Mitsubishi FGC18K, FGC20K, FGC25K, FGC15K, FGC20K HO Service Manual
...
FGC15K
AF81C-00011-up
FGC25K
AF82C-00011-up
AF81D-00011-up
AF82D-00011-up
AF81E-00011-up
AF82E-00011-up
FGC18K
AF81C-00011-up
FGC25K HO
AF82C-90011-up
AF81D-00011-up
AF82D-90011-up
AF81E-00011-up
AF82E-90011-up
FGC20K
AF82C-00011-up
FGC30K
AF83C-00011-up
AF82D-00011-up
AF83D-00011-up
AF82E-00011-up
AF83E-00011-up
FGC20K HO
AF82C-90011-up
AF82D-90011-up
AF82E-90011-up
Service Manual
Chassis & Mast
For use with 4G63 / 4G64 Engine Service Manual and
Liquefied Petroleum Gas Supplements.
99719-70150
FOREWORD
NOTE
CAUTION
WARNING
This service manual is a guide to servicing the 1-ton to 3-ton internal combustion cushion models
of Mitsubishi Forklift Trucks. The instructions are grouped by systems to serve the convenience
of your ready reference.
Long productive life of your forklift trucks depends to a great extent on correct servicing – the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know all the components you will work on before
attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual were of the trucks of
serial numbers in effect at the time it was approved for printing. Mitsubishi reserves the right
to change specifications or design without notice and without incurring obligation.
For the items pertaining to the engines, refer to the following service manuals:
• 4G63/4G64 Gasoline Engine Service Manual (Pub. No. 99729-74120)
For use with both gasoline and LP Gas engines.
• 4G63/4G64 LP Gas Supplement (Pub. No. 99729-75100)
For use with LP Gas units with a “D” in the chassis serial number.
• 4G63/4G64 LP Gas Supplement (Pub. No. 99729-75110)
For use with LP Gas units with an “E” in the chassis serial number.
Safety Related Signs
The following safety related signs are used in this service
manual to emphasize important and critical instructions:
Indicates a specific potential hazard
resulting in serious bodily injury or
death.
Indicates a specific potential hazard
resulting in bodily injury, or damage
to, or destruction of, the machine.
Indicates a condition that can cause
damage to, or shorten service life of, the
machine.
Pub. No. 99719-70150
Unit: mm (in.)
A: Standard value B: Repair or service limit
Clearance between
cylinder and piston
A
0.020 to 0.105
(0.00079 to 0.00413)
B
0.15
(0.0059)
and Suggestions for
Each disassembly dia
Disassembly sequence
disassembly.
Disassembly sequence
Sequence
1.
Cover, Bolt, Washer (part name)
2.
Output shaft (part name)
Disassembly diagram
(example)
HOW TO READ THIS MANUAL
Suggestion for disassembly
(1) Output shaft removal
Symbols or abbreviations
OP ...................Option
R1/4.................Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 ...............Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A..............Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8...............Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
WARNING
WARNING
Do not operate this truck unless you have
read and understand the instructions in the
OPERATION & MAINTENANCE MANUAL.
Improper truck operation is dangerous and
could result in injury or death.
WARNING
The proper and safe lubrication and
maintenance for this forklift truck,
recommended by Mitsubishi, are outlined in
the OPERATION & MAINTENANCE MANUAL
for these trucks.
Improper performance of lubrication or
maintenance procedures is dangerous and
could result in injury or death. Read and
understand the OPERATION &
MAINTENANCE MANUAL before performing
any lubrication or maintenance.
The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. A knowledge of the system and/or components
is important before the removal or disassembly of any
component.
Because of the size of some of the truck components,
the serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting procedures
when removing any components.
Following is a list of basic precautions that should
always be observed.
1. Read and understand all warning plates and decals
on the truck before operating, lubricating or
repairing the product.
2. Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any
part of the truck or its attachments with a hammer
or sledge. Use welders gloves, hood/goggles,
apron and other protective clothing appropriate to
the welding job being performed. Do not wear
loose-fitting or torn clothing. Remove all rings
from fingers when working on machinery.
3. Do not work on any truck that is supported only
by lift jacks or a hoist. Always use blocks or jack
stands to support the truck before performing any
disassembly.
SAFETY
4. Lower the forks or other implements to the ground
before performing any work on the truck. If this
cannot be done, make sure the forks or other
implements are blocked correctly to prevent them
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any mud
or debris from steps, walkways or work platforms
before using. Always face truck when using steps,
ladders and walkways. When it is not possible to
use the designed access system, provide ladders,
scaffolds, or work platforms to perform safe repair
operations.
6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting
operation.
7. To avoid burns, be alert for hot parts on trucks
which have just been stopped and hot fluids in
lines, tubes and compartments.
8. Be careful when removing cover plates.
Gradually back off the last two bolts or nuts
located at opposite ends of the cover or device and
pry cover loose to relieve any spring or other
pressure, before removing the last two bolts or
nuts completely.
9. Be careful when removing filler caps, breathers
and plugs on the truck. Hold a rag over the cap or
plug to prevent being sprayed or splashed by
liquids under pressure. The danger is even greater
if the truck has just been stopped because fluids
can be hot.
10. Always use tools that are in good condition and
be sure you understand how to use them before
performing any service work.
11. Reinstall all fasteners with same part number.
Do not use a lesser quality fastener if
replacements are necessary. Do not mix metric
fasteners with standard nuts and bolts.
12. If possible, make all repairs with the truck
parked on a level, hard surface. Block truck so it
does not roll while working on or under truck.
13. Disconnect battery and discharge any capacitors
(electric trucks) before starting to work on truck.
Hang “Do not Operate” tag in the Operator’s
Compartment.
14. Repairs, which require welding, should be
performed only with the benefit of the
appropriate reference information and by
personnel adequately trained and knowledgeable
in welding procedures. Determine type of metal
being welded and select correct welding
procedure and electrodes, rods or wire to provide
a weld metal strength equivalent at least to that
of parent metal.
15. Do not damage wiring during removal
operations. Reinstall the wiring so it is not
damaged nor will it be damaged in operation by
contacting sharp corners, or by rubbing against
some object or hot surface. Do not connect
wiring to a line containing fluid.
18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for
leaks with your hands. Pin hole (very small)
leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can
penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
19. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields that protect against oil spray
onto hot exhaust components in event of a line,
tube or seal failure, must be installed correctly.
20. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
21. Do not operate a truck if any rotating part is
damaged or contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.
16. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
GROUP INDEX
Items
GENERAL INFORMATION
Vehicle Exterior, Models, Serial Number Locations, Dimensions, Technical
Data (Standard Models)
COOLING SYSTEM
Structure and Function, Removal and Installation, Inspection and Adjustment
ELECTRICAL SYSTEM
Console Box – Disassembly and Reassembly, Major Electrical Components,
Battery Maintenance, Lamp Bulb Specifications, Troubleshooting, Electrical
Schematic
POWER TRAIN
Removal and Installation
POWERSHIFT TRANSMISSION
Structure and Function, Removal and Installation, Disassembly and
Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
FRONT AXLE AND
REDUCTION DIFFERENTIAL
Structure and Function, Removal and Installation, Disassembly and
Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
REAR AXLE
Structure and Function, Removal and Installation, Rear Axle Assembly,
Steering Cylinder, Adjustment, Troubleshooting, Service Data
BRAKE SYSTEM
Structure and Functions, Disassembly and Reassembly, Inspection and
Adjustment, Troubleshooting, Service Data
STEERING SYSTEM
Structure and Functions, Removal and Installation, Streering Gear,
Troubleshooting, Service Data
FUEL SYSTEM
Outline of Dual Fuel Type
HYDRAULIC SYSTEM
Hydraulic Tank, Hydraulic Pump, Control Valve, Lift Cylinder, Tilt Cylinder,
Structure and Functions, Removal and Installation, Disassembly and
Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
MAST AND FORKS
Mast Systems, Structure, Removal and Installation, Disassembly and
Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
SERVICE DATA
Maintenance Chart, Tightening Torques for Standard Bolts and Nuts, Planned
Replacement Parts, Lubrication Chart, Weight of Major Components, Special
Service Tools, Inspection Guide
GROUP INDEX
1 2 3
4
5 6 7 8 9 10 11
12 13
GENERAL INFORMATION
Vehicle Exterior .......................................................................................
1 – 1
Models .......................................................................................................
1 – 1
Serial Number Locations
......................................................................
1 – 2
Dimensions ..............................................................................................
1 – 4
Technical Data (Standard Models)
....................................................
1 – 6
1
GENERAL INFORMATION
1-1
Truck model Model code – Serial number Engine mounted
FGC15K
AF81C – 00011- up
AF81D – 00011- up
AF81E – 00011- up
Mitsubishi 4G63 gasoline engine
FGC18K
AF81C – 00011- up
AF81D – 00011- up
AF81E – 00011- up
FGC20K
AF82C – 00011- up
AF82D – 00011- up
AF82E – 00011- up
FGC25K
AF82C – 00011- up
AF82D – 00011- up
AF82E – 00011- up
FGC20K HO
AF82C – 90011- up
AF82D – 90011- up
AF82E – 90011- up
Mitsubishi 4G64 gasoline engine
FGC25K HO
AF82C – 90011- up
AF82C – 90011- up
AF82C – 90011- up
FGC30K
AF83C – 00011- up
AF83C – 00011- up
AF83C – 00011- up
Vehicle Exterior
Models
102696
GENERAL INFORMATION
1-2
Serial Number Locations
Nameplate
Mast serial number Transmission serial number
Engine serial number
207070
GENERAL INFORMATION
1-3
Memo
Loading...