Table of Contents
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Chassis & Mast
FGC15K
FGC18K
FGC20K
FGC20K HO
For use with 4G63 / 4G64 Engine Service Manual and
Liquefied Petroleum Gas Supplements.
Service Manual
AF81C-00011-up
AF81D-00011-up
AF81E-00011-up
AF81C-00011-up
AF81D-00011-up
AF81E-00011-up
AF82C-00011-up
AF82D-00011-up
AF82E-00011-up
AF82C-90011-up
AF82D-90011-up
AF82E-90011-up
FGC25K
FGC25K HO
FGC30K
AF82C-00011-up
AF82D-00011-up
AF82E-00011-up
AF82C-90011-up
AF82D-90011-up
AF82E-90011-up
AF83C-00011-up
AF83D-00011-up
AF83E-00011-up
99719-70150
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Chapters
Table of Contents
Related Manuals for Mitsubishi FGC18K
Summary of Contents for Mitsubishi FGC18K
- Page 1 Service Manual Chassis & Mast FGC15K FGC25K AF81C-00011-up AF82C-00011-up AF81D-00011-up AF82D-00011-up AF81E-00011-up AF82E-00011-up FGC18K FGC25K HO AF81C-00011-up AF82C-90011-up AF81D-00011-up AF82D-90011-up AF81E-00011-up AF82E-90011-up FGC20K FGC30K AF82C-00011-up 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 For use with 4G63 / 4G64 Engine Service Manual and Liquefied Petroleum Gas Supplements.
- Page 2 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.
- Page 3 HOW TO READ THIS MANUAL Disassembly diagram (example) gram is followed by Each disassembly dia Disassembly sequence and Suggestions for disassembly. Disassembly sequence Sequence 1. Cover, Bolt, Washer (part name 2. Output shaft (part name) Suggestion for disassembly (1) Output shaft removal Unit: mm (in.) 0.020 to 0.105 (0.00079 to 0.00413)
- Page 4 Mitsubishi, are outlined in OPERATION & MAINTENANCE MANUAL. the OPERATION & MAINTENANCE MANUAL Improper truck operation is dangerous and for these trucks. could result in injury or death.
- Page 5 10. Always use tools that are in good condition and 18. Loose or damaged fuel, lubricant and hydraulic be sure you understand how to use them before lines, tubes and hoses can cause fires. Do not performing any service work. bend or strike high pressure lines or install ones which have been bent or damaged.
- Page 6 GROUP INDEX GROUP INDEX Items Vehicle Exterior, Models, Serial Number Locations, Dimensions, Technical GENERAL INFORMATION Data (Standard Models) COOLING SYSTEM Structure and Function, Removal and Installation, Inspection and Adjustment Console Box – Disassembly and Reassembly, Major Electrical Components, ELECTRICAL SYSTEM Battery Maintenance, Lamp Bulb Specifications, Troubleshooting, Electrical Schematic POWER TRAIN...
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Page 7: Table Of Contents
GENERAL INFORMATION ..................1 – 1 Vehicle Exterior ....................... 1 – 1 Models ..............1 – 2 Serial Number Locations ....................1 – 4 Dimensions ............ 1 – 6 Technical Data (Standard Models) -
Page 9: General Information
FGC15K AF81E – 00011- up AF81C – 00011- up FGC18K AF81D – 00011- up AF81E – 00011- up Mitsubishi 4G63 gasoline engine AF82C – 00011- up FGC20K AF82D – 00011- up AF82E – 00011- up AF82C – 00011- up FGC25K AF82D –... -
Page 10: Serial Number Locations
GENERAL INFORMATION Serial Number Locations Nameplate Mast serial number Transmission serial number Engine serial number 207070... - Page 11 GENERAL INFORMATION Memo...
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Page 12: Dimensions
GENERAL INFORMATION Dimensions 207071... - Page 13 GENERAL INFORMATION Unit: mm (in.) Truck Model 1-ton models 2-ton models 3-ton models Ref. FGC20K FGC25K FGC15K FGC18K FGC30K FGC20K HO FGC25K HO Item Maximum fork height 3325 (131) 3340 (131) 3315 (130) Free fork height 115 (4.5) 130 (5.1) 135 (5.3)
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Page 14: Technical Data (Standard Models)
GENERAL INFORMATION Technical Data (Standard Models) Truck Model FGC15K FGC18K FGC20K FGC25K FGC30K Item Rated capacity/load center 1500/500 1800/500 200/500 2500/500 3000/500 kg/mm (lb/in.) (3000/24) (3500/24) (4000/24) (5000/24) (6000/24) Maximum fork height mm (in.) 3300 (131) 3300 (131) 3300 (131) - Page 15 GENERAL INFORMATION Truck Model FGC15K FGC18K FGC20K FGC25K FGC30K Item Compression ratio 8.5 : 1 8.5 : 1 8.6 : 1 Rated output Hp/rpm 46/2400 46/2400 57/2400 Maximum torque 139 (14.2) 139 (14.2) 176 (18) N·m (kgf·m) [lbf·ft]/rpm [105]/1600 [105]/1600 [130]/1600 576 ...
- Page 16 GENERAL INFORMATION Truck Model FGC15K FGC18K FGC20K FGC25K FGC30K Item Forced Type Forced circulation Forced circulation circulation Corrugated fin Corrugated fin Corrugated fin Radiator Cooling (pressure) type (pressure) type (pressure) type system Refill capacity liter (U.S. gal.) 9.85 (2.6) 9.85 (2.6) 9.85 (2.6)
- Page 17 GENERAL INFORMATION Truck Model FGC15K FGC18K FGC20K FGC25K FGC30K Item Self-adjusting Self-adjusting Self-adjusting Type duo-servo duo-servo duo-servo Drum diameter 254 (10.00) 310 (12.20) 310 (12.20) mm (in.) Lining (length 34460.06.42 width thickness 274.2 48.5 4.78 2 344 ...
- Page 18 GENERAL INFORMATION COOLING SYSTEM ................. 2 – 1 Structure and Function ..............2 – 2 Removal and Installation Fan Belt Removal ..................2 – 2 ..............2 – 4 Inspection and Adjustment Fan Belt Inspection ................... 2 – 4 Fan Belt Adjustment .................. 2 – 4...
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Page 19: Cooling System
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 radiator’s lower tank has a built-in transmission oil cooler. -
Page 20: Removal And Installation
COOLING SYSTEM Removal and Installation Fan Belt Removal 206419 Sequence Fan guard Universal joint Tensioner, Tensioner pulley Fan belt Support, Cooling fan 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. - Page 21 COOLING SYSTEM Installation To install, follow the reverse of removal procedure and take the following steps: (1) After removing the belt, turn the fan to examine the bearings for abnormal noise. Replace the bearings if abnormally noisy. (2) After installing the belt, push it inward midway between the pulleys to make sure the tensioner pulley moves freely before tightening the tensioner lock bolt and mounting bolt.
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Page 22: Inspection And Adjustment
COOLING SYSTEM Inspection and Adjustment Fan Belt Inspection (1) Make sure the belt is free from oil, grease or other foreign matter. Replace the belt if necessary. A slightly dirty belt can be reused by cleaning with cloth or paper. Do not clean the belt with gasoline or the like. - Page 23 COOLING SYSTEM ELECTRICAL SYSTEM .................... 3 – 1 Console Box ....................3 – 1 OK Monitor ............3 – 2 Disassembly and Reassembly ..................... 3 – 2 Console Box Components in Console Box ..............3 – 3 ................... 3 – 4 Combination Meter .............
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Page 25: Electrical System
ELECTRICAL SYSTEM Console Box Engine coolant temperature gauge Chock control Fuel gauge Service hourmeter OK monitor Starter switch Lighting switch Fuse box 209480 OK Monitor 209481 Function Indicator light ON or flickering Remarks Powershift transmission oil temp. indicator light Normal Overheating Option Air cleaner element indicator light... -
Page 26: Disassembly And Reassembly
ELECTRICAL SYSTEM Disassembly and Reassembly Console Box 206422A Disassembly Reassembly 1. Disconnect the electrical wires at connectors 1. To reassemble the console box, follow the reverse of (In the gasoline models, disconnect the choke cable disassembly procedure. on the engine side.) 2. -
Page 27: Components In Console Box
ELECTRICAL SYSTEM Components in Console Box 206423A Power relay Lighting switch Power relay Starter switch Turn signal relay Fuses... -
Page 28: Combination Meter
ELECTRICAL SYSTEM Combination Meter Disassembly 206480 Sequence Meter cover Meter case Dial Printed circuit Engine coolant temperature gauge Bulb Service hourmeter Socket Fuel gauge CAUTION Be careful not to damage the printed circuit when disassembling the combination meter. Reassembly Bulb Replacement To reassemble the combination meter, follow the reverse For bulb replacement, remove the socket from the of disassembly procedure. -
Page 29: Major Electrical Components
ELECTRICAL SYSTEM Major Electrical Components Starter Switch (with Anti-Restart Lock) This switch has a built-in anti-restart lock, so the key cannot be turned from (ON) to (START) position while the engine is running. (OFF) (ON) (START) 203561A Connection Chart Terminal Starter, neutral switch Component Fuse box, battery,... -
Page 30: Lighting Switch
ELECTRICAL SYSTEM Lighting Switch OFF 1st 2nd Knob position Stroke (0.3) (0.3) [Unit: mm (in.)] 206481 Connection Chart Terminal Tail lamps, licence Battery Working lamps Knob Component plate lamp, Head lamps (fuses) (option) position instrument lamp (OFF) 1st position ... -
Page 31: Fuse Box
ELECTRICAL SYSTEM Fuse Box Code Circuit 10 A SOLENOID (F-R) Stop lamp, turn signals, 15 A backup lamps 15 A Spare terminal Tail lamps, clearance lamps, 15 A working lamps (option), Instrument panel lamps 15 A Head lamps 10 A Spare fuse 10 A Horn... -
Page 32: Battery Maintenance
ELECTRICAL SYSTEM Battery Maintenance 1. State of charge and electrolyte specific gravity adjustment S.G.: specific gravity Specific gravity reading State of charge Adjustment at 20°C (68°F) 1.280 to 1.265 Fully charged If difference in S.G. between any two cells is 0.020 or more, effect a high current discharge to minimize the difference and then recharge battery. -
Page 33: Lamp Bulb Specifications
ELECTRICAL SYSTEM Lamp Bulb Specifications Watts No. of Color of Lamp description Shape Remarks bulbs lends 12 V Head lamp Frosted Turn signals Amber Option Combination lamps (front) Clearance lamps Frosted Option Turn signals Amber Option Combination Turn and stop lamps 8/23 Option lamps (rear) -
Page 34: Troubleshooting
ELECTRICAL SYSTEM Troubleshooting Starter System Dead or weak battery Recharge or replace. Short or open in circuit Repair or replace. Starter will not crank Poor continuity in starter switch Replace. engine Starter and starter relay defective Replace. Starter switch Open or short circuit Repair or replace. - Page 35 ELECTRICAL SYSTEM Lighting System Dead or weak battery Recharge or replace. Fuses blown out Check and replace. Open or short circuit Repair or replace. Will not light Poor ground Clean ground spot and re-make connection. Filament burnt off in bulbs Replace.
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