Mitsubishi FGC15K, FGC18K, FGC20K, FG20K HO, FGC25K, FGC25K HO, FGC30K Forklift Trucks Service Repair Workshop Manual

Service Manual 99719-70150 For use with 4G63 / 4G64 Engine Service Manual and Liquefied Petroleum Gas Supplements. Chassis & Mast 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 FGC20K HO AF82C-90011-up AF82D-90011-up AF82E-90011-up FGC25K AF82C-00011-up AF82D-00011-up AF82E-00011-up FGC25K HO AF82C-90011-up AF82D-90011-up AF82E-90011-up FGC30K AF83C-00011-up AF83D-00011-up AF83E-00011-up

FOREWORD 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. Pub. No. 99719-70150 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. NOTE CAUTION WARNING

HOW TO READ THIS MANUAL Disassembly diagram (example) Sequence 1. Cover, Bolt, Washer (part name) 2. Output shaft (part name) 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) Unit: mm (in.) A 0.020 to 0.105 Clearance between (0.00079 to 0.00413) cylinder and piston 0.15 B (0.0059) A: Standard value B: Repair or service limit Disassembly sequence Each disassembly diagram is followed by Disassembly sequence and Suggestions for disassembly.

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. 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 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. 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

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Mitsubishi FGC15K, FGC18K, FGC20K, FG20K HO, FGC25K, FGC25K HO, FGC30K Forklift Trucks Service Repair Workshop Manual

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