Mitsubishi Fuso FK FM Series 2005 Truck Service Manual – Complete Repair Guide

Description

Mitsubishi Fuso FK FM Series 2005 Truck Service Manual

The Mitsubishi Fuso FK FM Series 2005 Truck Service Manual is the complete workshop repair and maintenance guide for the 2005 model year FK and FM series trucks. This comprehensive service manual covers the FK61F, FM61F, FM64F, and FM65F models, providing detailed maintenance and repair methods for every major system on the vehicle. Published in May 2004, this manual was produced by Mitsubishi Fuso Truck of America for the 2005 model year, covering the 6M60T1 and 6M60T2 diesel engines.

File Details

• Manual Type: Service Manual (Workshop Repair & Maintenance)
• Brand: Mitsubishi Fuso
• Model Series: FK, FM
• Covered Models: FK61F, FM61F, FM64F, FM65F
• Covered Engines: 6M60T1, 6M60T2 (7.545 L Diesel, Turbocharged)
• Model Year: 2005
• Publication Date: May 2004
• Language: English
• Page Count: 1,639
• File Format: PDF

Chapters Covered

This service manual is organized into factory group sections, each covering a major vehicle system in detail. The complete chapter listing includes:

• Group 00 – General: How to read this manual, equipment model codes, chassis and engine numbers, power train labels, safety procedures, standard tightening torques, connector configurations
• Group 01 – Maintenance Schedule: Complete scheduled maintenance intervals and procedures, tire service standards, lubrication charts, greasing points
• Group 11 – Engine: Engine proper, rocker and bracket assembly, camshaft, cylinder head, valve mechanism, pistons, connecting rods, cylinder liners, flywheel, timing gears, crankshaft, crankcase
• Group 12 – Lubrication: Lubrication system, oil pump, oil filter, oil cooler, engine oil pressure switch, regulator valve
• Group 13A – Fuel and Engine Control: Fuel system, engine control, fuel filter, fuel tank, common rail assembly, supply pump, injectors
• Group 13E – Electronically Controlled Fuel System: Common rail system specifications, electronic control system, diagnosis codes, Multi-Use Tester operations
• Group 14 – Cooling: Cooling system, water pump, thermostat, radiator, cooling fan, V-belts
• Group 15 – Intake and Exhaust: Air cleaner, turbocharger, intercooler, intake manifold, exhaust manifold, exhaust pipe, muffler
• Group 17 – Emission Control: Exhaust gas recirculation system, crankcase emission control, PCV valve
• Group 21 – Clutch: Clutch system, master cylinder, power cylinder, booster, clutch body, control mechanisms
• Group 22A – Manual Transmission (M060S6, M070S6): Transmission body, gear shifter, mainshaft, countershaft, drive pinion, transmission control
• Group 22B – Manual Transmission (Eaton FS-8209): Removal, installation, transmission control, high-low control
• Group 23A – Automatic Transmission (Allison LCT1000, LTC2400): Specifications, electronic control system, troubleshooting, stall test, line pressure test
• Group 23B – Automatic Transmission (Allison MD3060P): Specifications, structure, troubleshooting, on-vehicle inspection
• Group 25 – Propeller Shaft: Propeller shaft specifications, removal and installation, rear and front propeller shafts, balancing
• Group 26 – Front Axle: Wheel hub, brake drum, front axle, knuckle, kingpin, wheel alignment, steering angle
• Group 27 – Rear Axle: Wheel hub, brake drum, axle housing, reduction and differential (D050H, D8H, D10H)
• Group 31 – Wheel and Tire: Wheel and tire specifications, removal and installation, tire inspection, wheel service
• Group 33 – Front Suspension: Leaf spring assembly, shock absorber, front suspension structure
• Group 34A – Rear Suspension (Leaf): Leaf spring assembly, rear suspension structure
• Group 34B – Rear Suspension (Air): Air suspension system, leveling valve, air spring, shock absorber
• Group 35A – Brake (Air Over Hydraulic): Brake system, air compressor, air dryer, brake pedal, dual brake valve, brake booster, front and rear wheel brakes
• Group 35B – Brake (Full Air): Full-air brake system, relay valve, quick release valve, front and rear wheel brakes, expander assembly
• Group 35E – Anti-lock Brake System: ABS structure, periodic inspection, wheel speed sensor, troubleshooting, diagnosis codes
• Group 36A – Parking Brake (Center): Parking brake control, parking brake assembly, support plate and shoe assembly
• Group 36B – Parking Brake (Wheel): Parking brake system, control valve, spring brake valve, double check valve
• Group 37 – Steering: Steering system, linkage, power steering booster, power steering oil pump, drag link, tie rod assembly
• Group 41 – Frame: Frame inspection and repair, crack repair procedures, rivet replacement
• Group 42 – Cab: Cab removal and installation, front and rear cab mounting, cab stay, cab tilt link, door, mirror, seat, seat belt, wiper and washer, instrument panel, trim, headlining, window glass
• Group 54 – Electrical: Starter, alternator, lamps, daytime running light system, MUTIC, engine electronic control unit, troubleshooting, power circuits, starting circuits, lighting circuits, meter circuits, indicator and warning circuits, cab side electrical circuits, chassis side electrical circuits, engine and transmission side electrical circuits
• Group 55A – Air-Conditioner: Air system, refrigerating circuit, compressor, magnetic clutch, check valve, condenser, receiver, cooling unit, expansion valve, control system
• Group 55B – Heater: Heater system, heater hoses, heater control, air ducts, heater unit and blower, air outlet ventilation

What This Manual Provides

This is not a generic overview or a collection of maintenance tips. It is the complete factory service manual that Mitsubishi Fuso dealership technicians would use to diagnose, repair, and maintain FK and FM series trucks. Every procedure is written with the level of detail required to actually perform the job — from removing and installing the engine to adjusting valve clearances, from diagnosing common rail fuel system codes to repairing frame cracks, from rebuilding the clutch to servicing the air suspension system.

The manual includes complete specifications with standard values, limits, and remedies for every measurable component. Torque values are given in N·m, ft.lbs, and kgf·m throughout. Special tools are identified with part numbers. Service standards tables tell you exactly what is within specification and what requires replacement or adjustment. Wiring diagrams and connector configuration charts allow proper diagnosis of electrical faults. The diagnostic trouble code charts for the common rail system, ABS, and automatic transmissions provide the same information the factory scan tools would show.

The 6M60 Engine Coverage

The 6M60 engine is a 7.545 L inline six-cylinder diesel with overhead camshaft, direct injection, and turbocharging. This manual covers both the 6M60T1 and 6M60T2 variants, including complete engine removal and installation, cylinder head service, valve clearance adjustment, piston and connecting rod service, cylinder liner replacement, flywheel service, timing gear service, crankshaft and crankcase service. The common rail fuel system section provides diagnostic procedures for the electronically controlled fuel injection system, including the supply pump, injectors, and common rail assembly. The engine electronic control unit section covers the preheating function, starter continuous-ON prevention function, and fault diagnosis function with diagnostic trouble codes readable via Multi-Use Tester III or the diagnostic switch.

Transmission Coverage

The manual covers both manual and automatic transmissions in detail. For manual transmissions, the M060S6, M070S6, and Eaton FS-8209 are covered with complete disassembly, inspection, and assembly procedures for the transmission body, mainshaft, countershaft, drive pinion, and shift mechanisms. For automatic transmissions, the Allison LCT1000, LTC2400, and MD3060P are covered with specifications, electronic control system operation, troubleshooting procedures, stall tests, line pressure tests, and diagnostic trouble code charts. This allows proper diagnosis and repair of the automatic transmission control systems without guesswork.

Electrical System Coverage

The electrical section covers the complete charging and starting system, lighting circuits, meter circuits, indicator and warning lamp circuits, cab side electrical circuits, chassis side electrical circuits, and engine and transmission side electrical circuits. The manual includes relay and fuse box layouts, fuse ratings and locations, connector configuration charts with terminal numbers, grounding points, and complete circuit diagrams. The daytime running light system, MUTIC (Multipurpose Timing Control Unit), and engine electronic control unit are covered in detail. Troubleshooting procedures for power and charging, engine starting, lighting, meter, horn, and accessory systems are included with probable causes and remedies.

Coverage by Model

The manual covers the following 2005 model year Mitsubishi Fuso trucks:

• FK61F — Equipped with 6M60-T1 engine, M060S6 or M070S6 manual transmission, or Allison LCT1000/LCT2400 automatic transmission
• FM61F — Equipped with 6M60-T1 engine, M060S6 or M070S6 manual transmission, or Allison LCT1000/LCT2400 automatic transmission
• FM64F — Equipped with 6M60-T1 engine and M060S6 manual transmission
• FM65F — Equipped with 6M60-T1 or 6M60-T2 engine, M070S6 or Eaton FS-8209 manual transmission, or Allison MD3060P automatic transmission

Who This Manual Is For

This manual is intended for professional diesel technicians, fleet maintenance shops, independent repair facilities, and serious owner-operators who need to perform their own maintenance and repairs on Mitsubishi Fuso FK and FM series trucks. The procedures assume access to common hand tools, specialty tools where noted, and a properly equipped workshop. The diagnostic information is equally valuable for troubleshooting specific fault codes and symptoms without disassembling systems unnecessarily.

Why This Manual Matters

Mitsubishi Fuso FK and FM series trucks are robust commercial vehicles, but proper maintenance and repair require accurate specifications. Using incorrect torque values can cause fastener failure or component damage. Misdiagnosing fuel system or electrical faults wastes time and money. This manual eliminates guesswork by providing the same information that factory-trained technicians use. Whether you are adjusting valve clearances on the 6M60 engine, diagnosing a common rail pressure fault, rebuilding a rear axle differential, or repairing the cab structure, the correct procedure and specification are here.

Get Instant Access

This Mitsubishi Fuso FK FM Series 2005 Truck Service Manual is delivered as a high-quality PDF file that can be viewed on any computer, tablet, or smartphone. There is no shipping, no waiting for a physical book, and no risk of a damaged or lost package. You can print individual pages or entire sections for use in the workshop, search for specific terms, and zoom in on detailed illustrations. Once you have the file, it is yours to keep and reference for as long as you own your truck. Whether you are performing routine maintenance, diagnosing a fault, or undertaking a major repair, this manual provides the guidance you need to do the job right.

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