Segment:
Industrial forklifts, material handling equipment.
Competitors:
Toyota, Nissan, Komatsu, Caterpillar, Hyster-Yale, Crown.
Vehicle Focus:
Reliability, durability, operator comfort, efficient operation in demanding environments.
Manual Purpose:
To provide authorized technicians and skilled mechanics with the complete information required for servicing, troubleshooting, and repairing the FGC20K model.
Powertrain:
Engine (diesel/LPG variants), transmission (hydrostatic/torque converter), drive axle, differential, cooling system, fuel system.
Hydraulics:
Hydraulic pump, control valve, cylinders (lift, tilt, side-shift), hoses, fittings, hydraulic fluid specifications.
Electrical:
Wiring diagrams, starter, alternator, battery, lighting, instrumentation, sensors, electronic control units (ECUs).
Chassis And Body:
Frame, mast assembly (single, duplex, triplex), forks, steering system, braking system, operator compartment, counterweight.
Maintenance:
Scheduled maintenance checks, lubrication points, filter replacement (oil, fuel, air, hydraulic), fluid changes, safety inspections.
Troubleshooting:
Diagnostic charts, common problem identification, symptom-based troubleshooting for all major systems, fault code explanations (if applicable).
Repair:
Step-by-step disassembly and reassembly procedures for all components and systems, including engine overhaul, transmission repair, hydraulic system rebuilds, brake system service.
Diagnostics:
Component testing, pressure testing (hydraulic, fuel), electrical circuit testing, specialized diagnostic tool usage (if applicable).
Electrical Diagnostics:
Detailed troubleshooting for starter, charging system, ignition system (LPG), lights, solenoids, and sensor circuits.
Mast And Fork Service:
Inspection, lubrication, and repair of mast channels, rollers, hydraulic cylinders for lift/tilt/side-shift, and fork assembly.
Steering System Repair:
Diagnosis and repair of hydraulic power steering components, steering cylinder, and tie rods.
Brake System Overhaul:
Service and replacement of brake shoes/pads, drums/rotors, wheel cylinders, master cylinder, and brake lines.
Depth:
Comprehensive factory-level detail, covering basic adjustments to complete component overhauls and major repairs.
Torque Specifications:
Includes critical torque values for engine components, drive axle, wheels, and hydraulic fittings.
Wiring Diagrams:
Comprehensive electrical schematics with component identification for accurate troubleshooting.
Specifications And Tolerances:
Precise measurements, clearances, and tolerances for critical engine, transmission, and hydraulic components during rebuilds.
Engine Type:
Likely a robust, industrial-grade internal combustion engine (e.g., LPG or Diesel). Specific model depends on region and exact FGC20K variant.
Horsepower Range:
Typically 40-60 HP, designed for torque and reliability rather than peak horsepower.
Torque Characteristics:
High low-end torque for load lifting and maneuvering.
Fuel Type:
Propane (LPG) or Diesel, depending on the specific configuration of the FGC20K.
Injection System:
Likely electronic fuel injection (EFI) for LPG, or direct injection for diesel.
Cooling Type:
Liquid-cooled, with radiator, fan, and coolant reservoir.
Oil Type:
Specific industrial engine oil, e.g., SAE 15W-40 or 10W-30, conforming to API classification (e.g., API CK-4 for diesel).
Ignition Type:
Spark ignition for LPG engines; compression ignition for diesel engines.
Type:
Likely a hydrostatic transmission (HST) or a torque converter automatic transmission, optimized for smooth operation and precise control.
Variants:
Depending on the exact model year and configuration, variations in transmission ratios or control systems might exist.
Control Type:
Power steering and hydraulic controls for lift, tilt, and side-shift functions.
Transmission Fluid:
Specific ATF (Automatic Transmission Fluid) or dedicated hydraulic fluid, adhering to Mitsubishi specifications (e.g., Mitsubishi DiaQueen Super ATF or equivalent).
Lift Capacity:
Rated for 2000 kg (4500 lbs) at a standard 500mm load center.
Mast Height Lowered:
Varies based on mast type (e.g., Duplex, Triplex), typically in the range of 2000-2500 mm.
Mast Height Raised:
Varies significantly based on mast type and configuration, can range from 4000 mm to over 7000 mm.
Overall Length:
Approx. 2500-3000 mm (without forks).
Overall Width:
Approx. 1100-1200 mm.
Operating Weight:
Approx. 3500-4000 kg (depending on configuration and attachments).
Tire Size:
Typically solid pneumatic or cushion tires, sizes like 7.00-12 or 6.00-9 front, 5.00-8 rear.
Design Standards:
Designed to meet relevant industry safety standards (e.g., ANSI B56.1, ISO 3691).
Braking System:
Hydraulic drum or disc brakes, often with parking brake mechanism.
Operator Presence System:
Often includes a seat-actuated switch that prevents lift/travel when the operator is not seated.
Overhead Guard:
Standard integral overhead protective structure (OHPS).
Seatbelt:
Typically equipped with a seatbelt for operator safety.
Engine Oil Change:
Typically every 250-500 operating hours or annually, whichever comes first, depending on operating conditions.
Transmission Fluid Change:
Generally every 1000-2000 operating hours, or as specified for the transmission type.
Hydraulic Filter Replacement:
Typically every 500-1000 operating hours.
Air Filter Replacement:
As needed based on operating environment, often inspected daily and replaced when dirty.
Engine Coolant:
Ethylene glycol-based antifreeze/coolant mixture, typically 50/50 concentration, meeting specific industry standards.
Hydraulic Fluid Type:
ISO VG 32 or VG 46 hydraulic fluid, or a specialized forklift hydraulic oil as per manufacturer recommendation.
Common Wear Items:
Wear on mast rollers, fork tips, hydraulic cylinder seals, brake components, and transmission seals are common over time.
Engine Considerations:
Glow plug issues (diesel), carburetor or LPG regulator issues (LPG), exhaust system leaks.
Hydraulic System:
Leaky cylinders, pump wear leading to reduced lift speed or holding capacity, control valve issues.
