Mitsubishi FG35 FG40 Forklift Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: FG35 / FG40 Forklift Trucks 👋 Introduction Market Position Target Audience: Professional forklift technicians, mechanics, workshops, and DIY individuals involved in repair, maintenance, and diagnostics of Mitsubishi FG35/FG40 forklift trucks. Key Features Manual Utility: Highly detailed, comprehensive, and illustrated guide designed to facilitate immediate problem-solving and in-depth repairs. Digital Access: Instant download, accessible on various devices (PC, iPad, hard drive), no shipping costs, three-day download window. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Troubleshooting, Diagnostics Engine Coverage: GM 4.3L (G6) Gasoline/LP Gas Chassis Mast Coverage: Cooling, Electrical, Power Train, Transmissions (Manual & Power Shift), Axles (Front/Rear), Brakes, Steering, Hydraulics, Masts & Forks Lp Gas Supplement Coverage: LP Gas System Operation, Troubleshooting, Maintenance, Emissions Control (CARB Tier 1) Specific Component Coverage: Masts and Forks, Clutch Assemblies, Axle and Differential components. Page Count Estimated Pages: Varies significantly due to large file sizes; manual states up to 4000 MB Data Size Indication: Up to 4000 MB (indicative of a highly detailed manual with extensive diagrams and information). Manual Type Type: Service Repair Workshop Manual Language Primary Language: English Format Delivery Format: Digital Download (PDF, ZIP, RAR, EXE) File Compatibility: PC & MAC compatible, works on Windows 97 through Windows 10. 📖 Manual Coverage Systems Covered Powertrain Systems: Engine (GM 4.3L G6), Fuel System (Gasoline & LP Gas), Ignition System, Starting System, Charging System, Transmissions (Manual & Power Shift), Clutches, Drive Axles, Differential Chassis And Operational Systems: Cooling System, Electrical System (including Schematics), Brake System, Steering System, Hydraulic System, Mast and Fork Assembly, LP Gas Fuel Systems Electrical System Detail: Includes detailed electrical system schematics for troubleshooting and repair. Power Train Components: Detailed coverage of power train components, including front axle and reduction differential. Procedures Included Diagnostic And Troubleshooting: General Troubleshooting, Engine Diagnosis, Valve Train Diagnosis (Noise), ECU Error Code Description, LP Gas Troubleshooting, Vacuum System Troubleshooting Repair And Rebuild: Engine Overhaul Determination, Engine Replacement, Component Disassembly and Reassembly, Transmission Repair, Brake System Repair, Hydraulic System Repair, Mast and Fork Repair Maintenance And Adjustment: Preventative Maintenance, Lubrication, Fluid Replacements, Belt Adjustments, Ignition System Adjustment, Fuel System Adjustments (Gasoline & LP Gas), LP Gas System Adjustments, Emissions Control System Adjustments Engine Diagnostics: Specific diagnostic information and procedures for the GM 4.3L (G6) engine, including valve train noise diagnosis. Component Replacement: Step-by-step instructions for replacing major components, including engine replacement. Technical Depth Depth Of Information: Comprehensive, step-by-step instructions suitable for professional technicians and DIY users; includes detailed diagrams, schematics, and repair data Repair Data: Includes specific repair data and specifications crucial for accurate repairs. 📊 Manual Specifications File Format Primary Format: PDF Compression Format: ZIP/RAR (may require unzipping software like WinZip or WinRAR) Print Quality Printability: Printable on any computer and printer Binding Type Physical Binding: Not Applicable (Digital Download) Paper Type Physical Paper: Not Applicable (Digital Download) Illustrations Visual Aids: Illustrated with clear step-by-step instructions, zoomable illustrations, detailed component explosions, exploded views, breakdown of part numbers ⚙️ Engine Specifications Primary Engine Engine Model: GM 4.3L (G6) Engine Type: Gasoline (also adapted for Liquefied Petroleum Gas - LP Gas) Engine Diagnostics: Procedures for determining when an engine overhaul is necessary. Performance Horsepower: Specific horsepower not detailed in product info, but typically in the 80-100 HP range for this engine in similar applications. Torque: Specific torque not detailed in product info. Fuel System Fuel Types: Gasoline and Liquefied Petroleum Gas (LP Gas) Lp Gas Components: Detailed information on LP Gas systems, including types of LP gas, structure, function, troubleshooting, and emissions control. Maintenance Specifications Tightening Torque: Detailed specifications for major nuts and bolts provided. Sealants Lubricants: Information on sealers, adhesives, and lubricants, including RTV and anaerobic sealers (gasket eliminators). 🔧 Transmission Standard Transmission Types Covered: Manual Transmission and Power Shift Transmission Gear Ratios: Detailed gear ratios and specifications for both transmission types are likely included. Features Transmission Details: Detailed information on clutch operation, manual transmission repair, and power shift transmission diagnostics and repair. Transmission Troubleshooting: Troubleshooting sections are provided for both manual and power shift transmissions. 📐 Dimensions Exterior Lift Capacity Fg35: Approximately 3500-4000 lbs (1588-1814 kg) nominal capacity. Specific model variations may exist. Lift Capacity Fg40: Approximately 4000-5000 lbs (1814-2268 kg) nominal capacity. Specific model variations may exist. Mast Type Coverage: Coverage for various mast types and fork assemblies, including their maintenance and repair. Overall Dimensions: Specific dimensions (length, width, height) are not provided in the product description but are integral to forklift operation and would be found within the 'General Information' section. Weights Operating Weight: Not specified in product information, but typically in the range of 7,000-9,000 lbs (3,175-4,082 kg) depending on configuration. 🛡️ Safety Features Active Features Brake System: Comprehensive coverage of the brake system, including diagnostics and repair procedures. Steering System: Detailed information on the steering system for safe operation and maintenance. 💡...
Professional forklift technicians, mechanics, workshops, and DIY individuals involved in repair, maintenance, and diagnostics of Mitsubishi FG35/FG40 forklift trucks.
Key Features
Manual Utility:
Highly detailed, comprehensive, and illustrated guide designed to facilitate immediate problem-solving and in-depth repairs.
Digital Access:
Instant download, accessible on various devices (PC, iPad, hard drive), no shipping costs, three-day download window.
Cooling System, Electrical System (including Schematics), Brake System, Steering System, Hydraulic System, Mast and Fork Assembly, LP Gas Fuel Systems
Electrical System Detail:
Includes detailed electrical system schematics for troubleshooting and repair.
Power Train Components:
Detailed coverage of power train components, including front axle and reduction differential.
Procedures Included
Diagnostic And Troubleshooting:
General Troubleshooting, Engine Diagnosis, Valve Train Diagnosis (Noise), ECU Error Code Description, LP Gas Troubleshooting, Vacuum System Troubleshooting
Repair And Rebuild:
Engine Overhaul Determination, Engine Replacement, Component Disassembly and Reassembly, Transmission Repair, Brake System Repair, Hydraulic System Repair, Mast and Fork Repair
Maintenance And Adjustment:
Preventative Maintenance, Lubrication, Fluid Replacements, Belt Adjustments, Ignition System Adjustment, Fuel System Adjustments (Gasoline & LP Gas), LP Gas System Adjustments, Emissions Control System Adjustments
Engine Diagnostics:
Specific diagnostic information and procedures for the GM 4.3L (G6) engine, including valve train noise diagnosis.
Component Replacement:
Step-by-step instructions for replacing major components, including engine replacement.
Technical Depth
Depth Of Information:
Comprehensive, step-by-step instructions suitable for professional technicians and DIY users; includes detailed diagrams, schematics, and repair data
Repair Data:
Includes specific repair data and specifications crucial for accurate repairs.
📊 Manual Specifications
File Format
Primary Format:
PDF
Compression Format:
ZIP/RAR (may require unzipping software like WinZip or WinRAR)
Print Quality
Printability:
Printable on any computer and printer
Binding Type
Physical Binding:
Not Applicable (Digital Download)
Paper Type
Physical Paper:
Not Applicable (Digital Download)
Illustrations
Visual Aids:
Illustrated with clear step-by-step instructions, zoomable illustrations, detailed component explosions, exploded views, breakdown of part numbers
⚙️ Engine Specifications
Primary Engine
Engine Model:
GM 4.3L (G6)
Engine Type:
Gasoline (also adapted for Liquefied Petroleum Gas - LP Gas)
Engine Diagnostics:
Procedures for determining when an engine overhaul is necessary.
Performance
Horsepower:
Specific horsepower not detailed in product info, but typically in the 80-100 HP range for this engine in similar applications.
Torque:
Specific torque not detailed in product info.
Fuel System
Fuel Types:
Gasoline and Liquefied Petroleum Gas (LP Gas)
Lp Gas Components:
Detailed information on LP Gas systems, including types of LP gas, structure, function, troubleshooting, and emissions control.
Maintenance Specifications
Tightening Torque:
Detailed specifications for major nuts and bolts provided.
Sealants Lubricants:
Information on sealers, adhesives, and lubricants, including RTV and anaerobic sealers (gasket eliminators).
🔧 Transmission
Standard
Transmission Types Covered:
Manual Transmission and Power Shift Transmission
Gear Ratios:
Detailed gear ratios and specifications for both transmission types are likely included.
Features
Transmission Details:
Detailed information on clutch operation, manual transmission repair, and power shift transmission diagnostics and repair.
Transmission Troubleshooting:
Troubleshooting sections are provided for both manual and power shift transmissions.
📐 Dimensions
Exterior
Lift Capacity Fg35:
Approximately 3500-4000 lbs (1588-1814 kg) nominal capacity. Specific model variations may exist.
Lift Capacity Fg40:
Approximately 4000-5000 lbs (1814-2268 kg) nominal capacity. Specific model variations may exist.
Mast Type Coverage:
Coverage for various mast types and fork assemblies, including their maintenance and repair.
Overall Dimensions:
Specific dimensions (length, width, height) are not provided in the product description but are integral to forklift operation and would be found within the 'General Information' section.
Weights
Operating Weight:
Not specified in product information, but typically in the range of 7,000-9,000 lbs (3,175-4,082 kg) depending on configuration.
🛡️ Safety Features
Active Features
Brake System:
Comprehensive coverage of the brake system, including diagnostics and repair procedures.
Steering System:
Detailed information on the steering system for safe operation and maintenance.
💡 Technology Features
Infotainment
Operator Interface:
Basic operator controls and instrumentation relevant to forklift operation. Advanced infotainment systems are not a feature of this type of equipment.
Driver Assistance
Operational Aids:
While not 'driver assistance' in an automotive sense, the manual covers systems like power steering and hydraulic controls crucial for safe and efficient operation.
Diagnostics
Electronic Control Unit:
Coverage of the ECU (Electronic Control Unit) with error code descriptions for the GM 4.3L engine.
Special Tools:
Information on special tools and equipment required for various repair and diagnostic procedures, particularly for the engine.
Electrical Diagnostics:
Extensive coverage of electrical system diagnostics, including wiring schematics.
🔧 Maintenance
Service Intervals
Scheduled Maintenance:
Manual provides information to determine maintenance needs, but specific intervals for oil changes, filter replacements, etc., would be detailed within the comprehensive sections not fully listed.
Engine Tune Up:
Information on ignition system and fuel system tune-ups for optimal performance and emissions.
Fluid Specifications
Engine Oil:
Specifications for engine oil viscosity and capacity are expected within the GM 4.3L engine sections.
Hydraulic Fluid:
Specifications for hydraulic fluid type and capacity are provided in the Hydraulic System section.
Transmission Fluid:
Specifications for transmission fluid are likely detailed for both manual and power shift transmissions.
Lubrication Points:
The manual would cover proper lubrication procedures for various moving parts and components.
Known Issues
Common Wear Items:
As an industrial forklift, common wear items typically include tires, brake pads/drums, hydraulic hoses, mast components, and engine tune-up parts. The manual would detail specific troubleshooting for these.
Common Failures:
The troubleshooting sections are designed to address common issues and failures encountered in these forklift models.
Troubleshooting Guide:
The manual serves as a comprehensive troubleshooting guide to help fix problems immediately.
📚 Vehicle History
Brand Heritage
Mitsubishi Heavy Industries:
Mitsubishi Heavy Industries (MHI) has a long history in manufacturing heavy equipment, including forklifts, known for their durability and reliability.
Model Evolution
Fg Series:
The FG series represents Mitsubishi's range of internal combustion engine (ICE) forklifts, popular in various industrial and warehousing applications. Specific year ranges for FG35/FG40 are not detailed but are generally considered part of a robust product line.
🏆 Awards & Recognition
Recognitions
Industry Reputation:
Mitsubishi forklifts are generally recognized for their robustness and suitability for demanding industrial environments.
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