Mitsubishi FG25 Forklift Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: FG25 Forklift Truck Product Type: Full Service Repair Manual 👋 Introduction Market Position Industry Segment: Material Handling Equipment - Internal Combustion Counterbalance Forklifts....

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Type: Forklift

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Sku: 81545

Tags: Cars FG25 Forklift Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

FG25 Forklift Truck

Product Type:

Full Service Repair Manual

👋 Introduction

Market Position

Industry Segment:

Material Handling Equipment - Internal Combustion Counterbalance Forklifts.

Target Audience:

Forklift technicians, maintenance departments, fleet managers, owner-operators.

Competitive Analysis

Competitors:

Toyota, Hyster, Yale, Komatsu, Caterpillar, Crown (in terms of forklift manufacturing and service documentation).

Key Features

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.

📋 Manual Details

Coverage Areas

Manual Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Variable (typically 500+ pages for comprehensive forklift manuals)

📖 Manual Coverage

Systems Covered

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.

Procedures Included

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.

Technical Depth

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.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, enabling quick access to specific information.

Print Quality:

Designed for clear printing of text and diagrams.

Binding Type

Binding For Digital:

N/A (Digital Download)

Paper Type

Recommended Print Medium:

Standard printer paper for home or workshop printing.

⚙️ Engine Specifications

Primary Engine

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.

Performance

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 System

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.

Maintenance

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.

🔧 Transmission

Standard

Transmission Type:

Likely a Powershift transmission or a robust automatic transmission designed for heavy-duty industrial use.

Transmission Fluid:

Dedicated automatic transmission fluid (ATF) or a specific industrial transmission oil, as per manual specification.

Features

Torque Converter:

Standard feature for smooth engagement and load handling.

Drive Axle:

Heavy-duty drive axle with integrated differential.

📐 Dimensions

Exterior

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.

Weights

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).

🛡️ Safety Features

Ratings

Design Standards:

Adheres to ANSI/ASME B56.1 safety standards for powered industrial trucks.

Active Features

Operator Presence System:

Likely includes an operator presence system (OPS) that disengages the drive and hydraulic functions if the operator leaves the seat.

Parking Brake:

Integral parking brake for secure immobilization.

Passive Features

Overhead Guard:

Standard overhead guard to protect the operator from falling loads.

Seatbelt:

Mandatory seatbelt for operator safety.

💡 Technology Features

Infotainment

Operator Interface:

Basic operator interface with essential gauges (fuel, temperature, oil pressure), warning lights, and control levers.

Driver Assistance

Load Sensing:

May incorporate basic load sensing for hydraulic operation and stability assistance.

Connectivity

Telematics:

Optional telematics for fleet management and usage tracking may be available on newer models.

🔧 Maintenance

Service Intervals

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).

Fluid Specifications

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.

Known Issues

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.

📚 Vehicle History

Brand Heritage

Mitsubishi Heavy Industries:

Mitsubishi Heavy Industries (MHI) has a long history of manufacturing robust industrial equipment, including forklifts, known for durability and reliability.

Model Evolution

Fg Series Designation:

The 'FG' designation typically signifies an internal combustion, cushion tire forklift. Mitsubishi has evolved its forklift designs over decades to incorporate improved ergonomics, safety, and performance.

Production

Manufacturing Locations:

Mitsubishi forklifts are manufactured globally, with significant production facilities in Japan, the USA, and other regions.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Mitsubishi forklifts are generally recognized for their reliability, durability, and cost-effectiveness in industrial environments. Specific model awards would depend on the production year.

Ratings

Customer Satisfaction:

Consistently high ratings for operational performance and ease of maintenance within the material handling industry.