🏷️ Basic Information

Make:

Mitsubishi

Model:

FG15 Forklift Truck

Product Type:

Full Service Repair Manual

Manual Format:

PDF Download

👋 Introduction

Industry Segment:

Material Handling Equipment - Counterbalance Forklift Trucks

Target User:

Forklift technicians, mechanics, maintenance personnel, fleet managers, and owner-operators involved in the service and repair of Mitsubishi FG15 forklifts.

Competitors:

Directly competes with service manuals for similar capacity forklifts from brands like Toyota, Komatsu, Nissan, Hyster, Yale, and Caterpillar. Focuses on specific Mitsubishi engineering and service practices.

Manual Benefit:

Empowers users with the technical knowledge to perform all maintenance and repair tasks accurately, reducing downtime and operational costs. Emphasizes correct procedures to ensure safety and longevity of the equipment.

📋 Manual Details

General Coverage:

Comprehensive service, repair, and maintenance procedures for the Mitsubishi FG15 Forklift Truck.

Key Systems Covered:

Engine, Powertrain (Transmission & Drive Axle), Hydraulics, Steering, Brakes, Electrical System, Operator Compartment, Chassis, Mast Assembly.

Estimated Pages:

Varies by specific model year and configuration, typically 500-1000+ pages for a comprehensive service manual.

Type:

Service and Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Detailed diagnostics, repair, overhaul, and component testing for gasoline, LPG, and diesel engine options commonly found in the FG15 series. Includes fuel system, ignition system (gasoline/LPG), emissions control, cooling system, lubrication system, and starting/charging systems.

Transmission:

Coverage for hydrostatic and torque converter automatic transmissions, including troubleshooting, adjustments, fluid changes, seal replacements, and component overhaul.

Hydraulics:

In-depth information on hydraulic pump, valve body, cylinder, and hose repairs. Includes circuit diagrams, pressure testing, fluid specifications, and troubleshooting of lift, tilt, and side-shift functions.

Steering:

Components of power steering systems (hydraulic assist), including steering gear, pump, hoses, and troubleshooting procedures.

Brakes:

Service procedures for drum or disc brake systems, including adjustment, component replacement (pads, shoes, drums, rotors, wheel cylinders, master cylinder), brake fluid specifications, and bleeding procedures.

Electrical System:

Wiring diagrams for various configurations, troubleshooting of lighting, instrumentation, starting and charging systems, sensors, and electronic control units (if applicable).

Mast And Attachments:

Service and repair of various mast types (e.g., Duplex, Triplex), including cylinder seals, chain adjustments, and carriage/fork maintenance. Covers common attachment hydraulics and mechanisms.

Routine Maintenance:

Scheduled maintenance, lubrication points, filter replacement intervals, fluid level checks and top-offs, belt adjustments, tire pressure, and battery maintenance.

Diagnostic Troubleshooting:

Systematic diagnostic charts and flowcharts for identifying and resolving common operational issues and failures.

Component Repair And Rebuild:

Detailed step-by-step instructions for disassembling, inspecting, repairing, and reassembling major components like engines, transmissions, hydraulic pumps, and masts.

Safety Precautions:

Essential safety guidelines and warnings relevant to forklift operation, maintenance, and repair.

Adjustment Procedures:

Calibration and adjustment specifications for various systems, including brakes, parking brake, clutch (if applicable), and hydraulic controls.

Depth:

Comprehensive. Covers from basic operator checks and routine maintenance to full engine and transmission overhauls, electrical system diagnostics, and hydraulic system repairs.

📊 Manual Specifications

PDF Quality:

High-resolution, searchable PDF with clear text and legible diagrams/illustrations. Optimized for printing.

Print Readability:

Designed for clear printing of all diagrams, schematics, and text, ensuring ease of use in a workshop environment.

Digital Format:

N/A (Digital PDF)

Digital Format:

N/A (Digital PDF)

⚙️ Engine Specifications

Common Gasoline Engine:

Typically a Mitsubishi 4G63 or similar industrial gasoline engine. Specific displacement and configuration vary by year and market. (e.g., 2.0L, 4-cylinder).

Common Lpg Engine:

Often a variant of the gasoline engine converted for LPG fuel, or a dedicated LPG industrial engine. Specific details provided within the manual.

Common Diesel Engine:

For higher capacity variants or specific markets, industrial diesel engines (e.g., Mitsubishi S4Q or similar) may be used. Manual will cover these if applicable.

Horsepower Range:

Typically in the 40-60 HP range for gasoline/LPG models, with diesel variants potentially offering more torque.

Torque Characteristics:

Designed for consistent torque output at lower RPMs, suitable for lifting and maneuvering loads in industrial environments.

Gasoline Lpg:

Carburetor or electronic fuel injection (EFI) for gasoline, and appropriate fuel delivery system for LPG (vapor or liquid phase).

Diesel:

Direct injection or indirect injection diesel fuel system with high-pressure fuel pump, injectors, and glow plug system for cold starting.

🔧 Transmission

Type:

Automatic transmission, typically a torque converter type or hydrostatic transmission (HST).

Variants:

Depending on specific FG15 model and year, variations in transmission ratios or control systems may exist. Manual will detail these.

Control System:

Lever or electronic controls for forward/reverse selection, speed modulation.

Fluid Type:

Dedicated automatic transmission fluid (ATF) or hydraulic fluid, specific type and capacity detailed in manual. (e.g., Dexron III equivalent or ISO VG 32/46).

📐 Dimensions

Lift Capacity:

Typically rated for 1.5 to 1.8 metric tons (approximately 3000-4000 lbs) at a standard 500mm load center.

Mast Height:

Varies significantly based on mast configuration (e.g., 2-stage, 3-stage) and lowered/raised heights. Manual will provide specific ranges.

Operating Weight:

Typically in the range of 2500-3500 kg (5500-7700 lbs) depending on configuration and fuel type.

🛡️ Safety Features

Certification:

Designed to meet relevant industry safety standards for forklift operation (e.g., ANSI/ITSDF B56.1 in North America, EN standards in Europe). Specific compliance may vary by market and model year.

Operator Presence System:

Often includes operator presence controls (OPC) that prevent hydraulic and drive functions when the operator is not seated.

Parking Brake:

Mechanical parking brake, typically hand-operated, designed to hold the forklift securely when parked.

Overhead Guard:

Standard feature to protect the operator from falling loads.

Seatbelt:

Typically equipped with a seatbelt for operator safety.

💡 Technology Features

Operator Interface:

Basic operator controls, including levers for lift, tilt, side-shift, and directional control. Digital displays for hour meter, fuel level, and warning lights.

Load Sensing:

While basic, some models may incorporate load sensing to indicate maximum capacity limits, though advanced electronic aids are less common on this class of forklift.

Diagnostics:

Onboard diagnostics typically rely on indicator lights and fault codes displayed on the dashboard. Advanced electronic diagnostics may require specialized tools detailed in the manual.

🔧 Maintenance

Oil Change Engine:

Typically every 250-500 operating hours or annually, whichever comes first. Specific interval depends on operating conditions and oil type. (Consult manual for precise intervals).

Hydraulic Oil Change:

Recommended every 1000-2000 operating hours or as indicated by oil analysis. Manual will specify.

Transmission Fluid Change:

Typically every 1000-2000 operating hours. Manual will specify fluid type and capacity.

Engine Oil Type:

API CD or higher, SAE 10W-30 or 15W-40 heavy-duty diesel/gasoline engine oil, depending on engine type and ambient temperature. (Consult manual for exact specifications and viscosity grades).

Hydraulic Fluid Type:

ISO VG 32 or VG 46 hydraulic oil, or equivalent specified by Mitsubishi. Manual will provide precise specifications and potential alternatives.

Transmission Fluid Type:

Mitsubishi Automatic Transmission Fluid (MATF) or equivalent, or heavy-duty transmission fluid. Manual will detail the specific type and capacity.

Coolant Type:

Ethylene glycol-based antifreeze/coolant with corrosion inhibitors, mixed 50/50 with distilled water. Manual will specify concentration and type.

Common Wear Items:

Fork bushings, lift chains, mast rollers, hydraulic hoses, brake pads/shoes, engine mounts, and drive tires are common wear items requiring regular inspection and replacement.

Hydraulic Performance Degradation:

Can occur due to fluid contamination, worn pump seals, or leaky valve spools, leading to slow lift or tilt speeds. Manual provides diagnostic steps.

Engine Starting Issues:

May be related to fuel system problems (clogged filters, weak pump), ignition system (spark plugs, coil), battery, or starter motor. Manual details troubleshooting.

Transmission Slipping:

Can result from low fluid level, worn clutch packs (in torque converter types), or issues with the hydraulic control system. Manual covers diagnostics.

📚 Vehicle History

Manufacturer:

Mitsubishi Heavy Industries, Ltd. (MHI) and its forklift division, known for robust industrial equipment manufacturing.

Fg Series:

The FG series represents Mitsubishi's line of internal combustion engine (ICE) forklifts, designed for a wide range of industrial applications. The FG15 model is a core product in the 1.5-ton capacity class.

Production Period:

The FG15 model has been in production for many years, with various updates and revisions across different model generations and years. The manual aims to cover a broad range of these variations.

🏆 Awards & Recognition

Industry Reputation:

Mitsubishi forklifts are generally recognized for their reliability, durability, and robust construction in demanding industrial environments.