Posts Tagged ‘FK’

1986-1987 Mitsubishi FUSO Fighter FM FK Truck Service Manual PDF Download

cover
Format: PDF
Pages: 751
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1986-1987 Mitsubishi FUSO Fighter FM, FK Series Truck (US/Canada) Service & Repair

  • FK415
  • FK455
  • FM555 (including 10-speed transmission)

Topics List:

Foreword
1. Group Classification
2. Definition of Terms and Unit Used
3. Notes On Illustrations
Group 00 – General
1. Exterior Views
2. Major Specifications
3. Power Train Table
4. Equipment Model Notation
5. Performance Curves
5.1 Operation Performance Curves
5.2 Engine Performance Curves
6. Servicing Precautions
7. Vehicle Identification Number
8. Standard Bolts and Nuts Tightening Torque Table
Group 01 – Maintenance Schedule
1. Using the Maintenance Schedule Table
2. Maintenance Schedule Table
2.1 Replacement of Oil Filter Element
2.2 Replacement of the Fuel Filter Element
2.3 Cleaning of the Fuel Feed Pump Gauze Filter
2.4 Bleeding of the Fuel System
2.5 Adjustment of V-Belt Tension
2.6 Cleaning and Replacement of Air Cleaner Element
2.6.1 Dry Dust Buildup
2.6.2 Oil Smoke, Soot, and Oil Black Deposits
2.6.3 Inspection After Drying
2.7 Inspection of Clutch Pedal
2.7.1 Inspection of Pedal Play
2.7.2 Clearance to Floorboard When Released
2.7.3 Clutch Operation
2.8 Servicing of Tires
2.8.1 Tire Inflation Pressure
2.8.2 Removal of Tire
2.8.3 Installation of Tire
2.8.4 Retightening of Wheel Nuts
2.8.5 Tire Rotation
2.9 Servicing of Air Drier
2.10 Adjustment of Wheel Brake Shoe Clearance
2.10.1 Adjusting Gear Type [FK415, FK455]
2.10.2 Adjusting Cam Type [FM555]
2.11 Adjustment of Parking Brake Shoe Clearance
2.12 Servicing of Battery
2.12.1 Cleaning of Battery Terminals
2.12.2 Inspection of Fluid Level
2.12.3 Specific Gravity
2.13 Replacement of Fuses
3. Lubrication
3.1 Engine
3.1.1 Engine Oil Level and Contamination
3.1.2 Replacement of Engine Oil
3.2 Clutch
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank
3.2.2 Replacement of Brake Fluid
3.2.3 Bleeding of Clutch System
3.3 Transmission
3.3.1 Inspection of Transmission Gear Oil Level
3.3.2 Replacement of Transmission Gear Oil
3.4 Rear Axle
3.4.1 Inspection of Rear Axle Gear Oil Level
3.4.2 Replacement of Rear Axle Gear Oil
3.5 Brakes
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank
3.5.2 Replacement of Brake Fluid
3.5.3 Bleeding of the Brake System
3.6 Power Steering
3.6.1 Inspection of Power Steering Oil Level
3.6.2 Replacement of Power Steering Oil
3.6.3 Bleeding of the Power Steering System
3.7 Lubrication
Group 11 – Engine
1. General
1.1 Engine Proper
1.2 Air Compressor
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Engine Proper
4.1.1 Measurement of Compression Pressure
4.1.2 Removal
4.1.3 Disassembly
4.1.4 Inspection and Correction
4.1.5 Reassembly
4.1.6 Installation
4.1.7 Adjustment
4.2 Air Compressor
4.2.1 Removal
4.2.2 Disassembly
4.2.3 Inspection and Correction
4.2.4 Reassembly
4.2.5 Installation
5. Special Tool
6. Troubleshooting
6.1 Engine
6.2 Valve Mechanism
Group 12 – Lubrication
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Oil Pump
4.1.1 Removal
4.1.2 Disassembly and Inspection
4.1.3 Reassembly
4.1.4 Installation
4.2 Oil Filter, Oil Cooler
4.2.1 Disassembly and Inspection
4.3 Regulator Valve, Check Valve [6D14T]
4.3.1 Regulator Valve
4.3.2 Check Valve [6D14T]
5. Special Tool
6. Troubleshooting
Group 13 – Fuel
1. General
1.1 Fuel System
1.2 Engine Control
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Injection Pump
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection and Correction
4.1.4 Reassembly
4.1.5 Test and Adjustment
4.2 Governor
4.2.1 Removal and Disassembly
4.2.2 Inspection and Reassembly
4.2.3 Adjustment
4.3 Auto Timer
4.3.1 Disassembly and Inspection
4.3.2 Reassembly
4.3.3 Adjustment
4.4 Feed Pump
4.4.1 Disassembly and Reassembly
4.4.2 Test
4.5 Injection Nozzle
4.5.1 Removal
4.5.2 Disassembly
4.5.3 Cleaning and Inspection
4.5.4 Reassembly
4.5.5 Test and Adjustment
4.5.6 Installation
4.6 Fuel Filter
4.6.1 Disassembly and Reassembly
4.7 Water Separator
4.7.1 Disassembly and Reassembly
4.8 Bleeding the Fuel System
4.9 Engine Control
4.9.1 Removal and Installation
4.9.2 Adjustment
5. Special Tool
6. Troubleshooting
Group 14 – Cooling
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Auto Cool Fan Coupling
4.1.1 Removal and Disassembly
4.1.2 Inspection and Correction
4.1.3 Reassembly and Installation
4.2 Water Pump
4.2.1 Removal
4.2.2 Disassembly and Inspection
4.2.3 Reassembly
4.3 Thermostat
4.3.1 Removal and Disassembly
4.3.2 Inspection
4.4 Radiator
4.4.1 Removal and Disassembly
4.4.2 Inspection
4.4.3 Installation
4.4.4 Gas Leak Test
4.5 Reservoir Tank
4.5.1 Removal and Inspection
4.6 Cleaning of Cooling System
5. Special Tool
6. Troubleshooting
Group 15 – Intake and Exhaust
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Turbocharger [6D14T]
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection and Correction
4.1.4 Reassembly
4.1.5 Installation
4.1.6 Adjustment
4.2 Air Cleaner
4.2.1 Disassembly and Reassembly
4.2.2 Inspection and Cleaning
4.3 Inlet Manifold
4.4 Exhaust Manifold
4.5 P.C.V. (Positive Crankcase Ventilation) Valve [6D14T]
5. Special Tool
6. Troubleshooting
Group 16 – Engine Electrical
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
3.3 Sealant, Oil and Grease
4. Service Procedure
4.1 Starter
4.1.1 Removal
4.1.2 Disassembly
4.1.3 Inspection
4.1.4 Reassembly
4.2 Alternator
4.2.1 Removal
4.2.2 Disassembly
4.2.3 Inspection
4.2.4 Reassembly
4.2.5 Tests
4.2.6 Installation
4.3 Glow Plug System
4.3.1 Removal and Installation
4.3.2 Inspection
5. Troubleshooting
Group 21 – Clutch [C5W33]
1. General
1.1 Clutch Control
1.2 Clutch Proper
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal
4.1.1 Removal From Vehicle
4.2 Clutch Proper
4.2.1 Disassembly and Inspection
4.2.2 Reassembly and Adjustment
4.3 Clutch Pedal
4.3.1 Diassembly and Inspection
4.3.2 Reassembly and Adjustment
4.4 Clutch Master Cylinder
4.4.1 Disassembly and Inspection
4.4.2 Reassembly and Adjustment
4.5 Clutch Power Cylinder
4.5.1 Disassembly and Inspection
4.5.2 Reassembly
4.6 Replacement of Clutch System Fluid
4.7 Bleeding Clutch System
4.8 Adjustment of Clutch Control
5. Special Tool
6. Troubleshooting
Group 21 – Clutch [C6W35]
1. General
1.1 Clutch Control
1.2 Clutch Proper
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal
4.1.1 Removal from Vehicle
4.2 Clutch Proper
4.2.1 Disassembly and Inspection
4.2.2 Reassembly and Adjustment
4.3 Clutch Pedal
4.3.1 Disassembly and Inspection
4.3.2 Reassembly and Adjustment
4.4 Clutch Master Cylinder
4.4.1 Disassembly and Inspection
4.4.2 Reassembly and Adjustment
4.5 Clutch Booster
4.5.1 Disassembly and Inspection
4.5.2 Reassembly and Adjustment
4.6 Inspection of Clutch Disc Wear
4.7 Replacement of Clutch System Fluid
4.8 Bleeding Clutch System
4.9 Adjustment of Clutch Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M5S5]
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Rear Cover
4.4.10 Speedometer Gears
4.4.11 Transmission Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M6S5]
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Rear Cover
4.4.10 Speedometer Gears
4.4.11 Transmission Control
5. Special Tool
6. Troubleshooting
Group 22 – Transmission [M8S2x5]
1. General
2. Specifications
2.1 Transmission Proper
2.2 Transmission Control
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Removal
4.2 Key Points for Installation
4.3 Adjustment After Installation
4.4 Disassembly, Inspection and Reassembly
4.4.1 Transmission Assembly
4.4.2 Main Shaft
4.4.3 Counter Shaft Gear
4.4.4 Reverse Gear
4.4.5 Drive Pinion
4.4.6 Reassembly of Clutch Housing
4.4.7 Gearshifter, Lower
4.4.8 Gearshifter, Upper
4.4.9 Splitter, Upper
4.4.10 Rear Cover
4.4.11 Speedometer Gears
4.4.12 Splitter Case and Gears
4.4.13 Power Shift
4.4.14 Splitter Control
4.4.15 Transmission Control
5. Special Tool
6. Troubleshooting
Group 25 – Propeller Shaft
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
4.4 Propeller Shaft Dynamic Balance Adjustment Procedures
5. Special Tool
6. Troubleshooting
Group 26 – Front Axle
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Wheel Hub and Brake Drum
4.2.1 Disassembly, Inspection and Correction
4.2.2 Reassembly
4.2.3 Adjustment of Bearing Starting Torque
4.3 Front Axle, Knuckle and Kingpin
4.3.1 Disassembly, Inspection and Correction
4.3.2 Measurement of Front Axle Bends
4.3.3 Measurement of Kingpin Inclination
4.3.4 Reassembly
4.4 Adjustment After Installation (Wheel Alignment)
5. Special Tool
6. Troubleshooting
Group 27 – Rear Axle
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Wheel Hub and Brake Drum
4.2.1 Disassembly, Inspection and Correction
4.2.2 Reassembly
4.2.3 Adjustment of Bearing Starting Torque
4.3 Reduction and Differential
4.3.1 Disassembly, Inspection and Correction
4.3.2 Reassembly
4.3.3 Adjustment of Starting Torque of Reduction Pinion Bearing
4.3.4 Selection of Reduction Pinion Mounting Adjusting Shim
4.3.5 Adjustment of Differential Case Side Bearing and Reduction Gear
4.3.6 Reduction Gear Tooth Contact
5. Special Tool
6. Troubleshooting
Group 31 – Wheel and Tire
1. Specifications
2. Service Procedure
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Troubleshooting
Group 33 – Front Suspension
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
5. Special Tool
6. Troubleshooting
Group 34 – Rear Suspension
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation
4.2 Disassembly, Inspection and Correction
4.3 Reassembly
5. Special Tool
6. Troubleshooting
Group 35 – Brake
1. General
1.1 Service Brake
1.2 Parking Brake
1.3 Exhaust Brake
2. Specifications
2.1 Service Brake
2.2 Parking Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standard Table
3.1.1 Service Brake
3.1.2 Parking Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Parking Brake
3.2.3 Exhaust Brake
4. Service Procedure of Service Brake
4.1 Brake System Diagram
4.2 Brake Pedal and Air Brake Valve
4.2.1 Removal and Installation
4.2.2 Brake Pedal
4.2.3 Air Brake Valve
4.2.4 Inspection and Adjustment After Reassembly
4.3 Brake Booster
4.3.1 Brake Booster for FK Series
4.3.2 Brake Booster for FM Series
4.3.3 Function Check After Reassembly
4.4 Air Pressure Governor
4.4.1 Function Check
4.4.2 Disassembly, Inspection and Correction
4.4.3 Reassembly
4.4.4 Inspection and Adjustment After Reassembly
4.5 Check Valve
4.5.1 Disassembly, Inspection and Correction
4.5.2 Reassembly and Inspection
4.6 Safety Valve
4.7 Low Air Pressure Switch
4.8 Stop Lamp Switch
4.9 Supply Valve
4.9.1 Disassembly, Inspection and Correction
4.9.2 Reassembly and Adjustment
4.10 Air Drier
4.10.1 Maintenance and Inspection
4.10.2 Disassembly, Inspection and Correction
4.10.3 Reassembly
4.10.4 Inspection After Installation in Vehicle
4.10.5 Troubleshooting
4.11 Wheel Brake
4.11.1 Removal and Installation
4.11.2 Disassembly, Inspection and Correction
4.11.3 Reassembly
4.11.4 Replacement of Brake Lining and Correction of Brake Drum
4.12 Inspection and Adjustment After Installation
4.12.1 Replacement of Brake Fluid and Bleeding of Brake (Oil) System
4.12.2 Brake Shoe Clearance Adjustment
5. Service Procedure of Parking Brake
5.1 Parking Brake Drum Assembly
5.1.1 Key Points for Removal
5.2 Parking Brake Proper
5.3 Parking Brake Control
5.4 Adjustment After Installation
6. Service Procedure of Exhaust Brake
6.1 Exhaust Brake Valve
6.1.1 Disassembly and Inspection
6.1.2 Reassembly and Adjustment
6.2 Control Cylinder
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Exhaust Brake Microswitch
7. Special Tool
7.1 Service Brake
7.2 Parking Brake
8. Troubleshooting
Group 37 – Steering
1. General
2. Specifications
3. Service Standards
3.1 Service Standard Table
3.2 Tightening Torque Table
4. Service Procedure
4.1 Removal and Installation of Steering System
4.1.1 Removal of Starter Switch Wires and Cables
4.1.2 Removal of Upper and Lower Shaft Assembly
4.1.3 Removal of Starter Switch
4.1.4 Installation of Starter Switch
4.2 Disassembly and Reassembly of Steering Wheel
4.3 Steering Shaft
4.3.1 Disassembly, Inspection and Correction
4.3.2 Reassembly
4.4 Details of Link and Bracket Section
4.5 Drag Link
4.6 Tie Rod
4.7 Integral Power Steering Booster
4.7.1 Disassembly, Inspection and Correction
4.7.2 Reassembly and Adjustment
4.8 Power Steering Oil Pump
4.8.1 Disassembly, Inspection and Correction
4.8.2 Reassembly
4.8.3 Adjustment
4.9 Power Steering Oil Tank
4.9.1 Disassembly
4.9.2 Reassembly
4.10 Adjustment After Installation
4.10.1 Bleeding
4.10.2 Performance Verification Tests
4.10.3 Steering Wheel Play
4.10.4 Adjustment of Steering Angle
5. Special Tool
6. Troubleshooting
Group 41 – Frame
1. General
2. Specifications
3. Service Procedure
3.1 Frame
3.2 Rivets
3.3 Shape of Frame
4. Troubleshooting
Group 42 – Cab
1. General
2. Specifications
3. Service Standards
3.1 Tightening Torque Table
4. Service Procedure
4.1 Key Points for Cab Removal and Installation
4.1.1 Removal
4.1.2 Installation
4.2 Doors
4.2.1 Removal of Doors
4.2.2 Door Installation Adjustment
4.2.3 Door Trim
4.2.4 Door Locking System
4.2.5 Parts Related to Glass
4.3 Seats
4.3.1 Seats
4.3.2 Seat Belts
4.4 Floor Mat
4.5 Overhead Console
4.6 Trims
4.7 Instrument Panel
4.8 Windshield Glass and Rear Window Glass
4.8.1 Removal
4.8.2 Installation
4.9 Rearview Mirrors
4.10 Removal of Front Panel and Related Parts
5. Troubleshooting
Group 54 – Chassis Electrical
1. General
2. Specifications
2.1 Electrical
2.2 Meter and Gauge
2.3 Lighting
2.4 Exhaust Brake
2.5 Wiper and Washer
2.6 Accessory
3. Service Procedure
3.1 Aiming of Headlamps
3.2 Warning and Indicator Lamps
4. Troubleshooting
Group 55 – Heater
1. General
2. Specifications
3. Service Procedure
3.1 Removal and Installation
3.2 Cleaning of Air Filter
3.3 Heater Control Adjustment Procedures
4. Troubleshooting
Wiring Diagram
Alphabetical Index

1990-1991 Mitsubishi FUSO FK FM Truck Service Manual PDF Download

cover
Format: PDF
Pages: 904
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1990-1991 Mitsubishi FUSO FK FM Series Trucks (U.S. models) Service & Repair

  • See full model list at bottom of page
  • FK415 w/ 6D14T2 engine
  • FK455 w/ 6D14T engine
  • FM555 w/ 6D14T engine
  • FM557 w/ 6D16T2 engine

Manual Part Number: TWME8910

Topics List:

Foreword
Compilation of this Manual
1. Group Classification
2. Definitions of Terms and Units Used
3. Notes On Illustrations
Group 00 – General
Table of Contents
1. Exterior Views
2. Major Specifications
3. Power Train Table
4. Equipment Model Notation
5. Performance Curves
5.1 Operation Performance Curves
5.2 Engine Performance Curves
6. Servicing Precautions
7. Standard Bolts and Nuts Tightening Torque Table
8. Towing Precautions
9. Chassis and Engine Numbers
10. Vehicle Identification Number
Group 01 – Maintenance Schedule
Table of Contents
1. Using Maintenance Schedule Table
2. Maintenance Schedule
2.1 Replacement of Oil Filter Element
2.2 Replacement of Fuel Filter Element
2.3 Cleaning of Fuel Feed Pump Gauze Filter
2.4 Bleeding of Fuel System
2.5 Adjustment of V-Belt Tension
2.6 Cleaning and Replacement of Air Cleaner Element
2.6.1 Dry Dust Buildup
2.7 Inspection of Clutch Pedal
2.7.1 Inspection of Pedal Play
2.7.2 Clearance to Floorboard When Released
2.7.3 Clutch Operation
2.8 Servicing of Tires
2.8.1 Tire Inflation Pressures
2.8.2 Removal of Tire
2.8.3 Installation of Tire
2.8.4 Retightening of Wheel Nuts
2.8.5 Tire Rotation
2.9 Servicing of Air Drier
2.10 Adjustment of Wheel Brake Shoe Clearance
2.10.1 Air Over Hydraulic Brake <FK415, FK455>
2.10.2 Full Air Brake <FM Series>
2.11 Adjustment of Parking Brake Shoe Clearance <FK415, FK455>
2.12 Servicing of Battery
2.12.1 Cleaning of Battery Terminals
2.12.2 Inspection of Fluid Level
2.12.3 Specific Gravity
2.13 Replacement of Fuses
3. Lubrication
3.1 Engine
3.1.1 Engine Oil Level and Contamination
3.1.2 Replacement of Engine Oil
3.2 Clutch
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank
3.2.2 Replacement of Brake Fluid
3.2.3 Bleeding of Clutch System
3.3 Transmission
3.3.1 Inspection of Transmission Gear Oil Level
3.3.2 Replacement of Transmission Gear Oil
3.4 Rear Axle
3.4.1 Inspection of Rear Axle Gear Oil Level
3.4.2 Replacement of Rear Axle Gear Oil
3.5 Brake <FK415, FK455>
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank
3.5.2 Replacement of Brake Fluid
3.5.3 Bleeding of Brake System
3.6 Power Steering
3.6.1 Inspection of Power Steering Fluid Level
3.6.2 Replacement of Power Steering Fluid
3.6.3 Bleeding of Power Steering System
3.7 Chassis Parts
Group 11 – Engine
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Engine and Transmission
6.2 Engine Proper
6.2.1 Measurement of Compression Pressure
6.2.2 Cylinder Head and Valve Mechanism
6.2.3 Flywheel, Timing Gear, and Camshaft
6.2.4 Crankcase and Main Moving Parts
6.2.5 Adjustment
Group 12 – Lubrication
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Oil Pump
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Oil Filter and Oil Cooler
6.2.1 Removal and Installation
6.2.2 Disassembly, Inspection, and Reassembly of Oil Filter
6.2.3 Disassembly, Inspection, and Reassembly of Oil Cooler
6.3 Regulator Valve
6.4 Check Valve
Group 13 – Fuel and Engine Control
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Fuel System
5.2 Engine Control
6. Service Procedure
6.1 Injection Pump Assembly
6.1.1 Removal and Installation
6.1.2 Inspection and Adjustment of Fuel Injection Timing
6.2 Feed Pump
6.2.1 Disassembly, Inspection, and Reassembly
6.2.2 Test
6.3 Injection Nozzle
6.3.1 Removal and Installation
6.3.2 Disassembly
6.3.3 Cleaning and Inspection
6.3.4 Reassembly
6.3.5 Test and Adjustment
6.4 Fuel Filter
6.5 Water Separator
6.6 Bleeding the Fuel System
6.7 Engine Control
6.7.1 Removal and Installation
6.7.2 Adjustment
6.8 Fuel Tank and Fuel Gauge Unit
Group 14 – Cooling
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Cooling System
6.2 Water Pump
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Inspection of Thermostat
6.4 Inspection of Auto Cool Fan Coupling
6.5 Inspection of Radiator
6.6 Inspection and Adjustment of V-Belt Tension
6.7 Cleaning of Cooling System
6.8 Gas Leak Test
6.9 Bleeding Cooling System
Group 15 – Intake and Exhaust
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal, Installation, and Inspection of Intake System
6.2 Air Cleaner
6.2.1 Disassembly and Reassembly
6.2.2 Inspection and Cleaning
6.3 Removal, Installation, and Inspection of Exhaust System
6.4 Turbocharger
6.4.1 Removal and Installation
6.4.2 Disassembly
6.4.3 Cleaning and Inspection
6.4.4 Reassembly
6.4.5 Measurement of Turbocharger Boost Pressure
6.5 Intercooler <6D16T2>
6.5.1 Removal and Installation
6.5.2 Inspection
Group 16 – Engine Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Starter
5.2 Alternator
5.3 Glow System
6. Service Procedure
6.1 Starter
6.1.1 Removal and Installation
6.1.2 Disassembly
6.1.3 Inspection
6.1.4 Reassembly
6.1.5 Inspection and Adjustment After Reassembly
6.2 Alternator
6.2.1 Removal and Installation
6.2.2 Disassembly
6.2.3 Inspection
6.2.4 Reassembly
6.2.5 Inspection and Adjustment After Installation
6.3 Glow System
6.3.1 Removal and Installation of Glow Plug
6.3.2 Inspection
Group 21 – Clutch
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Clutch Proper
5.2 Clutch Control
5.2.1 Clutch Master Cylinder
5.2.2 Clutch Booster
6. Service Procedure
6.1 Clutch
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Clutch Pedal
6.2.1 Removal and Installation
6.2.2 Disassembly and Inspection
6.2.3 Reassembly and Adjustment
6.3 Clutch Master Cylinder
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Power Cylinder
6.4.1 Removal and Installation
6.4.2 Disassembly and Inspection
6.4.3 Reassembly
6.5 Clutch Booster (Vehicles With M8S2x5)
6.5.1 Removal and Installation
6.5.2 Disassembly and Inspection
6.5.3 Reassembly
6.5.4 Performance Test
6.5.5 On-the-Vehicle Functional Check
6.6 Clutch Housing
6.6.1 Disassembly
6.6.2 Reassembly
6.7 Replacement of Brake Fluid in Clutch System
6.8 Bleeding the Clutch System
6.9 Adjustment of Clutch Pedal
6.10 Lubrication of Drive Pinion Splines
Group 22A – Manual Transmission (M5S5, M6S5)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Rear Cover
6.8.1 Disassembly and Inspection
6.8.2 Reassembly
6.9 Transmission Control
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.9.3 Adjustment After Installation
Group 22B – Manual Transmission (M8S5, M8S2x5)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Transmission Proper
2.2 Transmission Control
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Upper Splitter <M8S2x5 Only>
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Rear Cover
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.10 Splitter Case and Gear <M8S2x5 Only>
6.10.1 Inspection Before Disassembly
6.10.2 Disassembly and Inspection
6.10.3 Reassembly
6.11 Power Shift
6.11.1 Disassembly and Inspection
6.11.2 Reassembly
6.12 Splitter Control <M8S2x5 Only>
6.12.1 Splitter Air Piping
6.12.2 Power Cylinder
6.13 Transmission Control
6.13.1 Disassembly and Inspection
6.13.2 Reassembly
6.13.3 Adjustment After Installation
Group 23 – Automatic Transmission
Table of Contents
1. Troubleshooting
2. Specification
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Automatic Transmission Control
5.2 Oil Cooler
6. Service Procedure
6.1 Removal and Installation of Automatic Transmission
6.1.1 Removal
6.1.2 Installation
6.2 Oil Seal and Speedometer Worm
6.2.1 Removal and Installation
6.2.2 Replacement of Front Oil Seal
6.2.3 Replacement of Rear Oil Seal
6.2.4 Replacement of Speedometer Worm
6.3 Automatic Transmission Control System
6.3.1 Removal and Installation
6.3.2 Inspection After Installation
6.4 Oil Cooler
6.4.1 Removal and Installation
6.5 Oil Filter
6.5.1 Removal and Installation
6.6 Replacement of Oil and Oil Filter
Group 25 – Propeller Shaft
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Front Propeller Shaft
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Rear Propeller Shaft
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Adjustment After Reassembly
Group 26 – Front Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection, and Corrections
6.2.2 Reassembly
6.3 Front Axle, Knuckle, and Kingpin
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Inspection and Adjustment After Installation
Group 27 – Rear Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection, and Corrections
6.2.2 Reassembly
6.3 Reduction and Differential
6.3.1 Removal
6.3.2 Inspection Before Disassembly
6.3.3 Disassembly and Inspection
6.3.4 Reassembly
Group 31 – Wheel and Tire
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
5. Service Procedure
5.1 Removal
5.2 Disassembly and Reassembly
5.2.1 Tire With Tube
5.2.2 Tubeless Tire
5.3 Inspection and Correction
5.4 Installation
Group 33 – Front Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection, and Correction
6.3 Installation
Group 34 – Rear Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection, and Correction
6.3 Installation
Group 35A – Brake (Air Over Hydraulic Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Drier
5.4 Dual Brake Valve
5.5 Brake Booster (Airmaster)
5.6 Air Pressure Governor
5.7 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Drier
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Brake Booster (Airmaster)
6.2.5 Air Pressure Governor
6.2.6 Check Valve
6.2.7 Supply Valve
6.2.8 Safety Valve
6.2.9 Low Air Pressure Switch
6.2.10 Stop Lamp Switch
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Wheel Cylinder
6.3.3 Rear Wheel Brake
6.3.4 Rear Wheel Cylinder
6.4 Inspection and Adjustment After Installation
6.4.1 Shoe Clearance Adjustment
6.4.2 Replacement of Brake Fluid and Bleeding of Brake System
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control
6.5.4 Adjustment and Inspection After Installation
Group 35B – Brake (Full Air Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Drier
5.4 Dual Brake Valve
5.5 Air Pressure Governor
5.6 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Drier
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Air Pressure Governor
6.2.5 Check Valve
6.2.6 Supply Valve
6.2.7 Safety Valve
6.2.8 Low Air Pressure Switch
6.2.9 Stop Lamp Switch
6.2.10 Relay Valve
6.2.11 Quick Release Valve
6.2.12 Double Check Valve
6.2.13 Air Check Valve
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Brake Chamber
6.3.3 Rear Wheel Brake
6.3.4 Rear Brake Chamber
6.4 Inspection and Adjustment After Installation
6.4.1 Adjustment of Brake Shoe Clearance
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control
6.5.4 Adjustment and Inspection After Installation
Group 36A – Parking Brake (Center Parking Brake)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Parking Brake
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Parking Brake Control
6.2.1 Removal and Installation
6.2.2 Parking Brake Lever
6.3 Adjustment
Group 36B – Parking Brake (Wheel Parking Brake)
Table of Contents
1. Troubleshooting
2. Service Standards
2.1 Service Standards Table
2.2 Tightening Torque Table
3. General
3.1 Parking Brake System
3.2 Parking Brake Control Valve
3.3 Spring Brake Valve
4. Service Procedure
4.1 Parking Brake Control Valve
4.1.1 Disassembly
4.1.2 Reassembly
4.1.3 Inspection After Reassembly
4.2 Spring Brake Valve
4.2.1 Disassembly
4.2.2 Reassembly
4.2.3 Inspection After Reassembly
Group 37 – Steering
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Steering Shaft
6.2.1 Removal
6.2.2 Installation
6.2.3 Disassembly, Inspection, and Correction
6.2.4 Reassembly
6.3 Link and Bracket Section
6.3.1 Disassembly
6.3.2 Reassembly
6.4 Drag Link
6.5 Tie Rod
6.6 Integral Power Steering Booster
6.6.1 Disassembly, Inspection, and Correction
6.6.2 Reassembly and Adjustment
6.7 Power Steering Oil Pump
6.7.1 Removal
6.7.2 Installation
6.7.3 Disassembly, Inspection, and Correction
6.7.4 Reassembly
6.7.5 Adjustment
6.8 Power Steering Oil Tank
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Adjustment After Installation
6.9.1 Bleeding
6.9.2 Performance Verification Tests
6.9.3 Steering Wheel Play
6.9.4 Adjustment of Steering Angle
Group 41 – Frame
Table of Contents
1. General
2. Service Procedure
2.1 Inspection and Repair
2.1.1 Frame
2.1.2 Rivets
Group 42 – Cab
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Procedures
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
4.1 Cab Proper
4.2 Cab Mounting
4.2.1 Front Cab Mounting
4.2.2 Rear Cab Mounting
4.3 Cab Tilt System
5. Service Procedure
5.1 Removal
5.1.1 Key Points for Removal
5.1.2 Key Points for Installation
5.1.3 Inspection and Adjustment After Installation
5.2 Cab Mounting
5.2.1 Front Cab Mounting
5.2.2 Cab Stay
5.2.3 Rear Cab Mounting
5.2.4 Cab Tilt Link
5.3 Doors
5.3.1 Removal of Doors
5.3.2 Door Installation Adjustment
5.3.3 Front Door Assembly
5.4 Interior Parts
5.4.1 Seats and Center Console
5.4.2 Seat Belts
5.4.3 Floor Mat
5.4.4 Overhead Console
5.4.5 Trim and Headlining
5.4.6 Instrument Panel
5.5 Window Glass
5.5.1 Removal
5.5.2 Installation
5.6 Exterior Parts
5.6.1 Front Panel, Fender, and Allied Parts
5.6.2 Rear View Mirrors
Group 54 – Chassis Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
4. General
5. Service Procedure
5.1 Battery
5.1.1 General Description
5.1.2 Inspection
5.2 Fuses
5.2.1 General Description
5.2.2 Inspection
5.3 Fusible Link
5.3.1 General Description
5.3.2 Inspection
5.4 Starter Switch and Cold Starter Switch
5.4.1 General Description
5.4.2 Inspection
5.5 Sub-Starter System
5.5.1 General Description
5.5.2 Inspection
5.6 Combination Switch
5.6.1 General Description
5.6.2 Inspection
5.7 Lighting System
5.7.1 General Description
5.7.2 Inspection
5.7.3 Inspection and Adjustment After Installation
5.8 Meter System
5.8.1 General Description
5.8.2 Inspection
5.9 Indicators and Warning Lamps
5.9.1 General Description
5.9.2 Inspection
5.10 Wiper and Washer System
5.10.1 General Description
5.10.2 Inspection
5.10.3 Inspection and Adjustment After Installation
5.11 Horn
5.11.1 General Description
5.11.2 Inspection
5.12 Back-Up Buzzer
5.12.1 General Description
5.12.2 Inspection
5.13 Radio and Cassette Stereo
5.13.1 Mounting Position
5.13.2 AM/FM Radio
5.13.3 AM/FM Radio and Cassette Stereo
5.13.4 Troubleshooting
5.14 Cigarette Lighter
5.14.1 General Description
5.14.2 Inspection
Wiring Diagram – FK <Manual Transmission>
Wiring Diagram – FK <Automatic Transmission>
Wiring Diagram – FM
Group 55A – Air Conditioner
Table of Contents
1. Specifications
2. Outlines of Refrigeration System
2.1 Air System
2.2 Refrigerating Cycle
2.3 Electrical System
3. Construction
3.1 Engine Compartment
3.2 Cab
3.3 Control System
3.4 Compressor and Magnetic Clutch
3.4.1 Compressor
3.4.2 Check Valve
3.4.3 Magnetic Clutch
3.5 Condenser
3.6 Receiver Drier
3.7 Cooling Unit
3.8 Expansion Valve
3.9 A/C Switch
3.10 Thermo Sensor
3.11 Power Relay
3.12 Dual Pressure Switch
4. Troubleshooting
4.1 General Precautions
4.2 Trouble, Cause, and Remedy
4.3 Inspection Procedures
4.3.1 A/C Switch
4.3.2 Dual Pressure Switch
4.3.3 Thermo Sensor
4.3.4 Magnetic Clutch
4.3.5 Refrigerant Charge
4.3.6 Receiver Drier Assembly
4.3.7 Belt Tension
4.3.8 Expansion Valve
4.3.9 Compressor
4.3.10 Air Inclusion in Refrigerant Circuit
4.3.11 Moisture Inclusion in Refrigerant Circuit
5. Removal and Installation
5.1 Precaution for Removal and Installation
5.2 Removal
5.2.1 Inside the Engine Compartment
5.2.2 Inside the Cab
5.3 Installation
6. Treatment After Installation
6.1 Check and Adjustment
6.2 Leak Test
6.2.1 Test Point
6.2.2 Test Procedure
6.3 Evacuation
6.4 Gas Charge
6.5 Checking the Refrigerant Level
6.6 Performance Test
6.6.1 Preparation
6.6.2 Stationary Performance Test
7. Cooling Unit
7.1 Components
7.2 Cautions in Disassembling
7.3 Disassembling
8. Maintenance
9. Compressor
9.1 Disassembling the Clutch
9.2 Reassembly the Clutch
9.3 Disassembling the Shaft Seal
9.4 Reassembly the Shaft Seal
9.5 Special Tool Figure
Group 55B – Heater
Table of Contents
1. Troubleshooting
2. Specifications
3. General
3.1 Ventilation System
3.2 Heater
4. Service Procedure
4.1 Removal and Installation
4.2 Cleaning of Air Filter
4.3 Heater Control Adjustment Procedure

Full model list:

  • FK415HSLSU
  • FK415HSLSUB
  • FK415JSLSU
  • FK415JSLSUB
  • FK415KSLSU
  • FK415KSLSUB
  • FK415LSLSU
  • FK415LSLSUB
  • FK455HSLSU
  • FK455JSLSU
  • FK455KSLSU
  • FK455LSLSU
  • FK455MSLSU
  • FM555FSLSU
  • FM555FSLSUA
  • FM555HSLSU
  • FM555HSLSUA
  • FM555JSLSU
  • FM555JSLSUA
  • FM555LSLSU
  • FM555LSLSUA
  • FM555MSLSU
  • FM555MSLSUA
  • FM557FSLSU
  • FM557FSLSUA
  • FM557HSLSU
  • FM557HSLSUA
  • FM557JSLSU
  • FM557JSLSUA
  • FM557LSLSU
  • FM557LSLSUA
  • FM557MSLSU
  • FM557MSLSUA

1992-1995 Mitsubishi FUSO Fighter FK FM Truck Service Manual PDF Download

fkfmcover
Format: PDF
Pages: 1,252
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1992, 1993, 1994, 1995 Mitsubishi FUSO FK FM Series Truck (US/Canada) Service & Repair

  • FK417
  • FK457
  • FM457
  • FM557

Manual Part Number: TWME9107 plus model year changes

Topics List:

Group 00 – General
Group 00 – General [Supplement]
Table of Contents
Summary of Modifications
Group 01 – Maintenance Schedule
Group 35A – Brake (Air Over Hydraulic Brake)
Group 35B – Brake (Full Air Brake)
’95 Model Changes
’94 Minor Change
Table of Contents
1. Differences of 1994 Model from 1993 Model
2. Details of Change Due to Running Change Made on 1993 Model
’93 Minor Change
Table of Contents
1. FK457 (Vehicles with M6S6)
1.1 Major Specifications
1.2 Power Train Table
1.3 Operation Performance Curves
2. Differences of 1993 Model from 1992 Model
Group 00 – General
Table of Contents
1. Exterior Views
2. Major Specifications
3. Power Train Table
4. Equipment Model Notation
5. Peformance Curves
5.1 Operation Performance Curves
5.2 Engine Performance Curve
6. Servicing Precautions
7. Standard Bolts and Nuts Tightening Torque Table
8. Towing Precautions
9. Chassis and Engine Numbers
10. Vehicle Identification Number
Group 01 – Maintenance Schedule
Table of Contents
1. Using the Maintenance Schedule Table
2. Maintenance Schedule
2.1 Replacement of Oil Filter Element
2.2 Replacement of Fuel Filter Element
2.3 Cleaning of Fuel Feed Pump Gauze Filter
2.4 Bleeding of Fuel System
2.5 Adjustment of V-Belt Tension
2.6 Cleaning and Replacement of Air Cleaner Element
2.7 Inspection of Clutch Pedal
2.7.1 Inspection of Pedal Play
2.7.2 Clearance to Floorboard When Released
2.7.3 Clutch Operation
2.8 Servicing of Tires
2.8.1 Tire Inflation Pressures
2.8.2 Removal of Tire
2.8.3 Installation of Tire
2.8.4 Retightening of Wheel Nuts
2.8.5 Tire Rotation
2.9 Servicing of Air Drier
2.10 Adjustment of Wheel Brake Shoe Clearance
2.10.1 Air Over Hydraulic Brake <FK Series>
2.10.2 Full Air Brake <FM Series>
2.11 Adjustment of Parking Brake Shoe Clearance <FK Series>
2.12 Servicing of Battery
2.12.1 Cleaning of Battery Terminals
2.12.2 Inspection of Fluid Level
2.12.3 Specific Gravity
2.13 Replacement of Fuses
3. Lubrication
3.1 Engine
3.1.1 Engine Oil Level and Contamination
3.1.2 Replacement of Engine Oil
3.2 Clutch
3.2.1 Inspection of Fluid Level of the Clutch Reservoir Tank
3.2.2 Replacement of Brake Fluid
3.2.3 Bleeding of Clutch System
3.3 Transmission
3.3.1 Inspection of Transmission Gear Oil Level
3.3.2 Replacement of Transmission Gear Oil
3.4 Rear Axle
3.4.1 Inspection of Rear Axle Gear Oil Level
3.4.2 Replacement of Rear Axle Gear Oil
3.5 Brake <FK Series>
3.5.1 Inspection of Fluid Level of the Brake Reservoir Tank
3.5.2 Replacement of Brake Fluid
3.5.3 Bleeding of Brake System
3.6 Power Steering
3.6.1 Inspection of Power Steering Fluid Level
3.6.2 Replacement of Power Steering Fluid
3.6.3 Bleeding of Power Steering System
3.7 Chassis Parts
Group 11 – Engine
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Engine and Transmission
6.2 Engine Proper
6.2.1 Measurement of Compression Pressure
6.2.2 Cylinder Head and Valve Mechanism
6.2.3 Flywheel, Timing Gear and Camshaft
6.2.4 Crankcase and Main Moving Parts
6.2.5 Adjustment
Group 12 – Lubrication
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Oil Pump
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Oil Cooler
6.2.1 Removal and Installation
6.2.2 Disassembly and Inspection
6.3 Oil Filter
Group 13 – Fuel and Engine Control
Group 13 – Fuel and Engine Control
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Fuel System
5.2 Engine Control
6. Service Procedure
6.1 Injection Pump Assembly
6.1.1 Removal and Installation
6.1.2 Inspection and Adjustment of Fuel Injection Timing
6.1.3 Cleaning of Fuel Feed Pump Gauze Filter
6.2 Injection Nozzle
6.2.1 Removal and Installation
6.2.2 Disassembly
6.2.3 Cleaning and Inspection
6.2.4 Reassembly
6.2.5 Test and Adjustment
6.3 Fuel Filter
6.4 Water Separator
6.5 Bleeding the Fuel System
6.6 Engine Control
6.6.1 Removal and Installation
6.6.2 Inspection and Adjustment
6.7 Fuel Tank and Fuel Gauge Unit
Group 13A – Fuel and Engine Control <for 1995 Model>
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Fuel System
5.2 Prestroke Control Type Injection Pump System
5.3 Engine Control
6. Service Procedure
6.1 Injection Pump Assembly
6.1.1 Removal and Installation
6.1.2 Inspection and Adjustment of Fuel Injection Timing
6.1.3 Cleaning of Fuel Feed Pump Gauze Filter
6.1.4 Adjustment of No-Load Minimum and Maximum Speeds
6.2 Inspection of Prestroke Control Type Injection Pump System
6.2.1 Troubleshooting Procedures
6.2.2 Inspection Items by Multi-Use Tester (MUT)
6.2.3 Inspection on the Basis of DIAG Code
6.2.4 Other Inspections
6.2.5 Inspection of Transient Malfunctions
6.3 Injection Nozzle
6.3.1 Removal and Installation
6.3.2 Disassembly
6.3.3 Cleaning and Inspection
6.3.4 Reassembly
6.3.5 Test and Adjustment
6.4 Fuel Filter
6.5 Water Separator
6.6 Bleeding the Fuel System
6.7 Engine Control
6.7.1 Removal and Installation
6.7.2 Inspection and Adjustment
6.8 Fuel Tank and Fuel Gauge Unit
Group 14 – Cooling
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tool
5. General
6. Service Procedure
6.1 Removal and Installation of Cooling System
6.2 Water Pump
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Inspection of Thermostat
6.4 Inspection of Auto-Cool Fan Coupling
6.5 Inspection of Radiator
6.6 Inspection and Adjustment of V-Belt Tension
6.7 Cleaning of Cooling System
6.8 Gas Leak Test
6.9 Bleeding Cooling System
Group 15 – Intake and Exhaust
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal, Installation and Inspection of Intake System
6.2 Air Cleaner
6.2.1 Disassembly and Reassembly
6.2.2 Inspection and Cleaning
6.3 Removal, Installation and Inspection of Exhaust System
6.4 Turbocharger
6.4.1 Removal and Installation
6.4.2 Disassembly
6.4.3 Cleaning and Inspection
6.4.4 Reassembly
6.4.5 Measurement of Turbocharger Boost Pressure
6.5 Intercooler
6.5.1 Removal and Installation
6.5.2 Inspection
Group 16 – Engine Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
4.1 Starter
4.2 Alternator
4.3 Glow System
5. Service Procedure
5.1 Starter
5.1.1 Removal and Installation
5.1.2 Disassembly
5.1.3 Inspection
5.1.4 Reassembly
5.1.5 Inspection and Adjustment After Reassembly
5.2 Alternator
5.2.1 Removal and Installation
5.2.2 Disassembly
5.2.3 Inspection
5.2.4 Reassembly
5.2.5 Inspection and Adjustment After Installation
5.3 Glow System
5.3.1 Removal and Installation
5.3.2 Inspection
Group 21 – Clutch
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Clutch Proper
5.2 Clutch Control
5.2.1 Clutch Master Cylinder
5.2.2 Clutch Booster
6. Service Procedure
6.1 Clutch
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly and Adjustment
6.2 Clutch Pedal
6.2.1 Removal and Installation
6.2.2 Disassembly and Inspection
6.2.3 Reassembly and Adjustment
6.3 Clutch Master Cylinder
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Power Cylinder
6.4.1 Removal and Installation
6.4.2 Disassembly and Inspection
6.4.3 Reassembly
6.5 Clutch Booster (Vehicles with M8S2x5)
6.5.1 Removal and Installation
6.5.2 Disassembly and Inspection
6.5.3 Reassembly
6.5.4 Performance Test
6.5.5 On-the-Vehicle Functional Check
6.6 Clutch Housing
6.6.1 Disassembly
6.6.2 Reassembly
6.7 Replacement of Brake Fluid in Clutch System
6.8 Bleeding the Clutch System
6.9 Adjustment of Clutch Pedal
6.10 Lubrication of Drive Pinion Splines
Group 22 – Manual Transmission
Group 22A – Manual Transmission (M5S5, M6S5)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Rear Cover
6.8.1 Disassembly and Inspection
6.8.2 Reassembly
6.9 Transmission Control
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.9.3 Adjustment After Installation
6.10 Transmission PTO Control <Option>
6.10.1 Transmission PTO Control Circuit
6.10.2 Inspection
Group 22B – Manual Transmission (M8S5, M8S2x5)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Transmission Proper
2.2 Transmission Control
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Upper Splitter <M8S2x5 Only>
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Rear Cover <M8S2x5 Only>
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.10 Extension Housing <M8S6 Only>
6.10.1 Disassembly and Inspection
6.10.2 Reassembly
6.11 Splitter Case and Gear <M8S2x5 Only>
6.11.1 Inspection Before Disassembly
6.11.2 Disassembly and Inspection
6.11.3 Reassembly
6.12 Power Shift
6.12.1 Disassembly and Inspection
6.12.2 Reassembly
6.13 Splitter Control <M8S2x5 Only>
6.13.1 Splitter Air Piping
6.13.2 Power Cylinder
6.14 Transmission Control
6.14.1 Disassembly and Inspection
6.14.2 Reassembly
6.14.3 Adjustment After Installation
6.15 Transmission PTO Control <Option>
6.15.1 Transmission PTO Control Circuit
6.15.2 Inspection
Group 22C – Manual Transmission (M6S6)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation of Transmission
6.1.1 Key Points for Removal
6.1.2 Key Points for Installation
6.1.3 Inspection and Adjustment After Installation
6.2 Transmission Assembly
6.2.1 Disassembly
6.2.2 Reassembly
6.3 Transmission
6.3.1 Inspection Before Disassembly
6.3.2 Disassembly and Inspection
6.3.3 Reassembly
6.4 Main Shaft
6.4.1 Disassembly and Inspection
6.4.2 Reassembly
6.5 Counter Shaft
6.5.1 Disassembly
6.5.2 Reassembly
6.6 Lower Gear Shifter
6.6.1 Disassembly and Inspection
6.6.2 Reassembly
6.7 Upper Gear Shifter
6.7.1 Disassembly and Inspection
6.7.2 Reassembly
6.8 Extension Housing
6.8.1 Disassembly and Inspection
6.8.2 Reassembly
6.9 Transmission Control
6.9.1 Disassembly and Inspection
6.9.2 Reassembly
6.9.3 Adjustment After Installation
Group 23 – Automatic Transmission
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
5.1 Automatic Transmission Control
5.2 Oil Cooler
6. Service Procedure
6.1 Removal and Installation of Automatic Transmission
6.1.1 Removal
6.1.2 Installation
6.2 Oil Seal and Speedometer Worm
6.2.1 Removal and Installation
6.2.2 Replacement of Front Oil Seal
6.2.3 Replacement of Rear Oil Seal
6.2.4 Replacement of Speedometer Worm
6.3 Automatic Transmission Control System
6.3.1 Removal and Installation
6.3.2 Inspection After Installation
6.4 Oil Cooler
6.4.1 Removal and Installation
6.4.2 Inspection
6.5 Oil Filter
6.5.1 Removal and Installation
6.6 Replacement of Fluid and Oil Filter
Group 25 – Propeller Shaft
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Front Propeller Shaft
6.2.1 Disassembly and Inspection
6.2.2 Reassembly
6.3 Rear Propeller Shaft
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Adjustment After Reassembly
Group 26 – Front Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection and Corrections
6.2.2 Reassembly
6.3 Front Axle, Knuckle and Kingpin
6.3.1 Disassembly and Inspection
6.3.2 Reassembly
6.4 Inspection and Adjustment After Installation
Group 27 – Rear Axle
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Wheel Hub and Brake Drum
6.2.1 Disassembly, Inspection and Corrections
6.2.2 Reassembly
6.3 Reduction and Differential
6.3.1 Removal
6.3.2 Inspection Before Disassembly
6.3.3 Disassembly and Inspection
6.3.4 Reassembly
Group 31 – Wheel and Tire
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
5. Service Procedure
5.1 Removal
5.2 Disassembly and Procedure
5.2.1 Tubeless Tire
5.3 Inspection and Correction
5.4 Installation
Group 33 – Front Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection and Correction
6.3 Installation
Group 34 – Rear Suspension
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Disassembly, Inspection and Correction
6.3 Installation
Group 35 – Brake
Group 35A – Brake (Air Over Hydraulic Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Dryer
5.4 Dual Brake Valve
5.5 Brake Booster (Airmaster)
5.6 Air Pressure Governor
5.7 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Dryer
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Brake Booster (Airmaster)
6.2.5 Air Pressure Governor
6.2.6 Check Valve
6.2.7 Supply Valve
6.2.8 Safety Valve
6.2.9 Brake Fluid Tank
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Wheel Cylinder
6.3.3 Rear Wheel Brake
6.3.4 Rear Wheel Cylinder
6.4 Inspection and Adjustment After Installation
6.4.1 Shoe Clearance Adjustment
6.4.2 Replacement of Brake Fluid and Bleeding of Brake System
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control <Except A/T Vehicles>
6.5.4 Adjustment and Inspection After Installation <Except A/T Vehicles>
Group 35B – Brake (Full Air Brake)
Table of Contents
1. Troubleshooting
2. Specifications
2.1 Service Brake
2.2 Wheel Brake
2.3 Exhaust Brake
3. Service Standards
3.1 Service Standards Table
3.1.1 Service Brake
3.1.2 Wheel Brake
3.1.3 Exhaust Brake
3.2 Tightening Torque Table
3.2.1 Service Brake
3.2.2 Wheel Brake
3.2.3 Exhaust Brake
4. Special Tools
5. General
5.1 Service Brake
5.2 Air Compressor
5.3 Air Dryer
5.4 Dual Brake Valve
5.5 Air Pressure Governor
5.6 Exhaust Brake System
6. Service Procedure
6.1 Brake System Diagram
6.2 Service Brake Equipment
6.2.1 Air Compressor
6.2.2 Air Dryer
6.2.3 Brake Pedal and Dual Brake Valve
6.2.4 Air Pressure Governor
6.2.5 Check Valve
6.2.6 Supply Valve
6.2.7 Safety Valve
6.2.8 Relay Valve
6.2.9 Quick Release Valve
6.2.10 Double Check Valve
6.2.11 Air Check Valve
6.3 Wheel Brake
6.3.1 Front Wheel Brake
6.3.2 Front Brake Chamber
6.3.3 Rear Wheel Brake
6.3.4 Rear Brake Chamber
6.4 Inspection and Adjustment After Installation
6.4.1 Adjustment of Brake Shoe Clearance
6.5 Exhaust Brake
6.5.1 Exhaust Brake Unit
6.5.2 Control Cylinder
6.5.3 Exhaust Brake Control
6.5.4 Adjustment and Inspection After Installation
Group 36 – Parking Brake
Group 36A – Parking Brake (Center Parking Brake)
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Parking Brake
6.1.1 Removal and Installation
6.1.2 Disassembly and Inspection
6.1.3 Reassembly
6.2 Parking Brake Control
6.2.1 Removal and Installation
6.2.2 Parking Brake Lever
6.3 Adjustment
Group 36B – Parking Brake (Wheel Parking Brake)
Table of Contents
1. Troubleshooting
2. Service Standards
2.1 Service Standards Table
2.2 Tightening Torque Table
3. General
3.1 Parking Brake System
3.2 Parking Brake Control Valve
3.3 Spring Brake Valve
4. Service Procedure
4.1 Parking Brake Control Valve
4.1.1 Disassembly
4.1.2 Reassembly
4.1.3 Inspection After Reassembly
4.2 Spring Brake Valve
4.2.1 Disassembly
4.2.2 Reassembly
4.2.3 Inspection After Reassembly
Group 37 – Steering
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. General
6. Service Procedure
6.1 Removal and Installation
6.2 Steering Shaft
6.2.1 Removal
6.2.2 Installation
6.2.3 Disassembly, Inspection and Correction
6.2.4 Reassembly
6.3 Link and Bracket Section
6.3.1 Disassembly
6.3.2 Reassembly
6.4 Drag Link
6.5 Tie Rod
6.6 Integral Power Steering Booster
6.6.1 Disassembly, Inspection and Correction
6.6.2 Reassembly and Adjustment
6.7 Power Steering Oil Pump
6.7.1 Removal
6.7.2 Installation
6.7.3 Disassembly, Inspection and Correction
6.7.4 Reassembly
6.7.5 Adjustment
6.8 Power Steering Oil Tank
6.8.1 Disassembly
6.8.2 Reassembly
6.9 Adjustment After Installlation
6.9.1 Bleeding
6.9.2 Performance Verification Tests
6.9.3 Steering Wheel Play
6.9.4 Adjustment of Steering Angle
Group 41 – Frame
Table of Contents
1. General
2. Service Procedure
2.1 Inspection and Repair
2.1.1 Frame
2.1.2 Rivets
2.1.3 Bolts and Nuts
Group 42 – Cab
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. General
4.1 Cab Proper
4.2 Cab Mounting
4.2.1 Front Cab Mounting
4.2.2 Rear Cab Mounting
4.3 Cab Tilt System
5. Service Procedure
5.1 Removal
5.1.1 Key Points for Removal
5.1.2 Key Points for Installation
5.1.3 Inspection and Adjustment After Installation
5.2 Cab Mounting
5.2.1 Front Cab Mounting
5.2.2 Cab Stay
5.2.3 Rear Cab Mounting
5.2.4 Cab Tilt Link
5.3 Doors
5.3.1 Removal of Doors
5.3.2 Doors Installation Adjustment
5.3.3 Front Door Assembly
5.4 Interior Parts
5.4.1 Seats and Center Console
5.4.2 Air Suspension
5.4.3 Seat Belts (3-Point Type Seat Belts with ELR)
5.4.4 Floor Mat
5.4.5 Overhead Console
5.4.6 Trim and Headlining
5.4.7 Instrument Panel
5.5 Window Glass
5.5.1 Removal
5.5.2 Installation
5.6 Exterior Parts
5.6.1 Front Panel, Fender and Allied Parts
5.6.2 Rear View Mirrors
Group 54 – Electrical
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
4. General
5. Service Procedure
5.1 Battery
5.1.1 General Description
5.1.2 Inspection
5.2 Fuses
5.2.1 General Description
5.2.2 Inspection
5.3 Fusible Link
5.3.1 General Description
5.3.2 Inspection
5.4 Starter Switch and Cold Start Switch
5.4.1 General Description
5.4.2 Inspection
5.5 Sub-Starter System
5.5.1 General Description
5.5.2 Inspection
5.6 Combination Switch
5.6.1 General Description
5.6.2 Inspection
5.7 Lighting System
5.7.1 General Description
5.7.2 Inspection
5.7.3 Inspection and Adjustment After Installation
5.8 Meter System
5.8.1 General Description
5.8.2 Inspection
5.9 Indicators and Warning Lamps
5.9.1 General Description
5.9.2 Inspection
5.10 Wiper and Washer System
5.10.1 General Description
5.10.2 Inspection
5.10.3 Inspection and Adjustment After Installation
5.11 Horn
5.11.1 General Description
5.11.2 Inspection
5.12 Back Buzzer
5.12.1 General Description
5.12.2 Inspection
5.13 Radio and Cassette Stereo <Option>
5.13.1 Mounting Position
5.13.2 AM/FM Radio and AM/FM Radio With Cassette Stereo
5.13.3 Troubleshooting
5.14 Cigarette Lighter
5.14.1 General Description
5.14.2 Inspection
Group 55A – Air Conditioner
Group 55A (9107) – Air Conditioner
Foreword/Table of Contents
1. Specifications
2. Outlines of Refrigeration System
2.1 Air System
2.2 Refrigerating Cycle
2.3 Electrical System
3. Construction
3.1 Engine Room
3.2 Cabin Room
3.3 Control System
3.4 Compressor and Magnetic Clutch
3.4.1 Compressor
3.4.2 Check Valve
3.4.3 Magnetic Clutch
3.5 Condenser
3.6 Receiver Drier
3.7 Cooling Unit
3.8 Expansion Valve
3.9 Dual Pressure Switch
3.10 Power Relay
3.11 A/C Switch
3.12 Fin Thermo
4. Troubleshooting
4.1 General
4.2 Trouble Cause and Remedy
4.3 Inspection Procedures
4.3.1 A/C Switch
4.3.2 Dual Pressure Switch
4.3.3 Fin Thermo
4.3.4 Magnetic Clutch
4.3.5 Refrigerant Charge
4.3.6 Receiver Drier Assembly
4.3.7 Belting Tension
4.3.8 Expansion Valve
4.3.9 Compressor
4.3.10 Air Inclusion in Ref. Circuit
4.3.11 Moisture Inclusion in Ref. Circuit
5. Removal and Installation
5.1 Precautions for Removal and Installation
5.2 Removal
5.2.1 Inside the Engine Room
5.2.2 Cabin Room
6. Treatment After Installation
6.1 Check and Adjustment
6.2 Leak Test
6.2.1 Test Points
6.2.2 Test Procedure
6.4 System Charging
6.4.1 Installation of Charge Equipment
6.4.2 Charging System
6.4.3 Charging With Small Cans
6.4.5 Correcting Low Refrigerant Level
6.4.6 Discharging System
6.5 Checking the Refrigerant Level
6.6 Performance Test
6.6.1 Preparation
6.6.2 Stationary Performance Test
7. Compressor
7.1 Compressor
7.2 Disassembly and Reassembly Precautions
7.2.1 Disassembly Precautions
7.2.2 Reassembly Precautions
7.2.3 Tools and Instruments
7.3 Precautions at Disassembly
7.4 Maintenance and Check
7.4.1 Inspection Standards
7.4.2 Consumable Parts
7.5 Assembly Procedure
7.5.1 Tightening Torque
7.5.2 Assembly Procedure
7.6 Special Tool Figure
8. Cooling Unit
8.1 Components
8.2 Cautions in Disassembling
8.3 Disassembling
9. Maintenance
Group 55A (9403) – Air Conditioner
Table of Contents
1. Specifications
2. Outlines of Refrigeration System
2.1 Air System
2.2 Refrigerating Cycle
2.3 Electrical System
3. Construction
3.1 Engine Room
3.2 Cabin Room
3.3 Control System
3.4 Compressor and Magnetic Clutch
3.4.1 Compressor
3.4.2 Check Valve
3.4.3 Magnetic Clutch
3.5 Condenser
3.6 Receiver Assembly
3.7 Cooling Unit Assembly
3.8 Expansion Valve
3.9 Relief Valve
3.10 Dual Pressure Switch
3.11 Power Relay
3.12 A/C Switch
3.13 Fin Thermo
4. Troubleshooting
4.1 General Procedure
4.2 Trouble Cause and Remedy
4.3 Inspection Procedures
4.3.1 A/C Switch
4.3.2 Dual Pressure Switch
4.3.3 Fin Thermo
4.3.4 Magnetic Clutch
4.3.5 Refrigerant Charge
4.3.6 Receiver Assembly
4.3.7 Belting Tension
4.3.8 Expansion Valve
4.3.9 Compressor
4.3.10 Air Inclusion in Ref. Circuit
4.3.11 Moisture Inclusion in Ref. Circuit
5. Removal and Installation
5.1 Precautions for Removal and Installation
5.2 Removal
5.2.1 Inside the Engine Room
5.2.2 Cabin Room
6. Treatment After Installation
6.1 Check and Adjustment
6.2 Leak Test
6.2.1 Test Points
6.2.2 Test Procedure
6.3 System Charging
6.3.1 Evacuation
6.3.2 Evacuate the System
6.3.3 Removal of Charge Equipment
6.3.4 Discharging System
6.4 Checking the Refrigerant Level
6.5 Performance Test
6.5.1 Preparation
6.5.2 Stationary Performance Test
7. Compressor
7.1 Component of Compressor
7.2 Disassembly and Reassembly Precautions
7.2.1 Disassembly Precautions
7.2.2 Reassembly Precautions
7.2.3 Tools and Instruments
7.3 Precautions at Disassembly
7.4 Maintenance and Check
7.4.1 Inspection Standards
7.4.2 Consumable Parts
7.5 Assembly Procedure
7.5.1 Tightening Torque
7.5.2 Assembly Procedure
9.5 Special Tool Figure
8. Cooling Unit
8.1 Components
8.2 Cautions in Disassembling
8.3 Disassembling
9. Maintenance
Group 55B – Heater
Table of Contents
1. Troubleshooting
2. Specifications
3. General
3.1 Ventilation System
3.2 Heater
4. Service Procedure
4.1 Removal and Installation
4.2 Cleaning of Air Filter
4.3 Heater Control Adjustment Procedures

1996-2001 Mitsubishi FUSO Fighter FK FM Truck (USA) Service Manual PDF Download

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Format: PDF
Pages: 5,804
File size: 247mb
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1996, 1997, 1998, 1999, 2000, 2001 Mitsubishi FUSO Fighter FK FM Series Truck (USA models) Service & Repair

  • FK617
  • FM617
  • FM657

Manual Part Number: TWME9503 plus model year changes

Topics List:

  • GENERAL
  • MAINTENANCE SCHEDULE
  • ENGINE
  • LUBRICATION
  • FUEL AND ENGINE CONTROL
  • COOLING
  • INTAKE AND EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • AUTOMATIC TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM / WIRING DIAGRAMS
  • AIR-CONDITIONER & HEATER

2002-2004 Mitsubishi FUSO FE FG FH FK FM Truck (USA) Service Manual PDF Download

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Format: PDF
Pages: 4,655
Compatible with: Windows/Mac/Tablet/Phone

Covers: 2002, 2003, 2004 Mitsubishi FUSO FE, FG, FH, FK, FM Series Truck (U.S. models) Service & Repair

  • FE636
  • FE640
  • FE649
  • FG639
  • FG649
  • FH210
  • FH211
  • FK617
  • FM617
  • FM657

Manual Part Number: TWSE0101 TWME0202 TWME0103

Topics List:

  • GENERAL INFORMATION
  • SPECIFICATIONS
  • TORQUES
  • MAINTENANCE SCHEDULE
  • COMPLETE ENGINE SERVICE AND REPAIR
  • ENGINE TROUBLESHOOTING
  • LUBRICATION
  • FUEL AND ENGINE CONTROL
  • ELECTRONIC FUEL SYSTEM
  • COOLING
  • INTAKE AND EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • AUTOMATIC TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM / WIRING DIAGRAMS
  • AIR-CONDITIONER & HEATER
  • AND MUCH MORE…

2005 Mitsubishi FUSO FE FG FK FM Truck (USA) Service Manual PDF Download

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Format: PDF
Pages: 3,164
Compatible with: Windows/Mac/Tablet/Phone

Covers: 2005 Mitsubishi FUSO FE, FG, FK, FM Series Truck (U.S. models) Service & Repair

  • FE83
  • FE84
  • FE85
  • FG84
  • FK61
  • FM61
  • FM64
  • See full model list below

Manual Part Number: TWSE0405 TWME0404

The 2005 Mitsubishi FUSO FE FG FK FM Truck (USA) Service Manual PDF Download includes complete service procedures for the truck, including specifications, illustrations, diagrams and step-by-step instructions. This is the same manual used by professional technicians.

Topics List:

  • GENERAL INFORMATION
  • SPECIFICATIONS
  • MAINTENANCE SCHEDULE
  • COMPLETE ENGINE SERVICING
  • ENGINE TROUBLESHOOTING
  • LUBRICATION SYSTEM
  • FUEL SYSTEM
  • ENGINE CONTROL
  • ELECTRONIC FUEL SYSTEM
  • COOLING SYSTEM
  • INTAKE AND EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • AUTOMATIC TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM / WIRING DIAGRAMS
  • AIR-CONDITIONER & HEATER
  • AND MUCH MORE…

Complete model list covered:

FE83DDZSLSUA
FE83DEZSLSUA
FE83DGZSLSUA
FE83DDZSLSUB
FE83DEZSLSUB
FE83DGZSLSUB
FE84DDZSLSUA
FE84DEZSLSUA
FE84DGZSLSUA
FE84DHZSLSUA
FE84DDZSLSUB
FE84DEZSLSUB
FE84DGZSLSUB
FE84DHZSLSUB
FE84DHWSLSUB
FE85DDZSLSUC
FE85DEZSLSUC
FE85DGZSLSUC
FE85DHZSLSUC
FE85DJZSLSUC
FE85DDZSLSUB
FE85DEZSLSUB
FE85DGZSLSUB
FE85DHZSLSUB
FE85DJZSLSUB
FG84DC6SLSUA
FG84DE6SLSUA

FK61FH1LSUA
FK61FJ1LSUA
FK61FK1LSUA
FK61FL1LSUA
FK61FJ1LSUB
FK61FK1LSUB
FK61FL1LSUB
FM61FF1LSUA
FM61FJ1LSUA
FM61FL1LSUA
FM61FM1LSUA
FM61FP1LSUA
FM64FM1LSUA
FM64FP1LSUA
FM61FJ1LSUB
FM61FL1LSUB
FM61FM1LSUB
FM61FP1LSUB
FM64FM1LSUB
FM64FP1LSUB

2008 Mitsubishi FUSO Fighter FK FM Truck Service Manual PDF Download

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Format: PDF
Pages: 2,384
Compatible with: Windows/Mac/Tablet/Phone

Covers: 2008 Mitsubishi FUSO Fighter FK ,FM Series Truck (US Models Only) Service & Repair

  • FK61
  • FK62
  • FK65
  • FM65
  • See full model list at bottom of page

Manual Part Number: PWME0806

Topics List:

  • GENERAL
  • MAINTENANCE SCHEDULE
  • COMPLETE ENGINE SERVICING
  • ENGINE TROUBLESHOOTING
  • LUBRICATION
  • FUEL AND ENGINE CONTROL
  • ELECTRONIC FUEL SYSTEM
  • COMMON RAIL SYSTEM
  • COOLING
  • INTAKE AND EXHAUST
  • CLUTCH
  • MANUAL TRANSMISSION
  • AUTOMATIC TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • ELECTRICAL SYSTEM / WIRING DIAGRAMS
  • AIR-CONDITIONER & HEATER

Full list of models covered in this manual:

FK61FJ1LSUH
FK61FK1LSUH
FK61FM1LSUH
FK62FFZ1LSUG
FK62FJZ1LSUG
FK62FLZ1LSUG
FK62FMZ1LSUG
FK62FSZ1LSUG
FK65FMZ1LSUG
FK65FSZ1LSUG
FK62FJZ1LSUH
FK62FLZ1LSUH
FK62FMZ1LSUH
FK62FSZ1LSUH
FK65FMZ1LSUH
FK65FSZ1LSUH
FM65FJ1LSUG
FM65FL1LSUG
FM65FM1LSUG
FM65FP1LSUG
FM65FJ1LSUH
FM65FL1LSUH
FM65FM1LSUH
FM65FP1LSUH

Mitsubishi FUSO Fighter FK FM FN Truck (Euro3 AUS) Service Manual PDF Download

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Format: PDF (zipped)
Compatible with: Windows/Mac/Linux
File size: 275mb

Covers: Mitsubishi Fighter Euro3 Truck (AUSTRALIA) Service & Repair

  • FK617
  • FK61F
  • FM61F
  • FM65FH1
  • FM65FP1
  • FM65FJ1
  • FM65F-2
  • FM67F-1
  • FM67F-2
  • FN61F
  • FN62F
  • FN64F

Topics List:

  • GENERAL INFORMATION
  • ENGINE SHOP MANUAL 6M60T1, 6M60T2, 6D16T3
  • CLUTCH
  • MANUAL TRANSMISSION
  • AUTOMATIC TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL AND TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • AIR OVER HYDRAULIC BRAKE
  • FULL AIR BRAKE
  • PARKING BRAKE
  • CENTER PARKING BRAKE
  • PARKING BRAKE
  • WHEEL PARKING BRAKE
  • STEERING
  • FRAME
  • CAB
  • HEATER, AIR-CONDITIONER AND VENTILATION
  • ELECTRICAL / WIRING DIAGRAMS

Mitsubishi FUSO Fighter FK FM FN Truck (EPA04 AUS/NZ) Service Manual PDF Download

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Format: PDF (zipped)
Compatible with: Windows/Mac/Linux
File size: 200mb

Covers: Mitsubishi FUSO Fighter EPA04 Truck (AUSTRALIA/NEW ZEALAND) Service & Repair

  • FK61F, FK62F, FK65F
  • FM65F, FM67F
  • FN61F, FN62F, FN63F, FN64F

Topics List:

  • GENERAL
  • ENGINE SHOP MANUAL 6M60T1, 6M60T2
  • CLUTCH
  • MANUAL TRANSMISSION
  • PROPELLER SHAFT
  • FRONT AXLE
  • REAR AXLE
  • WHEEL, TIRE
  • FRONT SUSPENSION
  • REAR SUSPENSION
  • BRAKE
  • ANTI-LOCK BRAKE SYSTEM (ABS)
  • PARKING BRAKE
  • STEERING
  • BUMPER, FRAME
  • CAB MOUNTING, TILT
  • DOOR
  • EXTERIOR
  • INTERIOR
  • AIR-CONDITIONER, VENTILATION
  • ELECTRICAL / WIRING MANUAL

Full model list:

  • FK61FH1RFAA
  • FK61FL1RFAA
  • FK61FM1RFAA
  • FK61FH1RFAB
  • FK61FK1RFAB
  • FK61FL1RFAB
  • FK61FM1RFAB
  • FK61FKWRFAB
  • FK62FHZ1RFAA
  • FK62FLZ1RFAA
  • FK62FMZ1RFAA
  • FK65FLZ2RFAA
  • FK65FMZ2RFAA
  • FK65FLZ2RFAB
  • FK65FMZ2RFAB
  • FM65FH2RFAA
  • FM65FM2RFAA
  • FM65FS2RFAA
  • FM65FH2RFAB
  • FM65FS2RFAB
  • FM67FM2RFAB
  • FM67FS2RFAA
  • FM67FS2RFAB
  • FN61FU2RFAA
  • FN62FK2RFAA
  • FN63FU2RFAA
  • FN64FU2RFAA