15-1

15. Maintenance schedule

15-2 Maintenance schedule

Regular maintenance is vital to maximizing your vehicle’s performance, service life, and
safety.
Following the maintenance schedule will give optimum results.
The preceding sections describe simple maintenance checks and procedures that can be
carried out by the owner. If you have difficulty or your vehicle needs maintenance work that is
not shown in this manual, please take the vehicle to an authorized dealer.

1 For maintenance schedule in severe use

In some maintenance items, maintenance schedule in severe use is set.
Perform each item of inspection or replacement according the “Severe use” interval if the
type of severe use in Item column of the periodic inspection schedule table corresponds to
one of the conditions in the following table (A) ~ (J).

Severe
condition Conditions of severe use
types
Operating in slow vehicle speed (lower than 20 km/h (12 mph) in average and
A more than 30% of total operation) or operations involving frequent starts and
stops.

B Operations involving frequent engine starts and stops condition in 10 minutes

and in 10 km (6 miles) distance.
C Operating on over loading condition (more than 30% in total operation)
D Operating on rough roads (more than 30% in total operation)
E Operating in tropical region (above 46°C (114°F))
F Operating in cold region (lower than -25°C (-13°F))
G Operating in dusty areas
H Operating on long distance (10,000 km/month (6,000 miles/month) or more)
I Operating on frequent mountainous roads (more than 30% in total operation)
J Operating on frequent uphill roads trip (more than 30% in total operation)

2 Maintenance schedule
For the replacement intervals of lubricants and fluids, see the section entitled “Lubrication
schedule”.

Symbols used
I : Inspect, and correct or replace as necessary.
A : Adjust.
C : Clean.
R : Replace or change.
T : Tighten.
L : Lubricate.
•: No inspection is necessary.
 15-3
: Exhaust emission items.
: Noise control items.
Time of inspection and maintenance
Inspection interval

Pre-operational checks

4,000 km(2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Item Working procedures

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
(6,000 miles)
ENGINE
R:Every 20,000 km Replace oil filters.
Oil filter replacement • • ( ,000 miles) or
12 months P. 12-39
R:Every 40,000 km Replace fuel filter.
Fuel filter replacement • • (24,000 miles) or
12 months P. 12-42

Normal condition • • I:Every 24 months Check for leakage of fuel

Fuel line from the fuel line.
leakage and Severe condition Check the pipe, hose and
damage • • I:Every 12 months tube for damage and loose
(type (C), (D), (E))*
installation.
Inspect belts for crack, wear
V-belt tension and damage I • • • I • • and tension.
P. 12-61
Check radiator and pres-
sure cap for sealing perfor-
mance and mounting
I:Every 40,000 km condition.
Cooling system • • (24,000 miles) or Inspect hoses for loose-
ness, deterioration, damage
12 months causing leakage.
Remove dust and foreign
matter deposit from radia-
tor and intercooler front.
Check that the coolant level
is between the “FULL” and
Coolant level I • • • • • • “LOW” marks on the reser-
voir tank.
P. 12-56
Replace coolant.
Coolant replacement • • R:Every 24 months
P. 12-52
Replace air cleaner ele-
Air cleaner element replace- ment.
ment • • • • R • •
P. 12-47

I:Every 40,000 km Inspect the exhaust system

Exhaust system • • (24,000 miles) or for damage, corrosion and
loose connection causing
12 months leakage.
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2
15-4 Maintenance schedule

Time of inspection and maintenance

Inspection interval

Pre-operational checks

4,000 km(2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Item Working procedures

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
(6,000 miles)
Check DPF for damage and
for leaks of exhaust gases.
I:Every 40,000 km Check mounting bolts and
DPF • • (24,000 miles) or
12 months nuts for looseness.
Check mounting brackets
for damage.
Check for leakage of DEF
I:Every 40,000 km from the DEF line.
DEF line leakage and damage • • (24,000 miles) or Check the pipe, hose and
12 months tube for damage and loose
installation.
R:Every 240,000 km
Alternator tensioner replace- • • (144,000 miles) or Replace alternator ten-
ment sioner.
72 months
R:Every 240,000 km
Glow plug replacement • • (144,000 miles) or Replace glow plug.
72 months
POWER TRAIN

Propeller shaft flange torque and Check flange yoke bolts for
universal joint looseness • I • • I • • looseness and universal
joint for play.

Propeller shaft center bearing • • • • • • I Check center bearing for

wear, damage and play.
R:Every 200,000 km Replace propeller shaft
Propeller shaft bearing kit • • (120,000 miles) or
120 months bearing kit.
 15-5
Time of inspection and maintenance
Inspection interval

Pre-operational checks

4,000 km(2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Item Working procedures

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
(6,000 miles)
FRONT AND REAR AXLE
Check the disc wheels for
cracks and other damage.
Check the tires for inflation
pressure, tread groove
I • • • I • • depth, foreign objects in
grooves, cracks, and
uneven wear.
P. 12-67
Check tire tread and side
wall for cracks and damage.
Wheel and tire Measure tire tread groove
depth to make sure it is
I • • • • • • deep enough.
Check tire tread for uneven
wear, stepped wear and
other abnormal wear.
P. 12-67
Measure inflation pressure
A • • • • • • with tire gauge.
P. 12-67
I:Every 40,000 km
Normal condition • • (24,000 miles) or
Tie rod ball 24 months
joint dust Check the ball joint dust
I:Every 40,000 km boots for cracks and wear.
boots Severe condition
(type (C)~(J))* • • (24,000 miles) or
12 months
SUSPENSION SYSTEM
Check for broken springs
Suspension springs I • • • • • • and tilt of vehicle body
toward either side.
Check the leaf spring U-
bolts, damage and loose-
ness.
Check the leaf springs for
cracks and damage, or for
Leaf suspension system • I • • I • • displaced leaves.
Check the front axle
bumper and bump stopper
for cracks and damage.
Check the shock absorbers
for oil leaks.
Stabilizer rod ball joint dust boots • • • • I • • Check the ball joint dust
<Vehicles with stabilizer> boots for cracks and wear.
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2
15-6 Maintenance schedule

Time of inspection and maintenance

Inspection interval

Pre-operational checks

4,000 km(2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Item Working procedures

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
(6,000 miles)
BRAKING SYSTEM
Make sure that the brake
pedal has 0.1 to 3 mm
(0.0039 to 0.12 in.) free
play when pressed by fin-
ger.
Check also that when the
Service brake pedal I • • • • • • brake pedal is fully
depressed, there is a gap of
10 mm (0.39 in.) or more
between the pedal and the
floor.
P. 12-65
Depress the brake pedal
and check that the brakes
Brake performance I • • • • • • work effectively and evenly
on all wheels.
P. 12-65
I:Every 40,000 km
Normal condition • • (24,000 miles) or
Disc brake 24 months Check disc brake pad and
pad and disc I:Every 40,000 km disc for damage and wear.
Severe condition • • (24,000 miles) or
(type (C)~(I))* 12 months
Check lining for wear
I:Every 40,000 km through inspection hole.
Brake lining and drum • • (24,000 miles) or Disassemble and check
12 months drum for wear, crack and
damage.
Check that the parking
brake lever stroke is 7 to 9
notches when the lever is
Parking brake lever stroke I • • • • • • pulled with a force of 294 N
(66 lbs., 30 kgf).
P. 12-66
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2
 15-7
Time of inspection and maintenance
Inspection interval

Pre-operational checks

4,000 km(2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Item Working procedures

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
(6,000 miles)
Check the brake pedal for
play and its clearance to the
floorboard when it is
pressed all the way. Check
I:Every 40,000 km the brake system pipes,
Normal condition • • (24,000 miles) or tubes and hoses for loose-
24 months ness and damage and
check for brake
fluid leaks. Perform braking
Service tests in a safe place. After
brake sys- checking that warning lamp,
tem is not illuminated, drive the
vehicle at a low speed to
make sure that braking
I:Every 40,000 km power is sufficient and
Severe condition even. Check the vacuum
(type (C)~(I))* • • (24,000 miles) or
12 months hoses for damage. And
using FUSO Diagnostics,
check the condition of the
brake control valve. Inspect
brake fluid pressure.
STEERING SYSTEM
Gently turning the steering
wheel, check that its play is
more than 10 mm (0.39 in.)
Steering wheel free play I • • • • • • and less than 20 mm
(0.79 in.).
P. 12-63
Check that the steering
wheel does not vibrate or
pull to one side and that it is
not unduly heavy. Also
Steering wheel operation I • • • • • • make sure that the steering
wheel returns to its neutral
position smoothly.
P. 12-64
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2
15-8 Maintenance schedule

Time of inspection and maintenance

Inspection interval

Pre-operational checks

4,000 km(2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Item Working procedures

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
(6,000 miles)
Check the steering wheel
play and looseness. Also
drive slowly and check for
steering wheel shimmy,
pulling, unusually heavy
operation, and self-center-
ing motion. Sound the horn
and check the volume and
tone of its sound.
Also,remove the starter key,
give the steering wheel half
a turn to the left or right, and
check whether the steering
wheel locks in positionand
Steering system • • • • I • • becomes immovable.
Check the steering system
sections for looseness. Also
check for oil leaks from the
steering gear box. Check
the oil pipe and oil hose
connections for loose-
ness,damage and oil leaks.
Also check the power steer-
ing system operation. check
the power steering system
operation. Inspect power
steering hose damage.
P. 12-63
I:Every 40,000 km
Normal condition • • (24,000 miles) or
Drag link 24 months Check the ball joint dust
ball joint
dust boots I:Every 40,000 km boots for cracks and wear.
Severe condition • • (24,000 miles) or
(type (C)~(J))*
12 months
ELECTRICAL SYSTEM
Make sure that each lamp
lights up or flashes properly.
Lighting system I • • • • • • Check lamp lenses for dirt
and damage.
P. 5-16
Check that gauges, warning
Gauge, warning/indicator lamp lamps and indicators are
I • • • • • • working properly.
operation
P. 6-2
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2
 15-9
Time of inspection and maintenance
Inspection interval

Pre-operational checks

4,000 km(2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Item Working procedures

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
(6,000 miles)
Check that the battery fluid
level is between the
“UPPER” and “LOWER”
Battery fluid level I • • • • • • level lines marked on the
sides of the battery case.
P. 12-84
OTHERS
Check the underneath of
Leak -fuel, oil, coolant and fluid I • • • • • • the vehicle for any sign of
leakage.

I:Every 80,000 km Check the frame and cross

Chassis frame damage and • • (48,000 miles) or member bolts and rivets for
looseness cracks, damage and loose-
48 months ness.

3 Lubrication schedule

: Exhaust emission items.

Time of inspection and maintenance
Inspection interval
Pre-operational checks

4,000 km (2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km

Reference
Item
(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)

page
(6,000 miles)

Engine oil level I • • • • • •

R:Every 20,000 km
Normal condition • • (12,000 miles) or
Engine oil 12 months 12-22
replacement
Severe condition • • R • • • •
(type (A), (B))*
Transmission oil replacement • • • • • R • 12-28
Clutch control fluid replacement • • • • • R • –
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2
15-10 Maintenance schedule

Time of inspection and maintenance

Inspection interval

Pre-operational checks

4,000 km (2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Reference
Item

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
page

(6,000 miles)
Transfer gear oil replacement <FG> • • • • • R • 12-31
Rear axle housing gear oil replace- • • • • • R •
ment
12-33
Front axle housing gear oil replace-
ment <FG> • • • • • R •

Hub bearing
grease replace- R:Every 60,000 km
ment (Also Normal condition • • (36,000 miles) or
replace the oil 24 months
seal. Remove
the front and –
rear wheel hubs
and check for
wear and dam- R:Every 60,000 km
Severe condition • • (36,000 miles) or
age of the wheel (type (C)~(J))*
bearing. <NLGI 12 months
No. 2 ; Li soap>)
R:Every 40,000 km
Front axle bir- Normal condition • • (24,000 miles) or
field joint grease 24 months
–
replacement R:Every 40,000 km
<FG> Severe condition • • (24,000 miles) or
(type (C)~(J))* 12 months
R:Every 40,000 km
Front axle king- Normal condition • • (24,000 miles) or
pin bearing 24 months
–
grease replace- R:Every 40,000 km
ment <FG> Severe condition
(type (C)~(J))* • • (24,000 miles) or
12 months
R:Every 40,000 km
Front axle steer- Normal condition • • (24,000 miles) or
ing knuckle 24 months
grease replace- –
Severe condition R:Every 40,000 km
ment <FG> • • (24,000 miles) or
(type (C)~(J))*
12 months
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2
 15-11
Time of inspection and maintenance
Inspection interval

Pre-operational checks

4,000 km (2,500 miles)

1st maintenance at

Every 10,000 km

Every 20,000 km

Every 40,000 km

Every 60,000 km

Every 80,000 km
Reference
Item

(12,000 miles)

(24,000 miles)

(36,000 miles)

(48,000 miles)
page

(6,000 miles)
Brake fluid level I • • • • • • 12-37
Brake fluid replacement • • R:Every 24 months –
R:Every 40,000 km
Power steering fluid replacement • • (24,000 miles0 or –
12 months

Universal joint, L:Every 40,000 km

slip joint • L (24,000 miles) or 12-18
Lubrication of 24 months
propeller shaft L:Every 40,000 km
Double cardan
joint <FG> • • (24,000 miles) or 12-18
24 months
L:Every 40,000 km
Lubrication of rear suspension • • (24,000 miles) or
spring pin 24 months
L:Every 40,000 km
Normal condition • • (24,000 miles) or 12-18
Lubrication of 24 months
kingpins L:Every 40,000 km
Severe condition
• • (24,000 miles) or
(type (C)~(J))* 12 months
L:Every 80,000 km
Lubrication of door hinge • • (48,000 miles) or 12-22
48 months
Lubrication of anchor hook L:Every 80,000 km
<Vehicles other than Crew-cab mod- • • (48,000 miles) or 12-22
els> 48 months
* For about severe conditions, refer to the “For maintenance schedule in severe use”. P. 15-2