John Deere 300 3029 4039 4045 6059 6068 Engine Operation and Service Manual
Β
Mitsubishi fg25 k mc forklift trucks service repair manual sn ef17b 55001-up
1. CHASSIS
MAST
OPTIONS
Quality Makes the Difference
SERVICE MANUAL
99719-54120
MC
NOTE
For use with the 4G63/4G64
Gasoline Engine Service Manual.
For use with the S4Q2/S4S
Diesel Engine Service Manual.
FG15K EF31A-50001-up
FD15K EF16B-55001-up
FG18K EF31A-75001-up
FD18K EF16B-75001-up
FG20K EF17B-05001-up
FD20K EF18B-05001-up
FG25K EF17B-55001-up
FD25K EF18B-55001-up
FG30K EF13D-35001-up
FD30K EF14C-35001-up
FG35K EF13D-55001-up
FD35K EF14C-55001-up
2. 1
2
3
4
5
6
7
8
9
10
11
12
13
GROUP INDEX
Group Items
Vehicle Exterior, Models, Serial Number Locations, Dimensions, Technical Data
COOLING SYSTEM Fan Belt Removal, Fan Belt Inspection, Fan Belt Adjustment
Console Box, Combination Meter, Starter Switch (with Anti-restart Lock),
ELECTRICAL SYSTEM Lighting Switch, Fuse Box, Spare Terminals, Battery Maintenance, Light Bulb
Specifications, Electrical System Schematics
POWER TRAIN Engine and Transmission
Hydraulic Circuit, Control, Transmission Assembly, Pump Assembly, Control
Valve, Testing Hydraulic Pressure, Adjusting Inching Pedal, Testing Clutch
Valve, 10-m (33-ft) Start Acceleration Test
Front Wheels, Front Axle and Reduction Differential, Tooth Contact Patterns
and Adjustment
REAR AXLE
Rear Axle, Steering Cylinder, Rear Wheels, Rear Axle, Steering Cylinder,
Minimum Turning Radius Adjustment
Automatic Adjusting Device, Brake Pedal and Assembly, Master Cylinder,
BRAKE SYSTEM Wheel Brakes, Wheel Cylinders, Brake Pedal Adjustment, Bleeding Air Out of
the Brake Fluid Line, Brake Test
STEERING SYSTEM Steering System, Steering Control Valve, Tilt Steering Assembly
HYDRAULIC SYSTEM
Hydraulic Line, Hydraulic Tank, Hydraulic Pump, Control Valve, Lift and Tilt
Cylinders, Flow Regulator Valve, Down Safety Valve
MAST AND FORK Simplex Mast, Duplex Mast, Triplex Mast
Tightening Torques for Standard Bolts and Nuts, Periodic Replacement Parts,
SERVICE DATA Fuel and Lubricant Specifications, Recommended Brands of Lubricants, Refill
Capacities (Approximate)
Plate Fin Type Radiator Kit, Fan Speed Up Kit, Radiator Coolant Level, Warning
OPTIONS Kit, Torque Converter Oil Filter Kit, Radiator Net Kit, Combination Lamp and Turn
Signal Switch Kit, Back Buzzer Kit, etc.
FRONT AXLE AND
REDUCTION DIFFER-
ENTIAL
GENERAL
INFORMATION
POWERSHIFT
TRANSMISSION
3. GENERAL INFORMATION
Vehicle Exterior .......................................................................................................................... 1 - 1
Models ........................................................................................................................................ 1 - 1
Serial Number Locations ............................................................................................................ 1 - 2
Dimensions.................................................................................................................................. 1 - 4
Technical Data (Standard Models) ............................................................................................ 1 - 6
1
4. Truck Model Serial Number Engine Mounted
FG15K ET31A-50001-up Mitsubishi 4G63 Gasoline Engine
FD15K ET16B-55001-up Mitsubishi S4Q2 Diesel Engine
FG18K ET31A-75001-up Mitsubishi 4G63 Gasoline Engine
FD18K ET16B-75001-up Mitsubishi S4Q2 Diesel Engine
FG20K ET17B-05001-up Mitsubishi 4G63 Gasoline Engine
FD20K ET18B-05001-up Mitsubishi S4S Diesel Engine
FG25K ET17B-55001-up Mitsubishi 4G63 Gasoline Engine
FD25K ET18B-55001-up Mitsubishi S4S Diesel Engine
FG30K ET13D-35001-up Mitsubishi 4G64 Gasoline Engine
FD30K ET14C-35001-up Mitsubishi S4S Diesel Engine
FG35K ET13D-55001-up Mitsubishi 4G64 Gasoline Engine
FD35K ET14C-55001-up Mitsubishi S4S Diesel Engine
GENERAL INFORMATION
1-1
Vehicle Exterior
β’ This Service Manual deals with all components or systems of the Mitsubishi Forklift Trucks; except
for the engine and attachment, which are covered in the respective manuals.
Models
β’ This Service Manual furnishes servicing and maintenance information for the following trucks:
207151
5. GENERAL INFORMATION
1-2
Serial Number Locations
Nameplate
Mast Serial Number
Chassis Serial Number
Engine Serial Number
(gasoline models)
Engine Serial Number
(diesel models)
207344
1 ton models
2 β 3 ton models
1 ton models
2 to 3 ton models
2 to 3 ton models
1 ton models
Transmission Serial Number
6. GENERAL INFORMATION
1-3
Chassis and Mast Model Identification
[Chassis]
FG 35 K
Generation designator
Maximum capacity
35: 3500 kg (7640 lb)
Maximum lifting height
(β33β stands for 3300 mm.)
Order of the minor change
(βAβ for the original, βBβ for the first change, βCβ for
the second change, and so on)
Applicable truck model designation
35: 3.3 ton class
Kind of mast
A: simplex mast
B: duplex mast
C: triplex mast
Engine type
FG: gasoline engine type
DP: diesel engine type
[Mast]
A 35 A 33
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14. Type With external β With external β With external β
Ignition coil
resistor resistor resistor
Manufacturer Mitsubishi β Mitsubishi β Mitsubishi β
Electric Electric Electric
Non-contact Non-contact Non-contact
Type point type β point type β point type β
(C.E.I.) (C.E.I.) (C.E.I.)
Distributor Manufacturer Mitsubishi β Mitsubishi β Mitsubishi β
Electric Electric Electric
Spark advancer Centrifugal β Centrifugal β Centrifugal β
pneumatic type pneumatic type pneumatic type
Type W14EX-U W14EX-U W14EX-U β
Manufacturer Nippon β Nippon β Nippon β
Denso Denso Denso
Spark plugs Size 14 Γ 1.25 β 14 Γ 1.25 β 14 Γ 1.25 β
mm (in.)
(0.55 Γ 0.049) (0.55 Γ 0.049) (0.55 Γ 0.049)
Gap 0.7 to 0.8 β 0.7 to 0.8 β 0.7 to 0.8 β
(0.028 to 0.031) (0.028 to 0.031) (0.028 to 0.031)
Carburetor Type
Down-draft
β
Down-draft
β
Down-draft
β
type type type
Manufacturer
Mikuni
β
Mikuni
β
Mikuni
β
Kogyo Kogyo Kogyo
Governor Type
Pneumatic
β
Pneumatic
β
Pneumatic
β
type type type
Manufacturer
Mikuni
β
Mikuni
β
Mikuni
β
Kogyo Kogyo Kogyo
Fuel pump Type
Diaphragm
β
Diaphragm
β
Diaphragm
β
type type type
Manufacturer
Kyosan
β
Kyosan
β
Kyosan
β
Electric Electric Electric
Cyclone- Cyclone- Cyclone-
Type Γ number paper β paper β paper β
Air cleaner element Γ 1 element Γ 1 element Γ 1
Manufacturer
Nippon
β
Nippon
β
Nippon
β
Rokaki Rokaki Rokaki
Type β
Distributor
β
Distributor
β
Distributor
type (DPK) type (DPK) type (DPK)
Fuel injection Manufacturer β
Mikuni
β
Mikuni
β
Mikuni
pump
Precision Precision Precision
Plunger diam. β 6.5 (0.256) β 6.5 (0.256) β 7.0 (0.275)
Cam lift mm (in.)
β 1.5 (0.059) β 1.5 (0.059) β 1.5 (0.059)
(one side)
Type β
Throttle
β
Throttle
β
Throttle
type type type
Fuel injection
Spray holes,
mm (in.) β
1.00
β
1.00
β
1.00
nozzle
diam. Γ number (0.0394) Γ 1 (0.0394) Γ 1 (0.0394) Γ 1
Injection
kPa
11768000 11768000 13729000
pressure
(kgf/cm2
) β (120 ) β (120 ) β (140 )
[psi]
[1706 ] [1706 ] [1990 ]
Truck Model FG15K FD15K FG18K FD18K FG20K FD20K
GENERAL INFORMATION
1-10
+11
+ 5
+10
0
+10
0
+156
+ 71
+142
0
+142
0
+1079
0
+981
0
+981
0
Ignition
system
(gasoline
models)
Fuel
system
(gasoline
models)
Fuel
system
(diesel
models)
15. FG25K FD25K FG30K FD30K FG35K FD35K
With external
β
With external
β
With external
β
resistor resistor resistor
Mitsubishi
β
Mitsubishi
β
Mitsubishi
β
Electric Electric Electric
Non-contact Non-contact Non-contact
point type β point type β point type β
(C.E.I.) (C.E.I.) (C.E.I.)
Mitsubishi
β
Mitsubishi
β
Mitsubishi
β
Electric Electric Electric
Centrifugal
β
Centrifugal
β
Centrifugal
β
pneumatic type pneumatic type pneumatic type
W14EX-U β W14EX-U β W14EX-U β
Nippon
β
Nippon
β
Nippon
β
Denso Denso Denso
14 Γ 1.25
β
14 Γ 1.25
β
14 Γ 1.25
β
(0.55 Γ 0.049) (0.55 Γ 0.049) (0.55 Γ 0.049)
0.7 to 0.8
β
0.7 to 0.8
β
0.7 to 0.8
β
(0.028 to 0.031) (0.028 to 0.031) (0.028 to 0.031)
Down-draft
β
Down-draft
β
Down-draft
β
type type type
Mikuni
β
Mikuni
β
Mikuni
β
Kogyo Kogyo Kogyo
Pneumatic
β
Pneumatic
β
Pneumatic
β
type type type
Mikuni β Mikuni
β
Mikuni
β
Kogyo Kogyo Kogyo
Diaphragm
β
Diaphragm
β
Diaphragm
β
type type type
Kyosan
β
Kyosan
β
Kyosan
β
Electric Electric Electric
Cyclone- Cyclone- Cyclone-
paper β paper β paper β
element Γ 1 element Γ 1 element Γ 1
Nippon
β
Nippon
β
Nippon
β
Rokaki Rokaki Rokaki
β
Distributor
β
Distributor
β
Distributor
type (DPK) type (DPK) type (DPK)
β
Mikuni
β
Mikuni
β
Mikuni
Precision Precision Precision
β 7.0 (0.256) β 7.0 (0.256) β 7.0 (0.275)
β 1.5 (0.059) β 1.5 (0.059) β 1.5 (0.059)
β
Throttle
β
Throttle
β
Throttle
type type type
β
1.00
β
1.00
β
1.00
(0.0394) Γ 1 (0.0394) Γ 1 (0.0394) Γ 1
13729000 13729000 13729000
β (140 ) β (140 ) β (140 )
[1990 ] [1990 ] [1990 ]
GENERAL INFORMATION
1-11
+11
+ 5
+156
+ 71
+1 079
+ 490
+11
+ 5
+156
+ 71
+1 079
+ 490
+11
+ 5
+156
+ 71
+1 079
+ 490
16. Heater plugs
Type β Sheathed type β Sheathed type β Sheathed type
Voltage-current V β A β 22 β 5.4 β 22 β 5.4 β 22 β 5.4
Fuel feed pump
Type β Vane type β Vane type β Vane type
Manufacturer β Lusus CAV β Lusus CAV β Lusus CAV
Cyclone- Cyclone- Cyclone-
Type Γ number β paper β paper β paper
Air cleaner element Γ 1 element Γ 1 element Γ 1
Manufacturer β
Nippon
β
Nippon
β
Nippon
Rokaki Rokaki Rokaki
Type Pressure feed type Pressure feed type Pressure feed type
Oil pump Throchoid type Throchoid type Throchoid type
Oil filter Paper-element Paper-element Paper-element
Oil pan
liter
4.5 (1.2) 6.0 (2.4) 4.5 (1.2) 6.0 (2.4) 4.5 (1.2) 9.0 (2.4)
Refill capacities Oil filter
(U.S.gal)
0.3 (0.1) 0.7 (0.3) 0.3 (0.1) 0.7 (0.3) 0.3 (0.1) 1.0 (0.3)
Total 4.8 (1.3) 6.7 (1.8) 4.8 (1.3) 6.7 (1.8) 4.8 (1.3) 10.0 (2.7)
Type Forced circulation Forced circulation Forced circulation
Radiator
Corrugated fin Corrugated fin Corrugated fin
(pressure) type (pressure) type (pressure) type
Refill capacity
liter
7.65 (2.0) 8.55 (2.3) 7.65 (2.0) 8.55 (2.3)
8.9 9.6
(U.S.gal) (2.3) (2.5)
Water pump Centrifugal type Centrifugal type Centrifugal type
Thermostat Wax type Wax type Wax type
Voltage V 12 12 12 12 12 12
Capacity Ah 30 65 30 65 40 80
Alternator type 3-phase AC 3-phase AC 3-phase AC
Manufacturer Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric
Capacity V β A 12 β 50 12 β 50 12 β 50 12 β 50 12 β 50 12 β 50
Regulator Built-in IC type Built-in IC type Built-in IC type
Type Lever-shift type Lever-shift type Lever-shift type
Manufacturer Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric
Voltage - output V β kW 12 β 1.2 12 β 2.2 12 β 1.2 12 β 2.2 12 β 1.2 12 β 2.2
Type
Dry, single-disc type Dry, single-disc type Dry, single-disc type
(Op. wet type) (Op. wet type) (Op. wet type)
Clutch
Size (OD x ID) mm (in.)
275 Γ 180 275 Γ 175 275 Γ 180 275 Γ 175 275 Γ 180 275 Γ 175
(10.8 Γ 7.1) (10.8 Γ 6.9) (10.8 Γ 7.1) (10.8 Γ 6.9) (10.8 Γ 7.1) (10.8 Γ 6.9)
Material DR-8 Special DR-8 Special DR-8 Special
Type Master VAC Master VAC Master VAC
Clutch booster
Master cylinder
15.87 (0.6248) 15.87 (0.6248) 15.87 (0.6248)
(wet)
ID
mm (in.)
Release cylinder
19.05 (0.7500) 19.05 (0.7500) 19.05 (0.7500)
ID
Type
3-element, 1-stage, 3-element, 1-stage, 3-element, 1-stage,
2-phase 2-phase 2-phase
Torque converter Manufacturerβs type Daikin 66H7 Daikin 66H7 Daikin 66H8
Stall torque ratio 2.8 2.8 3.0
Truck Model FG15K FD15K FG18K FD18K FG20K FD20K
GENERAL INFORMATION
1-12
Power
train
Cooling
system
Battery
Alternator
and
regulator
Starter
Lubrication
system
Air
and
fuel
(diesel
model)