1990 Fuso FG 4x4

[BobbyB]

Hello all, I recently have purchased a 1990 FG and I'm trying to hunt down a service manual or at least ask some questions about wiring for the rear brakes (to get them working) and a few questions about the PTO (as it has a dump bed) any help would be great. Thank you in advance!

[BobbyB]

100+ views and no one can give me some insight....? I've found this link that has the factory service manual on CD, but I am always leery about them... Link HERE (http://www.trucktechhelp.com/store/index.php?main_page=product_info&cPath=2_8_22&products_id=755)

Are there any other forums that cover these trucks???

[FusoFG]

I have a 93 that had a dump body. All that's left is the PTO. I have the 3 set factory manuals that I paid $350 for (there wasn't a cd copy available when I purchased them) so it sounds like someone scanned them and put them on cd.
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The price sounds about right but you might want to call and ask if they are seachable or just pictures of the manual pages.
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What are your questions?
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What do mean by "wiring for the rear brakes"?

[BobbyB]

FusoFG thank you for the reply. Would you be interested in selling the manuals. Part of me wants to have a hard copy so that I can look at them while I am working on the truck. And I agree, I'll have to find out too if they can be searched for which topic. Would you be willing to part with them for a decent price or are you looking for what you paid.
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I guess my major questions are about the brakes. I have no tail lights at all, and I need to trace them. Do the rear brake lights come from the back left of the cab on the frame rails? Also, on the topic of brakes, this thing stops, but not well. The peddle goes almost all the way to the floor, but it will stop. If you pump them once more then the peddle is a little bit better. I have not bleed them yet (the guy I bought the truck off seems to think that is all they need) but will try. I also think that it might be an adjustment thing. Do you think that it would be better to check for adjustment first, is there anything weird that I need to know before tearing into this brake system?
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Also, as I saw you noted that you had a dump body on your Fuso... My PTO level is VERY hard to pull up on in-order to engage the PTO, I'm thinking it needs LUBED very well as it might have been neglected in its former life... Any thoughts? Again, thank you for taking the time to look at this!

[FusoFG]

FusoFG thank you for the reply. Would you be interested in selling the manuals. Part of me wants to have a hard copy so that I can look at them while I am working on the truck. And I agree, I'll have to find out too if they can be searched for which topic. Would you be willing to part with them for a decent price or are you looking for what you paid.

Sorry, my 93 only has 117,000 miles on it and I'm keeping it until I die so I need the factory manuals. The CD with the 2004 manuals is only about $100 and there's a dealer in Cleveland - wouldn't be perfect, but might be better than nothing.
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I guess my major questions are about the brakes. I have no tail lights at all, and I need to trace them. Do the rear brake lights come from the back left of the cab on the frame rails? Also, on the topic of brakes, this thing stops, but not well. The peddle goes almost all the way to the floor, but it will stop. If you pump them once more then the peddle is a little bit better. I have not bleed them yet (the guy I bought the truck off seems to think that is all they need) but will try. I also think that it might be an adjustment thing. Do you think that it would be better to check for adjustment first, is there anything weird that I need to know before tearing into this brake system?

Yes. the brake lights, tail lights, license plate lites, rear marker lights and backup lights run down the inside of the driver side chassis rail and then across the frame to the passenger rear corner. Mine ends in 2 connectors that plugged into the factory tail light assemblies, but the body builder removed those and wired the connectors to lights mounedt on the body.
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I will look for the wiring diagram in my manual and maybe I will be able to scan it and post as a picture.
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Don't have much advice about the brakes. Mine are original and work very well. They may have been adjusted but that would have been done during service, I've never done it myself.
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The pumping might have something to do with the vacumm assist. On mine there is a pump and a storage tank. A leak somewhere might explain your symptoms.
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As far as adjusting them, I believe someone on this forum was asking about adjusting the brakes and after doing it said it was pretty easy. You might want to search for that. It wasn't too long ago.
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Bleeding can't hurt, but if the truck has a lot of miles you might want to change the brake fluid before bleeding them.

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Also, as I saw you noted that you had a dump body on your Fuso... My PTO level is VERY hard to pull up on in-order to engage the PTO, I'm thinking it needs LUBED very well as it might have been neglected in its former life... Any thoughts? Again, thank you for taking the time to look at this!

The dump body was removed when I bought the truck new in 1993. The only thing left is the PTO, the shaft sticking out of the side of the transmission and a cable pull to engage it from the driver's compartment. It looks like the cable is attached to a homemade lever on the side of the transmission that moves something in the transmission to engage it. I think I engaged it a couple of times when I first got the truck because I was thinking of driving an air compressor, but I haven't done anything with it in years.
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I'll look at my manual and see if there is anything useful that would be simple to scan. I know the manual sounds expensive, but without it your pretty much guessing at how to fix things. I bought it because with it, I figured any good mechanic could repair the truck whereever I was when it needed servicing.

[FusoFG]

There wasn't anything in my manual about the PTO on the manual transmission. There was a page or two in the Automatic transmission section, but the PTO didn't look anything like mine.
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Is your transmission a manual or an automatic?
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The secition on changing the fluids and bleeding the brakes looked very standard. It showed the front brakes done first, the rear brakes and then the brake bypass valve mounted on the inside drivers side frame rail done last.
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Adjusting the brakes looked very standard as well. It just noted that there were 2 brake adjusters on each wheel you just turned the adjusters until the wheel wouldn't turn and then backed the adjuster off 4 or 5 clicks until there was no drag.
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I scanned the wiring diagram for the manual transmission version into a PDF. If I can't post it here on the forum. Send me a PM with your email address and I will send it to you.
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I couldn't upload it, maybe it was too big. Send me an email address.

[BobbyB]

First off, FusoFG, THANK YOU VERY MUCH for the reply. you have given me some great insight as to what to look for and I just really want to thank you for taking the time to write back. Depending on time, I am considering documenting all the work that I perform so that others that have a Fuso truck might find it useful. My truck has 90,000 on it and was serviced quite regularly and I am in the process of going through all the paper work to see what was done. I know that the first things I am going to tackle will be in this following order:
1.) Brake lights / marker lights
2.) Bleeding brakes, going over booster / checking on why I have to pump the peddle to get a better feel
3.) PTO cable and linkage greasing.

This is the first truck that I have driven where the shifting is done through a series of linkages and cables, I guess I've been spoiled with shifters mounted right to the transmission. Does your truck shift okay? Mine seems to have some slop in it (the shifter), I don't know if that is normal or not, but it seems to feel solid in gear and the clutch does not slip...

I think I am going to take your advice and get the service books. I plan on doing the same thing as you and keep this thing for a long time. Is there any way that you could scan and post some information on the brakes, and maybe even wiring, like you stated above. I understand that it takes time and whatnot, so I appreciate whenever you get to it! In the meantime I'm going to look around and try and find a little bit better of a price, I'm also going to my local Fuso dealer and see if they have any service books that they might want to unload cheap or at least point me in the right direction....

Having said that... I'll also have to ask them about my heater. Since this truck was used for plowing, the heater is toast. They must have run it all the time, plugging up the core, or at least, I hope that is what the issue is. I was told that a new thermostat was installed, but that did not seem to do anything. I won't be running the truck too much in the winter time, but when I do, it would be nice to have some heat.

Thank you VERY much for the heads up with where the brake wiring goes, I'm going to try and crawl under this thing during the up and coming weekend and figure out some stuff... This will be made much more easy once my "powerprobe" gets here (if you do not know what it is, Google it and take a look, great for chasing electrical issues).

Looking back at your post, you stated that there was a dealer in Cleveland that has the Service Manual on CD for a 2004. Did these trucks change much over the year(s)? My old man is in the Cleveland area and I can have him swing by. Doing a quick Google search, it looks like there are quite a few repair shops that service these trucks, which one did you find that has the manual on CD?

Anyway, thanks again for taking the time to read this and scan photos if you choose to do so, they would be VERY helpful. I'm going to keep a good record of what I do with this truck and keep updating this thread so that others might find it useful. I cannot believe that there are not other resources on the net for these great trucks!

[blackduck]

Bobby
my apologies, i was going to respond yesterday but someone dropped work on my desk that took priority (but i suppose i have to earn a livung somehow)
as far as your wiring problem i assume youve checked the basics (fuses, globes connections etc). If thats all good the next easiest thing is to grab your miltimeter and chase voltage through the system
start at the brake light wire on the tail light housing and check for voltage all the way back to the fuse box, dont forget about the switch on the brake pedal
sooner or later youll find power then you can isolate the problem. Chances are it will be somthing minor (it always is)
If your brake pedal fades and the trucks 22 years old it might be time for a brake rebuild (new seals and fluid at least)
performance is great but if you cant stop your just bug splat on the windscreen
A workshop manual may be helpful but FG's are farm machinery everythings pretty basic on them just trace the systems and the faults will drop in your lap

[BobbyB]

Sorry about the random order...
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78184
(scary wiring I have to deal with)
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78185
(I HOPE these are some brake lights...?)
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78186
(trans)
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78187
(pto engagment?)
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78188
(she's a beaut Clark!)
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78189
(pump for Dump Box)
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78190
(exhaust that I need to repair...)
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78191
(my hard to pull PTO lever...)

[BobbyB]

Bobby
my apologies, i was going to respond yesterday but someone dropped work on my desk that took priority (but i suppose i have to earn a livung somehow)
as far as your wiring problem i assume youve checked the basics (fuses, globes connections etc). If thats all good the next easiest thing is to grab your miltimeter and chase voltage through the system
start at the brake light wire on the tail light housing and check for voltage all the way back to the fuse box, dont forget about the switch on the brake pedal
sooner or later youll find power then you can isolate the problem. Chances are it will be somthing minor (it always is)
If your brake pedal fades and the trucks 22 years old it might be time for a brake rebuild (new seals and fluid at least)
performance is great but if you cant stop your just bug splat on the windscreen
A workshop manual may be helpful but FG's are farm machinery everythings pretty basic on them just trace the systems and the faults will drop in your lap

Thank you for the reply! I am going to do exactly as you (and others) have stated and start with the basics... Checking wires and busting out my Fluke and Power Probe 3 to check everything out. That is the thing that I love about this truck, it reminds my a lot of my diesel tractor, and for the most part you are correct, things are pretty basic... I can't wait to get some time away from work (maybe this weekend) to get down to business... I'll be posting what I can, when I can for others... I hope that some where down the road there will be someone like me that will find this thread and it'll help them! That is the best part about the internet! Thank you again guys! I'm lucky I found this site!

[BobbyB]

There wasn't anything in my manual about the PTO on the manual transmission. There was a page or two in the Automatic transmission section, but the PTO didn't look anything like mine.
.
Is your transmission a manual or an automatic?
.
The secition on changing the fluids and bleeding the brakes looked very standard. It showed the front brakes done first, the rear brakes and then the brake bypass valve mounted on the inside drivers side frame rail done last.
.
Adjusting the brakes looked very standard as well. It just noted that there were 2 brake adjusters on each wheel you just turned the adjusters until the wheel wouldn't turn and then backed the adjuster off 4 or 5 clicks until there was no drag.
.
I scanned the wiring diagram for the manual transmission version into a PDF. If I can't post it here on the forum. Send me a PM with your email address and I will send it to you.
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I couldn't upload it, maybe it was too big. Send me an email address.

PM Sent!

Trans is manual. Thank you for the information on the bleeding, I was going to go from furthest away, but I'm glad you told me what it stated! I'll be looking for that email, when you get time... No rush! Thank you again!

[BobbyB]

By the way, looking through all the docs and records I got for this truck, the dump bed was after market, and it looks like this was the second bed they put on. The pictures of my trans could only be taken when I removed the HUGE tool box that was bolted to the frame rail. I'm going to resize it so that I can see out of the back window...

[gait]

not quite what you are looking for but its a start ...
http://www.ebay.co.uk/itm/290611004274?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
Mostly FE with not a lot about FG on it.

[BobbyB]

not quite what you are looking for but its a start ...
http://www.ebay.co.uk/itm/290611004274?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
Mostly FE with not a lot about FG on it.

Thanks, I emailed the seller... Maybe they would send it to the 'ol US of A... I'd pay extra of course...

[gait]

sorry, forgot to mention, he sets up a download for overseas ....

[BobbyB]

sorry, forgot to mention, he sets up a download for overseas ....

That works for me...

[BobbyB]

Just a quick update to those that are interested... Much to my surprise all 6 of the bleeder screws backed out okay with no issue (after using PB Blaster of course) I was really happy about that! I have not bleed them yet, as I ran out of time, my children wanted me to come back inside and watch goofy Christmas movies... While I was crawling under the truck, I noticed a VERY small rubber plug... I did not remove it yet, but is that where I would adjust the "drag" on the shoes? When I adjust my other trucks rear brakes, the rubber plug is much bigger for my brake spoon... So, am I correct in adjusting them this way? I don't have to remove the whole wheel to adjust the brake do I??? Thanks guys!

[BobbyB]

I am trying to get a handle on all the filters I will need. Am I missing anything??? Primary Oil ME014833. By-Pass Oil ME014838. Fuel Filter ME016872. Are their any other filters that I need to get for this beast? I also will get the primary air cleaner. Thanks in advance!

[Bobby B.]

Sorry that I don't have Fuso info to add, I did want to pop in to compliment you on what is a stellar user name. :wavey:

[BobbyB]

Sorry that I don't have Fuso info to add, I did want to pop in to compliment you on what is a stellar user name. :wavey:

And from one BobbyB to another, amen brother!

[BobbyB]

I'm glad that my Power Probe 3 came in the mail today... It only took about 30 minutes to chase wires and get all my lights working... So now I have brake lights! If you guys have ever had to mess with electrical junk, the Power Probe makes it really easy... Just google it... Next stop... bleeding and/or adjusting brakes...

[BobbyB]

Just wanted everyone to know that I was able to get the brakes working MINT on this truck. It is AMAZING how far out of adjustment they were. I think the last goof that owned this thing neglected to adjust them. I also fab'd a new exhaust system for the truck, it's a straight shot and sounds great. I'm impressed how easy it is to work on this thing!

[blackduck]

I'm impressed how easy it is to work on this thing!

good news bobby

This is the beauty of farm machinery
no gizmos - no electrikery just good old fashioned mechanicals
how could you go wrong

[BobbyB]

good news bobby

This is the beauty of farm machinery
no gizmos - no electrikery just good old fashioned mechanicals
how could you go wrong

You are correct my friend, it reminds me of working on a tractor. Currently I have fixed all brakes and adjusted them. All the lights to the back are good too... I replaced the air cleaner box with a really nice rust free one from South Carolina and I am in the process of installing a new windshield with new weather stripping. Truck will be put on the road soon... Cant wait!

[blackduck]

bobby
you could always check out alans build of his 1990 fg
definatley a milestone for any budding doerupperer
ypu could be the envy of all around

[Mit Fuso]

bobby
you could always check out alans build of his 1990 fg
definatley a milestone for any budding doerupperer
ypu could be the envy of all around

I have been in love with my 1990 Fuso FG 4x4 diesel ever since I saw it on Craig's list a few months ago. Here's my first problem: All four (two mounted on top of the RV body) of the brake lights are out, but the fuse is ok and the horn still honks. I'm thinking it's the switch but can't find one on the web. Has anybody had this problem? If so, where did you get the switch and what's the part number?

140594140595

[Mit Fuso]

I understand that there are ways to get more power out of this engine, but that can introduce problems? Comments?

What about the automatic transmission? Comments?

Will a bigger engine fit? Cost?

The Fuso FG will do just about anything off-road, but it is no speed demon on the highway. Any practical experience towing up long grades?

[alan]

How come i've never seen this thread before? I thought i was the only one with an old fuso canter.

[FG Surfari]

I had a similar problem on a trip a few years ago.
What it ended up being was a wire along the frame rail had worked its way out of the harness sheathing, and had become pinched between the frame and the camper box, causing the lights to short out.
It happened on and off over the course of the week, and was a bear to track down.
I eventually re-wrapped and re-routed the harness to prevent a recurrence.
Hope that helps

[Mit Fuso]

How come i've never seen this thread before? I thought i was the only one with an old fuso canter.

Yeah, I just stumbled into it by searching the web. I wish this site had a way to get notification of posts to selected threads. Maybe it does, but I haven't seen any way to sign up.

[Mit Fuso]

Thanks! Did you splice the wire?

[Mit Fuso]

I had a similar problem on a trip a few years ago.
What it ended up being was a wire along the frame rail had worked its way out of the harness sheathing, and had become pinched between the frame and the camper box, causing the lights to short out.
It happened on and off over the course of the week, and was a bear to track down.
I eventually re-wrapped and re-routed the harness to prevent a recurrence.
Hope that helps

Do you mean that you had brake lights some of the time, but not all of the time? Mine seem to just completely gone, leading me to suspect the switch, but I'll check both.

Got any photos of your rig anywhere?

[SkiFreak]

Yeah, I just stumbled into it by searching the web. I wish this site had a way to get notification of posts to selected threads. Maybe it does, but I haven't seen any way to sign up.

At the upper right of the post click on Thread Tools > Subscribe to this Thread

140657

[SkiFreak]

You said that all of the brake lights do not work. Do the tail lights work?

[FG Surfari]

What had happened is that the wire got wedged between the camper body and the frame, and over time, the situation wore away the plastic coating on the wire a bit.
As such, it would only short out now and again, and I can only assume it happened more so when the camper body would twist off road, over speed bumps at an angle etc ...
That's what made it so frustrating, because when it was happening I did not have the hindsight of knowing what was going on.
Eventually, I ended rerouting the rearward harness through the camper floor to protect it from the elements and further incident.
So far so good.

[alan]

I have the wiring diagram for these canters if you need them..

[Mit Fuso]

How devilishly CLEVER--THANKS!

[Beaniam]

I came across this thread via google. We have a 95 Fuso Canter here at work that I'm trying to track down a brake light issue on. I'm finding it next to impossible to find information online for them. I've got rear turn signals and running lights but no brake lights. Do these have a brake light switch up near the brake pedal or something down on the air/hydraulics for the brakes outside the truck? If someone still has the wiring diagrams handy for them I'd appreciate it.

[Mit Fuso]

I came across this thread via google. We have a 95 Fuso Canter here at work that I'm trying to track down a brake light issue on. I'm finding it next to impossible to find information online for them. I've got rear turn signals and running lights but no brake lights. Do these have a brake light switch up near the brake pedal or something down on the air/hydraulics for the brakes outside the truck? If someone still has the wiring diagrams handy for them I'd appreciate it.

I just had the same problem with my 1990. I ordered the switch, which was not the same--smaller and with different connections. I ended up putting the old "defective" switch back in and adjusting it, and viola'! it's working fine now. The switch is located in a rough spot to get at to the left of the brake pedal, almost hidden, but if you use a bright light and push on the brake pedal, you will see the black actuator plate which moves backwards (not downwards). you will see that it it is behind the switch, which is mounted on a rigid mounting plate for the switch with a galvanized bolt and a set-nut. Adjust this nut until the brake lights start coming on where you want them to. I tossed the "replacement" switch into my parts box. It is difficult because the nut is hard to get a wrench on, but a small end wrench loosened mine just enough to get my two index fingers on it. I kept turning and testing the lights until I got it where I wanted it, then tightened it with the wrench. It's a quick job that took me hours, but now it's easy. I suspect that vibrations loosened the set-nut and it backed out over time. I resisted the temptation to put Locktite on it; I would sure as hell not use the red, and I'm glad the nut was easy to turn. Hope this helps. If you run into any problems, contact me. We are heading off on an expedition on Monday; will be incognito until about April 23. We are going to Expedition Expo in May, if the creeks don't rise too high for the truck.

[Beaniam]

Thanks I'll look up in there closer tomorrow. I couldn't see anything in there resembling a switch but I didn't really know where to look.

[Mit Fuso]

Thanks I'll look up in there closer tomorrow. I couldn't see anything in there resembling a switch but I didn't really know where to look.

You'll see a fairly large roundish sheet metal housing or part (what is this?), and it's tucked up under it. You have to get down low with a good light, push the clutch pedal up and down, and you'll see the black actuator plate coming toward you. Everything is painted black, but my switch's attachment "bolt" is shiny, as is the switch, with two wires coming out of it. The bolt is hollow, with a black plastic, spring-loaded switch-button on the back-end that activates the switch when the actuator plate (about an inch or so square) touches it. I set mine so that if I even touch the brake pedal the lights go on. I don't know whether or not this is to spec or not. Does anybody else know for sure? It just seemed sensible to me, but ya never know . . .

[blackduck]

151231

look at part 11
hard to see but if you run your hand up the brake pedal (be careful there are some sharp edges) youll feel it

[Beaniam]

Thanks I'm about to dig into it again. It wouldn't be different being it's an FH truck would it?

[Beaniam]

Here's a few pictures of what I'm looking at. I don't see any switches or wires coming off anything the brake pedal is related to. The air junction box that the plunger the brake pedal actuates has 2 sensors and wires coming off the left side of it. There's a stop screw to adjust return distance on the brake pedal but I don't see a switch on it. I've circled the items I'm talking about. Also a shot of the plunger as seen looking up under the dash.