1986 1987 Mitsubishi Fuso FK FM Series Truck Service Manual – PDF DOWNLOAD
DESCRIPTION:
1986 1987 Mitsubishi Fuso FK FM Series Truck Service Manual – PDF DOWNLOAD
FOREWORD:
This service manual contains the instructions for the servicing of the Mitsubishi Fuso FK, FM series trucks ENGINE ELECTRICAL Please make the most of this service manual to perform correct servicing and wasteless operations . Note that some of the contents of this service manual are subject to change owing to improvements, etc that may be introduced after publication of the service manual
INDEX:
1986 1987 Mitsubishi Fuso FK FM Series Truck Service Manual – PDF DOWNLOAD
Adjustment of clutch control [C5W33] 21-14 Engine control 13-36
Adjustment of clutch control [C6W35j 21-19 Engine proper 11-10
Air cleaner 15-12 Exhaust brake microswitch 35-80
Air compressor 11-52 Exhaust brake valve 35-77
Air drier 35-47 Exhaust manifold 15-14
Air pressure governor 35-43
Alternator 16-9 F
Auto cool fan coupling 14-6 Feed pump 13-30
Autotimer 13-27 Froor mat 42-13
Frame 41-2
B Front axle knuckle and kingpin (Front) 26-11
Bleeding clutch system [C5W33] 21-13 Front suspension 33-2
Bleeding clutch system [C6W35] 21-18 Fuel filter 13-35
Bleeding the fuel system 13-35
Brake booster 35-32 G
Brake pedal and air brake valve 35-25 Gearshifter, lower [M5S5] 22-23
Brake system diagram 35-23 Gearshifter, lower [M6S5] 22-23
Gearshifter, lower [M8S2x5] 22-25
C Gearshifter, upper [M5S5] 22-27
Chassis electrical 54-2 Gearshifter, upper [M6S5] 22-27
Check valve 35-45 Gearshifter, upper [M8S2x5] 22-29
Cleaning of cooling system 14-15 Glow plug system 16-15
Clutch booster [C6W35] 21-14 Governor 13-19
Clutch master cylinder [C5W33] 21-11
Clutch master cylinder [C6W35] 21-13 H
Clutch pedal [C5W33] 21-10 Heater 55-2
Clutch pedal [C6W35] 21-12
Clutch power cylinder [C5W33] 21-12
Clutch proper [C5W33] 21-6 Injection nozzle 13-31
Clutch proper [C6W35] 21-8 Injection pump 13-10
Control cylinder 35-79 Inlet manifold 15-14
Counter shaft Gear [M8S2x5j 22-20 Inspection of clutch disc wear [C6W35] 21-17
Counter shaft gear [M5S5] 22-18 Instrument panel 42-17
Counter shaft gear [M6S5] 22-18 Integral power steering booster 37-13
Details of link and bracket section 37-12 Low air pressure switch 35-46
Disassembly and reassembly of steering M
wheel 37-10
Doors 42-6
Main shaft [M5S5] 22-14
Drag link
Drive pinion [M5S5]
Drive pinion [M6S5]
Main shaft [M6S5]
Main shaft [M8S2x5]
Maintenance schedule
Drive pinion [M8S2x5] 22-24
ALPHABETICAL INDEX
Oil filter, oil cooler 12-13 Safety valve 35-46
Oil pump 12-9 Seats 42-12
Overhead console ,, 42-14 Shape of frame 41-4
Speedometer gears [M5S5] 22-31
P Speedometer gears [M6S5] 22-31
Parking brake drum assembly 35-69 Speedometer gears [M8S2x5] 22-34
Parking brake proper 35-70 Splitter case and gears [M8S2x5] 22-35
PCV (Positive Crankcase Ventilation) Splitter control [M8S2x5] 22-39
valve [6014J 15-15 Splitter, upper [M8S2x5] 22-31
Power shift [M8S2x5] 22-37 Starter 16-6
Power steering oil pump 37-19 Steering shaft 37-11
Power steering oil tank 37-21 Stop lamp switch 35-46
Propeller shaft 25-2 Supply valve 35-47
Radiator 14-11 Thermostat 14-10
Rear cover [M5S5] 22-29 Tie rod 37-13
Rear cover [M6S5] 22-29 Transmission assembly [M5S5] 22-10
Rear cover [M8S2x5] 22-33 Transmission assembly [M6S5] 22·10
Rear suspension 34-2 Transmission assembly [M8S2x5! 22-12
Rearview mirrors 42-19 Transmission control [M5S5] 22-31
Reassembly of clutch housing [M5S5] 22-22 Transmission control [M6S5] 22-31
Reassembly of clutch housing [M6S5] 22-22 Transmission control [M8S2x5] 22-41
Reassembly of clutch housing [M8S2x5] 22-25 Trims 42-15
Reduction and differential (Rear) 27-11 Turbocharger [6014T] 15-5
Regulator valve, check valve [6014T] 12-15
Removal of front panel and related parts 42-20 W
Replacement of clutch system fluid
[C5W33]
Replacement of clutch system fluid
Water pump
Water separator
Wheel and tire
Reservoirtank 14-14 Wheel brake 35-51
Reverse gear [M5S5j 22-20 Wheel hub and brake drum (Front) 26-6
Reverse gear [M6S5] 22-20 Wheel hub and brake drum (Rear) 27-6
Reverse gear [M8S2x5] 22-23 Windshield glass and rear window glass 42-17
Rivets 41-3
TABLE OF CONTENTS:
1986 1987 Mitsubishi Fuso FK FM Series Truck Service Manual – PDF DOWNLOAD
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
51 Operation Performance Curves 16
52 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
21 Replacement of Oil Filter Element 36
22 Replacement of the Fuel Filter Element 36
23 Cleaning of the Fuel Feed Pump Gauze Filter 37
24 Bleeding of the Fuel System 37
25 Adjustment of V-Belt Tension 37
26 Cleaning and Replacement of Air Cleaner Element 38
261 Dry Dust Buildup 38
262 Oil Smoke, Soot, and Oil Black Deposits 38
263 Inspection After Drying 39
27 Inspection of Clutch Pedal 39
271 Inspection of Pedal Play 39
272 Clearance to Floorboard When Released 39
273 Clutch Operation 39
28 Servicing of Tires 40
281 Tire Inflation Pressure 40
282 Removal of Tire 40
283 Installation of Tire 41
284 Retightening of Wheel Nuts 41
285 Tire Rotation 42
29 Servicing of Air Drier 42
210 Adjustment of Wheel Brake Shoe Clearance 42
2101 Adjusting Gear Type [FK415, FK455] 42
2102 Adjusting Cam Type [FM555] 43
211 Adjustment of Parking Brake Shoe Clearance 44
212 Servicing of Battery 45
2121 Cleaning of Battery Terminals 45
2122 Inspection of Fluid Level 45
2123 Specific Gravity 46
213 Replacement of Fuses 46
3 Lubrication 48
31 Engine 49
311 Engine Oil Level and Contamination 49
312 Replacement of Engine Oil 49
32 Clutch 50
321 Inspection of Fluid Level of the Clutch Reservoir Tank 50
322 Replacement of Brake Fluid 51
323 Bleeding of Clutch System 51
33 Transmission 51
331 Inspection of Transmission Gear Oil Level 51
332 Replacement of Transmission Gear Oil 52
34 Rear Axle 52
341 Inspection of Rear Axle Gear Oil Level 52
342 Replacement of Rear Axle Gear Oil 52
35 Brakes 52
351 Inspection of Fluid Level of the Brake Reservoir Tank 52
352 Replacement of Brake Fluid 52
353 Bleeding of the Brake System 53
36 Power Steering 54
361 Inspection of Power Steering Oil Level 54
362 Replacement of Power Steering Oil 54
363 Bleeding of the Power Steering System 55
37 Lubrication 55
Group 11 – Engine 58
1 General 59
11 Engine Proper 59
12 Air Compressor 61
2 Specifications 61
3 Service Standards 62
31 Service Standard Table 62
32 Tightening Torque Table 66
33 Sealant, Oil and Grease 66
4 Service Procedure 67
41 Engine Proper 67
411 Measurement of Compression Pressure 67
412 Removal 68
413 Disassembly 73
414 Inspection and Correction 80
415 Reassembly 96
416 Installation107
417 Adjustment108
42 Air Compressor109
421 Removal109
422 Disassembly110
423 Inspection and Correction111
424 Reassembly114
425 Installation115
5 Special Tool116
6 Troubleshooting120
61 Engine120
62 Valve Mechanism126
Group 12 – Lubrication129
1 General130
2 Specifications134
3 Service Standards135
31 Service Standard Table135
32 Tightening Torque Table136
4 Service Procedure136
41 Oil Pump137
411 Removal137
412 Disassembly and Inspection138
413 Reassembly140
414 Installation140
42 Oil Filter, Oil Cooler141
421 Disassembly and Inspection141
43 Regulator Valve, Check Valve [6D14T]143
431 Regulator Valve143
432 Check Valve [6D14T]143
5 Special Tool144
6 Troubleshooting145
Group 13 – Fuel147
1 General148
11 Fuel System148
12 Engine Control152
2 Specifications153
3 Service Standards153
31 Service Standard Table153
32 Tightening Torque Table155
4 Service Procedure156
41 Injection Pump156
411 Removal156
412 Disassembly157
413 Inspection and Correction158
414 Reassembly159
415 Test and Adjustment160
42 Governor165
421 Removal and Disassembly165
422 Inspection and Reassembly166
423 Adjustment168
43 Auto Timer173
431 Disassembly and Inspection173
432 Reassembly175
433 Adjustment175
44 Feed Pump176
441 Disassembly and Reassembly176
442 Test177
45 Injection Nozzle177
451 Removal177
452 Disassembly177
453 Cleaning and Inspection178
454 Reassembly179
455 Test and Adjustment179
456 Installation180
46 Fuel Filter181
461 Disassembly and Reassembly181
47 Water Separator181
471 Disassembly and Reassembly181
48 Bleeding the Fuel System181
49 Engine Control182
491 Removal and Installation182
492 Adjustment183
5 Special Tool185
6 Troubleshooting186
Group 14 – Cooling192
1 General193
2 Specifications195
3 Service Standards196
31 Service Standard Table196
32 Tightening Torque Table196
33 Sealant, Oil and Grease196
4 Service Procedure197
41 Auto Cool Fan Coupling197
411 Removal and Disassembly197
412 Inspection and Correction197
413 Reassembly and Installation198
42 Water Pump198
421 Removal198
422 Disassembly and Inspection199
423 Reassembly201
43 Thermostat201
431 Removal and Disassembly201
432 Inspection202
44 Radiator202
441 Removal and Disassembly202
442 Inspection203
443 Installation204
444 Gas Leak Test205
45 Reservoir Tank205
451 Removal and Inspection205
46 Cleaning of Cooling System206
5 Special Tool207
6 Troubleshooting208
Group 15 – Intake and Exhaust210
1 General211
2 Specifications213
3 Service Standards213
31 Service Standard Table213
32 Tightening Torque Table213
4 Service Procedure214
41 Turbocharger [6D14T]214
411 Removal214
412 Disassembly215
413 Inspection and Correction216
414 Reassembly218
415 Installation219
416 Adjustment219
42 Air Cleaner221
421 Disassembly and Reassembly221
422 Inspection and Cleaning222
43 Inlet Manifold223
44 Exhaust Manifold223
45 PCV (Positive Crankcase Ventilation) Valve [6D14T]224
5 Special Tool225
6 Troubleshooting226
Group 16 – Engine Electrical229
1 General230
2 Specifications232
3 Service Standards232
31 Service Standard Table232
32 Tightening Torque Table233
33 Sealant, Oil and Grease233
4 Service Procedure234
41 Starter234
411 Removal234
412 Disassembly234
413 Inspection235
414 Reassembly236
42 Alternator237
421 Removal237
422 Disassembly238
423 Inspection239
424 Reassembly239
425 Tests240
426 Installation241
43 Glow Plug System243
431 Removal and Installation243
432 Inspection244
5 Troubleshooting245
Group 21 – Clutch [C5W33]250
1 General251
11 Clutch Control251
12 Clutch Proper252
2 Specifications252
3 Service Standards253
31 Service Standard Table253
32 Tightening Torque Table254
4 Service Procedure254
41 Removal254
411 Removal From Vehicle254
42 Clutch Proper255
421 Disassembly and Inspection255
422 Reassembly and Adjustment257
43 Clutch Pedal259
431 Diassembly and Inspection259
432 Reassembly and Adjustment259
44 Clutch Master Cylinder260
441 Disassembly and Inspection260
442 Reassembly and Adjustment260
45 Clutch Power Cylinder261
451 Disassembly and Inspection261
452 Reassembly261
46 Replacement of Clutch System Fluid262
47 Bleeding Clutch System262
48 Adjustment of Clutch Control263
5 Special Tool264
6 Troubleshooting265
Group 21 – Clutch [C6W35]274
1 General275
11 Clutch Control275
12 Clutch Proper276
2 Specifications276
3 Service Standards277
31 Service Standard Table277
32 Tightening Torque Table279
4 Service Procedure280
41 Removal280
411 Removal from Vehicle280
42 Clutch Proper281
421 Disassembly and Inspection281
422 Reassembly and Adjustment283
43 Clutch Pedal285
431 Disassembly and Inspection285
432 Reassembly and Adjustment285
44 Clutch Master Cylinder286
441 Disassembly and Inspection286
442 Reassembly and Adjustment286
45 Clutch Booster287
451 Disassembly and Inspection287
452 Reassembly and Adjustment288
46 Inspection of Clutch Disc Wear290
47 Replacement of Clutch System Fluid290
48 Bleeding Clutch System291
49 Adjustment of Clutch Control292
5 Special Tool293
6 Troubleshooting295
Group 22 – Transmission [M5S5]305
1 General306
2 Specifications309
3 Service Standards310
31 Service Standard Table310
32 Tightening Torque Table312
4 Service Procedure313
41 Key Points for Removal313
42 Key Points for Installation314
43 Adjustment After Installation314
44 Disassembly, Inspection and Reassembly314
441 Transmission Assembly314
442 Main Shaft318
443 Counter Shaft Gear322
444 Reverse Gear324
445 Drive Pinion326
446 Reassembly of Clutch Housing326
447 Gearshifter, Lower327
448 Gearshifter, Upper331
449 Rear Cover333
4410 Speedometer Gears335
4411 Transmission Control335
5 Special Tool338
6 Troubleshooting343
Group 22 – Transmission [M6S5]350
1 General351
2 Specifications354
3 Service Standards355
31 Service Standard Table355
32 Tightening Torque Table357
4 Service Procedure358
41 Key Points for Removal358
42 Key Points for Installation359
43 Adjustment After Installation359
44 Disassembly, Inspection and Reassembly359
441 Transmission Assembly359
442 Main Shaft363
443 Counter Shaft Gear367
444 Reverse Gear369
445 Drive Pinion371
446 Reassembly of Clutch Housing371
447 Gearshifter, Lower372
448 Gearshifter, Upper376
449 Rear Cover378
4410 Speedometer Gears380
4411 Transmission Control380
5 Special Tool383
6 Troubleshooting388
Group 22 – Transmission [M8S2x5]395
1 General396
2 Specifications399
21 Transmission Proper399
22 Transmission Control399
3 Service Standards400
31 Service Standard Table400
32 Tightening Torque Table403
4 Service Procedure405
41 Key Points for Removal405
42 Key Points for Installation406
43 Adjustment After Installation406
44 Disassembly, Inspection and Reassembly406
441 Transmission Assembly406
442 Main Shaft410
443 Counter Shaft Gear414
444 Reverse Gear417
445 Drive Pinion418
446 Reassembly of Clutch Housing419
447 Gearshifter, Lower419
448 Gearshifter, Upper423
449 Splitter, Upper425
4410 Rear Cover427
4411 Speedometer Gears428
4412 Splitter Case and Gears429
4413 Power Shift431
4414 Splitter Control433
4415 Transmission Control435
5 Special Tool438
6 Troubleshooting443
Group 25 – Propeller Shaft452
1 General453
2 Specifications453
3 Service Standards454
31 Service Standard Table454
32 Tightening Torque Table454
4 Service Procedure455
41 Removal and Installation455
42 Disassembly, Inspection and Correction456
43 Reassembly459
44 Propeller Shaft Dynamic Balance Adjustment Procedures462
5 Special Tool464
6 Troubleshooting466
Group 26 – Front Axle468
1 General469
2 Specifications469
3 Service Standards470
31 Service Standard Table470
32 Tightening Torque Table471
4 Service Procedure472
41 Removal and Installation472
42 Wheel Hub and Brake Drum473
421 Disassembly, Inspection and Correction473
422 Reassembly475
423 Adjustment of Bearing Starting Torque476
43 Front Axle, Knuckle and Kingpin478
431 Disassembly, Inspection and Correction478
432 Measurement of Front Axle Bends479
433 Measurement of Kingpin Inclination480
434 Reassembly480
44 Adjustment After Installation (Wheel Alignment)481
5 Special Tool482
6 Troubleshooting485
Group 27 – Rear Axle488
1 General489
2 Specifications489
3 Service Standards490
31 Service Standard Table490
32 Tightening Torque Table491
4 Service Procedure492
41 Removal and Installation492
42 Wheel Hub and Brake Drum493
421 Disassembly, Inspection and Correction493
422 Reassembly495
423 Adjustment of Bearing Starting Torque497
43 Reduction and Differential498
431 Disassembly, Inspection and Correction498
432 Reassembly502
433 Adjustment of Starting Torque of Reduction Pinion Bearing505
434 Selection of Reduction Pinion Mounting Adjusting Shim505
435 Adjustment of Differential Case Side Bearing and Reduction Gear506
436 Reduction Gear Tooth Contact507
5 Special Tool510
6 Troubleshooting516
Group 31 – Wheel and Tire519
1 Specifications520
2 Service Procedure520
3 Service Standards521
31 Service Standard Table521
32 Tightening Torque Table521
4 Troubleshooting521
Group 33 – Front Suspension524
1 General525
2 Specifications525
3 Service Standards526
31 Service Standard Table526
32 Tightening Torque Table526
4 Service Procedure527
41 Removal and Installation527
42 Disassembly, Inspection and Correction528
43 Reassembly529
5 Special Tool531
6 Troubleshooting532
Group 34 – Rear Suspension534
1 General535
2 Specifications535
3 Service Standards536
31 Service Standard Table536
32 Tightening Torque Table536
4 Service Procedure537
41 Removal and Installation537
42 Disassembly, Inspection and Correction538
43 Reassembly539
5 Special Tool540
6 Troubleshooting541
Group 35 – Brake543
1 General545
11 Service Brake545
12 Parking Brake553
13 Exhaust Brake554
2 Specifications555
21 Service Brake555
22 Parking Brake556
23 Exhaust Brake556
3 Service Standards557
31 Service Standard Table557
311 Service Brake557
312 Parking Brake561
313 Exhaust Brake561
32 Tightening Torque Table562
321 Service Brake562
322 Parking Brake564
323 Exhaust Brake564
4 Service Procedure of Service Brake565
41 Brake System Diagram565
42 Brake Pedal and Air Brake Valve567
421 Removal and Installation567
422 Brake Pedal568
423 Air Brake Valve569
424 Inspection and Adjustment After Reassembly573
43 Brake Booster574
431 Brake Booster for FK Series574
432 Brake Booster for FM Series579
433 Function Check After Reassembly584
44 Air Pressure Governor585
441 Function Check585
442 Disassembly, Inspection and Correction586
443 Reassembly587
444 Inspection and Adjustment After Reassembly587
45 Check Valve587
451 Disassembly, Inspection and Correction587
452 Reassembly and Inspection588
46 Safety Valve588
47 Low Air Pressure Switch588
48 Stop Lamp Switch588
49 Supply Valve589
491 Disassembly, Inspection and Correction589
492 Reassembly and Adjustment589
410 Air Drier589
4101 Maintenance and Inspection589
4102 Disassembly, Inspection and Correction589
4103 Reassembly591
4104 Inspection After Installation in Vehicle592
4105 Troubleshooting592
411 Wheel Brake593
4111 Removal and Installation593
4112 Disassembly, Inspection and Correction593
4113 Reassembly600
4114 Replacement of Brake Lining and Correction of Brake Drum608
412 Inspection and Adjustment After Installation608
4121 Replacement of Brake Fluid and Bleeding of Brake (Oil) System608
4122 Brake Shoe Clearance Adjustment610
5 Service Procedure of Parking Brake611
51 Parking Brake Drum Assembly611
511 Key Points for Removal611
52 Parking Brake Proper612
53 Parking Brake Control616
54 Adjustment After Installation617
6 Service Procedure of Exhaust Brake619
61 Exhaust Brake Valve619
611 Disassembly and Inspection619
612 Reassembly and Adjustment620
62 Control Cylinder621
621 Disassembly and Inspection621
622 Reassembly621
63 Exhaust Brake Microswitch622
7 Special Tool623
71 Service Brake623
72 Parking Brake624
8 Troubleshooting625
Group 37 – Steering639
1 General640
2 Specifications643
3 Service Standards644
31 Service Standard Table644
32 Tightening Torque Table645
4 Service Procedure646
41 Removal and Installation of Steering System646
411 Removal of Starter Switch Wires and Cables647
412 Removal of Upper and Lower Shaft Assembly647
413 Removal of Starter Switch648
414 Installation of Starter Switch648
42 Disassembly and Reassembly of Steering Wheel648
43 Steering Shaft649
431 Disassembly, Inspection and Correction649
432 Reassembly649
44 Details of Link and Bracket Section650
45 Drag Link650
46 Tie Rod651
47 Integral Power Steering Booster651
471 Disassembly, Inspection and Correction652
472 Reassembly and Adjustment654
48 Power Steering Oil Pump657
481 Disassembly, Inspection and Correction657
482 Reassembly658
483 Adjustment659
49 Power Steering Oil Tank659
491 Disassembly659
492 Reassembly660
410 Adjustment After Installation660
4101 Bleeding660
4102 Performance Verification Tests661
4103 Steering Wheel Play662
4104 Adjustment of Steering Angle662
5 Special Tool662
6 Troubleshooting663
Group 41 – Frame673
1 General674
2 Specifications674
3 Service Procedure674
31 Frame674
32 Rivets675
33 Shape of Frame676
4 Troubleshooting679
Group 42 – Cab680
1 General681
2 Specifications681
3 Service Standards681
31 Tightening Torque Table681
4 Service Procedure682
41 Key Points for Cab Removal and Installation682
411 Removal682
412 Installation683
42 Doors685
421 Removal of Doors685
422 Door Installation Adjustment686
423 Door Trim687
424 Door Locking System688
425 Parts Related to Glass689
43 Seats691
431 Seats691
432 Seat Belts691
44 Floor Mat692
45 Overhead Console693
46 Trims694
47 Instrument Panel696
48 Windshield Glass and Rear Window Glass696
481 Removal696
482 Installation697
49 Rearview Mirrors698
410 Removal of Front Panel and Related Parts699
5 Troubleshooting701
Group 54 – Chassis Electrical709
1 General710
2 Specifications710
21 Electrical710
22 Meter and Gauge711
23 Lighting712
24 Exhaust Brake713
25 Wiper and Washer713
26 Accessory714
3 Service Procedure714
31 Aiming of Headlamps714
32 Warning and Indicator Lamps716
4 Troubleshooting718
Group 55 – Heater740
1 General741
2 Specifications741
3 Service Procedure742
31 Removal and Installation742
32 Cleaning of Air Filter742
33 Heater Control Adjustment Procedures743
4 Troubleshooting745
Wiring Diagram747
Alphabetical Index749
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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