Mitsubishi FGC18K Forklift Trucks Service Repair Manual SN AF81D-00011-UP by 1637738

Service Manual Chassis & Mast FGC15K

AF81C-00011-up AF81D-00011-up AF81E-00011-up

FGC25K

AF82C-00011-up AF82D-00011-up AF82E-00011-up

FGC18K

AF81C-00011-up AF81D-00011-up AF81E-00011-up

FGC25K HO

AF82C-90011-up AF82D-90011-up AF82E-90011-up

FGC20K

AF82C-00011-up AF82D-00011-up AF82E-00011-up

FGC30K

AF83C-00011-up AF83D-00011-up AF83E-00011-up

FGC20K HO

AF82C-90011-up AF82D-90011-up AF82E-90011-up

For use with 4G63/4G64 Engine Service Manual and Liquefied Petroleum Gas Supplements.

99719-70150

GROUP INDEX 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 â&#x20AC;&#x201C; 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

GENERAL INFORMATION 1 Vehicle Exterior ....................................................................................... Models ....................................................................................................... Serial Number Locations ...................................................................... Dimensions .............................................................................................. Technical Data (Standard Models) ....................................................

1– 1 1– 1 1– 2 1– 4 1– 6

GENERAL INFORMATION

Vehicle Exterior

102696

Models Truck model

Model code – Serial number

FGC15K

AF81C – 00011- up AF81D – 00011- up AF81E – 00011- up

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

FGC25K HO

AF82C – 90011- up AF82C – 90011- up AF82C – 90011- up

FGC30K

AF83C – 00011- up AF83C – 00011- up AF83C – 00011- up 1-1

Engine mounted

Mitsubishi 4G63 gasoline engine

Mitsubishi 4G64 gasoline engine

GENERAL INFORMATION

Serial Number Locations Nameplate

Mast serial number

Transmission serial number

Engine serial number 207070

1-2

GENERAL INFORMATION

Dimensions

E J

F 207071

1-4

GENERAL INFORMATION

Unit: mm (in.) Ref. No.

Truck Model Item

Maximum fork height

1-ton models FGC15K

FGC18K

2-ton models FGC20K FGC20K HO

FGC25K FGC25K HO

3-ton models FGC30K

3325 (131)

3340 (131)

3315 (130)

Free fork height

115 (4.5)

130 (5.1)

135 (5.3)

Fork spacing (out-to-out) minimum/maximum

200/820 (8.0/32.3)

200/920 (8.0/36.2)

200/960 (10/38)

Fork length

Tilt angle (forward–backward)

Overall length

Overall width (outside of tires)

945 (37.5)

1055 (41.5)

1105 (43.5)

Overall height (to top of mast lowered)

2105 (83)

2110 (83.5)

2155 (85)

Overall height (to top of overhead guard)

2022 (79.6)

Overall height (to top of mast extended)

4550 (179)

4565 (180)

4535 (176)

Trend (front)

793 (31.2)

877 (34.5)

902 (35.5)

Trend (rear)

826 (32.5)

Wheelbase

1190 (46.9)

1350 (53.1)

1500 (59.1)

Load moment constant

376 (14.8)

399 (15.7)

412 (16.2)

Rear overhang

Ground clearance (at frame)

1067 (42) 5–10° 2055 (80.9)

479 (18.9)

5–10°

2083 (82.0)

507 (20.0)

95 (3.7)

1-5

2227 (87.5)

5–6° 2287 (90)

2455 (96.7)

2060 (81.1)

922 (36.3)

475 (18.7)

897 (35.5)

532 (20.9) 130 (5.1)

897 (35.5)

529 (20.8)

GENERAL INFORMATION

Technical Data (Standard Models) Truck Model Item Rated capacity/load center kg/mm (lb/in.)

Work performance

FGC15K

FGC18K

FGC20K

FGC25K

FGC30K

1500/500 (3000/24)

1800/500 (3500/24)

200/500 (4000/24)

2500/500 (5000/24)

3000/500 (6000/24)

Maximum fork height

mm (in.)

3300 (131)

Lift speed (rated load)

mm/sec (fpm)

590 (116)

510 (100)

470 (93)

610 (120)

550 (108)

500 (98)

Lowering speed (rated load) mm/sec (fpm) Tilt angle (forward – backward) Free fork height

Traveling performance

mm (in.)

Forward Travel speed (loaded) km/h (mph) Reverse Minimum turning radius

mm (in.)

Gradeability (rated load) [at 1.6 km/h (1 mph)]

% tan

Overall length

mm (in.)

Overall width

mm (in.) To top of mast lowered

Overall height

To top of mm (in.) mast extended To top of overhead guard

Dimensions

Wheel base Tread

mm (in.) mm (in.)

5–10°

5–6°

115 (4.5)

130 (5.1)

135 (5.3)

15 (9.3)

16 (9.9)

15 (9.3)

16 (9.9)

1760 (69.3)

1790 (70.4)

1945 (76.6)

2002 (78.8)

2169 (85.4)

25.5

2949 (116.1)

2980 (117.3)

4335 (170.7)

4392 (172.9)

4559 (179.5)

945 (37.2)

1055 (41.5)

1105 (43.5)

2105 (83)

2110 (83.1)

2155 (85)

4550 (179)

4565 (180)

4535 (176)

2022 (79.6)

2060 (81.1)

1190 (46.9)

1350 (53.1)

1500 (59.1)

Front

793 (31.2)

877 (34.5)

902 (35.5)

Rear

826 (32.5)

Load moment constant

mm (in.)

Rear overhang

mm (in.)

Ground clearance (at frame)

376 (14.8) 479 (18.9)

507 (20.0)

922 (36.3)

897 (35.5)

399 (15.7) 475 (18.7)

532 (20.9)

897 (35.5) 412 (16.2) 529 (20.8)

95 (3.7)

130 (5.1)

18 × 6 × 12-1/8

21 × 7 × 15

21 × 8 × 15

14 × 4-1/2 × 8

16 × 6 × 10-1/2

2630 (5800)

3650 (8050)

4170 (9190)

4G63

4G64

Make

Mitsubishi Motors

Type

Gasoline

Tire size

mm (in.)

Front Rear

Service weight (empty)

kg (lb)

Engine model

Cooling System No. of cylinders - arrangement

Water

4 -in-line

No. of strokes Types of combustion chambers

Semi-spherical

Semispherical

Valve arrangement

Overhead valve and OHC

Type of cylinder liners

Integral with cylinder block

85 × 88 (3.346 × 3.465)

86.5 × 100 (3.406 × 3.937)

1997 (121.8)

2350 (143.4)

Engine

Cylinder bore × stroke Displacement

mm (in.) cc (cu in.)

1-6

GENERAL INFORMATION Truck Model Item Compression ratio

8.6 : 1 57/2400

139 (14.2) [105]/1600

176 (18) [130]/1600

576 × 604.6 × 730.7 (22.7 × 23.8 × 28.8)

576× 604.6× 736.7 (22.7 × 23.8 × 29.0)

150 (330)

Rear

Open BTDC

12°

Close ABDC

40°

40° 54°

Dimensions (length × width × height)

mm (in.)

Weight (service)

kg (lb)

Location

Open BBDC

54°

Close ATDC

6°

Intake valves

0.00 (hot)

mm Exhaust valves Ignition Firing order Ignition timing BTDC Fuel tank rated capacity

Spark

1-3-4-2

degree/rpm liter (U.S. gal.)

4 / 700 ± 50 (gasoline)

9/ 700 ± 50 (LPG)

34 (9)

46 (12)

56 (15)

Type

With external resistor

Make

Mitsubishi Electric

Type

Non-contact point type (C.E.I.)

Make

Mitsubishi Electric

Centrifugal pneumatic type

W14EX-U

Ignition coil

Ignition system (gasoline models)

Distributor

Spark advancer Type Spark plugs

Make

Denso

Size mm (in.)

14 × 1.25 (0.55 × 0.049)

mm (in.)

0.7 to 0.8 (0.028 to 0.031)

Gap

Carburetor Governor

Fuel system

Fuel pump

Air cleaner

Type

Down-draft

Make

Mikuni Kogyo

Type

Pneumatic

Pneumatic Mikuni Kogyo

Make

Mikuni Kogyo

Type

Diaphragm

Make

Kyosan Electric

Type × number

Cyclone-paper element × 1

Make

Nippon Rokaki

Pressure feed

Gear type

Paper-element type

Type Oil pump

Lubrication system

FGC30K

8.5 : 1

N·m (kgf·m) [lbf·ft]/rpm

Valve clearance

FGC25K

46/2400

Maximum torque

Exhaust valves

FGC20K

8.5 : 1 Hp/rpm

Intake valves

FGC18K

46/2400

Rated output

Engine

FGC15K

Oil filter Oil pan Refill capacities Oil filter liter (U.S. gal.) Total

Paper-element type 45 (1.2)

45 (1.2)

0.3 (0.1)

4.8 (1.3)

1-7

GENERAL INFORMATION Truck Model

FGC15K

Item Type

Cooling system

Radiator Refill capacity

liter (U.S. gal.)

Water pump Thermostat

Battery Alternator and regulator Starter

Power train

Powershaft transmission

Reduction gear

Differential

9.85 (2.6)

Centrifugal type

Centrifugal type 12 40

3-phase

V - kW Type Model

12 - 65

Built-in IC type

Lever-shift type

12 - 1.2

3-element, 1-stage, 2-phase

3-element, 1-stage, 2-phase Daikin DC6649

Daikin XT027

Daikin DC6649

Stall torque ratio

2.8

3.0

Control and shift

Hydraulic column shift

Ratios

Forward

2.913

Reverse

2.913

2.913 Skew bevel

Type of gears

Skew bevel

Ratio

4.571

Axle housing

Banjo

Straight bevel - 2

straight bevel - 2

Straight bevel - 2

Full hydrostatic power stearing

Type of gears- Gears number Pinions

Inside

83°

78°05´

Outside

54°

56°

52°14´

330 (13)

mm (in.)

63.5 × 40 (2.5 × 1.575)

76.2 × 50 (3.0 × 1.97)

195 (7.68)

210 (8.27)

Relief pressure kPa (kgf/cm2) [psi]

7845 (80) [1138]

Flow rate liter (U.S. gal.)/min

23 (6.07)

Rear axle Front wheels Rear wheels Toe-in Wheel alignment

Corrugated fin (pressure) type

Front axle

Traveling system

Corrugated fin (pressure) type

Effective stroke

Mounting

Corrugated fin (pressure) type

Steering cylinder ID × rod OD mm (in.) Steering cylinder

Forced circulation

Wax type

V-A

Steering wheel diameter

Steering system

Forced circulation

Type Turning angle

Forced circulation

Wax type

Type

Torque converter

FGC30K

Regulator Voltage - output

FGC25K

Wax type

Alternator type Capacity

FGC20K

Voltage 5-hr rating

FGC18K

Full-floating tubular type

Elliott type

Fixed type

Center-pivot type

Center-pivot type 0

Camber

mm (in.)

1°

Caster

0°

Kingpin inclination

0°

1-8

GENERAL INFORMATION Truck Model Item

Brake system

Parking brake

FGC18K

Drum diameter mm (in.)

254 (10.00)

310 (12.20)

Lining (length × width × thickness × number) mm (in.)

274.2 × 48.5 × 4.78 × 2 (10.80 × 1.91 × 0.19 × 2)

344 × 60.0 × 6.4 × 2 (13.54 × 2.36 × 0.24 × 2)

344× 60.0× 6.4× 2 (13.54 × 2.36 × 0.24 × 2)

Master cylinder ID mm (in.)

22.22 (0.8748)

Wheel cylinder ID mm (in.)

22.22 (0.8748)

28.58 (1.1252)

Mechanical, mounted on front wheels

Unitized type

Gear

Shimadzu SGP1-27

Shimadzu SGP1-30

Shimadzu SGP1-34

64.8 (3954) /2400 rpm

72.0 (4394) /2400 rpm

79.9 (4876) /2400 rpm

Universal joint

Type Model Rated output liter (cu in.) Drive line

Universal joint

Model

Shimadzu MSV 04-3-7645

Relief pressure kPa (kgf/cm2) [psi]

Hydraulic system

Type Flow regulator valve Lift cylinders Tilt cylinders

Regulated flow rate liter (cu in.)/min ID mm (in.) Stroke ID mm (in.) Stroke

Hydraulic tank capacity (approx.) liter (U.S. gal) Mast Outer Mast dimensions mm (in.) (Flange inside width × Flange × thk (F.R)×Flange Inner thk (R.E) × Web thk) mm (in.) Type Main rollers

Mast and forks

FGC30K Self-adjusting duo-servo

Body-frame

Control valve

FGC25K

Self-adjusting duo-servo

Type

Hydraulic pump

FGC20K

Self-adjusting duo-servo

Type

Service brake

FGC15K

18142

+490 0

[2361

(185 0 ) +71 0

]

+490 0

[2361

+490

18142 0 +5 (185 0 ) +71 [2361 0 ]

(185 0 ) +71 0

]

Variable

50 ± 3 (3051 ± 183)

65 ± 3 (3967 ± 183)

75 ± 3 (4577 ± 183)

45 (1.77)

50 (1.97)

55 (2.17)

1650 (64.96)

1600 (62.99)

63 (2.48)

70 (2.76)

80 (3.15)

96 (3.78)

111 (4.37)

21 (5.5)

30 (7.9)

36 (9.5)

Roller type CL

100 × 17 × 19 × 11 (3.94 × 0.67 × 0.75 × 0.43)

115 × 22 × 27 × 12 (4.53 × 0.87 × 1.06 × 0.47)

100 × 17 × 19 × 10 (3.94 × 0.67 × 0.75 × 0.39)

115 × 22 × 23 × 11 (4.53 × 0.87 × 0.91 × 0.43)

#6308 ball bearing

Diam × width mm (in.)

18142

100 × 27 (3.94 × 1.06)

#6309 ball bearing

#6309 ball bearing 115 × 30 (4.53 × 1.18)

Type

Lubricating type needle roller bearing

Diam × width mm (in)

42 × 36 (1.65 × 1.42)

42×36 (1.65 × 1.42)

Side rollers

Lift chains

BL534

BL634

BL834

mm (in.)

1067 × 100 × 35 (42 × 4 × 1.4)

1067 × 100 × 40 (42 × 4 × 1.6)

1067 × 125 × 45 (42 × 5 × 1.8)

mm (in.)

200 to 820 (8 to 32.5)

200 to 920 (8 to 36)

200 to 960 (10 to 38)

Fork (length × width × thickness) Fork spacing (out-to-out)

1-9

COOLING SYSTEM Structure and Function ......................................................................... 2 – 1 Removal and Installation ...................................................................... 2 – 2 Fan Belt Removal ..................................................................................... 2 – 2

Inspection and Adjustment ................................................................. 2 – 4 Fan Belt Inspection ................................................................................... 2 – 4 Fan Belt Adjustment .................................................................................. 2 – 4

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COOLING SYSTEM

Structure and Function

209479

The cooling fan is installed inside the engine compartment. This helps minimize radiator core clogging and retain high cooling efficiency even in continuous operation for hours. The radiatorâ&#x20AC;&#x2122;s lower tank has a built-in transmission oil cooler.

2-1

COOLING SYSTEM

Removal and Installation Fan Belt Removal

206419

Sequence 1 2 3

Fan guard Tensioner, Tensioner pulley Support, Cooling fan

4 5

Start by:

Remove the engine hood and gas-filled cylinder.

Suggestions for Removal Make sure the muffler, engine and exhaust pipe is cool enough to touch with your hand.

2-2

Universal joint Fan belt