Mitsubishi Fuso Truck Service Repair Manual FK FM Series 2005
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🏷️ Basic Information Identification Make: Mitsubishi Fuso Model: FK FM Series Year: 2005 Codes Chassis Codes: FK61F, FM61F, FM64F, FM65F Engine Code: 6M60 👋 Introduction Market Position Target Audience: Professional truck technicians, fleet maintenance departments, and serious DIY mechanics specializing in heavy-duty commercial vehicles. Application Types: Suitable for various commercial applications including delivery, utility work, and specialized services. Competitive Analysis Value Proposition: Provides extensive, in-depth technical data crucial for maintaining and repairing the specified Mitsubishi Fuso FK/FM Series trucks, offering a critical resource for operational efficiency and longevity. Key Features Instant Access: Digital download eliminates shipping delays and costs, providing immediate access to essential repair information. Comprehensive Coverage: Covers nearly all major mechanical, electrical, and body systems of the truck, ensuring a holistic approach to maintenance and repair. 📋 Manual Details Coverage Areas Covered Sections: 00 GENERAL, 01 MAINTENANCE SHEDULE, 11 ENGINE, 12 LUBRICATION, 13 FUEL & ENGINE CONTROL, 14 COOLING, 15 INTAKE & EXHAUST, 17 EMISSION CONTROL, 21 CLUTCH, 22 MANUAL TRANSMISSION, 23 AUTOMATIC TRANSMISSION, 25 PROPELLER SHAFT, 26 FRONT AXLE, 27 REAR AXLE, 31 WHEEL & TIRE, 33 FRONT SUSPENSION, 34 REAR SUSPENSION, 35A BRAKE, 36 PARKING BRAKE, 37 STEERING, 41 FRAME, 42 CAB, 54 ELECTRICAL, 55A AIR CONDITIONER & HEATER Page Count Total Pages: 1639 Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format Digital Format: PDF, ZIP Compatibility: Win95/98/ME/XP/vista/7/Linux/MAC Searchability: PDF format allows for text searching, significantly improving efficiency in finding information. 📖 Manual Coverage Systems Covered Powertrain: Engine (6M60), Lubrication, Fuel & Engine Control, Cooling, Intake & Exhaust, Emission Control, Clutch, Manual Transmission, Automatic Transmission, Propeller Shaft, Front Axle, Rear Axle Chassis And Suspension: Wheel & Tire, Front Suspension, Rear Suspension, Brake System (including Parking Brake), Steering System, Frame Body And Electrical: Cab, Electrical Systems, Air Conditioning & Heater Vehicle Identification And Numbers: Identification of VIN, engine serial numbers, and chassis numbering systems. Emission Control Systems Detailed: Specific coverage for EGR, exhaust after-treatment systems, and related sensors. Procedures Included Maintenance: Scheduled maintenance, lubrication procedures, fluid checks and changes Diagnostics And Troubleshooting: System-specific diagnostic procedures, fault code interpretation, troubleshooting guides Repair And Overhaul: Detailed step-by-step repair instructions for all major components, engine overhaul procedures, transmission rebuilds, brake system repairs Electrical And Electronic Systems: Wiring diagrams, component testing, diagnostic procedures for electronic control units (ECUs) Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, including lighting, power, engine controls, and accessories. Special Tools: Listing of specialized tools required for specific maintenance or repair procedures. Troubleshooting Charts: Diagnostic flowcharts and symptom-to-cause tables. Technical Depth Depth Of Information: Comprehensive coverage suitable for professional technicians, including detailed specifications, torque values, special tool requirements, and diagnostic strategies. Component Tolerances: Detailed specifications for component clearances, tolerances, and measurements crucial for rebuilds. Torque Specifications: Precise torque values for all fasteners, critical for ensuring structural integrity and preventing component failure. Diagnostic Codes: Explanations of diagnostic trouble codes (DTCs) and their meanings. 📊 Manual Specifications File Format Digital Format: PDF (Searchable text, printable) Compression Format: ZIP Print Quality Image Resolution: High-resolution scans ensuring clarity of diagrams and text. Binding Type Binding: Not Applicable (Digital Format) Paper Type Paper Type: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Model: 6M60 Engine Type: Inline 6-cylinder Diesel (Turbocharged and Intercooled, likely) Displacement: Approximately 6.0-7.5 Liters (Specific displacement for 6M60 series varies, but this is typical for this engine family) Performance Horsepower Range: Typically ranges from 180 HP to 250 HP depending on specific variant and emissions regulations. Torque Range: Ranges from approximately 500 Nm to 700 Nm or higher. Fuel System Fuel Delivery: Common Rail Direct Injection (CRDI) system is highly probable for a 2005 model year engine for efficiency and emissions compliance. Emission Control Systems: May include EGR (Exhaust Gas Recirculation), potentially DPF (Diesel Particulate Filter) or SCR (Selective Catalytic Reduction) depending on market and specific engine tune for 2005 compliance. Injection System: Electronic Fuel Injection (EFI) with Common Rail technology. Engine Type Aspiration: Turbocharged and Intercooled (very likely for 6M60 in this application). 🔧 Transmission Standard Transmission Types: Manual and Automatic Transmissions are covered, indicating options were available. Optional Automatic Transmission Features: Details likely include torque converter operation, shift logic, electronic control units (TCUs), and diagnostic procedures for automatic units. Features Manual Transmission Features: Coverage will include clutch operation, gear selection, synchronizers, and lubrication requirements for manual gearboxes. 📐 Dimensions Exterior Chassis Configurations: FK and FM series represent different classes/wheelbases. FK typically refers to lighter-duty, while FM can encompass medium-duty configurations. Specific dimensions vary greatly by wheelbase and body type. Wheelbase: Variable, depending on specific chassis configuration (FK61F, FM61F, etc.) and intended body type (e.g., cab-and-chassis, box truck). Weights Gvwr: Gross Vehicle Weight Rating varies significantly by chassis code (FK vs. FM) and intended application, ranging from Class 4 to Class 7 GVWRs. Curb Weight: Variable based on configuration...
Professional truck technicians, fleet maintenance departments, and serious DIY mechanics specializing in heavy-duty commercial vehicles.
Application Types:
Suitable for various commercial applications including delivery, utility work, and specialized services.
Competitive Analysis
Value Proposition:
Provides extensive, in-depth technical data crucial for maintaining and repairing the specified Mitsubishi Fuso FK/FM Series trucks, offering a critical resource for operational efficiency and longevity.
Key Features
Instant Access:
Digital download eliminates shipping delays and costs, providing immediate access to essential repair information.
Comprehensive Coverage:
Covers nearly all major mechanical, electrical, and body systems of the truck, ensuring a holistic approach to maintenance and repair.
Detailed step-by-step repair instructions for all major components, engine overhaul procedures, transmission rebuilds, brake system repairs
Electrical And Electronic Systems:
Wiring diagrams, component testing, diagnostic procedures for electronic control units (ECUs)
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, including lighting, power, engine controls, and accessories.
Special Tools:
Listing of specialized tools required for specific maintenance or repair procedures.
Troubleshooting Charts:
Diagnostic flowcharts and symptom-to-cause tables.
Technical Depth
Depth Of Information:
Comprehensive coverage suitable for professional technicians, including detailed specifications, torque values, special tool requirements, and diagnostic strategies.
Component Tolerances:
Detailed specifications for component clearances, tolerances, and measurements crucial for rebuilds.
Torque Specifications:
Precise torque values for all fasteners, critical for ensuring structural integrity and preventing component failure.
Diagnostic Codes:
Explanations of diagnostic trouble codes (DTCs) and their meanings.
📊 Manual Specifications
File Format
Digital Format:
PDF (Searchable text, printable)
Compression Format:
ZIP
Print Quality
Image Resolution:
High-resolution scans ensuring clarity of diagrams and text.
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper Type:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Model:
6M60
Engine Type:
Inline 6-cylinder Diesel (Turbocharged and Intercooled, likely)
Displacement:
Approximately 6.0-7.5 Liters (Specific displacement for 6M60 series varies, but this is typical for this engine family)
Performance
Horsepower Range:
Typically ranges from 180 HP to 250 HP depending on specific variant and emissions regulations.
Torque Range:
Ranges from approximately 500 Nm to 700 Nm or higher.
Fuel System
Fuel Delivery:
Common Rail Direct Injection (CRDI) system is highly probable for a 2005 model year engine for efficiency and emissions compliance.
Emission Control Systems:
May include EGR (Exhaust Gas Recirculation), potentially DPF (Diesel Particulate Filter) or SCR (Selective Catalytic Reduction) depending on market and specific engine tune for 2005 compliance.
Injection System:
Electronic Fuel Injection (EFI) with Common Rail technology.
Engine Type
Aspiration:
Turbocharged and Intercooled (very likely for 6M60 in this application).
🔧 Transmission
Standard
Transmission Types:
Manual and Automatic Transmissions are covered, indicating options were available.
Optional
Automatic Transmission Features:
Details likely include torque converter operation, shift logic, electronic control units (TCUs), and diagnostic procedures for automatic units.
Features
Manual Transmission Features:
Coverage will include clutch operation, gear selection, synchronizers, and lubrication requirements for manual gearboxes.
📐 Dimensions
Exterior
Chassis Configurations:
FK and FM series represent different classes/wheelbases. FK typically refers to lighter-duty, while FM can encompass medium-duty configurations. Specific dimensions vary greatly by wheelbase and body type.
Wheelbase:
Variable, depending on specific chassis configuration (FK61F, FM61F, etc.) and intended body type (e.g., cab-and-chassis, box truck).
Weights
Gvwr:
Gross Vehicle Weight Rating varies significantly by chassis code (FK vs. FM) and intended application, ranging from Class 4 to Class 7 GVWRs.
Curb Weight:
Variable based on configuration and options.
🛡️ Safety Features
Active Features
Braking System:
Hydraulic service brakes, potentially with ABS (Anti-lock Braking System) depending on GVWR and market. Parking brake system (likely mechanical or spring-assisted) is detailed.
Passive Features
Cab Construction:
Information on cab structure, mounting, and potential safety reinforcements.
💡 Technology Features
Infotainment
Infotainment Systems:
Likely basic for a 2005 commercial truck, possibly including an AM/FM radio, CD player, and basic HVAC controls. Manual covers dashboard and audio system removal/installation.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) diagnostic and repair information will be present if equipped.
Connectivity
On Board Diagnostics:
The manual will detail OBD-II (or equivalent heavy-duty diagnostic) protocols and connector locations for engine and transmission control modules.
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Typical intervals for 2005 diesel engines are often between 5,000 to 10,000 miles (or 8,000 to 16,000 km), but the manual will specify exact intervals based on operating conditions.
Transmission Fluid:
Intervals for manual and automatic transmission fluid changes will be provided, usually between 30,000 to 60,000 miles (48,000 to 96,000 km).
Coolant:
Coolant flush and replacement intervals typically range from 2 to 4 years or 50,000 to 100,000 miles.
Air Filter:
Replacement intervals based on operating conditions and inspection.
Fuel Filter:
Replacement intervals for primary and secondary fuel filters.
Fluid Specifications
Engine Oil:
The manual will specify the correct API service classification (e.g., CI-4, CH-4) and viscosity grade (e.g., 15W-40, 10W-30) for the 6M60 engine.
Transmission Fluid:
Specifications for manual transmission gear oil (e.g., GL-4 or GL-5) and automatic transmission fluid (ATF, likely a specific DEXRON or Mercon type) will be detailed.
Coolant Type:
Specifies the type of engine coolant (e.g., HD Extended Life Coolant) and its mixture ratio with water.
Brake Fluid:
Specification for DOT 3 or DOT 4 brake fluid depending on system requirements.
Power Steering Fluid:
Type of fluid required for the power steering system.
Known Issues
Common Wear Items:
As with many commercial trucks of this era, common wear items could include clutch components, brake pads/rotors, suspension bushings, and certain engine fuel system components (injectors, fuel pump) under high mileage use. The manual will guide diagnosis.
Diagnostic Challenges:
The manual's detailed diagnostic procedures are invaluable for addressing complex electrical or fuel system issues common in modern diesel engines.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Fuso Truck and Bus Corporation (part of Daimler AG at the time of 2005, though ownership structures have evolved).
Model Evolution
Series Context:
The FK and FM series are long-standing lines of medium-duty commercial trucks known for their reliability and versatility in various vocational applications.
Production
Manufacturing Locations:
Produced globally by Mitsubishi Fuso, with major manufacturing bases historically in Japan and other international facilities.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Mitsubishi Fuso trucks are generally recognized for their durability and reliability in demanding commercial applications. Specific awards for the 2005 FK/FM series would be market-dependent.