Product Category:
Industrial Material Handling Equipment
Competitors:
Competes with other major forklift manufacturers such as Toyota, Hyster, Yale, Komatsu, and Caterpillar in the internal combustion engine forklift segment.
Manual Value:
Provides essential information for efficient operation, preventive maintenance, and accurate repairs, crucial for minimizing downtime and maximizing the lifespan of the forklift.
Manual Content Quality:
Features high-quality images, detailed circuit diagrams, and step-by-step instructions.
Primary Focus:
Comprehensive repair, maintenance, and troubleshooting
Included Models:
Mitsubishi Gasoline/LPG Forklift Truck FG-Series (FG20S, FG25S, FG30S)
Chassis Mast Manual Pages:
480
Type:
Factory Original Workshop Service Manual
Format:
ZIP (Contained Set of PDF Manuals)
File Organization:
ZIP archive containing separate PDF files for the Chassis and Mast Service Manual and the Engine Service Manual for efficient organization.
Powertrain:
Engine (Gasoline/LPG, Diesel), Powershift Transmission, Torque Converter, Front Axle, Reduction Differential, Rear Axle
Chassis And Frame:
Chassis, Mast Systems (Simplex, Duplex, Triplex), Forks, Overhead Guard
Operating Systems:
Cooling System, Electrical System, Brake System, Steering System, Hydraulic System
Mast Types:
Covers Simplex, Duplex, and Triplex mast systems, detailing their structure, functions, removal, installation, disassembly, inspection, and adjustment procedures.
Front Axle Differential:
Detailed coverage of the front axle and reduction differential, including structure, removal, installation, disassembly, inspection, repair, assembly, and troubleshooting for both 2-ton and 3-ton classes.
Rear Axle:
Comprehensive sections on the rear axle assembly, wheel hub, knuckle section (kingpin), steering cylinder, and tie rod, including removal, disassembly, inspection, repair, and assembly.
Maintenance:
Scheduled maintenance, lubrication, fluid changes, component inspections
Repair And Rebuild:
Engine mechanical, transmission overhaul, brake system repair, hydraulic component disassembly/assembly, mast component repair
Troubleshooting:
System-specific diagnostic procedures, fault finding charts, common issues
Technical Adjustments:
Cooling system adjustments, brake pedal/cable adjustments, parking brake adjustments, wheel alignment, mast roller clearance adjustment, chain tension adjustment
Hydraulic System Components:
Detailed procedures for hydraulic pump, control valve (inlet, lift, tilt, end cover sections), lift cylinders (various configurations), and tilt cylinders.
Electrical Troubleshooting:
Specific troubleshooting guides for the starter system, gauges, lighting system, alarm unit, and battery.
Reading Diagrams:
Includes a dedicated chapter ('How to Read Circuit Diagrams') explaining symbols, connector diagrams, and how to interpret electrical schematics.
Depth:
Detailed technical information suitable for professional technicians, including disassembly, assembly, inspection, and adjustment procedures.
Special Tools:
Chapter 12 lists 'Special Service Tools' required for specific maintenance and repair procedures on components like the Powershift Transmission, Front Axle, Brake System, Steering System, and Hydraulic System.
Engine Types:
Gasoline/LPG, Diesel (specific engine models vary by forklift configuration)
Gasoline Lpg Engine Details:
K15, K21, K25 series engines (detailed in the Engine Service Manual).
Performance Data:
Specifications for horsepower, torque, and fuel consumption are detailed within the engine service manual chapters.
Fuel Types:
Gasoline, Liquefied Petroleum Gas (LPG), Diesel
Fuel System Coverage:
Manual covers fuel system components, diagnosis, and repair for both gasoline/LPG and diesel variants.
Cooling System Coverage:
Detailed instructions for radiator, fan belt, cooling hoses, and coolant maintenance and repair.
Electrical System Coverage:
Coverage of battery, charging system, starter system, lighting, gauges, switches, and detailed circuit diagrams for Gasoline/LPG and Diesel models.
Engine Control Coverage:
The Engine Service Manual includes a section on 'EC ENGINE CONTROL', covering electronic engine management and diagnostic procedures for applicable models.
Transmission Type:
Powershift Transmission
Optional Types:
Not specified as optional, but details for different engine configurations (Dual Gas/LPG vs. Diesel) may imply variations.
Torque Converter:
Includes detailed structure, disassembly, assembly, and inspection of the torque converter.
Control Valve:
Comprehensive coverage of the control valve, including its structure, disassembly, assembly, and troubleshooting.
Powershift Transmission Disassembly:
Detailed steps for disassembling the torque converter transmission, including removing transmission accessories, oil pump, housing, shafts, and gears.
Powershift Transmission Assembly:
Comprehensive assembly instructions for the torque converter transmission, including component reassembly, installation, and adjustments.
Service Data:
Includes service data for transmission components such as pump boss, pilot boss, oil pump, flexible plate, clutches, and input shaft.
General Dimensions:
Chapter 1 includes 'Dimensions' for applicable truck models, likely covering overall length, width, height, and mast height.
Wheel Alignment Steering:
Chapter 7 (Rear Axle) includes 'Specifications for Wheel Alignment and Steering Angle', vital for ensuring proper handling and tire wear.
Weight Specifications:
Chapter 1 includes 'Technical Data' which likely encompasses curb weight and load capacities relevant to the FG20S, FG25S, and FG30S models.
Load Capacity:
The model designations FG20S, FG25S, and FG30S indicate nominal load capacities of 2000 kg, 2500 kg, and 3000 kg respectively (approximately 4000, 5000, and 6000 lbs).
Safety Features Coverage:
While specific safety ratings are not listed, the manual covers critical safety systems such as Brakes, Steering, and Hydraulic systems, essential for safe operation.
Active Safety Systems:
Brake system (master cylinder, wheel brakes, fluid lines), parking brake, steering system (valve, cylinder).
Passive Safety Systems:
Overhead guard (mentioned in powertrain removal), seat belt (implied for operator safety).
Infotainment Systems:
N/A (Industrial forklift, focus is on operational mechanics rather than user interface technology)
Driver Assistance Features:
Basic operational controls (steering wheel, pedals), direction (FNR) switch, GAS/LPG select switch. Advanced driver-assistance systems are not typically found in this class of equipment.
Connectivity Features:
N/A (Industrial forklift, focus is on operational mechanics rather than user interface technology)
Electrical System Features
Meter Panel:
Detailed coverage of the meter panel, including disassembly, assembly, bulb replacement, warning lamps, indicators, hour meter, and fuel gauge.
Wiring Diagrams:
Comprehensive wiring diagrams are provided for both Gasoline/LPG and Diesel engine models, crucial for electrical system diagnostics and repair.
Scheduled Maintenance:
Chapter 12 includes a 'Maintenance Schedule' which outlines recommended service intervals for various components and systems.
Lubrication Chart:
Chapter 12 provides a 'Lubrication Chart' detailing recommended lubricants for different points and intervals.
Fuel Lubricant Specs:
Chapter 12 details 'Fuel and Lubricant Specifications', including recommended types and capacities for engine oil, transmission fluid, hydraulic fluid, and grease.
Oil Capacity:
Chapter 12 provides 'Adjustment Value and Oil Capacity' for various systems, including the engine and transmission.
Common Problems:
Troubleshooting sections within each system chapter (e.g., Electrical System, Powershift Transmission, Hydraulic System) provide guidance for diagnosing and resolving common operational issues.
Periodic Replacement Parts:
Chapter 12 lists 'Periodic Replacement Parts', including 'Safety Critical Parts', advising on routine replacement to ensure operational safety and reliability.
Torque Specifications:
Chapter 12 provides 'Tightening Torques for Standard Bolts and Nuts' (Metric Fine Thread and Metric Coarse Thread), essential for correct assembly and preventing component damage.
