod Big End Bearing and Crankpin Clearance

1. Use a cylinder indicator to measure the
connecting rod big end inside diameter.
Connecting Rod Big End Inside Diameter
(Reference) mm (in)
70 (2.756) 40.009 – 40.034

85 (3.347) (1.5751 – 1.5761)
2. Use a micrometer to measure the crankpin

diameter.
Crankpin Diameter (Reference) mm (in)
70 (2.756) 39.959 – 39.975

85 (3.347) (1.5732 – 1.5738)
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3. Calculate the clearance between the connecting

rod big end and the crankpin.
Connecting Rod Big End Bearing and
Crankpin Clearance mm (in)
Standard Limit
0.034 – 0.075 0.15

(0.0013 – 0.0030) (0.006)

connecting rod and/or the crankshaft must be
replaced.
Crankshaft
Crankshaft and Ball Bearing
1. Check the oil seal fitting faces for excessive wear
and damage.
If the fitting faces are excessively worn or
damaged, they must be replaced.
2. Listen for excessive bearing operating noise.
Excessive bearing operating noise indicates
severe bearing wear.
The bearings must be replaced.
Ball Bearing Replacement
Ball Bearing Removal
1. Set the bearing remover 1 to the ball bearing.
2. Place the crankshaft 2 with the bearings installed
between the base plates 3 of the bench press.
3. Use the bench press to gradually apply pressure
to the crankshaft to remove the ball bearings from
the crankshaft.
Take care not to damage the crankshaft.
Ball Bearing Installation

1. Place the ball bearings 1 between the base plates
2.
2. Apply engine oil to the crankshaft.
3. Set the crankshaft to the ball bearings.
4. Use the bench press to gradually press the
crankshaft down until the two ball bearings are
correctly positioned.
Be absolutely sure that the bearing inner race is
supported by the base plates.
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REASSEMBLY (6HH1 EURO-2 MODEL)
9
13 8
12
11
15
10
14
2 1
039MY00002
Ressembly Steps
1. Crankcase 9. Snap ring
2. Oil seal 10. Cylinder and O-ring
3. Crankshaft and bearing 11. Gasket
4. Bearing cover 12. Cylinder head
5. Connecting rod assembly 13. Unloader
6. Piston ring 14. Injection pump timing gear
7. Piston 15. Nut
8. Piston pin
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Reassembly Steps
1. Crankcase
2. Oil Seal
1. Install the oil seal to the crankcase.
The oil seal lip must be facing the bearing.
2. Apply engine oil to the oil seal lip.
3. Set the crankshaft and bearing to the crankcase.
4. Use the bench press to gradually insert the
crankshaft until the crankshaft bearing makes
contact with the crankcase.
4. Bearing Cover
6 (0.6 / 4.3)
5. Connecting Rod Assembly

1. Apply engine oil to the connecting rod bearings.
2. Install the connecting rod to the crankshaft.
3. Tighten the connecting rod nuts to the specified
torque.
Connecting Rod Bolt Torque N•m (kg•m / lb•ft)
25 (2.5 / 18)
4. Bend back the connecting rod lock plate tangs.
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6. Piston Ring
Use a piston ring replacer to install the piston rings to
the piston ring grooves.
The piston ring punched mark must be facing the
cylinder head.
7. Piston
8. Piston Pin
9. Snap Ring
1. Set the piston to the connecting rod small end.
2. Insert the piston pin to the piston and the
connecting rod.
3. Use snap ring pliers to install the snap rings to the
piston.
10. Cylinder and O-Ring

1. Apply engine oil to the O-ring circumference.
2. Apply engine oil to the cylinder bore and the
piston.
3. Position the piston ring gaps as shown in the

illustration.
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4. Install the cylinder to the piston and the

crankcase.
5. Tighten the cylinder bolts to the specified torque.
Cylinder Bolt Torque N•m (kg•m / lb•ft)
29 (3.0 / 22)
11. Gasket
12. Cylinder Head
1. Install the cylinder head to the cylinder.
The air inlet port must be facing the injection
pump.
2. Tighten the cylinder head bolts to the specified
torque.
Cylinder Head Bolt Torque N•m (kg•m / lb•ft)

49 (5.0 / 36)
13. Unloader
Tighten the unloader to the specified torque.
Unloader Torque N•m (kg•m / lb•ft)
49 (5.0 / 36)
14. Injection Pump Timing Gear

15. Nut
1. Install the injection pump timing gear to the
crankshaft.
2. Clamp the injection pump timing gear assembly
in a vise to prevent the crankshaft from turning.
Take care not to damage the crankshaft.
3. Tighten the injection pump timing gear nut to the
specified torque.
Injection Pump Timing Gear Nut
255 (26.0 / 188)
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REASSEMBLY (EXCEPT 6HH1 EURO-2 MODEL)
11
7
8
10 6
4
3
9
6HE1-TC 3
6HH1
Reassembly Steps
1. Crankshaft and bearing 6. Piston
2. Connecting rod 7. Piston pin
3. Bearing 8. Snap ring
4. Bearing cover and O-ring and Oil 9. Cylinder body and O-ring
seal 10. Cylinder head assembly and gasket
5. Piston ring assembly 11. Unloader
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Reassembly Steps
2. Connecting Rod
3. Bearing
Use a bench press and suitable bar to reassemble
each parts.
4. Bearing Cover and O-ring and Oil seal

Bearing Cover Bolt Torque
6HE1-TC 8 (0.8 / 69) N•m (kg•m / lb•in)
6HH1 23 (2.3 / 17) N•m (kg•m / lb•ft)
5. Piston Ring Assembly

• The 1st and 2nd rings should be installed with the
“R” mark turned up.
• Install the piston ring using a piston ring pliers.
• Set the piston rings to position as recommended.
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6. Piston
7. Piston Pin
8. Snap Ring
9. Cylinder Body and O-ring
Cylinder Body Bolt Torque N•m (kg•m / lb•ft)
29 (3.0 / 22)
10. Cylinder Head Assembly and Gasket

Cylinder Head Bolt and
Unloader Valve Torque N•m (kg•m / lb•ft)
49 (5.0 / 36)
11. Unloader
Tighten the unloader to the specified torque.
Unloader Torque N•m (kg•m / lb•ft)
49 (5.0 / 36)
After reassembling the air compressor, install the

drive gear to the specified torque.
Drive Gear Nut Torque N•m (kg•m / lb•ft)
147 (15.0 / 108)
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AIR GOVERNOR
during inspection.
This part cannot be overhauled. If it is found faulty, replace its assembly with a new one.
1. Operating Test
Start the engine and check for an increase in the
pressure of air within the air tank using a pressure
gauge. Check to make certain compressor action
stops as the reading of the pressure gauge reaches
760 – 800 kPa (7.8 – 8.2 kg / cm2).
For South Africa: 790 – 830 kPa (8.1 – 8.5 kg/cm2).
NOTE:
Charging action of the compressor can be checked
easily by hand-feeling the pulse at the air pipe
between the compressor and air tank. When a pulse
is felt, it indicates that the air tank is being charged.
Operating pressure kPa (kg / cm2 / psi)
General Export 780 ± 20 (8 ± 0.2 / 114 ± 3)
For South Africa 830 +0
±40(8.5 +0
–40 ±0./ 121 +0
–0.4 ±)
–6
2. Low Pressure Valve Leak Test

With the engine running at idle, depress and release
the brake pedal repeatedly to discharge air and check
to make certain the compressor starts charging when
pressure of air within the air tank is lowered to 670 –
710 kPa (6.8 – 7.2 kg / cm2).
For South Africa: 700 – 740 kPa (7.1 – 7.5 kg/cm2).
Operating pressure kPa (kg / cm2 / psi)
General Export 690 ± 20 (7 ± 0.2 / 100 ± 3)
+0 +0 +0
For South Africa 740 –40
±40 (7.5 –0.4
±0. / 107 –6
±)
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EXHAUST BRAKE 5E-1
SECTION 5E
EXHAUST BRAKE
CONTENTS
PAGE
General Description ........................................................................................................ 5E- 2
Exhaust Brake ................................................................................................................ 5E- 3
Removal ...................................................................................................................... 5E- 3
Installation .................................................................................................................. 5E- 4
Exhaust Brake Valve ...................................................................................................... 5E- 6
Disassembly ................................................................................................................ 5E- 6
Inspection and Repair ................................................................................................ 5E- 7
Reassembly ................................................................................................................ 5E- 8
Control Cylinder .............................................................................................................. 5E- 10
Disassembly ................................................................................................................ 5E- 10
Inspection and Repair ................................................................................................ 5E- 11
Reassembly ................................................................................................................ 5E- 12
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5E-2 EXHAUST BRAKE
GENERAL DESCRIPTION
The exhaust brake system, when turned on, increases with compressed air, the control cylinder pushes the
the amount of power absorbed by the engine while exhaust brake valve shut. With the exhaust brake
coasting with the clutch engaged. valve shut, exhaust pressure allows the engine to
When both accelerator and clutch pedals are in the become a more effective brake.
released position, current flows to the exhaust brake If the accelerator or clutch pedal is pushed in, the
switch. Both the accelerator switch and clutch switch accelerator switch or clutch switch opens. The power
are normally closed. When the exhaust brake switch supply to the magnetic valve is interrupted. The
is turned on, current flows to the magnetic valve and magnetic valve closes, removing air pressure from
to the indicator light. When energized, the magnetic the control cylinder. The control cylinder then pulls
valve opens, allowing compressed air to flow from the exhaust brake valve back open. Normal engine
the air tank to the control cylinder. When supplied operation resumes.
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EXHAUST BRAKE 5E-3
EXHAUST BRAKE
REMOVAL
Removal steps
1. Flexible hose 3. Control cylinder
2. Valve assembly 4. Bracket
Removal Steps
1. Flexible Hose
2. Valve Assembly
3. Control Cylinder
Plug the open holes of the removed parts to prevent
the entry of foreign material.
4. Bracket
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5E-4 EXHAUST BRAKE
INSTALLATION
Installation Steps
1. Bracket 3. Valve assembly
2. Control cylinder 4. Flexible hose
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EXHAUST BRAKE 5E-5
Installation Steps
1. Bracket
2. Control Cylinder
Tighten the control cylinder and bracket bolts to the
specified torque.
Control Cylinder and
Bracket Bolt Torque N•m (kg•m / lb•ft)
24 (2.4 / 17)
3. Valve Assembly
1. Tighten the valve assembly and bracket bolts to
the specified torque.
Valve Assembly and
Bracket Bolt Torque N•m (kg•m / lb•ft)
13 (1.3 / 113)
2. Connect the links.

3. Adjust the valve lever stop bolt so that control
cylinder shaft will be 0.5 mm (0.020 in) taken out.
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5E-6 EXHAUST BRAKE
EXHAUST BRAKE VALVE

DISASSEMBLY
Disassembly Steps
1. Brake valve lever 3. Seal ring
2. Body plate 4. Body cover
Disassembly Steps
1. Brake Valve Lever
2. Body Plate
3. Seal Ring
4. Body Cover
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EXHAUST BRAKE 5E-7

during inspection.
Visual Inspection
Visually inspect the following parts for excessive wear
and damage.
1. Body
2. Exhaust brake shaft
3. Butterfly valve
4. Bushings
5. Control rod
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5E-8 EXHAUST BRAKE
REASSEMBLY
Reassembly Steps
1. Body cover 3. Body plate
2. Seal ring 4. Brake valve lever
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EXHAUST BRAKE 5E-9
Reassembly Steps
1. Body Cover
Tighten the body cover bolts to the specified torque.
Body Cover Bolt Torque N•m (kg•m / lb•ft)
D
ø70 and ø75 13 (1.3 / 9.4)
ø80 27 (2.8 / 20)
2. Seal Ring
3. Body Plate
Tighten the body plate bolts to the specified torque.
Body Cover Bolt Torque N•m (kg•m / lb•ft)
ø70 and ø75 13 (1.3 / 9.4)

ø80 27 (2.8 / 20)
4. Brake Valve Lever

Tighten the brake valve lever nuts to the specified
torque.
Brake Lever Nut Torque N•m (kg•m / lb•ft)
D
ø70 and ø75 13 (1.3 / 9.4)
ø80 19 (1.9 / 14)
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5E-10 EXHAUST BRAKE
CONTROL CYLINDER
DISASSEMBLY
Disassemble Steps
1. Cover 8. Gasket
2. O-ring 9. Wear ring
3. Piston assembly 10. Piston plate
4. Return spring 11. Shaft assembly
5. Nut 12. Dust seal
6. Washer 13. Retainer and Filter
7. Retainer 14. Cylinder Body
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EXHAUST BRAKE 5E-11
Disassembly Steps
1. Cover
2. O-ring
3. Piston Assembly
4. Return Spring
5. Nut
6. Washer
7. Retainer
8. Gasket
9. Wear Ring
10. Piston Plate
11. Shaft Assembly
12. Dust Seal
13. Retainer and Filter
14. Cylinder Body

during inspection.
Visual Inspection
Visually inspect the following parts for excessive wear
and damage.
If excessive wear or damage is discovered during
inspection, the part(s) must be replaced.
1. Cover
2. Retainer
3. Wear ring
4. Piston plate
5. Shaft assembly
6. Return spring
7. Cylinder body
8. Gasket
9. O-ring
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5E-12 EXHAUST BRAKE
REASSEMBLY
Reassembly Steps
1. Cylinder body 8. Retainer
2. Filter and retainer 9. Washer
3. Dust seal 10. Nut
4. Shaft assembly 11. Return spring
5. Piston plate 12. Piston assembly
6. Wear ring 13. O-ring
7. Gasket 14. Cover
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EXHAUST BRAKE 5E-13
Reassembly Steps
1. Cylinder Body
the entire inside surface of the cylinder body.
2. Apply a coat of liquid gasket to the dust seal
installation position of the cylinder body.
2. Filter and Retainer
3. Dust Seal
1. Apply grease to the dust seal lip.
2. Apply a coat of liquid gasket to the dust seal outer
circumference.
4. Shaft Assembly
entire surface of the shaft assembly.
5. Piston Plate
6. Wear Ring
7. Gasket
gasket.
8. Retainer
9. Washer
10. Nut
Tighten the retainer nut to the specified torque.
Retainer Nut Torque N•m (kg•m / lb•in)
13 (1.3 / 113)
11. Return Spring

12. Piston Assembly
13. O-ring
14. Cover Assembly
Tighten the cover assembly bolts to the specified
torque.
Cover Assembly Bolt Torque N•m (kg•m / lb•in)
13 (1.3 / 113)
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HSA 5G-1
SECTION 5G
HSA
CONTENTS
PAGE
Inspection and Adjustment of HSA (Hill Start Aid) .................................................... 5G- 2
System Diagram (Power Supply).............................................................................. 5G- 2
System Diagram (Electrical Control) ........................................................................ 5G- 3
System Diagram (HSA Control Unit) ........................................................................ 5G- 4
Wiring Diagram .......................................................................................................... 5G- 5
HSA Pilot Lamp .......................................................................................................... 5G- 6
HSA Control Unit ........................................................................................................ 5G- 6
Adjustment.................................................................................................................. 5G- 9
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5G-2 HSA
Inspection and Adjustment of

HSA (Hill Start Aid)
When the HSA is active, foot pressure on the brake pedal is not required to apply braking force to the wheels.
This eliminate the need to move your foot quickly from the brake pedal to accelerator pedal when starting vehicle
movement on an uphill slope. It also reduces parking brake operations.
It is especially effective in starting the vehicle on an uphill slope in a traffic jam.
SYSTEM DIAGRAM (POWER SUPPLY)

Safety Valve
Air Tank
φ12 φ12
1
Secondary Primary
φ10
φ10
Air Conpressor
L.P L.P
Air Dryer
Check Valve
φ12 φ15
φ22.3
φ11 φ6.35 φ6.35 φ6.35
φ11 φ11
Dual Pressure Gauge Governor
φ12
φ12
φ4.76 φ4.76 Brake Valve
φ12
Primary Oil Steel Pipe
φ10 φ10
φ12 Air Steel Pipe

Second
φ10 ary φ10 Air Flexible Hose
Oil Flexible Hose
φ10 φ10 Nylon Tube
1
HSA VALVE
φ10 φ10
φ14 φ14
Servo Unit
Oil Tank φ6.35
Servo Unit
φ10.5 φ10.5
φ6.35 φ6.35 Rear Wheel Cylinder
φ6.35
φ6.35
φ6.35
Front Wheel Cylinder φ6.35
φ10.5
D05M200004
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HSA 5G-3
SYSTEM DIAGRAM (ELECTRICAL CONTROL)
Clutch Stroke Sensor

OFF Switch General Description
and Clutch Oil HSA
SW
(Cancel)
Pressure Switch 1. The HSA valve (electromagnetic valve)
is installed in the middle of the piping
FAST
Adjust Switch between the brake valve and the servo
Stop Lamp Switch HSA
ADJ
SLOW
(Fast Slow) unit, and controlled by the control unit.
2. The HSA maintains the pressure from

Neutral Switch HSA
RESET
Reset Switch the brake valve, but if it exceeds
(Initial Adjustment) 196kPa{2kgf/cm2}, the HSA lowers the
pressure to 196kPa{2kgf/cm2} and
Control Unit
maintains it.
(Built-in Buzzer)
Parking Brake Switch
Door Switch HSA Pilot Lamp

HSA Valve
Speed Sensor
Servo Unit Servo Unit

Oil Tank
Rear
Front Wheel
Wheel Cylinder
Cylinder
C05M200001
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5G-4 HSA
SYSTEM DIAGRAM (HSA CONTROL UNIT)
Ignition Battery Voltage OFF Switch

(Key ON) (Cancel)
13
Ignition Battery Voltage
14
Adjust Switch (Fast)
21
Adjust Switch (Slow)
15
Reset Switch
7
Sub-start Clutch Oil Pressure Switch
Switch 6
HSA
28
Valve
Neutral
Relay
Starter
18
Neutral
Switch
Clutch Stroke
Speed Speed SIG Sensor
Speed 17 (+)
Control Unit
Sensor 24
Sensor Control Speed GND
27 SIG
Unit 25
(-)
26
2
Parking
HSA Switch
Lamp
12
Checker
9 Connector
SIG
19 22
Stop
Lamp Stop
Lamp
Stop Lamp Switch GND
30
Relay
Back Up Battery Voltage

29
Battery Memory Clear Switch Ignition Battery Voltage
3
(Key ON)
ACG.L Terminal
ACG 10
Door Switch
11 1
D05M200003
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HSA 5G-5
WIRING DIAGRAM
POWER SUPPLY (KEY ON)
POWER SUPPLY OF FUSE 5 (BATTERY DIRECT)
POWER SUPPLY OF FUSE 11 (KEY ON)

FUSE22
(7.5A)
TAIL LIGHT RELAY
ACGL
0.3BR
0.85V
0.5RG
0.5R
0.5V
SW; HSA OFF
C/U; HSA
2 5
BACK UP
8 14 29
0.5Y
7 0.5WR
6 10
23
SW; CLUTCH 0.5R
OIL PRESS 22
0.5VR
6
SW;
MEMORY CLEAR
0.5RL 0.5B CHECKER
3
CONN (2) 10P
SW; RESET
0.5Y GND 0.3GB 21 22 27 23 24
7 26
SIG 0.3G
SW; ADJ 25
QUICK 0.5YR +5V 0.3GW 25 28 26 29 30
21 24
SLOW 0.5YB
15
HSA
0.5B
WARNING
(+) 0.3PG
13 12 P/L
(–)
28
0.85B JOINT
30
CONN A
2
17
9
19 11
18 1
C/U; SPEED SENSOR 0.5G 0.5G

SW; PARKING 0.3LB
C/U; SPEED SENSOR 0.5PL
SW; STOP LAMP 0.5GW
SW; DOOR 0.5RB
SW; NEUTRAL 0.5BG

0.5VW
0.5VG
M/V; HSA
D08M200061
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5G-6 HSA
HSA PILOT LAMP

The lamp turns on and stays on whenever the HSA
is active and braking force is maintained.
If the HSA control unit detects an operation error or
a fault, it warns a driver of the problem by the HSA
lamp on and off.
322M200001
HSA CONTROL UNIT

HSA Operation and Cancellation Requirement
HSA OPERATE REQUIREMENT
HSA Cancel Switch=OFF
Stop Lamp Switch=ON
Parking Switch=OFF
Speed:Less than 0.5km/h AND HSA OPERATE
Neutral Switch=ON
OR
Clutch=Disengage
ACG,L Voltage=More than 27V
HSA CANCEL REQUIREMENT
HSA Cancel Switch=ON
Parking Switch=ON
Speed:More than 4.5km/h OR HSA CANCEL
Neutral Switch=OFF
AND
Clutch=Engage
C05M200002
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HSA 5G-7
HSA problems may be indicated by the flashing HSA lamp and/or the warning buzzer.
HSA lamp Warning

Symptom Countermeasure
indication buzzer
HSA applies braking force for a
long time (more than 8 minutes)
Short tone
preventing vehicle forward
movement. Set the parking brake or use the
foot brake to hold the vehicle
With the gearshift lever in neutral, stationary.
the HSA is active. However, the Long tone
Flashing
vehicle begins to creep.
Newly installed HSA has not been
Broken tone Perform initial adjustments.
adjusted.
Short tone Park the vehicle in a safe place
Other problem indicated by pilot and press the HSA off switch to
Off
lamp or warning buzzer. suspend electrical power to the
On Long tone HSA control unit.
Indication Method of HSA Diagnosis Trouble Code

(DTC)
1. Set the parking brake and confirm that the HSA
OFF switch is not pushed. (HSA ON)
2. Continue to push the HSA adjustment switch to
the “SLOW” side.
3. The diagnosis trouble code is indicated by
flashing the HSA lamp. The warning buzzer
sounds at the same time.
HSA Adjust Switch
322M200002
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5G-8 HSA
Example of Diagnosis Trouble Code (DTC)
Speed Sensor Abnormal : Code 25
2 5
HSA Lamp 2.4 (Sec) 1.2 1.2 0.3 0.3 0.3 0.3 0.3 2.4
0.6 0.6 0.6 0.6 0.6
ON
OFF
Code 25
Second Time
F05M200001
NOTE: Time between flashing on and off.

1. After the HSA lamp turns off for 2.4 sec, the diagnosis trouble code is indicated.
2. In the case of double figures, the HSA Lamp turns on for 1.2 sec and off for 0.6 sec. In the case of a
figure it turns on for 0.3 sec and off for 0.6 sec.
3. It indicates three times for each diagnosis trouble code. After that if a new code does not exist, it
indicates three times from the first code.
In the case of more than two codes: Code 25 and Code 91
25 25 25 91 91 91
Diagnosis Trouble Code (DTC) Table
No. Detection Item DTC

1. Output voltage of the clutch stroke sensor is abnormal. 08
2. Output voltage of the speed sensor is abnormal. 25
When the clutch pedal is pressed, the clutch oil pressure switch does not turn on. Or when
3. 86
the clutch is engaged, the clutch oil pressure switch stays on.
4. The back up fuse is disconnection. 03
(1) Solenoid valve drive signal does not correspond to solenoid valve operate monitor. 91
With the gearshift lever in neutral, the HSA is active. However, the HSA control unit
(2) –
5. has detected more than 1 km/h of vehicle speed.
HSA applies braking force for a long time (more than 8 minutes) without pressing the
(3) –
brake pedal.
The HSA adjustment switch has been pushed beyond the adjusting limit of clutch
6. 19
engagement or when more than 5 km/h of vehicle speed.
7. HSA control unit is abnormal. 33
8. L terminal voltage of AC generator is abnormal. 36
9. Normal 01
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HSA 5G-9
ADJUSTMENT
HSA OFF Switch
Before beginning adjustment
1. Set the parking brake.
2. Start the engine.
3. Make sure that air pressure is adequate.
4. The HSA is active. (HSA OFF switch is not
pushed.)
322M200003
Initial adjustment procedure

HSA RESET Switch
1. Depress the clutch pedal and move the
gearshift lever to the 3rd gear position.
2. Press the reset switch. The buzzer will sound.
3. Slowly release the clutch until it is partially
engaged (engine speed should fall
approximately 100 rpm).
4. Press the HSA adjustment switch to move the
switch toward either the FAST side or the
SLOW side. The buzzer will stop.
5. Fully depress the clutch and move the gearshift
lever to the neutral position.
6. Slowly release the clutch pedal.
NOTE: Rapid release of the clutch pedal will result
in poor HSA adjustment.
322M200004
Initial adjustment is required if any of the following

conditions are present.
• New HSA control unit (Replacement)
• Clutch or clutch pedal adjustment
• Extremely poor brake release timing
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5G-10 HSA
Adjustment of Brake Release Timing

1. Press the brake pedal and release the parking
brake.
2. Depress the clutch pedal and move the
gearshift lever to any position except for the
neutral. Then confirm that the HSA lamp turns
on.
3. When some brake drag is felt because brake
release timing is slow, press the HSA
adjustment switch toward the “FAST” side.
HSA Adjust Switch
4. When the vehicle slips back slightly on an uphill
slope because brake release timing is fast,
press the HSA adjustment switch toward the
“SLOW” side.
322M200002
Use the following table to determine how many

times to press the adjustment switch.
Condition Number of presses

Precise adjustment Press the switch 1 or 2 times
not required. to move it toward the SLOW
or FAST side.
Some brake drag is Press the switch 2 or 3 times
felt. to move it toward the FAST
side.
Vehicle slips back Press the switch 2 or 3 times
slightly when to move it toward the SLOW
parked on grade. side.
Significant brake Press the switch 3, 4, or 5
drag is felt. times to move it toward the
SLOW side.
Vehicle slips back Press the switch 3, 4, or 5
significantly when times to move it toward the
parked on grade. SLOW side.
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NOTICE
USE THIS MANUAL".

Brakes (Air Over Hydraulic) Parking and Exhaust Brake (MGBRA-WE-681)
00 Service information
5A Hydraulic brakes
5C Parking brakes
5D Air compressor and generator
5E Exhaust brake
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NOTICE
Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is
recommended that you carefully read and thoroughly understand the information contained in Section 0A under
the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
publication. All rights reserved to make changes at any time without prior notice.
Applicable Model: FTR, FVR, FVD, FVM, FVZ, FVY, GVR, GVD
Brakes (Full Air) (MGBRF-WE-0001)
For the disassembly, reassembly and inspection of MERITOR made air brakes refer to the MERITOR brake
service manual.
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NOTICE
USE THIS MANUAL".
Brakes (Full Air) Exhaust Brake (MGBRF-WE-681)

5B Air brakes
5D Air compressor and governor
5E Exhaust brake
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NOTICE
publication.
Applicable Model: FVR, FVD, FVZ, FVY, GVR, GVD
This manual is applicable to 2000 year model and later vehicles Except those sold in the United States of America
and Canada.
Meritor Brakes (MGMEB-WE-0001)
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MERITOR
WHEEL BRAKES
MERITOR
AUTOMATIC SLACK
ADJUSTER
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WHEEL BRAKES
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MERITOR
AUTOMATIC SLACK
ADJUSTER
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NOTICE
USE THIS MANUAL".
Applicable Model: FVR, FVZ
ROCKWELL BRAKE (MGROB-WE-661)

APPLICABLE CHART
FVR FVZ
Front ROCKWELL ROCKWELL
16.5” Q Plus (16.5”x6”) 16.5” Q Plus (16.5”x6”)

Rear ROCKWELL ROCKWELL
16.5” Q Plus (16.5”x7”) 16.5” Q Plus (16.5”x7”)
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SERVICE NOTES..........................................................................................................i
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NOTICE
recommended that you carefully read and thoroughly understand the information contained in Section 0A
publication.
Applicable Model: FRR32, FSR32, FTR32, FVR32.
This manual is applicable to 2000 year model and later vehicles Except those sold in the United States of
America, Canada and Thailand.
Engine (6HE1TC) (MG6HE-WE-0001)
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NOTICE
publication.
Applicable Model: FRR33, FSR33, FTR33, FVR33, FSS33, FTS33
Engine (6HH; 2 Valve) (MG6HH-WE-681)
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publication.
Except those sold in the United States of America, Canada and Thailand.
Engine (6SD1 and 6SD1TC) (MG6SD-WE-9601)
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NOTICE
publication.
Applicable Model: FRR32, FRR33, FSR32, FSR33, FSS33, FTS33
Manual Transmission (MBJ) and Clutch (MGTRJ-WE-681)
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publication.
Manual Transmission (MLD) and Clutch (MGTRD-WE-681)

Applicable Model
F & G Series
FRR32 FTR32 FTR33 FTS33
FSR32 FVR32 FVR33 FVM33
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7B - 2 MANUAL TRANSMISSION
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CHARL WAS HERE
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NOTICE
it is recommended that you carefully read and thoroughly understand the information contained in Section-
OA under the headings, "GENERAL REPAIR INSTRUCTIONS" and "HOW TO USE THIS MANUAL".
All material contained in this manual is based on latest product information available at the time of
publication.
Applicable Model: FVR23, FVM23
This manual is applicable to 1996 year model and later
Manual Transmission (MAL) and Clutch (MGTRL-WE-661)

7B Manual Transmission
7C Clutch
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NOTICE
publication. All rights reserved to make changes at any time without prior notice.
Applicable Model: 1996 FVR, FVM

2000 FVM, FVD, GVD
1998 FVR, GVR, FVM
Except those sold in the United States of America, Canada and Thailand
Manual Transmission (EATON FS8203) (MGFS8-WE-661)
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NOTICE
publication.
Applicable Model: FVZ
Except those sold in the United States of America, Canada and Thailand
Manual Transmission (Fuller RT7608LL) (MGRT7-WE-661)

APPLICABLE CHART
TRANSMISSION
Model FVR FVM FVZ
ZF 9S109 x
EATON FS8209 x x
EATON RT7608LL x
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NOTICE
USE THIS MANUAL”.
Applicable Model: AT545/542: FRR33, FSR33, FRR32, FSR32
MD3560P: FVZ23, MD3060P: FVR23
Automatic Transmission (MGATM-WE-9601)
THIS MANUAL INCLUDES THE FOLLOWING SECTIONS
7A Automatic Transmission
7D -
FOREWORD
This service information manual has been prepared to acquaint you with important points for servicing
Allison automatic transmission model AT545 and 542, and MD3560 (P) and 3060 (P) adopted by
Isuzu vehicles. For more information refer to the manuals issued by Allison.
The disassembly, repair and reassembly of the AT545 and AT542, and MD3560 (P) and MD3060 (P)
should be done by an authorized Allison dealer.
THE LIST OF MANUAL

AT545 and 542
DESCRIPTION ALLISON FORM NUMBERS
DRIVERS HAND BOOK (English) OOSA 1334
- ditto - (Spanish) OOSA 1623
- ditto - (French) OOSA 1624
MECHANICS TIPS
(English) OOSA 1321
AT545 and AT542
(Spanish) OOSA 1619
- ditto-
(French) OOSA 1620
- ditto -
SERVICE MANUAL
(English) OOSA 1241
AT545 and AT542
(Spanish) OOSA 1522
- ditto -
(French) OOSA 1523
- ditto -
REPAIR MANUAL
(English) OOSA 2125
AT542
MD3560 (P) and MD3060 (P)

DESCRIPTION ALLISON FORM NUMBERS
OPERATORS MANUAL SA 2995
MECHANICS TIPS SA 3004
SERVICE MANUAL SA 2148
TROUBLESHOOTING MANUAL SA 2973
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NOTICE
USE THIS MANUAL”.

Applicable Model: FSS33, FTS33
Transfer Case (MGTRF-WE-661)
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publication.
Applicable Model : All F&G-Series Vehicles
Chassis Electrical (MGCEL-WE-0111)

8 CAB AND CHASSIS ELECTRICAL
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CAB AND CHASSIS ELECTRICAL 8 – 1
SECTION 8
CAB AND CHASSIS ELECTRICAL
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength for (stronger) may
be used. Fasteners that are not reused, and those requiring thread locking compound, will be called out.
The correct torque values must be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
Page 1 of 2 PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 3
Notes for Working on Electrical Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 3
Symbols and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 9
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 9
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 9
Parts for Electrical Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 10
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 10
Fuse, Fusible Link Wire and Slow Blow Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 12
Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 13
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 14
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 15
Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 16
Bulb Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 16
Fuse, Fusible Link wire and Slow Blow Fuse Location . . . . . . . . . . . . . . . . . . . . . . . 8– 18
Fuse Block Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 21
Reference Table of Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 23
Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 26
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8 – 2 CAB AND CHASSIS ELECTRICAL
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System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 27
Start and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 27
IVES (Isuzu Variable Electronic Economy Swirl System) . . . . . . . . . . . . . . . . . . . 8– 31
Exhaust Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 35
Engine Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 41
Headlight, Fog Light and Clearance Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 44
Taillight, License Plate Light, Stoplight and Roof Marker Light . . . . . . . . . . . . . 8– 51
Turn Signal Light and Hazard Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 56
Horn, Backup Light and Backup Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 60
Dome Light and Fluorescent Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 66
Power Window, Door Lock and Keyless Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 70
Windshield Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 80
Cigarette Lighter and Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 83
Meter and Warning/Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 87
Speedometer, Tachograph and Speed Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 99
Heater, Ventilation and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–105
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–109
Power Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–112
Power Take Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–115
Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–119
4WD Transfer and Front Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–122
MD3560 Auto T/M (FVZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–126
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–129
Retractable Mirror System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–136
Front Diff Lock System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–138
Brake Lock System (For Thailand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–140
Retarder System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–142
HSA (Hill Start Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–144
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GENERAL DESCRIPTION
The chassis electrical system operates on a twenty The harness use a split corrugated tube to protect
four volt power supply with negative ground the wires from the elements. Each circuit consists
polarity. Each wire in the vehicle is of a specific size of the following:
and has an identifying colored insulation. • Power source — the battery and the alternator.
These colors are indicated in wiring diagrams and • Wires — To carry electrical current through the
will help in tracing circuits and making proper circuit.
connections. Wire size is determined by load
• Fuses — To protect the circuit against current
capacity and circuit length. Some wires are
overload.
grouped together and taped. Such a grouping of
wires is called a harness. The main cable harness • Relays — To protect voltage drop between the
consists of the facia harness, frame harness, floor battery and the circuit parts and to protect the
harness, Headlight harness and the roof harness. switch points against burning.
• Switches — To open and close the circuit.
• Load — Any device, such as a light or a motor,
which converts the electrical current into useful
work.
• Ground — To allow the current to flow back to
the power source.
In this manual, such electrical device is classified by system. For major parts shown on the circuit based on
the circuit diagram for each system, inspection and removal and installation procedures are detailed.
NOTES FOR WORKING ON ELECTRICAL ITEMS

BATTERY CABLE
1
Disconnecting the Battery Cable
2
1) All switches should be in the "OFF" position.
2) Disconnect the battery ground cable.
3) Disconnect the battery positive cable
4) Disconnect the battery cable 3.
3 CAUTION:
For 24 Volt It is important that the battery ground cable be
061MY00001 disconnected first.
Disconnecting the battery positive cable first can
result in a short circuit.
Connecting the Battery Cable

Follow the disconnecting procedure in the reverse
order.
CAUTION:
Clean the battery terminal and apply a light coat of
grease to prevent terminal corrosion.
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Connecting Handling
Disconnecting The Connectors
Some connectors have a tang lock to hold the
connectors together during vehicle operation.
Some tang locks are released by pulling them towards
you 1.
Other tang locks are released by pressing them
forward 2.
Determine which type of tang lock is on the connector
being handled.
Firmly grasp both sides (male and female) of the
connector.
Release the tang lock and carefully pull the two halves
of the connector apart.
Never pull on the wires to separate the connectors.

OK This will result in wire breakage.
NO
Connecting the Connector

Firmly grasp both sides (male and female) of the
connector. Be sure that the connector pins and pin
NO
holes match. Be sure that both sides of the connector
are aligned with each other. Firmly but carefully push
the two sides of the connector together until a distinct
click is heard.
OK
Connector Inspection
Use a circuit tester to check the connector for
OK continuity. Insert the test probes from the connector
wire side.
Test probe
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Never insert the circuit tester test probes into the

NO connector open end to test the continuity. Broken or
open connector terminals will result.
Test probe
Waterproof Connector Inspection

1 It is not possible to insert the test probes into the
connector wire side of a waterproof connector. Use
2 one side of a connector (1) with its wires cut to make
the test. Connect the test connector (2) to the
connector to be tested. Connect the test probes to the
cut wires to check the connector continuity.
Test probe
Slender shaft Connector Pin Removal

Tang lock Connector Housing Tang Lock Type
1) Insert a slender shaft into the connector housing
open end.
2) Push the tang lock up (in the direction of the arrow
in the illustration). Pull the wire with pin free from
the wire side of the connector.
Housing open pad Pin Wire
Pin Tang Lock Type

Slender shaft
Tang lock 1) Insert a slender shaft into the Connector housing
Wire
open end.
2) Push the tang lock flat (toward the wire side of the
connector). Pull the wire with pin free from the
wire side of the connector.
Housing open pad Pin
Connector Pin Insertion

Tang lock Wire 1) Check that the tang lock is fully up.
2) Insert the pin from the connector wire side.
Push the pin in until the tang lock closes firmly.
3) Gently pull on the wires to make sure that the
connector pin is firmly set in place.
Pin
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Parts Handling
Be careful when handling electrical parts. They
should not be dropped or thrown, because short
circuit or other damage may result.
Cable Harness
When installing the parts, be careful not to pinch or
wedge the wiring harness.
All electrical connections must be kept clean and tight.
Use a grommet or guard tube to protect the wiring

NO harness from contacting a sharp edge or surface.
OK
Position the wiring harness with a enough clearance

NO from the other parts and guard the wiring harness
with a vinyl tube and clips to avoid direct contact.
OK Vinyl tube
Clip
The wiring harness between engine and chassis

should be long enough to prevent chafing or damage
due to various vibrations.
NO
OK
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SPLICING WIRE
1. Open the Harness
If the harness is taped, remove the tape. To avoid
wire insulation damage, use a sewing "seam ripper"
(available from sewing supply stores) to cut open the
harness.
If the harness has a block plastic conduit, simply pull
out the desired wire.
2. Cut the wire
Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire later
if you decide to cut more wire off to change the
location of a splice. You may have to adjust splice
locations to make certain that each splice is at least
1-1/2in (40 mm) away from other splices, harness
branches, or connectors.
3. Strip the insulation
When replacing a wire, use a wire of the same size as
the original wire. Check the stripped wire for nicks or
cut stands. If the wire is damaged, repeat the
procedure on a new section of wire. The two stripped
wire ends should be equal in length.
4. Crimp the Wires

Select the proper clip to secure the splice. To
Over lap bare wires
determine the proper clip size for the wire being
spliced, follow the directions included with your clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.) Overlap the two stripped wire ends and
Splice clip hold them between your thumb and forefinger. Then,
center the splice clip under the stripped wires and
hold it in place.
Wings of clip
• Open the crimping tool to its full width and rest
touching former one handle on a firm flat surface.
• Center the back of the splice clip on the proper
anvil and close the crimping tool to the point
where the back of the splice clip touches the wings
of the clip.
• Make sure that the clip and wires are still in the
correct position. then, apply steady pressure until
Back of clip the crimping tool closes.
centered on anvil
Before crimping the ends of the clip, be sure that:

Splice clip
• The wires extend beyond the clip in each direction.
• No stands of wire are cut loose, and
Align tool with
edge of clip to • No insulation is caught under the clip.
crimp ends of
splice Crimp the splice again, once on each end. Do not let
the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires.
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5. Solder
Apply 60/40 rosin core colder to the opening in the
back of the clip. Follow the manufacturer's
instructions for the solder equipment you are using.
6. Tape the Splice

Good (Rolled) Bad (Flagged) Center and roll the splicing tape. The tape should
cover the entire splice. Roll on enough tape to
duplicate the thickness of the insulation on the
existing wires. Do not flag the tape. Flagged tape
may not provide enough insulation, and the flagged
ends will tangle with the other wires in the harness.
If the wire does not belong in a conduit or other

harness covering, tape the wire again. Use a winding
motion to cover the first piece of tape.
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SYMBOLS AND ABBREVIATIONS

Symbols
Fuse Single filament light
Fusible link Double filament light
Fusible link wire M Motor
Buzzer
Switch
Meter
Ground
Consent
Condenser
Battery
Resistor
Variable resistance Connected portion
Coil
Crossed portion
Diode
Zener diode Relay
NPN type transistor

Circuit breaker
PNP type transistor
F08MT001
Abbreviations
Abbreviation Meaning of Abbreviation Abbreviation Meaning of Abbreviation
A/C Air Conditioner M/T Manual transmission
ACC Accessories M/V Magnetic valve
A/T Automatic transmission P/L Pilot light (Indicator light)
Conn Connector PTO Power take off
DIFF Differential RH Right hand side
ECU Electronic Control Unit R/L Relay
FLW Fusible link wire RR Rear side
FT Front Side SBF Slow blow fuse
H/L Headlight SW Switch
Isuzu variable electronic economy TR Trailer
IVES
swirl system W/ With
LH Left hand side W/O Without
ADR Australian design rule TICS Timing and injection rate control system
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PARTS FOR ELECTRICAL CIRCUIT

Wiring
Wire Color
All wires have color-coded insulation.
Single color
Wires belonging to a system's main harness will have
a single color. Wires belonging to a system's sub
circuits will have a colored stripe. Striped wires use
the following code to show wire size and colors.
Example: 0.5 G R
Colored stripe
Red (Stripe color)
Green (Base color)
Wire size (0.5 mm)

Abbreviations are used to indicate wire color within a
circuit diagram.
Refer to the following table.
Wire Color Coding

Color-coding Meaning Color-coding Meaning
B Black Br Brown
W White Lg Light green
R Red Gr Gray
G Green P Pink
Y Yellow Sb Sky blue
L Blue V Violet
O Orange
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Distinction of Circuit by Wire Base Color

Base color Circuits Base color Circuits
B Starter circuit and grounding circuit Y Instrument circuit
W Charging circuit
L, O, Br,
R Lighting circuit Lg, Gr, Other circuits
P, Sb, V
G Signal circuit
Wire Size
Outside diameter The size of wire, used in a circuit is determined by the
amount of current (amperage), the length of the
circuit, and the voltage drop allowed. The following
wire size and load capacity, shown below, are
specified by JIS (Japanese Industrial Standard)
(Nominal size means approximate cross sectional
area)
Cross sectional area
Nominal size Cross sectional area Outside diameter Allowable current (A)
(mm2) (mm)
0.3 0.372 1.8 9

0.5 0.563 2.0 12
0.85 0.849 2.2 15
1.25 1.287 2.5 21
2 2.091 2.9 27
3 3.297 3.6 37
5 5.228 4.4 50
8 7.952 5.5 66
15 13.36 7.0 92
20 20.61 8.2 121
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FUSE, FUSIBLE LINK WIRE AND SLOW

BLOW FUSE
Normal Blown
FUSE
Fuses are the most common form of circuit protection
used in vehicle wiring. A fuse is a thin piece of wire or
strip of metal encases in a glass or plastic housing. It
is wired in series with the circuit in protects. When
there is an overload of current in a circuit, such as a
short of a ground, the wire or metal strip is designed
to burn out and interrupt the flow of current. This
prevents a surge of high current from reaching and
damaging other components in the circuit.
Determine the cause of the overloaded before
replacing the fuse.
The replacement fuse must have the same amperage
specifications as the original fuse.
Never replace a blown fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other
serious circuit damage. A blown fuse is easily
identified.
FUSIBLE LINK WIRE

The fusible link wire is primarily used to protect circuit
where high amounts of current flow and where would
not be practical to use a fuse. For example, the starter
circuit. When a current overload occurs, the fusible
link wire melts open and interrupts the flow of current
so as to prevent the rest of the wiring harness from
burning.
Determine the cause of the overload before replacing
the fusible link wire. The replacement fusible link wire
810MT026
must have the same amperage specification as the
original fusible link wire.
Never replace a blown fusible link wire with fusible
link wire of a different amperage specification. Doing
so can result in an electrical fire or other serious
circuit damage.
Specifications
Nominal size Wire color Continuous allowable current
0.5 Green 15A
0.85 Red 21A
3.0 White 68A
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SLOW BLOW FUSE

40A 60A
Type A Type B Two types of slow blow fuses are used-type A (female
terminal type) and type B (male terminal type). The
slow blow fuse primarily used to protect circuits
where high amounts of current flow and where would
not be practical to use a fuse. When a current
overload occurs, the slow blow fuse melts open and
interrupts the flow of current so as to prevent the rest
of the wiring harness from burning. Determine the
cause of the overload before replacing the slow blow
810MT027 fuse. The replacement slow blow fuse must have the
same amperage specification as the original slow
blow fuse. Never replace a blown slow blow fuse with
Normal Blown slow blow fuse of a different amperage specification.
Doing so can result in an electrical fire or other
serious circuit damage.
A blown slow blow fuse is easily identified through a
transparent window provided on the housing upper
surface.
810MT025
Specifications
Type Rating Case color
A
40A Green
B
A
60A Yellow
B
RELAY
Battery and load location may require that a switch be
Load Load
placed some distance from either component. This
means a longer wire and a higher voltage drop 1.
Relay
The installation of a relay between the battery and the
➀ ➁ load reduces the voltage drop 2.
Because the switch controls the relay, amperage
through the switch can be reduced.
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RELAY SPECIFICATION AND CONFIGURATION
Rated Rated
Name/ Name/
voltage/Coil Internal circuit voltage/Coil Internal circuit
Color Color
resistance resistance
24V/ 1
3
24V/ 3 2
Approx. 266Ω 3 Approx. 100Ω

MR5C 4
2
MR82C/ 2 3
Minimum 5 1 Minimum
(1T)/ Green
operating 2 4 operating 4 5
Green label
voltage: 16V 5 voltage: 16V
5 4
at 25°C (77°F) at 20°C (68°F)
826LX040 826LX042
CONNECTOR
The connector pin shape determines whether the
connector is male or female.
The connector housing configuration does not
determine whether a connector is male or female.
Female Connector Male

connector pin shape connector
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DIODE
DIODE SPECIFICATIONS AND CONFIGURATIONS
THERE SHOULD BE CONTINUITY IN
MARK/ EITHER A OR B WHEN A CIRCUIT
SHAPE CONSTRUCTION CHECKING TESTER IS CONNECTED WITH
COLOR
DIODE TERMINAL
TERMINAL NO.
2 1
CONNECTION A + –
BLACK PATTERN B – +
TERMINAL NO.
3 2 1
– +
A
CONNECTION + –
PATTERN + –
B
– +
BLACK
TERMINAL NO.
3 2 1
– +
A
CONNECTION + –
PATTERN + –
B
BLACK – +
TERMINAL NO.
4 3 2 1
4 + –
3 A – +
– +
2 CONNECTION
PATTERN – +
1
B + –
BLACK + –
MAXIMUM RATING (Temp. =25°C)
Items Rating Remarks

Peak reverse voltage 400V
Transient peak reverse voltage 500V
Average output current 1.5A Temp. = 40°C
Working ambient temperature –30°C~80°C
Storage temperature –40°C~100°C
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MAIN DATA AND SPECIFICATIONS

BULB SPECIFICATIONS
Light Name Rated Power No. of Bulb Lens Color Remarks
Headlight Rectangular Outside 70/75W 2
White –
assembly type Inside 70W 2
Variant square type 70/75W 2 White –
Headlight
Fog light 55W 2 White
assembly
Clearance light 5W 2 White
Front Turn signal light 21W 2 Amber –
combination
light Clearance light 5W 2 White –
Cornering light 30W 2 White –
Front turn signal light 21W 2 Amber –
Side turn signal light 12W 2 Amber –
Amber New Zealand
Roof. marker light 5W 2 Australia,
White
South Africa, China
Identification light 12W 2 Amber New Zealand
Turn signal light 21W 2 Amber –
Rear
combination Stop light/Taillight 21/5W 2 Red –
light
Backup light 21W 2 White –
License plate light 10W 1 White –
Dome light 10W 2 White –
Fluorescent Fluorescent light 20W 1 White –
light assembly Dome light 20W 1 White –
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Light Name Rated Power No. of Bulb Lens Color Remarks

Charge 1.8W 1 Red
Tails & Stop 1.8W 1 Red
Engine over run 1.8W 1 Red
High beam 1.8W 1 Blue
Seat belt 1.8W 1 Red
T/M low range (ZF) 1.8W 1 Green
Air pressure 1.8W 1 Red
Parking brake 1.8W 1 Red
Engine oil pressure 1.8W 1 Red
A/T oil pressure 1.8W 1 Red
Trailer brake 1.8W 1 Red
Turn signal (LH) 1.8W 1 Green
Incorporated in
Indicator/ Turn signal (RH) 1.8W 1 Green the meter
Warning Light PTO 1.8W 1 Red assembly
Diff lock 1.8W 1 Amber
Exhaust brake 1.8W 1 Green
Brake fluid level 1.8W 1 Red
Transfer high 1.8W 1 Blue
FT drive 1.8W 1 Green
Retarder 1.8W 1 Green
Transmission high 1.8W 1 Blue
Diff lock FT 1.8W 1 Amber
Service engine soon 1.8W 1 Amber
Transfer low 1.8W 1 Green
Do Not SHIFT 1.8W 1 Red
QOS 1.8W 1 Amber
HSA 1.8W 1 Green
Illumination light
Illumination 3W 4
for meter assembly
Light
Cigarette lighter 1.8W 1
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FUSE, FUSIBLE LINK WIRE AND SLOW BLOW FUSE LOCATION

FUSE AND FUSIBLE LINK WIRE
FUSE box location
7.5 7.5 15 15
7.5 7.5 15
7.5 7.5 15 15
7.5 15
7.5 15 15
7.5
7.5 7.5 15 15
7.5 15
7.5
Fusible link wire
Nominal size Continuous allowable current
3.0 68A
FUSE LABEL (Except FSS FTS)

1 Headlight(Upper) 11 Meter 21 Engine control 26 Taillight 36 Blower motor 46
Fog light
7.5A Left 7.5A 7.5A 15A Illumination 15A
2 Headlight(Upper) 12 Backup light 22 HSA 27 Stop light 37 Condenser fan 47

Sub starter,Horn motor
7.5A Right 7.5A Window washer 7.5A 15A 15A Compressor
3 Headlight(Lower) 13 Power take off 23 28 Starter(Relay) 38 Wiper 48
IVES
7.5A Left 7.5A Exhaust brake 15A 15A Window washer
4 Headlight(Lower) 14 Auto T/M (Relay) 24 29 (Power outlet) 39 Retractable 49

7.5A Right 7.5A 15A Receptacle, 24V 15A mirror
5 Clock, Dome light 15 Transfer low 25 30 Turn signal 40 Cigarette lighter 50
7.5A Backup 7.5A 15A 15A
6 Engine stop 16 4WD 31 41 (Power outlet)
7.5A 7.5A 15A Receptacle, 12V
7 Door lock 17 Transfer high 32 Power window 42
7.5A 7.5A 15A (Left)
8 Radio 18 Auto T/M ECU 33 Power window 43

7.5A Cassette stereo 7.5A 15A (Right)
9 Glow plug(Relay) 19 Engine ECU 34 Auto T/M ECU 44 Engine ECU

7.5A 7.5A 15A 15A
10 Engine ECU 20 Engine ECU 35 45 Engine ECU

7.5A 7.5A 15A
740MY00015*
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FUSE LABEL(FSS,FTS W/O 12V Power outlet)
1 Headlight(Upper) 11 Meter 21 26 Taillight 36 Blower motor 46

Fog light
7.5A Left 7.5A 15A Illumination 15A
2 Headlight(Upper) 12 Backup light 22 27 Stop light 37 Condenser fan 47

7.5A Right 7.5A Window washer 15A 15A Compressor

7.5A Left 7.5A Exhaust brake 15A 15A
4 Headlight(Lower) 14 24 29 (Power outlet) 39 Retractable 49

7.5A Right 15A Receptacle 15A mirror

6 Engine stop 16 4WD 31 41

7.5A 7.5A

7.5A 7.5A 15A (Left)
8 Radio 18 33 Power window 43

7.5A Cassette stereo 15A (Right)
9 Glow plug(Relay) 19 34 44
7.5A
10 20 Engine ECU 35 45 Engine ECU

7.5A 15A
FUSE LABEL(FSS,FTS W/ 12V Power outlet)
1 Headlight(Upper) 11 Meter 21 26 Taillight 36 Blower motor 46

Fog light
7.5A Left 7.5A 15A Illumination 15A
2 Headlight(Upper) 12 Backup light 22 27 Stop light 37 Condenser fan 47

7.5A Right 7.5A Window washer 15A 15A Compressor

Exhaust brake
7.5A Left 7.5A 15A 15A
4 Headlight(Lower) 14 24 29 (Power outlet) 39 Retractable 49

7.5A Right 15A Receptacle 15A mirror

6 Engine stop 16 4WD 31 41 (Power outlet)

7.5A 7.5A 15A 12V Socket

7.5A 7.5A 15A (Left)
8 Radio 18 33 Power window 43

7.5A Cassette stereo 15A (Right)
9 Glow plug(Relay) 19 34 AUTO T/M ECU 44

7.5A 15A
10 20 Engine ECU 35 AUTO T/M ECU 45 Engine ECU

7.5A 15A 15A
740MY00016
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SLOW BLOW FUSE

Slow blow fuse box
No. Capacity
1 40A
2 40A
3 —
4 60A
5 —
6 40A
810MT023
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FUSE BLOCK CIRCUIT
INDICATION ON LABEL
FLW (3sq)
SBF 1 (40A) FUSE28 (15 A)
S STARTER (RELAY)
FUSE 9 (7.5A)
G GLOW PLUG (RELAY)
FUSE 8 (7.5A)
M1 RADIO,CASSETTE STEREO
FUSE11 (7.5A)
M2 METER
FUSE12 (7.5A)
BACK UP LIGHT,SUB STARTER, HORN, WINDOW WASHER
FUSE13 (7.5A)
POWER TAKE OFF, EXHAUST BRAKE
FUSE14 (7.5A)
AUTO T/M (RELAY)
FUSE45 (15A)
ENGINE ECU
FUSE20 (7.5A)
ENGINE ECU
FUSE18 (7.5A)
AUTO T/M ECU
FUSE 5 (7.5A)
CLOCK, DOME LIGHT, BACK UP
FUSE 44 (15 A)
ENGINE ECU
FUSE 45 (15 A)
ENGINE ECU
FUSE 6 (7.5A)
ENGINE STOP
FUSE 7 (7.5A)
DOOR LOCK
FUSE10 (7.5A)
ENGINE ECU
FUSE29 (15 A)
(POWER OUTLET), RECEPTACLE
FUSE30 (15 A)
TURN SIGNAL
FUSE31 (15 A)
R/L ; FOG/L, R/L ; RR FOG/L (FOR CHINA)
FUSE32 (15 A)
POWER WINDOW (LH)
FUSE33 (15 A)
POWER WINDOW (RH)
FUSE34 (15 A)
AUTO T/M ECU
FUSE35
SBF 2 (40A) FUSE26 (15 A)

TAIL LIGHT, FOG LIGHT, ILLUMINATION
FUSE27 (15 A)
STOP LIGHT
FUSE 1 (7.5A)
UP HEAD LIGHT (UP) LH
FUSE 2 (7.5A)
HEAD LIGHT (UP) RH
FUSE 3 (7.5A)
LOW HEAD LIGHT (LOW) LH
FUSE 4 (7.5A)
HEAD LIGHT (LOW) RH
R/L ; HEAD LIGHT
D08M200053
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INDICATION ON LABEL
SBF 4 (60A)
SBF 5 FUSE42
FUSE43
FUSE44
FUSE46
SBF 6 (40A) 18.3A FUSE36 (15 A)

BLOWER MOTOR
FUSE37 (15 A)
CONDENSER FAN MOTOR, COMPRESSOR
FUSE38 (15 A)
WIPER
R/L: CIGARETTE
LIGHTER
FUSE39 (15 A)
RETRACTABLE MIRROR
FUSE40 (15 A)
CIGARETTE LIGHTER
FUSE15 (7.5 A)
TRANSFER LOW
FUSE16 (7.5 A)
4WD
FUSE17 (7.5 A)
TRANSFER HIGH
FUSE41 (15 A)
12V SOCKET (POWER OUTLET)
D08MY00090
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REFERENCE TABLE OF FUSE

FUSE
Fuse
Capacity Indication on label Main parts (Load)
No.
1 7.5A Headlight (Upper) Headlight (Upper) (LH)
Left
2 7.5A Headlight (Upper) Headlight (Upper) (RH)
Right
3 7.5A Headlight (Lower) Headlight (Lower) (LH)
Left
4 7.5A Headlight (Lower) Headlight (Lower) (RH)
Right
5 7.5A Clock, Dome light, Dome light, Door, Switch, Fluorescent light, Rear
Dome light (Crew cab), Power tilt relay, Back up,
Back up Dome light diode, Tilt buzzer
6 7.5A Engine stop Engine stop actuator
7 7.5A Door lock Door switch module (Driver's side), Door lock actuator,
Door lock remote C/U
8 7.5A Radio Radio
Cassette stereo
9 7.5A Glow plug (Relay) Glow relay
0 7.5A Engine ECU TICS; ECU (TYPE-RED 4)
A 7.5A Meter Meters (Water temp., Fuel, Tachometer, Tachograph,
Speedometer), Warning lights (Charge, Tail & Stop,
Engine overrun, High beam, Seat belt, T/M low, Air
pressure, Parking brake, Engine oil pressure, A/T oil
pressure, Trailer brake, Brake fluid level, Brake lock,
T/M high, Retarder, Do not shift, T/F high, FT diff lock,
FT drive, Service engine soon, Diff lock, Bulb check
switch, Meter illumination, Engine overrun buzzer, Air
buzzer, Parking brake switch, Wheel park relay (Wheel
park), P/L check relay (ADR), Speed limiter control unit,
Speed limiter actuator, Speedometer ECU, Speed
sensor, Diff lock M/V, FT diff lock M/V, Range relay
B 7.5A Backup light Horn relay, Horn switch, Horn, Backup light relay,
Sub starter, Horn Backup light switch (A/T), Back buzzer, Backup light,
Washer motor, Intermittent relay, Cigarette lighter,
Blower motor fan relay, Seat belt timer relay, Door
switch module, Seat belt relay, Sub starter switch,
Seat belt buzzer, Air dryer
C 7.5A Power take off Stop light relay, Exhaust brake relay, Exhaust brake
IVES indicator light (Meter), Accel switch, IVES relay 1,
Exhaust brake IVES relay 2, PTO relay (Side), PTO relay (Clutch),
PTO indicator light (Meter), PTO M/V, Brake lock relay
(1), Brake lock relay (2), Brake lock buzzer, Brake lock
M/V, Brake lock control unit, Retarder relay, Retarder
cut relay, Stoplight relay, Thermo sensor
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Fuse
No.
D 7.5A Auto T/M (Relay) A/T Relay (EXH Cut), A/T Relay (EXH Sensor)
E 7.5A Transfer low Transfer low M/V
F 7.5A 4WD Front drive MV
G 7.5A Transfer high Transfer high M/V
H 7.5A Auto T/M ECU A/T control unit
I — — —
J 7.5A Engine ECU Engine ECU
K 7.5A Engine control Exhaust shutter relay C/U; TYPE RED-4
L — — —
M — — —
N — — —
O — — —
P 15A Taillight Ft diff lock switch, Retractable mirror, Transfer
Fog light switch(Low-High), Brake lock switch, Ft drive switch,
Illumination Taillight relay, Taillight, Meter Illumination,
Speedometer, Tachograph, Radio illumination, Stop &
Tail indicator light, PTO switch, Diff lock switch,
Clearance light, Fog light relay, Fog light, License plate
light, Cigarette lighter, A/C mode switch, Roof marker
light, Rr fog light switch, Rr fog light relay
Q 15A Stop light Stop light
Stop & Tail indicator light
R 15A Starter (Relay) Starter switch, Starter relay,
Neutral switch (A/T)
S 15A (Power outlet) Receptacle
Receptacle
T 15A Turn signal Flasher unit, Combination switch, Front turn signal,
Front side turn signal, Rear turn signal, Trailer brake
switch, Trailer flasher switch, Trailer socket, Turn (LH)
indicator light, Turn (RH) indicator light
U 15A Fog light (For CHINA) Rr fog light, Rr fog light switch indicator light
V 15A Power window Door switch module, Power window motor
(Left)
W 15A Power window Door switch module, Power window motor
(Right)
X 15A Auto T/M ECU A/T control unit, Neutral relay (A/T)
Y — — —
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Fuse
No.
Z 15A Blower motor A/C actuator (TEMP), A/C actuator (MODE), A/C
actuator (Fresh-circulate), Resistor, Blower motor,
A/C mode switch, Condenser relay, Compressor relay,
Thermo switch
[ 15A Condenser fan motor, Condenser fan motor, Compressor, Condenser relay,
Compressor Pressure Switch
\ 15A Wiper Wiper motor
] 15A Retractable mirror Motor; r/mirror, Retractable mirror C/U

^ 15A Cigarette lighter Cigarette lighter
a 15A (Power outlet) Socket
12V Socket
b — — —
c — — —
d 15A Engine ECU MAIN relay, Engine ECU
e 15A Engine ECU Power steering power cut relay, Common rail
f — — —
g — — —
h — — —
i — — —
j — — —
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RELAY LOCATION
A B
This illustlation is based on the RHD.
Model
F F F F F F F F G G F F
R S T V V V V V V V S T
Name R R R R D M Z Y R D S S Remarks
RETARDER With Retarder
1
NEUTRAL(A/T) MD3560P T/M
FOG Model with fog light
2
1 4 7 FOG With BUMP Headlights (CHINA)
3 CIGAR LIGHTER
A 4 LIGHTING Headlight (Upper)
2 5 8
5 LIGHTING Headlight (Lower)
6 HORN
3 6 9 7 TAIL LIGHT
8 STOP LIGHT
9 EXH BRAKE All models without A/T
1 AIR CON Cooler condenser (Air conditioner)
2 AIR CON Cooler compressor (Air conditioner)
3 FAN Fan motor
4 BACK LIGHT For Australia
5 PARKING BRAKE Model with wheel park
6 PTO CONTROL PTO relay (Model with M/T)
IVES(1) Model with 6HH1 eng. for Australia
1 4 7 10 7 MAIN (COMMON RAIL) 6S eng.
P/S POWER CUT EURO II
B
2 5 8 11 8
IVES(2) Model with 6HH1 eng. for Australia
RETARDER CUT With Retarder
3 6 9 12 9
BRK FLUID CHECK For Australia
SEAT BELT WARNING For Saudi Arabia
10 A/T(BACK LAMP) MD3560P T/M
A/T(EXH.CUT) MD3560P T/M
11 PCV (COMMON RAIL) 6S eng.
BRAKE LOCK
A/T(EXH.SENS) MD3560P T/M
12
BRAKE LOCK
: Standard : Option
740MY00017*
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SYSTEM REPAIR
START AND CHARGING
GENERAL DESCRIPTION
The system consists of the starter switch, sub starter switch, starter, AC generator, starter relay, glow relay,
inhibitor switch and neutral switch. When the starter SW is set to the "ST" position, the battery voltage is
applied to the starter solenoid coil through the starter relay to start the starter.
STARTING CIRCUIT
BATTERY (+)
OFF
STARTER SW
"ST" POSITION
ST
STARTER
RELAY
STARTER
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CIRCUIT DIAGRAM
SLOW BLOW FUSE NO.1

SLOW BLOW FUSE NO.2
SLOW BLOW FUSE NO.6

STARTER FUSE 8 (ACC)
STARTER (KEY ON)
STARTER FUSE 12 (KEY ON)
FUSE28
FUSE12
FUSE 8
FUSE 9
(7.5A)
(7.5A)
(7.5A)
3WR (15A)
1.25BR
2L
3L
SW;STARTER 3L
B1 S G M1 M2 B2 P2 P1
OFF
0.85BG
ACC
ON
HEAT
START
R/L;GLOW
<A/T>
0.85BW
0.85B
5BR
CHARGE WARNING
0.85BW
P/L
5W
<A/T>
CONTROL
0.85Br
RESISTOR
<M/T>
SW;NEUTRAL
3W
3G
3R
(AT542 T/M)
(AT545 T/M) 0.5WR
C/U;HSA
0.5WR R/L;EXHAUST
0.85BW <M/T>
0.85BR <A/T>
SHUT
(TYPE RED-4)
C/U;A/T
0.5WR
5BY
R/L;NEUTRAL(A/T)
(MD3560P T/M ONLY)
5W 5W
POWER TILT MOTOR
0.5BW
0.85BW
C/U;TICS
0.85BW
STARTER RELAY C/U;TYPE RED-4

0.85Br
C/U;COMMON RAIL
5BY
3W
8W
<M/T>
3G
3R
0.85WR
SW;NEUTRAL
0.85BL
(ALL LHD)
(AUSTRALIA)
(NEW ZEALAND) (EXCEPT THAILAND)
0.85Br GLOW PLUG
8BW
SLOW BLOW1
SLOW BLOW2
SLOW BLOW4
SLOW BLOW6
SW;SUB STARTER
(ALL LHD)
(40A)
(40A)
(60A)
(40A)
(AUSTRALIA)
(NEW ZEALAND) L
R E 5B
F/L BOX 0.85Br 0.85BW R/L; TYPE-RED4
( (
8W
NEUTRAL COMMON RAIL

8W B
F.L SG
3
(C)
BATTERY AIR DRYER(OPTION) GENERATOR 0.85BG
0.85Br C/U;TYPE RED-4
+ - + - C/U;COMMON RAIL
STARTER
0.85
BL
SW;NEUTRAL
SW;SUB STARTER
0.85Br 0.85BW
D08M200054
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H GFDC,

@
A
B
C
D
E
F
G
H

A
B
E

@

, ST
ART
H ON
C
C
LO
ACCK
STARTER SWITCH
The starter switch positions are LOCK, ACC, ON, HEAT

and START. Turning the starter key to these positions
a circuit for starting the engine, the operation of
accessories, or stop the engine.
639NT993
INSPECTION
Check the continuity between the starter switch
connector terminals.
Repair or replace the switch when the result of
inspection is found abnormal.
P2
M1 B1
P1
G
B2
M2 S
P1 B1 S G
P2 B2 M2 M1
Terminal No.
Starter SW B1 S G M1 M2 B2 P2 P1
key position
OFF
ACC
ON
HEAT
START
730MT002
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Neutral switch NEUTRAL SWITCH

Neutral switch
INSPECTION
Check to see if there is any continuity between the
Gear shift
switch terminals.
shaft
Replace the switch when the result of inspection is
found abnormal.
825M100013
STARTER RELAY
C
INSPECTION
E Check to see if there is any Ω (8Ω~12Ω) between the
terminals C and E.
S
Replace the relay when the result of inspection is
found abnormal.
B There is continuity between terminal S and B. When
the battery voltage is applied between terminal C and
060MT005
E.
035MW001
SUB STARTER SWITCH

INSPECTION
1. Check the continuity between the switch connector
1
terminals.
2
2. Check to see if switch push rod operate smoothly.

ON OFF Repair or replace the switch when result of
Terminal
SW No. 1 2
position
Push rod in ● ●
Push rod out
730MT001
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ISUZU VARIABLE ELECTRONIC ECONOMY SWIRL SYSTEM

(IVES)
GENERAL DESCRIPTION
This circuit consists of starter switch, accel switch, air low pressure switch, tachometer (meter), thermo
switch, vacuum switching valve and relay.
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CIRCUIT DIAGRAM
FUSE No.13
0.85Sb
(COMMON USE WITH

EXH.BRAKE)
SW;ACCEL
0.5Sb
0.5LB
R/L;IVES 1
DIODE
0.5BY
0.5YG
0.3Sb
R/L;IVES 2
0.5BY
0.5LB
TACHOMETER 1
TACHOMETER 2
SW; AIR LOW
0.5LO
0.5BY
SW;THERMO
0.5BL
IVES M/V
0.5BL
D08MT008
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ACCEL SWITCH
INSPECTION
terminals.
Repair or replace the switch when result of
Terminal
SW No. 1 2
position
Push rod in ● ●
Push rod out
101MT001
THERMO SWITCH
Characteristic of thermo switch
10°C
OFF
ON
0°C
CDFG

060MT008
IVES MAGNETIC VALVE
828MT009
828MT010
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828MT008
IVES RELAY
1
3 INSPECTION
4 2 3 Check to see if there is any continuity between the
relay terminals.
5 1
2 4 found abnormal.
5 3 – 5..... Continuity
1 – 5..... No continuity
825MY00050 (When battery voltage is applied between 2 – 4)
3 – 5..... No Continuity
1 – 5..... Continuity
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EXHAUST BRAKE SYSTEM

GENERAL DESCRIPTION
This circuit consists of starter switch, exhaust brake switch (combination switch), accelerator switch, clutch
switch, vacuum switching valve, neutral switch and relay.
Exhaust brake is a system to increase exhaust pressure by means of squeezing exhaust gas from engine
and exert engine brake.
Turn the exhaust brake SW on, and the exhaust brake valve starts to work by the function of the magnetic
valve to enable the exhaust brake to operate, when the exhaust brake indicator light will be on.
When either the accelerator pedal or the clutch pedal is depressed while driving, the switch of the
depressed pedal will turn off, subsequently the exhaust braking will stop working.
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CIRCUIT DIAGRAM
POWER SUPPLY OF FUSE 13(KEY ON)
R/L;A/T(EXH.CUT)
(MD3560P T/M ONLY)
0.5Sb
FUSE(14)
C/U;A/T
0.5Sb
R/L;
EXHAUST BRAKE EXHAUST BRAKE
0.3LY
P/L
0.5Sb
0.5LP
DIODE;EXH.SENSOR
(MD3560P T/M ONLY)
0.5LO
0.5LY
0.5L
SW; SW;
ACCEL CLUTCH
SW; 0.5LW 0.5LR 0.5B
COMBINATION
EXHAUST 18 17 (COMMON USE (M/T ONLY)
SW WITH IVES)
EXH.B
OFF
ON
SW;COMBI(RETARDER)
R/L;A/T(EXH.SENSOR)
R/L;PTO
0.5LY
M/V;
EXHAUST BRAKE
0.5BL
D08MY00092
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CIRCUIT DIAGRAM (TYPE RED-4)
0.5Sb R/L;
0.3LY
P/L
0.5Sb
DIODE
0.5LW
C/U;TYPE RED-4
0.5LW
0.5LO
0.5LY
SW;
CLUTCH
SW; 0.5B
COMBINATION
EXHAUST 18 17 (M/T ONLY)
SW
EXH.B
OFF
ON
0.5LW
SW;COMBI(RETARDER)
0.5LR
R/L;PTO
0.5LY
M/V;
EXHAUST BRAKE
0.5BL
54496A 矢数
01/07/20 01/07
D08M200055
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CIRCUIT DIAGRAM (TYPE COMMON RAIL)
0.5Sb
R/L;
0.3LY
P/L
0.5Sb
DIODE
0.5LP 0.5LP
0.5LW
C/U;COMMOM RAIL
0.5LW
0.5LO
SW; 0.5LY
CLUTCH
SW; 0.5B
COMBINATION
EXHAUST 18 17 (M/T ONLY)
SW
EXH.B
OFF
ON
C/U;COMMOM RAIL
0.5LR
R/L;PTO
0.5LY
M/V;
EXHAUST BRAKE
0.5BL
54496A
01/07/20
D08M200056
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CLUTCH SWITCH
INSPECTION
terminals.
Terminal
SW No. 1 2
position
Push rod in ● ●
Push rod out
101MT001
EXHAUST BRAKE SWITCH

INSPECTION
Check the continuity between the terminals of the
exhaust brake switch.
Repair or replace the switch when result of inspection
is found abnormal.
10 9 8 7 6 5 4 3 2 1
2221201918 17 16 1514131211
Switch side
Exhaust brake Switch
Terminal
SW No. 18 17
position
S
OFF
● ●
INT
INT
F
TIME OFF
ON
UP ON
L
PASS HI OFF OFF
R ON OFF
Combination Switch
825MT025
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EXHAUST BRAKE MAGNETIC VALVE
156MT002
156MT003
EXHAUST BRAKE RELAY

1
3
INSPECTION
4 2 3
Check to see if there is any continuity between the
5 1 relay terminals.
2 4 Replace the relay when the result of inspection is
found abnormal.
5
3 – 5 ..... Continuity
1 – 5 ..... No continuity
3 – 5 ..... No Continuity
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ENGINE STOP SYSTEM

GENERAL DESCRIPTION
The circuit consists of starter switch and engine stop motor.
The engine stop mechanism aims at shut-off of fuel supply.
Motor type is forcible pull the injection pump control rack to the direction of fuel supply reduction by means
of engine stop motor, thus shutting it off.
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CIRCUIT DIAGRAM
SLOW BLOW FUSE No.1
FUSE 6
(7.5A)
P1
SW; STARTER P2
B2
0.85LW
0.85LY
1.25LR
0.85L
ACTUATOR; ENG STOP
M
作業番号 8045
発注者川島発注日 '98/ 4
受注番号 E7128 希望納期 '98/ 4
1.25BL
ｲﾗｽﾄｻｲｽﾞ 180 × 240 ｲﾗｽﾄ担当大野
ﾊﾟｰﾂｲﾗｽﾄ番号
対象車型 F V R
イラスト区分ＢＫＴＧＳ L D
D08MW042
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FUNCTION OF ENGINE STOP MOTOR
SLOW BLOW FUSE No.1 SLOW BLOW FUSE No.1
Turn the starter switch from "ACC" position to "ON",

FUSE 6
FUSE 6
(7.5A)
(7.5A)
and the engine stop motor will turn by 180 degrees
(from 0° to 180°) so that the stop motor's electrode
Starter SW Starter SW will be in potential equal to that of the starter switch
B2 B2 for the stop.
P2 P1 P2 P1
Turn the starter switch from "ON" position to "ACC"
or "LOCK", and then the stop motor will rotate by
180 degree (from 180° to 360°) and cease operating.
P2 P2
B B
P1 P1
Stop motor Stop motor
060MY00073
Connector No. B-68

Terminal B2 P1 P2 Stop motor Stop lever
Starter position
SW key position No. 1 2 4
LOCK ● ●
0° (360°) Stop
ACC ● ●
ACC → ON 0° → 180° Stop → Run
ON ● ●
HEAT ● ● 180° Stop
START ● ●
ON → ACC
LOCK 0° → 360° Stop → Run
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HEADLIGHT, FOG LIGHT AND CLEARANCE LIGHT

GENERAL DESCRIPTION
The circuit consists of headlight, fog light, clearance light, Combination switch (Lighting switch,
dimmer·passing switch, high beam indicator light and relay.
For the vehicle equipped with the auto-light system, in addition of above lights, the auto-light sensor and
the auto-light controller are equipped.
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CIRCUIT DIAGRAM – VARIANT SQUARE HEADLIGHT (FOR CHINA)
SLOW BLOW FUSE No.1
SLOW BLOW FUSE No.2
FUSE No.12
FUSE No.5
FUSE 31
(15A)
FUSE 2
FUSE 4
FUSE 3
FUSE 1
(7.5A)
(7.5A)
(7.5A)
(7.5A)
TAIL LIGHT
1.25RW
1.25RB
1.25RY
1.25RL
0.5RG
HEAD LIGHT(LH)
0.5 RG
1.25 G
3RY
3RB
(UPEPER)
3R
3R
HEAD LIGHT (LOWER)
2B
RELAY
(UPPER)
CLEARANCE
FOG LIGHT
RELAY
3R
H/L CONN LH
0.5R 0.85 RL
HEAD LIGHT
RELAY (LOWER) H/L CONN RH
HEAD LIGHT(RH)
CLEARANCE
(LOWER)
HIGH BEAM (UPPER)

2B
P/L 0.3RG
0.5RW
0.5RG
SW;COMBINATION
SW;FOG LIGHT
0.5GY
22
OFF
TAIL
HEAD
21 6 5
3 1 0.5B
4 IND 3
4 30
UPPER 2 1
LOWER DIODE;RR FOG
PASSING 5 0.5B SW;RR FOG RR FOG
13 2 LIGHT RELAY
REMIND BUZZER
11 14
SW;DOOR(Dr) REMIND BUZZER
TAIL LIGHT REALY COMBINATION

SW.
D08M200057
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CIRCUIT DIAGRAM – VARIANT SQUARE HEADLIGHT (W/O CHINA)
SLOW BLOW
FUSE No.2
FUSE No.12 FUSE 2
FUSE 4
FUSE 3
FUSE 1
(7.5A)
(7.5A)
(7.5A)
(7.5A)
TAIL LIGHT
1.25RW
1.25RB
1.25RY
1.25RL
0.5RG
3RY
3RB
3R
3R
HEAD LIGHT
RELAY
(UPPER)
HEAD LIGHT(LH)
0.5 RG
(UPPER)
3R
0.5R
2B
(LOWER)
HEAD LIGHT
RELAY(LOWER)
CLEARANCE
FOG
R/L;FOG LIGHT
0.85 RL
HIGH BEAM
P/L 0.3RG
0.5RW
0.5RG
FOG
SW;COMBINATION
CLEARANCE
SW;FOG LIGHT
0.5GY
22
2B
(LOWER)
NEW ZEALAND
OFF
TAIL
STD
(UPPER)
HEAD
1.25 G
HEAD LIGHT(RH)
21
1 0.5B
30
3
4
UPPER
LOWER
PASSING 5 0.5B
2
AUTO LIGHT SENSOR
1 2 3 4
2 8 3 9
AUTO LIGHT CONTROLLER
1 6 7 5 4
CUSTOM ONLY
TAIL LIGHT RALAY

TAIL LIGHT RALAY COMBINATION SW.
D08MY00094
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CIRCUIT DIAGRAM – RECTANGULAR HEADLIGHT (ON THE CAB)
SLOW BLOW FUSE No.2
FUSE 2
FUSE 4
FUSE 3
FUSE 1
(7.5A)
(7.5A)
(7.5A)
(7.5A)
TAIL LIGHT
1.25RW
1.25RB
1.25RY
1.25RL
HEAD LIGHT(LH)
3RY
3RB
3R
3R
(UPPER)
HEAD LIGHT
2B
(LOWER)
RELAY
(UPPER) (UPPER)
3R
0.5R
HEAD LIGHT
RELAY(LOWER)
HEAD LIGHT(RH)
(UPPER)
(LOWER)
HIGH BEAM (UPPER)

P/L 0.3RG
0.5RW
0.5RG
SW;COMBINATION
OFF
TAIL
HEAD
21
3 1 0.5B
4 30
UPPER
LOWER
PASSING 5 0.5B
0.5GW
TAIL LIGHT RELAY
CLEARANCE(LH)
0.5GR 0.5BL
0.5GR 0.5BL
CLEARANCE(RH)
d08mt013
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CIRCUIT DIAGRAM – RECTANGULAR HEADLIGHT (ON THE FRONT BUMPER)
SLOW BLOW FUSE No.1

SLOW BLOW FUSE No.2
FUSE No.12(KEY ON)

FUSE No.5
(BATTERY DIRECT)
FUSE 31
FUSE 2
FUSE 4
FUSE 3
FUSE 1
(7.5A)
(7.5A)
(7.5A)
(7.5A)
(15A)
TAIL LIGHT
1.25RW
1.25RB
1.25RY
1.25RL
0.5RG
CHINA EQUIP ONLY
0.5 RG
1.25 G
HEAD
3RB
3RY
3R
3R
LIGHT
RELAY
(UPPER)
FOG LIGHT
RELAY
3R
0.5R 0.85 RL
HEAD LIGHT
RELAY(LOW)
CLEARANCE(L)
HIGT BEAM
WARNING CLEARANCE(R)
P/L 0.3RG
SW;COMBINATION
SW;FOG LIGHT
0.5RW
0.5RG
22
<CHINA EQUIP ONLY>
OFF
TAIL SW;RR FOG RR FOG
HEAD LIGHT RELAY
21 6 5
3
1 0.5B 4 IND 3
4 30 2 1
UPPER DIODE;RR FOG
LOWER
PASSING 5 0.5B
13 2
REMIND BUZZER
11 14
SW;DOOR (Dr)
TAIL LIGHT R/L

1.25RW
1.25RB
1.25RY
1.25RL
HEAD LIGHT(LH)
(UPPER)
(LOWER)
2B
(UPPER)
HEAD LIGHT(RH)
(UPPER)
(LOWER)
2B
(UPPER)
FOG LIGHT(L)
RR FOG LIGHT
FOG LIGHT(R)
D08MY00095
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HIGH BEAM INDICATOR LIGHT

Refer to "METER AND WARNING/INDICATOR LIGHT"
in this section.
HEADLIGHT BULB
REMOVAL
Preparation:
Disconnect the battery ground cable.
1. Headlight Bulb
1) Tilt up the cab.
5 2) Disconnect the connector.
3) Remove the gasket.
4) Remove the dust cover.
5) Remove the bulb by loosen the clip.
NOTE:
4
In case of non-tilt type cab, and depending on the
equipment fitted, above removal is not applied.
In such a case, the bulbs can be removed after
headlight and fog light assembly is removed.
(Refer to HEADLIGHT ASSEMBLY in this section.
3
INSTALLATION
To install, follow the removal steps in the reverse
2 order.
801MT007
COMBINATION SWITCH
INSPECTION
Check the continuity between the terminals of the
switch.
W/O AUTO LIGHT
Position E T H Position H HU HL E
– UPPER
OFF LOWER
TAIL PASSING
10 9 8 7 6 5 4 3 2 1 HEAD Color – RB RY –
Switch side Terminal
2221201918 17 16 1514131211
Color BGGW – No. – 8 7 –
Terminal
No. 10 9 –
S
OFF INT
TIME OFF
INT ON
F UP
L
PASS HI OFF OFF
R ON
Combination Switch
825MT024
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W/AUTO LIGHT
Position E T H AUTO Position H' HU HL E

OFF UPPER
TAIL LOWER
23 28 31 24 10 9 8 7 6 5 4 3 2 1 HEAD PASSING
2221201918 17 16 1514131211 AUTO Color RW RB RY –
25 29 26 30 27
Color BG GW – LgB Terminal
No. 30 8 7 –
Terminal 10 9 – 12
Switch side No.
S
OFF INT
TIME OFF
INT ON
F UP
L OFF
PASS HI OFF OFF
R ON
AUTO
Combination Switch
825MY00043
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TAIL LIGHT, LICENSE PLATE LIGHT, STOPLIGHT AND

ROOF MARKER LIGHT
GENERAL DESCRIPTION
The circuit consists of the lighting switch, taillight, license plate light, stoplight switch, stoplight and relay.
All these lights come on when the lighting switch are turned on with the switch to either clearance or
headlight position.
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CIRCUIT DIAGRAM
SLOW BLOW FUSE No.2
STARTER (ON)
FUSE26
FUSE13
FUSE27
(7.5A)
(15A)
(15A)
2G
1.25RG
0.5Sb
1.25R
TAIL LIGHT RELAY STOP LIGHT RELAY
2G TR.
DIODE
0.5GW
0.5LO
TRAILER BRAKE SW
TYPE
DIODE
RED-4ONLY
0.5GW
C/U;HSA(19)
0.5GW
C/U;TYPE RED4
1.25GR
0.5GW
1.25G
0.85G
C/U;COMMONRAIL
SW;STOP LIGHT
1.25RG
0.5B
FOG LIGHT RELAY

COMBINATION SW
FLASHER UNIT(LH)
FLASHER UNIT(RH)
0.85GR TRAILER SOCKET
0.85G
TRAILER SOCKET
0.85GR
0.85G
1.25RG
REAR COMBINATION
LIGHT(LH) LICENSE PLATE LIGHT
TAIL 1.25BL 0.85BL
STOP
0.85GB
FLASHER
OPTION (LH)
0.85BL
0.85GR
0.85GY
OPTION (RH)
0.85BL
REAR COMBINATION
LIGHT(RH)
TAIL 1.25BL
STOP
0.85GO
FLASHER
D08M200058
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CIRCUIT DIAGRAM – DELUXE TYPE
SLOW BLOW FUSE No.2
STARTER (ON)
FUSE26
FUSE13
FUSE27
(7.5A)
(15A)
(15A)
1.25RG
＜NEWZEALAND EQUIP＞
2G
ROOF MARKER LAMP

0.5Sb
1.25R
TAIL LIGHT RELAY STOP LIGHT RELAY
2G
0.5
GW
GW
0.5
STOP & TAIL

DIODE
P/L TYPE RED-4 TR.
ONLY DIODE
＜CHINA EQUIP＞
＜AUSTRALIA EQUIP＞
ROOF MARKER LAMP
GW
0.5
1.25GR
0.3GW
0.5GW
SW;STOP LIGHT
1.25G
0.85G
0.5B
C/U;HSA(19)
C/U;TYPE RED-4
C/U;COMMONRAIL
0.5LO
TRAILER BRAKE SW.
FOG LIGHT RELAY
COMBNATION SW.
FLASHER UNIT (LH)

FLASHER UNIT (RH)
0.85GR
0.85G
1.25RG
REAR COMBINATION
LIGHT(LH) LICENSE PLATE LIGHT
TAIL 1.25BL 0.85BL
0.5GW
STOP
TURN
OPTION (LH)
0.85BL
0.85GR
0.85GY
OPTION (RH)
0.85BL
SIDE MARKER CONN(RH)
SIDE MARKER CONN(LH)
REAR COMBINATION
CHAINA EQUIP ONLY
LIGHT(RH)
TAIL 1.25BL
STOP
TURN
D08M200059
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STOPLIGHT BULB
TAILLIGHT BULB
REMOVAL
Preparation:
1. Lens
2 1
2. Bulb
803MY00005
INSTALLATION
order.
LICENSE PLATE LIGHT BULB

3
2
REMOVAL
1 1. Cover
2. Lens
3. Bulb
INSTALLATION
803MT006 order.
ROOF MARKER LIGHT BULB
1
REMOVAL
1. Lens
2. Bulb
2
INSTALLATION
order.
801MY00001
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STOPLIGHT SWITCH
Switch side
1 2 INSPECTION
1) Check to see if stoplight switch is installed
Terminal No. correctly to the specified position. Adjust the
SW position
1 2 position when the result of the inspection is found
Depress brake pedal (Push abnormal.
rod out) 2) Check to see if there is any continuity between the
Release brake pedal (Push terminals of the stoplight switch.
rod in)
Replace the switch when the result of inspection is
found abnormal.
TAIL LIGHT RELAY

1
3
STOP LIGHT RELAY
4 2 3 INSPECTION
5 1 Check to see if there is any continuity between the
2 4
relay terminals.
5
found abnormal.
3 – 5 ........... Continuity
803MY00050 1 – 5 ........... No continuity
(When battery voltage is applied between 2 – 4)
3 – 5 ........... No Continuity
1 – 5 ........... Continuity
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TURN SIGNAL LIGHT AND HAZARD LIGHT

GENERAL DESCRIPTION
The circuit consists of turn signal light (front, side and rear), turn signal light switch, hazard switch and
flasher & hazard unit.
When turning on the respective switches, the turn signal light will operate. When the turn signal light is
flashing, the indicator light in the meter also start flashing. When the hazard warning switch is turned on,
the current flows to the flasher unit through the hazard warning switch to cause the hazard warning light to
flash, independent of the position of the starter switch. At the same time, the indicator lights in the meter
also start flashing.
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CIRCUIT DIAGRAM
SLOW BLOW FUSE No.1
3W
FUSE30
(15A)
1.25G
TAIL LIGHT
RELAY
1
CORNER FLASHER UNIT
LIGHT(RH) 6 5 4 3 2
0.5RG
CORNER
LIGHT(LH)
0.85GO
0.85GB
0.5LO
0.5LB
0.5LR
0.5GO
0.5GB
SW;
COMBINATION (W/BUMPER H/L)
8 9 6 7
HAZ. TURN FRONT TURN(LH)
L 0.5GB 0.5BL
L'
OFF NEUTRAL FRONT TURN(RH)
R' 0.5GO 0.5BL
R
ON
SIDE TURN(LH)
0.5GB 0.5BL
TURN(LH) SIDE TURN(RH)

P/L 0.3GB 0.5GO 0.5BL
TURN(RH)
P/L 0.3GO
SW; TR. FLASHER
TRAILER SOCKET
TRAILER SOCKET
0.85GO
0.85GB
(W/O BUMPER H/L)
FRONT TURN(LH)
0.5GB 0.5BL
FRONT TURN(RH)
0.5GO 0.5BL
D08M200060
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FRONT TURN SIGNAL LIGHT/BULB

2 REMOVAL
1 Preparation:
1. Front Combination Light Lens
Remove two screws
2. Bulb
801MT005 INSTALLATION
order.
SIDE TURN SIGNAL LIGHT/BULB

REMOVAL
Preparation:
1. Lens
2
2. Bulb
1 INSTALLATION
801MT006 To install, follow the removal steps in the reverse
order.
FLASHER & HAZARD UNIT

INSPECTION
When a 55W bulb is connected to the unit side
connector terminals "5" and "2" while connecting the
3 2 1
battery (+) terminal to terminal "1", and the battery (–)
6 5 4 terminal to terminal "2" does the bulb light on and off?
Replace the unit when the result of inspection is found
abnormal.
828MT015
REAR TURN SIGNAL LIGHT/BULB

REMOVAL
Preparation:
1. Lens
2. Bulb
2 1
INSTALLATION
803MY00004 To install, follow the removal steps in the reverse
order.
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CORNER LIGHT/BULB
REMOVAL
Preparation:
1. Socket
2. Bulb
INSTALLATION
order.
HAZARD SWITCH
TURN SIGNAL LIGHT SWITCH
(COMBINATION SWITCH)
INSPECTION
Check the continuity between the terminals of the turn
signal light switch.
TURN HZ HZ HZ
HAZARD SIGNAL TL E1 TR CL CE CR ON E OFF
L
L
OFF NEUTRAL
R
R
10 9 8 7 6 5 4 3 2 1
Switch side
-
2221201918 17 16 1514131211
ON
-
Color GY BG GO WL - WR - - -
Terminal No. 5 10 4 3 - 2 - - -
S
OFF INT
TIME OFF
INT ON
F UP
L
PASS HI OFF OFF
R ON
Combination Switch
825MT029
REMOVAL AND INSTALLATION

Refer to "HEADLIGHT, FOG LIGHT AND CORNERING
LIGHT" in this section.
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HORN, BACKUP LIGHT AND BACKUP BUZZER

GENERAL DESCRIPTION
The circuit consists of the starter switch, horn, horn switch, backup light (Rear combination light), backup
light switch, back buzzer and the relay.
When the horn switch is turned on independent of the position of the starter switch, the relay is activated to
sound the horn. When the backup light switch turns on with the starter switch on, the backup light will
operate.
BACKUP LIGHT AND BACKUP BUZZER CIRCUIT
Starter sw.(ON)
Backup light
sw.
Backup light
(Rear combination Backup Backup
light-LH) light buzzer
(Rear combination
light-RH)
D08MY00114
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CIRCUIT DIAGRAM
FUSE No.12
0.85Br
0.85Br
AIR HORN
0.85GR
R/L;HORN
0.85GW
0.5GR
SW;HORN
(COMBINATION
0.85B
SW)
10
<A/T ONLY>
0.85Br
<M/T ONLY>
SW;BACK LIGHT
0.85Br
(AT542 T/M)
(AT545 T/M)
0.85Br(M/T)
0.85RL(A/T)
C/U;A/T
R/L;A/T(BACK LIGHT)
0.85GW
(MD3560P T/M ONLY)
ELEC.HORN
0.85BL
0.85GW
TRAILER SOCKET
0.85BL
0.85R
ELEC HORN
SW;
BACK UP LIGHT
REAR COMBINATION
0.85RL
LIGHT (RH)
BACK BUZZER
1.25BL
BACK UP LIGHT
1.25BL
REAR COMBINATION
LIGHT (LH)
BACK UP LIGHT
D08MY00098
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STARTER SWITCH
Refer to "START AND CHARGING" in this section.
Horn ELEC. HORN

INSPECTION
Check to see if horn sound when a battery voltage
between horn terminal and the fixing bracket. Repair
Battery or replace the horn when the result of inspection is
found abnormal.
+ –
828MY00002
REMOVAL
Preparation:
1 Disconnect the battery ground cable.
1. Horn Assembly
Remove the screw.
2. Horn
Disconnect the connector.
2
828MT007
INSTALLATION
order.
AIR HORN
1
2 INSPECTION
When there is the air on the vehicle, apply battery
voltage to the horn connector (horn side) to check the
horn sound.
4
REMOVAL
3 Preparation:
905MW005
1. Air pipe
2. Harness connector
3. Air horn fixing 2 BOLTS
4. Air horn
INSTALLATION
order.
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HORN HORN SWITCH

RELAY; HORN
COIL H INSPECTION
B With the contact point of the horn switch pressed to
S
CONTACT POINT
the switch bracket, check the continuity between the
connector terminal and the bracket of the switch.
HORN SWITCH
TERMINAL
Check the contact condition between horn contact of
the combination switch and contact plate of steering
BATTERY
wheel.
828MT013
REMOVAL
Steering wheel nut
Preparation:
3 1 Disconnect the battery ground cable.
1. Horn Pad
1) Hold the horn pad and pull it upward.
2. Steering Wheel
1) Remove the steering wheel nut.
2) Remove the steering wheel by using steering
2
wheel remover.
430MT001
(Refer to Section 3B4 "STEERING COLUMN"

for steering wheel removal steps.)
3. Horn Switch
INSTALLATION
order, noting the following point.
1. Tighten the steering shaft nut to the specified torque
Shaft nut torque N·m (kg·m/lb·ft)
49 (5/36)
BACKUP LIGHT BULB

REMOVAL
Preparation:
1. Lens
2. Bulb
2 1
803MY00003
INSTALLATION
order.
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BACKUP LIGHT SWITCH

INSPECTION
1. With the switch installed to the transmission,
check the continuity between the terminals of the
switch connectors.
When the continuity is found between the
terminals only with the switch shifted to the
1.8
reverse position, the switch is normal.
825MY00049
2. When the result of the above inspection is found
abnormal, remove the switch from the
transmission and conduct a test on the switch
alone.
If the continuity appears between the connector
terminals when the ball of the switch is released,
the switch is normal. (When the ball is pushed, the
continuity disappears.)
3. If there is no continuity with the switch installed to
the transmission, even though the switch is found
to be normal, then adjust the stroke of the switch
by changing the thickness of the switch gasket.
REMOVAL
Preparation:
1. Backup Light Switch
1) Disconnect the connectors.
2) Remove the switch by turning it counterclockwise.
INSTALLATION
1. Backup Light Switch
Apply liquid gasket to the screw portion of the switch
to prevent oil leak.
HORN RELAY
1
3
BACKUP LIGHT RELAY
4 2 3 INSPECTION
5 1 Check to see if there is any continuity between the
relay terminals.
2 4
5
found abnormal.
825MY00050 1 – 5 ..... No continuity
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Connector BACKUP BUZZER

INSPECTION
Apply battery voltage to the backup buzzer connector
to check the buzzer sound.
Repair or replace the buzzer when the result of
803MY00001
REMOVAL
Preparation:
Connector
1. Rear Combination Light Cover
2. Backup Buzzer
2
1) Remove the rear combination light connector
fixing screw.
1 2) Remove buzzer fixing screw.
3) Disconnect the connector.
803MY00002
INSTALLATION
order.
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DOME LIGHT AND FLUORESCENT LIGHT

GENERAL DESCRIPTION
The circuit consists of dome light, dome light switch, fluorescent light and door switch.
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CIRCUIT DIAGRAM
SLOW BLOW FUSE NO.1
FUSE No. 5
FUSE 5
(7.5A)
DOME LIGHT
SW;DOOR(DRIVER)
0.5RY
0.85R
FLUORESCENT LIGHT
0.85B
(DOME LIGHT)
DIODE;DOME LIGHT
(FOR CUSTOM)
(FOR CHINA)
<CREW CAB>
REAR DOME LIGHT
D08MY00099
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2
DOME LIGHT BULB
REMOVAL
Preparation:
2 Disconnect the battery ground cable.
1. Lens
Hold the lens and pull it downward.
1
2. Bulb
805MT001
INSTALLATION
order.
DOME LIGHT SWITCH
ROOM
805MT002
FLUORESCENT LIGHT
660MW001
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DOOR SWITCH
Slide INSPECTION
Terminal – Release Push Check to see if there is any continuity between the
Terminal +
terminals and the body while operating the door
switch.
Repair or replace the switch, when the result of
Terminal
SW No. 1 Body
operation
Push
Release
825MY00047
REMOVAL
Preparation:
Slide part Disconnect the battery ground cable.
1. Door Switch
1) Remove the screw.
2) Disconnect the connector of the switch.
825MY00048
INSTALLATION
order.
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POWER WINDOW, DOOR LOCK AND KEYLESS ENTRY

GENERAL DESCRIPTION
The circuit consists of the starter switch, door lock switch, door switch module, door lock actuator and
power window motor.
The door switch module is always provided with battery voltage. The key or the inside lock knob on the
driver's door can activate the lock mechanism of all the doors.
When the starter switch is turned on, the battery voltage is applied to each of the power window switches
through the circuit breaker and the power window relay on the circuit.
By operating the switches of each window to select "UP" or "DOWN", the revolving direction of the power
window motor changes to open or close the window.
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CIRCUIT DIAGRAM – FOR RHD
SLOW BLOW FUSE No.1
FUSE No.12
FUSE32
FUSE33
FUSE 7
(7.5A)
(15A)
(15A)
1.25GB
1.25GR
0.85RL
<DRIVER'S SIDE>
0.5Br
<ASSISTANT'S SIDE> DOOR SW MODULE

DOOR SW MODULE
5
1 1
6
7 0.5LgW 7
14 0.5LgR 14
8 0.5LgB 8
3 SW;DOOR LOCK
0.5RG 12
0.5GB 11
0.5B
4 2
UP
DOWN
1.25B
3
9
1.25W
1.25B
10
4 2
1.25L
1.25L DOWN
UP
POWER
WINDOW
MOTOR
1.25W
M
POWER
DOOR LOCK ACTUATOR WINDOW
0.5BrR MOTOR
0.5BrY M
D08MT020
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CIRCUIT DIAGRAM – FOR RHD CUSTOM (W/KEYLESS ENTRY)
SLOW BLOW FUSE No.1
FUSE No.8
FUSE No.12
FUSE32
FUSE33
FUSE7
(15A)
(15A)
(7.5)
1.25GB
1.25GR
0.85RL
O.5Br <DRIVER SIDE>

0.5L
<PASSENGER SIDE> DOOR SW MODULE

DOOR SW MODULE
5
1 1
0.5LgW
7 7
0.5LgR
14 14
0.5LgB
8 8
3 3
1.25B
1.25B
4 2 4 2
DOWN
DOWN
UP
UP
1.25W
1.25W
1.25L
1.25L
DOOR LOCK
R/C UNIT
POWER POWER
5 3
WINDOW WINDOW
MOTOR MOTOR
4 1 2 8 7
M M
0.5B
DOOR LOCK ACTUATOR LH DOOR LOCK ACTUATOR RH

0.5BrR
M 4 4 M
0.5BrY
2 2
0.5BrL
1 3
0.5RB
0.5B
SW;DOOR(PASS)
0.5B
SW;DOOR (Dr)
D08MY00100
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CIRCUIT DIAGRAM – FOR LHD
SLOW BLOW FUSE No.1
FUSE No.12
FUSE33
FUSE32
FUSE 7
(7.5A)
(15A)
(15A)
1.25GB
1.25GR
0.85RL
<DRIVER'S SIDE>
0.5Br
<ASSISTANR'S SIDE> DOOR SW MODULE

DOOR SW MODULE
5
1 1
6
7 0.5LgW 7
14 0.5LgR 14
8 0.5LgB 8
3 SW;DOOR LOCK
0.5RG 12
0.5GB 11
0.5B
4 2
1.25L DOWN
1.25W UP
1.25B
3
9
1.25B
10
4 2
1.25L DOWN
UP
POWER
WINDOW
1.25W
MOTOR
M
POWER
DOOR LOCK ACTUATOR WINDOW
0.5BrR MOTOR
0.5BrY
M
D08MT021
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TRANSMITTER
825MY00038
TRANSMITTER BATTERY
BATTERY
825MY00045
KEYLESS ENTRY KEYLESS ENTRY CONTROL UNIT

CONTROL UNIT
CONNECTOR
4 3 2 1
10 9 8 7 6 5
OVERRIDE SWITCH
ANTENNA JACK
825MY00051
DOOR SWITCH
DOOR SWITCH
PUSH(ON)
SELF-
RETURN
(OFF)
825MY00046
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TROUBLE SHOOTING
Step Action Yes No
1 1. Close all the doors. The system is Go to step 2
2. Operate the transmitter. normal
Do the doors lock and unlock?
2 1. Turn the starter switch to ACC position. Go to step 4 Go to step 3
2. Hold the control unit override switch depressed for at least
two seconds.
Does the door lock knob operate?
3 Does the relay operating noise sound? Go to step 15 Go to step 9
4 1. Replace the transmitter battery. Go to step 8 Go to step 5
2. Close all the doors.
3. Operate the transmitter.
Do the doors lock and unlock?
5 1. Replace the transmitter. Go to step 8 Go to step 6
2. Input ID code.
Can ID code be input?
6 1. Replace the keyless entry control unit. Go to step 8 Go to step 7
2. Input ID code.
Can ID code be input?
7 1. Replace the antenna. Go to step 8 Move the vehicle
2. Input ID code. to a new location
Can ID code be input? and perform the
tests again
8 Check the keyless entry system operation. – Go to step 1
Does the system work normally?
9 Is the fuse 7 normal? Go to step 10 Replace the fuse
10 Disconnect the keyless entry control unit connector. Go to step 11 Repair the circuit
Is the battery voltage applied to the control unit harness side
connector terminal No. 5?
11 Turn the starter switch to ACC position. Go to step 12 Repair the circuit
Is the battery voltage applied to the control unit harness side
connector terminal No. 3?
12 Is there continuity between the control unit harness side Go to step 13 Repair the circuit
connector terminal No. 7 and the ground?
13 Is there continuity and no continuity alternately between the Replace the Go to step 14
control unit harness side connector terminal No. 4 and the control unit
ground when the doors are open and closed.
14 Is the door switch normal? Replace the Repair or replace
control unit the switch
15 1. Disconnect the keyless entry control unit connector. Replace the Go to step 16
2. Connect the control unit harness side connector terminal control unit
No. 2 to the battery positive terminal, and No. 1 to the
negative terminal.
3. Connect the control unit harness side connector terminal
No. 1 to the battery positive terminal, and No. 2 to the
negative terminal.
Does the door lock actuator work?
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Step Action Yes No

16 1. Remove the door lock actuator and disconnect the Repair the circuit Go to step 17
connector.
2. Connect the actuator side connector terminal No. 2 to the
battery positive terminal, and No. 4 to the negative
terminal.
3. Connect the actuator side connector terminal No. 4 to the
battery positive terminal, and No. 2 to the negative
terminal.
Does the actuator work?
17 Is the continuity and no continuity alternately between the Go to step 18 Repair or replace
actuator side connector terminal No. 1 and No. 1 when the the actuator
actuator works?
18 1. Connect the actuator connector. Replace the Repair the circuit
2. Perform the operation of step No. 15. control unit
Is there continuity between the control unit harness side
connector terminal No. 8 and the ground?
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KEYLESS ENTRY CIRCUIT CHECK

Use the table below to check the keyless entry system circuit.
1 2 3 4
5 6 7 8 9 10
Harness side
Terminal Connecting
Connection Check item Condition Criteria
No. terminal
1
Door lock actuator Continuity 1-2 – Continuity
2
Starter SW “ACC” Approx. 24V

3 Starter SW (ACC) Voltage 3-Ground
Starter SW “OFF” 0V
Door “Open” Continuity

4 Door SW Continuity 4-Ground
Door “Closed” No continuity
5 Fuse 7 (Battery) Voltage 5-Ground – Approx. 24V
6 – – – – –
7 Ground Continuity 7-Ground – Continuity
Door “Locked” No continuity

8 Door lock actuator Continuity 8-Ground
Door “Unlocked” Continuity
9 – – – – –
10 – – – – –
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INSPECTION 4. Press and hold the LOCK or UNLOCK button

on the transmitter until the doors lock and
After replacing the keyless entry control unit
unlock a single time.
and/or the transmitter, perform the following
steps. NOTE:
1. Make sure that the battery cables are This step must be done within 5 seconds of
connected securely. completion of step 3.
2. Input the keyless entry ID code. 5. Check the keyless entry system operation.
NOTE:
ID Code Deletion
Refer to “ID Code Input”.
1. Close all the doors.
3. Make sure that the system works normally
by operating the transmitter.
NOTE:
Make sure that all the doors are unlocked.
NOTE:
2. Turn the starter switch to the ON position.
• Operate the transmitter within 2 meters (6
feet) away from the vehicle. 3. Depress the override button for at least 2
seconds by using the tip of a ballpoint pen
• Hold the LOCK and UNLOCK buttons pressed
or some similar object until the doors lock
at least 1 second when operating.
and unlock a single time.
NOTE:
CAUTION:
The override button is next to the antenna jack
If the system does not work normally, check the of the control unit.
following points.
4. Depress the override button for at least 2
• Make sure that the battery terminals are seconds by using the tip of a ballpoint pen
connected securely. or some similar object until the doors lock
• Make sure that all the doors are closed. and unlock two times.
• Make sure that the antenna cable is NOTE:
connected to the control unit securely. This step must be done within 5 seconds of
• Make sure that the harness connectors are completion of step 3.
connected securely.
CAUTION:
KEYLESS ENTRY ID CODE
Delete the old ID code immediately if the
Before using the keyless entry control unit, the
transmitter is lost or stolen. This protects you
transmitter ID codes must be properly input into
against vehicle theft.
the keyless entry control unit. The following
paragraphs describe old ID code deletion and
new ID code input following control unit and/or
OPERATING PRECAUTIONS
transmitter replacement due to loss or damage. • ID codes stored in the keyless entry control
unit are erased whenever the battery is
Two ID codes can be input into a single control
disconnected.
unit. Identical ID code can be input into more
than one control unit. • Do not allow the transmitters to get wet.
• Do not drop the transmitters or subject it to
ID Code Input shock.
1. Close all the doors. • Do not put the transmitters on the vehicle
NOTE: floor or some other area where it is likely to
be stepped on.
Make sure that all the doors are unlocked.
• Do not leave the transmitters in the vehicle
2. Turn the starter switch to the ON position.
or some other location where temperatures
3. Depress the override button for at least 2 exceed 60°C (140°F). Battery failure and
seconds by using the tip of a ballpoint pen other damage will result.
or some similar object until the doors lock
• Press and hold the transmitter
and unlock a single time.
LOCK/UNLOCK buttons for at least 1 second
NOTE: when locking and unlocking the doors.
The override button is next to the antenna jack • The keyless entry system does not work
of the control unit. when the doors are open.
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• The doors must be opened within 20

seconds of the time they are unlocked. If
they are not, they automatically relock. This
provides additional protection against
vehicle theft.
• After locking the doors by the transmitter,
check that doors are locked by pulling on the
outside door handle.
• Transmitter maximum range is
approximately 2 meters (6 feet) from the
vehicle. Range may vary slightly with
conditions surrounding the vehicle.
• Transmitter battery life is approximately 1
year. Replacement batteries can be
purchased at electrical stores and camera
shops.
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WINDSHIELD WIPER AND WASHER

GENERAL DESCRIPTION
The circuit consists of the starter switch, windshield wiper & washer switch, wiper motor, washer motor
and the intermittent relay.
When the wiper & washer switch is turned on with starter switch on, the battery voltage is applied to the
wiper motor to activate the wiper.
The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The intermittent
relay is used to control motion of the wiper.
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CIRCUIT DIAGRAM
SLOW BLOW FUSE No.6
FUSE No.12
FUSE38
(15A)
0.85Br
WASHER MOTOR
1 M 2
0.85LR
SW;COMBINATION
SW;WIPER&WASHER
W P I E H L
WASHER
HIGH
LOW
INT
OFF
0.85LO 12 25
INTERMITTENT
0.5B
RELAY
11 26 24 23
WIPER MOTOR
BREAKER
0.5LW
+
0.85BrW
0.85BrY
M S
L H -
0.85B
COMPRESSOR
D08MY00101
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STARTER SWITCH
Refer to "START AND CHARGING" in this section.
Windshield wiper & washer SW

WINDSHIELD WIPER & WASHER
SWITCH
With the starter switch on, the windshield wiper and
S
washer switch controls the start and stop operation as
well as change of operating speeds.
OFF INT
TIME OFF
INT ON
F UP
L
PASS HI OFF OFF
R ON
Both the windshield washer motor and the wiper

motor jointly operate while the washer button is
pushed.
Combination Switch
825MT026
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CIGARETTE LIGHTER AND POWER OUTLET

GENERAL DESCRIPTION
The circuit consists of the starter switch, 24V power outlet, 12V power outlet, cigarette lighter and the relay.
When the cigar lighter is pushed in with the starter switch at either "ON", "HEAT" or "START" position, a
circuit is formed in the cigar lighter case to heat the lighter coil. The cigar lighter springs back to its original
position after the lighter coil is heated.
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CIRCUIT DIAGRAM
SLOW BLOW FUSE No.1
SLOW BLOW FUSE No.6
FUSE No.12
FUSE29
FUSE40
FUSE41
(15A)
(15A)
(15A)
TAIL LIGHT
3GW
DC CONVERTER
1.25GW
1.25GO
R/L;
0.5RG
0.5Br
CIGARETTE
3G
LIGHTER
0.3B
POWER
OUTLET;
12V
CIGARETTE LIGHTER
0.5B
1.25B
POWER
OUTLET;
24V
1.25B
D08MY00102
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CIGARETTE LIGHTER
REMOVAL
Preparation:
1. Center Cluster
2. Cigar Lighter Assembly
Remove the nut, then remove cigarette lighter
assembly and outer case.
826MT005
INSTALLATION
order.
OUTLET (24V RECEPTACLE)
1
2
745MT001
OUTLET (12V SOCKET)
−
826MY00004
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CIGARETTE LIGHTER RELAY

1
3 INSPECTION
5 1
relay terminals.
2 4
found abnormal.
5
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METER AND WARNING/INDICATOR LIGHT

GENERAL DESCRIPTION
The circuit consists of the starter switch, meter assembly, air low pressure switch, seat belt switch, oil
pressure switch, brake fluid switch, parking brake switch, fuel tank unit, thermo unit and engine speed
sensor.
The meter assembly contains the speedometer, tachometer, fuel meter, thermometer and the
warning/indicator light.
The meter warning/indicator lights and their bulb sockets are a unit, they are installed from the back of the
meter assembly.
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CIRCUIT DIAGRAM
POWER SUPPLY
(KEY ON)
FUSE NO.11
FUSE NO.11
FUSE11
(7.5A)
R/L; RANGE
0.5Y
WARNING LIGHT 0.5Y

0.5BL
0.85Y 0.85YR CHARGE 0.5WR
A6 A1 ACG(L) SW:RANGE
0.5Y 0.5B TAIL STOP
0.5LW
A5 TAIL
0.5G
BUZZER O/RUN ENG.O/RUN
A3 A2
METERS BEAM
0.5WG
A14 HEAD LIGHT 0.5BL
0.5Y
WATER TEMP. SEAT BELT
0.5G
0.5Y B2 SEAT BELT SW:RANGE
C12 C15 T/M HIGH
B8 EATON T/M
T/M LOW
0.5B
B9 ZFT/M LOW
FUEL EATON T/M
AIR 0.5YG
A10
0.5YG
PARKING
0.5LB
0.5B
B5
RETARDER
B2
OIL
TACHOMETER B1 <A/T> MD3560 T/M ONLY
C8 A/T OIL
0.5Y B6 B8 0.5LW (C/U;A/T)
C7 TR.BRAKE
C16 C10 C17 C6 A4
DO NOT SHIFT
B9 C/U A/T
0.5GW
T/F/HIGH
0.5LO
B9 4WD
FRONT DRIVE
0.5BW
0.5YV
0.5YR
0.5RB
0.5BY
(W/O THAI GXZ)

0.5LR
B2 4WD
R/L;
BRAKE
SW;TR
HOLDING A8 P/L CHECK
BRAKE CIRCUIT (W/ADR)
SW;
0.5GO
0.5YB
BULB CHECK
0.5G
B7 DIODE
STOP LIGHT REALY
IVES (2)
IVES (1)
C/U;TICS ※ 1 , 2 , 3
C/U;TICS ※ 1 , 2 , 3
FLASHER UNIT
STOP LIGHT
TAIL LIGHT
FLASHER (LH)
FLASHER (RH)
BACK UP LIGHT
0.85BrB
SW;TR.BRAKE
(THAI GXZ
0.5GO
0.5YB
ONLY) 2 7 5 3 6 4
TRAILER SOCKET
0.5YG
1
0.5BW
0.85BL
0.5RB
0.5YV
0.5YR
SW;TR.FLASHER
0.5BL
(AT 542) SW;A/T OIL

TACHO SENSOR (AT 545) 0.85BL
SW;OIL PRESS
0.85BL
UNIT;FUEL TANK SW;BRAKE FLUID
0.5BL
0.5BL SW;BRAKE
0.5BL
UNIT;WATER THERMO SW;BRAKE
0.5BL
※ 1 C/U ; COMMONRAIL
※ 2 C/U ; EVT
※ 3 C/U ; TYPE RED-4
D08M200066
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TAIL LIGHT
FUSE No.12
FUSE No.11
0.5YG
C/U; BRAKE LOCK
WARNING LIGHT
0.5Y GLOW
DIODE E4 E5 C/U;RED-4
WITH B/L ONLY HSA
0.5Y
E2 E3 C/U;HSA
W/WHEEL PARKING BRAKE LOCK(RED)
BRAKE BRAKE LOCK
0.5Y
BRAKE LOCK(GREEN)
R/L;WHEEL BRAKE LOCK
AIR BUZZER PARKING BRAKE DIFF LOCK(FRONT)
0.5GW FRT SEAT BELT
A7 A15 D/LOCK
SERVICE ENG SOON P/L
0.5Y
A15 C/U;TICS
0.3YR
0.5RG
FLASHER LH
0.5Br
FLASHER LH B3
HAND BRAKE CIRCUIT FLASHER RH
FLASHER RH A13 P/L;
SW; PTO SEAT BELT
PARKING BRAKE
PTO B4
DIFF LOCK
0.5B D/LOCK A11
0.3B
TYPE EXHAUST BRAKE
RED-4 ONLY EXHAUST BRAKE A12
0.5LB T/F LOW
4WD
0.5LO
B4
0.5LR
0.5YG C1
PTO
PTO A11
C2 METER SW.
ILLUMINATION SEAT BELT
0.5LB
BUZZER
0.85B
TIMER RELAY
0.5B
0.5B
0.3LB
C/U; HSA(2)
0.5LB 0.5LB C/U; TYPE RED-4
C/U; COMMON RAIL
C/U; BRAKE LOCK, IVES
C/U; TICS
RETARDER
0.5LB
0.5YG
SW;WHEEL
SW;AIR LOW PRESS PARKING BRAKE
0.5BL 0.5BL
D08M200067
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METER ASSEMBLY
GAGES AND WARNING INDICATOR LIGHTS LAYOUT
A/T LOW TR
OIL BRAKE
BRAKE /T ENGINE
AIR PTO P S
O/RUN
5 0
20 25
5 80
30 60 00
C
0 5 0
kg/cm
2
35 40 000000 20
F H
5
40 20 40
0 0 0 0 0
E C
0
km/h
LOCK
HIGH ABS
HSA LOW ABS FRONT

LOCK PTO
These warning or indicator lights are only for FXZ.
821M200008
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BULB LOCATION
WARNING / INDICATOR LIGHTS
ILLUMINATION LIGHTS
WARNING / INDICATOR LIGHTS
821M200010
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METER CONNECTOR TERMINAL ASSIGNMENT
CONNECTOR A CONNECTOR B
CONNECTOR C CONNECTOR D CONNECTOR E
CONNECTOR A CONNECTOR B CONNECTOR C CONNECTOR D CONNECTOR E

1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 1 2 3 4 5 6
8 9 10 11 12 13 14 15 5 6 7 8 9 9 10 11 12 13 14 15 16 17 4 5 6 7 7 8 9 10 11 12 13
No. Connected to No. Connected to No. Connected to No. Connected to No. Connected to
1 CHARGE 1 OIL 1 GND 1 1
SEAT BELT,
2 IGN 2 FRT DRIVE, RETARDER
2 ILLUMI( +) 2 2 HSA
3 ENG. O/RUN 3 FLASHER(LH) 3 ILLUMI( - ) 3 3 HSA
TR.BRAKE,
4 FUEL FILTER 4 PTO,LOW 4 4 4 GLOW PLUG
5 TAIL STOP 5 PARK BRAKE 5 5 5 GLOW PLUG
TACHOMETER TACHOMETER
6 IGN 6 (IGN) 6 (GND) 6 6
DIFF LOCK,
7 SERVICE ENGINE SOON 7 7 IVES SW.(1) 7 7
BRAKE, IVES SW.(2)
8 AIR MASTER 8 A/T OIL,T/M HIGH 8 ENG. O/RUN SW. 8
LOW, HIGH OIL TEMP.
9 9 DO NOT SHIFT 9 GAUGE UNIT 9
10 BRAKE AIR 10 FUEL GAUGE 10
UNIT
DIFF LOCK,
11 PTO 11 11
GAUGE UNIT
12 EXH.BRAKE 12 (IGN) 12
13 FLASHER(RH) 13 13
14 BEAM 14
DIFF LOCK, GAUGE UNIT
15 SERVICE ENGINE SOON 15 (GND)
WATER TEMP.
16 GAUGE UNIT
TACHOMETER
17 (PULSE)
821M200009
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SPEEDOMETER
The speedometer is made up of the cross coil type
60 80 ammeter (movement) that displays indications, the
40 stepper motor that drives and adds up the odometer
0000000
100
and trip meter, and the driving circuit (printed circuit
20 120 board) that makes exchanges between the pulse
0000000
0 signals and the current.

140
km/h
821MT016
km/h ON-VEHICLE SERVICE

Tester display Meter display Check the meter display accuracy and the operation of
speed permissible level the odometer with the speedometer tester.
20 17 – 23
NOTE:
Inappropriate the inflation may affect the accuracy of
40 38.5 – 43.0
the odometer.
60 0.59 – 63.5
(To conduct this test, refer to the tester
100 100 – 105 manufacturer's instruction manual.)
120 120 – 126 Since the meter display permissible levels above are
specifications solely for the meter, they are to be
used as reference values when conducting on-vehicle
service.
INDIVIDUAL INSPECTION
Remove the speedometer from the meter assembly
and measure the resistance and the current
consumption between each terminal.
Replace the speedometer when the result of
TACHOMETER
The tachometer is made up of the cross coil type
20 25 ammeter (movement) that displays indications, and
5 the drive circuit (printed board) that makes exchange
30
between the pulse signals and the current.
0
35
5
40
0
821MT020
r/min ON-VEHICLE SERVICE INSPECTION

Tester display Meter display 1. Set up the tune-up tester to the engine.
speed permissible level
2. Start the engine and compare the readings displayed
500 450 – 5500 by the tachometer and the tester.
1000 900 – 1100
When the difference between these two readings
1500 1380 – 1620
differs largely from the specified value, replace it with
2000 1880 – 2120
a correct one.
2500 2350 – 2650
3000 2850 – 3150
3500 3350 – 3650
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NOTE:
Since the meter display permissible levels above are
5 specifications solely for the meter, they are to be
20
0 used as reference values when conducting on-vehicle
inspection.
25
5
30
0
821MT019
rpm
Tester display Meter display
speed permissible level
500 450 – 550
1000 900 – 1100
1500 1380 – 1620
2000 1880 – 2120
2500 2350 – 2650
INDIVIDUAL INSPECTION
Remove the tachometer from the meter assembly and
measure the resistance value and the current
consumption between each terminals.
Replace the tachometer when the result of inspection
is found abnormal.
Vehicle speed sensor (Installed on the

transmission)
The vehicle speed sensor is installed on the rear
portion of the transmission.
The number of pulses generated is eight pulses per
one rotation of the pinion shaft.
820MT001
The vehicle speed sensor is installed on the rear

portion of the transmission.
The number of pulses generated is 25 pulses per one
rotation of the pinion shaft.
821MW003
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INSPECTION
Vehicle speed 1. Connect the vehicle speed sensor connector
3 2 1
sensor connector
terminal No.3 to the battery (+) terminal and
connector terminal No. 1 to the battery (–)
terminal.
2. Connect a resistance of 1.3kÍ between connector
terminals No. 2 and No. 3.
CAUTION: Be extremely careful not to connect the
battery (+) terminal to the connector
terminal No. 2. This may damage the
vehicle speed sensor.
3. Rotate the shaft of the vehicle speed sensor slowly
and measure the voltage at both ends with a
Resistance
digital tester.
– + The voltage, with one rotation of shaft, fluctuates
eight times in the following range 20 to 28V <—>
2V or less.
Replace the sensor when the result of inspection is
found abnormal.
820MT002
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FUEL TANK UNIT

The tank unit varies the internal resistance according
to the float position (fluid level) to operate the fuel
meter needle.
INSPECTION
Check the resistance between the connector terminals
"1" and "2" while shifting the float from "E" to "F"
point. If found defective replace the fuel tank unit.
2 1
1/2
Float position Float position

resistance value(Ω) stroke(mm) Capacity Model
F 1/2 E F 1/2 E
RSS,FTS,FRR,FSR
35 208 381 200 FTR,FVD,FVM,FVR
+1.2 ±1.5 ±3.5 FVY,FVZ
0 FSR
0 50 150 35.7 181 326 140
E FTR,FTS,FVM,FVZ
32.8 255 477.2 200 FVR,GVR
140MY00007
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INSPECTION
30.4mm
(F) (26
°)
167.8mm
296mm
(6
0°
)
作
動
角
度
(1/2)
2 1
(E) Float Resistance Capacity Model

position value(Ω)
+3
F 0 0
FSS
±3
1/2 50 200 FSR
±10
FRR
E 150
140MY00005
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INSPECTION
607±4
(86)°
509
R15
Float Resistance
Capacity Model
Position Value(Ω)
F 0 +1.5
0
FVY
FVR
1/2 50 ±1 400 FVM
GVD
E 95.4 ±3 GVR
140MY00008
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SPEEDOMETER, TACHOGRAPH AND SPEED LIMITER
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CIRCUIT DIAGRAM
FUSE No.5
FUSE No.11
TAIL LIGHT
0.5RG
0.5RG
0.5BR
0.5Y
0.5Y
0.5Y
0.5R
0.5Y
SPEEDOMETER
0.5B
CHECKER CONNECTOR
0.5P
0.5G
4
C/U;SPEEDOMETER C/UNIT
0.5P
(8P) 1 SPEED LIMITER
(25P) (25P)
3 10 12 9 2 CHECKER
CONNECTOR TACHOGRAPH
0.5P 0.5BR
0.5B
A
0.5B
0.5R
0.5Y
0.5P
0.5L
0.5B
0.5P
JOINT CONN.
0.3PL 0.3PL
C/U; SPEED CHECK (4WD), C/U; HSA
0.5PL
C/U; TYPE RED-4, C/U; COMMON RAIL
0.5G
CHECKER FOR HSA
0.5W
0.85R
0.85Y
0.85L
0.5Y
0.5B
GND
IGN
SIG
ACTUATOR
SPEED LIMITER
SPEED SENSOR
D08M200068
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SPEEDOMETER
60 80
IGN GND
40
0000000
100
20 120
INPUT
0000000
0 140
km/h
No. Connected to
4 1 Illumi(GND)
3
2 Illumination
5
3 IGN
1
2 4 GND
5 Pulse
821MT018
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SPEEDOMETER CONTROL UNIT
Speedometer
control unit
パルス整合器
Speed sensor
60 80
40
0000000
100
20 120
0000000
U L 0 140
km/h
Speedometer gear
Speedometer
or
Adjust switch
Tachograph
826HY00065
Adjustment of speedometer control unit

1. After obtaining the conversion ratio 1/γ by using
the expression given below, get from the list of
conversion ratio a switch adjustment value
corresponding to the value closest to the 1/γ value
obtained.
NOTE:
On this occasion, be sure to get a switch adjustment
value equal to the obtained conversion ration 1/γ, or a
larger value most approximate to it.
2. Set "U" and "L" of the adjust switch of the
speedometer control unit to the switch adjustment
value obtained in Step 1 above. At this time, be
sure to leave the harness connector connected to
the control unit.
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Expression:
1 15925 1
= 3
×
γ 10 M X
×A× × 25
2πR N
R: Dynamic load radius (m) of the tire

A: Final ratio
M Coefficient of the speedometer
:
N 1/3 for MAL, MBJ and MLD, Allison MD3560,
 MD3060 
5/17 for AT545, 
 
6/14 for Fuller FS8209 and Fuller RT7608LL, 
11/17 for ZF 9S - 109 
X: Correction ratio
Tire Size R (m) Tire Size R (m)

7.50-20-12PR 0.457 10.00-20-14PR 0.516
8.25-16-12PR 0.412 10.00R20-14PR 0.513
8.25-16-14PR 0.412 10.00-20-16PR 0.516
8.25R-16-14PR 0.413 10.00R20-16PR 0.513
8.25-20-14PR 0.477 10R22.5-14PR 0.497
8.25R-20-14PR 0.475 11.00-20-14PR 0.530
9.00-20-12PR 0.500 11.00-20-16PR 0.530
9.00-20-14PR 0.500 11R22.5-14PR 0.513
9.00R20-14PR 0.497 11R22.5-16PR 0.513
9R22.5-14PR 0.475 255/70R22.5 0.458
9.5R17.5-129/127 0.414 275/70R22.5PR 0.465
10.00-20-12PR 0.516
SW set value Conversion SW set value Conversion SW set value Conversion SW set value Conversion
U L Ratio 1/γ U L Ratio 1/γ U L Ratio 1/γ U L Ratio 1/γ
0 0 0.4375 1 0 0.4853 2 0 0.5384 3 0 0.5973
0 1 0.4404 1 1 0.4885 2 1 0.5419 3 1 0.6011
0 2 0.4433 1 2 0.4917 2 2 0.5454 3 2 0.6050
0 3 0.4462 1 3 0.4949 2 3 0.5489 3 3 0.6090
0 4 0.4490 1 4 0.4981 2 4 0.5525 3 4 0.6128
0 5 0.4520 1 5 0.5013 2 5 0.5561 3 5 0.6169
0 6 0.4549 1 6 0.5046 2 6 0.5597 3 6 0.6208
0 7 0.4579 1 7 0.5079 2 7 0.5634 3 7 0.6250
0 8 0.4608 1 8 0.5112 2 8 0.5670 3 8 0.6290
0 9 0.4639 1 9 0.5144 2 9 0.5706 3 9 0.6331
0 A 0.4668 1 A 0.5178 2 A 0.5745 3 A 0.6372
0 B 0.4698 1 B 0.5213 2 B 0.5782 3 B 0.6414
0 C 0.4730 1 C 0.5246 2 C 0.5820 3 C 0.6454
0 D 0.4761 1 D 0.5280 2 D 0.5856 3 D 0.6497
0 E 0.4791 1 E 0.5314 2 E 0.5895 3 E 0.6539
0 F 0.4822 1 F 0.5349 2 F 0.5933 3 F 0.6581
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SW set value Conversion SW set value Conversion SW set value Conversion SW set value Conversion
U L Ratio 1/γ U L Ratio 1/γ U L Ratio 1/γ U L Ratio 1/γ
4 0 0.6624 7 0 0.9042 A 0 1.2337 D 0 1.6842
4 1 0.6667 7 1 0.9098 A 1 1.2420 D 1 1.6954
4 2 0.6710 7 2 0.9159 A 2 1.2503 D 2 1.7067
4 3 0.6755 7 3 0.9217 A 3 1.2580 D 3 1.7181
4 4 0.6797 7 4 0.9280 A 4 1.2665 D 4 1.7283
4 5 0.6843 7 5 0.9339 A 5 1.2744 D 5 1.7400
4 6 0.6886 7 6 0.9399 A 6 1.2832 D 6 1.7504
4 7 0.6931 7 7 0.9460 A 7 1.2913 D 7 1.7625
4 8 0.6978 7 8 0.9521 A 8 1.2995 D 8 1.7747
4 9 0.7023 7 9 0.9584 A 9 1.3078 D 9 1.7855
4 A 0.7067 7 A 0.9647 A A 1.3170 D A 1.7965
4 B 0.7114 7 B 0.9711 A B 1.3256 D B 1.8092
4 C 0.7161 7 C 0.9771 A C 1.3342 D C 1.8204
4 D 0.7206 7 D 0.9837 A D 1.3421 D D 1.8318
4 E 0.7252 7 E 0.9899 A E 1.3509 D E 1.8450
4 F 0.7301 7 F 0.9966 A F 1.3599 D F 1.8568
5 0 0.7348 8 0 1.0029 B 0 1.3690 E 0 1.8686
5 1 0.7396 8 1 1.0094 B 1 1.3782 E 1 1.8806
5 2 0.7445 8 2 1.0159 B 2 1.3866 E 2 1.8928
5 3 0.7494 8 3 1.0225 B 3 1.3960 E 3 1.9051
5 4 0.7541 8 4 1.0291 B 4 1.4047 E 4 1.9176
5 5 0.7591 8 5 1.0359 B 5 1.4144 E 5 1.9303
5 6 0.7639 8 6 1.0428 B 6 1.4232 E 6 1.9431
5 7 0.7688 8 7 1.0492 B 7 1.4322 E 7 1.9561
5 8 0.7740 8 8 1.0562 B 8 1.4412 E 8 1.9673
5 9 0.7790 8 9 1.0633 B 9 1.4515 E 9 1.9807
5 A 0.7841 8 A 1.0700 B A 1.4608 E A 1.9942
5 B 0.7892 8 B 1.0768 B B 1.4702 E B 2.0059
5 C 0.7941 8 C 1.0842 B C 1.4798 E C 2.0197
5 D 0.7994 8 D 1.0911 B D 1.4895 E D 2.0317
5 E 0.8047 8 E 1.0981 B E 1.4993 E E 2.0460
5 F 0.8098 8 F 1.1052 B F 1.5081 E F 2.0583
6 0 0.8150 9 0 1.1124 C 0 1.5182 F 0 2.0729
6 1 0.8205 9 1 1.1197 C 1 1.5284 F 1 2.0855
6 2 0.8258 9 2 1.1271 C 2 1.5387 F 2 2.1005
6 3 0.8312 9 3 1.1346 C 3 1.5480 F 3 2.1135
6 4 0.8366 9 4 1.1416 C 4 1.5586 F 4 2.1267
6 5 0.8418 9 5 1.1493 C 5 1.5681 F 5 2.1400
6 6 0.8473 9 6 1.1564 C 6 1.5790 F 6 2.1558
6 7 0.8530 9 7 1.1643 C 7 1.5888 F 7 2.1695
6 8 0.8583 9 8 1.1716 C 8 1.5988 F 8 2.1834
6 9 0.8641 9 9 1.1790 C 9 1.6101 F 9 2.1974
6 A 0.8696 9 A 1.1872 C A 1.6203 F A 2.2117
6 B 0.8752 9 B 1.1949 C B 1.6306 F B 2.2261
6 C 0.8809 9 C 1.2026 C C 1.6410 F C 2.2407
6 D 0.8866 9 D 1.2140 C D 1.6516 F D 2.2555
6 E 0.8924 9 E 1.2183 C E 1.6623 F E 2.2705
6 F 0.8982 9 F 1.2263 C F 1.6732 F F 2.2832
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HEATER, VENTILATION AND AIR CONDITIONING

GENERAL DESCRIPTION
The circuit consists of compressor, blower motor, condenser, A/C mode switch, A/C actuator, resistor and
relay.
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CIRCUIT DIAGRAM – MANUAL AIRCON
SLOW BLOW FUSE No.6
FUSE No.12
FUSE37
FUSE36
(15A)
(15A)
TAIL LIGHT
0.5Br
2LgR
0.5RG
0.5BR
R/L;FAN
BLOWER MOTOR SW;A/C MODE
A/C ACTUATOR (MODE)
2Lg 1.25LR 0.5LgL
M B4 A13
A8 0.5Br
RESISTOR B8
A7 0.5BrW
C5
0.85GR
0.5LY 0.5BrG
M
C4 B1 CHANGE
0.3B
0.5Lg
0.5LB A16 0.5BrY SWITCH

C3
0.5LW A5 0.5BrL
C2
A6 0.5BrB
0.5Lg A14 0.5P
B5
0.5B
R/L; A/C ACTUATOR (TEMP)
CONDENSER CONDENSER 0.5RL 0.5LgW
FAN MOTOR B7 A4
A3 0.5P
0.85LW 0.85B 0.5PL
M
M A10
A11 0.5PB
C6
A12 0.5Lg
DIODE
0.5BG
B3
A2
B10
R/L;
COMPRESSOR SW; C1
PRESSURE A/C ACTUATOR (R/F)
B2 0.5VY
0.5B
0.85GY CHANGE
B6 0.5VG SWITCH
0.5GY
0.5GR
THERMO SW 0.5Lg
DIODE
DIODE M
0.5Lg
DIODE
0.5LO
WASHER SW.
0.85GW
COMPRESSOR
C
D08MY00113
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CIRCUIT DIAGRAM – MANUAL AIRCON (TYPE RED-4)

SLOW BLOW FUSE No.6
FUSE No.12
FUSE37
FUSE36
(15A)
(15A)
TAIL LIGHT
0.5Br
2LgR
0.5RG
0.5BR
R/L;FAN
A/C ACTUATOR (MODE)
2Lg 1.25LR 0.5LgL
M B4 A13
A8 0.5Br
RESISTOR B8
A7 0.5BrW
C5
0.85GR
0.5LY 0.5BrG
M
C4 B1 CHANGE
0.3B
0.5Lg
0.5LB A16 0.5BrY SWITCH

C3
0.5LW A5 0.5BrL
C2
A6 0.5BrB
0.5Lg A14 0.5P
B5
0.5B
R/L; A/C ACTUATOR (TEMP)
CONDENSER CONDENSER 0.5RL 0.5LgW
FAN MOTOR B7 A4
A3 0.5P
0.85LW 0.85B 0.5PL
M
M A10
A11 0.5PB
C6
A12 0.5Lg
DIODE
0.5BG
B3
A2
0.5Br
B10
R/L;
COMPRESSOR SW; C1
PRESSURE A/C ACTUATOR (R/F)
B2 0.5VY
0.5B
0.85GY CHANGE
B6 0.5VG SWITCH
0.5GY
0.5GR
THERMO SW 0.5Lg
DIODE
DIODE M
0.5Lg
0.5RG
DIODE
0.5GR
R/L;WASHER DIODE
0.5GR 0.5GR 0.5RG C/U;TYPERED-4
0.5LO
WASHER SW.
0.85GW
COMPRESSOR
C
D08M200069
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CIRCUIT DIAGRAM – HEATER, VENTILATION
SLOW BLOW FUSE No.6
FUSE No.12
FUSE36
(15A)
TAIL LIGHT
0.5Br
2LgR
0.5RG
0.5BR
R/L;FAN
A/C ACTUATOR (MODE)
2Lg 1.25LR
M B4 A13 0.5LgL
RESISTOR B8 A8 0.5Br
C5 A7 0.5BrW
0.5LY B1 0.5BrG
M
C4 CHANGE
0.3B
0.5Lg
0.5LB C3 A16 0.5BrY SWITCH

0.5LW C2 A5 0.5BrL
A6 0.5BrB
B5 A14 0.5P
0.5B
A/C ACTUATOR (TEMP)
0.5RL 0.5LgW
B7 A4
A3 0.5P
0.5PL
M
A10
C6 0.5PB
A11
0.5Lg
A12
A2
B10
C1
A/C ACTUATOR (R/F)
B2 0.5VY
0.5B
CHANGE
B6 0.5VG SWITCH
0.5Lg
M
D08MW00013
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RADIO
GENERAL DESCRIPTION
The circuit consists of radio and speaker. Battery voltage is always applied to memory circuit inside of radio
regardless of starter switch position. When radio switch is turned on with starter switch in “ACC” or “ON”,
battery voltage is applied to receiver circuit of radio.
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CIRCUIT DIAGRAM
FUSE No.8
FUSE No.5
TAIL LIGHT
RR SPEAKER ONLY RR SPEAKER ONLY

0.5RG
SPEAKER SPEAKER
0.85L
0.5R
RR.LH RR.RH
0.5WL 0.5WR
0.5BL 0.5OB
FT SPEAKER ONLY FT SPEAKER ONLY

SPEAKER SPEAKER
FT.LH FT.RH
0.5LW 0.5GW
BACK UP
ILLUMI.
0.5L 0.5G
IGN
5 12 1 3 2 11 4 10 13 6
9 0.5B
1 7 8 2
D08MW039
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RADIO
clarion PLL SYNTHE SIZED AM RECEVER RESET ON-VOL
AM CH
18:00
PM
R DISP SCN
TONE
V
1 2 3 4 5 V
890MT001
No. Connected to
1 −
2 −
3 −
4 ACC( + )
5 SPEAKER-LH( + )
6 5 4 3 2 1 6 SPEAKER-RH( + )
13 12 11 10 9 8 7 7 −
8 −
9 GROUND
10 ILLUMINATION( + )
11 BACK UP
12 SPEAKER-LH( - )
13 SPEAKER-RH( - )
890MT002
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POWER TILT
GENERAL DESCRIPTION
The circuit consists of the cab lock switch, stay lock switch, up switch, power tilt switch, buzzer, pump and
relay.
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CIRCUIT DIAGRAM (Double cab only)
FUSE No.5
0.5R
SW;CAB LOCK
BUZZER
TILT SW;STAY LOCK
0.5B
0.5WV
0.5WL
SLOW BLOW FUSE No.4

5W
SW;UP
0.5BL
SW;P/TILT
0.5BR
R/L;
POWER TILT PUMP;P/TILT
5R M
0.5WB
D08MT030
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CAB LOCK SWITCH

INSPECTION
terminals.
OFF ON
Terminal
SW No. 1 2
position
Push rod in ● ●
Push rod out
825MT028
UP SWITCH
INSPECTION
OFF ON terminals.
1
2
Terminal
SW No. 1 2
position
Push rod in
Push rod out ● ●
825MT027
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POWER TAKE OFF (PTO)

GENERAL DESCRIPTION
The circuit consists of the starter switch, pto switch, clutch switch, vacuum switching valve and relay.
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CIRCUIT DIAGRAM
FUSE No.13
TAIL LIGHT
0.3BR
0.5RG
0.5Sb
SW;PTO
5 6
1 2
0.5LR
0.5B
0.5Sb
R/L;PTO
0.85Sb
(SIDE)
0.5Sb
<A/T ONLY>
0.5LgR
0.85Sb
R/L;PTO
(CLUTCH)
0.85Sb
<M/T ONLY>
0.5Lg
PTO
0.3Lg
P/L
0.5LR
CLUTCH SW.
0.85Lg
作業番号 8045
発注者川島発注日
受注番号 E7128 希望納
M/V;PTO ｲﾗｽﾄｻｲｽﾞ 180 × 240 ｲﾗｽﾄ担
0.5BL ﾊﾟｰﾂｲﾗｽﾄ番号
対象車型 F V R
イラスト区分ＢＫＴＧ
D08MW044
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PTO SWITCH
PTO
3
6
2
5
1
4
INSPECTION
1. Check the continuity between the dome light
switch connector terminals.
Terminal Repair or replace the switch when the result of
SW No. 3 1 6 2
position inspection is found abnormal.
ON
OFF
825MY00042
PTO CONTROL RELAY

Terminal Arrangement
1 ... Earth
2 .... M/V; P.T.O
1 3
3 .... SW; P.T.O
4 .... Fuse 13
2 4
828MT012
PTO RELAY
1
3 INSPECTION
relay terminals.
5 1
2 4 inspection is found abnormal.
5 Replace the relay when the result of inspection is
found abnormal.
825MY00050 3 – 5 ..... Continuity
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PTO MAGNETIC VALVE
828MT011
828MT008
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DIFFERENTIAL LOCK
GENERAL DESCRIPTION
The circuit consists of the starter switch, diff lock switch and vacuum switching valve.
When the differential lock switch is turned on with the starter switch on, the battery voltage is applied to the
differential lock magnetic valve.
At the same time, the differential indicator light turns on.
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CIRCUIT DIAGRAM
FUSE No.11
(KEY ON)
TAIL LIGHT
0.5BR
0.5RG
0.5LY
SW;DIFF LOCK
5 6
1 2
0.5V
DIFF LOCK
0.5V
P/L
0.5V
M/V;DIFF LOCK
0.5BL
51239A
D08MY00106
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DIFF-LOCK SWITCH
3
6
2
5
1
4
INSPECTION
Check the continuity between the dome light switch
Terminal Repair or replace the switch when the result of
SW No. 3 1 6 2
position inspection is found abnormal.
ON
OFF
825MY00041
MAGNETIC VALVE
Specification
Rated current (Amperage) 0.8 or less
OUT Min. operating voltage (V)
(When tested with compressed air
20
833.5 kPa {8.5 kgf/cm2} applied
into unit from input side)
IN OUT
828MT014
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4WD TRANSFER AND FRONT DRIVE

GENERAL DESCRIPTION
The circuit consists of the starter switch, front drive switch, clutch switch, transfer switch (low/high), ECU
and vacuum switching valve.
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FUSE No.11 (STARTER SW. ON)
3GW
R/L:CIGAR LIGHTER
FUSE16
FUES15
FUSE17
(7.5A)
(7.5A)
(7.5A)
TAIL LIGHT SW;TRANSFER
0.5RG
(LOW/HIGH)
0.3BR
0.5RG
5 4
1
3 2
0.5Lg
0.5G
0.5L
5 3
SW;FRONT
DRIVE
0.5Sb
0.5PB
4 2
T/F;LOW
0.3BR
P/L
ECU;SPEED
SW;CLUTCH CHECK
(T/F) 1
2 4
FRONT 3 5
T/F;HIGH DRIVE
0.5B
P/L P/L
A
0.5LgR
0.5LgB
0.5WL
0.5YV
0.5YR
0.5OL
0.5LY
0.5LB
0.5G
JOINT
CONNECTOR
0.3PL
C/U ; SPEED METER
M/V;HIGH
SW;HIGH
M/V;LOW
SW;LOW
M/V;FRONT DRIVE
SW;FRONT DRIVE
D08MY00107
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TRANSFER SWITCH
INSPECTION
1. With the switch installed to the transfer, check the
continuity between the terminals of the switch
connectors.
When the continuity is not found between the
terminals only with the switch shifted to the front
drive position, the switch or transfer is abnormal.
261MT003
When the result of the above inspection is found
abnormal, remove the switch from the transfer.
If the continuity appears (when the ball is
released) between the connector terminals, the
switch is normal.
If there is no continuity with the switch installed to
the transfer, even though the switch is found to be
normal, then adjust stroke of the switch by
changing the thickness of the switch gasket.
2. With the switch installed to the transfer, check the

continuity between the terminals of the switch
connectors.
When the transfer switch is low position and if the
continuity does not appear between the connector
terminals, the switch or transfer is abnormal.
When the result of the above inspection is found
abnormal, remove the switch from the transfer.
With the rod pushed, if the continuity appears
between the terminals of the connector, the switch
261MT002
is normal.
If there is no continuity with the switch installed to
the transfer, even though the switch is found to be
normal, then adjust stroke of the switch by
changing the thickness of the switch gasket or
stroke of transfer rod.
REMOVAL
Preparation:
1. Transfer Switch
1) Disconnect the connectors.
2) Remove the switch by turning it counterclockwise.
INSTALLATION
1. Transfer Switch
Apply liquid gasket to the screw portion of the switch
to prevent oil leak.
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TRANSFER LOW/HIGH SWITCH

HIGH
3 2 1 INSPECTION
6 5 4
Check the continuity between the transfer low/high
LOW switch connector terminals.
825MY00040

SW position
LOW HIGH
Terminal No.
FRONT DRIVE SWITCH

OFF
3 2 1 INSPECTION
6 5 4
Check the continuity between the front drive switch
ON connector terminals.
825MY00039
SW position ON
OFF
Terminal No. (I)
MAGNETIC VALVE (TRANS LOW/HIGH)

Specification
Rated current (Amperage) 0.8 or less
OUT
Min. operating voltage (V)
(When tested with compressed air
20
833.5 kPa {8.5 kgf/cm2} applied
into unit from input side)
IN OUT
828MT014
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MD3560 AUTO T/M (FVZ)

GENERAL DESCRIPTION
The circuit consists of C/U;A/T selector switch, auto mission, mission sensor, throttle sensor and relay.
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CIRCUIT DIAGRAM
POWER SUPPLY OF BOW FUSE NO.1 (BATTERY DIRECT)

(7.5A)
(7.5A)
FUSE 14
FUSE 18
FUSE 34
(15A)
TAIL LIGHT
1.25YB
0.5RG
DO NOT SHIFT
V26
V1
V16
R/L;NEUTRAL(A/T) 0.85GW
S31 P/L
SW;STARTER
0.85B R/L;STARTER
A/T OIL SELECTOR SWITCH
0.85LB V6 0.85LW P/L
V19
0.85RY
T
S14 0.85R S
R/L;A/T(BACK LAMP) 0.85RB
(-RR3) FUSE(12) S15 L
(&RR3) R/L;BACK LAMP S10 0.85RW M
BACK LAMP S9 0.85RG E
S8 0.85RY D
V4 S7 0.85RL C
CONTROL UNIT ; A/T S6 0.85G B
S5 0.85GB A
R/L;A/T(EXH. CUT) 0.85GW
S16 R
FUSE(13) R/L;EXH. BRAKE S3 0.85GR N
S32 0.85GY P
0.5RY
0.5GB V3 V
0.85L K
S17 0.85Y J A 0.85GY
0.5B
R/L;A/T(EXH. SENSOR) S1 0.85RY H
S4
0.5RB S11 DIAG CONN.
0.85RY
0.85B
V17 0.85B
V32 A
V10
V24
T14
T30
T16
T32
T15
T31
T20
T21
T17
T22
T26
T25
T27
T12
0.85B
V8
T4
T5
T1
T6
T2
T7
T3
T9
V25
0.85RY
0.5L
DIODE;EXH. SENSOR
0.85OW
0.85PW
0.85OG
0.85LW
0.85GR
0.85OB
0.85PG
0.85OL
0.85PB
0.85LB
0.85LR
0.85PL
0.85LP
0.85LY
0.85W
0.85W
0.85O
0.85G
0.85O
0.85R
0.85B
0.85B
0.85R
0.85P
0.85L
C POWER
B SIG
A GND
THROTTLE SENSOR
PNSR V U G J BMA K H C L E F D Y N P X
TRANSMISSION
AUTO TRANSMISSION
SENSOR
D08MY00108
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BUTTON TYPE SELECTOR SWITCH

Display(Available gear range)
INSPECTION
Drive mode
Refer to "AUTOMATIC TRANSMISSION" section 7.
Drive mode「ON」
Indicator
Reverse button POWER

Mode button
Neutral button R MODE
Manual select
N button(up)
Drive button
Manual select
D button(down)
235MW001
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ENGINE CONTROL SYSTEM

GENERAL DESCRIPTION
TICS (Timing and Injection Control System)
Basic prestroke is sought from loaded engine condition (rack position) and engine revolution, and the target
prestroke is determined after adjusted reflecting information from each sensor input.
Prestroke sensor detects the actual prestroke, and move a prestroke actuator to the target prestroke so that
the prestroke will be controlled.
IVES (Isuzu variable electric and economy swirl)

Swirl condition (magnetic valve condition) is sought from loaded engine condition (rack position) and
engine revolution, and final swirl (magnetic valve) is sought after adjusted reflecting information from each
input.
The IVES magnetic valve is actuated so that a valve within the intake manifold opens and closes on air
pressure to control swirl conditions.
EC GOVERNOR (ELECTRICAL CONTROL GOVERNOR TYPE; RED-4)

The Actuator circuit (SABO circuit, drive circuit, sensor circuit), the rack sensor, DC motor, a rotation sensor,
the control rack, etc. are prepared in the governor case, ad the control rack is operated on the basis of the
signal from ECU, and the signal of the actuator control circuit. (Determination of fuel injection)
Refer to 6E section for details.
COMMON RAIL (ELECTRICAL CONTROL COMMON RAIL)

The common rail is installed to intake manifold, equipped with flow damper, pressure limiter, and common
rail pressure sensor.
The common rail unit has a common fuel pressure, fuel passage holes, and intalling threaded holes. The
comon fuel passage is a through hole made in the common rail unit. The common rail pressure sensor is
installed at the left end of the hole.
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CIRCUIT DIAGRAM (TICS + VSS)
POWER SUPPLY OF FUSE 11(KEY ON) POWER SUPPLY OF FUSE 11(KEY ON)
FUSE20
FUSE45
(7.5A)
(15A)
SW ; STARTER (S)
TACHO METER
2R
R/L;PS POWER CUT 3

CHECKER CONN.
1.25R
SERVICE ENG SOON

4 13
P/L
0.5B W
0.5BW
0.5RB
1.25R
1.25R
0.5Y
TACHO OUT
DIAG LAMP
P.SCUT
START
PS VB
+VB
37 36 27 45 35 40 33
CONTROL UNIT;TICS+VSS
14 1 5 18 39 25 12 6 19 7 20 10 23 8 9 21 47 48 46 38 29 28
(+)
(-)
SIG
GND
WITH VSS
0.5YG AIR PRESS SW
(+)
(-)
OSC
GND
MDL
SHLD
SIG
GND
+5V
SIG
GND
GND-1
GND-2
EMI GND
P.S GND
CASE GND
DIAG SW
MEM.CLR.SW
1.25RL
DIAG. 0.5L R
0.5YB
0.5RB
1.25B
0.5LB
0.25B
0.25B
1.25B
1.25B
0.5W
0.5W
0.5W
0.5R
0.5B
0.5B
0.5B
0.5B
0.5R
0.5B
0.5B
MEMORY CLR
DIODE
SW;AIR PRESS 0.5YG A

W/TEMP METER 0.5YV
EARTH;BATTERY
P.S M/V P.S NE RACK

ACTUATOR VSS POSITION SENSOR SENSOR
SENSOR
METER SENSOR.
WATER TEMP (DUAL)
VB: Battery Voltage DIAG: Diagnosis

OSC: Oscillator SIG: Signal
MDL: Middle SHLD: Shield
EMI GND: Electromagnetism Impediment Ground
D08MW050
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CIRCUIT DIAGRAM (TYPE RED-4)
SLOW BLOW FUSE 1

SW; STARTER (P1)
SW; STARTER (P2)
SW; STARTER (B2)
SW; STARTER (Q)
FUSE10
FUSE44
FUSE45
FUSE20
(7.5A)
(7.5A)
(15A)
(15A)
3L
0.5Y
SW; STARTER (S)
0.5Y
0.5Y
1.25VY
0.5Y CHECKER P/L; ACCEL SENSOR
CONN (1) SERVICE R/L; P.S
20P ENG. SOON POWER CUT
13 3 P/L P/L
SW; MEM CLR
4 12 1.25VW
GND1
GND2
P/L P/L
+5V1
+5V2
SIG1
SIG2
SW; DIAG
Q3
0.5B
0.5B
0.5B
Q-CONT.
0.85VW
1.25VW
CHECKER
0.5BrW
Q2
1.25BR
0.5LgB
0.5WR
0.5BW
0.5W
0.5BG
0.5RG
0.5Sb
0.5G
0.5RL
0.5LR
0.85V
0.5Y
0.5R
0.5B
0.5L
0.5B CONN (2)
3P (EXP)
3
A
Q1
JOINT 4 12
CONN
SW;MEM CLR
GLOW LAMP
DIAG LAMP
0.3BrW
0.3BrR
0.3BrY
0.3BW
SW;DIAG
P.S CUT
0.5Br
0.5GyG
M/V;VB
START
P.S VB
0.5Gy
HEAT
VB-2
VB-1
RXD
TXD
13 35 45 19 41 5 12 60 51 59 68 48 3 2 1 30 73 74 22 33 44 21 32 43
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
C/U; ELECTRICAL GOVERNOR (TYPE RED-4)
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
67 66 47 15 25 11 39 29 26 38 92 102 88 31 86 61 70 62 71 54 69 72 55 53 63 52 75 79 91 80 93
TACHO OUT
BRAKE 2
PTO SW
SIG GND
EXH.B.SIG
GND-1
M/V; EXH.B
PULL DOWN
SPEED
SOL-2 (PWM)
SOL-1 (PWM)
PARKING SW
AIR P SW
SIG
0.5GyR
GND-2
GND-1
GND-2
SIG
5V-2
5V-1
GND
SIG-2
SIG-1
SIG
LIMP HOME
VB-2
VB-1
SW; AIR CON 0.5RG
0.5GyW
SW; NEUTRAL 0.5BG
(SUB STARTER)
C/U; HSA
<M/T> 0.5LgL
0.5LW
0.5LB
R/L; PTO (MAIN)

0.5LY
R/L; EXH. BRAKE
0.5RB
TACHO METER (C17)
0.5GW
SW; STOP LAMP
0.5PL
C/U; SPEED SENSOR
0.5LB ATM
SW; PARKING
0.5YG SENSOR
SW; AIR LOW PRESS
0.5YG
WATER TEMP METER (C16)
0.5BG
(SUB STARTER
SW; NEUTRAL
LESS)
0.5LgW
0.5OW
0.5WG
0.5PW
0.5WL
0.5LW
0.5RG
0.5YG
0.5VG
0.5YB
0.5OL
0.5LB
0.5LR
0.5LB
0.5W
0.5G
0.5O
0.5R
0.5P
0.5L
0.5GyW
★ ★ ★
14 13 12 10 11 9 2 1 3 4 5 8 7 6
WATER ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
FUEL
TEMP THERMO 3P 6P 8P TDC(N)
SENSOR SENSOR SENSOR
RED-4
RACK SENSOR
D08M200062
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CIRCUIT DIAGRAM

FUSE21
FUSE19
(7.5A)
(7.5A)
R/L;
0.5Sb
EXH SHUT
0.5Y
SW; IDLE CONT 0.85VR
0.5LY
1 M/V; EXH.BRAKE
2
3
0.5B
0.5Y <M/T>
0.5Y
0.5Y
0.5WR
SW; IDLE CONT ACG L
R/L;
(A/T)
MAG. V. CUT
0.85R
1 2
SW; LIMP HOME
SW; CLUTCH
SW; ACCLE
R/L;
GLOW
0.5PG
0.5PB
0.5P
R/L; PTO (CLUTCH)

0.5GW
0.5RG
0.5LO
0.5GR
DOWN
0.5BP
A/M
UP
5BY
5W
23 36 46 9 17 20 42 95
★ ★ ★ ★ ★ ★ ★ ★
C/U; ELECTRICAL GOVERNOR (TYPE RED-4)
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
84 85 76 87 98 99 77 89 100 40 64 97 6 7 78 90 101 96 82 104 103
GND
C/U; GND1
C/U; GND2
M/V; GND
CASE GND
P.S GND
(–)
GND
SIG
(+)
REF
+5V
5V
MEAS
(–)
(–)
MDL
SIG
0.5LW
SW; EXH.BRAKE
0.5RL
SW; BACK LAMP
0.5Gy
0.5Gy
0.5RB
0.85B
0.85B
1.25B
0.85B
0.85B
0.5RL
0.5W
0.5R
0.5B
A
POWER TILT
JOINT
CONN
GLOW PLUG
1.25LW
1.25LB
0.5W
0.5W
0.5R
0.5B
0.5R
0.5B
EARTH;
M/V; EGR-1
M/V; EGR-2
BATTERY
0.5Gy
0.5Gy
★ ★ ★ ★ ★ ★
★ ★ ★ ★
P.S ACTUATER P.S SENSOR BOOST

SENSOR
BLIND CAP
THE SAME ALL SPEED
CONNECTOR ACCEL SENSOR
D08M200063
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CIRCUIT DIAGRAM (COMMON RAIL)
SLOW BLOW FUSE 1

FUSE45
FUSE20
(7.5A)
(15A)
SW; START(S)
0.5Y
1.25G
R/L P/L
P.C.V. SERVICE
ENG. SOON
P/L P/L
2VG
1.25VW
R/L; MAIN
0.5B
DIODE
0.5RB 0.5VW
1.25RW
0.5BrW
0.5Y
0.5B
+VB
24 109 118 101 91 23 13 105

0.5G
SW; STOP LAMP 26 ★ ★ ★ ★ ★ ★
C/U; U2
★ ★ ★
0.5RB
TACHO METER (C17) 112 ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
36 15 8 2 16 33 19 75 22 21 31 32 30 66 52 53 90 99 88 97 86 95 110 100 89 98 87 96 85 94 120 119
(+)
(+)
(+)
(–)
1.25GW
1.25GW
1.25LW
1.25LW
1.25GR
1.25GR
1.25RY
1.25RY
1.25LR
1.25LR
1.25RL
1.25RL
1.25G
1.25G
1.25L
1.25L
1.25BrB
1.25BrB
A
1.25Br
1.25Br
0.5YG
0.5BG
0.5RL
0.5LB
0.5Lg
0.5PL
0.5LY
0.5L
0.5B
0.5LW
0.5LB
0.5LR
SW; BACK LAMP

SW; AIR PRESS
SW; EXH.
R/L; EXH.
R/L; PTO (MAIN)
SW; NEUTRAL ATM
SENSOR
SW; PARKING
C/U; SPEED SENSOR
WATER TEMP METER (C16)
1.25BrB
1.25BrB
0.5BG
1.25Br
1.25Br
NEUTRAL
SW;
PRESSURE
PRESSURE
VALVE-1
VALVE-2
CONT.
CONT.
0.85BL
CYLINDER-1
CYLINDER-3
CYLINDER-2
CYLINDER-5
CYLINDER-6
CYLINDER-4
INJ1
INJ3
INJ5
INJ2
INJ4
INJ6
0.5YG
0.5YB
0.5LB
0.5LR
0.5LB
ENGINE HEAD COVER

ENGINE HEAD COVER
WATER FUEL
TEMP THERMO
SENSOR SENSOR
D08M200064
BACK FORWARD
0.5Y
BACK
1
2
SW
SW
(A/T)
0.5Gy 0.5Gy
IDLE CONT.
IDLE CONT.
1
3
2
0.5B 0.5B (–)
NE
0.5W 0.5W (+)
★ ★ ★
76 57 48
A/M
SENSOR
0.5P
DOWN 0.5PB
0.5Gy 0.5GyR
UP 0.5PG
★ ★ ★
27 29 10
0.5G 0.5G (–)
G
BACK TO CHAPTER INDEX
0.5R 0.5R (+)
★ ★ ★
77 58 49
SENSOR
SW; ACCEL
CIRCUIT DIAGRAM
0.5LO 0.5Y
★
20
0.5R SIG 0.5R
0.5R 0.5G SIG 0.5G

SW; CLUTCH
VCC 0.5W 0.5Y
FUEL
0.5W 0.5RG
7
★
GND 0.5B
SENSOR
0.5B 0.5Gy R/L; PTO (CLUTCH)
★ ★ ★ ★
62 71 73 55
PRESSURE
0.5Gy 0.5Gy
C/U; U2
SIG 0.5R 0.5R
VCC 0.5W 0.5W 0.5Y ACC1
BOOST
GND 0.5B 0.5B 0.5Gy 0.5L VCC1
SENSOR
★ ★ ★
★ ★ ★
61 72 56
SLD 0.5Gy 0.5GyG 0.5G GND1
★ ★ ★
41 44 45
VCC 0.5W 0.5W 0.5W ACC2
GND 0.5B 0.5B 0.5R VCC2 ACCEL SENSOR
SIG 0.5R 0.5R 0.5Gy 0.5B GND2
★ ★ ★
★ ★ ★
★
63
42 54 46
ALL SPEED
0.5Gy SLD
ACCEL SENSOR
1.25B CASE GND
1.25B POWER GND 0.5LR
RXD 0.5Y
3
★
12
113
2B POWER GND
★ ★ ★
59 82 81
TXD 0.5WR
4
★
114
EARTH;
1.25B 1.25BO 1.25B ECU GND 0.5B
BATTERY
CHECKER
A
13
ECU GND
111 102
CONN. (20P)
0.85BO
JOINT
JOINT
CONN.
CONN.
FUSE19
SW; MEM.CLR. (7.5A)
0.5B 0.5RL 0.5Sb 0.5VW
6
★
★
115
SW; DIAG.
0.5B 0.5LgR
★
25
M/V; A (VGS1)
0.5YG 0.5YG
0.5VW
1
★
M/V; B (VGS2)
0.5YV 0.5YV
R/L;
3
★
M/V; C (VGS3)
0.5YBr 0.5YBr
★
39
MAG. V. CUT
★ 93 0.5PL
0.5PL 0.5PL
180
0.5PL 0.5PL
7/23
0.5PL 0.5PL
230
Job No. 5 4 4 9 6 発注者
7/30
矢数
D08M200065
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ISUZU F & G SERIES WORKSHOP MANUAL
TO MODEL INDEX
CIRCUIT DIAGRAM (EVT)

FUSE20
(7.5A)
0.85VW
TACHO METER(C17)
0.5Y
3 1
(20P) (3P)
CHECKER CONN. CHECKER CONN.
SERVICE ENG SOON
4 13 3 2
P/L
0.85VW
0.5B W
CHECKER TXD
BXD 0.5LR
0.5RB
CHECKER
0.5WR
0.5B
0.5B
TACHO OUT
DIAG LAMP
POWER
B8 B14 A20 A10 A22
CONTROL UNIT;TICS+VSS
A2 A13 B7 B6 A15 A4 A16 A5 B17 B5 A1 A11 A12 B10 B18 B9 A6 A19

SIG
GND
SIG
GND
SIG
GND
+5V
SIG
GND
GND-1
GND-2
CASE GND
DIAG SW
MEM.CLR.SW
DIAG. 0.5L R
0.5YB
0.5RB
0.5PB
0.5LB
0.5LB
0.25B
0.25B
1.25B
0.5W
0.5W
0.5G
0.5R
0.5B
0.5R
0.5B
0.5P
0.5L
MEMORY CLR
A
0.5YV
W/TEMP METER(C16)
EARTH;BATTERY
0.5
GyR
(NA
ONLY)
TCV TDC(N) TIMING TCV RACK

PUMP SENSOR SENSOR RETURN SENSOR
METER SENSOR.
WATER TEMP (DUAL)
D08M200070
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RETRACTABLE MIRROR SYSTEM

GENERAL DESCRIPTION
The circuit consists of control unit, SW;R/Mirror, Motor;R/ and relay.
The battery voltage is applied to the retractable mirror control unit through the cigarette lighter relay. When
the retractable mirror switch is operated, SET or CLOSE signal is sent to the controller and the retractable
mirror motor rotates in the SET or CLOSE direction.
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CIRCUIT DIAGRAM
POWER SUPPLY OF BLOW FUSE NO.6(BATTERY DIRECT)

FUSE39
(15A)
TAIL LIGHT
1.25BrR
R/L;
0.5RG
3GW
0.5B
CIGAR
3G
LIGHTER
0.3B
SW;R/MIRROR
5 4 0.3BR
0.5BrR 3 0.5Y
2
1 0.5YR
CLOSE
SET
2 6 5 8 9
C/U;RETRACTABLE MIRROR
1 4 3
SET
1.25G CLOSE
1.25B
1.25R
M
MOTOR;R/MIRROR
D08MY00109
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FRONT DIFF LOCK SYSTEM

GENERAL DESCRIPTION
The circuit consists of FT diff lock switch and diff lock magnetic valve.
When the front differential lock switch is turned on with the starter switch on, the differential lock magnetic
valve is activated and the differential is locked.
At the same time, the differential lock switch is turned on to turn the differential lock indicator light on.
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CIRCUIT DIAGRAM
FUSE 11(KEY ON)
TAIL LIGHT
0.5RG
0.5YR
0.5Y
SW;DIFF LOCK(FRONT)
5 6 0.3BR
1 2
DIFF LOCK
P/L
0.85L
0.5G
SW;DIFF LOCK
0.85BL
M/V;DIFF LOCK
0.85BL
D08MY00110
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BRAKE LOCK SYSTEM (FOR THAILAND)

GENERAL DESCRIPTION
The circuit consists of brake lock control unit, brake lock relay 1 and 2 brake lock switch, brake lock buzzer,
air pressure switch, strain switch and brake lock magnetic valve.
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CIRCUIT DIAGRAM
FUSE13
(7.5A)
TAIL LIGHT
0.5RG
SW;BRAKE LOCK
0.5BR
3 5
0.85Sb
1 2
0.85LY
0.5YG
0.5YB
0.85B
0.5LY
0.5Sb
1 2 3 4
0.85Sb
CONT.UNIT
BRAKE LOCK
5 6 7 8
BRAKE LOCK
0.5LO
P/L
(RED)
0.5BrW
0.85BL
0.5LO
R/L;B.LOCK(2)
0.5L
0.5B
(GREEN)
0.5Sb 0.5BrW
P/L
0.5GO
BRAKE LOCK
0.5GO
R/L;B.LOCK(1)
0.5GO
0.5B
DIODE;B.LOCK
0.85GO
SW;BRAKE
DIODE;B.LOCK
0.5YG
SW;LOW PRESS
BUZZER;
BRAKE LOCK
SW;STRAIN
M/V;BRAKE LOCK SW;AIR PRESS
D08MY00111
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RETARDER SYSTEM
GENERAL DESCRIPTION
The circuit consists of combinations switch, retarder relay, retarder cut relay, retarder warning light, thermo
sensor and retarder magnetic valve.
When the retarder switch is turned on, with the starter switch on, the battery voltage is applied to the
retarder magnetic valve through the retarder relay and the retarder cut relay. The thermo sensor monitors
temperature of the retarder coil. When it gets higher than specified temperature, the thermo sensor
activates the retarder cut relay to cut off the power circuit for the retarder magnetic valve. Also, when the
accel switch is depressed or the parking brake lever is pulled, the power circuit for the retarder magnetic
valve is cut off.
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CIRCUIT DIAGRAM
FUSE 13 (KEY ON)
SW;
COMBINATION
19
0.5Sb
0.5LB
SW;
RETARDER
RETA
OFF
R/L;
I
RETARDER
II
20
DIODE
0.5LW 0.5LY
0.5LR RETARDER
WARNING
R/L;
P/L
RETARDER CUT
0.5LW
0.5LB
DIODE
SW ; ACCEL
SW ; PARKING
THERMO
SENSOR
2 1 M/V;
RETARDER
3 4
0.5BL
0.5BL
D08MY00112
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HSA (HILL START AID)

GENERAL DESCRIPTION
During ordinary vehicle operation, braking force is applied to the wheels only when the brake pedal is
depressed with your foot. However, when the HSA is active, foot pressure on the brake pedal is not
required to apply braking force to the wheels. This eliminates the need to move your foot quickly from the
brake pedal to the accelerator pedal when starting vehicle movement on an uphill slope. It also reduces
parking brake wear.
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CIRCUIT DIAGRAM
POWER SUPPLY OF FUSE 5 (BATTERY DIRECT)

FUSE22
(7.5A)
TAIL LIGHT RELAY
ACGL
0.3BR
0.85V
0.5RG
0.5R
0.5V
SW; HSA OFF
C/U; HSA
2 5
BACK UP
8 14 29
0.5Y
7 0.5WR
6 10
23
SW; CLUTCH 0.5R
OIL PRESS 22
0.5VR
6
SW;
MEMORY CLEAR
0.5RL 0.5B CHECKER
3
CONN (2) 10P
SW; RESET
0.5Y GND 0.3GB 21 22 27 23 24
7 26
SIG 0.3G
SW; ADJ 25
QUICK 0.5YR +5V 0.3GW 25 28 26 29 30
21 24
SLOW 0.5YB
15
HSA
0.5B
WARNING
(+) 0.3PG
13 12 P/L
(–)
28
0.85B JOINT
30
CONN A
2
17
9
19 11
18 1
0.5G
C/U; SPEED SENSOR 0.5G
SW; PARKING 0.3LB
C/U; SPEED SENSOR 0.5PL
SW; STOP LAMP 0.5GW
SW; DOOR 0.5RB
SW; NEUTRAL 0.5BG

0.5VW
0.5VG
M/V; HSA
D08M200061
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HSA OFF SWITCH

8 4
7 3
INSPECTION
HSA Check the continuity between the dome light switch
OFF
6 2
5 1 Repair or replace the switch when the result of
825M200008
OFF ON Connection place

8 嘷嘷 IGNITION
7 嘷 CONTROL UNIT
3 嘷
1 嘷 P/L
4 嘷
2 嘷 GND
6 嘷 LIGHTING
嘸
5 嘷 GND
HSA RESET SWITCH

INSPECTION
4
HSA Check the continuity between the dome light switch
RESET
6 Repair or replace the switch when the result of
825M200009
Terminal Connection
OFF ON
No. place
4 嘷 BATTERY +
6 嘷 CONTROL UNIT
HSA ADJUST SWITCH

FAST
5 2
HSA
INSPECTION
ADJ Check the continuity between the dome light switch
4
SLOW
825M200010 Repair or replace the switch when the result of
SW
position
FAST OFF SLOW
Terminal
No.
2 嘷
5 嘷
4 嘷嘷
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NOTICE
it is recommended that you carefully read and thoroughly understand the information contained in Section-
OA under the headings, "GENERAL REPAIR INSTRUCTIONS" and "HOW TO USE THIS MANUAL".
All material contained in this manual is based on latest product information available at the time of
publication.
Applicable Model: All F & G Series Vehicles
This manual is applicable to 1996 year model and later
Cab and Chassis Electrical (MGCEL-WE-681)

8 CAB AND CHASSIS ELECTRICAL
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Isuzu F & G Series 96-02

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BACK TO MODEL INDEX ISUZU F & G SERIES WORKSHOP MANUAL

F & G SERIES Workshop Manual

Applicable Model: All F&G-series vehicles

This manual is applicable to 2000 year model and later vehicle.

General Information (MGGEN-WE-0001)

General Information (MGGEN-WE-681)

SECTION NO. CONTENTS

OB Maintenance and Lubrication

Applicable Model: All F&G-series vehicles

This manual is applicable to 1996 year model and later vehicle.

Frame and Cab (MGFRM-WE-9601)

Applicable Model: All F&G-series vehicles

This manual is applicable to 1996 year model and later vehicle.

x For the disassembly, reassembly, and inspection of MERITOR made

Steering, Suspension, Tires and Wheels (MGSTG-WE-9601)

3B1 Power Steering

3B3 Steering Linkage

3B4 Steering Column

3E Wheels and Tires

Applicable Model: FVD 32, FVD 23, GVD 23, FVY 23

This manual is applicable to 2000 year model and later vehicle.

Applicable Model: All F&G-series vehicles.

This manual is applicable to 1996 year model and later vehicles.

Propeller Shaft and Axle (MGPRO-WE-681)

SECTION NO. CONTENTS

Before using this Workshop Manual to assist you in performing vehicle

All material contained in this Manual is based on the latest product

Applicable Model: FVR, FVD, FVZ, FVY, GVR, GVD

This manual is applicable to 2000 year model and later vehicles

Mentor Axle (MGMEA-WE-0001)

Applicable Model: All F&G-series vehicles

This manual is applicable to 1996 year model and later vehicle.

Rockwell Axle (MGPRO-WE-681)

This manual is applicable to 2000 year model and later vehicles.

Brakes (Air Over Hydraulic) (MGBRA-WE-0011)

SECTION NO. CONTENTS

SERVICE INFORMATION 00-1

Brake System .............................................................................................................. 00- 2

Brake Lining ................................................................................................................ 00- 9

Brake Drum ................................................................................................................ 00- 10

Air Booster .................................................................................................................. 00- 11

Air Dryer ...................................................................................................................... 00- 12

Parking Brakes ............................................................................................................ 00- 13

Air Compressor and Governor .................................................................................. 00- 14

Exhaust Brake ............................................................................................................ 00- 15

Main Data and Specifications ........................................................................................ 00- 17

Service Standard ............................................................................................................ 00- 21

Servicing .......................................................................................................................... 00- 25

Fixing Torque .................................................................................................................. 00- 36

Special Tools.................................................................................................................... 00- 47

SERVICE INFORMATION 00-3

Brake System (Cont.)

Brake System (Cont.)

SERVICE INFORMATION 00-5

Brake System (Cont.)

Brake System (Cont.)

SERVICE INFORMATION 00-7

Brake System (Cont.)

Brakes Chatter 1. Incorrect lining at drum clearance. 1. Adjust to specification.

Brake System (Cont.)

SERVICE INFORMATION 00-9

Linings Glazed 1. Grease on lining.

Cracks at Bolt Holes 1. Overtightened bolts.