Mitsubishi Fuso FK FM Series 1986-2001 Workshop Repair Service Manual PDF - MMTBSFUSOFKFM8601.zip
This comprehensive service and repair guide for the Mitsubishi Fuso FK/FM Series (1986–2001) comes complete with Electrical Wiring Diagrams, containing every technical detail needed to service, troubleshoot, fix, and overhaul your vehicle just like a certified technician.
Covering the 1986–2001 Mitsubishi Fuso FK/FM Series, this workshop manual contains:
* 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