2002-2005 Mitsubishi Forklift Trucks FGC15K-FGC30K & FG20-FG35A Service Manual (P/N 99719-70150)
658 Pages • 28.01 MB • Printable PDFs (ZIP Download)
Mitsubishi Models Covered & Key Technical Specifications
Models: FGC15K, FGC18K, FGC20K, FGC20K HO, FGC25K, FGC25K HO, FGC30K, FG20, FG25, FG30, FG35A
Sub-models / Variants: 1-ton models, 2-ton models, 3-ton models, HO (High Output variants), Gasoline engines, Powershift transmission units
Model Years: 2002–2005
Serial Numbers: 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, AF83C-00011-up, AF83D-00011-up, AF83E-00011-up
Technical Data:
- Engine models: Mitsubishi 4G63 (1997 cc), 4G64 (2350 cc)
- Engine configuration: 4-cylinder, in-line, 4-stroke, overhead valve, OHC
- Transmission type: Powershift, single-speed, constant mesh
- Torque converter stall ratio: 2.8 to 3.0
- Main hydraulic pressure: 930–1180 kPa (135–171 psi) at 1600 rpm
- Hydraulic tank capacity: 21L, 30L, or 36L depending on model
- Brake system: Self-adjusting duo-servo
Mitsubishi Manual Features & Content Preview
This official 658-page Mitsubishi OEM service manual (Pub. No. 99719-70150) provides comprehensive technical documentation for the 1-ton to 3-ton capacity class chassis and mast systems. It specifically details the FGC15K–FGC30K and FG20–FG35A forklift series equipped with 4G63 and 4G64 gasoline engines.
- Supported Models: Covers 2002–2005 Mitsubishi FGC15K, FGC18K, FGC20K, FGC25K, FGC30K, and FG20–FG35A internal combustion cushion tire trucks.
- Visual Aids: Contains 83 exploded-view diagrams, 28 detailed technical specification tables, and 14 electrical schematics for rapid component identification.
System Documentation & Subsystem Breakdown
The manual breaks down structural theory and disassembly sequences to help streamline daily workshop operations. It delivers a clear path for servicing the engine power train, powershift transmission, front axle reduction differential, and hydraulic lifting components. Technicians will find dedicated sections outlining console box instrumentation, lighting systems, and mast assembly adjustments. The documentation covers complete chassis, mast, and engine diagnostics alongside essential part numbers.
Specification Highlights & Technical Data
Accurate technical data is critical for proper identification and routine maintenance. For instance, the manual documents the main regulator valve pressure for the transmission at 930–1180 kPa (135–171 psi) at 1600 engine rpm. It also includes crucial reference data for the FGC30K lift trucks, noting a rated capacity of 3000 kg at 500 mm load centers. You will find detailed tolerance charts covering pump clearance, gear backlash, and clutch friction plate thickness for both standard and repair limits. Torque values for flexible plate bolts are clearly specified at 16.4 N·m or 29.4 N·m, depending on the variant. The extensive service data section further details special service tools, lubrication charts, and planned replacement schedules.
Always prioritize shop safety. The specifications provided here serve as a brief overview; ensure all maintenance is performed by qualified personnel using appropriate protective equipment, and always rely on the complete original OEM documentation for hands-on work.
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