Basic Information Identification Make: Mitsubishi Model: FG20 Forklift Trucks Product Type: Workshop Service Manual Introduction Market Position Market Position: The Mitsubishi FG20 series represents a robust line of internal combustion engine (ICE) forklifts, typically designed for medium-duty industrial applications, offering a balance of power, maneuverability, and durability. These forklifts are often positioned as reliable workhorses in warehousing, manufacturing, and logistics environments. Competitive Analysis Competitive Analysis: Competes with similar models from manufacturers like Toyota (e.g., 8-Series), Clark, Hyster, Yale, and Komatsu. Key competitive factors include engine performance, lift capacity, fuel efficiency, operator comfort, hydraulic responsiveness, and overall reliability. The FG20's ability to utilize a readily available internal combustion engine (often LPG or gasoline) makes it a popular choice in applications where electric forklifts may not be suitable due to charging infrastructure or operational demands. Key Features Key Features: Known for robust construction, user-friendly controls, efficient engine performance, and a comfortable operator station. The FG20 series typically offers reliable hydraulic systems for precise load handling and a sturdy mast for various lifting applications. Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Language: English Format: PDF Download Page Count Page Count: To be determined based on actual manual content, typically 300-800 pages for comprehensive forklift service manuals. Manual Coverage Systems Covered Systems Covered: Engine, Drivetrain (Transmission, Differential, Drive Axle), Hydraulics (Lift, Tilt, Steering), Electrical System (Ignition, Charging, Lighting, Controls), Braking System, Steering System, Chassis, Mast Assembly, Operator Controls, Safety Systems, Troubleshooting, Specifications. Procedures Included Procedures Included: Scheduled Maintenance, Engine Overhaul, Transmission Repair, Hydraulic System Diagnosis and Repair, Electrical System Troubleshooting, Brake System Service, Mast Component Replacement, Steering System Adjustment, General Repair Procedures, Torque Specifications, Diagnostic Flowcharts, Component Removal and Installation. Technical Depth Technical Depth: Comprehensive, covering detailed diagnostic procedures, component-level repairs, overhaul instructions, and all necessary technical specifications for effective servicing and repair. Manual Specifications File Format File Format: Digital PDF (Searchable, Printable) Print Quality Print Quality: High-resolution scans suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Primary Engine: Typically powered by reliable industrial internal combustion engines. Common engine options include LPG (Liquefied Petroleum Gas) or gasoline engines from reputable manufacturers, often in the 2.0L to 3.0L displacement range. Specific engine models may vary by region and production year (e.g., Mitsubishi's own industrial engines or those from suppliers like Nissan/Isuzu). Performance Lift Capacity: Nominal capacity is typically around 2000 kg (4,000 lbs), but actual rated capacity will be specified on the forklift's data plate and within the manual, accounting for load center and mast configuration. Fuel System Fuel Type: Primarily LPG, with gasoline variants also common. The manual will detail fuel filter replacement, fuel pump checks, and LPG system components. Ignition System Ignition System: Conventional spark ignition system for gasoline engines, detailing spark plug specifications, ignition timing, coil packs, and distributor (if applicable). Cooling System Cooling System Type: Water-cooled system. Manual covers coolant type, capacity, radiator maintenance, thermostat replacement, and water pump service. Transmission Standard Transmission Type: Automatic transmission (torque converter) is standard on most FG20 models, designed for smooth operation and durability in industrial environments. Optional Optional Transmission: While less common for this class, manual transmission might have been an option in certain markets or for specific industrial requirements. The manual will detail the specific transmission fitted. Features Transmission Fluid Type: Specific Automatic Transmission Fluid (ATF) type will be detailed in the manual (e.g., Dexron III/Mercon equivalent, or a specific manufacturer-grade ATF). Transmission Maintenance: Manual covers fluid level checks, fluid and filter replacement intervals, and troubleshooting common transmission issues such as slipping or harsh shifting. Dimensions Exterior Overall Length: Varies based on mast and tire configuration, typically around 2.0-2.5 meters excluding forks. Overall Width: Typically around 1.0-1.2 meters. Mast Height Lowered: Varies, but commonly around 2.0-2.2 meters. Mast Height Lifted: Varies significantly based on mast type (e.g., Duplex, Triplex) and its extended height, often ranging from 3.5 to 7.0 meters or more. Weights Operating Weight: Typically in the range of 3500-4500 kg (7700-9900 lbs), depending on configuration and fuel type. Tire Size: Commonly pneumatic or solid rubber tires. Specific sizes will be detailed, e.g., 6.00-9 or 7.00-12. Safety Features Ratings Safety Standards: Adheres to relevant industry safety standards such as ANSI/ASME B56.1 or ISO 5057 for internal combustion engine powered industrial trucks. Active Features Active Safety: Features like reliable braking systems (often hydraulic drum or disc), audible backup alarms, and operator presence sensing systems (OPS) which prevent lifting/driving if the operator is not seated. Passive Features Passive Safety: Includes overhead guards (OHG) for operator protection from falling loads, seat belts, and robust chassis design. Technology Features Infotainment Infotainment Features: Basic operator interface, typically including hour meter, fuel gauge, engine warning lights, and diagnostic indicators. Advanced infotainment systems are not standard on industrial forklifts. Driver Assistance Driver Assistance Features: Operator Presence System (OPS), parking brake indicator, safety interlocks for operation. Connectivity Connectivity Features: No standard connectivity features like Bluetooth or Wi-Fi. Focus is on operational performance and safety. Maintenance Service Intervals Daily Checks: Engine oil level, coolant level, hydraulic fluid level, tire condition, brake operation, horn, lights, safety devices, any visual leaks. 250 Hour Service: Engine oil and filter change, air filter inspection/replacement, fuel filter check/replacement, general lubrication, inspection of hoses and belts, transmission fluid check, hydraulic filter inspection. 500 Hour Service: Includes 250-hour items plus: transmission fluid and filter change, hydraulic fluid and filter change, differential oil check, brake system inspection, cooling system flush and refill (as per schedule), spark plug replacement (if applicable). Fluid Specifications Engine Oil Type: API classification and viscosity grade will be specified (e.g., SAE 15W-40, API CI-4 or higher for diesel, or appropriate gasoline engine oil). Hydraulic Fluid Type: ISO VG 32 or VG 46 hydraulic oil is common, or a specific Mitsubishi-approved fluid. Manual will specify viscosity and type. Transmission Fluid Type: Specific ATF designation will be provided, e.g., Dexron III or equivalent. Coolant Type: Ethylene glycol based antifreeze/coolant, typically a 50/50 mix with deionized water. Manual specifies type...