🏷️ Basic Information

Make:

Mitsubishi

Model:

FG10, FG15, FG18, FG20, FG25, FG30, FG35A Forklift Trucks

Chassis Codes:

FG10, FG15, FG18, FG20, FG25, FG30, FG35A

👋 Introduction

Market Segment:

Industrial Material Handling Equipment (Counterbalance Forklift Trucks).

Target Industry:

Warehousing, manufacturing, logistics, shipping, construction, and general industrial applications where material handling is required.

Competitors:

Toyota, Hyster, Yale, Komatsu, Nissan, Caterpillar (in the industrial forklift segment).

Design Philosophy:

Robust construction, reliable performance, operator comfort, and efficient operation for demanding industrial environments.

📋 Manual Details

Coverage:

All major mechanical, electrical, hydraulic, and structural systems for Mitsubishi FG series forklift trucks.

Page Count:

Estimated 500-1000+ pages (specific count varies by actual manual edition, typically comprehensive).

Manual Type:

Full Service Repair Manual / Workshop Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Systems:

Engine overhaul, diagnostics, fuel system, lubrication, cooling system, ignition system (for gasoline models), emission control systems, engine disassembly and reassembly.

Transmission Systems:

Automatic transmission (torque converter) service, repair, diagnostics, fluid service, and component replacement.

Hydraulic Systems:

Hydraulic pump, control valve, cylinder repair, hydraulic circuit diagrams, troubleshooting, fluid specifications, and maintenance.

Electrical Systems:

Wiring diagrams, component testing, starter system, charging system, lighting, instrumentation, control circuits, and troubleshooting.

Brake Systems:

Brake system overhaul, component replacement (drums, shoes, master cylinder, hydraulic lines), adjustment, and maintenance.

Steering Systems:

Steering column, linkage, power steering pump, and hydraulic steering system repair and adjustment.

Mast And Forks:

Mast assembly inspection, repair, lubrication, cylinder service, and forklift attachment (forks) inspection.

Chassis And Frame:

Frame inspection, weld integrity, body component removal and installation, operator compartment.

Cooling System:

Radiator inspection and cleaning, water pump replacement, thermostat service, fan belt adjustment, and coolant flush procedures.

Fuel System Gasoline Lpg:

Carburetor adjustment and overhaul, fuel pump testing, fuel filter replacement, LPG regulator and vaporizer service.

Electrical Wiring Diagrams:

Comprehensive color-coded wiring diagrams for all vehicle systems, facilitating diagnosis and repair of electrical faults.

Routine Maintenance:

Scheduled maintenance, fluid changes, filter replacement, lubrication points, pre-operation checks.

Troubleshooting Guides:

Diagnostic flowcharts for common problems, error code explanations, symptom-based troubleshooting.

Disassembly And Reassembly:

Step-by-step instructions for component removal, overhaul, and installation with torque specifications.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Engine Overhaul:

Complete engine disassembly, inspection of internal components (pistons, rings, bearings, valves), cylinder head service, crankshaft and camshaft inspection, and reassembly with correct torque values and clearances.

Transmission Repair:

Detailed steps for removing, disassembling, inspecting, and rebuilding the torque converter automatic transmission, including clutch pack replacement, seal replacements, and valve body service.

Hydraulic System Troubleshooting:

Systematic approach to identifying hydraulic leaks, pressure drops, and performance issues, including testing of pumps, valves, and cylinders.

Depth Of Coverage:

Comprehensive: Covers basic adjustments, routine maintenance, diagnostics, component overhauls, and complete unit rebuilds.

📊 Manual Specifications

File Format:

Searchable PDF

Search Functionality:

Fully searchable text allows for quick access to specific topics and components.

Print Quality:

High-resolution scans for clear text and diagrams, suitable for printing.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Likely 4-cylinder gasoline/LPG (Liquefied Petroleum Gas) or Diesel engines depending on specific model and regional variant. Common engines include Mitsubishi 4G-series gasoline engines (e.g., 4G53, 4G63) or industrial diesel engines (e.g., Isuzu C-series, Mitsubishi S-series).

Typical Displacement:

1.5L to 3.0L (depending on model capacity: FG10-FG35A signifies lift capacity in hundreds of kg, e.g., FG20 is 2000kg).

Power Output:

Approx. 40-70 HP (gasoline/LPG), 50-80 HP (diesel) - varies by engine and model.

Fuel Delivery:

Carbureted or Electronic Fuel Injection (EFI) for gasoline/LPG; Direct Injection or Indirect Injection for Diesel.

🔧 Transmission

Transmission Type:

Automatic (Torque Converter with Hydraulic Shift)

Optional Transmission:

Manual transmission may be available on some early or specific configurations, but automatic is standard for this series.

Transmission Fluid Type:

Typically DEXRON-III or equivalent ATF (Automatic Transmission Fluid).

📐 Dimensions

Overall Length:

Varies significantly by mast type and configuration, but typically around 2.5-3.5 meters without forks.

Overall Width:

Approx. 1.0-1.5 meters.

Mast Lowered Height:

Approx. 2.0-2.5 meters (standard 2-stage mast).

Mast Raised Height:

Approx. 4.0-6.0 meters (standard mast height).

Operating Weight:

Approx. 2500-4500 kg (including battery, fluids, and operator).

Load Capacity Range:

1000 kg to 3500 kg (as indicated by model numbers FG10 to FG35).

🛡️ Safety Features

Iso Standards:

Conforms to relevant ISO 3691 standards for industrial trucks, including stability and safety requirements.

Operator Presence System:

Often equipped with operator presence sensors to prevent hydraulic operation when the operator is not seated.

Overhead Guard:

Standard overhead guard (mast-integrated or frame-mounted) for operator protection.

Seat Belt:

Standard seat belt for operator restraint.

💡 Technology Features

Operator Controls:

Basic controls including steering wheel, lift/tilt levers, gear selector, accelerator, brake pedal, and horn. Instrumentation typically includes hour meter, fuel gauge, and warning lights.

Safety Features Integration:

While not 'driver assistance' in the automotive sense, features like operator presence system and seatbelt interlocks are key for safe operation.

Diagnostic Ports:

Early models may rely on direct electrical testing. Later models might incorporate basic diagnostic ports for engine control modules if equipped with EFI.

🔧 Maintenance

Engine Oil Change:

Typically every 250-500 operating hours or annually, whichever comes first, depending on operating conditions and oil type.

Hydraulic Fluid Change:

Typically every 1000-2000 operating hours or annually.

Transmission Fluid Change:

Typically every 1000-2000 operating hours or annually.

Engine Oil Specification:

API SG or higher, SAE 30 or 10W-30 for gasoline/LPG engines. Diesel engines may require specific API CH-4 or CI-4 rated oils.

Coolant Type:

Ethylene Glycol based antifreeze with corrosion inhibitors (typically a 50/50 mix with water).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Common Wear Items:

Forklift tires, brake linings, mast rollers, hydraulic hoses, engine mounts, and transmission seals are common wear items requiring periodic inspection and replacement.

Common Engine Problems:

Overheating due to clogged radiators or faulty thermostats, fuel system issues (carburetor or injector clogging), and ignition system faults (spark plugs, ignition coils).

Common Hydraulic Problems:

Slow lift speeds or tilting due to low fluid levels, worn pump, or leaking cylinders/hoses. Control valve issues.

Common Steering Issues:

Play in the steering wheel, stiff steering, or noisy hydraulic power steering pump.

📚 Vehicle History

Mitsubishi Forklift:

Mitsubishi Heavy Industries (MHI) has a long history in heavy industrial machinery, with its forklift division being a significant global player.

Mitsubishi Heavy Industries:

A global leader in manufacturing heavy equipment, including engines, ships, and industrial machinery, with a strong reputation for durability and reliability.

Fg Series Development:

The FG series represents a line of reliable internal combustion (IC) engine counterbalance forklifts, evolving over decades to incorporate improved ergonomics, safety features, and more efficient powertrains.

Production Period:

These models were primarily produced from the late 1980s through the early 2000s, with variations and updates during that period. Later models may have different designations (e.g., FG20N, FG25N).