🏷️ Basic Information

Make:

Mitsubishi

Product Type:

Service Repair Workshop Manual

Vehicle Type:

Forklift Trucks

Model Codes:

FGC15K, FGC18K, FGC20K, FG20K HO, FGC25K, FGC25K HO, FGC30K

👋 Introduction

Product Niche:

Industrial material handling equipment, specifically forklifts designed for a range of lifting capacities and operational environments.

Target Industry:

Warehousing, manufacturing, distribution, and logistics sectors requiring reliable material handling equipment.

Industry Standing:

Mitsubishi forklifts are recognized for their reliability, durability, and performance, competing with brands like Toyota, Hyster-Yale, Komatsu, and Crown.

Manual Value Proposition:

Provides essential, factory-authorized information for maintaining and repairing these specific Mitsubishi forklift models, crucial for optimizing uptime and ensuring safety.

Manual Completeness:

Original factory manual ensures accuracy and completeness of information, reflecting the manufacturer's intended service procedures.

📋 Manual Details

Manual Scope:

Comprehensive service and repair information

Estimated Page Count:

Extensive (specific count not provided, typical for comprehensive service manuals)

Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, as indicated by 'easy-to-read text sections' and 'top quality diagrams')

📖 Manual Coverage

Major Systems:

Engine, Powertrain, Hydraulic System, Electrical System, Steering, Brakes, Chassis, Operator Compartment, Mast Assembly, Safety Systems

Engine Specifics:

Engine identification, disassembly and reassembly, lubrication system, cooling system, fuel system (carburetor/injection), ignition system, exhaust system, emission controls, engine overhaul procedures, troubleshooting engine performance issues.

Hydraulic System Details:

Hydraulic pump, control valve, cylinders (lift, tilt, side-shift), hoses, filters, fluid reservoirs, troubleshooting hydraulic leaks, pressure checks, performance issues.

Electrical System Diagnostics:

Wiring diagrams, component identification (starter, alternator, battery, lights, sensors), troubleshooting electrical faults, starter motor removal/installation, charging system checks.

Mast And Carriage Servicing:

Mast inspection, roller adjustment, hydraulic cylinder seals, chain inspection and adjustment, carriage assembly, fork inspection and replacement.

Steering System Repair:

Steering column, tie rods, steering cylinder/actuator, hydraulic steering pump, troubleshooting steering responsiveness.

Brake System Servicing:

Brake pedal, master cylinder, brake lines, calipers/wheel cylinders, brake pads/shoes, parking brake system, bleeding the brake system.

Repair Procedures:

Detailed step-by-step repair instructions, diagnostic procedures, component overhauls, electrical troubleshooting, hydraulic system repairs, engine tuning, brake system servicing, mast and carriage repairs

Troubleshooting Methodology:

Systematic fault finding using diagnostic charts, symptom analysis, and component testing procedures.

Maintenance Tasks:

Lubrication schedules, filter replacement, fluid changes, belt adjustments, tire maintenance, brake adjustments, general inspection checklists.

Component Replacement:

Detailed instructions for replacing major components such as engine, transmission, hydraulic pump, mast assembly, drive axle, and operator seat.

Depth Of Information:

In-depth technical specifications, diagnostic flowcharts, schematics, torque specifications, clearances, wear limits, troubleshooting guides, maintenance schedules, component identification

Torque Specifications:

Detailed torque values for critical fasteners throughout the forklift, ensuring proper assembly and preventing component damage.

Clearances And Wear Limits:

Specific measurements for component wear, such as bearing clearances, seal clearances, and chain stretch limits, crucial for proper operation and longevity.

Schematics And Diagrams:

Comprehensive electrical schematics, hydraulic schematics, and detailed exploded view diagrams for major components, aiding in identification and repair.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair or diagnostic procedures.

📊 Manual Specifications

Digital Format Details:

Searchable PDF, high-resolution diagrams, printable pages

Searchability:

Full text search functionality enabling quick access to specific information within the manual.

Diagram Quality:

Top quality, detailed, clear line drawings and schematics

Diagram Resolution:

High-resolution graphics ensuring clarity for intricate details in diagrams and schematics.

Physical Binding:

Not applicable for digital format, but original factory manuals are typically professionally bound.

Physical Paper Quality:

Not applicable for digital format, but original factory manuals are printed on durable paper stock.

⚙️ Engine Specifications

Engine Type:

Internal Combustion (likely LPG/Gasoline or Diesel variants depending on specific model configuration, with gasoline/LPG being common for the FG/FGC series)

Engine Series Examples:

Likely powered by robust Mitsubishi industrial engines such as the S4S, S4E2, or similar series, known for their durability and fuel efficiency in demanding applications.

Lifting Capacity Range:

Approximately 1,500 kg to 3,000 kg (3,000 lbs to 6,500 lbs) based on model numbers (e.g., 15, 18, 20, 25, 30 indicating nominal capacity in hundreds of kg).

Fuel Type:

Propane (LPG), Gasoline (Petrol), and potentially Diesel for some variations not explicitly listed. The 'FG' designation often implies gasoline/LPG.

🔧 Transmission

Transmission Type:

Automatic Transmission (likely Hydrostatic or Torque Converter based) for smooth power delivery and operational ease.

Transmission Options:

Specific optional transmissions are not detailed, but variations in transmission control might exist.

Transmission Characteristics:

Designed for robust industrial use, providing efficient power transfer and precise control during lifting and maneuvering operations.

Drive System:

Rear-wheel drive is standard for most forklifts of this class.

📐 Dimensions

Overall Dimensions Range:

Varies significantly by model capacity and mast configuration. Typical dimensions include length, width, and height (mast lowered/raised).

Tire Type:

Typically cushion tires for indoor use or pneumatic tires for outdoor/rougher terrain, depending on model configuration.

Load Center:

Standard load center for this class of forklift is typically 500mm (20 inches), influencing stability and lifting capacity.

Operating Weight Range:

Ranges from approximately 3,000 kg to 5,000 kg depending on model and specifications.

🛡️ Safety Features

Industry Safety Standards:

Compliance with relevant ANSI/ASME B56.1 and ISO standards for industrial trucks.

Operator Safety Features:

Operator presence system, seatbelt, audible alarms, safety interlocks, parking brake.

Structural Safety:

Overhead guard, load backrest, mast protection, stable chassis design.

💡 Technology Features

Operator Interface:

Basic operator controls, dashboard indicators for engine status, fuel level, hour meter, and warning lights. Advanced infotainment systems are not typical for this class of industrial equipment.

Operational Assistance:

Ergonomic controls, power steering, safety systems designed for operational efficiency and operator comfort.

Telematics Options:

While not standard on all models of this era, some industrial forklifts can be equipped with telematics for fleet management, usage tracking, and maintenance monitoring.

🔧 Maintenance

Routine Maintenance Schedule:

Daily checks (fluid levels, tires, safety devices), weekly checks, monthly checks, and periodic servicing (e.g., every 250, 500, 1000, 2000 operating hours for oil changes, filter replacements, inspections) as detailed in the manual.

Engine Oil Type:

Typically SAE 10W-30 or 15W-40 API CD/CE/CF or higher classification, specific viscosity may vary by ambient temperature. Manual will specify exact API rating and viscosity grade.

Hydraulic Fluid Type:

ISO VG 32 or 46 hydraulic oil is common. Manual will specify exact type, viscosity, and potential OEM-approved fluids.

Transmission Fluid Type:

Specific ATF (Automatic Transmission Fluid) or equivalent industrial transmission fluid. Manual will specify exact type and capacity.

Coolant Type:

Ethylene glycol-based antifreeze (50% mixture with distilled water) for engine cooling system. Manual will specify exact type and capacity.

Common Wear Points:

Fork wear, mast rollers, hydraulic hose degradation, brake wear, engine tune-up needs, transmission fluid contamination, electrical connections.

Preventive Maintenance Focus:

Emphasis on regular inspection and lubrication of lift chains, mast channels, and pivot points to prevent premature wear.

📚 Vehicle History

Mitsubishi Heavy Industries:

Mitsubishi Heavy Industries has a long history in manufacturing heavy machinery and industrial equipment, known for engineering excellence.

Forklift Development:

The FGC/FG series represents Mitsubishi's commitment to providing reliable and efficient internal combustion forklifts, evolving over decades with technological advancements.

Manufacturing Origin:

Mitsubishi forklifts are manufactured globally, with significant production facilities in Japan and the United States, ensuring quality and adherence to standards.