1990-1991 Mitsubishi Fuso FE/FG/FH/FK/FM Series Service & Repair Manual
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J... Service Manual
MllSUBISHI
AlSO
FK.FM 1990
Pub. No. 1WME891 0
FI<.FM
Service Manual
FOREWORD
This service manual contains the instructions for the
servicing of the Mitsubishi Fuso FK, FM series trucks.
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.
For more details, consult your local Mitsubishi Fuso
Dealers and Distributors.
May 1989
GROUP INDEX
GENERAL ................................................... 00
MAINTENANCE SCHEDULE ..................... 0 1
ENGINE ...................................................... 11
LUBRICATION ............................................ 12
FUEL AND ENGINE CONTROL ................. 1 3
COOLING ................................................... 14
INTAKE AND EXHAUST ............................ 1 5
ENGINE ELECTRICAL ................................ 1 6
CLUTCH ...................................................... 21
....................... 22A
....................... 22 8
AUTOMATIC TRANSMISSION ................. 23
PROPELLER SHAFT ................................... 2 5
FRONT AXLE .............................................. 2 6
REAR AXLE ................................................ 2 7
WHEEL AND TIRE ...................................... 31
FRONT SUSPENSION ............................... 33
REAR SUSPENSION .................................. 34
BRAKE
35
A
(AIR OVER HYDRAULIC BRAKE) ···················
BRAKE) ········································ 358
PARKING BRAKE 36A
(CENTER PARKING BRAKE) ··························
PARKING BRAKE 368
(WHEEL PARKING BRAKE) ···························
STEERING .................................................. 37
FRAME ....................................................... 41
CAB ............................................................. 42
CHASSIS ELECTRICAL .............................. 54
AIR CONDITIONER .................................... 55 A
HEATER ...................................................... 558
COMPILATION OF THIS MANUAL- GROUP CLASSIFICATION
1. GROUP CLASSIFICATION
This manual is organized into groups as follows:
Group No. Group
Name
Contents
00 General Exterior views, major specifications, power train table, equipment model notation,
performance curves, servicing precautions, standard bolts and nuts tightening torque
table, towing precautions, chassis and engine number, vehicle identification number
01 Maintenance schedule Maintenance schedule table, simple maintenance procedures, lubrication chart, simple
lubrication procedures
11 Engine Troubleshooting, specifications, service standards, special tools, general.
engine proper (cylinder head, valve mechanism, camshaft, piston, crankshaft, timing
gear, flywheel)
12 Lubrication Troubleshooting, specifications, service standards, special tools, general,
lubrication system (oil pump, oil filter, oil cooler)
13
Fuel and engine control Troubleshooting, specifications, service standards, special tools, general,
fuel system (injection pump, injection nozzle, fuel filter, water separator), engine
control (accelerator pedal, fuel control, stop button)
14
Cooling
Troubleshooting, specifications, service standards, special tools, general,
cooling system (water pump, thermostat, radiator, fan)
15 Intake and exhaust Troubleshooting, specifications, service standards, special tools, general,
air cleaner, turbocharger, manifold, intercooler
16 Engine electrical Troubleshooting, specifications, service standards, special tools, general,
starter, alternator, glow system
21
Clutch
Troubleshooting, specifications, service standards, special tools, general,
clutch proper, clutch pedal, clutch master cylinder, power cylinder, clutch booster,
clutch housing, replacement of clutch fluid and bleeding of clutch system, clutch pedal
adjustment, lubricating of drive pinion splines
22A
Manual transmission
Troubleshooting, specifications, service standards, special tools, general,
<M5S5, M655> removal and installation of transmission, transmission assembly, transmission proper
(main shaft, counter shaft), gear shifter, rear cover, transmission control
228
Manual transmission Troubleshooting, specifications, service standards, special tools, general,
<MBS5, MBS2x5> removal and installation of transmission, transmission assembly, transmission proper
(main shaft, counter shaft), gear shifter, rear cover, splitter, power shift,
transmission control. splitter control
23 Automatic transmission Troubleshooting, specifications, service standards, special tools, general,
removal and installation of automatic transmission, oil seal and speedometer, automatic
transmission control system, oil cooler, oil filter, replacement of oil and oil filter
25 Propeller shaft Troubleshooting, specifications, service standards, special tools, general,
propeller shaft, center bearing, universal joint
26 Front axle
Troubleshooting, specifications, service standards, special tools, general,
front axle, kingpin, knuckle, wheel hub, brake drum
27
Rear axle
Troubleshooting, specifications, service standards, special tools, general,
rear axle, reduction and differential, wheel hub, brake drum
31 Wheel and tire Troubleshooting, specifications, service standards, general, tire, disc wheel
33
Front suspension Troubleshooting, special tools, specifications, service standards, general,
leaf springs, shock absorber
34 Rear suspension Troubleshooting, special tools, specifications, service standards, general, leaf springs
35A Brake
Troubleshooting, specifications, service standards, special tools, general,
(air over hydraulic brake) service brake !dual brake valve, brake booster, wheel brake (wheel cylinder, brake
drum, brake shoe)J, exhaust brake (exhaust brake valve, control cylinder)
358
Brake
Troubleshooting, specifications, service standards, special tools, general.
(full air brake)
service brake !dual brake valve, relay valve, quick release valve, slack adjuster,
brake chamber, wheel brake (brake drum, brake shoe)], exhaust brake (exhaust brake
valve, control cylinder)
36A Parking brake Troubleshooting, special tools, specifications, service standards, general,
(center parking brake) parking brake, parking brake control
368 Parking brake
Troubleshooting, service standards, general, spring brake control valve, spring brake
(wheel parking brake)
valve
2
r
COMPILATION OF THIS MANUAL- GROUP CLASSIFICATION,
DEFINITIONS OF TERMS AND UNITS USED
Group No. Group Name Contents
37 Steering Troubleshooting, specifications, service standards, special tools, general, steering wheel,
power steering booster, power steering oil pump, steering linkage, tie rod, steering shaft
41 Frame Frame, rivet, inspection and correction
42 Cab Troubleshooting, specifications, service standards, general,
removal and installation of cab, cab mounting, door, seat, seat belt, floor mat, trim,
instrument panel, windshield, rear window, front panel. wiper, rearview mirror
54 Chassis electrical Troubleshooting, specifications, service standards, general. battery, fuses,
fusible link, starter switch and cold starter switch, sub-starter switch,
combination switch, lighting system, meter system, indicators and warming system,
wiper and washer system, horn, back-up buzzer, radio and cassette stereo, cigarette lighter
55 A Air Conditioner Air conditioner ventilation system
558 Heater Troubleshooting, specifications, heater, ventilation system
Page numbers start at "1" for each section.
2. DEFINITIONS OF TERMS AND UNITS
USED
Terms and units used commonly throughout this
manual have specific meanings, as defined below.
(1) Front and rear
When the vehicle is travelling forward, that part of
the vehicle which is in a leading position is
referred to as the front; the opposite end of the
vehicle referred to as the rear, or back.
(2) Left and right
When an observer is facing in the same direction
as the vehicle's forward direction of motion, the
observer's right and left correspond to the right
and left sides of the vehicle; i.e., that part of the
car which is on the observer's right when facing
forward is referred to as the right side of the car.
(3) Maintenance standards terms
• Norminal value
Indicates the design dimentions of the vehicle
body and individual parts, the standard clearance
between assembled parts, and the standard per-
formance of assemblies. Values in brackets are
basic diameters.
• Limit
Indicates the dimension limit of a part, at which
point the part is no longer serviceable from the
view point of both performance as well as
strength, and requires replacement.
(4) Tightening torque
Tightening bolts and nuts too much or too little
can have a large influence on performance and
function.
Thus, tightening torque is specified for each
location that must be tightened in a particular
range. When tightening must be performed under
wet conditions, this is specified. If not specified,
tightening is performed dry.
When tightening torque is not specified, tighten
according to the standard bolts and nuts tighten-
ing torque table.
(5) Units
Length, weight, surface area and capacity are
given in International Systems of Units, with foot
pounds units indicated in brackets. Temperatures
are given in degrees Celsius, with degrees in
Fahrenheit in brackets.
3
COMPILATION OF THIS MANUAL- NOTES ON ILLUSTRATIONS
3. NOTES ON ILLUSTRATIONS
Example 1 Disassembly and inspection
2
rv_i_su_a_u_v_ch_e_c_ke---,d '
Deterioration ""
6
1
3
Clearance
80 20.64 (0.81)
NV 0.04 to 0.125 (0.0016 to 0.0049) BD ... Basic Diameter
L 0.15 (0.0059)
NV ... Nominal Value
L ... Limit
Indicates typical disassembly sequence.
/
Indicates service standard value.
Disassembly sequence
1 Push rod 5 Gasket 9 Return spring
2 Lock nut 6 Piston stop ring 10 Cylinder
3 Boot 7 Piston stop plate 11 Nipple
4 Supply valve stopper
®
Piston
Indicates part of which Disassembly Procedures are given in the
text. E0485A
Example 2 Reassembly
Indicates special instructions /- Specifies tightening torque.
/ for assembly.
Apply sufficient 25 to 34 Nm
amount of grease (18 to 25lbf.ft, 2.5 to 3.5 kgfm)
(Metal Rubber
9
Primary cup 11
No.20, Chuo-
Kagaku product)
to cylinder and
piston sliding
surfaces
0 0 G 0
9)
I
Supply
valve
10 5 4
Indicates typical assembly sequence.
Assembly sequence
6
part of which Reassembly Procedures are
· gtven In the text.
E0457A
CAUTION 2. Only a typical equipment illustration is given
regardless of availability of type variations if
there is only one applicable service procedure.
1. The unit mm (in.) is omitted in the illustrations.
4
MITSUBISHI
FUSO
II
1111
IC anual
Group 00
General
J... MITSUBISHI FUSO TRUCK OF AMERICA, Inc.
Pub. No. TWME891 0-00
GENERAL
CONTENTS
1. EXTERIORVIEWS .................................. 00- 2 6. SERVICING PRECAUTIONS .................. 00-22
2. MAJOR SPECIFICATIONS ..................... 00- 4 7. STANDARD BOLTS AND NUTS
3. POWERTRAINTABLE ........................... 00-11 TIGHTENING TORQUE TABLE .............. 00-27
4. EQUIPMENT MODEL NOTATION ......... 00-12 8. TOWING PRECAUTIONS ....................... 00-28
5. PERFORMANCE CURVES ..................... 00-13 9. CHASSIS AND ENGINE NUMBERS ...... 00-28
5.1 Operation Performance Curves ........ 00-13
5.2 Engine Performance Curves ............. 00-21
10. VEHICLE IDENTIFICATION
NUMBER ................................................. 00-29
00-1
1. EXTERIOR VIEWS
FK415H
1745168.7)
FK455H
1900 174.8)
00-2
GENERAL - EXTERIOR VIEWS
0
<D
N
x
E
c.
c.
<l: • .L-!----"'+'--
11195147.011
W.B. 4210 1165.7)
7220 1284.3)
W.B.4160I163.8)
7220 1284.3)
A0255A
1815171.5)
A0256A
FM555H
'""'
0 a
1920 175.6)
FM557H
ocpa
I 1920 175.6)
'"
,;
!1!
0
N
GENERAL - EXTERIOR VIEWS
_,
0'
N
r-
N
x
0
c.
c.
<(
W.B. 4280 1168.5)
7455 1293.5)
A0257A
W.B. 4280 1168.5)
1930 176.0)
74551293.5)
A0258A
00-3
GENERAL- MAJOR SPECIFICATIONS
2. MAJOR SPECIFICATIONS
Model
FK415HSLSU
FK415HSLSUB
......__ -----------. T
-------------.. ---. ransmission
M5S5
M4A4 IAT545)
----------
Item
8.25·20-12PR 9R22.5-12PR
8.25-20·12PR
9R22.5-12PR
Type
Forward control type
Drive system
4 X 2
Dimensions
mm(in.)
Wheel base
4210 (165.7) 4210 (165.7) 4210 (165.7)
4210 (165.7)
Overall length
7220 (284.3) 7220 (284.3)
7220 (284.3)
7220 (284.3)
Overall width
2370 (93.3) 2370 (93.3)
2370 (93.3)
2370 (93.3)
Overall height, approx.
2610 (102.8)
2600 I 102.41
2610 (102.8)
2600 (102.4)
Tread, front
1745 (68.7) 1745 (68.7) 1745 (68.7)
1745 (68.7)
rear
1725 (67.9)
1725 (67.9) 1725 167.9)
1725 (67.9)
Weights
kg llbf)
Vehicle weight
3595 (7925)
3595 (7925)
3635 18015)
3635 (8015)
Gross vehicle weight
10450 (23000) 10450 (23000)
10450 123000) 10450 (23000)
Max. GVW
Seating capacity
2 2 2
2
Performance (Computed)
Max. speed
km/h (mph)
108 (67.1)
109 (67.71
97 (60.3)
98 (60.9)
Climbing ability
(tan O)
29.0 29.0 31.5
31.5
with Max. GVW
Min. turning radius
m (ft.) 7.8 125.6) 7.8 125.6) 7.8 (25.6)
7.8 (25.6)
Model FK415JSLSU FK415JSLSUB
..
::--- ..... _ T
M5S5
M4A4 IAT545)
Item
8.25-20-12PR
9R22.5·12PR 8.25-20-12PR
9R22.5·12PR
Type
Forward control type
Drive system
4 X 2
Dimensions
mm(in.)
Wheel base
4510 (177.6) 4510 (177.6) 4510 (177.6)
4510 (177.6)
Overall length
7655 (301.4) 7655 (301 .4) 7655 (301.4)
7655 (301.41
Overall width
2370 193.3)
2370 193.3) 2370 193.3) 2370 (93.31
Overall height, approx.
2610 (102.8)
2600 1102.4)
2610 (102.8) 2600 (102.4)
Tread, front
1745 (68.7) 1745 (68.7)
1745 (68.7) 1745 (68.71
rear
1725 (67.9)
1725 (67.9) 1725 (67.9) 1725 (67.9)
Weights
kg (lbf)
Vehicle weight
3610 (7960)
3610 (7960) 3650 (8045)
3650 (8045)
Gross vehicle weight
10450 (23000) 10450 (23000) 10450 (23000)
1 0450 I 23000 I
Max. GVW
Seating capacity 2
2
2 2
Performance (Computed)
Max. speed
km/h (mph)
108 167.1) 109 (67.7)
97 (60.3) 98 160.9)
Climbing ability (tan O)
29.0 29.0 31.5 31.5
with Max. GVW
Min. turning radius
m (ft.) 8.3 (27.7)
8.3 (27.7) 8.3 (27.7) 8.3 127.71
00-4
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$41.99
1990-1991 Mitsubishi Fuso FE/FG/FH/FK/FM Series Service & Repair Manual
Engines covered:
- 4D31T2
- 4D31T
- 6D14T
- 6D14T2
- 6D16T2
Whether you are a professional mechanic or a DIY enthusiast, this truck repair manual provides comprehensive troubleshooting and replacement procedures recommended by the manufacturer. It includes step-by-step instructions, clear images, and exploded-view illustrations to assist you in fixing problems on your truck.
Regular maintenance is essential for the durability of your truck. Over time, certain parts will wear out and require replacement, even with proper maintenance.
A reliable truck repair manual is invaluable, offering manufacturer-recommended troubleshooting charts and replacement procedures to help you save on repairs, enhance your vehicle's reliability, and minimize visits to the repair shop.
Featuring step-by-step instructions, exploded-view illustrations, and clear images, this manual eliminates the need to search through numerous pages for specific information. It provides a convenient alternative to traditional bound manuals, allowing easy access, searchability, and portability.
Additionally, you have the option to print a physical copy if preferred.
Format: .pdf
Printable: Yes
Language: English
Compatibility: Compatible with various electronic devices, including PC, Mac computers, Android and Apple smartphones, and tablets.
Requirements: Adobe Reader (free)
