The Mitsubishi FG25 Forklift Truck is a robust piece of material handling equipment designed for efficiency and reliability in demanding industrial environments. Known for its durable construction and dependable performance, this internal combustion counterbalance forklift is engineered to handle loads up to approximately 5000 lbs. Mitsubishi Heavy Industries brings a legacy of quality manufacturing to the FG25, ensuring it meets the rigorous standards expected in its class. Its design prioritizes operational effectiveness, making it a valuable asset for businesses requiring consistent material movement capabilities. This comprehensive service and repair manual provides detailed information for the maintenance and repair of the Mitsubishi FG25 Forklift Truck. It covers all major systems, including the engine, transmission, hydraulics, mast and forks, electrical system, brakes, and steering. The manual offers guidance on routine maintenance, troubleshooting common issues, and performing complex rebuilding and component replacement procedures. Its purpose is to equip technicians, maintenance departments, and owner-operators with the technical knowledge necessary to ensure the forklift's optimal performance, minimize downtime, and extend its service life. 🏷️ 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: PDF 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...