Mitsubishi FUSO FE 2012 Owner's Manual

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Owner's Manual

2012 Model

Pub. No. MH996530

Table of Contents

Summary of Contents for Mitsubishi FUSO FE 2012

Page 1 Owner’s Manual 2012 Model Pub. No. MH996530...
Page 2 OWNER AND VEHICLE INFORMATION OWNER NAME: USER/COMPANY NAME: MAILING ADDRESS: CITY, STATE: ZIP: VEHICLE IDENTIFICATION NUMBER: DATE OF DELIVERY (WARRANTY START DATE): SELLING DEALER IMPRINT HERE...
Page 4 Please keep this manual in the vehicle so it is always available for reference. If you sell the vehicle, make sure the next owner receives this manual and is aware of its contents. © 2011 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan...
Page 5 Reading the handbook The information in this manual is accurate as of the time of printing. Because of differ- ences in specifications and improvements that may be added after preparation of this manual, some of the explanations and illustrations in this handbook may not apply to your vehicle.
Page 6: Table Of Contents
CONTENTS 1. Recommendation to drivers ......... . . 1-1 2.
Page 8: Table Of Contents
1. Recommendation to drivers Chassis and engine numbers .................... 1-2 Vehicle identification number (VIN) ..................1-3 Maintenance ........................1-4 Fuels ..........................1-5 DEF (Diesel exhaust fluid) ....................1-8 Handling of the new vehicle ..................... 1-13 Reporting safety defects ....................1-14 Obtaining service ......................
Page 9: Chassis And Engine Numbers
Recommendation to drivers Chassis and engine numbers 1 Chassis number The chassis number is indicated on the left frame, near the left front wheel. Example: FEC52 - Chassis number Vehicle model 2 Engine number The engine number is indicated on the front side of the cylinder head.
Page 10: Vehicle Identification Number (Vin)
G: 3.8 to 4.09 m (12.46 to 13.41 ft.) 4.1 to 4.39 m (13.45 to 14.40 ft.) 4.7 to 4.99 m (15.41 to 16.37 ft.) Cab chassis type Chassis cab for Mitsubishi Fuso and make Engine 2.998 L Diesel turbo charged and charge air cooled...
Page 11: Maintenance
Recommendation to drivers Maintenance Checking your vehicle at regular intervals is very important for maximizing performance and extend- ing service life. It is recommended that you make a habit of performing the following inspections. This manual describes simple maintenance checks and procedures that can be carried out by the owner.
Page 12: Fuels
Mitsubishi Fuso trucks. 1 Diesel-fuel properties The following recommendations concerning diesel fuel used with Mitsubishi Fuso diesel engines are given for optimum fuel economy and performance. Use condition Recommendation Normal operation at...
Page 13 Recommendation to drivers 3 Danger of fire and explosion by using mixed fuel Fuel containing 5% gasoline has a flash point as low as 0°C (32°F), which can lead to a fire or explo- sion while the engine is running. DANGER NEVER MIX DIESEL FUEL WITH GASOLINE, GASOHOL OR ALCOHOL.
Page 14 5 Refueling WARNING • Stop the engine before fueling. • Never smoke when fueling since diesel fuel could ignite or explode. Never operate lighters or other items that emit sparks. • If you inadvertently put gasoline in the fuel tank, pump it all out. Running the engine with gasoline in the tank could cause a fire or explosion endangering your or other people’s lives.
Page 15: Def (Diesel Exhaust Fluid)
Recommendation to drivers • 113-liter fuel tank <FE> The fuel tank is at the rear of the vehicle. To open the fuel tank cap, slowly turn it counterclockwise. To close the cap, turn it clockwise until you hear a click. Fuel tank capacity 113 liters (29.8 gallons) •...
Page 16 WARNING DEF is a colorless, transparent, odorless and harmless water solution (urea 32.5%, water 67.5%; Freezing temperature -11°C (12°F)), so no problem will occur if you get it on your skin. However, some persons with delicate skin may in very rare cases get a rash, so carry out the following procedure.
Page 17 1-10 Recommendation to drivers CAUTION Do not rest your foot on the DEF tank or step on it, because this may damage the tank and/or the sensors on it. NOTE: • Replenish the DEF well before it is used up. •...
Page 18: In Cold Weather
1-11 3 Method for canceling the driving restric- tion that has engaged due to an empty DEF tank If the DEF tank becomes empty, a driving restriction automatically engages, locking the gear in first or reverse, so the vehicle can be driven only slowly. In the event of a driving restriction, replenish the DEF and then disengage the restriction as follows.
Page 19 1-12 Recommendation to drivers NOTE: • You can use frozen DEF after allowing it to thaw, without loss of quality. • If you seal the container so as to prevent the water from evaporating, the quality of the DEF will not change. •...
Page 20: Handling Of The New Vehicle
1-13 4000 km Handling of the new vehicle (2500 miles) The way the vehicle is handled when new greatly affects its subsequent performance and service life. Observe the following precautions when handling the new vehicle. 1 Maintenance The “first maintenance at 4,000 km (2,500 miles)” is Z18524 very important for extending the service life of your vehicle.
Page 21: Reporting Safety Defects
National Highway Traffic Safety Administration (NHTSA) and the Mitsubishi Fuso Truck of America, Inc. (MFTA). If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
Page 22 Name of Dealer contacted under Step 1, if appli- cable • Details of the Complaint/Comment You also may correspond with the Customer Ser- vice Representative in writing, addressed to: MITSUBISHI FUSO TRUCK OF AMERICA, INC. CUSTOMER SERVICE REPRESENTATIVE 2015 CENTER SQUARE RD. LOGAN TOWNSHIP, NJ 08085...
Page 24: Warning Labels
2. Warning labels Labels inside the cab ......................2-3 Exterior labels ........................2-5...
Page 25 Warning labels • The caution and warning labels show important information. Be sure to read them before using the vehicle. • If any label has peeled so it is difficult to read, is scratched or otherwise damaged, or has peeled off completely, please inform an authorized dealer.
Page 26 Labels inside the cab 1 Around the driver’s seat Z21445 Location Category Information Ref. page WARNING High temperatures of exhaust system components 5-50 WARNING Handling of DPF system with regeneration control 5-50 WARNING Handling of DEF WARNING Use of specified fuses 13-10 WARNING Engine oil level check 12-23...
Page 27 Warning labels 2 On driver’s door and door pillar Z21446 Location Category Information Ref. page CAUTION Handling of PTO <option> 5-45 WARNING Handling of DUONIC 5-20 WARNING 4WD <FG> CAUTION Towing precautions 13-32 Standard value Tire pressure 12-66 WARNING 113-liter fuel tank refilling precaution <FE> WARNING Precautions for vehicles with limited slip differential 12-69 <FE: option;...
Page 28 Exterior labels 1 On frame and exterior equipment Z21448 Location Category Information Ref. page DANGER High temperatures of exhaust system components 5-50 CAUTION Use of diesel fuel <FG> WARNING Fuel to use WARNING 113-liter fuel tank refilling precautions <FE> CAUTION Prohibition against standing on DEF tank CAUTION Use of DEF...
Page 29 Warning labels 2 On cab outside and engine Z21197 Location Category Information Ref. page WARNING Handling of cab tilt function (Vehicles other than 12-6 Crew-cab models) WARNING Handling of pressure cap 12-56 CAUTION Inspection and replacement of engine oil 12-23 CAUTION Oil to use for clutch and transmission 12-28...
Page 30: Opening And Closing
3. Opening and closing Starter key .......................... 3-2 Engine immobilizer (theft prevention device) ..............3-3 Doors ..........................3-6 Central door locks ......................3-8 Keyless entry system ......................3-9 Entering and leaving the vehicle ..................3-13 Door window glass ......................3-15...
Page 31: Starter Key
Opening and closing Starter key • Your vehicle comes with a two-piece starter key • The starter key can be used to start and stop the engine and lock and unlock the doors. • Be sure to remove the number plate and keep it in a safe place.
Page 32: Engine Immobilizer
Engine immobilizer (theft prevention device) 1 Engine immobilizer NOTE: The immobilizer complies with part 15 of the FCC Rules. Operation is subject to the following two con- ditions: (1) The immobilizer may not cause harmful inter- ference. (2) The immobilizer must accept any interference received, including interference that may cause undesired operation.
Page 33 Opening and closing • A metallic ring is on top of the handle of the engine immobilizer starter key. Z20929 • The handle of the engine immobilizer starter key is in contact with a metallic part of another key. Z20930 •...
Page 34 The engine immobilizer starter key is an electronic device containing a signal transmitter. Bear in mind the following cautions: • Do not bend the engine immobilizer starter key or subject it to strong shocks. • Do not leave the engine immobilizer starter key in any part of the cab where it could be exposed to direct sunlight and get extremely hot (60°C (140°F) or higher).
Page 35 Opening and closing Doors WARNING • To help prevent accidents, always check for vehicles and pedestrians approaching from behind before opening the doors. • Driving with a door ajar can be very dan- gerous. Make sure the doors are com- pletely closed before starting.
Page 36 1 From the outside • To open, pull the outer handle toward you. • Use the starter key to lock or unlock the door. • It is possible to lock each door without using the starter key. With the driver’s door or assistant driver’s door, push the lock knob toward the front of the vehicle then pull the outer handle...
Page 37: From The Inside
Opening and closing 2 From the inside • To close, use the door waist bar . Close the door completely. • To lock the driver’s door or assistant driver’s door, push the lock knob toward the front of the vehicle. To lock a rear door, push the lock knob down.
Page 38: Keyless Entry System
Keyless entry system 1 The Grant of Equipment Authorization certificate for wireless transmitter (remote control switch) 1. FCC ID: OBIH7079TX 2. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: • This device may not cause harmful interference.
Page 39 3-10 Opening and closing 2 Keyless entry system The keyless entry system allows you to lock/unlock the driver’s door, assistant driver’s door and rear doors (Crew-cab model vehicles) by operating the remote control switch WARNING If you carry the keyless entry remote control switch with you when traveling on an air- Z21332 plane, avoid pressing any button on the...
Page 40 3-11 • When you press the buttons, be sure to press them for at least one second. If a button does not work after one press, press the button again after one or two seconds. • After locking the doors with the remote control switch, always check that the doors are locked by lifting the outside handle of a door.
Page 41 3-12 Opening and closing CAUTION • Use the designated standard type of battery. If the battery is replaced with an incorrect type, the battery could explode. • Attach the battery with the “+” mark facing upward. • Do not use a metal tool such as tweezers to replace the battery.
Page 42 3-13 Entering and leaving the vehicle WARNING • Always use the step to climb into or down from the vehicle. Never put your foot on the wheel or tire since it could easily slip off. • The step can become slippery in rain or snow.
Page 43 3-14 Opening and closing Z21333 CAUTION • Climb into and out of the cab by holding only the grip. If you hold onto any other parts of the vehicle, they could break or fail. • When entering or leaving an FG model truck, do not place your feet or hands on the fender .
Page 44 3-15 Door window glass WARNING Do not allow a child to put its hands or head out of a window. The child’s head or hands could hit an object outside the vehicle, and the child could be seriously injured in the event of hard braking.
Page 45 3-16 Opening and closing To fully close the driver’s window with a single touch of the switch, pull the switch firmly. If you wish to stop the window part-way, give the switch a gentle push. CAUTION Do not keep any door or window open in rainy weather, and be careful not to spill a drink on any of the window switches.
Page 46: Seat And Steering Wheel Adjustments
4. Seat and steering wheel adjustments Seats ..........................4-2 Seat belts ........................... 4-5 Steering wheel ........................4-9...
Page 47 Seat and steering wheel adjustments Seats WARNING • Adjusting the seat while the vehicle is in motion is dangerous as the seat may move more than you intend. Be sure to stop the vehicle and set the parking brake before performing any adjustment of the seat.
Page 48 Making adjustments • Slide seat forward or backward while holding slide adjustment lever raised. After making the adjustment, release the lever and move the seat back and forth slightly to lock it in position. • To adjust the angle of the seatback , raise reclining lever •...
Page 49 Seat and steering wheel adjustments 3 Rear seat – Crew-cab models Storage compartments are located under the rear seat. The rear seat can be folded up for access to them. When you wish to stow or remove something from these compartments, release the clamps the base of the seat and raise the seat cushion To retain the seat cushion, use the retaining bands that are attached to the seatback.
Page 50: Seat Belts
Seat belts • To help prevent injury in the event of a sudden stop or accident, the driver and all passengers must wear their seat belts correctly. • When wearing your seat belt, sit back in your seat with your back straight. If a seat belt is used incorrectly, its effectiveness is greatly dimin- Z21338 ished and it could aggravate injuries in the event...
Page 51 Seat and steering wheel adjustments 1 Lap and shoulder belts with ELR NOTE: It is not necessary to adjust the length of these seat belts. An ELR seat belt extends and retracts automatically as its wearer moves but locks automatically for pro- tection in the event of a sudden stop or shock.
Page 52: Lap Belt
Seat belt anchor <Driver’s seat> WARNING The shoulder belt can be dangerous if worn across the neck. Adjust its position so that it does not cross over the neck. Adjust the seat belt anchor upward or downward Z08772 to ensure that the belt passes across your shoulder. You will need to keep the lock button pulled while moving the seat belt anchor downward.
Page 53: Pregnant Women
Seat and steering wheel adjustments 3 Children and babies • When carrying children or babies, they must be restrained properly to minimize the risk of injury in the event of a sudden stop or accident. Never allow children to stand or kneel on the seats. For maximum safety, we recommend fitting and using a restraint system that complies with Fed- eral Motor Vehicle Safety Standards.
Page 54: Steering Wheel
Steering wheel WARNING • After every adjustment, try to move the steering wheel back and forth to make sure that it is securely locked. Unless the lever returns to its original position, the steering wheel may move while the vehicle is in motion and cause an accident.
Page 56: Switches And Controls
5. Switches and controls Arrangement of switches and controls ................5-2 Starter switch ........................5-3 Starting the engine ......................5-5 Warming up the engine ....................5-10 Stopping the engine ......................5-12 Pedals ..........................5-14 Parking brake lever ......................5-15 Combination switch ......................5-16 DUONIC ........................
Page 57 Switches and controls Arrangement of switches and controls Starter switch Accelerator pedal Brake pedal Gearshift lever Parking brake lever Hazard warning lamp switch Combination switch (wiper and washer switch, exhaust brake switch <option>) Combination switch (lighting switch, passing/dimmer switch, turn sig- nal switch) Front drive switch <FG>...
Page 58: Starter Switch
Starter switch 1 Starter switch position WARNING Never turn the starter switch to any position other than the “ON” position while driving the vehicle. Turning the starter switch to the “ACC” position would be dangerous because the engine would stop and the following problems would occur: •...
Page 59 Switches and controls • LOCK The starter key can be inserted and removed in this position only. To place the key in the “LOCK” position, turn it to the “ACC” position then press it in. Keep it pressed in while turning it to the “LOCK”...
Page 60: Starting The Engine
Starting the engine WARNING • Do not start or warm up the engine in a garage or other closed area. When starting the engine or entering or leaving a garage, do not run the engine for longer than is necessary as the accumulation of exhaust gas in closed areas is very dangerous.
Page 61 Switches and controls CAUTION • Do not try to push-start the engine. Push- starting the engine is impossible for this vehicle and could damage the transmission. • Do not use ether or other vapor compound type starting aids. Use of such fluid on this engine could result in serious damage.
Page 62: Starting Procedure
2 Starting procedure 1. Depress the brake pedal fully. CAUTION For safety, keep the brake pedal depressed until the engine has started. Z15222 2. Turn the starter switch to the “ON” position. Z21163 3. Check whether the indicator lamp illumi- nates or not.
Page 63 Switches and controls • When the indicator lamp illuminates Wait until the indicator lamp goes out. While holding down the brake pedal, turn the starter switch to the “START” position to start the engine. NOTE: If the engine is difficult to start after the indicator lamp has gone out, there may be a problem with the engine preheating system.
Page 64 CAUTION • To ensure maximum safety, be sure to pull the parking brake lever fully to apply the parking brake and block the wheels with chocks thus preventing the vehicle from accidentally moving. • Performing the cranking is of essential importance in terms of protecting the turbo- charger.
Page 65 5-10 Switches and controls Warming up the engine Let the engine warm up for 1 to 2 minutes before starting the vehicle. WARNING • Do not warm up the engine in a garage or other closed area. When starting the engine or entering or leaving a garage, do not run the engine for longer than is nec- essary as the accumulation of exhaust gas...
Page 66 5-11 NOTE: • Idling the engine for long time wastes fuel, and is therefore detrimental to environmental protec- tion and resource conservation. So shut down the engine whenever you leave the vehicle, even for a short period. If you start to drive immediately after starting the engine (while the engine is still cold), you will encounter the following problems: •...
Page 67: Stopping The Engine
5-12 Switches and controls Stopping the engine WARNING • Never allow the vehicle to coast with the engine stopped as braking may be danger- ously sluggish and extremely difficult steering may result. This may also cause trouble in the fuel injection system. •...
Page 68 5-13 CAUTION • If you stop the engine immediately after uphill or high-speed driving, the oil supplied to the rotor shaft of the turbocharger will rise to an abnormally high temperature and the rotor shafts could seize up. To avoid this, run the engine at idle for at least 3 minutes instead of stopping it immediately.
Page 69 5-14 Switches and controls Pedals Accelerator pedal WARNING If you use a floor mat, be sure to use a Mitsu- bishi Fuso genuine floor mat and lay it cor- rectly. Do not lay the floor mat over the accelerator pedal or accelerator pedal stop- per.
Page 70: Parking Brake Lever
5-15 Parking brake lever WARNING • Do not use the parking brake when driv- ing except in an emergency, like if the ser- vice brakes have failed. Such use of the parking brake may make the vehicle spin or, at worst, roll over. It may also cause faults in vehicle components.
Page 71: Combination Switch
5-16 Switches and controls Combination switch 1 Arrangement of switches Lighting switch Passing/dimmer switch Turn signal switch Exhaust brake switch <option> Wiper and washer switch Z21344 2 Lighting switch CAUTION Keeping the headlamps on for a long period without the engine running can drain the bat- tery, making the engine impossible to start.
Page 72 5-17 3 Passing signal/dimmer switch Passing signal Pulling the lever up activates the high beams until the lever is released. Use this to flash a signal when overtaking another vehicle. Dimmer With the headlamps illuminated, pushing the lever down activates the headlamp high beams and pull- ing it back to the original position reactivates the low Z21346 beams.
Page 73 5-18 Switches and controls NOTE: • Do not keep the exhaust brake switch in the activation position at all times. Keeping the switch in the activation position worsens fuel consumption, as doing so causes the exhaust brake to work frequently and thus the vehicle to decelerate and accelerate frequently.
Page 74 5-19 • Do not operate the wipers when the rubber parts of the wiper blades are frozen onto the windshield or otherwise stuck to the wind- shield. The wiper blades could get damaged, and the wiper motor could fail. • When the wipers are not used for a long time, dust, sand, and other substances can collect between the wiper blades and wind-...
Page 75 5-20 Switches and controls DUONIC The DUONIC system combines the controls of the clutch, transmission and engine into a single system to achieve automatic clutch engagement/ disengagement and gear shifting during start-out and driving. The clutch mechanism incorporates two clutch sys- tems (called “dual-clutch”),...
Page 76 5-21 Brake pedal operation CAUTION Get into the habit of always using the right foot to depress the brake pedal. If you use the left foot, the pedal-pressing action will not be fully responsive, which could lead to an accident especially in the case of emergency braking.
Page 77 5-22 Switches and controls Driving on a slippery road WARNING Use the manual shift mode when driving on slippery surfaces (such as a wet or frozen road). Using the automatic shift mode on slippery roads could cause an accident for the following reasons: Skidding is more likely to be caused by auto- matic shift-downs that take place normally...
Page 78: Controls And Indicators
5-23 2 Controls and indicators Z21533 Gearshift lever Used to control the operation of the DUONIC system. Move the lever until it completely engages in each position. Gear position indicator Indicates the selected gear of the transmission. Automatic shift mode indicator This indication appears while driving in the auto- matic shift mode.
Page 79: Gearshift Lever
5-24 Switches and controls • (amber) Indicates that the DUONIC system is faulty (but the vehicle may be driven if auto- matic or manual gear shifting is possible). 3 Gearshift lever This lever is used to control the operation of the DUONIC system.
Page 80 5-25 N: Neutral • No power is transmitted to the wheels. • Although you can also use this position when starting the engine, we strongly recommend using the “P” position for increased safety. D: Drive • This is the position for driving. •...
Page 81 5-26 Switches and controls 4 ECO mode switch You can use the ECO mode switch only while driv- ing in the automatic shift mode. When the ECO mode is turned on using this switch, the DUONIC system applies the following con- trol: •...
Page 82 5-27 • On downhill roads, never start the vehicle with the gearshift lever in the “N” position. Be sure to place the lever in the “D” position instead. If the gearshift lever is in the “N” position, engine braking does not work, which increases the risk of an accident.
Page 83 5-28 Switches and controls 2. Check that the multi-information display is show- ing “ ” and that the gear position indicator is showing “1” or “2”. Z21300 NOTE: • The DUONIC system selects the starting gear automatically according to the steepness of the slope and the vehicle loading.
Page 84 5-29 • Start the vehicle only when the gear position indicator indicates “1”, “2” or “3”. When starting after the ABS has been activated, the system may take longer than usual to engage the starting gear. 1. Fully depress the brake pedal. 2.
Page 85 5-30 Switches and controls Reversing 1. While holding the brake pedal fully depressed, place the gearshift lever into the “R” position. 2. Check that the gear position indicator shows “R”. NOTE: • While the vehicle is moving, the reverse gear does not engage even if you place the gearshift lever into the “R”...
Page 86 5-31 NOTE: • In cold weather when the temperature of the transmission oil is low, you may experience slower automatic shift-downs from 3rd to 2nd and from 2nd to 1st than usual. This does not indicate any problem; shifting will return to nor- mal speed as the oil temperature rises.
Page 87 5-32 Switches and controls In the manual shift mode, the gear is fixed at the presently selected one even when the vehicle speed changes. So you should change the gear appropriately according to the vehicle speed. • The gear shifts up by one gear each time you move the gearshift lever to the “+”...
Page 88 5-33 Move the gearshift lever between the “D” and “N” positions to rock the vehicle and thereby get it out of the mud, snow, or sand. Z16687 8 Short stops WARNING Never race the engine when the vehicle is stopped. If the gearshift lever happens to have been placed in any position other than “P”...
Page 89 5-34 Switches and controls 9 Leaving the vehicle with the engine running Leave the vehicle after confirming the following: 1. The parking brake is firmly applied. 2. The gearshift lever is in the “P” position. 3. The gear position indicator is showing “P”. NOTE: A buzzer sounds continuously if the driver’s door or assistant driver’s door is opened while the engine is...
Page 90 5-35 10.2 warning (amber) • If this warning appears while driving: • You may continue to drive if automatic gear (Amber) shifting is possible in the automatic shift mode. However, have the vehicle inspected by an authorized dealer as soon as possible. •...
Page 91: Cruise Control
5-36 Switches and controls Cruise control Cruise control memorizes any desired speed above the speed indicated below and, maintains that speed automatically without having to operate the accelerator pedal. This is especially useful for free- way driving when there is little chance of having to pull over and stop.
Page 92 5-37 1 Controls and indicator Z21520 Main switch This switch is used to activate and deactivate the cruise control function. The lamp inside the switch illuminates when the cruise control is on. The switch returns automatically to the neutral position after having been pressed. WARNING For safety, turn off the main switch when the cruise control is not in use.
Page 93 5-38 Switches and controls Cruise control indicator lamp If the cruise control is activated, this lamp illumi- nates during driving. Cancel switch Press this switch to stop cruise control opera- tion. 2 To set a desired speed 1. If your vehicle is equipped with an exhaust brake, check that the exhaust brake switch is in the “OFF”...
Page 94 5-39 3. When the desired speed is reached, turn the RESUME/SET switch toward the “SET” side. indicator lamp will illuminate indicating that the cruise control is activated. Now the desired speed is memorized, so release the accelerator pedal. The vehicle will run maintain- ing that speed automatically.
Page 95 5-40 Switches and controls 2. When the desired speed is reached, turn the SET/RESUME switch to the “SET” side for 1 second or longer. The vehicle will then cruise at the new, higher speed. Z21526 4 To decrease the set speed in cruise con- trol mode Turn the SET/RESUME switch toward the “SET”...
Page 96 5-41 CAUTION Placing the gearshift lever in the “N” position temporarily deactivates the cruise control. How- ever, such practice is dangerous during driving because engine braking will no longer be possi- ble. It will also cause malfunction of the trans- mission.
Page 97: Hazard Warning Lamp Switch
5-42 Switches and controls 8 To deactivate the cruise control Deactivate the cruise control by doing either of the following: • Press the “OFF” side of the main switch • Press the cancel switch CAUTION When there is a problem with the engine control system, the cruise control cannot be used.
Page 98: Front Fog Lamp Switch
5-43 Front fog lamp switch CAUTION Avoid using the front fog lamps unless visibility is poor, as they may prove distracting to other motorists during normal driving conditions. Use the front fog lamps when visibility is poor due to fog or snow. The front fog lamps can be used with the lighting switch in the position.
Page 99: Mirror Heater Switch
5-44 Switches and controls WARNING • During normal driving, the mirrors must be in their outward positions and adjusted so that clear rear views may be obtained through them. • When turning right or left, bear in mind the difference in tracking of the front and rear inner wheels, and use the rearview mirrors to confirm safety behind you.
Page 100: Horn Switch
5-45 Horn switch Press the horn switch pad at the center of the steering wheel to sound the horn. Z21355 Transmission PTO CAUTION • Engage the PTO only with the engine run- ning at idle. • Pay careful attention to the indicator lamp when using the PTO.
Page 101 5-46 Switches and controls NOTE: • The transmission PTO delivers power taken from the truck’s transmission to a hydraulic pump or other equipment/implement. • Both automatic DPF regeneration and parked DPF regeneration do not work while the PTO is being used. •...
Page 102 5-47 Disengagement Press the “OFF” side of the PTO switch. Make sure the multi-information display indicates neither Z21735...
Page 103 5-48 Switches and controls ® BlueTec system Z20011 DPF muffler Pump module Dosing module Muffler with SCR/Oxidation catalyst DEF tank DEF tube NOTE: ® BlueTec : A brand of Daimler AG • ® The BlueTec system is a combination of the regeneration controlling DPF system and the ®...
Page 104 5-49 • Continuous filter regeneration is impossible under certain conditions such as low-speed driv- ing. Under these conditions, the system auto- matically raises the exhaust temperature to burn the PM to regenerate the filter (automatic DPF regeneration). However, even automatic DPF regeneration is sometimes impossible if the vehicle is repeatedly driven very slowly and the engine is frequently started and stopped.
Page 105 5-50 Switches and controls 1 Regeneration controlling DPF system Controls and indicators Z21882 DPF cleaning switch Use this switch for parked DPF regeneration to burn PM in the DPF. Multi-information display The multi-information display indicates the amount of PM in the DPF, a prompt for performing parked DPF regeneration, the predicted time until comple- tion of parked DPF regeneration, and warnings.
Page 106 5-51 PM indicator If you select the DPF monitor on the multi-informa- tion display, you can check the amount of PM col- lected in the DPF. • Select the DPF monitor mode by pressing the MODE switch to see the PM indicator •...
Page 107 5-52 Switches and controls Indication by Warning/indicator Parked/automatic Ref. PM indicator lamp regeneration page When the number of displayed segments is 7 or 8: Perform parked DPF regenera- lamp tion within 50 km (amber) (31 miles) or 5-55 flashes slowly 1 hour, which- 5-56 (0.5-second...
Page 108 5-53 Indication by Warning/indicator Parked/automatic Ref. PM indicator lamp regeneration page When automatic DPF regeneration is in progress: • The lamp (green) lights. • If a prompt for parked DPF regeneration has been issued Automatic DPF following indica- regeneration is in 5-53 tion of 7 or more progress.
Page 109 5-54 Switches and controls • If you select the DPF monitor mode on the multi- information display during automatic DPF regeneration, the “CLEANING” message is dis- played above the PM indicator, and the PM indi- cator flashes. WARNING If the vehicle must be stopped during auto- matic DPF regeneration, do so after checking that there are no flammable materials, such as dead grass or paper, near the exhaust pipe...
Page 110 5-55 Parked DPF regeneration (performed fol- lowing illumination of the (amber) indi- cator lamp) system sometimes cannot automatically remove the DPF trapped PM by oxidation, typically when you drive the vehicle at very low speeds or start and stop the engine frequently during opera- tion.
Page 111 5-56 Switches and controls CAUTION If the (amber) indicator lamp flashes quickly or the warning appears on the multi-informa- tion display, promptly perform parked DPF regeneration by using the DPF cleaning switch to remove PM in the DPF by burning. Continuing to drive with an overloaded DPF will result in system failure.
Page 112 5-57 • While the accelerator pedal or brake pedal is being depressed • While the vehicle is moving • When the gearshift lever is in any position other than “P” or “N” 1. Park the vehicle in a safe place and warm up the engine.
Page 113 5-58 Switches and controls ® 2 BlueTec exhaust gas aftertreatment ® Warnings for BlueTec exhaust gas after- treatment Five different combinations (patterns) of warning lamp/indicator lamp operation and buzzer sound warn you of the different abnormal conditions with ® the BlueTec exhaust gas aftertreatment as shown below.
Page 114 5-59 *1: If you drive more than another 160 km (100 miles) or additional 2 hours, the warning lamp, which has been lit, starts flashing. *2: If you drive more than another 320 km (200 miles) or additional 4 hours, the warning lamp, which has been lit, starts flashing.
Page 115 5-60 Switches and controls Further reduced DEF level (warning pattern 2) If the DEF level drops further, you are warned of the condition as follows. Refill the DEF tank immedi- ately. P. 1-9 • A buzzer sounds. • indication changes from amber to red. •...
Page 116 5-61 CAUTION If you continue to drive with the warning lamps lit and/or flashing and a buzzer sounding, the NOx level of exhaust emissions will increase, damaging the environment. In addition, the ® BlueTec exhaust gas aftertreatment will be damaged. Continuing to drive in this condition also results in reduced engine output and finally in the engagement of driving restrictions after which the vehicle can be driven only at slow...
Page 117 5-62 Switches and controls ® Faulty BlueTec exhaust gas aftertreat- ment (warning pattern 5) ® If there is a problem with the BlueTec exhaust gas aftertreatment, warning lamps will come on, the engine power will be reduced, and a buzzer will sound.
Page 118 5-63 3 Precautions for inspection and mainte- nance • DEF dosing system The DEF dosing system (pump module plus dosing module) continues to operate for about 2 minutes after the starter switch has been put in the “LOCK” position. Wait for at least 2 min- utes before disconnecting the battery and elec- trical system connectors in order to carry out an inspection, maintenance and so on.
Page 120: Instruments And Warning Lamps
6. Instruments and warning lamps Arrangement of instruments and warning lamps ............... 6-2 Speedometer ........................6-2 Tachometer ........................6-2 Water temperature gauge ....................6-3 Fuel gauge ......................... 6-4 DEF level indicator ......................6-5 Multi-information system ....................6-7 Warning/indicator telltale ....................6-21 Warning/indicator lamps ....................
Page 121: Warning Lamps
Instruments and warning lamps Arrangement of instruments and warning lamps Speedometer Tachometer Fuel gauge Warning/indicator lamps DEF level indicator Multi-information display Z21356 Speedometer The speedometer indicates vehicle speed in miles or kilometers per hour. Z21357 Tachometer • The tachometer indicates engine speed in revo- lutions per minute.
Page 122: Water Temperature Gauge
Water temperature gauge • The water temperature gauge is displayed on the multi-information display and indicates the temperature of the engine coolant. • With the engine running normally, the coolant temperature indicator will indicate around the middle point of the scale. •...
Page 123: Fuel Gauge
Instruments and warning lamps Fuel gauge The fuel gauge indicates the amount of fuel still remaining in the fuel tank. F: Full E: Empty When the Low-fuel warning lamp is illuminated, Z20965 the approximate quantity of fuel remaining in the tank is as indicated below.
Page 124 DEF level indicator CAUTION Do not let the DEF tank become empty. If the tank becomes empty, the vehicle’s operation is automatically restricted, so you can drive only at low speeds. We recommend carrying DEF in a portable con- tainer on your vehicle in case the DEF tank becomes empty.
Page 125 Instruments and warning lamps • If the DEF level drops further, a different type of warning is issued and additional engine power control is applied as follows: • A buzzer sounds. • indication changes from amber to red. • warning lamp comes on. •...
Page 126 Multi-information system 1 Outline of multi-information system MODE switch SELECT switch SET/RES switch Multi-information display Information area Warning/indicator area Transmission information area Odometer/trip meter area Time/outside temperature area (outside temper- ature indication is available for vehicles with a fully automatic air conditioner) The multi-information system indicates the following types of information on the multi-information display located on the meter cluster.
Page 127 Instruments and warning lamps 2 Odometer/trip meter When the starter switch is turned to “ON”, either “ODO” (odometer) or “TRIP” (trip meter) is dis- played. The display toggles between “ODO” and “TRIP” each time the ODO/TRIP switch pressed. • ODO (odometer) Indicates the total distance covered by the vehicle to the nearest mile.
Page 128 Z21552 Display mode Ref. page Calendar and clock 6-10 Outside air temperature (vehicles with fully automatic air conditioner) 6-12 DPF monitor 6-13 Fuel mileage information 6-14 Maintenance information 6-16 Illumination intensity (brightness adjustment) 6-19...
Page 129 6-10 Instruments and warning lamps Calendar and clock • Date/time Press the MODE switch to display the date and time on the screen. Z22061 • If you press the SELECT switch while the date and time are displayed on the screen, the month part of the date will change from numeri- cal representation to English representation.
Page 130 6-11 1. Give a long press on the SET/RES switch while the date and time indication is displayed on the screen. The adjustment screen will appear. 2. Each time you press the SET/RES switch, one of the indication items is selected in the sequence shown below with the selected item flashing.
Page 131 6-12 Instruments and warning lamps Outside air temperature <vehicles with fully automatic air conditioner> If you select the outside air temperature mode by pressing the MODE switch , the outside air tem- perature around the front of the cab is indicated. NOTE: As the temperature is sensed at the outside air inlet on the cab, the indicated temperature may differ...
Page 132 6-13 1. Select the outside air temperature mode pressing the MODE switch Give a long press on the SET/RES switch display the adjustment screen 2. Select the adjusting/setting item using the SET/ RES switch. Each time you press the SET/RES switch, the display changes in the following sequence: →...
Page 133 6-14 Instruments and warning lamps Fuel mileage information The fuel mileage information includes: average fuel mileage , real-time fuel mileage , instantaneous fuel mileage , and average speed • The average fuel mileage indicates the average of the fuel mileage from the time it was last reset to the present.
Page 134 6-15 NOTE: If you press the SET/RES switch for more than 1 second in the correction coefficient change screen, the coefficient will return to the default value. • The fuel mileages can be indicated in units of “mpg”, “km/l”, or “l/100 km”. •...
Page 135 6-16 Instruments and warning lamps Maintenance information If you select this mode, the multi-information display indicates the running distance and the number of months since the distance was last reset after replacing oils, fluids, or filter elements according to your selection of screen. Z21556 •...
Page 136 6-17 • How to set replacement intervals Set the replacement interval for each replacement item according to the table below. Item Replacement interval Engine oil Every 30,000 km (18,000 miles) or every 12 months Engine oil filter (OIL FILTER) Every 30,000 km (18,000 miles) or every 12 months Fuel filter (FUEL FILTER) Every 30,000 km (18,000 miles) or every 12 months Brake fluid...
Page 137 6-18 Instruments and warning lamps • Each time you press the MODE switch, the period decreases by 1 month. • A long press on the SELECT or MODE switch increases or decreases the period by 2 months, respectively. • If the replacement interval is controlled by the distance (not by the period of time), leave the period space blank (“-- month”).
Page 138 6-19 • Resetting of maintenance information After replacing a periodic replacement item such as the oil, filter element, or engine coolant, reset the maintenance information for the item as follows: 1. Press the MODE switch to select the mainte- nance information mode. 2.
Page 139 6-20 Instruments and warning lamps 1. Press the MODE switch to select the illumina- tion intensity mode 2. Press the SELECT switch . Each time you press the switch, the display toggles between “DISP (DAY)” and “GAUGE (DAY)” . When the light switch is in the position, the display toggles between “DISP (NIGHT)”...
Page 140 6-21 Warning/indicator telltale The warning/indicator telltale function provides warning and indicator indications on the multi-infor- mation display in the following situations: • When a problem occurs with a vehicle system • When a system is activated • When the distance/period remaining before the replacement time becomes short 1 Telltale indications Indication colors...
Page 141 6-22 Instruments and warning lamps Red and amber indications Ref. Indication Warning/indicator Condition for lighting/flashing page Engine power is being automatically Engine system warning 6-24 restricted. (red) Engine system warning Engine must be inspected. 6-24 (amber) Transmission oil temperature Clutch control fluid temperature is too 6-24 warning high.
Page 142 6-23 Black indications Ref. Indication Warning/indicator Condition for lighting/flashing page <Vehicles with transmis- sion PTO> Lights when transmission PTO is engaged. 5-45 PTO indicator <Vehicles with transmis- sion PTO> Lights when transmission PTO is preparing to 5-45 PTO engagement engage. preparation indicator Distance or period remaining before sched- Engine oil replacement...
Page 143 6-24 Instruments and warning lamps Engine system warning • Red warning If an engine system warning is shown, have the vehicle inspected by the nearest authorized dealer. • Amber warning If an engine system warning is shown, have the vehicle inspected by the nearest authorized dealer. Z21711 Transmission oil temperature warning This warning is displayed when the clutch control...
Page 144 6-25 3. Turn the starter switch to “ON”. 4. If the warning remains displayed but driving in the manual gearshift mode is possible, take the vehicle to an authorized dealer for inspection as soon as possible. 5. If the warning remains displayed and gear shift- ing is impossible in the manual gearshift mode, contact your nearest authorized dealer.
Page 145 6-26 Instruments and warning lamps Meter cluster warning This warning is displayed when the electrical sys- tem of the meter cluster is faulty. If this warning appears while driving, stop the vehi- cle in a safe place and do the following: 1.
Page 146 6-27 Warning/indicator lamps Z21716 The illustration shows the standard arrangement of the warning and indicator lamps. Some lamps shown here, however, may not be installed on your vehicle. Illumination of certain warning lamps is accompa- nied by sounding of a buzzer. CAUTION The red warning lamps, if illuminated, warn you of vehicle component failures and possible dan-...
Page 147 6-28 Instruments and warning lamps Lamp Ref. Warning/indicator lamp If illuminates or flashes symbol page Level of fuel in fuel tank excessively • Fuel level warning lamp Turn signal or hazard warning lamps Turn signal indicator lamp 5-17 flashing Headlamp high beam indicator Headlamp high beams illuminated 5-17 lamp...
Page 148 6-29 Lamp Ref. Warning/indicator lamp If illuminates or flashes symbol page Slow flashing (0.5-second inter- val; amber) DPF contains a lot of PM Fast flashing (0.25-second interval; amber) DPF indicator lamp 5-50 Parked DPF Illumination regeneration in (amber) progress Automatic DPF Illumination regeneration in (green)
Page 149 6-30 Instruments and warning lamps The warning lamps shown below come on when the starter switch is turned from the “ACC” position to the “ON” position but almost immediately go off. Lamp Warning lamp Operation symbol Goes off when the parking brake is released.
Page 150 6-31 1 Vacuum pressure warning lamp WARNING Braking is dangerously sluggish when the vacuum warning lamp is illuminated. For safety, never drive with the vehicle in this condition. This lamp illuminates when the starter switch is Z10909 turned to the “ON” position. As long as the lamp goes out when the engine is started, the vehicle may be driven.
Page 151: Brake Warning Lamp
6-32 Instruments and warning lamps 2 Brake warning lamp WARNING If the brake warning lamp comes on owing to an excessively low level of brake fluid, the brakes will not be fully effective and driving will thus be dangerous. Do not drive the vehi- cle in this condition.
Page 152 6-33 4 Engine oil pressure warning lamp The engine oil pressure/level warning lamp lights up when the starter switch is turned to the “ON” posi- tion and goes out as soon as the engine is turned over. If the lamp lights up while the engine is run- ning, the cause may be an excessively low engine oil pressure.
Page 153: Abs Warning Lamp
6-34 Instruments and warning lamps 6 ABS warning lamp This lamp comes on when the starter key is turned to “ON”. It should go out a few seconds later. If the lamp comes on again, this indicates there is a mal- function in the antilock braking system (ABS).
Page 154 6-35 8 Engine immobilizer warning lamp This lamp should normally come on when the starter switch is turned to “ON” and go out a few seconds later. If the lamp fails to go out, communi- cation with the engine immobilizer starter key may be obstructed or the engine immobilizer itself may be faulty.
Page 156: Starting And Driving
7. Starting and driving Precautions when setting the vehicle in motion ..............7-2 Precautions for driving ....................... 7-3 Tips for improving fuel economy ..................7-7 Braking ..........................7-8 Antilock braking system (ABS) ................... 7-9 On uphill and downhill roads .................... 7-12 On rough roads and in bad weather ................
Page 157 Starting and driving Precautions when setting the vehicle in motion • Do not carry containers of fuel or spray cans in the cabin. WARNING • Carrying fuel in the cabin is extremely dan- gerous because an increase in the cabin temperature could cause fuel vapor to catch fire or cause the container to rup- ture.
Page 158 • Do not attach anything to the windshield. • You should be familiar with how to use the DUONIC system controls before starting your vehicle. P. 5-20 • Check the immediate area around the vehicle, using mirrors as necessary: there should be no persons or obstacles under, in front of, on either side, or behind the vehicle.
Page 159 Starting and driving WARNING • Never place the starter switch in any posi- tion other than the “ON” position while operating the vehicle. If you turn the starter switch to the “ACC” position, the engine will stop. This is dan- gerous.
Page 160 • If you notice a strange noise, vibration, or smell, or if steering or braking feels unusual, pull the vehicle off the road as soon as it is safe to do so and check for the source of the trouble. If you cannot determine the cause of the problem and/ or cannot rectify it, contact the nearest autho- rized dealer.
Page 161 Starting and driving • When driving at high speeds in the rain, it some- times happens that the tires ride on a film of water and lose contact with the road surface. This is known as “hydroplaning”. If this should happen, you will lose control of both steering and braking.
Page 162 • If you stop temporarily when driving uphill, depress the brake pedal and pull the parking brake lever. Do not attempt to stop the vehicle from rolling backwards with the accelerator pedal. Tips for improving fuel economy Observe the following precautions to achieve maxi- mum fuel economy and to extend tire life.
Page 163 Starting and driving Braking When driving downhill, use engine braking as well as exhaust braking <option> in combination with the foot brake. P. 7-12 WARNING • When warning lamps and/or light up, immediately stop the vehicle and per- form necessary checks. P.
Page 164 WARNING Never operate the vehicle if the brake system is faulty or brake fluid is leaking. Failure to observe this instruction could lead to a seri- ous accident. Antilock braking system (ABS) If a vehicle is driven on a slippery road or it is run- ning with no or only light load, the wheels can lock and then skid when the brake pedal is strongly depressed.
Page 165 7-10 Starting and driving 1 Driving tips NOTE: • If the ABS is malfunctioning and the ABS warn- ing lamp stays on, no ABS functions are avail- able. Even if this condition happens, the brakes work normally. If the warning lamp stays on, have the vehicle repaired by an authorized dealer as soon as possible.
Page 166 7-11 Brake pedal operation Hold the brake pedal depressed as necessary even when the ABS is in operation. When the ABS is working, you may feel very slight or slow vibration through the brake pedal, but this does not indicate an abnormal condition. Continue depressing the brake pedal.
Page 167 7-12 Starting and driving On uphill and downhill roads 1 Uphill roads When driving the vehicle using the manual shift mode, downshift early if the vehicle speed begins to drop to minimize the load on the engine. 2 Downhill roads •...
Page 168 7-13 • First decelerate the engine sufficiently before downshifting. Shifting down will be prohibited by a safety device if the vehicle is driving fast. In such cases, depress the brake pedal and reduce the vehicle speed. NOTE: “Overrev” refers to an operating state of the engine in which it rotates at an RPM higher than the recom- mended maximum RPM.
Page 169 7-14 Starting and driving CAUTION Do not operate more than 5 minutes since it causes the transmission oil to heat up rapidly. • Drive very slowly on bumpy roads and take care not to allow the undercarriage to bottom out. When the muffler strikes a rock or other obsta- cle, its internal catalyst and ceramic filter may be damaged.
Page 170 7-15 Parking WARNING • Park the vehicle on a level, flat surface if possible. Do not park on a slope. If it is unavoidable to park the vehicle on a slope, do the following: Firmly apply the parking brake while fully depressing the brake pedal, place the gearshift lever in the “P”...
Page 171 7-16 Starting and driving WARNING • Never leave lighters, cans of carbonated drink, and spectacles in the cabin when parking the vehicle in hot sunshine. The cabin will become extremely hot, so light- ers and other flammable items may catch fire and unopened drink cans (including beer cans) may rupture.
Page 172 7-17 CAUTION • Before stopping the engine, allow it to idle so the coolant temperature comes down. Engine parts are particularly hot immediately after the vehicle has been driven uphill or on an expressway. Let the engine idle for at least three minutes.
Page 173 7-18 Starting and driving NOTE: A vehicle with limited slip differential can be identi- fied by precautionary stickers near its driver’s seat and on the rear axle housing. Z21359 The limited slip differential actions take place auto- matically, but you are recommended to pay atten- tion to the following points: •...
Page 174: Loading Cargo
7-19 Loading cargo 1 Do not overloading the vehicle. • Overloading the vehicle causes braking per- formance to deteriorate and can thus cause an accident. Also, overloading the vehicle places excessive stress on vehicle parts, shortening their service lives. The vehicle is designed to perform best when loaded within its Gross Vehi- cle Weight Rating (GVWR) and within its front and rear Gross Axle Weight Ratings (GAWR).
Page 175 7-20 Starting and driving 2 How to load cargo Improperly loaded cargo not only is unstable but also may result in uneven weight distribution which could damage the cargo deck and frame. WARNING • When roping up cargo or covering it with a tarpaulin, make sure that neither the rope nor the end of the tarpaulin hang down between the cab and the cargo deck as a...
Page 176 8. 4WD operation <FG models> Control and indicator lamps for 4WD operation ..............8-2 Advice on use of the 4WD mode ..................8-6 Precautions to be taken when selecting the 4WD mode ........... 8-8...
Page 177 4WD operation <FG models> Control and indicator lamps for 4WD operation Select the 2WD (rear-wheel-drive) mode or 4WD (all-wheel-drive) mode as necessary for the condi- tion of the road surface. The 4WD mode can be used for extra traction on rough road surfaces and on snow-covered road surfaces (in mountainous regions, for example).
Page 178 1 Location of control and indicator lamps Front drive switch 4WD indicator lamp Z21361 Front drive switch The front drive switch is used to select either the two-wheel drive (2WD) mode that uses only the two rear wheels as driving wheels or the four-wheel drive (4WD) mode in which the engine power is transmitted to all four wheels.
Page 179 4WD operation <FG models> 2 Selecting drive mode-transfer gear range combinations You can select any desired drive mode and transfer gear range combination from among those shown in the following table. Select the most suitable com- bination according to the driving conditions. Illumi- Mode-range nated...
Page 180 4 Free-wheeling hub • Even when the 4WD vehicle is running in the two-wheel drive mode with the engine power transmitted only to the rear wheels, the front wheels are always connected to the power train (differential, propeller shaft and transfer). The free-wheeling hub is a device to release the wheels from the power train to allow them to rotate freely, thus saving energy and improving...
Page 181 4WD operation <FG models> Advice on use of the 4WD mode When you select the 4WD mode to drive on off-road terrain (sandy or muddy ground) or snow-laden or frozen roads, take sufficient care to avoid inappro- priate operation. 1 Driving on snow-covered or frozen roads Select the 4WD mode if necessary for the snow or road surface conditions.
Page 182 4 Descending steep hills • Select 4WD mode and descend slowly using engine braking so that the wheels do not slip. • Quick braking can slip the wheels and result in a loss of vehicle control. Check road conditions before descending. •...
Page 183 4WD operation <FG models> Precautions to be taken when selecting the 4WD mode • In the 4WD mode, you may feel the steering wheel move differently from the way it does in the 2WD mode. Operate the steering wheel carefully until you get the complete feel of 4WD operation.
Page 184: Heating And Air Conditioning
9. Heating and air conditioning Front air outlets ........................9-2 Rear air outlets ........................9-3 Manual air conditioner ......................9-4 Fully automatic air conditioner ..................9-10 Rear heater ........................9-15 Outside air inlets ......................9-15...
Page 185: Front Air Outlets
Heating and air conditioning Front air outlets Z21365 1 Adjusting the airflow direction • Adjust the up/down direction of airflow from each outlet as desired by moving up or down the knob or fin • Adjust the left/right direction of airflow from each outlet as desired by pressing the right or left side of the outlet.
Page 186: Rear Air Outlets
Rear air outlets Air outlets in vehicle equipped with rear heater Z13164...
Page 187: Manual Air Conditioner
Heating and air conditioning Manual air conditioner WARNING Never leave children alone in the cab espe- cially when the air-conditioning is on. They will suffer from dangerously high interior temperatures should the air conditioning accidentally stop. CAUTION To protect the environment, your vehicle’s air conditioning system uses refrigerant HFC-134a which does not harm the ozone layer.
Page 188: Control Panel
1 Control panel Z21036 Mode selector dial Fan speed dial Temperature adjustment dial Air selector switch Air conditioner switch...
Page 189 Heating and air conditioning Fan speed dial Fan speed dial allows you to select 4 fan speeds. Select the desired speed. 0: Turned off 1: Breeze 2: Weak 3: Medium 4: Strong Z21037 Temperature adjustment dial Turn the dial in the direction of arrow to increase the air temperature and in the direction of arrow to reduce it.
Page 190 Air conditioner switch Pressing the air conditioner switch activates the air conditioner, which has cooling and dehumidifying functions. The indicator lamp in the switch comes on at this time. Pressing the air conditioner switch once more stops the air conditioner. NOTE: •...
Page 191 Heating and air conditioning • For airflow toward the feet and toward the windshield Place the mode selector dial in the position. Z21370 • For airflow toward the windshield Place the mode selector dial in the position. Z21371 2 Using the controls To heat the cab Place the mode selector dial in the position or...
Page 192: Cleaning The Air Filter
To defog the windshield Place the mode selector dial in the position. If you wish to defog the windshield quickly, use the fan speed dial to select the maximum fan speed and use the temperature adjustment dial to select the maximum temperature. Z21050 To ventilate the cab Press the air selector switch to select outside air,...
Page 193: Fully Automatic Air Conditioner
9-10 Heating and air conditioning Fully automatic air conditioner WARNING Never leave children alone in the vehicle. If the air conditioner stops for some rea- son or other, the temperature inside the vehicle will rise, and can cause heat stroke, for example.
Page 194 9-11 1 Using the air conditioner automatically 1. Set the air volume adjustment dial to “AUTO”. Z21055 2. Set the desired temperature using the tempera- ture adjustment dial. You can adjust the set temperature to a value between 65°F and 85°F (18°C and 29°C). Z21373 3.
Page 195 9-12 Heating and air conditioning 2 Using the air conditioner manually • Operate each dial as desired. Even during automatic (AUTO) operation, the operated function will take priority. • Functions other than the operated one will be controlled automatically. • To stop operation, set the air volume adjustment dial to OFF.
Page 196 9-13 Changing the air volume To increase the air volume, turn the air volume adjustment dial to the right, and to reduce the air volume, turn the dial to the left. : Strong : Weak Z21061 Dehumidifying and air conditioning Pressing the air conditioner switch activates the air conditioner, which has cooling and dehumidifying functions.
Page 197 9-14 Heating and air conditioning • Blowing air toward your feet Z21379 • Blowing air toward your feet and the wind- shield Z21380 • Blowing air toward the windshield Z21381 Stopping all operations Set the air volume adjustment dial to OFF. Z21068...
Page 198: Rear Heater
9-15 Rear heater <Crew-cab vehicle> The rear heater blows warm air from below the rear seat. Select the desired blower speed by pressing the LO or HI side of the rear heater switch. When operation of the rear heater is not required, keep the switch in its middle position (with neither the LO nor HI side pressed).
Page 200: Interior Equipment And Accessories
10-1 10. Interior equipment and accessories Cigarette lighter ........................ 10-2 Ashtrays ........................... 10-3 Coat hooks ........................10-4 Sun visors ........................10-4 Interior lamp ........................10-5 Step lamp ......................... 10-6 Small article compartments ....................10-7 Using the radio ....................... 10-11 AM/FM radio and CD player ..................10-11 Accessories ........................
Page 201: Cigarette Lighter
10-2 Interior equipment and accessories Cigarette lighter The cigarette lighter can be used when the starter switch is in the “ON” or “ACC” position. Push the cigarette lighter all the way in. It will soon pop back to the original position with its core red hot.
Page 202 10-3 Ashtrays Remove and empty the ashtrays when they become full. WARNING • Be sure to put out cigarettes and match- sticks before putting them in the ashtrays. Close ashtrays completely. Leaving an ashtray open could cause a fire, as the heat from cigarettes or matchsticks may ignite things in the ashtray.
Page 203: Coat Hooks
10-4 Interior equipment and accessories 2 Rear ashtray in crew-cab model • Pull the lid of the ashtray toward you for use. • When you wish to empty the ashtray, push down the spring and pull the ashtray out toward you.
Page 204 10-5 Interior lamp The interior lamp(s) can be used with the starter switch in any position. WARNING Do not leave the interior lamp or spot lamps lit while driving. Otherwise, the light reflected by interior surfaces will form images on the windshield which will disturb your forward vision, increasing the risk of an accident.
Page 205 10-6 Interior equipment and accessories 2 Interior lamp with built-in spot lamps <Option> • “ON” position The interior lamp is illuminated regardless of the door positions. • “•” position The interior lamp comes on when a door is opened and goes off when the door is closed. If the engine is stopped, the lamp will gradually dim and go out 10 seconds after closing the Z21388...
Page 206: Small Article Compartments
10-7 Small article compartments Z21389 WARNING Always close the glove compartment before operating the vehicle. If left open, their covers could cause injury in the event of a collision or sudden stop. CAUTION • Fuses, relays, and other electrical items are located below the tray .
Page 207 10-8 Interior equipment and accessories Overhead shelf WARNING Do not use the overhead shelf to hold items that are heavy and/or prone to rolling. Such items could fall down and cause injuries as the vehicle starts and stops moving. Vertical compartment Hook <Vehicles other than Crew-cab models>...
Page 208 10-9 Cup holder Pull out the cup holders to use them. Keep them pushed in when they are not being used. WARNING • The contents in a cup or can held in the cup holder may spill during movement of the vehicle.
Page 209 10-10 Interior equipment and accessories Lower pocket NOTE: If you accidentally drop something like a pen into the lower pocket, take it out through one of the holes that open at both sides of the pocket's inside bottom using a long, thin rod or similar object. Z21738 Key-locked glove compartment Lock...
Page 210: Using The Radio
10-11 Using the radio The radio (optional) can be used with the starter switch in the “ON” position or “ACC” position. CAUTION Using the radio for an extended period without the engine running could drain the battery. • Extend the antenna before using the radio. Retract the antenna when it is likely to cause an obstruction, for example, when tilting the cab.
Page 211 10-12 Interior equipment and accessories CAUTION • Do not put coins or any other objects in the disc slot of the CD player. • Press the buttons gently; pressing them roughly could cause system malfunctions. Also, avoid touching the display screen (LCD).
Page 212 10-13 • Use a soft cloth to remove dirt from the disc. Wipe it in straight lines from the center toward the outer edge. Never use thinner or antistatic fluid to clean a CD. • Do not use cracked or evidently warped CDs. Also avoid using CDs with a printable label sur- face.
Page 213 10-14 Interior equipment and accessories • MP3/WMA files • MP3 (MPEG1/2 Audio Layer III) is a standard coding format for digital audio data compres- sion. • ® WMA (Windows Media Audio) is the coding format for digital audio data compression devel- oped by Microsoft Corporation.
Page 214 10-15 • The system cannot reproduce the following files: • MP3i and MP3PRO format files • MP3 files in an inappropriate format • Layer 1/Layer 2 format files • When reproducing WMP 10/WMP 9 encoded WMA files, those parts with functional expan- sion from WMA 8 (i.e., Pro, Lossless and Voice) are not supported.
Page 215 10-16 Interior equipment and accessories 2 Volume and tone adjustments Power/volume knob SOUND button Display Volume/adjustment mode indication Z21760 Volume • Use the power/volume knob to adjust the vol- ume. • Press the knob to turn on the audio system. Give the knob a long press to turn off the sys- tem.
Page 216 10-17 Adjusting the tone and fade/balance Use both the “SOUND” button and power/volume knob to adjust the tone of the sound and the fader (frond-rear audio level balance)/balance (right-left audio level balance). 1. Press the “SOUND” button to select the desired adjustment mode.
Page 217 10-18 Interior equipment and accessories • Adjustment modes Display Adjustable Adjustment mode Description indication range If the displayed number has a minus sign, bass tone is de-emphasized as the number increases; bass tone is Bass tone adjustment BASS –5 to +5 emphasized if the number has a plus sign.
Page 218 10-19 3 Radio “AM/FM” button (FM1/FM2/AM1/AM2 selec- tor button) “ ” and “ ” tuning buttons Scan search button “PS/AS” button (automatic tuning/memory button) Preset buttons Z21761 To listen to the radio 1. With the starter switch in the “ACC” or “ON” position, press the power/volume knob or the “AM/FM”...
Page 219 10-20 Interior equipment and accessories • To tune to a preset station, use either of the fol- lowing methods: • Press one of the preset buttons “1” to “6”. • Press the “PS/AS” button. The radio will automatically tune to a preset station and receive signals from the station for 10 sec- onds before tuning to the next preset station.
Page 220 10-21 Programming stations to preset buttons • Manual programming 1. Select the desired band from FM1, FM2, AM1 and AM2 using the “AM/FM” button. Z21762 2. Make the frequency of your desired station appear on the display by using the “ ”...
Page 221 10-22 Interior equipment and accessories • Automatic programming 1. Select the desired band from FM1, FM2, AM1 and AM2 using the “AM/FM” button. 2. Give the “PS/AS” button a long press. The radio will start automatic tuning. Each time the radio tunes to a station with good reception, the station is automatically programmed to a preset button.
Page 222 10-23 4 CD player Z21766 “CD” button Disc slot Display Disc eject button Upward track search button/fast forward but- Downward track search button/fast reverse button “DISP” button (display selector button) Upward folder search button (MP3/WMA) Downward folder search button (MP3/WMA) Directory button (MP3/WMA) Random play button Repeat button...
Page 223 10-24 Interior equipment and accessories Playing a CD 1. Insert the CD into the disc slot with the labeled surface facing up. 2. The CD player will automatically turn on and start playback. • In the case of a music CD, the track number and the playing time are displayed.
Page 224 10-25 Basic operations • Fast forwarding/fast reversing • Press the “ ” or “ ” tuning button for as long as necessary. Rapid disc reading con- tinues forward or backward until the button is released. : Press this button for fast forwarding. : Press this button for fast reversing.
Page 225 10-26 Interior equipment and accessories Repeating the music programs in a folder (MP3/WMA file CDs) • Press the “4” preset button. • The display will show “DIR”. • Pressing the same button again cancels the repeated playback mode. Z21084 Playing the tracks in random order •...
Page 226 10-27 Scan search playback The player plays back the first 10-second part of each track one after another. This function is useful for finding your favorite piece of music. • Press the “1” preset button. • The display shows “INT”, and the player starts playing the first 10-second part of each of the next and following tracks one after another.
Page 227 10-28 Interior equipment and accessories NOTE: To protect the disc from dust or other contamination, the disc is drawn back inside the player automati- cally if it is left in the ejected state for 10 seconds. Automatic playback does not start in this case. 5 Clock Power/volume knob “DISP”...
Page 228 10-29 Setting the clock 1. Give the “DISP” button a long press while the display is showing the time of day. A short beep will sound, and the hour part of the time display will start flashing. Z21847 2. Adjust the hour by turning the power/volume knob.
Page 229 10-30 Interior equipment and accessories 5. Press the power/volume knob to complete the clock setting. The original display will resume about 5 sec- onds later. Z21093 6 Alarm If you set the alarm to the desired time, a buzzer will sound at the preset time.
Page 230 10-31 3. Adjust the hour by turning the power/volume knob. Clockwise: The hour increases. Counterclockwise: The hour decreases. Z21096 4. Press the “DISP” button. A short beep will sound, and the minute part of the time display will start flashing. Z21850 5.
Page 231 10-32 Interior equipment and accessories Activating the alarm • Giving the “ALARM” button a long press acti- vates (arms) the alarm; giving another long press deactivates (disarm) the alarm. A short beep sounds every time the alarm is activated or deactivated.
Page 232 10-33 7 Audio system problems, probable causes and actions • General problems Symptom Probable cause Action System pro- • The mute is turned on. • Turn off the mute. duces no • Fader adjustment is inappropriate. • Adjust the fader appropriately. sound.
Page 233 10-34 Interior equipment and accessories Accessories • See an authorized dealer if you are considering adding accessories to your vehicle. • Your vehicle contains electronic devices. Even though these are protected against interference from electromagnetic emissions, you should refer to an authorized dealer before fitting equip- ment that emits strong signals, such as mobile telephones.
Page 234 11-1 11. In cold weather Coolant ..........................11-2 Engine oil ......................... 11-2 Fuels ..........................11-2 When parking the vehicle after replenishing the DEF (Diesel exhaust fluid) ....11-3 Other recommendations for cold weather operation ............11-3 Installing tire chains ......................11-4...
Page 235 11-2 In cold weather Coolant • When vehicles are shipped from the factory, genuine FUSO DIESEL LONGLIFE COOLANT is added to the coolant in their cooling systems. This additive combines both antifreeze and anti- rust capabilities to sufficiently protect the cooling system from freezing up.
Page 236: Diesel Exhaust Fluid
11-3 When parking the vehicle after replenishing the DEF (Diesel exhaust fluid) If the DEF tank becomes empty in cold weather, perform the driving restriction canceling procedure immediately after refilling the tank with DEF. P. 1-11 Other recommendations for cold weather operation •...
Page 237 11-4 In cold weather • Do not apply the parking brake in extremely cold conditions that could cause it to freeze up and become impossible to release. In such condi- tions, take the following steps: 1. Stop the vehicle and pull the parking brake lever.
Page 238 11-5 1. Place the chains over the tires with the hook ends of cross chains facing outward. Z09325 2. Connect the hook of inside chain , leaving no excess links. Then, take up the slack in the inside chain by pulling cross chains for the inside tire outward.
Page 239 11-6 In cold weather 6. Ensure that hooks are flat on the tire sidewalls. Also make sure that the chains are not twisted. 7. Fasten extra chain links with a metal wire to pre- vent them from hitting against other vehicle parts.
Page 240: Simple Inspection And Service
12-1 12. Simple inspection and service General precautions for servicing the vehicle ..............12-2 To reach the access opening ................... 12-4 Tilting the cab ........................12-6 Pre-operational checks ....................12-11 Lubrication ........................12-18 Greasing ........................12-19 Oils and fluids ........................ 12-23 Filter elements .......................
Page 241: The Vehicle
12-2 Simple inspection and service General precautions for servicing the vehicle WARNING • Never run the engine in a poorly ventilated area. Exhaust emissions contain carbon monoxide, which can cause unconscious- ness or death if breathed. • Never smoke when servicing your vehicle since its fuel and the gases given off by its battery are highly flammable.
Page 242 12-3 Please take the following precautions when servic- ing your vehicle: • Make sure the vehicle is on safe, level ground. • Prevent the vehicle from moving by pulling the parking brake lever and blocking the wheels with chocks. • Remove the starter key unless you need to run the engine.
Page 243: To Reach The Access Opening
12-4 Simple inspection and service To reach the access opening <Crew-cab models> 1 Engine access opening There is an opening under the assistant driver’s seat which provides access to the engine for inspection and servicing. Uncover and cover the opening as follows: •...
Page 244 12-5 2 Power steering fluid and engine coolant level inspection opening In front of the rear seat, there is an opening for inspecting and replenishing the power steering fluid and engine coolant. Uncover and cover the opening as follows: 1. Remove the cover 2.
Page 245: Tilting The Cab
12-6 Simple inspection and service Tilting the cab <Vehicles other than Crew-cab models> NOTE: A Crew-cab cannot be tilted. 1 Preparation WARNING • Before tilting or lowering the cab, make sure that the area around the cab is clear of people and obstructions. •...
Page 246 12-7 • Park the vehicle on a flat and level surface and stop the engine. Tilting the cab on a slope is dangerous since the cab could swing up unexpectedly. This could also damage the mechanism because of the huge, sudden stresses on it. •...
Page 247 12-8 Simple inspection and service 2. Grasp tilt grip and pull lever C . The cab will rise slightly. Z09215 3. Hold the tilt grip and raise the cab until the end of cab stay engages with the notch of the lock lever .
Page 248 12-9 1. Release the stopper and retain it in the clip Z11913 2. Hold the tilt grip to support the cab. Lift the lock lever and fold the cab stay WARNING • When you have unlocked the cab stay, immediately move your hands away from the lock lever.
Page 249 12-10 Simple inspection and service 4 Checking locking of the cab When the cab is lowered down, the state of locking should be checked as follows. If incomplete locking is identified, repeat the cab tilting procedure and lower once again. If incomplete locking still exists, never drive the vehicle and contact your authorized dealer.
Page 250 12-11 Pre-operational checks Be sure to perform the pre-operational checks for the items listed below at the start of each day’s operation in order to ensure safe and comfortable driving. If you find anything unusual which you are unable to repair yourself, you should have this cor- rected at an authorized dealer before operating the vehicle.
Page 251 12-12 Simple inspection and service Coolant level Check that the coolant level is between the “FULL” and “LOW” marks on the reservoir tank. P. 12-55 Z15730 Engine oil level Check that there is sufficient engine oil using the oil level gauge. Change the engine oil if its level is above the circle mark on the oil level gauge.
Page 252 12-13 Engine conditions Check the engine for smooth starting and quiet running. Z09197 Parking brake lever stroke Check that the parking brake lever stroke is 7 to 9 notches when the lever is pulled with a force of 294 N (66 lbs., 30 kgf). P.
Page 253 12-14 Simple inspection and service Windshield washer fluid level Confirm that the windshield washer fluid level is above the bottom of the inspection window. P. 12-81 Z21402 Steering wheel free play Gently turning the steering wheel, check that its play is more than 10 mm (0.39 in.) and less than 20 mm (0.79 in.).
Page 254 12-15 Defroster Make sure that warm air blows properly onto the windshield. P. 9-4, 9-9 Z21050 Lighting system Make sure that each lamp lights up or flashes properly. Check lamp lenses for dirt and dam- age. P. 5-16 Z21403 Gauge, warning/indicator lamp operation Check that gauges, warning lamps and indi- cators are working properly.
Page 255 12-16 Simple inspection and service Door locks Push the lock knob and verify that the door does not open even when the inner handle is operated. Z11951 Seat belts Confirm that the seat belt buckles function correctly when fastening and unfastening. Z11943 3 While walking around the vehicle Z21406...
Page 256 12-17 Wheels and tires Check the disc wheels for cracks and other damage. Check the tires for inflation pres- sure, tread groove depth, foreign objects in grooves, cracks, and uneven wear. P. 12-66 Z21588 Suspension springs Check for broken springs and tilt of vehicle body toward either side.
Page 257 12-18 Simple inspection and service 4 While driving at slow speeds Perform the following checks while driving in a safe place at speeds lower than 20 km/h (12 mph). Steering wheel operation Check that the steering wheel does not vibrate or pull to one side and that it is not unduly heavy.
Page 258 12-19 CAUTION • Apply and replace lubricants regularly. Use of lubricants beyond their designed service life could cause bearings or other compo- nents to seize up and cause an accident. • Any checking, application, or replacement of lubricants should be carried out with the vehicle parked on level ground.
Page 259 12-20 Simple inspection and service <FE> Z21409 <FG> Z21410...
Page 260 12-21 Z21152 Z09226 Grease nipple Dust cover Z09227 Z09228 Grease nipple Dust plug hole Z16543 Z09498...
Page 261 12-22 Simple inspection and service Recommended lubricant: Chassis grease NLGI No. 1 (Li soap) Every 30,000 km Greasing intervals (18,000 miles) or every 12 months Rear spring pin, front (2 points each on both sides) Rear spring pin, rear (4 points each on both sides) King pin bearing (4 points in total on both sides) Recommended lubricant:...
Page 262 12-23 3 Anchor hooks (two places) <Not applicable to Crew-cab models> Every 30,000 km Greasing intervals (18,000 miles) or every 12 months Recommended lubricant: Chassis grease NLGI No. 1 (Li soap) Z21154 Atmospheric temperatures when engine is started. Oils and fluids 1 Engine oil Performance, life, and startability of the engine depend to a large degree on the engine oil.
Page 263 12-24 Simple inspection and service CAUTION • Use only the specified engine oil. Any other oils may contain substances that cause the ceramic filter inside the DPF to be loaded with particulate matter (PM) prematurely to the capacity and thus shorten the effectively functioning period of the DPF.
Page 264 12-25 4. The oil level marked on the oil level gauge should be within the “inspection level range” indicated in the figure (between the lower notch and circle mark). 5. If necessary, add engine oil to a level within the “replenishing level range”...
Page 265 12-26 Simple inspection and service • Take care not to add more than the specified quantity of oil. The engine can be severely damaged if the correct engine oil level is not maintained. • When adding engine oil, take care not to spill If oil is spilled on a belt, the belt will slip on pulleys.
Page 266 12-27 6. Carefully pour fresh engine oil through the oil filler. 7. Wait for more than 5 minutes and check the oil level using the oil level gauge 8. Crank the engine with the starter switch, then start the engine. P.
Page 267 12-28 Simple inspection and service 2 Clutch control fluid Every 60,000 km Replacement intervals (36,000 miles) or every 24 months Recommended oil: FUSO ATF SP III Clutch control fluid quantity Quantity required 2.0 liters (2.1 qts) Check, addition, and replacement Have the clutch control fluid checked, added, or replaced by an authorized dealer.
Page 268 12-29 Check WARNING Do not check the oil level immediately after driving, as you could be scalded by extremely hot oil. Give the oil time to cool before performing the inspection. NOTE: Do not confuse the transmission oil inspection plug with the clutch control fluid inspection plug and drain plug , which are located nearer to the front...
Page 269 12-30 Simple inspection and service WARNING Do not replace the oil immediately after driv- ing, as you could be scalded by extremely hot oil. Give the oil time to cool before drain- ing it. NOTE: • Oil removal is quicker if performed not so long after the vehicle has been stopped and while the oil is still warm.
Page 270 12-31 4 Transfer gear oil <FG> Every 60,000 km Replacement intervals (36,000 miles) or every 24 months Recommended oil: Gear oil API classification GL-3 SAE 80 (general) API classification GL-3 SAE 90 (warm regions) API classification GL-4 SAE 90 (tropical regions) Quantity required: Quantity Approx.
Page 271 12-32 Simple inspection and service 4. Coat the inspection plug’s threads with the specified sealant and install and tighten the plug. Sealant ThreeBond 1105 68.6 ± 14.7 N·m (51 ± 11 Tightening torque ft.lbs., 7.0 ± 1.5 kgf·m) Replacement 1. Remove inspection plug and drain plug let the oil flow out.
Page 272 12-33 7. Like with the drain plug, replace the gasket of the inspection plug with a new one, coat the plug’s threads with the specified sealant, and then install and tighten the plug. 68.6 ± 14.7 N·m (51 ± 11 Tightening torque ft.lbs., 7.0 ±...
Page 273 12-34 Simple inspection and service Check WARNING Do not check the oil level immediately after driving, as you could be scalded by extremely hot oil. Give the oil time to cool before performing the inspection. Z09245 1. Remove inspection plug 2.
Page 274: Brake Fluid
12-35 3. Add oil through the inspection plug hole until it reaches the bottom of the hole. 4. Install the inspection plug. Tightening 110 ± 10 N·m (81 ± 7 ft.lbs., torque 11 ± 1 kgf·m) 6 Brake fluid Inspection At the time of pre-operational intervals check...
Page 275 12-36 Simple inspection and service WARNING • Be sure to use the recommended brake fluid. • Use only one brand of recommended brake fluid. Mixing of different brands or types of fluid will change the properties of the fluid possibly resulting in a lower fluid boiling point and damaged brake compo- nents.
Page 276 12-37 Check The fluid level should be between the “MAX” and “MIN” lines on reservoir tank . Check whether the reservoir tank contains foreign matter. If you see foreign matter in the reservoir tank, have the reser- voir tank inspected and cleaned by an authorized dealer.
Page 277: Power Steering Fluid
12-38 Simple inspection and service 7 Power steering fluid Every 30,000 km Replacement intervals (18,000 miles) or every 12 months Have an authorized dealer replace the fluid. Recommended fluid: Automatic transmission fluid DEXRON II or DEXRON III type CAUTION When adding power steering fluid, be sure to use fluid of the same brand as the existing fluid.
Page 278: Filter Elements
12-39 8. If the fluid level is below the “MIN” line, clean the reservoir tank’s cap and the surrounding area then open the cap and add power steering fluid until it reaches the “MAX” line. 9. Securely fit the cap. CAUTION •...
Page 279 12-40 Simple inspection and service WARNING • Spilt engine oil should be wiped off clean. Oil remaining on the engine surface could catch fire. • Do not replace the oil filter immediately after operating the vehicle since the engine, transmission, exhaust pipe, engine oil, and other items will be...
Page 280 12-41 6. Remove the oil filter case by turning it counter- clockwise. Use a rag to prevent oil from drip- ping down. Z21175 7. Clean the O-ring contact surface of the oil filter support and the O-ring groove of the oil filter case.
Page 281 12-42 Simple inspection and service 2 Fuel filter replacement Replacement Every 30,000 km (18,000 miles) intervals or every 12 months WARNING • Fuel is highly flammable and should be kept away from hot objects and open flames owing to the risk of fire or explo- sion.
Page 282 12-43 1. Make sure that the parking brake is firmly applied. 2. Chock the wheels. 3. Clean the area around the filter to prevent dirt from contaminating the new filter element when it is installed later. 4. Place a container under the fuel filter to collect the fuel.
Page 283 12-44 Simple inspection and service 7. Disconnect the connector from the fuel filter case. Do this by pulling the bottom part of the connector toward you to release the lock then pulling the connector directly upward. Z21456 8. Remove the fuel filter case by turning it counter- clockwise using the special tool (separately available).
Page 284 12-45 12. Install the fuel filter case by turning it clockwise. Turn the case until it stops. Make sure the pro- jection on the case is in contact with the filter head CAUTION • Install the fuel filter case carefully so as not to twist or damage the O-ring.
Page 285 12-46 Simple inspection and service CAUTION Clean the air cleaner element at the specified interval. Failure to follow this instruction will result in premature accumulation of PM in the DPF and eventually cause the systems to mal- function. On the contrary, unnecessarily fre- quent cleaning can damage the air cleaner element, allowing dust and other foreign matter to be drawn into the engine.
Page 286 12-47 The air cleaner is located in the illustrated position. • Removal 1. Undo the two clamps and then pull the cover toward the clamps to remove it. Z21179 2. Move the lock lever in the air cleaner element case to the “UNLOCK” position. Z21180 3.
Page 287 12-48 Simple inspection and service • Installation 1. Insert the air cleaner element into the air cleaner element case in a straight line. 2. Move the lock lever in the air cleaner element case to the “LOCK” position. Z21182 3. Install the cover on the case by inserting the projections on the cover into the holes the case and then fasten the clamps.
Page 288 12-49 2. Put a light on the gasket side of the air cleaner element to check that there are no holes that allow light to leak in the element. Also check the gasket for cracks or other damage. Z21185 3. Clean the inside of the case and cover with a clean cloth.
Page 289: Draining Water From Fuel Filter
12-50 Simple inspection and service Draining water from fuel filter If the warning is indicated, there is water in the fuel filter in an amount exceeding the limit. Drain the water as follows: WARNING • Z21454 Fuel is highly flammable and should be kept away from hot objects and open flames owing to the risk of fire or explo- sion.
Page 290 12-51 WARNING • The drain contains not only water but also fuel. Be sure to wipe clean the surfaces around the fuel filter to remove all splashed fuel. Fuel remaining on the surfaces could cause a fire. • Make sure fuel does not leak from the filter or from related parts.
Page 291 12-52 Simple inspection and service 2 Water used with coolant Use soft water with the properties shown in the fol- lowing table. Do no use hard water from wells and rivers as it is liable to form scales and cause corro- sion.
Page 292 12-53 DANGER • FUSO DIESEL LONGLIFE COOLANT IS TOXIC. IF A PERSON HAS ACCIDEN- TALLY SWALLOWED IT, FORCE HIM/HER TO VOMIT AND CONSULT A DOCTOR IMMEDIATELY. IF IT SPLASHES IN THE EYES, IMMEDIATELY FLUSH THE EYES WITH WATER FOR MORE THAN 15 MIN- UTES, AND SEEK MEDICAL ATTENTION.
Page 293 12-54 Simple inspection and service CAUTION Do not use methanol-based or methoxypro- panol-based antifreeze products. They can severely damage the engine. Never mix FUSO DIESEL LONGLIFE COOLANT with other brands of long-life coolant or any antifreeze or corrosion-preventive additives. Doing so would reduce the performance of the coolant.
Page 294 12-55 CAUTION Use FUSO DIESEL LONGLIFE COOLANT at a concentration of between 50% and 60%. The proper concentration under normal tempera- tures is 50%. At a concentration below 30%, this additive performs poorly as an anticorrosive, while at a concentration exceeding 60%, it per- forms poorly as an antifreeze.
Page 295: Adding Coolant
12-56 Simple inspection and service 5 Adding coolant CAUTION • Coolant should normally be added through the reservoir tank without opening the pres- sure cap on the surge tank. • When adding coolant, use new coolant addi- tive of the same brand and concentration as the additive that is already in the vehicle.
Page 296 12-57 6 Replacement Be sure to flush the cooling system when replacing the coolant. WARNING • Do not replace the coolant immediately after operating the vehicle since the engine, radiator, coolant, and other items will be extremely hot. If you try to drain the coolant immediately after driving the vehi- cle, you may be scalded.
Page 297 12-58 Simple inspection and service 4. Remove the pressure cap of the surge tank by turning it counterclockwise. Z21190 5. Remove the undercover below the radiator. Z21264 6. Open the radiator drain cock to drain engine coolant. NOTE: You can prevent splashes from draining engine coolant by connecting a hose (commercially avail- able with a 7 mm (0.28 in.) inside diameter) to the drain cock nipple...
Page 298 12-59 For details on handling the multi-information dis- play, refer to page 6-8. CAUTION If the radiator tubing is clogged or coolant is more contaminated than usual, have your vehi- cle inspected at an authorized dealer. 9. Make sure the radiator drain cock is securely fit- ted.
Page 299 12-60 Simple inspection and service 17. Screw the pressure cap down tightly by turning it clockwise. NOTE: Be sure to screw the pressure cap tightly. Other- wise, boiling water and steam under high pressure will gush out if the engine overheats. 18.
Page 300 12-61 At the time of pre-operational Inspection check and every 30,000 km (18,000 miles) or 12 months Every 120,000 km (75,000 Replacement miles) or every 24 months 1 Check 1. Confirm that the parking brake lever is pulled. Prevent the vehicle from moving by blocking the wheels with chocks.
Page 301 12-62 Simple inspection and service Steering wheel – check The steering wheel is a safety-critical part of the vehicle. If an inspection reveals any abnormality, contact an authorized dealer and have the abnor- mality rectified before you again drive the vehicle. Driving the vehicle with the abnormality unrectified could result in a serious accident.
Page 302 12-63 2 Steering wheel looseness Every 30,000 km Inspection intervals (18,000 miles) or every 12 months 1. Try moving steering wheel up and down and also right and left to check for excessive loose- ness. 2. If anything abnormal is found, contact an autho- rized dealer.
Page 303 12-64 Simple inspection and service 1 Brake pedal play 1. With the engine stopped, turn the starter switch to the “ON” position. 2. Make sure that the gearshift lever is in the “P” position. 3. Pump the brake pedal several times to release all the vacuum from the brake system (zero vac- uum).
Page 304 12-65 WARNING Perform brake tests in a safe place that pro- vides good visibility all around. During the tests, be attentive to surrounding traffic con- ditions. Parking brake – check and adjustment Inspection At the time of pre-operational intervals check 1 Parking brake lever stroke check 1.
Page 305 12-66 Simple inspection and service Tires – check At the time of pre-operational Inspection check and every 30,000 km intervals (18,000 miles) or 12 months 1 Inflation pressure check • Use an air pressure gauge to check for proper tire inflation pressure. If the pressure is incorrect, adjust it to the indi- cated standard pressure.
Page 306 12-67 CAUTION • Your vehicle’s tires will heat up during use, with a corresponding increase in air pres- sure. This is normal; do not release air from the tires when they are hot. Always check tire pressures before driving, when the tires are cold. •...
Page 307 12-68 Simple inspection and service 2 Checking tread depth Check the entire circumference of each tire to make sure that the remaining depth of the tread pattern on the part that contacts the road surface is sufficient. Tread groove depth 1.6 mm (0.06 in.) limit When the tread wears down, wear indicators...
Page 308: Tire Replacement
12-69 Tire replacement 1 Preparation for tire replacement • Park the vehicle on a flat, hard surface. Pull the parking brake all the way on. Place the gearshift lever in the “P” position. • Be sure to stop the engine. •...
Page 309: Removing The Wheel
12-70 Simple inspection and service 2 Removing the wheel Front axle jacking points <FE> Bottom surface of the leaf spring at the rear of tie rod. Z12085 <FG> Jack support under the front axle. Z12567 Rear axle jacking point <FE> Bottom surface of the axle housing (beside leaf spring U-bolt mounting).
Page 310 12-71 How to remove a wheel WARNING • After raising the vehicle slightly, confirm that the jack is securely in position. If the jack slipped out of position with the vehicle fully raised, the vehicle could fall and cause a serious injury. •...
Page 311 12-72 Simple inspection and service WARNING • Fit the socket wrench securely on the wheel nut. If fitted improperly, the wrench will slip off the nut, and could cause injury. • Do not loosen the wheel nuts too much or you could damage the threads.
Page 312 12-73 WARNING • If the above items are dirty, the nuts will become loose during vehicle operation. If wheel bolt or nut threads are damaged or the disc wheel is cracked or otherwise damaged, replace the wheel with a new genuine part.
Page 313 12-74 Simple inspection and service NOTE: • The wheel bolts and nuts on the right-hand wheels have right-hand threads, and those on the left-hand wheels have left-hand threads. The bolts and nuts have stamped marks easy identification; an “R” mark for right-hand wheels and an “L”...
Page 314 12-75 WARNING • Fit the socket wrench securely on the wheel nut. If fitted improperly, the wrench will slip off the nut, and could cause injury. • Do not jump or jerk on the wrench handle when tightening the nut by using your own weight.
Page 315 12-76 Simple inspection and service 6. If only the outer wheel of dual wheels is replaced, retighten the inner wheel nuts to the specified torque before mounting the outer wheel. WARNING As the vehicle is driven after a wheel has been replaced, the wheel nuts loosen up somewhat during the early stages of driving due to “wear-in.”...
Page 316 12-77 WARNING • A loose wheel nut could cause parts dam- age, and result in a tire falling off. This could result in impossibility of driving, and damage of the vehicle and physical injury. Be sure to check the wheel nuts regularly. •...
Page 317: Tire Rotation
12-78 Simple inspection and service NOTE: The wheel bolts and nuts on the right-hand wheels have right-hand threads, and those on the left-hand wheels have left-hand threads. The bolts and nuts have stamped marks for easy identification; an “R” mark for right-hand wheels and an “L”...
Page 318 12-79 WARNING • Be sure to use the specified type of tires. Mixing bias and radial tires results in poor steering and should be avoided at all cost. • As the vehicle is driven after a wheel has been replaced, the wheel nuts loosen up somewhat during the early stages of driv- ing due to “wear-in”.
Page 319: Replacing Wiper Blade
12-80 Simple inspection and service Wiper blade – replacement 1 Replacing wiper blade 1. Raise wiper arm , and then push clip spring in the direction of the arrow (see figure). Z05981 2. With the clip spring kept in the pushed position, press wiper toward the wiper arm.
Page 320 12-81 Windshield washer – fluid level check and refilling 1 Fluid level check Check the washer fluid level through level check window When the level has dropped to the lower part of the window or is not visible at all, refill the tank with washer fluid.
Page 321 12-82 Simple inspection and service Battery – check Inspection At the time of pre-operational intervals check WARNING • The battery generates flammable hydro- gen gas and should be kept away from open flame and spark. • When removing the battery, always dis- connect the negative (–) terminal first and reconnect it last.
Page 322 12-83 2 Inspecting the battery • The battery fluid level should be between the “UPPER LEVEL” line and “LOWER LEVEL” line marked on the battery case. If the battery fluid level is low, add electrolyte or distilled water to the “UPPER” level line. •...
Page 323 12-84 Simple inspection and service CAUTION • Whenever battery fluid has been added, either charge the battery or run the vehicle for a while. It is especially important in cold weather as the battery can freeze up and be damaged. •...
Page 324 12-85 4 Battery removal and installation 1. Disconnect the battery cables (each indicated by an arrow in the illustration) from the bat- tery terminals. WARNING When disconnecting the battery cables, dis- connect the (–) cable first. When connecting the battery cables, connect the (–) cable last. Z21441 If you accidentally touched the (+) terminal and the vehicle body with a tool with the (–)
Page 325 12-86 Simple inspection and service CAUTION Install the battery securely in position. If it is left loose, shocks and vibrations from road surface could damage the battery case and electrode plates, shortening battery life. Air filters – cleaning Remove and clean the air filters (heater or air condi- tioner filters) with water or compressed air to elimi- nate dust and dirt at regular intervals (6 months or so).
Page 326: Cleaning Your Vehicle
12-87 2 Dashboard air filter 1. Remove the lower panel in front of the assis- tant driver’s seat. 2. Pull out the air filter while pushing inward both the tabs on the filter. 3. Reinstall the lower panel by first aligning the claws with the corresponding slots and then pushing the panel forward.
Page 327: Exterior Cleaning
12-88 Simple inspection and service 1 Exterior cleaning Cleaning glass surfaces Keep the vehicle’s windows and screens clean at all times. Use glass cleaner and wipe it off with a sponge or soft cloth. CAUTION Never apply rubbing compound to glass since it leaves scratches.
Page 328 12-89 • In cold weather, the key holes and rubber parts of the door sometimes freeze, making it hard to open the door. After washing, remove moisture on and around the doors. Applying silicone with antifreeze capabilities is one solution to this problem. •...
Page 329 12-90 Simple inspection and service NOTE: Aluminum wheels may become whitish as oxide film forms on their surface over time. The color on the wheel near the exhaust pipe end may become yel- lowish. Regardless of the color, you can remove the oxide film by using a commercially available polish when washing the wheel.
Page 330 12-91 • The outside air inlets Z21896 Waxing Wax the vehicle once or twice a month or whenever the wax on the vehicle ceases to repel water. Apply wax out of direct sunlight and only when the vehicle’s paintwork is cooler than human body tem- perature.
Page 331 12-92 Simple inspection and service 3 Interior cleaning • Do not use any organic solvent (for example, thinner or gasoline) or any acidic or alkaline sol- vent. It could cause discoloration and/or stains. • Dirt can leave marks or stains and should be cleaned off as soon as possible.
Page 332 12-93 • Shoe polish, wax, crayon, tar, and asphalt can stain the trim if not cleaned off quickly. Carefully use cleaner because it dissolve these contaminants and can cause a smudge. Organic contaminants Use this method to remove marks resulting from tomato ketchup, black coffee, egg, fruit, fruit juice, milk, cold drinks, wine, vomit, urine, and blood.
Page 333 12-94 Simple inspection and service Removing floor mat for cleaning 1. Remove the accelerator stopper by removing its screws 2. Install the accelerator stopper being careful not to let the cut edge of the floor mat become caught under the stopper. CAUTION After cleaning the floor mat, dry the felt backing before putting the mat back on the floor.
Page 334: Useful Advice For Emergencies
13-1 13. Useful advice for emergencies Possible failures, causes and remedies ................13-2 Stopping your vehicle in an emergency ................13-7 If the engine overheats ....................13-8 When a fuse has blown ....................13-10 When a lamp has burned out ..................13-18 When braking is sluggish ....................
Page 335 13-2 Useful advice for emergencies Possible failures, causes and remedies Performing daily checks and good maintenance are keys to preventing mechanical failures and the resultant accidents. Be sure to check and service your vehicle regularly. Should your vehicle suffer a mechanical failure or malfunction, the measures needed to correct the problem can be found using the following chart.
Page 336 13-3 Possible cause Remedy Ref. page The engine preheating time is insuffi- Follow the preheating instructions. cient. The fuel injection system is malfunc- Have an authorized dealer perform – tioning. necessary inspection. ® The BlueTec exhaust gas aftertreat- Add the specified DEF. ment is short of DEF.
Page 337 13-4 Useful advice for emergencies Possible cause Remedy Ref. page The engine pressure cap is not closed Install the cap firmly. – completely. The fan belt is loose. Have an authorized dealer perform – necessary inspection. The coolant is contaminated. Flush the cooling system and replace 12-51 the coolant.
Page 338 13-5 Drive power is insufficient. Possible cause Remedy Ref. page The parking brake is activated. Release the parking brake com- 5-15 pletely. The air cleaner is clogged. Clean or replace the air cleaner ele- 12-45 ment. The fuel filter is clogged. Replace the filter element.
Page 339 13-6 Useful advice for emergencies Steering is difficult. Possible cause Remedy Ref. page Cargo is over-loaded on the front Load cargo evenly. 7-19 side. Power steering fluid is insufficient. Add power steering fluid. 12-38 Front tire pressure is insufficient. Inflate tires to recommended pres- 12-66 sures.
Page 340 13-7 Possible cause Remedy Ref. page Idling speed setting is too low. Have an authorized dealer perform – necessary inspection. Vehicle is used only at nighttime. Charge the battery. – Switches are left on. Be sure to turn off the switches. –...
Page 341: If The Engine Overheats
13-8 Useful advice for emergencies 2 Repair Check the mechanical failure and if you judge it readily repairable, fix it while paying attention to the traffic. If you are unable to repair it, call an autho- rized dealer for help. WARNING Never attempt to perform repairs on an expressway or in a tunnel as doing so is very...
Page 342 13-9 If the warning lamp comes on, the multi-informa- tion display shows (red), and a buzzer sounds, the engine has overheated. Stop the vehicle in a safe place, stop the engine, and perform the following inspections: 1. Tilt the cab. P.
Page 343 13-10 Useful advice for emergencies When a fuse has blown Your vehicle uses a 12V electrical system. WARNING • Be sure to use fuses of the specified amperages. A fire could result if a fuse of incorrect amperage is used. If a fuse is blown, have the vehicle inspected and the blown fuse replaced by an authorized dealer.
Page 344 13-11 1 Blade-type fuses Removal and installation of lower panel in front of assistant driver’s seat 1. Remove the lower panel in front of the assis- tant driver’s seat. 2. Reinstall the lower panel by first aligning the claws with the corresponding slots and then pushing the panel forward.
Page 345 13-12 Useful advice for emergencies Inspection and replacement of blade-type fuses 1. Place the starter switch in the “LOCK” position and turn all other switches OFF. 2. To remove the fuse that is to be replaced, grip it using the fuse puller in the fuse box .
Page 346 13-13 How to remove the spare fuse Insert the puller into the gap on the outer side of the fuse holder wall to remove the spare fuse Z21577 CAUTION Do not force the puller into the gap on the inner side of the fuse holder wall.
Page 347 13-14 Useful advice for emergencies Z21425 Fuse Amperage Protected circuit Starter – – Accessory power supply (ignition circuit) Power window (driver’s) – Power window (assistant driver’s) Identification lamp Meter cluster, diagnostic connector – Air conditioner blower fan Z21747 Audio system, room lamp Starter switch, engine immobilizer control unit Horn...
Page 348 13-15 Fuse Amperage Protected circuit Audio system – Fuel heater ABS control unit Engine control unit – – Meter cluster, air condi- tioner control, rear air con- ditioner – DUONIC control unit Accessory power supply (starter switch ACC circuit) Accessory power supply (battery circuit) Van body dome lamp Engine control unit...
Page 349 13-16 Useful advice for emergencies Fuse Amperage Protected circuit – – Spare fuse 2 High-current fuse The high-current fuses, which protect circuits in the same way as regular fuses, are fitted in a box next to the battery. If a high-current fuse is blown, most of the vehicle’s electrical circuits become inopera- tive.
Page 350 13-17 Amperage Protected circuit (casing color) HF08 HF01 140A (russet) HF02 – – HF07 HF03 80A (black) HF06 HF04 – – HF04 HF05 60A (yellow) Glow ECU HF05 HF03 HF06 40A (green) Starter relay HF07 – – HF02 HF08 50A (red) Hydraulic unit HF01 HF21...
Page 351 13-18 Useful advice for emergencies When a lamp has burned out Whenever replacing a lamp, be sure to place the starter switch in the “LOCK” position and all other switches in the OFF position. WARNING • Use a lamp of the specified voltage and wattage shown in the following table.
Page 352 13-19 Z21427 Ref. No. Lamp Bulb wattage (bulb type) Q’ty Headlamp 12V-60/55W (HB2) Parking lamp 12V-5W (W5W) Front and side turn signal lamp 12V-21W (W21W) Front fog lamp <option> 12V-55W (H3) Stop/tail lamp (double filament) 12V-21/5W (P21/5W) Rear turn signal lamp 12V-21W (P21W) Backup lamp 12V-21W (P21W)
Page 353: Headlamp Bulb Replacement
13-20 Useful advice for emergencies 1 Headlamp bulb replacement For safety and simplicity, bulb replacement is per- formed with the headlamp removed. The radiator grill and the front and side turn signal lamp must be removed before the headlamp can be removed. Headlamp removal and installation •...
Page 354 13-21 • Headlamp removal 1. For removal of the headlamp , first remove the screw and rivet , then move the lamp rub- under the headlamp toward the centerline of the vehicle and release it from the tabs CAUTION When removing the lamp rubber, do not pull it with excessive force or the tabs could break.
Page 355 13-22 Useful advice for emergencies 6. Remove the screws of the garnish , then remove the garnish toward the outside of the vehicle. Z21431 NOTE: Do not remove the end rubber piece from the garnish. Z22067 7. Remove the headlamp’s bolts Z21750 8.
Page 356 13-23 9. Remove the connectors from the headlamp thus pulled out. CAUTION • Do not turn the beam adjusting gear . Turn- ing the beam adjusting gear would change the beam setting, thus creating a nuisance for drivers of other vehicles. If you acciden- tally turn the beam adjusting gear, have an authorized dealer perform necessary inspec- Z21752...
Page 357 13-24 Useful advice for emergencies 4. Insert the grommet on the garnish into the grommet hole , fit the garnish in place, and tighten the screws CAUTION Do not tighten the screw too tightly or the mounting could get damaged. Z21433 5.
Page 358 13-25 Headlamp bulb replacement CAUTION • Do not directly touch the glass part of a halo- gen bulb with your fingers. Any oil and other substances contaminating the glass surface could shorten the bulb’s service life. • Do not clean lamps with alcohol and thinner, because their lenses are made of plastic.
Page 359 13-26 Useful advice for emergencies 2 Replacing the fog lamp bulb • Removal 1. Tilt up the cab if it has a tilting mechanism. 2. Remove the cover after turning it counter- clockwise to a stop. 3. Disconnect the bulb connector 4.
Page 360 13-27 Type 2 <option> 1. Insert a flat-blade screwdriver into the notches and use it to release the tabs on the top end of the lens . Remove the lens. 2. Remove the bulb by turning it counterclock- wise while pushing inward. 3.
Page 361 13-28 Useful advice for emergencies When braking is sluggish WARNING • Never use the parking brake during driving except in an emergency. Pulling the park- ing brake lever with full force while driving could cause the vehicle to topple over. •...
Page 362 13-29 When the battery has run down Perform the following procedure to start your engine by connecting your battery to the well charged bat- tery of another vehicle with booster cables. WARNING • Check the battery’s fluid level before con- necting booster cables.
Page 363 13-30 Useful advice for emergencies Z21703 1. Stop the engine of the vehicle giving the boost. 2. Remove the battery cover. P. 12-82 3. Connect one end of the red booster cable to the positive (+) terminal of the dead battery. Con- nect the other end of the red booster cable to the positive (+) terminal of the booster bat-...
Page 364: Bleeding The Fuel System
13-31 If fuel tank becomes empty (Bleeding the fuel system) When the vehicle runs out of fuel and the engine stalls, also when the fuel filter has been replaced, or if water has been drained from the fuel filter, air that has entered the fuel system prevents the engine from being started even if the engine has been refu- eled after running dry.
Page 365 13-32 Useful advice for emergencies Towing If you are forced to tow the vehicle, take the follow- ing precautions: • Disconnect either the propeller shaft or the rear axle shaft, whichever is easier. If you disconnect the rear axle shaft, cover the opening to prevent oil and grease from escap- ing.
Page 366 13-33 • Never use the tie-down hook(s) under the frame for towing purpose. The tie-down hook is to secure the vehicle when transporting it. If the hook is used for towing, damage to the front bumper or frame may result. Z21440 When the vehicle becomes stuck in soft ground...
Page 367 13-34 Useful advice for emergencies • Never use the tie-down hook(s) under the frame for towing purpose. The tie-down hook is to secure the vehicle when transporting it. If the hook is used for towing, damage to the front bumper or frame may result. Z21440 1.
Page 368 13-35 6. Slowly drive both vehicles forward. Do not race either vehicle’s engine. 7. When the towed vehicle becomes free, promptly stop it each vehicle by applying the brake pedal. To make the rope or wire rope easy to remove from the towing hooks, let it become slightly slack before stopping the towed vehicle.
Page 370: Service Data
14-1 14. Service data Recommended lubricants/hydraulic fluids and quantities ..........14-2 Service data ........................14-4...
Page 371 14-2 Service data Recommended lubricants/hydraulic fluids and quantities 1 Quantities of lubricants/hydraulic fluids liters (qts) Item Quantity Engine Approx. 6.2 (6.5) Clutch Approx. 2.0 (2.1) Transmission Approx. 3.5 (3.7) Transfer <FG> Approx. 3.6 (3.8) Approx. 4.5 (4.8) Axle housing Front axle Approx.
Page 372 14-3 2 Recommended lubricants/hydraulic fluids Be sure to use the specified lubricants. Viscosity Parts Category Classification Atmospheric SAE viscosity temperature number Below 0°C (32°F) 10W–30 API CJ-4 Above –15°C (5°F) 15W–40 Engine Engine oil Above 30°C (86°F) ACEA C2 Below 0°C (32°F) 5W–30 General API GL-3...
Page 373 14-4 Service data Service data Description Standard value Engine idling speed 650 rpm Vehicles other than those Approx. 14 liters specified below (14.8 qts) Crew cab (with rear air Approx. 15.1 liters Coolant quantity conditioner) (16 qts) Crew cab (with rear Approx.
Page 374 15-1 15. Maintenance schedule...
Page 375: Maintenance Schedule
15-2 Maintenance schedule Regular maintenance is vital to maximizing your vehicle’s performance, service life, and safety. Following the maintenance schedule will give optimum results. The preceding sections describe simple maintenance checks and procedures that can be carried out by the owner. If you have difficulty or your vehicle needs maintenance work that is not shown in this manual, please take the vehicle to an authorized dealer.
Page 376 15-3 Time of inspection and maintenance Inspection interval Ref. Item Working procedures page Every 120,000 km/ V-belt replacement • • 72,000 miles or Replace V-belt. – 24 months Check radiator and pressure cap for sealing performance Every 30,000 km/ and mounting condition. •...
Page 377 15-4 Maintenance schedule Time of inspection and maintenance Inspection interval Ref. Item Working procedures page POWER TRAIN Propeller shaft Every 30,000 km/ Check flange yoke bolts for flange torque and • 18,000 miles or looseness and universal joint – universal joint loose- 12 months for play.
Page 378 15-5 Time of inspection and maintenance Inspection interval Ref. Item Working procedures page SUSPENSION SYSTEM Check for broken springs and Suspension springs • • • • • • tilt of vehicle body toward – either side. Check U-bolt nuts for loose- Every 30,000 km/ ness.
Page 379 15-6 Maintenance schedule Time of inspection and maintenance Inspection interval Ref. Item Working procedures page Check steering system for Every 30,000 km/ looseness, steering wheel Steering system • • 18,000 miles or play and operating condition. 12-62 12 months Inspect for oil leaks, booster and oil pump function.
Page 380: Lubrication Schedule
15-7 Time of inspection and maintenance Inspection interval Ref. Item Working procedures page Gauge, warning/ Check that gauges, warning indicator lamp oper- • • • • • • lamps and indicators are ation working properly. Battery • • • • •...
Page 381 15-8 Maintenance schedule Time of inspection and maintenance Inspection interval Reference Item page Every 60,000 km/ Hub bearing grease replacement • • 36,000 miles or – 12 months Front axle birfield joint grease • • • • • • – replacement <FG>...
Page 382: Alphabetical Index
16-1 16. Alphabetical index...
Page 383: Maintenance Record
16-2 Alphabetical index 4WD operation ........8-1 Engine overheats ........ 13-8 Accelerator pedal ........ 5-14 Entering and leaving the vehicle ..3-13 Air cleaner ........12-45 Exhaust brake ........5-17 Air conditioner ......9-4, 9-10 Free-wheeling hub ........ 8-5 Air filters ..........12-86 Front air outlets ........
Page 384 16-3 Alphabetical index Periodic inspection ........ 1-4 Warming up the engine ...... 5-10 Possible failures, causes and Warning labels ........2-1 remedies ..........13-2 Warning lamps ........6-27 Power steering fluid ......12-38 Washer switch ........5-18 Power window switches ...... 3-15 Water temperature gauge ....
Page 386 17. MAINTENANCE RECORD NOTE: • The symbols prefixed to some check items stand for Exhaust Emission Control item and Noise Control item respectively. • The latter half of the maintenance record contains the maintenance record sheets used for periodic maintenance scheduled by time (months). 17-1...
Page 388 4,000 km / 2,500 miles 4,000 km / 2,500 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of universal joints, slip joint Address: Inspection and maintenance Power train Propeller shaft flange torque and universal joint looseness Front and rear axle Wheel nuts looseness...
Page 390 10,000 km / 6,000 miles 10,000 km / 6,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 392 20,000 km / 12,000 miles 20,000 km / 12,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 394 30,000 km / 18,000 miles 30,000 km / 18,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Front axle birfield joint grease replacement <FG> Address: Front axle kingpin bearing grease replace- ment <FG>...
Page 395 Power train Propeller shaft flange torque and universal joint looseness (or 12 months) Front and rear axle Wheel and tire (or 12 months) Tie rod ball joint dust boots (or 12 months) Wheel nuts looseness (or 12 months) Suspension system U-bolts looseness (or 12 months) Braking system Disc brake pad and disc (or 12 months)
Page 396 40,000 km / 24,000 miles 40,000 km / 24,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 398 50,000 km / 30,000 miles 50,000 km / 30,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 400 60,000 km / 36,000 miles 60,000 km / 36,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil replacement (or 24 months) Address: Clutch control fluid replacement (or 24 months) Transfer gear oil replacement <FG>...
Page 401 Inspection and maintenance Engine Oil filter replacement (or 12 months) Fuel filter replacement (or 12 months) Fuel line leakage and damage (or 12 months) V-belts tension and damage (or 12 months) Cooling system (or 12 months) Air cleaner element replacement (or 12 months) Exhaust system (or 12 months) DPF (or 12 months)
Page 402 70,000 km / 42,000 miles 70,000 km / 42,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 404 80,000 km / 48,000 miles 80,000 km / 48,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 406 90,000 km / 54,000 miles 90,000 km / 54,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Front axle birfield joint grease replacement <FG> Address: Front axle kingpin bearing grease replace- ment <FG>...
Page 407 Power train Propeller shaft flange torque and universal joint looseness (or 12 months) Front and rear axle Wheel and tire (or 12 months) Tie rod ball joint dust boots (or 12 months) Wheel nuts looseness (or 12 months) Suspension system U-bolts looseness (or 12 months) Braking system Disc brake pad and disc (or 12 months)
Page 408 100,000 km / 60,000 miles 100,000 km / 60,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 410 110,000 km / 66,000 miles 110,000 km / 66,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 412 120,000 km / 72,000 miles 120,000 km / 72,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil replacement (or 24 months) Address: Clutch control fluid replacement (or 24 months) Transfer gear oil replacement <FG>...
Page 413 Inspection and maintenance Engine Oil filter replacement (or 12 months) Fuel filter replacement (or 12 months) Fuel line leakage and damage (or 12 months) V-belts replacement (or 24 months) Cooling system (or 12 months) Air cleaner element replacement (or 12 months) Exhaust system (or 12 months) DPF (or 12 months) DEF line leakage and damage (or 12...
Page 414 130,000 km / 78,000 miles 130,000 km / 78,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 416 140,000 km / 84,000 miles 140,000 km / 84,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 418 150,000 km / 90,000 miles 150,000 km / 90,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Front axle birfield joint grease replacement <FG> Address: Front axle kingpin bearing grease replace- ment <FG>...
Page 419 Power train Propeller shaft flange torque and universal joint looseness (or 12 months) Front and rear axle Wheel and tire (or 12 months) Tie rod ball joint dust boots (or 12 months) Wheel nuts looseness (or 12 months) Suspension system U-bolts looseness (or 12 months) Braking system Disc brake pad and disc (or 12 months)
Page 420 160,000 km / 96,000 miles 160,000 km / 96,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 422 170,000 km / 102,000 miles 170,000 km / 102,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 424 180,000 km / 108,000 miles 180,000 km / 108,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil replacement (or 24 months) Address: Clutch control fluid replacement (or 24 months) Transfer gear oil replacement <FG>...
Page 425 Inspection and maintenance Engine Oil filter replacement (or 12 months) Fuel filter replacement (or 12 months) Fuel line leakage and damage (or 12 months) V-belts tension and damage (or 12 months) Cooling system (or 12 months) Air cleaner element replacement (or 12 months) Exhaust system (or 12 months) DPF (or 12 months)
Page 426 190,000 km / 114,000 miles 190,000 km / 114,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 428 200,000 km / 120,000 miles 200,000 km / 120,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 430 210,000 km / 126,000 miles 210,000 km / 126,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Front axle birfield joint grease replacement <FG> Address: Front axle kingpin bearing grease replace- ment <FG>...
Page 431 Power train Propeller shaft flange torque and universal joint looseness (or 12 months) Front and rear axle Wheel and tire (or 12 months) Tie rod ball joint dust boots (or 12 months) Wheel nuts looseness (or 12 months) Suspension system U-bolts looseness (or 12 months) Braking system Disc brake pad and disc (or 12 months)
Page 432 220,000 km / 132,000 miles 220,000 km / 132,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 434 230,000 km / 138,000 miles 230,000 km / 138,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 436 240,000 km / 144,000 miles 240,000 km / 144,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil replacement (or 24 months) Address: Clutch control fluid replacement (or 24 months) Transfer gear oil replacement <FG>...
Page 437 Inspection and maintenance Engine Oil filter replacement (or 12 months) Fuel filter replacement (or 12 months) Fuel line leakage and damage (or 12 months) V-belts replacement (or 24 months) Cooling system (or 12 months) Air cleaner element replacement (or 12 months) Exhaust system (or 12 months) DPF (or 12 months) DEF line leakage and damage (or 12...
Page 438 250,000 km / 150,000 miles 250,000 km / 150,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 440 260,000 km / 156,000 miles 260,000 km / 156,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 442 270,000 km / 162,000 miles 270,000 km / 162,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Front axle birfield joint grease replacement <FG> Address: Front axle kingpin bearing grease replace- ment <FG>...
Page 443 Power train Propeller shaft flange torque and universal joint looseness (or 12 months) Front and rear axle Wheel and tire (or 12 months) Tie rod ball joint dust boots (or 12 months) Wheel nuts looseness (or 12 months) Suspension system U-bolts looseness (or 12 months) Braking system Disc brake pad and disc (or 12 months)
Page 444 280,000 km / 168,000 miles 280,000 km / 168,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 446 290,000 km / 174,000 miles 290,000 km / 174,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Lubrication of double cardan joint <FG> Address: Total mileage: Servicing dealer’s name: Address: Signature:...
Page 448 300,000 km / 180,000 miles 300,000 km / 180,000 miles SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Engine oil replacement (or 12 months) Transmission oil replacement (or 24 months) Address: Clutch control fluid replacement (or 24 months) Transfer gear oil replacement <FG>...
Page 449 Inspection and maintenance Engine Oil filter replacement (or 12 months) Fuel filter replacement (or 12 months) Fuel line leakage and damage (or 12 months) V-belts tension and damage (or 12 months) Cooling system (or 12 months) Air cleaner element replacement (or 12 months) Exhaust system (or 12 months) DPF (or 12 months)
Page 450 24 months (2 years) 24 months (2 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 452 48 months (4 years) 48 months (4 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 454 72 months (6 years) 72 months (6 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 456 96 months (8 years) 96 months (8 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 458 120 months (10 years) 120 months (10 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 460 144 months (12 years) 144 months (12 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 462 168 months (14 years) 168 months (14 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 464 192 months (16 years) 192 months (16 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 466 216 months (18 years) 216 months (18 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 468 240 months (20 years) 240 months (20 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 470 264 months (22 years) 264 months (22 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 472 288 months (24 years) 288 months (24 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 474 312 months (26 years) 312 months (26 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 476 336 months (28 years) 336 months (28 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 478 360 months (30 years) 360 months (30 years) SERVICE OPERATIONS SERVICE OPERATIONS Owner’s name: Date: Owner’s name: Address: Vehicle identification number: Lubrication Date: Brake fluid replacement Address: Inspection and maintenance Engine Coolant replacement Total mileage: Servicing dealer’s name: Address: Signature:...
Page 480 • DUONIC is a trademark of Daimler AG • ® BlueTec : A brand of Daimler AG • Windows is a registered trademark of Microsoft Corporation in the United States and other countries. • Windows Media is either a registered trademark or trademark of Microsoft Corporation in the United States and/or other countries.
Page 481 Pub. No. MH996530 FEBRUARY ’11 Printed in Japan...

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