Industry Segment:
Material Handling Equipment - Internal Combustion Counterbalance Forklifts.
Target Audience:
Forklift technicians, maintenance departments, fleet managers, owner-operators.
Competitors:
Toyota, Hyster, Yale, Komatsu, Caterpillar, Crown (in terms of forklift manufacturing and service documentation).
Manual Value Proposition:
Provides in-depth technical knowledge to perform all necessary repairs and maintenance, reducing reliance on external service providers and minimizing downtime.
Documentation Style:
Likely includes detailed diagrams, exploded views, specifications, and step-by-step instructions, typical of factory-authorized service manuals.
Engine:
Engine overhaul, component diagnostics, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission controls.
Transmission:
Automatic transmission (if applicable), hydrostatic transmission (if applicable), torque converter, drive axles, differentials, lubrication, adjustments, repairs.
Hydraulics:
Hydraulic pump, control valves, cylinders, hoses, fittings, hydraulic fluid specifications, troubleshooting, repairs, system pressure checks.
Mast And Forks:
Mast assembly, lift cylinders, tilt cylinders, chains, rollers, fork carriage, hydraulic hoses, lubrication, inspection, maintenance, replacement procedures.
Electrical System:
Battery, starter, alternator, ignition system, lighting, sensors, wiring diagrams, fuses, relays, diagnostics, common electrical faults.
Brakes:
Brake system components (drum, disc, hydraulic, mechanical), brake fluid, adjustments, bleeding, component replacement, parking brake.
Steering:
Steering system components, hydraulic steering, power steering pump, steering linkage, adjustments, repairs.
Chassis And Frame:
Frame inspection, welds, structural integrity, counterweight, attachments.
Operator Station:
Seat, controls, dashboard, gauges, overhead guard, safety features, ergonomics.
Routine Maintenance:
Oil change intervals, filter replacements (oil, fuel, air, hydraulic), lubrication points, tire pressure, battery maintenance, visual inspections.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common issues and their solutions, error code interpretation.
Rebuilding And Overhaul:
Detailed step-by-step procedures for engine rebuild, transmission overhaul, hydraulic component rebuilding, mast and fork assembly overhaul.
Component Replacement:
Instructions for replacing major components such as engine, transmission, hydraulic pump, cylinders, mast sections, wheels, and tires.
Adjustments:
Brake adjustments, clutch adjustments (if applicable), parking brake adjustments, hydraulic pressure adjustments, linkage adjustments.
Depth Level:
Comprehensive: Covers everything from basic operator checks and routine maintenance to advanced diagnostics, component rebuilding, and complete unit overhauls.
Diagnostic Tools:
Mentions necessary tools for diagnostics, torque specifications for all fasteners, clearance measurements, and pressure testing procedures.
Engine Type:
Internal Combustion (Gasoline/LPG or Diesel - Specifics depend on FG25 variant, likely a reputable industrial engine manufacturer).
Fuel Type:
Likely Gasoline/LPG for FG25 designation, but Diesel variants may exist.
Displacement:
Typically in the 2.0L - 3.0L range for this class of forklift, e.g., 2.0L or 2.4L industrial gasoline engines.
Horsepower:
Estimated 40-60 HP, depending on specific engine model and tuning for industrial applications.
Torque:
Sufficient torque for lifting and maneuvering loads up to its rated capacity, typically in the 100-150 lb-ft range.
Fuel Delivery:
Carbureted or Fuel Injection (EFI), depending on the specific engine variant and year.
Ignition System:
Electronic Ignition (distributorless or distributor-based).
Cooling System:
Water-cooled, typically with a radiator, fan, and thermostat.
Oil Type:
Specific industrial engine oil grade, e.g., SAE 30 or 10W-30, as per manual's recommendation.
Oil Capacity:
Typically 4-6 quarts, exact capacity specified in manual.
Lift Capacity:
Approximately 5000 lbs (2500 kg) at a standard 24-inch load center.
Mast Height Lowered:
Variable, but typically in the range of 80-90 inches for a standard 3-stage mast.
Mast Height Raised:
Variable depending on mast type (duplex, triplex), typically 180-240 inches for standard configurations.
Fork Length:
Standard 42 inches or 48 inches.
Operating Weight:
Typically in the range of 8,000 - 10,000 lbs, depending on configuration and attachments.
Tire Type:
Pneumatic or Solid/Cushion tires, depending on application environment (indoor/outdoor, surface condition).
Daily Checks:
Fluid levels (engine oil, hydraulic oil, coolant, brake fluid), tire condition and pressure, visual inspection for leaks, horn, lights, brakes, steering operation.
Weekly Checks:
Battery water level (if applicable), clean air filter indicator.
Monthly Checks:
Hydraulic system filter, check hose and fitting condition, inspect mast chains and rollers.
Engine Oil Change:
Typically every 250-500 operating hours, or annually, whichever comes first (as per manual).
Hydraulic Filter Change:
Typically every 500-1000 operating hours, or annually (as per manual).
Transmission Fluid Change:
Typically every 1000-2000 operating hours, or biennially (as per manual).
Engine Oil Grade:
Specific industrial engine oil, e.g., SAE 30, 10W-30, 15W-40 (refer to manual for precise specification).
Hydraulic Fluid Type:
ISO VG 32 or ISO VG 46 hydraulic oil (refer to manual for precise specification).
Transmission Fluid Type:
Specific ATF (e.g., Dexron III) or industrial transmission fluid (refer to manual for precise specification).
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture.
Common Wear Items:
Wear on mast rollers, fork carriage, lift chains, and tilt cylinders due to continuous operation. Hydraulic hose degradation. Brake shoe/pad wear.
Common Engine Issues:
Spark plug fouling (gasoline), fuel injector issues (EFI), cooling system leaks, exhaust leaks.
Common Hydraulic Issues:
Slow lift/tilt speeds, external leaks from seals and hoses, pump noise indicating wear or low fluid.
