🏷️ Basic Information

Make:

Mitsubishi

Model:

FG20, FG25, FG30, FG35A Forklift Trucks

Model Series Codes:

FG20, FG25, FG30, FG35A

👋 Introduction

Product Type:

Industrial Material Handling Equipment

Manual Purpose:

To provide comprehensive technical information for the service, repair, and maintenance of Mitsubishi FG20, FG25, FG30, and FG35A forklift trucks.

Manual Origin:

Original Factory Manual

Market Segment:

Counterbalance forklifts, typically used in warehousing, manufacturing, and distribution environments.

📋 Manual Details

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, implied by online sales)

Model Years Covered:

Specific to the FG20, FG25, FG30, FG35A series, likely covering a range of production years within their lifecycle. Manual would need to be consulted for exact year ranges.

Estimated Page Count:

High (typical for comprehensive service manuals, often 500+ pages)

Content Scope:

Comprehensive; includes all necessary information for service and repair from basic maintenance to complex diagnostics.

📖 Manual Coverage

Major Systems:

Engine, Transmission, Hydraulics, Electrical, Chassis, Steering, Braking, Mast Systems, Operator Compartment

Engine Systems:

Engine mechanical, cooling system, lubrication system, fuel system, ignition system (if applicable), exhaust system.

Transmission Systems:

Torque converter, transmission hydraulic control, gearbox, drive axle.

Hydraulic Systems:

Hydraulic pump, control valves, lift and tilt cylinders, steering cylinder, hydraulic reservoir, hoses, and fittings.

Electrical Systems:

Battery, starter, alternator, ignition system, lighting, instrumentation, wiring harnesses, sensors, safety interlocks.

Chassis And Steering:

Frame, steering mechanism (hydraulic power steering), front and rear axles, suspension (if applicable), wheels, tires.

Braking Systems:

Service brake system (hydraulic), parking brake system, brake components (drums/discs, shoes/pads, cylinders).

Mast And Attachments:

Mast assembly (inner/outer masts), lift chains, rollers, tilt cylinders, side shifter (if equipped), forks.

Operator Compartment:

Seating, controls, dashboard, safety features, operator protection structures.

Diagnostic Procedures:

Troubleshooting guides, fault code interpretation, diagnostic testing for all major systems.

Maintenance Procedures:

Scheduled maintenance, lubrication, filter changes, fluid checks and replacements, adjustments.

Repair Procedures:

Detailed step-by-step repair instructions for components and systems, including disassembly, assembly, and reconditioning.

Troubleshooting Methodology:

Systematic approach to diagnosing faults, using symptoms, test procedures, and specifications.

Component Replacement:

Detailed steps for replacing major components like the engine, transmission, hydraulic pump, cylinders, and brake assemblies.

Adjustment Procedures:

Setting of brake pedal travel, steering system adjustments, valve adjustments (if applicable).

Special Tools:

Identification and usage of specialized tools required for specific repair or maintenance tasks.

Wiring Diagrams:

Essential electrical wiring diagrams for all circuits and components.

Hydraulic Schematics:

Detailed hydraulic circuit schematics to understand fluid flow and control.

Diagnostic Depth:

Advanced diagnostics, including electrical schematic analysis and hydraulic circuit tracing.

Repair Depth:

Comprehensive repair procedures, from minor adjustments to complete component overhaul and replacement.

Specifications Data:

Torque specifications for fasteners, clearance measurements, pressure readings for hydraulic systems, electrical resistance values.

Rebuild Procedures:

Likely includes procedures for rebuilding major components such as the engine, transmission, hydraulic pump, and cylinders.

📊 Manual Specifications

File Type:

PDF (most common for digital manuals)

Searchability:

Likely text-searchable PDF for quick information retrieval.

Digital Rights:

User is typically granted rights for personal use, printing for reference, but not redistribution.

Diagram Quality:

High quality, easy-to-read diagrams and illustrations.

Illustration Clarity:

Illustrations are crucial for forklift repair; expect clear exploded views and step-by-step diagrams.

Binding:

N/A (Digital format)

Paper Quality:

N/A (Digital format)

⚙️ Engine Specifications

Engine Type:

Internal Combustion (LPG/Gasoline - specific engine may vary by sub-model and region)

Specific Engine Models:

Likely uses Mitsubishi's own industrial engines or engines from reputable suppliers (e.g., Nissan, Kubota) depending on the specific FG model variant and production era. Manual will detail exact engine codes.

Horsepower Range:

Varies by specific model and engine configuration (typically in the 40-60 HP range for this class of forklift)

Torque Specifications:

Not directly provided in description, but the manual will contain detailed torque values for engine components.

Fuel Type:

LPG (Liquefied Petroleum Gas) / Gasoline

🔧 Transmission

Transmission Type:

Automatic Transmission (Torque Converter)

Transmission Control:

Hydraulic control for smooth power delivery.

Transmission Fluid Type Spec:

Refer to manual for specific Mitsubishi transmission fluid part numbers and specifications (e.g., ATF Type H or equivalent).

Transmission Options:

Primarily automatic. Manual transmission is highly unlikely for this forklift class.

📐 Dimensions

Operating Weight:

Varies significantly by model (e.g., FG20 ~4,000 kg, FG35A ~4,500 kg)

Load Capacity:

2000 kg (FG20) to 3500 kg (FG35A)

Load Center:

Typically 500mm (24 inches) for this class of forklift, but specified in the manual.

Overall Dimensions:

Varies by model and mast configuration; manual will detail specific dimensions (length, width, height, mast lowered/raised height).

🛡️ Safety Features

Safety Standards:

Compliance with relevant industrial safety standards (e.g., OSHA, ANSI, ISO).

Braking System:

Hydraulic power brakes, parking brake.

Operator Protection:

Operator restraint system (seatbelt), overhead guard, load backrest.

Operator Presence System:

May include an operator presence sensor to prevent operation if the operator is not seated.

💡 Technology Features

Operator Interface:

Basic dashboard with gauges for engine temperature, fuel level, oil pressure, and hour meter. Indicator lights for system warnings.

Instrumentation:

Analog gauges, warning lights, and possibly a digital hour meter. Simple operator controls.

Control Systems:

Manual levers and pedals for lift, tilt, steering, and drive control. Electronic control for specific functions may be present in later models.

Diagnostics Port:

May feature a diagnostic port for connecting specialized diagnostic equipment, detailed in the manual.

🔧 Maintenance

Engine Oil Change:

Typically every 250-500 operating hours, depending on operating conditions and oil type.

Transmission Fluid Change:

Typically every 1000-2000 operating hours, or as specified in the manual.

Hydraulic Filter Change:

Typically every 500-1000 operating hours, or as indicated by system performance.

Air Filter Replacement:

Regular inspection and replacement based on operating environment (e.g., dusty conditions require more frequent changes).

Engine Oil Type:

API Service Classification SG or higher, viscosity SAE 10W-30 or 15W-40 (specific grade dependent on ambient temperature).

Hydraulic Fluid Type:

Mitsubishi genuine hydraulic fluid or equivalent (e.g., ISO VG 32 or 46, depending on application and climate).

Brake Fluid Type:

DOT 3 or DOT 4 automotive brake fluid (manual will specify).

Engine Coolant Type:

Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.

Common Wear Items:

Tires, brake pads/linings, hydraulic filters, air filters, fuel filters, lift chains, mast rollers.

Potential Failures:

Overheating due to cooling system issues, hydraulic system leaks, transmission wear, ignition system problems (for gasoline models).

📚 Vehicle History

Manufacturer:

Mitsubishi Heavy Industries Forklift & Engine (MHI-F&E)

Series Development:

The FG series represents a line of reliable internal combustion engine forklifts known for their performance and durability in various industrial applications.

Manufacturing Location:

Likely manufactured by Mitsubishi Forklift Trucks factories in Japan or through their global manufacturing network.

🏆 Awards & Recognition

Industry Reputation:

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