1987 Mitsubishi FGC25 Service Manual

The 1987 Mitsubishi FGC25 is a heavy-duty forklift truck designed for industrial material handling applications. This comprehensive service manual covers maintenance procedures, technical specifications, troubleshooting guides, and repair instructions for the FGC25 model. Below are key sections for safety precautions, technical data, maintenance schedules, engine systems, hydraulic systems, electrical systems, and troubleshooting procedures.

1. General Information 2. Specifications 3. Maintenance Schedule 4. Engine Systems 5. Hydraulic Systems 6. Electrical Systems 7. Transmission & Drivetrain 8. Brake Systems 9. Steering Systems 10. Safety Precautions 11. Troubleshooting

General Information

Key components: Diesel engine, hydraulic lift system, mast assembly, counterweight, operator cabin, and control systems.

ComponentDescription
ModelFGC25
ManufacturerMitsubishi
Year1987
TypeInternal Combustion Forklift
Capacity2,500 kg (5,500 lbs)
Power SourceDiesel Engine
Mast TypeStandard Duplex
TransmissionPower Shift
SteeringPower Steering
BrakesHydraulic Service Brakes

Specifications

Maintenance Schedule

Regular maintenance is essential for optimal performance and safety.

  1. Daily: Check engine oil level, coolant level, hydraulic oil level, tire pressure, and brake function.
  2. Every 50 hours: Lubricate all fittings, check battery electrolyte level.
  3. Every 250 hours: Change engine oil and filter, check transmission fluid.
  4. Every 500 hours: Replace fuel filter, air filter, hydraulic filter.
  5. Every 1000 hours: Adjust brakes, check valve clearance, inspect mast chains.
  6. Every 2000 hours: Flush cooling system, replace transmission fluid.

WARNING! Always perform maintenance with engine off and key removed. Use proper lifting equipment.

Engine Systems

The FGC25 is equipped with a 4G63 diesel engine requiring regular maintenance.

  1. Engine Oil: SAE 15W-40, capacity 7.5 liters
  2. Cylinder Arrangement: 4-cylinder in-line
  3. Bore x Stroke: 85 mm x 88 mm
  4. Compression Ratio: 17.5:1
  5. Fuel Injection: Direct injection with mechanical pump
  6. Cooling System: Pressurized with radiator, capacity 10 liters
  7. Air Filter: Dry element type with pre-cleaner
  8. Valve Clearance: Intake 0.25 mm, Exhaust 0.35 mm (cold)

CAUTION! Allow engine to cool before performing maintenance. Avoid contact with hot surfaces.

Hydraulic Systems

The hydraulic system provides lifting, tilting, and attachment functions.

ComponentSpecification
Hydraulic PumpGear type, 35 L/min @ 2000 rpm
Relief Valve Setting16.5 MPa (165 bar)
Hydraulic OilISO VG 32, capacity 45 liters
Lift CylinderSingle acting, 80 mm diameter
Tilt CylinderDouble acting, 70 mm diameter
Control Valve3-spool with float position
Filter10 micron element, replace every 500 hours

Electrical Systems

12-volt electrical system with alternator and battery.

  1. Battery: 12V, 100 Ah maintenance-free type
  2. Alternator: 12V, 45A output
  3. Starter: 12V, 2.5 kW
  4. Fuses: Blade type, located in dashboard panel
  5. Lighting: Headlights, tail lights, warning lights
  6. Instrumentation: Hour meter, fuel gauge, temperature gauge
  7. Safety Devices: Seat switch, neutral start switch, overhead guard switch

Tip: Always disconnect battery before performing electrical work.

Transmission & Drivetrain

Power shift transmission with torque converter.

  1. Transmission Type: Powershift, 2-speed forward, 2-speed reverse
  2. Torque Converter: Single stage with lock-up clutch
  3. Transmission Oil: SAE 10W-30, capacity 12 liters
  4. Drive Axle: Rigid type with planetary reduction
  5. Differential: Bevel gear type
  6. Parking Brake: Mechanical, acting on transmission output
  7. Clutch: Wet multi-disc type

WARNING! Transmission oil may be hot after operation. Allow to cool before servicing.

Brake Systems

Dual brake system with service brakes and parking brake.

Brake TypeSpecification
Service BrakesHydraulic, disc type on front wheels
Parking BrakeMechanical, drum type on transmission
Brake FluidDOT 3 or DOT 4
Brake Disc Diameter280 mm
Brake Pad ThicknessNew: 12 mm, Replace at 2 mm
Adjustment IntervalEvery 1000 hours or as needed

Steering Systems

Full hydraulic power steering for easy maneuverability.

  1. Steering Type: Full hydraulic power steering
  2. Steering Wheel: 380 mm diameter
  3. Steering Cylinder:Double acting, 50 mm diameter
  4. Steering Pump: Vane type, integrated with hydraulic system
  5. Turns Lock-to-Lock: 3.5 turns
  6. Turning Radius: 2,150 mm
  7. Steering Oil: Same as hydraulic system (ISO VG 32)

CAUTION! Check for hydraulic leaks regularly. Low oil can cause steering failure.

Safety Precautions

Essential safety procedures for operation and maintenance.

Troubleshooting

SymptomPossible CauseCorrective Action
Engine won't startBattery, fuel, or electrical issueCheck battery charge, fuel level, fuses, and connections
Poor lifting performanceHydraulic oil low, pump wornCheck oil level, inspect pump, check relief valve
Transmission slippingLow oil, clutch wornCheck transmission oil level, inspect clutch plates
Steering hardLow oil, pump failureCheck hydraulic oil, inspect steering pump
Brakes not holdingWorn pads, air in systemInspect brake pads, bleed brake system
Electrical failureBattery, alternator, wiringTest battery and alternator, check wiring connections
OverheatingCoolant low, radiator blockedCheck coolant level, clean radiator, check thermostat

Service Support: Contact authorized Mitsubishi dealer for technical assistance and genuine parts.

Parts Information: Use genuine Mitsubishi parts for optimal performance and safety.

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