Target User:
Professional mechanics, service technicians, fleet maintenance managers, and skilled DIY operators.
Value Proposition:
Provides professional-grade repair and maintenance information, enabling efficient and accurate servicing, reducing downtime, and potentially lowering repair costs compared to dealership services.
Accessibility:
Instant download, usable on various digital devices including smartphones for on-site diagnosis.
Usability:
Step-by-step instructions, clear diagrams, and easy-to-read text cater to users with varying levels of mechanical knowledge.
Completeness:
Aims to be the most complete service and repair manual, covering every detail of the machine's disassembly and reassembly.
Engine:
Detailed information on engine systems, including maintenance, troubleshooting, and repair of internal components, fuel delivery, ignition/starting, cooling, and exhaust.
Transmission:
Comprehensive coverage of transmission operation, maintenance, diagnosis, and repair for both hydrostatic and automatic transmission variants commonly found in these series.
Hydraulics:
In-depth procedures for the hydraulic system, including pump, valves, cylinders, hoses, filters, fluid specifications, and troubleshooting hydraulic performance issues.
Electrical System:
Detailed wiring diagrams, component identification, troubleshooting guides for electrical faults, starter, alternator, battery, lighting, and control systems.
Braking System:
Service and repair procedures for braking systems, including brake adjustments, component replacement (pads, shoes, drums, discs), hydraulic lines, and parking brake.
Steering System:
Information on steering mechanism, including power steering components, linkages, and troubleshooting steering issues.
Chassis And Frame:
Procedures for inspecting, maintaining, and repairing chassis components, frame structures, and related hardware.
Mast And Attachments:
Detailed sections on mast assembly, lift cylinders, chains, rollers, and common forklift attachments, including their inspection and maintenance.
Operator Compartment:
Procedures related to operator controls, seat, safety features, and dashboard instrumentation.
Routine Maintenance:
Scheduled maintenance tasks, lubrication points, filter changes, fluid checks, and general inspections.
Troubleshooting:
Diagnostic charts and step-by-step troubleshooting guides for identifying and resolving common operational issues and component failures.
Component Overhaul:
Detailed procedures for the disassembly, inspection, repair, and reassembly of major components like engines, transmissions, and hydraulic pumps.
Adjustment Procedures:
Specific instructions for adjusting various systems, such as parking brake, valve clearances, and hydraulic pressures.
Replacement Procedures:
Step-by-step guides for replacing wear items and faulty components, with emphasis on safety and correct procedure.
Depth:
Comprehensive; covers from basic user maintenance to advanced diagnostic and repair procedures suitable for professional technicians.
Detail Level:
High; includes exploded views, detailed diagrams, torque specifications, and part identification.
Engine Types Common:
Diesel (e.g., Mitsubishi S4 series, Nissan H20/H25 variants), Gasoline/LPG (e.g., Mitsubishi 4G5, 4G6 series variants). Specific engine models vary greatly by sub-model and year.
Power Output:
Varies by engine size and model, typically ranging from 40 HP to over 80 HP for common industrial forklift applications.
Torque Output:
Specific torque figures are highly model-dependent; crucial for lifting capacity and operational performance.
Fuel Types:
Diesel, Gasoline, LPG (Liquid Propane Gas)
Injection Systems:
Commonly indirect injection for diesel, carburetor or EFI for gasoline/LPG, and specific LPG injection systems.
Transmission Type Standard:
Often a hydrostatic transmission (HST) or torque converter automatic transmission, designed for smooth power delivery and precise control in material handling.
Transmission Type Optional:
Manual transmissions are less common in this class of forklift but could be present in older or specialized models.
Control Modes:
Features like inching control for precise load placement and forward/reverse shuttle operation.
Fluid Type:
Specific ATF (Automatic Transmission Fluid) or hydraulic oil, dependent on transmission design. Manual specifies exact types and capacities.
Lift Height Capacity:
Range from standard lift heights (e.g., 3-4 meters) to high-lift configurations, supporting various load capacities (e.g., 2000 kg to 5000 kg or more).
Overall Width:
Highly variable based on model, typically between 1.0 to 1.5 meters for standard models.
Overall Length:
Highly variable based on model and mast configuration, typically between 2.0 to 3.0 meters excluding forks.
Operating Weight:
Ranges significantly based on capacity and configuration, typically from 2500 kg to 5000 kg or more.
Industry Safety Standards:
Adherence to ANSI/ITSDF B56.1 standards (or equivalent international standards) for forklift safety.
Operator Presence System:
Many models incorporate operator presence systems that disable hydraulic functions if the operator leaves the seat.
Overhead Guard:
Standard feature to protect the operator from falling loads.
Seatbelts:
Often standard or optional depending on model and region.
Operator Interface:
Basic operator controls, hour meter, fuel gauge, warning lights. Advanced features are generally limited compared to automotive.
Operational Aids:
Features like power steering, hydrostatic transmission for precise control, and sometimes speed limiters.
Telematics:
Modern units may offer telematics for fleet management (hours, maintenance alerts, location), though not always standard on older series.
Daily Checks:
Fluid levels (engine oil, hydraulic oil, coolant, brake fluid), tire pressure, forks, mast operation, safety devices, horn, lights.
Hourly Checks:
Lubrication points, drive axle, steering linkages, tilt and lift cylinders.
Periodic Maintenance:
Engine oil and filter change (e.g., every 250-500 hours), hydraulic filter replacement (e.g., every 1000-2000 hours), transmission fluid service, coolant flush, brake system inspection.
Engine Oil:
Specific viscosity grades (e.g., 15W-40 for diesel, 10W-30 for gasoline) and API service classifications as per manual. Example: API CH-4 or CI-4 for diesel.
Hydraulic Fluid:
ISO VG 32 or ISO VG 46 anti-wear hydraulic oil is common. Specific Mitsubishi designations may apply.
Transmission Fluid:
Dexron III/Mercon or equivalent for torque converter automatics, specific hydrostatic fluids as required by the manual.
Coolant:
Ethylene glycol-based coolant with appropriate corrosion inhibitors, mixed with distilled water (typically 50/50).
Common Wear Items:
Tire wear, mast rollers, lift chains, hydraulic hoses, brake pads/shoes, engine mounts, transmission seals.
Electrical Problems:
Wiring harness degradation, sensor failures, control module issues are possible with age and environmental exposure.
Hydraulic Leaks:
Common due to seal wear in cylinders, pumps, and valve bodies, especially with heavy usage.
Mitsubishi Heavylift:
Mitsubishi Heavy Industries (MHI) and later Mitsubishi Logisnext (formed from integration of TCM and other material handling divisions) have a long history in the industrial equipment sector.
Series Development:
The FD, FG, and FGE series represent evolutionary lines of Mitsubishi forklifts, with continuous improvements in design, ergonomics, efficiency, and safety over various production years.
Production Locations:
Typically manufactured in Japan and potentially other global locations depending on the specific model and market.
