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Mitsubishi Fuso Truck Service Repair Manual FK FM 2009

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🏷️ Basic Information Identification Make: Mitsubishi Fuso Model: FK Series / FM Series Trucks Year: 2009 Chassis Codes: FK61F, FM65F, FK62F, FK65F Engine Codes: 6M60T1 👋 Introduction Market Position Target Audience: Professional truck technicians, fleet maintenance personnel, and experienced vehicle owners. Competitive Analysis Value Proposition: Provides comprehensive, in-depth technical information crucial for accurate diagnosis and repair, reducing downtime and repair costs. Key Features Coverage Breadth: Extensive coverage spanning all major mechanical, electrical, and body systems of the specified truck models. Digital Accessibility: Instant download format eliminates shipping delays and costs, providing immediate access to critical repair data. 📋 Manual Details Coverage Manual Type: Service Repair Manual / Workshop Manual Language: English Format: PDF, ZIP Page Count: 2384 Compatibility: Windows (95, 98, ME, XP, Vista, 7), Linux, MAC Availability: Instant Download 📖 Manual Coverage Systems Covered General Information: 00 GENERAL - Overview, vehicle identification, safety precautions, torque specifications. Maintenance Schedule: 01 MAINTENANCE SCHEDULE - Recommended service intervals, inspections, and fluid changes. Engine Mechanical: 11 ENGINE - Complete engine overhaul procedures, cylinder head, pistons, crankshaft, camshafts, timing system. Lubrication System: 12 LUBRICATION - Oil pump, oil filter, oil cooler, lubrication passages, oil pressure testing. Fuel And Engine Control: 13A FUEL & ENGINE CONTROL - Fuel injection system, throttle control, engine management system (EMS) diagnosis. Common Rail System: 13EA COMMON RAIL SYSTEM - High-pressure fuel pump, fuel injectors, fuel pressure sensor, rail pressure control. Cruise And Speed Limitation: 13EB AUTO CRUISE & VEHICLE SPEED LIMITATION SYSTEM - Operation, diagnosis, and repair of cruise control and speed limiter functions. Cooling System: 14 COOLING - Radiator, water pump, thermostat, cooling fan, coolant specifications, troubleshooting leaks. Intake And Exhaust: 15 INTAKE & EXHAUST - Air intake system, turbocharger, exhaust manifold, muffler, emissions control components. Emission Control: 17 EMISSION CONTROL - EGR system, DPF system (if applicable), catalytic converter, emission sensor diagnostics. Clutch System: 21 CLUTCH - Clutch assembly, clutch master cylinder, slave cylinder, hydraulic system, adjustment and repair. Manual Transmission: 22A MANUAL TRANSMISSION M060S6, M070S6 - Gearbox disassembly, assembly, internal components, shift mechanism, lubrication. Automatic Transmission Allison 1000 2200: 23A AUTOMATIC TRANSMISSION M065A5, ALLISON 1000RDS, 2200RDS - Transmission removal, installation, torque converter, internal components, fluid specifications, electronic control unit (ECU) diagnosis. Automatic Transmission Allison 3000: 23B AUTOMATIC TRANSMISSION M100A6, ALLISON 3000RDS - Transmission overhaul, electronic controls, hydraulic circuits, fluid types, diagnostic procedures. Propeller Shaft: 25 PROPELLER SHAFT - Driveshaft removal, installation, U-joints, universal joint maintenance, balancing. Front Axle Fk61: 26A FRONT AXLE FK61 - Steering knuckle, kingpins, wheel bearings, hub assembly, differential (if applicable). Front Axle Fk62 Fk65 Fm: 26B FRONT AXLE FK62, FK65, FM - Kingpins, steering linkage, wheel hub assembly, braking components mounting. Rear Axle: 27 REAR AXLE - Drive axle housing, differential, axle shafts, wheel bearings, hub assembly, axle ratios. Wheel And Tire: 31 WHEEL & TIRE - Tire pressure recommendations, wheel torque specifications, lug nut tightening sequence, tire wear analysis. Front Suspension: 33 FRONT SUSPENSION - Leaf springs, shock absorbers, suspension arms, bushings, alignment specifications. Rear Suspension Leaf: 34A REAR SUSPENSION LEAF - Leaf spring replacement, U-bolts, spring pins, bushings, overload springs. Rear Suspension Air: 34B REAR SUSPENSION AIR - Air suspension system components, air springs, leveling valves, air lines, compressor (if applicable). Air Over Hydraulic Brake: 35A BRAKE Air Over Hydraulic Brake - Brake system operation, master cylinder, wheel cylinders, brake fluid, bleeding procedures, component replacement. Full Air Brake: 35B BRAKE Full Air Brake - Air brake system components, air compressor, air dryer, brake valves (foot valve, relay valves), brake chambers, slack adjusters, system troubleshooting. ABS System: 35E ANTI-LOCK BRAKE SYSTEM ABS - ABS control module, wheel speed sensors, hydraulic modulator, diagnostic codes, testing procedures. Parking Brake Center: 36A PARKING BRAKE Center Parking Brake - Parking brake mechanism, cables, adjustment, service, and repair. Parking Brake Wheel: 36B PARKING BRAKE Wheel Parking Brake - Parking brake integrated into wheel hubs or drums, linkage, adjustments. Steering System: 37 STEERING - Steering gear, power steering pump, hydraulic hoses, steering column, tie rods, alignment. Frame And Bumper: 41 BUMPER & FRAME - Frame inspection, repair, damage assessment, bumper removal and installation. Cab Systems: 42 CAB - Cab mounting, interior trim, seat adjustments, sound deadening, structural components. Door Mechanisms: 43 DOOR - Door panel removal, window regulators, door latches, hinges, seals, lock mechanisms. Exterior Components: 51 EXTERIOR - Body panels, fenders, mirrors, lights, grille, badges, paint repair guidance. Interior Components: 52 INTERIOR - Dashboard layout, instrument cluster, seating, interior trim panels, carpeting, headliner. Electrical System: 54 ELECTRICAL - Wiring diagrams, battery, alternator, starter motor, lighting systems, fuses, relays, diagnostic connectors, sensor testing. HVAC System: 55A AIR CONDITIONER & HEATER - HVAC system operation, refrigerant handling, compressor, evaporator, condenser, blower motor, heater core, diagnostic procedures. Procedures Included Troubleshooting: Comprehensive diagnostic flowcharts and troubleshooting guides for all major vehicle systems. Repair Procedures: Detailed step-by-step instructions for component removal,...
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Mitsubishi Fuso Truck Service Repair Manual FK FM 2009
🏷️ Basic Information
Identification
Make:
Mitsubishi Fuso
Model:
FK Series / FM Series Trucks
Year:
2009
Chassis Codes:
FK61F, FM65F, FK62F, FK65F
Engine Codes:
6M60T1
👋 Introduction
Market Position
Target Audience:
Professional truck technicians, fleet maintenance personnel, and experienced vehicle owners.
Competitive Analysis
Value Proposition:
Provides comprehensive, in-depth technical information crucial for accurate diagnosis and repair, reducing downtime and repair costs.
Key Features
Coverage Breadth:
Extensive coverage spanning all major mechanical, electrical, and body systems of the specified truck models.
Digital Accessibility:
Instant download format eliminates shipping delays and costs, providing immediate access to critical repair data.
📋 Manual Details
Coverage
Manual Type:
Service Repair Manual / Workshop Manual
Language:
English
Format:
PDF, ZIP
Page Count:
2384
Compatibility:
Windows (95, 98, ME, XP, Vista, 7), Linux, MAC
Availability:
Instant Download
📖 Manual Coverage
Systems Covered
General Information:
00 GENERAL - Overview, vehicle identification, safety precautions, torque specifications.
Maintenance Schedule:
01 MAINTENANCE SCHEDULE - Recommended service intervals, inspections, and fluid changes.
Engine Mechanical:
11 ENGINE - Complete engine overhaul procedures, cylinder head, pistons, crankshaft, camshafts, timing system.
Lubrication System:
12 LUBRICATION - Oil pump, oil filter, oil cooler, lubrication passages, oil pressure testing.
Fuel And Engine Control:
13A FUEL & ENGINE CONTROL - Fuel injection system, throttle control, engine management system (EMS) diagnosis.
Common Rail System:
13EA COMMON RAIL SYSTEM - High-pressure fuel pump, fuel injectors, fuel pressure sensor, rail pressure control.
Cruise And Speed Limitation:
13EB AUTO CRUISE & VEHICLE SPEED LIMITATION SYSTEM - Operation, diagnosis, and repair of cruise control and speed limiter functions.
Cooling System:
14 COOLING - Radiator, water pump, thermostat, cooling fan, coolant specifications, troubleshooting leaks.
Intake And Exhaust:
15 INTAKE & EXHAUST - Air intake system, turbocharger, exhaust manifold, muffler, emissions control components.
Emission Control:
17 EMISSION CONTROL - EGR system, DPF system (if applicable), catalytic converter, emission sensor diagnostics.
Clutch System:
21 CLUTCH - Clutch assembly, clutch master cylinder, slave cylinder, hydraulic system, adjustment and repair.
Manual Transmission:
22A MANUAL TRANSMISSION M060S6, M070S6 - Gearbox disassembly, assembly, internal components, shift mechanism, lubrication.
Automatic Transmission Allison 1000 2200:
23A AUTOMATIC TRANSMISSION M065A5, ALLISON 1000RDS, 2200RDS - Transmission removal, installation, torque converter, internal components, fluid specifications, electronic control unit (ECU) diagnosis.
Automatic Transmission Allison 3000:
23B AUTOMATIC TRANSMISSION M100A6, ALLISON 3000RDS - Transmission overhaul, electronic controls, hydraulic circuits, fluid types, diagnostic procedures.
Propeller Shaft:
25 PROPELLER SHAFT - Driveshaft removal, installation, U-joints, universal joint maintenance, balancing.
Front Axle Fk61:
26A FRONT AXLE FK61 - Steering knuckle, kingpins, wheel bearings, hub assembly, differential (if applicable).
Front Axle Fk62 Fk65 Fm:
26B FRONT AXLE FK62, FK65, FM - Kingpins, steering linkage, wheel hub assembly, braking components mounting.
Rear Axle:
27 REAR AXLE - Drive axle housing, differential, axle shafts, wheel bearings, hub assembly, axle ratios.
Wheel And Tire:
31 WHEEL & TIRE - Tire pressure recommendations, wheel torque specifications, lug nut tightening sequence, tire wear analysis.
Front Suspension:
33 FRONT SUSPENSION - Leaf springs, shock absorbers, suspension arms, bushings, alignment specifications.
Rear Suspension Leaf:
34A REAR SUSPENSION LEAF - Leaf spring replacement, U-bolts, spring pins, bushings, overload springs.
Rear Suspension Air:
34B REAR SUSPENSION AIR - Air suspension system components, air springs, leveling valves, air lines, compressor (if applicable).
Air Over Hydraulic Brake:
35A BRAKE Air Over Hydraulic Brake - Brake system operation, master cylinder, wheel cylinders, brake fluid, bleeding procedures, component replacement.
Full Air Brake:
35B BRAKE Full Air Brake - Air brake system components, air compressor, air dryer, brake valves (foot valve, relay valves), brake chambers, slack adjusters, system troubleshooting.
ABS System:
35E ANTI-LOCK BRAKE SYSTEM ABS - ABS control module, wheel speed sensors, hydraulic modulator, diagnostic codes, testing procedures.
Parking Brake Center:
36A PARKING BRAKE Center Parking Brake - Parking brake mechanism, cables, adjustment, service, and repair.
Parking Brake Wheel:
36B PARKING BRAKE Wheel Parking Brake - Parking brake integrated into wheel hubs or drums, linkage, adjustments.
Steering System:
37 STEERING - Steering gear, power steering pump, hydraulic hoses, steering column, tie rods, alignment.
Frame And Bumper:
41 BUMPER & FRAME - Frame inspection, repair, damage assessment, bumper removal and installation.
Cab Systems:
42 CAB - Cab mounting, interior trim, seat adjustments, sound deadening, structural components.
Door Mechanisms:
43 DOOR - Door panel removal, window regulators, door latches, hinges, seals, lock mechanisms.
Exterior Components:
51 EXTERIOR - Body panels, fenders, mirrors, lights, grille, badges, paint repair guidance.
Interior Components:
52 INTERIOR - Dashboard layout, instrument cluster, seating, interior trim panels, carpeting, headliner.
Electrical System:
54 ELECTRICAL - Wiring diagrams, battery, alternator, starter motor, lighting systems, fuses, relays, diagnostic connectors, sensor testing.
HVAC System:
55A AIR CONDITIONER & HEATER - HVAC system operation, refrigerant handling, compressor, evaporator, condenser, blower motor, heater core, diagnostic procedures.
Procedures Included
Troubleshooting:
Comprehensive diagnostic flowcharts and troubleshooting guides for all major vehicle systems.
Repair Procedures:
Detailed step-by-step instructions for component removal, installation, and repair.
Maintenance Tasks:
Routine maintenance procedures, fluid level checks, filter replacements, lubrication points.
Technical Specifications:
Torque specifications, fluid capacities, component clearances, alignment data, electrical resistance values.
Wiring Diagrams:
Complete electrical wiring schematics for all vehicle systems.
Technical Depth
Depth Level:
Expert-level technical detail suitable for professional mechanics and advanced DIYers.
📊 Manual Specifications
File Attributes
File Format:
PDF (Portable Document Format) - Widely compatible, searchable text.
Digital Delivery:
Provided in a ZIP archive for efficient download.
Print Quality Potential:
PDF format allows for high-quality printing of individual pages or sections.
Searchability:
Text-based PDF allows for easy keyword searching within the manual.
⚙️ Engine Specifications
Primary Engine
Engine Model:
6M60T1
Engine Type:
Turbocharged Diesel
Displacement:
Typically around 7.5 Liters (specific cubic inches may vary based on exact variant, consult manual for precise data)
Performance
Horsepower Range:
Refer to manual for exact HP ratings, often in the 200-300 HP range for this class of engine.
Torque Range:
Refer to manual for exact torque ratings, typically in the 500-700 lb-ft range.
Fuel System
Injection Type:
Common Rail Direct Injection (CRDI)
Fuel Type:
Diesel Fuel
Other
Emissions Compliance:
Designed to meet EPA 2007/2010 or equivalent emissions standards of the time.
🔧 Transmission
Standard Transmission
Type:
Manual Transmissions: M060S6, M070S6 (6-speed)
Optional Transmission
Type:
Automatic Transmissions: M065A5 (5-speed, likely an Allison 1000/2200 variant), M100A6 (6-speed, likely an Allison 3000 variant)
Features
Fluid Type Manual:
Refer to manual for specific GL-4 or GL-5 gear oil specifications.
Fluid Type Automatic:
Allison TES 295 approved fluids (e.g., Dexron III/VI, or specific TES 295 synthetic) as specified in the manual.
📐 Dimensions
Exterior
Chassis Variants:
FK61F, FM65F, FK62F, FK65F indicate different wheelbase and chassis configurations for various vocational applications.
Weights
Gvwr:
Gross Vehicle Weight Rating varies by chassis configuration, typically ranging from Class 4 to Class 6 GVWR depending on the specific FK/FM model designation. Consult manual for precise ratings.
🛡️ Safety Features
Active Features
ABS:
Anti-lock Braking System (ABS) is a covered feature, enhancing braking control during deceleration.
Passive Features
Cab Construction:
Reinforced cab structure for driver protection (details not specified in product info, but standard for commercial trucks).
💡 Technology Features
Driver Assistance
Cruise Control:
Equipped with an automatic cruise control system for improved driver comfort and fuel efficiency on highways.
Speed Limitation:
Includes a vehicle speed limitation system, often configurable for fleet management or regulatory compliance.
Infotainment
Basic Features:
Typically includes basic audio systems (radio, CD player), though advanced infotainment was less common in commercial trucks of this period. Manual would cover electrical aspects of the audio system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to 01 MAINTENANCE SCHEDULE; typically 5,000 to 15,000 miles or annually, depending on operating conditions.
Fluid Specifications
Engine Oil:
Refer to manual for API CJ-4 or equivalent diesel engine oil specification, and recommended viscosity grade (e.g., 15W-40).
Coolant:
Refer to manual for heavy-duty ethylene glycol coolant specifications (e.g., OAT or HOAT).
Brake Fluid:
Refer to manual for DOT 3 or DOT 4 brake fluid specification for air-over-hydraulic systems.
Known Issues
Common Concerns:
While specific issues are best addressed via the manual's troubleshooting sections, common areas for diesel trucks of this era can include EGR system clogging, DPF regeneration issues (if equipped), and potential common rail system component wear (injectors, pump) with high mileage. Refer to manual for specific diagnostic procedures.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Fuso Truck and Bus Corporation, a subsidiary of Daimler Truck AG.
Model Evolution
Series Significance:
The FK and FM series are established light to medium-duty commercial trucks known for their durability and versatility in various applications.
Production
Manufacturing Region:
Mitsubishi Fuso vehicles are manufactured globally, with key production facilities in Japan and other international locations.
🏆 Awards & Recognition
Recognitions
Industry Standing:
Mitsubishi Fuso trucks are generally well-regarded in the commercial vehicle sector for their reliability and operational efficiency.
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