Mitsubishi Fuso FK.FM Series Repair Service Manual 1986-2001
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi Fuso FK.FM Series 1986-2001, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Mitsubishi Fuso FK/FM Series 1986-2001 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
FK.FM Series 1996-2001 Fuso Service Manual (TWME9503).pdf
FK.FM Series 1986-1987 Fuso Service Manual (TWME8514).pdf
FK.FM Series 1990-1991 Fuso Service Manual (TWME8910).pdf
FK.FM Series 1992-1995 Fuso Service Manual (TWME9107).pdf
PRODUCT DETAILS:
Total Pages: 4,801 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
FK.FM Series 1986-1987 Fuso Service Manual (TWME8514 - 751 pages)...1
1986-1987 FK/FM Service Manual...1
Foreword...2
1. Group Classification...3
2. Definition of Terms and Unit Used...4
3. Notes On Illustrations...5
Group 00 - General...7
1. Exterior Views...8
2. Major Specifications...9
3. Power Train Table...14
4. Equipment Model Notation...15
5. Performance Curves...16
5.1 Operation Performance Curves...16
5.2 Engine Performance Curves...20
6. Servicing Precautions...21
7. Vehicle Identification Number...24
8. Standard Bolts and Nuts Tightening Torque Table...26
Group 01 - Maintenance Schedule...27
1. Using the Maintenance Schedule Table...29
2. Maintenance Schedule Table...30
2.1 Replacement of Oil Filter Element...36
2.2 Replacement of the Fuel Filter Element...36
2.3 Cleaning of the Fuel Feed Pump Gauze Filter...37
2.4 Bleeding of the Fuel System...37
2.5 Adjustment of V-Belt Tension...37
2.6 Cleaning and Replacement of Air Cleaner Element...38
2.6.1 Dry Dust Buildup...38
2.6.2 Oil Smoke, Soot, and Oil Black Deposits...38
2.6.3 Inspection After Drying...39
2.7 Inspection of Clutch Pedal...39
2.7.1 Inspection of Pedal Play...39
2.7.2 Clearance to Floorboard When Released...39
2.7.3 Clutch Operation...39
2.8 Servicing of Tires...40
2.8.1 Tire Inflation Pressure...40
2.8.2 Removal of Tire...40
2.8.3 Installation of Tire...41
2.8.4 Retightening of Wheel Nuts...41
2.8.5 Tire Rotation...42
2.9 Servicing of Air Drier...42
2.10 Adjustment of Wheel Brake Shoe Clearance...42
2.10.1 Adjusting Gear Type [FK415, FK455]...42
2.10.2 Adjusting Cam Type [FM555]...43
2.11 Adjustment of Parking Brake Shoe Clearance...44
2.12 Servicing of Battery...45
2.12.1 Cleaning of Battery Terminals...45
2.12.2 Inspection of Fluid Level...45
2.12.3 Specific Gravity...46
2.13 Replacement of Fuses...46
3. Lubrication...48
3.1 Engine...49
3.1.1 Engine Oil Level and Contamination...49
3.1.2 Replacement of Engine Oil...49
3.2 Clutch...50
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank...50
3.2.2 Replacement of Brake Fluid...51
3.2.3 Bleeding of Clutch System...51
3.3 Transmission...51
3.3.1 Inspection of Transmission Gear Oil Level...51
3.3.2 Replacement of Transmission Gear Oil...52
3.4 Rear Axle...52
3.4.1 Inspection of Rear Axle Gear Oil Level...52
3.4.2 Replacement of Rear Axle Gear Oil...52
3.5 Brakes...52
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank...52
3.5.2 Replacement of Brake Fluid...52
3.5.3 Bleeding of the Brake System...53
3.6 Power Steering...54
3.6.1 Inspection of Power Steering Oil Level...54
3.6.2 Replacement of Power Steering Oil...54
3.6.3 Bleeding of the Power Steering System...55
3.7 Lubrication...55
Group 11 - Engine...58
1. General...59
1.1 Engine Proper...59
1.2 Air Compressor...61
2. Specifications...61
3. Service Standards...62
3.1 Service Standard Table...62
3.2 Tightening Torque Table...66
3.3 Sealant, Oil and Grease...66
4. Service Procedure...67
4.1 Engine Proper...67
4.1.1 Measurement of Compression Pressure...67
4.1.2 Removal...68
4.1.3 Disassembly...73
4.1.4 Inspection and Correction...80
4.1.5 Reassembly...96
4.1.6 Installation...107
4.1.7 Adjustment...108
4.2 Air Compressor...109
4.2.1 Removal...109
4.2.2 Disassembly...110
4.2.3 Inspection and Correction...111
4.2.4 Reassembly...114
4.2.5 Installation...115
5. Special Tool...116
6. Troubleshooting...120
6.1 Engine...120
6.2 Valve Mechanism...126
Group 12 - Lubrication...129
1. General...130
2. Specifications...134
3. Service Standards...135
3.1 Service Standard Table...135
3.2 Tightening Torque Table...136
4. Service Procedure...136
4.1 Oil Pump...137
4.1.1 Removal...137
4.1.2 Disassembly and Inspection...138
4.1.3 Reassembly...140
4.1.4 Installation...140
4.2 Oil Filter, Oil Cooler...141
4.2.1 Disassembly and Inspection...141
4.3 Regulator Valve, Check Valve [6D14T]...143
4.3.1 Regulator Valve...143
4.3.2 Check Valve [6D14T]...143
5. Special Tool...144
6. Troubleshooting...145
Group 13 - Fuel...147
1. General...148
1.1 Fuel System...148
1.2 Engine Control...152
2. Specifications...153
3. Service Standards...153
3.1 Service Standard Table...153
3.2 Tightening Torque Table...155
4. Service Procedure...156
4.1 Injection Pump...156
4.1.1 Removal...156
4.1.2 Disassembly...157
4.1.3 Inspection and Correction...158
4.1.4 Reassembly...159
4.1.5 Test and Adjustment...160
4.2 Governor...165
4.2.1 Removal and Disassembly...165
4.2.2 Inspection and Reassembly...166
4.2.3 Adjustment...168
4.3 Auto Timer...173
4.3.1 Disassembly and Inspection...173
4.3.2 Reassembly...175
4.3.3 Adjustment...175
4.4 Feed Pump...176
4.4.1 Disassembly and Reassembly...176
4.4.2 Test...177
4.5 Injection Nozzle...177
4.5.1 Removal...177
4.5.2 Disassembly...177
4.5.3 Cleaning and Inspection...178
4.5.4 Reassembly...179
4.5.5 Test and Adjustment...179
4.5.6 Installation...180
4.6 Fuel Filter...181
4.6.1 Disassembly and Reassembly...181
4.7 Water Separator...181
4.7.1 Disassembly and Reassembly...181
4.8 Bleeding the Fuel System...181
4.9 Engine Control...182
4.9.1 Removal and Installation...182
4.9.2 Adjustment...183
5. Special Tool...185
6. Troubleshooting...186
Group 14 - Cooling...192
1. General...193
2. Specifications...195
3. Service Standards...196
3.1 Service Standard Table...196
3.2 Tightening Torque Table...196
3.3 Sealant, Oil and Grease...196
4. Service Procedure...197
4.1 Auto Cool Fan Coupling...197
4.1.1 Removal and Disassembly...197
4.1.2 Inspection and Correction...197
4.1.3 Reassembly and Installation...198
4.2 Water Pump...198
4.2.1 Removal...198
4.2.2 Disassembly and Inspection...199
4.2.3 Reassembly...201
4.3 Thermostat...201
4.3.1 Removal and Disassembly...201
4.3.2 Inspection...202
4.4 Radiator...202
4.4.1 Removal and Disassembly...202
4.4.2 Inspection...203
4.4.3 Installation...204
4.4.4 Gas Leak Test...205
4.5 Reservoir Tank...205
4.5.1 Removal and Inspection...205
4.6 Cleaning of Cooling System...206
5. Special Tool...207
6. Troubleshooting...208
Group 15 - Intake and Exhaust...210
1. General...211
2. Specifications...213
3. Service Standards...213
3.1 Service Standard Table...213
3.2 Tightening Torque Table...213
4. Service Procedure...214
4.1 Turbocharger [6D14T]...214
4.1.1 Removal...214
4.1.2 Disassembly...215
4.1.3 Inspection and Correction...216
4.1.4 Reassembly...218
4.1.5 Installation...219
4.1.6 Adjustment...219
4.2 Air Cleaner...221
4.2.1 Disassembly and Reassembly...221
4.2.2 Inspection and Cleaning...222
4.3 Inlet Manifold...223
4.4 Exhaust Manifold...223
4.5 P.C.V. (Positive Crankcase Ventilation) Valve [6D14T]...224
5. Special Tool...225
6. Troubleshooting...226
Group 16 - Engine Electrical...229
1. General...230
2. Specifications...232
3. Service Standards...232
3.1 Service Standard Table...232
3.2 Tightening Torque Table...233
3.3 Sealant, Oil and Grease...233
4. Service Procedure...234
4.1 Starter...234
4.1.1 Removal...234
4.1.2 Disassembly...234
4.1.3 Inspection...235
4.1.4 Reassembly...236
4.2 Alternator...237
4.2.1 Removal...237
4.2.2 Disassembly...238
4.2.3 Inspection...239
4.2.4 Reassembly...239
4.2.5 Tests...240
4.2.6 Installation...241
4.3 Glow Plug System...243
4.3.1 Removal and Installation...243
4.3.2 Inspection...244
5. Troubleshooting...245
Group 21 - Clutch [C5W33]...250
1. General...251
1.1 Clutch Control...251
1.2 Clutch Proper...252
2. Specifications...252
3. Service Standards...253
3.1 Service Standard Table...253
3.2 Tightening Torque Table...254
4. Service Procedure...254
4.1 Removal...254
4.1.1 Removal From Vehicle...254
4.2 Clutch Proper...255
4.2.1 Disassembly and Inspection...255
4.2.2 Reassembly and Adjustment...257
4.3 Clutch Pedal...259
4.3.1 Diassembly and Inspection...259
4.3.2 Reassembly and Adjustment...259
4.4 Clutch Master Cylinder...260
4.4.1 Disassembly and Inspection...260
4.4.2 Reassembly and Adjustment...260
4.5 Clutch Power Cylinder...261
4.5.1 Disassembly and Inspection...261
4.5.2 Reassembly...261
4.6 Replacement of Clutch System Fluid...262
4.7 Bleeding Clutch System...262
4.8 Adjustment of Clutch Control...263
5. Special Tool...264
6. Troubleshooting...265
Group 21 - Clutch [C6W35]...274
1. General...275
1.1 Clutch Control...275
1.2 Clutch Proper...276
2. Specifications...276
3. Service Standards...277
3.1 Service Standard Table...277
3.2 Tightening Torque Table...279
4. Service Procedure...280
4.1 Removal...280
4.1.1 Removal from Vehicle...280
4.2 Clutch Proper...281
4.2.1 Disassembly and Inspection...281
4.2.2 Reassembly and Adjustment...283
4.3 Clutch Pedal...285
4.3.1 Disassembly and Inspection...285
4.3.2 Reassembly and Adjustment...285
4.4 Clutch Master Cylinder...286
4.4.1 Disassembly and Inspection...286
4.4.2 Reassembly and Adjustment...286
4.5 Clutch Booster...287
4.5.1 Disassembly and Inspection...287
4.5.2 Reassembly and Adjustment...288
4.6 Inspection of Clutch Disc Wear...290
4.7 Replacement of Clutch System Fluid...290
4.8 Bleeding Clutch System...291
4.9 Adjustment of Clutch Control...292
5. Special Tool...293
6. Troubleshooting...295
Group 22 - Transmission [M5S5]...305
1. General...306
2. Specifications...309
3. Service Standards...310
3.1 Service Standard Table...310
3.2 Tightening Torque Table...312
4. Service Procedure...313
4.1 Key Points for Removal...313
4.2 Key Points for Installation...314
4.3 Adjustment After Installation...314
4.4 Disassembly, Inspection and Reassembly...314
4.4.1 Transmission Assembly...314
4.4.2 Main Shaft...318
4.4.3 Counter Shaft Gear...322
4.4.4 Reverse Gear...324
4.4.5 Drive Pinion...326
4.4.6 Reassembly of Clutch Housing...326
4.4.7 Gearshifter, Lower...327
4.4.8 Gearshifter, Upper...331
4.4.9 Rear Cover...333
4.4.10 Speedometer Gears...335
4.4.11 Transmission Control...335
5. Special Tool...338
6. Troubleshooting...343
Group 22 - Transmission [M6S5]...350
1. General...351
2. Specifications...354
3. Service Standards...355
3.1 Service Standard Table...355
3.2 Tightening Torque Table...357
4. Service Procedure...358
4.1 Key Points for Removal...358
4.2 Key Points for Installation...359
4.3 Adjustment After Installation...359
4.4 Disassembly, Inspection and Reassembly...359
4.4.1 Transmission Assembly...359
4.4.2 Main Shaft...363
4.4.3 Counter Shaft Gear...367
4.4.4 Reverse Gear...369
4.4.5 Drive Pinion...371
4.4.6 Reassembly of Clutch Housing...371
4.4.7 Gearshifter, Lower...372
4.4.8 Gearshifter, Upper...376
4.4.9 Rear Cover...378
4.4.10 Speedometer Gears...380
4.4.11 Transmission Control...380
5. Special Tool...383
6. Troubleshooting...388
Group 22 - Transmission [M8S2x5]...395
1. General...396
2. Specifications...399
2.1 Transmission Proper...399
2.2 Transmission Control...399
3. Service Standards...400
3.1 Service Standard Table...400
3.2 Tightening Torque Table...403
4. Service Procedure...405
4.1 Key Points for Removal...405
4.2 Key Points for Installation...406
4.3 Adjustment After Installation...406
4.4 Disassembly, Inspection and Reassembly...406
4.4.1 Transmission Assembly...406
4.4.2 Main Shaft...410
4.4.3 Counter Shaft Gear...414
4.4.4 Reverse Gear...417
4.4.5 Drive Pinion...418
4.4.6 Reassembly of Clutch Housing...419
4.4.7 Gearshifter, Lower...419
4.4.8 Gearshifter, Upper...423
4.4.9 Splitter, Upper...425
4.4.10 Rear Cover...427
4.4.11 Speedometer Gears...428
4.4.12 Splitter Case and Gears...429
4.4.13 Power Shift...431
4.4.14 Splitter Control...433
4.4.15 Transmission Control...435
5. Special Tool...438
6. Troubleshooting...443
Group 25 - Propeller Shaft...452
1. General...453
2. Specifications...453
3. Service Standards...454
3.1 Service Standard Table...454
3.2 Tightening Torque Table...454
4. Service Procedure...455
4.1 Removal and Installation...455
4.2 Disassembly, Inspection and Correction...456
4.3 Reassembly...459
4.4 Propeller Shaft Dynamic Balance Adjustment Procedures...462
5. Special Tool...464
6. Troubleshooting...466
Group 26 - Front Axle...468
1. General...469
2. Specifications...469
3. Service Standards...470
3.1 Service Standard Table...470
3.2 Tightening Torque Table...471
4. Service Procedure...472
4.1 Removal and Installation...472
4.2 Wheel Hub and Brake Drum...473
4.2.1 Disassembly, Inspection and Correction...473
4.2.2 Reassembly...475
4.2.3 Adjustment of Bearing Starting Torque...476
4.3 Front Axle, Knuckle and Kingpin...478
4.3.1 Disassembly, Inspection and Correction...478
4.3.2 Measurement of Front Axle Bends...479
4.3.3 Measurement of Kingpin Inclination...480
4.3.4 Reassembly...480
4.4 Adjustment After Installation (Wheel Alignment)...481
5. Special Tool...482
6. Troubleshooting...485
Group 27 - Rear Axle...488
1. General...489
2. Specifications...489
3. Service Standards...490
3.1 Service Standard Table...490
3.2 Tightening Torque Table...491
4. Service Procedure...492
4.1 Removal and Installation...492
4.2 Wheel Hub and Brake Drum...493
4.2.1 Disassembly, Inspection and Correction...493
4.2.2 Reassembly...495
4.2.3 Adjustment of Bearing Starting Torque...497
4.3 Reduction and Differential...498
4.3.1 Disassembly, Inspection and Correction...498
4.3.2 Reassembly...502
4.3.3 Adjustment of Starting Torque of Reduction Pinion Bearing...505
4.3.4 Selection of Reduction Pinion Mounting Adjusting Shim...505
4.3.5 Adjustment of Differential Case Side Bearing and Reduction Gear...506
4.3.6 Reduction Gear Tooth Contact...507
5. Special Tool...510
6. Troubleshooting...516
Group 31 - Wheel and Tire...519
1. Specifications...520
2. Service Procedure...520
3. Service Standards...521
3.1 Service Standard Table...521
3.2 Tightening Torque Table...521
4. Troubleshooting...521
Group 33 - Front Suspension...524
1. General...525
2. Specifications...525
3. Service Standards...526
3.1 Service Standard Table...526
3.2 Tightening Torque Table...526
4. Service Procedure...527
4.1 Removal and Installation...527
4.2 Disassembly, Inspection and Correction...528
4.3 Reassembly...529
5. Special Tool...531
6. Troubleshooting...532
Group 34 - Rear Suspension...534
1. General...535
2. Specifications...535
3. Service Standards...536
3.1 Service Standard Table...536
3.2 Tightening Torque Table...536
4. Service Procedure...537
4.1 Removal and Installation...537
4.2 Disassembly, Inspection and Correction...538
4.3 Reassembly...539
5. Special Tool...540
6. Troubleshooting...541
Group 35 - Brake...543
1. General...545
1.1 Service Brake...545
1.2 Parking Brake...553
1.3 Exhaust Brake...554
2. Specifications...555
2.1 Service Brake...555
2.2 Parking Brake...556
2.3 Exhaust Brake...556
3. Service Standards...557
3.1 Service Standard Table...557
3.1.1 Service Brake...557
3.1.2 Parking Brake...561
3.1.3 Exhaust Brake...561
3.2 Tightening Torque Table...562
3.2.1 Service Brake...562
3.2.2 Parking Brake...564
3.2.3 Exhaust Brake...564
4. Service Procedure of Service Brake...565
4.1 Brake System Diagram...565
4.2 Brake Pedal and Air Brake Valve...567
4.2.1 Removal and Installation...567
4.2.2 Brake Pedal...568
4.2.3 Air Brake Valve...569
4.2.4 Inspection and Adjustment After Reassembly...573
4.3 Brake Booster...574
4.3.1 Brake Booster for FK Series...574
4.3.2 Brake Booster for FM Series...579
4.3.3 Function Check After Reassembly...584
4.4 Air Pressure Governor...585
4.4.1 Function Check...585
4.4.2 Disassembly, Inspection and Correction...586
4.4.3 Reassembly...587
4.4.4 Inspection and Adjustment After Reassembly...587
4.5 Check Valve...587
4.5.1 Disassembly, Inspection and Correction...587
4.5.2 Reassembly and Inspection...588
4.6 Safety Valve...588
4.7 Low Air Pressure Switch...588
4.8 Stop Lamp Switch...588
4.9 Supply Valve...589
4.9.1 Disassembly, Inspection and Correction...589
4.9.2 Reassembly and Adjustment...589
4.10 Air Drier...589
4.10.1 Maintenance and Inspection...589
4.10.2 Disassembly, Inspection and Correction...589
4.10.3 Reassembly...591
4.10.4 Inspection After Installation in Vehicle...592
4.10.5 Troubleshooting...592
4.11 Wheel Brake...593
4.11.1 Removal and Installation...593
4.11.2 Disassembly, Inspection and Correction...593
4.11.3 Reassembly...600
4.11.4 Replacement of Brake Lining and Correction of Brake Drum...608
4.12 Inspection and Adjustment After Installation...608
4.12.1 Replacement of Brake Fluid and Bleeding of Brake (Oil) System...608
4.12.2 Brake Shoe Clearance Adjustment...610
5. Service Procedure of Parking Brake...611
5.1 Parking Brake Drum Assembly...611
5.1.1 Key Points for Removal...611
5.2 Parking Brake Proper...612
5.3 Parking Brake Control...616
5.4 Adjustment After Installation...617
6. Service Procedure of Exhaust Brake...619
6.1 Exhaust Brake Valve...619
6.1.1 Disassembly and Inspection...619
6.1.2 Reassembly and Adjustment...620
6.2 Control Cylinder...621
6.2.1 Disassembly and Inspection...621
6.2.2 Reassembly...621
6.3 Exhaust Brake Microswitch...622
7. Special Tool...623
7.1 Service Brake...623
7.2 Parking Brake...624
8. Troubleshooting...625
Group 37 - Steering...639
1. General...640
2. Specifications...643
3. Service Standards...644
3.1 Service Standard Table...644
3.2 Tightening Torque Table...645
4. Service Procedure...646
4.1 Removal and Installation of Steering System...646
4.1.1 Removal of Starter Switch Wires and Cables...647
4.1.2 Removal of Upper and Lower Shaft Assembly...647
4.1.3 Removal of Starter Switch...648
4.1.4 Installation of Starter Switch...648
4.2 Disassembly and Reassembly of Steering Wheel...648
4.3 Steering Shaft...649
4.3.1 Disassembly, Inspection and Correction...649
4.3.2 Reassembly...649
4.4 Details of Link and Bracket Section...650
4.5 Drag Link...650
4.6 Tie Rod...651
4.7 Integral Power Steering Booster...651
4.7.1 Disassembly, Inspection and Correction...652
4.7.2 Reassembly and Adjustment...654
4.8 Power Steering Oil Pump...657
4.8.1 Disassembly, Inspection and Correction...657
4.8.2 Reassembly...658
4.8.3 Adjustment...659
4.9 Power Steering Oil Tank...659
4.9.1 Disassembly...659
4.9.2 Reassembly...660
4.10 Adjustment After Installation...660
4.10.1 Bleeding...660
4.10.2 Performance Verification Tests...661
4.10.3 Steering Wheel Play...662
4.10.4 Adjustment of Steering Angle...662
5. Special Tool...662
6. Troubleshooting...663
Group 41 - Frame...673
1. General...674
2. Specifications...674
3. Service Procedure...674
3.1 Frame...674
3.2 Rivets...675
3.3 Shape of Frame...676
4. Troubleshooting...679
Group 42 - Cab...680
1. General...681
2. Specifications...681
3. Service Standards...681
3.1 Tightening Torque Table...681
4. Service Procedure...682
4.1 Key Points for Cab Removal and Installation...682
4.1.1 Removal...682
4.1.2 Installation...683
4.2 Doors...685
4.2.1 Removal of Doors...685
4.2.2 Door Installation Adjustment...686
4.2.3 Door Trim...687
4.2.4 Door Locking System...688
4.2.5 Parts Related to Glass...689
4.3 Seats...691
4.3.1 Seats...691
4.3.2 Seat Belts...691
4.4 Floor Mat...692
4.5 Overhead Console...693
4.6 Trims...694
4.7 Instrument Panel...696
4.8 Windshield Glass and Rear Window Glass...696
4.8.1 Removal...696
4.8.2 Installation...697
4.9 Rearview Mirrors...698
4.10 Removal of Front Panel and Related Parts...699
5. Troubleshooting...701
Group 54 - Chassis Electrical...709
1. General...710
2. Specifications...710
2.1 Electrical...710
2.2 Meter and Gauge...711
2.3 Lighting...712
2.4 Exhaust Brake...713
2.5 Wiper and Washer...713
2.6 Accessory...714
3. Service Procedure...714
3.1 Aiming of Headlamps...714
3.2 Warning and Indicator Lamps...716
4. Troubleshooting...718
Group 55 - Heater...740
1. General...741
2. Specifications...741
3. Service Procedure...742
3.1 Removal and Installation...742
3.2 Cleaning of Air Filter...742
3.3 Heater Control Adjustment Procedures...743
4. Troubleshooting...745
Wiring Diagram...747
Alphabetical Index...749
FK.FM Series 1990-1991 Fuso Service Manual (TWME8910 - 904 pages)...752
1990-1991 FK/FM Service Manual...752
Foreword...753
Compilation of this Manual...754
1. Group Classification...754
2. Definitions of Terms and Units Used...755
3. Notes On Illustrations...756
Group 00 - General...757
Table of Contents...758
1. Exterior Views...759
2. Major Specifications...761
3. Power Train Table...768
4. Equipment Model Notation...769
5. Performance Curves...770
5.1 Operation Performance Curves...770
5.2 Engine Performance Curves...778
6. Servicing Precautions...779
7. Standard Bolts and Nuts Tightening Torque Table...784
8. Towing Precautions...785
9. Chassis and Engine Numbers...785
10. Vehicle Identification Number...786
Group 01 - Maintenance Schedule...787
Table of Contents...788
1. Using Maintenance Schedule Table...789
2. Maintenance Schedule...790
2.1 Replacement of Oil Filter Element...796
2.2 Replacement of Fuel Filter Element...796
2.3 Cleaning of Fuel Feed Pump Gauze Filter...797
2.4 Bleeding of Fuel System...797
2.5 Adjustment of V-Belt Tension...797
2.6 Cleaning and Replacement of Air Cleaner Element...798
2.6.1 Dry Dust Buildup...798
2.7 Inspection of Clutch Pedal...799
2.7.1 Inspection of Pedal Play...799
2.7.2 Clearance to Floorboard When Released...799
2.7.3 Clutch Operation...799
2.8 Servicing of Tires...800
2.8.1 Tire Inflation Pressures...800
2.8.2 Removal of Tire...800
2.8.3 Installation of Tire...801
2.8.4 Retightening of Wheel Nuts...801
2.8.5 Tire Rotation...802
2.9 Servicing of Air Drier...802
2.10 Adjustment of Wheel Brake Shoe Clearance...803
2.10.1 Air Over Hydraulic Brake <FK415, FK455>...803
2.10.2 Full Air Brake <FM Series>...803
2.11 Adjustment of Parking Brake Shoe Clearance <FK415, FK455>...805
2.12 Servicing of Battery...805
2.12.1 Cleaning of Battery Terminals...806
2.12.2 Inspection of Fluid Level...806
2.12.3 Specific Gravity...806
2.13 Replacement of Fuses...807
3. Lubrication...809
3.1 Engine...810
3.1.1 Engine Oil Level and Contamination...810
3.1.2 Replacement of Engine Oil...811
3.2 Clutch...812
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank...812
3.2.2 Replacement of Brake Fluid...812
3.2.3 Bleeding of Clutch System...812
3.3 Transmission...813
3.3.1 Inspection of Transmission Gear Oil Level...813
3.3.2 Replacement of Transmission Gear Oil...813
3.4 Rear Axle...813
3.4.1 Inspection of Rear Axle Gear Oil Level...813
3.4.2 Replacement of Rear Axle Gear Oil...813
3.5 Brake <FK415, FK455>...814
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank...814
3.5.2 Replacement of Brake Fluid...814
3.5.3 Bleeding of Brake System...814
3.6 Power Steering...815
3.6.1 Inspection of Power Steering Fluid Level...815
3.6.2 Replacement of Power Steering Fluid...816
3.6.3 Bleeding of Power Steering System...816
3.7 Chassis Parts...817
Group 11 - Engine...818
Table of Contents...819
1. Troubleshooting...820
2. Specifications...822
3. Service Standards...823
3.1 Service Standards Table...823
3.2 Tightening Torque Table...826
4. Special Tools...827
5. General...832
6. Service Procedure...835
6.1 Removal and Installation of Engine and Transmission...835
6.2 Engine Proper...840
6.2.1 Measurement of Compression Pressure...840
6.2.2 Cylinder Head and Valve Mechanism...841
6.2.3 Flywheel, Timing Gear, and Camshaft...854
6.2.4 Crankcase and Main Moving Parts...864
6.2.5 Adjustment...881
Group 12 - Lubrication...882
Table of Contents...883
1. Troubleshooting...884
2. Specifications...884
3. Service Standards...885
3.1 Service Standards Table...885
3.2 Tightening Torque Table...885
4. Special Tools...886
5. General...886
6. Service Procedure...892
6.1 Oil Pump...892
6.1.1 Removal and Installation...892
6.1.2 Disassembly and Inspection...893
6.1.3 Reassembly...895
6.2 Oil Filter and Oil Cooler...895
6.2.1 Removal and Installation...895
6.2.2 Disassembly, Inspection, and Reassembly of Oil Filter...896
6.2.3 Disassembly, Inspection, and Reassembly of Oil Cooler...896
6.3 Regulator Valve...897
6.4 Check Valve...897
Group 13 - Fuel and Engine Control...898
Table of Contents...899
1. Troubleshooting...900
2. Specifications...904
3. Service Standards...905
3.1 Service Standards Table...905
3.2 Tightening Torque Table...905
4. Special Tools...906
5. General...907
5.1 Fuel System...907
5.2 Engine Control...911
6. Service Procedure...912
6.1 Injection Pump Assembly...912
6.1.1 Removal and Installation...912
6.1.2 Inspection and Adjustment of Fuel Injection Timing...913
6.2 Feed Pump...915
6.2.1 Disassembly, Inspection, and Reassembly...915
6.2.2 Test...915
6.3 Injection Nozzle...916
6.3.1 Removal and Installation...916
6.3.2 Disassembly...916
6.3.3 Cleaning and Inspection...916
6.3.4 Reassembly...917
6.3.5 Test and Adjustment...917
6.4 Fuel Filter...919
6.5 Water Separator...919
6.6 Bleeding the Fuel System...920
6.7 Engine Control...921
6.7.1 Removal and Installation...921
6.7.2 Adjustment...921
6.8 Fuel Tank and Fuel Gauge Unit...923
Group 14 - Cooling...924
Table of Contents...925
1. Troubleshooting...926
2. Specifications...927
3. Service Standards...927
3.1 Service Standards Table...927
3.2 Tightening Torque Table...928
4. Special Tools...928
5. General...929
6. Service Procedure...933
6.1 Removal and Installation of Cooling System...933
6.2 Water Pump...936
6.2.1 Disassembly and Inspection...936
6.2.2 Reassembly...938
6.3 Inspection of Thermostat...939
6.4 Inspection of Auto Cool Fan Coupling...939
6.5 Inspection of Radiator...940
6.6 Inspection and Adjustment of V-Belt Tension...941
6.7 Cleaning of Cooling System...941
6.8 Gas Leak Test...943
6.9 Bleeding Cooling System...943
Group 15 - Intake and Exhaust...944
Table of Contents...945
1. Troubleshooting...946
2. Specifications...947
3. Service Standards...947
3.1 Service Standards Table...947
3.2 Tightening Torque Table...948
4. Special Tools...948
5. General...948
6. Service Procedure...954
6.1 Removal, Installation, and Inspection of Intake System...954
6.2 Air Cleaner...955
6.2.1 Disassembly and Reassembly...955
6.2.2 Inspection and Cleaning...955
6.3 Removal, Installation, and Inspection of Exhaust System...957
6.4 Turbocharger...958
6.4.1 Removal and Installation...958
6.4.2 Disassembly...960
6.4.3 Cleaning and Inspection...963
6.4.4 Reassembly...966
6.4.5 Measurement of Turbocharger Boost Pressure...972
6.5 Intercooler <6D16T2>...974
6.5.1 Removal and Installation...974
6.5.2 Inspection...974
Group 16 - Engine Electrical...975
Table of Contents...976
1. Troubleshooting...977
2. Specifications...978
3. Service Standards...979
3.1 Service Standards Table...979
3.2 Tightening Torque Table...980
4. Special Tools...980
5. General...981
5.1 Starter...981
5.2 Alternator...984
5.3 Glow System...987
6. Service Procedure...989
6.1 Starter...989
6.1.1 Removal and Installation...989
6.1.2 Disassembly...989
6.1.3 Inspection...992
6.1.4 Reassembly...999
6.1.5 Inspection and Adjustment After Reassembly...1001
6.2 Alternator...1002
6.2.1 Removal and Installation...1002
6.2.2 Disassembly...1003
6.2.3 Inspection...1005
6.2.4 Reassembly...1009
6.2.5 Inspection and Adjustment After Installation...1010
6.3 Glow System...1013
6.3.1 Removal and Installation of Glow Plug...1013
6.3.2 Inspection...1013
Group 21 - Clutch...1016
Table of Contents...1017
1. Troubleshooting...1018
2. Specifications...1021
3. Service Standards...1022
3.1 Service Standards Table...1022
3.2 Tightening Torque Table...1024
4. Special Tools...1025
5. General...1027
5.1 Clutch Proper...1027
5.2 Clutch Control...1028
5.2.1 Clutch Master Cylinder...1029
5.2.2 Clutch Booster...1030
6. Service Procedure...1032
6.1 Clutch...1032
6.1.1 Removal and Installation...1032
6.1.2 Disassembly and Inspection...1034
6.1.3 Reassembly...1039
6.2 Clutch Pedal...1042
6.2.1 Removal and Installation...1042
6.2.2 Disassembly and Inspection...1043
6.2.3 Reassembly and Adjustment...1045
6.3 Clutch Master Cylinder...1047
6.3.1 Disassembly and Inspection...1047
6.3.2 Reassembly...1048
6.4 Power Cylinder...1048
6.4.1 Removal and Installation...1048
6.4.2 Disassembly and Inspection...1049
6.4.3 Reassembly...1049
6.5 Clutch Booster (Vehicles With M8S2x5)...1050
6.5.1 Removal and Installation...1050
6.5.2 Disassembly and Inspection...1050
6.5.3 Reassembly...1053
6.5.4 Performance Test...1055
6.5.5 On-the-Vehicle Functional Check...1055
6.6 Clutch Housing...1057
6.6.1 Disassembly...1057
6.6.2 Reassembly...1058
6.7 Replacement of Brake Fluid in Clutch System...1060
6.8 Bleeding the Clutch System...1060
6.9 Adjustment of Clutch Pedal...1062
6.10 Lubrication of Drive Pinion Splines...1063
Group 22A - Manual Transmission (M5S5, M6S5)...1064
Table of Contents...1065
1. Troubleshooting...1066
2. Specifications...1067
3. Service Standards...1068
3.1 Service Standards Table...1068
3.2 Tightening Torque Table...1070
4. Special Tools...1071
5. General...1074
6. Service Procedure...1076
6.1 Removal and Installation of Transmission...1076
6.1.1 Key Points for Removal...1076
6.1.2 Key Points for Installation...1078
6.1.3 Inspection and Adjustment After Installation...1078
6.2 Transmission Assembly...1079
6.2.1 Disassembly...1079
6.2.2 Reassembly...1080
6.3 Transmission...1080
6.3.1 Inspection Before Disassembly...1080
6.3.2 Disassembly and Inspection...1082
6.3.3 Reassembly...1085
6.4 Main Shaft...1088
6.4.1 Disassembly and Inspection...1088
6.4.2 Reassembly...1092
6.5 Counter Shaft...1094
6.5.1 Disassembly...1094
6.5.2 Reassembly...1095
6.6 Lower Gear Shifter...1096
6.6.1 Disassembly and Inspection...1096
6.6.2 Reassembly...1098
6.7 Upper Gear Shifter...1099
6.7.1 Disassembly and Inspection...1099
6.7.2 Reassembly...1100
6.8 Rear Cover...1102
6.8.1 Disassembly and Inspection...1102
6.8.2 Reassembly...1104
6.9 Transmission Control...1106
6.9.1 Disassembly and Inspection...1106
6.9.2 Reassembly...1107
6.9.3 Adjustment After Installation...1108
Group 22B - Manual Transmission (M8S5, M8S2x5)...1109
Table of Contents...1110
1. Troubleshooting...1111
2. Specifications...1112
2.1 Transmission Proper...1112
2.2 Transmission Control...1113
3. Service Standards...1113
3.1 Service Standards Table...1113
3.2 Tightening Torque Table...1115
4. Special Tools...1116
5. General...1121
6. Service Procedure...1123
6.1 Removal and Installation of Transmission...1123
6.1.1 Key Points for Removal...1123
6.1.2 Key Points for Installation...1124
6.1.3 Inspection and Adjustment After Installation...1124
6.2 Transmission Assembly...1125
6.2.1 Disassembly...1125
6.2.2 Reassembly...1126
6.3 Transmission...1127
6.3.1 Inspection Before Disassembly...1127
6.3.2 Disassembly and Inspection...1128
6.3.3 Reassembly...1130
6.4 Main Shaft...1134
6.4.1 Disassembly and Inspection...1134
6.4.2 Reassembly...1137
6.5 Counter Shaft...1139
6.5.1 Disassembly...1139
6.5.2 Reassembly...1140
6.6 Lower Gear Shifter...1141
6.6.1 Disassembly and Inspection...1141
6.6.2 Reassembly...1143
6.7 Upper Gear Shifter...1144
6.7.1 Disassembly and Inspection...1144
6.7.2 Reassembly...1145
6.8 Upper Splitter <M8S2x5 Only>...1147
6.8.1 Disassembly...1147
6.8.2 Reassembly...1147
6.9 Rear Cover...1148
6.9.1 Disassembly and Inspection...1148
6.9.2 Reassembly...1149
6.10 Splitter Case and Gear <M8S2x5 Only>...1150
6.10.1 Inspection Before Disassembly...1150
6.10.2 Disassembly and Inspection...1151
6.10.3 Reassembly...1153
6.11 Power Shift...1155
6.11.1 Disassembly and Inspection...1155
6.11.2 Reassembly...1156
6.12 Splitter Control <M8S2x5 Only>...1157
6.12.1 Splitter Air Piping...1157
6.12.2 Power Cylinder...1157
6.13 Transmission Control...1159
6.13.1 Disassembly and Inspection...1159
6.13.2 Reassembly...1160
6.13.3 Adjustment After Installation...1161
Group 23 - Automatic Transmission...1162
Table of Contents...1163
1. Troubleshooting...1164
2. Specification...1166
3. Service Standards...1166
3.1 Service Standards Table...1166
3.2 Tightening Torque Table...1167
4. Special Tools...1168
5. General...1169
5.1 Automatic Transmission Control...1169
5.2 Oil Cooler...1170
6. Service Procedure...1171
6.1 Removal and Installation of Automatic Transmission...1171
6.1.1 Removal...1171
6.1.2 Installation...1173
6.2 Oil Seal and Speedometer Worm...1175
6.2.1 Removal and Installation...1175
6.2.2 Replacement of Front Oil Seal...1176
6.2.3 Replacement of Rear Oil Seal...1176
6.2.4 Replacement of Speedometer Worm...1176
6.3 Automatic Transmission Control System...1178
6.3.1 Removal and Installation...1178
6.3.2 Inspection After Installation...1179
6.4 Oil Cooler...1180
6.4.1 Removal and Installation...1180
6.5 Oil Filter...1180
6.5.1 Removal and Installation...1180
6.6 Replacement of Oil and Oil Filter...1181
Group 25 - Propeller Shaft...1183
Table of Contents...1184
1. Troubleshooting...1185
2. Specifications...1186
3. Service Standards...1186
3.1 Service Standards Table...1186
3.2 Tightening Torque Table...1186
4. Special Tools...1187
5. General...1188
6. Service Procedure...1189
6.1 Removal and Installation...1189
6.2 Front Propeller Shaft...1190
6.2.1 Disassembly and Inspection...1190
6.2.2 Reassembly...1194
6.3 Rear Propeller Shaft...1197
6.3.1 Disassembly and Inspection...1197
6.3.2 Reassembly...1199
6.4 Adjustment After Reassembly...1201
Group 26 - Front Axle...1203
Table of Contents...1204
1. Troubleshooting...1205
2. Specifications...1206
3. Service Standards...1207
3.1 Service Standards Table...1207
3.2 Tightening Torque Table...1208
4. Special Tools...1209
5. General...1212
6. Service Procedure...1213
6.1 Removal and Installation...1213
6.2 Wheel Hub and Brake Drum...1214
6.2.1 Disassembly, Inspection, and Corrections...1214
6.2.2 Reassembly...1216
6.3 Front Axle, Knuckle, and Kingpin...1220
6.3.1 Disassembly and Inspection...1220
6.3.2 Reassembly...1223
6.4 Inspection and Adjustment After Installation...1226
Group 27 - Rear Axle...1230
Table of Contents...1231
1. Troubleshooting...1232
2. Specifications...1233
3. Service Standards...1234
3.1 Service Standards Table...1234
3.2 Tightening Torque Table...1235
4. Special Tools...1236
5. General...1241
6. Service Procedure...1242
6.1 Removal and Installation...1242
6.2 Wheel Hub and Brake Drum...1243
6.2.1 Disassembly, Inspection, and Corrections...1243
6.2.2 Reassembly...1245
6.3 Reduction and Differential...1250
6.3.1 Removal...1250
6.3.2 Inspection Before Disassembly...1250
6.3.3 Disassembly and Inspection...1252
6.3.4 Reassembly...1255
Group 31 - Wheel and Tire...1264
Table of Contents...1265
1. Troubleshooting...1266
2. Specifications...1266
3. Service Standards...1267
3.1 Service Standards Table...1267
3.2 Tightening Torque Table...1267
4. General...1267
5. Service Procedure...1268
5.1 Removal...1268
5.2 Disassembly and Reassembly...1270
5.2.1 Tire With Tube...1270
5.2.2 Tubeless Tire...1275
5.3 Inspection and Correction...1278
5.4 Installation...1281
Group 33 - Front Suspension...1283
Table of Contents...1284
1. Troubleshooting...1285
2. Specifications...1285
3. Service Standards...1286
3.1 Service Standards Table...1286
3.2 Tightening Torque Table...1286
4. Special Tools...1287
5. General...1287
6. Service Procedure...1288
6.1 Removal and Installation...1288
6.2 Disassembly, Inspection, and Correction...1289
6.3 Installation...1292
Group 34 - Rear Suspension...1294
Table of Contents...1295
1. Troubleshooting...1296
2. Specifications...1296
3. Service Standards...1297
3.1 Service Standards Table...1297
3.2 Tightening Torque Table...1297
4. Special Tools...1298
5. General...1299
6. Service Procedure...1300
6.1 Removal and Installation...1300
6.2 Disassembly, Inspection, and Correction...1302
6.3 Installation...1305
Group 35A - Brake (Air Over Hydraulic Brake)...1307
Table of Contents...1308
1. Troubleshooting...1309
2. Specifications...1312
2.1 Service Brake...1312
2.2 Wheel Brake...1313
2.3 Exhaust Brake...1313
3. Service Standards...1313
3.1 Service Standards Table...1313
3.1.1 Service Brake...1313
3.1.2 Wheel Brake...1316
3.1.3 Exhaust...1316
3.2 Tightening Torque Table...1317
3.2.1 Service Brake...1317
3.2.2 Wheel Brake...1318
3.2.3 Exhaust Brake...1318
4. Special Tools...1319
5. General...1323
5.1 Service Brake...1323
5.2 Air Compressor...1324
5.3 Air Drier...1325
5.4 Dual Brake Valve...1327
5.5 Brake Booster (Airmaster)...1329
5.6 Air Pressure Governor...1331
5.7 Exhaust Brake System...1332
6. Service Procedure...1333
6.1 Brake System Diagram...1333
6.2 Service Brake Equipment...1334
6.2.1 Air Compressor...1334
6.2.2 Air Drier...1341
6.2.3 Brake Pedal and Dual Brake Valve...1344
6.2.4 Brake Booster (Airmaster)...1351
6.2.5 Air Pressure Governor...1357
6.2.6 Check Valve...1360
6.2.7 Supply Valve...1361
6.2.8 Safety Valve...1362
6.2.9 Low Air Pressure Switch...1362
6.2.10 Stop Lamp Switch...1362
6.3 Wheel Brake...1363
6.3.1 Front Wheel Brake...1363
6.3.2 Front Wheel Cylinder...1366
6.3.3 Rear Wheel Brake...1367
6.3.4 Rear Wheel Cylinder...1370
6.4 Inspection and Adjustment After Installation...1371
6.4.1 Shoe Clearance Adjustment...1371
6.4.2 Replacement of Brake Fluid and Bleeding of Brake System...1372
6.5 Exhaust Brake...1373
6.5.1 Exhaust Brake Unit...1373
6.5.2 Control Cylinder...1376
6.5.3 Exhaust Brake Control...1377
6.5.4 Adjustment and Inspection After Installation...1378
Group 35B - Brake (Full Air Brake)...1379
Table of Contents...1380
1. Troubleshooting...1381
2. Specifications...1383
2.1 Service Brake...1383
2.2 Wheel Brake...1384
2.3 Exhaust Brake...1384
3. Service Standards...1385
3.1 Service Standards Table...1385
3.1.1 Service Brake...1385
3.1.2 Wheel Brake...1387
3.1.3 Exhaust Brake...1388
3.2 Tightening Torque Table...1388
3.2.1 Service Brake...1388
3.2.2 Wheel Brake...1390
3.2.3 Exhaust Brake...1390
4. Special Tools...1391
5. General...1393
5.1 Service Brake...1393
5.2 Air Compressor...1394
5.3 Air Drier...1395
5.4 Dual Brake Valve...1397
5.5 Air Pressure Governor...1399
5.6 Exhaust Brake System...1400
6. Service Procedure...1401
6.1 Brake System Diagram...1401
6.2 Service Brake Equipment...1402
6.2.1 Air Compressor...1402
6.2.2 Air Drier...1408
6.2.3 Brake Pedal and Dual Brake Valve...1412
6.2.4 Air Pressure Governor...1419
6.2.5 Check Valve...1421
6.2.6 Supply Valve...1422
6.2.7 Safety Valve...1423
6.2.8 Low Air Pressure Switch...1423
6.2.9 Stop Lamp Switch...1424
6.2.10 Relay Valve...1424
6.2.11 Quick Release Valve...1426
6.2.12 Double Check Valve...1427
6.2.13 Air Check Valve...1428
6.3 Wheel Brake...1428
6.3.1 Front Wheel Brake...1428
6.3.2 Front Brake Chamber...1432
6.3.3 Rear Wheel Brake...1433
6.3.4 Rear Brake Chamber...1437
6.4 Inspection and Adjustment After Installation...1439
6.4.1 Adjustment of Brake Shoe Clearance...1439
6.5 Exhaust Brake...1441
6.5.1 Exhaust Brake Unit...1441
6.5.2 Control Cylinder...1444
6.5.3 Exhaust Brake Control...1445
6.5.4 Adjustment and Inspection After Installation...1446
Group 36A - Parking Brake (Center Parking Brake)...1447
Table of Contents...1448
1. Troubleshooting...1449
2. Specifications...1449
3. Service Standards...1450
3.1 Service Standards Table...1450
3.2 Tightening Torque Table...1450
4. Special Tools...1450
5. General...1451
6. Service Procedure...1452
6.1 Parking Brake...1452
6.1.1 Removal and Installation...1452
6.1.2 Disassembly and Inspection...1452
6.1.3 Reassembly...1453
6.2 Parking Brake Control...1454
6.2.1 Removal and Installation...1454
6.2.2 Parking Brake Lever...1455
6.3 Adjustment...1456
Group 36B - Parking Brake (Wheel Parking Brake)...1457
Table of Contents...1458
1. Troubleshooting...1459
2. Service Standards...1459
2.1 Service Standards Table...1459
2.2 Tightening Torque Table...1459
3. General...1460
3.1 Parking Brake System...1460
3.2 Parking Brake Control Valve...1460
3.3 Spring Brake Valve...1461
4. Service Procedure...1463
4.1 Parking Brake Control Valve...1463
4.1.1 Disassembly...1463
4.1.2 Reassembly...1464
4.1.3 Inspection After Reassembly...1464
4.2 Spring Brake Valve...1465
4.2.1 Disassembly...1465
4.2.2 Reassembly...1466
4.2.3 Inspection After Reassembly...1466
Group 37 - Steering...1468
Table of Contents...1469
1. Troubleshooting...1470
2. Specifications...1474
3. Service Standards...1475
3.1 Service Standards Table...1475
3.2 Tightening Torque Table...1476
4. Special Tools...1477
5. General...1482
6. Service Procedure...1485
6.1 Removal and Installation...1485
6.2 Steering Shaft...1486
6.2.1 Removal...1486
6.2.2 Installation...1487
6.2.3 Disassembly, Inspection, and Correction...1488
6.2.4 Reassembly...1489
6.3 Link and Bracket Section...1490
6.3.1 Disassembly...1490
6.3.2 Reassembly...1491
6.4 Drag Link...1492
6.5 Tie Rod...1493
6.6 Integral Power Steering Booster...1494
6.6.1 Disassembly, Inspection, and Correction...1494
6.6.2 Reassembly and Adjustment...1498
6.7 Power Steering Oil Pump...1504
6.7.1 Removal...1504
6.7.2 Installation...1504
6.7.3 Disassembly, Inspection, and Correction...1504
6.7.4 Reassembly...1506
6.7.5 Adjustment...1508
6.8 Power Steering Oil Tank...1508
6.8.1 Disassembly...1508
6.8.2 Reassembly...1508
6.9 Adjustment After Installation...1509
6.9.1 Bleeding...1509
6.9.2 Performance Verification Tests...1509
6.9.3 Steering Wheel Play...1510
6.9.4 Adjustment of Steering Angle...1510
Group 41 - Frame...1511
Table of Contents...1512
1. General...1513
2. Service Procedure...1513
2.1 Inspection and Repair...1513
2.1.1 Frame...1513
2.1.2 Rivets...1516
Group 42 - Cab...1517
Table of Contents...1518
1. Troubleshooting...1519
2. Specifications...1521
3. Service Procedures...1521
3.1 Service Standards Table...1521
3.2 Tightening Torque Table...1521
4. General...1522
4.1 Cab Proper...1522
4.2 Cab Mounting...1523
4.2.1 Front Cab Mounting...1523
4.2.2 Rear Cab Mounting...1523
4.3 Cab Tilt System...1523
5. Service Procedure...1524
5.1 Removal...1524
5.1.1 Key Points for Removal...1524
5.1.2 Key Points for Installation...1526
5.1.3 Inspection and Adjustment After Installation...1527
5.2 Cab Mounting...1528
5.2.1 Front Cab Mounting...1528
5.2.2 Cab Stay...1530
5.2.3 Rear Cab Mounting...1531
5.2.4 Cab Tilt Link...1533
5.3 Doors...1536
5.3.1 Removal of Doors...1536
5.3.2 Door Installation Adjustment...1536
5.3.3 Front Door Assembly...1538
5.4 Interior Parts...1542
5.4.1 Seats and Center Console...1542
5.4.2 Seat Belts...1543
5.4.3 Floor Mat...1545
5.4.4 Overhead Console...1546
5.4.5 Trim and Headlining...1547
5.4.6 Instrument Panel...1549
5.5 Window Glass...1553
5.5.1 Removal...1553
5.5.2 Installation...1553
5.6 Exterior Parts...1555
5.6.1 Front Panel, Fender, and Allied Parts...1555
5.6.2 Rear View Mirrors...1557
Group 54 - Chassis Electrical...1558
Table of Contents...1559
1. Troubleshooting...1560
2. Specifications...1566
3. Service Standards...1568
4. General...1570
5. Service Procedure...1571
5.1 Battery...1571
5.1.1 General Description...1571
5.1.2 Inspection...1571
5.2 Fuses...1573
5.2.1 General Description...1573
5.2.2 Inspection...1574
5.3 Fusible Link...1575
5.3.1 General Description...1575
5.3.2 Inspection...1575
5.4 Starter Switch and Cold Starter Switch...1576
5.4.1 General Description...1576
5.4.2 Inspection...1577
5.5 Sub-Starter System...1578
5.5.1 General Description...1578
5.5.2 Inspection...1578
5.6 Combination Switch...1579
5.6.1 General Description...1579
5.6.2 Inspection...1580
5.7 Lighting System...1581
5.7.1 General Description...1581
5.7.2 Inspection...1582
5.7.3 Inspection and Adjustment After Installation...1583
5.8 Meter System...1584
5.8.1 General Description...1584
5.8.2 Inspection...1585
5.9 Indicators and Warning Lamps...1590
5.9.1 General Description...1590
5.9.2 Inspection...1592
5.10 Wiper and Washer System...1596
5.10.1 General Description...1596
5.10.2 Inspection...1597
5.10.3 Inspection and Adjustment After Installation...1600
5.11 Horn...1601
5.11.1 General Description...1601
5.11.2 Inspection...1601
5.12 Back-Up Buzzer...1602
5.12.1 General Description...1602
5.12.2 Inspection...1602
5.13 Radio and Cassette Stereo...1602
5.13.1 Mounting Position...1602
5.13.2 AM/FM Radio...1603
5.13.3 AM/FM Radio and Cassette Stereo...1603
5.13.4 Troubleshooting...1604
5.14 Cigarette Lighter...1605
5.14.1 General Description...1605
5.14.2 Inspection...1605
Wiring Diagram - FK <Manual Transmission>...1607
Wiring Diagram - FK <Automatic Transmission>...1608
Wiring Diagram - FM...1609
Group 55A - Air Conditioner...1610
Table of Contents...1611
1. Specifications...1612
2. Outlines of Refrigeration System...1613
2.1 Air System...1613
2.2 Refrigerating Cycle...1613
2.3 Electrical System...1614
3. Construction...1615
3.1 Engine Compartment...1615
3.2 Cab...1615
3.3 Control System...1616
3.4 Compressor and Magnetic Clutch...1618
3.4.1 Compressor...1618
3.4.2 Check Valve...1619
3.4.3 Magnetic Clutch...1619
3.5 Condenser...1619
3.6 Receiver Drier...1619
3.7 Cooling Unit...1620
3.8 Expansion Valve...1620
3.9 A/C Switch...1620
3.10 Thermo Sensor...1621
3.11 Power Relay...1621
3.12 Dual Pressure Switch...1621
4. Troubleshooting...1622
4.1 General Precautions...1622
4.2 Trouble, Cause, and Remedy...1623
4.3 Inspection Procedures...1625
4.3.1 A/C Switch...1625
4.3.2 Dual Pressure Switch...1625
4.3.3 Thermo Sensor...1626
4.3.4 Magnetic Clutch...1626
4.3.5 Refrigerant Charge...1626
4.3.6 Receiver Drier Assembly...1627
4.3.7 Belt Tension...1627
4.3.8 Expansion Valve...1627
4.3.9 Compressor...1628
4.3.10 Air Inclusion in Refrigerant Circuit...1628
4.3.11 Moisture Inclusion in Refrigerant Circuit...1628
5. Removal and Installation...1629
5.1 Precaution for Removal and Installation...1629
5.2 Removal...1629
5.2.1 Inside the Engine Compartment...1629
5.2.2 Inside the Cab...1630
5.3 Installation...1631
6. Treatment After Installation...1632
6.1 Check and Adjustment...1632
6.2 Leak Test...1632
6.2.1 Test Point...1632
6.2.2 Test Procedure...1632
6.3 Evacuation...1633
6.4 Gas Charge...1634
6.5 Checking the Refrigerant Level...1634
6.6 Performance Test...1635
6.6.1 Preparation...1635
6.6.2 Stationary Performance Test...1635
7. Cooling Unit...1636
7.1 Components...1636
7.2 Cautions in Disassembling...1637
7.3 Disassembling...1637
8. Maintenance...1638
9. Compressor...1639
9.1 Disassembling the Clutch...1639
9.2 Reassembly the Clutch...1640
9.3 Disassembling the Shaft Seal...1641
9.4 Reassembly the Shaft Seal...1642
9.5 Special Tool Figure...1644
Group 55B - Heater...1647
Table of Contents...1648
1. Troubleshooting...1649
2. Specifications...1650
3. General...1650
3.1 Ventilation System...1650
3.2 Heater...1651
4. Service Procedure...1652
4.1 Removal and Installation...1652
4.2 Cleaning of Air Filter...1653
4.3 Heater Control Adjustment Procedure...1654
FK.FM Series 1992-1995 Fuso Service Manual (TWME9107 - 1,252 pages)...1656
92-95 FK/FM Service Manual...1656
Compilation of This Manual...1657
Group 00 - General...1660
Group 00 - General [Supplement]...1661
Table of Contents...1662
Summary of Modifications...1663
Group 01 - Maintenance Schedule...1665
Group 35A - Brake (Air Over Hydraulic Brake)...1668
Group 35B - Brake (Full Air Brake)...1680
'95 Model Changes...1690
'94 Minor Change...1722
Table of Contents...1723
1. Differences of 1994 Model from 1993 Model...1724
2. Details of Change Due to Running Change Made on 1993 Model...1725
'93 Minor Change...1729
Table of Contents...1730
1. FK457 (Vehicles with M6S6)...1731
1.1 Major Specifications...1731
1.2 Power Train Table...1735
1.3 Operation Performance Curves...1736
2. Differences of 1993 Model from 1992 Model...1738
Group 00 - General...1740
Table of Contents...1741
1. Exterior Views...1742
2. Major Specifications...1744
3. Power Train Table...1751
4. Equipment Model Notation...1752
5. Peformance Curves...1753
5.1 Operation Performance Curves...1753
5.2 Engine Performance Curve...1763
6. Servicing Precautions...1763
7. Standard Bolts and Nuts Tightening Torque Table...1769
8. Towing Precautions...1770
9. Chassis and Engine Numbers...1770
10. Vehicle Identification Number...1771
Group 01 - Maintenance Schedule...1772
Table of Contents...1773
1. Using the Maintenance Schedule Table...1774
2. Maintenance Schedule...1775
2.1 Replacement of Oil Filter Element...1781
2.2 Replacement of Fuel Filter Element...1781
2.3 Cleaning of Fuel Feed Pump Gauze Filter...1782
2.4 Bleeding of Fuel System...1782
2.5 Adjustment of V-Belt Tension...1782
2.6 Cleaning and Replacement of Air Cleaner Element...1783
2.7 Inspection of Clutch Pedal...1784
2.7.1 Inspection of Pedal Play...1784
2.7.2 Clearance to Floorboard When Released...1784
2.7.3 Clutch Operation...1784
2.8 Servicing of Tires...1785
2.8.1 Tire Inflation Pressures...1785
2.8.2 Removal of Tire...1785
2.8.3 Installation of Tire...1786
2.8.4 Retightening of Wheel Nuts...1786
2.8.5 Tire Rotation...1787
2.9 Servicing of Air Drier...1787
2.10 Adjustment of Wheel Brake Shoe Clearance...1788
2.10.1 Air Over Hydraulic Brake <FK Series>...1788
2.10.2 Full Air Brake <FM Series>...1788
2.11 Adjustment of Parking Brake Shoe Clearance <FK Series>...1790
2.12 Servicing of Battery...1790
2.12.1 Cleaning of Battery Terminals...1791
2.12.2 Inspection of Fluid Level...1791
2.12.3 Specific Gravity...1791
2.13 Replacement of Fuses...1792
3. Lubrication...1794
3.1 Engine...1795
3.1.1 Engine Oil Level and Contamination...1795
3.1.2 Replacement of Engine Oil...1796
3.2 Clutch...1797
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank...1797
3.2.2 Replacement of Brake Fluid...1797
3.2.3 Bleeding of Clutch System...1798
3.3 Transmission...1798
3.3.1 Inspection of Transmission Gear Oil Level...1798
3.3.2 Replacement of Transmission Gear Oil...1799
3.4 Rear Axle...1799
3.4.1 Inspection of Rear Axle Gear Oil Level...1799
3.4.2 Replacement of Rear Axle Gear Oil...1799
3.5 Brake <FK Series>...1799
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank...1799
3.5.2 Replacement of Brake Fluid...1799
3.5.3 Bleeding of Brake System...1800
3.6 Power Steering...1801
3.6.1 Inspection of Power Steering Fluid Level...1801
3.6.2 Replacement of Power Steering Fluid...1801
3.6.3 Bleeding of Power Steering System...1802
3.7 Chassis Parts...1802
Group 11 - Engine...1804
Table of Contents...1805
1. Troubleshooting...1806
2. Specifications...1808
3. Service Standards...1809
3.1 Service Standards Table...1809
3.2 Tightening Torque Table...1812
4. Special Tools...1813
5. General...1818
6. Service Procedure...1821
6.1 Removal and Installation of Engine and Transmission...1821
6.2 Engine Proper...1826
6.2.1 Measurement of Compression Pressure...1826
6.2.2 Cylinder Head and Valve Mechanism...1827
6.2.3 Flywheel, Timing Gear and Camshaft...1839
6.2.4 Crankcase and Main Moving Parts...1851
6.2.5 Adjustment...1867
Group 12 - Lubrication...1868
Table of Contents...1869
1. Troubleshooting...1870
2. Specifications...1870
3. Service Standards...1871
3.1 Service Standards Table...1871
3.2 Tightening Torque Table...1871
4. Special Tools...1872
5. General...1872
6. Service Procedure...1878
6.1 Oil Pump...1878
6.1.1 Removal and Installation...1878
6.1.2 Disassembly and Inspection...1880
6.1.3 Reassembly...1882
6.2 Oil Cooler...1882
6.2.1 Removal and Installation...1882
6.2.2 Disassembly and Inspection...1883
6.3 Oil Filter...1884
Group 13 - Fuel and Engine Control...1885
Group 13 - Fuel and Engine Control...1886
Table of Contents...1887
1. Troubleshooting...1888
2. Specifications...1892
3. Service Standards...1893
3.1 Service Standards Table...1893
3.2 Tightening Torque Table...1893
4. Special Tools...1894
5. General...1895
5.1 Fuel System...1895
5.2 Engine Control...1900
6. Service Procedure...1901
6.1 Injection Pump Assembly...1901
6.1.1 Removal and Installation...1901
6.1.2 Inspection and Adjustment of Fuel Injection Timing...1904
6.1.3 Cleaning of Fuel Feed Pump Gauze Filter...1905
6.2 Injection Nozzle...1905
6.2.1 Removal and Installation...1905
6.2.2 Disassembly...1905
6.2.3 Cleaning and Inspection...1906
6.2.4 Reassembly...1907
6.2.5 Test and Adjustment...1907
6.3 Fuel Filter...1908
6.4 Water Separator...1909
6.5 Bleeding the Fuel System...1909
6.6 Engine Control...1910
6.6.1 Removal and Installation...1910
6.6.2 Inspection and Adjustment...1910
6.7 Fuel Tank and Fuel Gauge Unit...1912
Group 13A - Fuel and Engine Control <for 1995 Model>...1913
Table of Contents...1914
1. Troubleshooting...1915
2. Specifications...1918
3. Service Standards...1919
3.1 Service Standards Table...1919
3.2 Tightening Torque Table...1920
4. Special Tools...1921
5. General...1922
5.1 Fuel System...1922
5.2 Prestroke Control Type Injection Pump System...1927
5.3 Engine Control...1934
6. Service Procedure...1935
6.1 Injection Pump Assembly...1935
6.1.1 Removal and Installation...1935
6.1.2 Inspection and Adjustment of Fuel Injection Timing...1939
6.1.3 Cleaning of Fuel Feed Pump Gauze Filter...1939
6.1.4 Adjustment of No-Load Minimum and Maximum Speeds...1940
6.2 Inspection of Prestroke Control Type Injection Pump System...1941
6.2.1 Troubleshooting Procedures...1941
6.2.2 Inspection Items by Multi-Use Tester (MUT)...1945
6.2.3 Inspection on the Basis of DIAG Code...1946
6.2.4 Other Inspections...1960
6.2.5 Inspection of Transient Malfunctions...1964
6.3 Injection Nozzle...1965
6.3.1 Removal and Installation...1965
6.3.2 Disassembly...1965
6.3.3 Cleaning and Inspection...1965
6.3.4 Reassembly...1966
6.3.5 Test and Adjustment...1967
6.4 Fuel Filter...1968
6.5 Water Separator...1968
6.6 Bleeding the Fuel System...1969
6.7 Engine Control...1970
6.7.1 Removal and Installation...1970
6.7.2 Inspection and Adjustment...1972
6.8 Fuel Tank and Fuel Gauge Unit...1973
Group 14 - Cooling...1974
Table of Contents...1975
1. Troubleshooting...1976
2. Specifications...1977
3. Service Standards...1977
3.1 Service Standards Table...1977
3.2 Tightening Torque Table...1978
4. Special Tool...1978
5. General...1979
6. Service Procedure...1983
6.1 Removal and Installation of Cooling System...1983
6.2 Water Pump...1986
6.2.1 Disassembly and Inspection...1986
6.2.2 Reassembly...1988
6.3 Inspection of Thermostat...1989
6.4 Inspection of Auto-Cool Fan Coupling...1990
6.5 Inspection of Radiator...1990
6.6 Inspection and Adjustment of V-Belt Tension...1991
6.7 Cleaning of Cooling System...1991
6.8 Gas Leak Test...1994
6.9 Bleeding Cooling System...1994
Group 15 - Intake and Exhaust...1995
Table of Contents...1996
1. Troubleshooting...1997
2. Specifications...1998
3. Service Standards...1998
3.1 Service Standards Table...1998
3.2 Tightening Torque Table...1999
4. Special Tools...1999
5. General...2000
6. Service Procedure...2005
6.1 Removal, Installation and Inspection of Intake System...2005
6.2 Air Cleaner...2006
6.2.1 Disassembly and Reassembly...2006
6.2.2 Inspection and Cleaning...2006
6.3 Removal, Installation and Inspection of Exhaust System...2008
6.4 Turbocharger...2009
6.4.1 Removal and Installation...2009
6.4.2 Disassembly...2010
6.4.3 Cleaning and Inspection...2013
6.4.4 Reassembly...2016
6.4.5 Measurement of Turbocharger Boost Pressure...2022
6.5 Intercooler...2024
6.5.1 Removal and Installation...2024
6.5.2 Inspection...2024
Group 16 - Engine Electrical...2025
Table of Contents...2026
1. Troubleshooting...2027
2. Specifications...2028
3. Service Standards...2029
3.1 Service Standards Table...2029
3.2 Tightening Torque Table...2030
4. General...2031
4.1 Starter...2032
4.2 Alternator...2037
4.3 Glow System...2040
5. Service Procedure...2043
5.1 Starter...2043
5.1.1 Removal and Installation...2043
5.1.2 Disassembly...2043
5.1.3 Inspection...2046
5.1.4 Reassembly...2053
5.1.5 Inspection and Adjustment After Reassembly...2055
5.2 Alternator...2056
5.2.1 Removal and Installation...2056
5.2.2 Disassembly...2057
5.2.3 Inspection...2059
5.2.4 Reassembly...2063
5.2.5 Inspection and Adjustment After Installation...2064
5.3 Glow System...2067
5.3.1 Removal and Installation...2067
5.3.2 Inspection...2067
Group 21 - Clutch...2071
Table of Contents...2072
1. Troubleshooting...2073
2. Specifications...2076
3. Service Standards...2077
3.1 Service Standards Table...2077
3.2 Tightening Torque Table...2079
4. Special Tools...2080
5. General...2082
5.1 Clutch Proper...2082
5.2 Clutch Control...2083
5.2.1 Clutch Master Cylinder...2084
5.2.2 Clutch Booster...2085
6. Service Procedure...2087
6.1 Clutch...2087
6.1.1 Removal and Installation...2087
6.1.2 Disassembly and Inspection...2089
6.1.3 Reassembly and Adjustment...2093
6.2 Clutch Pedal...2095
6.2.1 Removal and Installation...2095
6.2.2 Disassembly and Inspection...2096
6.2.3 Reassembly and Adjustment...2099
6.3 Clutch Master Cylinder...2101
6.3.1 Disassembly and Inspection...2101
6.3.2 Reassembly...2103
6.4 Power Cylinder...2103
6.4.1 Removal and Installation...2103
6.4.2 Disassembly and Inspection...2104
6.4.3 Reassembly...2104
6.5 Clutch Booster (Vehicles with M8S2x5)...2105
6.5.1 Removal and Installation...2105
6.5.2 Disassembly and Inspection...2105
6.5.3 Reassembly...2108
6.5.4 Performance Test...2110
6.5.5 On-the-Vehicle Functional Check...2110
6.6 Clutch Housing...2112
6.6.1 Disassembly...2112
6.6.2 Reassembly...2113
6.7 Replacement of Brake Fluid in Clutch System...2115
6.8 Bleeding the Clutch System...2115
6.9 Adjustment of Clutch Pedal...2117
6.10 Lubrication of Drive Pinion Splines...2118
Group 22 - Manual Transmission...2119
Group 22A - Manual Transmission (M5S5, M6S5)...2120
Table of Contents...2121
1. Troubleshooting...2122
2. Specifications...2123
3. Service Standards...2124
3.1 Service Standards Table...2124
3.2 Tightening Torque Table...2126
4. Special Tools...2127
5. General...2130
6. Service Procedure...2132
6.1 Removal and Installation of Transmission...2132
6.1.1 Key Points for Removal...2132
6.1.2 Key Points for Installation...2134
6.1.3 Inspection and Adjustment After Installation...2134
6.2 Transmission Assembly...2135
6.2.1 Disassembly...2135
6.2.2 Reassembly...2136
6.3 Transmission...2137
6.3.1 Inspection Before Disassembly...2137
6.3.2 Disassembly and Inspection...2138
6.3.3 Reassembly...2141
6.4 Main Shaft...2145
6.4.1 Disassembly and Inspection...2145
6.4.2 Reassembly...2149
6.5 Counter Shaft...2151
6.5.1 Disassembly...2151
6.5.2 Reassembly...2152
6.6 Lower Gear Shifter...2153
6.6.1 Disassembly and Inspection...2153
6.6.2 Reassembly...2155
6.7 Upper Gear Shifter...2156
6.7.1 Disassembly and Inspection...2156
6.7.2 Reassembly...2157
6.8 Rear Cover...2159
6.8.1 Disassembly and Inspection...2159
6.8.2 Reassembly...2161
6.9 Transmission Control...2163
6.9.1 Disassembly and Inspection...2163
6.9.2 Reassembly...2164
6.9.3 Adjustment After Installation...2165
6.10 Transmission PTO Control <Option>...2166
6.10.1 Transmission PTO Control Circuit...2166
6.10.2 Inspection...2166
Group 22B - Manual Transmission (M8S5, M8S2x5)...2168
Table of Contents...2169
1. Troubleshooting...2170
2. Specifications...2171
2.1 Transmission Proper...2171
2.2 Transmission Control...2172
3. Service Standards...2172
3.1 Service Standards Table...2172
3.2 Tightening Torque Table...2175
4. Special Tools...2176
5. General...2181
6. Service Procedure...2183
6.1 Removal and Installation of Transmission...2183
6.1.1 Key Points for Removal...2183
6.1.2 Key Points for Installation...2184
6.1.3 Inspection and Adjustment After Installation...2185
6.2 Transmission Assembly...2186
6.2.1 Disassembly...2186
6.2.2 Reassembly...2187
6.3 Transmission...2188
6.3.1 Inspection Before Disassembly...2188
6.3.2 Disassembly and Inspection...2190
6.3.3 Reassembly...2196
6.4 Main Shaft...2202
6.4.1 Disassembly and Inspection...2202
6.4.2 Reassembly...2205
6.5 Counter Shaft...2208
6.5.1 Disassembly...2208
6.5.2 Reassembly...2209
6.6 Lower Gear Shifter...2210
6.6.1 Disassembly and Inspection...2210
6.6.2 Reassembly...2212
6.7 Upper Gear Shifter...2213
6.7.1 Disassembly and Inspection...2213
6.7.2 Reassembly...2214
6.8 Upper Splitter <M8S2x5 Only>...2216
6.8.1 Disassembly...2216
6.8.2 Reassembly...2216
6.9 Rear Cover <M8S2x5 Only>...2217
6.9.1 Disassembly and Inspection...2217
6.9.2 Reassembly...2218
6.10 Extension Housing <M8S6 Only>...2220
6.10.1 Disassembly and Inspection...2220
6.10.2 Reassembly...2221
6.11 Splitter Case and Gear <M8S2x5 Only>...2222
6.11.1 Inspection Before Disassembly...2222
6.11.2 Disassembly and Inspection...2223
6.11.3 Reassembly...2225
6.12 Power Shift...2227
6.12.1 Disassembly and Inspection...2227
6.12.2 Reassembly...2228
6.13 Splitter Control <M8S2x5 Only>...2229
6.13.1 Splitter Air Piping...2229
6.13.2 Power Cylinder...2230
6.14 Transmission Control...2231
6.14.1 Disassembly and Inspection...2231
6.14.2 Reassembly...2232
6.14.3 Adjustment After Installation...2233
6.15 Transmission PTO Control <Option>...2234
6.15.1 Transmission PTO Control Circuit...2234
6.15.2 Inspection...2234
Group 22C - Manual Transmission (M6S6)...2236
Table of Contents...2237
1. Troubleshooting...2238
2. Specifications...2239
3. Service Standards...2240
3.1 Service Standards Table...2240
3.2 Tightening Torque Table...2242
4. Special Tools...2244
5. General...2247
6. Service Procedure...2249
6.1 Removal and Installation of Transmission...2249
6.1.1 Key Points for Removal...2249
6.1.2 Key Points for Installation...2251
6.1.3 Inspection and Adjustment After Installation...2251
6.2 Transmission Assembly...2252
6.2.1 Disassembly...2252
6.2.2 Reassembly...2253
6.3 Transmission...2254
6.3.1 Inspection Before Disassembly...2254
6.3.2 Disassembly and Inspection...2255
6.3.3 Reassembly...2260
6.4 Main Shaft...2266
6.4.1 Disassembly and Inspection...2266
6.4.2 Reassembly...2270
6.5 Counter Shaft...2272
6.5.1 Disassembly...2272
6.5.2 Reassembly...2273
6.6 Lower Gear Shifter...2274
6.6.1 Disassembly and Inspection...2274
6.6.2 Reassembly...2276
6.7 Upper Gear Shifter...2277
6.7.1 Disassembly and Inspection...2277
6.7.2 Reassembly...2278
6.8 Extension Housing...2280
6.8.1 Disassembly and Inspection...2280
6.8.2 Reassembly...2281
6.9 Transmission Control...2283
6.9.1 Disassembly and Inspection...2283
6.9.2 Reassembly...2284
6.9.3 Adjustment After Installation...2286
Group 23 - Automatic Transmission...2287
Table of Contents...2288
1. Troubleshooting...2289
2. Specifications...2291
3. Service Standards...2291
3.1 Service Standards Table...2291
3.2 Tightening Torque Table...2292
4. Special Tools...2293
5. General...2294
5.1 Automatic Transmission Control...2294
5.2 Oil Cooler...2295
6. Service Procedure...2296
6.1 Removal and Installation of Automatic Transmission...2296
6.1.1 Removal...2296
6.1.2 Installation...2299
6.2 Oil Seal and Speedometer Worm...2301
6.2.1 Removal and Installation...2301
6.2.2 Replacement of Front Oil Seal...2302
6.2.3 Replacement of Rear Oil Seal...2302
6.2.4 Replacement of Speedometer Worm...2302
6.3 Automatic Transmission Control System...2304
6.3.1 Removal and Installation...2304
6.3.2 Inspection After Installation...2305
6.4 Oil Cooler...2306
6.4.1 Removal and Installation...2306
6.4.2 Inspection...2307
6.5 Oil Filter...2308
6.5.1 Removal and Installation...2308
6.6 Replacement of Fluid and Oil Filter...2309
Group 25 - Propeller Shaft...2312
Table of Contents...2313
1. Troubleshooting...2314
2. Specifications...2315
3. Service Standards...2315
3.1 Service Standards Table...2315
3.2 Tightening Torque Table...2315
4. Special Tools...2316
5. General...2317
6. Service Procedure...2318
6.1 Removal and Installation...2318
6.2 Front Propeller Shaft...2319
6.2.1 Disassembly and Inspection...2319
6.2.2 Reassembly...2323
6.3 Rear Propeller Shaft...2326
6.3.1 Disassembly and Inspection...2326
6.3.2 Reassembly...2328
6.4 Adjustment After Reassembly...2330
Group 26 - Front Axle...2332
Table of Contents...2333
1. Troubleshooting...2334
2. Specifications...2335
3. Service Standards...2336
3.1 Service Standards Table...2336
3.2 Tightening Torque Table...2337
4. Special Tools...2338
5. General...2341
6. Service Procedure...2342
6.1 Removal and Installation...2342
6.2 Wheel Hub and Brake Drum...2343
6.2.1 Disassembly, Inspection and Corrections...2343
6.2.2 Reassembly...2345
6.3 Front Axle, Knuckle and Kingpin...2349
6.3.1 Disassembly and Inspection...2349
6.3.2 Reassembly...2352
6.4 Inspection and Adjustment After Installation...2356
Group 27 - Rear Axle...2360
Table of Contents...2361
1. Troubleshooting...2362
2. Specifications...2363
3. Service Standards...2364
3.1 Service Standards Table...2364
3.2 Tightening Torque Table...2365
4. Special Tools...2366
5. General...2372
6. Service Procedure...2373
6.1 Removal and Installation...2373
6.2 Wheel Hub and Brake Drum...2374
6.2.1 Disassembly, Inspection and Corrections...2374
6.2.2 Reassembly...2376
6.3 Reduction and Differential...2381
6.3.1 Removal...2381
6.3.2 Inspection Before Disassembly...2381
6.3.3 Disassembly and Inspection...2383
6.3.4 Reassembly...2387
Group 31 - Wheel and Tire...2397
Table of Contents...2398
1. Troubleshooting...2399
2. Specifications...2399
3. Service Standards...2400
3.1 Service Standards Table...2400
3.2 Tightening Torque Table...2400
4. General...2400
5. Service Procedure...2401
5.1 Removal...2401
5.2 Disassembly and Procedure...2403
5.2.1 Tubeless Tire...2403
5.3 Inspection and Correction...2406
5.4 Installation...2409
Group 33 - Front Suspension...2411
Table of Contents...2412
1. Troubleshooting...2413
2. Specifications...2413
3. Service Standards...2414
3.1 Service Standards Table...2414
3.2 Tightening Torque Table...2414
4. Special Tools...2415
5. General...2415
6. Service Procedure...2416
6.1 Removal and Installation...2416
6.2 Disassembly, Inspection and Correction...2417
6.3 Installation...2421
Group 34 - Rear Suspension...2423
Table of Contents...2424
1. Troubleshooting...2425
2. Specifications...2425
3. Service Standards...2426
3.1 Service Standards Table...2426
3.2 Tightening Torque Table...2426
4. Special Tools...2427
5. General...2428
6. Service Procedure...2429
6.1 Removal and Installation...2429
6.2 Disassembly, Inspection and Correction...2431
6.3 Installation...2434
Group 35 - Brake...2436
Group 35A - Brake (Air Over Hydraulic Brake)...2437
Table of Contents...2438
1. Troubleshooting...2439
2. Specifications...2442
2.1 Service Brake...2442
2.2 Wheel Brake...2443
2.3 Exhaust Brake...2443
3. Service Standards...2443
3.1 Service Standards Table...2443
3.1.1 Service Brake...2443
3.1.2 Wheel Brake...2446
3.1.3 Exhaust Brake...2446
3.2 Tightening Torque Table...2447
3.2.1 Service Brake...2447
3.2.2 Wheel Brake...2448
3.2.3 Exhaust Brake...2448
4. Special Tools...2449
5. General...2450
5.1 Service Brake...2450
5.2 Air Compressor...2451
5.3 Air Dryer...2452
5.4 Dual Brake Valve...2454
5.5 Brake Booster (Airmaster)...2460
5.6 Air Pressure Governor...2463
5.7 Exhaust Brake System...2464
6. Service Procedure...2465
6.1 Brake System Diagram...2465
6.2 Service Brake Equipment...2466
6.2.1 Air Compressor...2466
6.2.2 Air Dryer...2473
6.2.3 Brake Pedal and Dual Brake Valve...2476
6.2.4 Brake Booster (Airmaster)...2484
6.2.5 Air Pressure Governor...2492
6.2.6 Check Valve...2495
6.2.7 Supply Valve...2496
6.2.8 Safety Valve...2497
6.2.9 Brake Fluid Tank...2498
6.3 Wheel Brake...2499
6.3.1 Front Wheel Brake...2499
6.3.2 Front Wheel Cylinder...2504
6.3.3 Rear Wheel Brake...2505
6.3.4 Rear Wheel Cylinder...2509
6.4 Inspection and Adjustment After Installation...2510
6.4.1 Shoe Clearance Adjustment...2510
6.4.2 Replacement of Brake Fluid and Bleeding of Brake System...2511
6.5 Exhaust Brake...2513
6.5.1 Exhaust Brake Unit...2513
6.5.2 Control Cylinder...2516
6.5.3 Exhaust Brake Control <Except A/T Vehicles>...2517
6.5.4 Adjustment and Inspection After Installation <Except A/T Vehicles>...2518
Group 35B - Brake (Full Air Brake)...2519
Table of Contents...2520
1. Troubleshooting...2521
2. Specifications...2523
2.1 Service Brake...2523
2.2 Wheel Brake...2524
2.3 Exhaust Brake...2524
3. Service Standards...2525
3.1 Service Standards Table...2525
3.1.1 Service Brake...2525
3.1.2 Wheel Brake...2527
3.1.3 Exhaust Brake...2528
3.2 Tightening Torque Table...2528
3.2.1 Service Brake...2528
3.2.2 Wheel Brake...2530
3.2.3 Exhaust Brake...2530
4. Special Tools...2531
5. General...2532
5.1 Service Brake...2532
5.2 Air Compressor...2533
5.3 Air Dryer...2534
5.4 Dual Brake Valve...2535
5.5 Air Pressure Governor...2541
5.6 Exhaust Brake System...2542
6. Service Procedure...2544
6.1 Brake System Diagram...2544
6.2 Service Brake Equipment...2545
6.2.1 Air Compressor...2545
6.2.2 Air Dryer...2551
6.2.3 Brake Pedal and Dual Brake Valve...2555
6.2.4 Air Pressure Governor...2562
6.2.5 Check Valve...2564
6.2.6 Supply Valve...2565
6.2.7 Safety Valve...2566
6.2.8 Relay Valve...2567
6.2.9 Quick Release Valve...2569
6.2.10 Double Check Valve...2570
6.2.11 Air Check Valve...2571
6.3 Wheel Brake...2571
6.3.1 Front Wheel Brake...2571
6.3.2 Front Brake Chamber...2577
6.3.3 Rear Wheel Brake...2578
6.3.4 Rear Brake Chamber...2584
6.4 Inspection and Adjustment After Installation...2586
6.4.1 Adjustment of Brake Shoe Clearance...2586
6.5 Exhaust Brake...2588
6.5.1 Exhaust Brake Unit...2588
6.5.2 Control Cylinder...2591
6.5.3 Exhaust Brake Control...2592
6.5.4 Adjustment and Inspection After Installation...2593
Group 36 - Parking Brake...2594
Group 36A - Parking Brake (Center Parking Brake)...2595
Table of Contents...2596
1. Troubleshooting...2597
2. Specifications...2597
3. Service Standards...2598
3.1 Service Standards Table...2598
3.2 Tightening Torque Table...2598
4. Special Tools...2598
5. General...2599
6. Service Procedure...2600
6.1 Parking Brake...2600
6.1.1 Removal and Installation...2600
6.1.2 Disassembly and Inspection...2600
6.1.3 Reassembly...2601
6.2 Parking Brake Control...2602
6.2.1 Removal and Installation...2602
6.2.2 Parking Brake Lever...2603
6.3 Adjustment...2604
Group 36B - Parking Brake (Wheel Parking Brake)...2605
Table of Contents...2606
1. Troubleshooting...2607
2. Service Standards...2607
2.1 Service Standards Table...2607
2.2 Tightening Torque Table...2607
3. General...2608
3.1 Parking Brake System...2608
3.2 Parking Brake Control Valve...2608
3.3 Spring Brake Valve...2609
4. Service Procedure...2611
4.1 Parking Brake Control Valve...2611
4.1.1 Disassembly...2611
4.1.2 Reassembly...2612
4.1.3 Inspection After Reassembly...2612
4.2 Spring Brake Valve...2613
4.2.1 Disassembly...2613
4.2.2 Reassembly...2614
4.2.3 Inspection After Reassembly...2614
Group 37 - Steering...2616
Table of Contents...2617
1. Troubleshooting...2618
2. Specifications...2622
3. Service Standards...2623
3.1 Service Standards Table...2623
3.2 Tightening Torque Table...2624
4. Special Tools...2625
5. General...2629
6. Service Procedure...2632
6.1 Removal and Installation...2632
6.2 Steering Shaft...2633
6.2.1 Removal...2633
6.2.2 Installation...2634
6.2.3 Disassembly, Inspection and Correction...2635
6.2.4 Reassembly...2636
6.3 Link and Bracket Section...2637
6.3.1 Disassembly...2637
6.3.2 Reassembly...2638
6.4 Drag Link...2639
6.5 Tie Rod...2640
6.6 Integral Power Steering Booster...2641
6.6.1 Disassembly, Inspection and Correction...2641
6.6.2 Reassembly and Adjustment...2645
6.7 Power Steering Oil Pump...2651
6.7.1 Removal...2651
6.7.2 Installation...2652
6.7.3 Disassembly, Inspection and Correction...2652
6.7.4 Reassembly...2654
6.7.5 Adjustment...2656
6.8 Power Steering Oil Tank...2656
6.8.1 Disassembly...2656
6.8.2 Reassembly...2656
6.9 Adjustment After Installlation...2657
6.9.1 Bleeding...2657
6.9.2 Performance Verification Tests...2657
6.9.3 Steering Wheel Play...2658
6.9.4 Adjustment of Steering Angle...2658
Group 41 - Frame...2659
Table of Contents...2660
1. General...2661
2. Service Procedure...2661
2.1 Inspection and Repair...2661
2.1.1 Frame...2661
2.1.2 Rivets...2664
2.1.3 Bolts and Nuts...2664
Group 42 - Cab...2665
Table of Contents...2666
1. Troubleshooting...2667
2. Specifications...2669
3. Service Standards...2669
3.1 Service Standards Table...2669
3.2 Tightening Torque Table...2669
4. General...2670
4.1 Cab Proper...2670
4.2 Cab Mounting...2671
4.2.1 Front Cab Mounting...2671
4.2.2 Rear Cab Mounting...2671
4.3 Cab Tilt System...2671
5. Service Procedure...2672
5.1 Removal...2672
5.1.1 Key Points for Removal...2672
5.1.2 Key Points for Installation...2674
5.1.3 Inspection and Adjustment After Installation...2675
5.2 Cab Mounting...2676
5.2.1 Front Cab Mounting...2676
5.2.2 Cab Stay...2678
5.2.3 Rear Cab Mounting...2679
5.2.4 Cab Tilt Link...2681
5.3 Doors...2684
5.3.1 Removal of Doors...2684
5.3.2 Doors Installation Adjustment...2684
5.3.3 Front Door Assembly...2686
5.4 Interior Parts...2690
5.4.1 Seats and Center Console...2690
5.4.2 Air Suspension...2691
5.4.3 Seat Belts (3-Point Type Seat Belts with ELR)...2693
5.4.4 Floor Mat...2695
5.4.5 Overhead Console...2696
5.4.6 Trim and Headlining...2697
5.4.7 Instrument Panel...2699
5.5 Window Glass...2703
5.5.1 Removal...2703
5.5.2 Installation...2703
5.6 Exterior Parts...2705
5.6.1 Front Panel, Fender and Allied Parts...2705
5.6.2 Rear View Mirrors...2707
Group 54 - Electrical...2708
Table of Contents...2709
1. Troubleshooting...2710
2. Specifications...2716
3. Service Standards...2718
4. General...2721
5. Service Procedure...2724
5.1 Battery...2724
5.1.1 General Description...2724
5.1.2 Inspection...2724
5.2 Fuses...2726
5.2.1 General Description...2726
5.2.2 Inspection...2727
5.3 Fusible Link...2729
5.3.1 General Description...2729
5.3.2 Inspection...2729
5.4 Starter Switch and Cold Start Switch...2730
5.4.1 General Description...2730
5.4.2 Inspection...2731
5.5 Sub-Starter System...2732
5.5.1 General Description...2732
5.5.2 Inspection...2732
5.6 Combination Switch...2733
5.6.1 General Description...2733
5.6.2 Inspection...2734
5.7 Lighting System...2735
5.7.1 General Description...2735
5.7.2 Inspection...2739
5.7.3 Inspection and Adjustment After Installation...2743
5.8 Meter System...2744
5.8.1 General Description...2744
5.8.2 Inspection...2745
5.9 Indicators and Warning Lamps...2749
5.9.1 General Description...2749
5.9.2 Inspection...2752
5.10 Wiper and Washer System...2756
5.10.1 General Description...2756
5.10.2 Inspection...2757
5.10.3 Inspection and Adjustment After Installation...2760
5.11 Horn...2762
5.11.1 General Description...2762
5.11.2 Inspection...2762
5.12 Back Buzzer...2763
5.12.1 General Description...2763
5.12.2 Inspection...2763
5.13 Radio and Cassette Stereo <Option>...2763
5.13.1 Mounting Position...2763
5.13.2 AM/FM Radio and AM/FM Radio With Cassette Stereo...2764
5.13.3 Troubleshooting...2765
5.14 Cigarette Lighter...2766
5.14.1 General Description...2766
5.14.2 Inspection...2766
Group 55A - Air Conditioner...2768
Group 55A (9107) - Air Conditioner...2769
Foreword/Table of Contents...2770
1. Specifications...2771
2. Outlines of Refrigeration System...2772
2.1 Air System...2772
2.2 Refrigerating Cycle...2772
2.3 Electrical System...2773
3. Construction...2774
3.1 Engine Room...2774
3.2 Cabin Room...2774
3.3 Control System...2775
3.4 Compressor and Magnetic Clutch...2777
3.4.1 Compressor...2777
3.4.2 Check Valve...2778
3.4.3 Magnetic Clutch...2778
3.5 Condenser...2778
3.6 Receiver Drier...2778
3.7 Cooling Unit...2779
3.8 Expansion Valve...2779
3.9 Dual Pressure Switch...2780
3.10 Power Relay...2780
3.11 A/C Switch...2780
3.12 Fin Thermo...2780
4. Troubleshooting...2781
4.1 General...2781
4.2 Trouble Cause and Remedy...2782
4.3 Inspection Procedures...2784
4.3.1 A/C Switch...2784
4.3.2 Dual Pressure Switch...2784
4.3.3 Fin Thermo...2785
4.3.4 Magnetic Clutch...2785
4.3.5 Refrigerant Charge...2785
4.3.6 Receiver Drier Assembly...2786
4.3.7 Belting Tension...2786
4.3.8 Expansion Valve...2786
4.3.9 Compressor...2787
4.3.10 Air Inclusion in Ref. Circuit...2787
4.3.11 Moisture Inclusion in Ref. Circuit...2787
5. Removal and Installation...2788
5.1 Precautions for Removal and Installation...2788
5.2 Removal...2788
5.2.1 Inside the Engine Room...2788
5.2.2 Cabin Room...2789
6. Treatment After Installation...2791
6.1 Check and Adjustment...2791
6.2 Leak Test...2791
6.2.1 Test Points...2791
6.2.2 Test Procedure...2791
6.4 System Charging...2792
6.4.1 Installation of Charge Equipment...2793
6.4.2 Charging System...2793
6.4.3 Charging With Small Cans...2794
6.4.5 Correcting Low Refrigerant Level...2795
6.4.6 Discharging System...2795
6.5 Checking the Refrigerant Level...2795
6.6 Performance Test...2796
6.6.1 Preparation...2796
6.6.2 Stationary Performance Test...2796
7. Compressor...2797
7.1 Compressor...2797
7.2 Disassembly and Reassembly Precautions...2798
7.2.1 Disassembly Precautions...2798
7.2.2 Reassembly Precautions...2798
7.2.3 Tools and Instruments...2798
7.3 Precautions at Disassembly...2799
7.4 Maintenance and Check...2807
7.4.1 Inspection Standards...2807
7.4.2 Consumable Parts...2808
7.5 Assembly Procedure...2811
7.5.1 Tightening Torque...2811
7.5.2 Assembly Procedure...2812
7.6 Special Tool Figure...2821
8. Cooling Unit...2831
8.1 Components...2831
8.2 Cautions in Disassembling...2832
8.3 Disassembling...2832
9. Maintenance...2833
Group 55A (9403) - Air Conditioner...2834
Table of Contents...2835
1. Specifications...2836
2. Outlines of Refrigeration System...2837
2.1 Air System...2837
2.2 Refrigerating Cycle...2837
2.3 Electrical System...2838
3. Construction...2839
3.1 Engine Room...2839
3.2 Cabin Room...2839
3.3 Control System...2840
3.4 Compressor and Magnetic Clutch...2842
3.4.1 Compressor...2842
3.4.2 Check Valve...2843
3.4.3 Magnetic Clutch...2843
3.5 Condenser...2843
3.6 Receiver Assembly...2843
3.7 Cooling Unit Assembly...2844
3.8 Expansion Valve...2844
3.9 Relief Valve...2844
3.10 Dual Pressure Switch...2845
3.11 Power Relay...2845
3.12 A/C Switch...2845
3.13 Fin Thermo...2845
4. Troubleshooting...2846
4.1 General Procedure...2846
4.2 Trouble Cause and Remedy...2847
4.3 Inspection Procedures...2849
4.3.1 A/C Switch...2849
4.3.2 Dual Pressure Switch...2849
4.3.3 Fin Thermo...2850
4.3.4 Magnetic Clutch...2850
4.3.5 Refrigerant Charge...2850
4.3.6 Receiver Assembly...2851
4.3.7 Belting Tension...2851
4.3.8 Expansion Valve...2851
4.3.9 Compressor...2852
4.3.10 Air Inclusion in Ref. Circuit...2852
4.3.11 Moisture Inclusion in Ref. Circuit...2852
5. Removal and Installation...2853
5.1 Precautions for Removal and Installation...2853
5.2 Removal...2853
5.2.1 Inside the Engine Room...2853
5.2.2 Cabin Room...2854
6. Treatment After Installation...2856
6.1 Check and Adjustment...2856
6.2 Leak Test...2856
6.2.1 Test Points...2856
6.2.2 Test Procedure...2856
6.3 System Charging...2857
6.3.1 Evacuation...2858
6.3.2 Evacuate the System...2858
6.3.3 Removal of Charge Equipment...2860
6.3.4 Discharging System...2860
6.4 Checking the Refrigerant Level...2860
6.5 Performance Test...2861
6.5.1 Preparation...2861
6.5.2 Stationary Performance Test...2861
7. Compressor...2862
7.1 Component of Compressor...2862
7.2 Disassembly and Reassembly Precautions...2863
7.2.1 Disassembly Precautions...2863
7.2.2 Reassembly Precautions...2863
7.2.3 Tools and Instruments...2863
7.3 Precautions at Disassembly...2864
7.4 Maintenance and Check...2872
7.4.1 Inspection Standards...2872
7.4.2 Consumable Parts...2873
7.5 Assembly Procedure...2876
7.5.1 Tightening Torque...2876
7.5.2 Assembly Procedure...2877
9.5 Special Tool Figure...2886
8. Cooling Unit...2896
8.1 Components...2896
8.2 Cautions in Disassembling...2897
8.3 Disassembling...2897
9. Maintenance...2898
Group 55B - Heater...2899
Table of Contents...2900
1. Troubleshooting...2901
2. Specifications...2902
3. General...2902
3.1 Ventilation System...2902
3.2 Heater...2903
4. Service Procedure...2904
4.1 Removal and Installation...2904
4.2 Cleaning of Air Filter...2905
4.3 Heater Control Adjustment Procedures...2906
FK.FM Series 1996-2001 Fuso Service Manual (TWME9503 - 1,909 pages)...2908
GR00 GENERAL...2908
GR00 97MC...2951
GR00 98MC...2971
GR00 99MC...2998
GR00 00MC...3048
GR00 01MC...3104
GR01 Maintenance Schedule...3159
GR10 REMOVAL AND ISTALLATION OF ENGINE...3203
GR11 ENGINE...3211
GR12 LUBRICATION...3274
GR13 FUEL AND ENGINE CONTROL...3297
GR13 MC99 FUEL AND ENGINE CONTROL '99 Minor changes...3371
GR14 COOLING...3455
GR15 INTAKE AND EXHAUST...3481
GR21 CLUTCH...3513
GR22A MANUAL TRANSMISSION M060S5,S6,M070S6...3571
GR22A MANUAL TRANSMISSIO UPDATE...3656
GR22B MANUAL TRANSMISION M8S2X5...3749
GR23 AUTOMATIC TRANSMISSION...3820
GR23 AUTOMATIC TRANSMISSION 2001 MODEL YEAR CHANGE...3851
GR25 PROPELLER SHAFT...3930
GR26 FRONT AXLE...3965
GR27 REAR AXLE...4000
GR31 WHEEL AND TIRE...4046
GR33 FRONT SUSPENSION...4054
GR34 REAR SUSPENSION...4067
GR35A BRAKE...4081
GR35B BRAKE FULL AIR BRAKE...4183
GR35C ABS '99 MINOR CHANGE...4279
GR36A PARKING BRAKE...4361
GR36B Parking Brake...4375
GR37 STEERING...4389
GR41 FRAME...4434
GR42 CAB...4441
GR54 ELECTRICAL...4514
GR55A AIR- CONDITIONER...4765
GR55B Heater...4799
Mitsubishi Fuso FK.FM Series Repair Service Manual 1986-2001
