Mitsubishi 4G63 4G64 Gasoline Engine FG35A Forklift

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🏷️ Basic Information Identification Make: Mitsubishi Model: FG35A Forklift Truck Engine Code: 4G63, 4G64 Codes Manual Product Name: MITSUBISHI 4G63 4G64 GASOLINE ENGINE FG35A FORKLIFT TRUCK WORKSHOP SERVICE REPAIR MANUAL...

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Type: Forklift

Vendor:

Sku: 509921

Tags: 4G63 4G64 Cars FG35A Forklift Misc Mitsubishi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

FG35A Forklift Truck

Engine Code:

4G63, 4G64

Codes

Manual Product Name:

MITSUBISHI 4G63 4G64 GASOLINE ENGINE FG35A FORKLIFT TRUCK WORKSHOP SERVICE REPAIR MANUAL

👋 Introduction

Market Position

Equipment Type:

Industrial Material Handling Equipment

Target User:

Forklift technicians, mechanics, maintenance engineers, and fleet managers.

Competitive Analysis

Competitor Brands Forklifts:

Toyota, Komatsu, Hyster, Yale, Caterpillar (for forklifts of similar capacity).

Engine Market Position:

Mitsubishi's 4G series engines are known for their reliability and are widely used in various automotive and industrial applications, including forklifts.

Key Features

Manual Value Proposition:

Provides essential, in-depth technical information for maintaining and repairing the Mitsubishi FG35A forklift, specifically focusing on the 4G63/4G64 gasoline engines.

Technical Accuracy:

Authoritative source for correct procedures, specifications, and troubleshooting guidance, crucial for efficient and safe operation.

📋 Manual Details

Coverage Areas

Primary Focus:

Workshop Service and Repair

Engine Coverage:

Mitsubishi 4G63 and 4G64 Gasoline Engines

Vehicle Coverage:

Mitsubishi FG35A Forklift Truck

Page Count

Estimated Pages:

Likely extensive; typical workshop manuals for this class of equipment range from 500-1500 pages, depending on detail and inclusion of diagrams.

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

Likely English, based on product description and typical market.

Format

Format:

Digital (PDF) or Printed Copy (details depend on actual product offering).

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, inspection, assembly, overhaul procedures for 4G63 and 4G64 gasoline engines, including cylinder head, block, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system.

Engine Fuel System:

Fuel pump, carburetor (if applicable to specific FG35A variants), fuel injectors, fuel lines, fuel filter replacement, fuel system diagnosis.

Engine Ignition System:

Spark plugs, ignition coils, distributor (if applicable), ECU ignition control, ignition timing adjustment.

Engine Emission Control:

EGR system, PCV system, catalytic converter (if fitted), emission control component testing and diagnosis.

Cooling System:

Radiator, thermostat, water pump, hoses, fan, coolant specifications, system flushing and maintenance.

Lubrication System:

Oil pump, oil filter, oil pan, oil pressure specifications, oil change intervals and specifications.

Transmission System:

Forklift transmission (type not specified, but would cover operation, maintenance, fluid checks, and common repair procedures).

Hydraulic System:

Lift and tilt cylinders, hydraulic pump, control valves, hydraulic fluid specifications, troubleshooting and repair of hydraulic functions.

Electrical System:

Battery, starter, alternator, wiring diagrams, lighting system, safety interlocks, diagnostic connectors.

Chassis And Steering:

Steering column, tie rods, steering linkage, chassis lubrication, frame inspection.

Braking System:

Brake pedal, master cylinder, brake lines, calipers/wheel cylinders, brake pads/shoes, parking brake, brake fluid specifications.

Mast And Attachments:

Mast assembly, forks, side shifter (if applicable), roller maintenance, lubrication, inspection.

Procedures Included

Scheduled Maintenance:

Routine checks, fluid level checks, filter replacements, lubrication points, service intervals.

Diagnostic Troubleshooting:

Step-by-step guides for identifying and resolving common faults and issues across all covered systems.

Component Removal Installation:

Detailed instructions for the removal and installation of major and minor components.

Overhaul Rebuild:

Comprehensive procedures for the complete disassembly, inspection, repair, and reassembly of engine and other major components.

Torque Specifications:

Essential torque values for critical fasteners throughout the forklift.

Special Tools:

Identification and usage of specialized tools required for certain repair or maintenance tasks.

Technical Depth

Depth:

Comprehensive (covers from basic maintenance to complete engine rebuilds and major system overhauls).

Diagnostics:

Advanced diagnostic procedures, including electrical circuit tracing and component testing.

Specifications:

Detailed technical specifications, tolerances, clearances, and performance data.

📊 Manual Specifications

File Format

Digital Format:

Typically PDF, enabling searchable text, bookmark navigation, and high-resolution diagrams.

Print Quality

Diagram Clarity:

High-resolution diagrams, schematics, and illustrations are critical for accurate repairs.

Binding Type

Printed Binding:

If printed, likely coil-bound or perfect-bound for durability and ease of use in workshop environments.

Paper Type

Printed Paper:

Durable paper stock suitable for workshop conditions, often with protective coatings.

⚙️ Engine Specifications

Primary Engine

Engine Family:

Mitsubishi 4G Series

Engine Displacement 4G63:

2.0 L (1997 cc)

Engine Displacement 4G64:

2.4 L (2351 cc)

Engine Configuration:

Inline 4-cylinder, SOHC or DOHC depending on specific variant.

Fuel Type:

Gasoline

Performance

Horsepower Range Approx:

Typically in the 70-90 HP range for forklift applications, depending on specific engine tune and load.

Torque Range Approx:

Torque delivery optimized for forklift operation, emphasizing low-end grunt.

Fuel System

Fuel Delivery:

Could be carburetor or fuel injection depending on the FG35A model year and specification. Manual will detail specific system.

Ignition System:

Distributor-based or distributorless ignition system (DIS), depending on variant.

🔧 Transmission

Standard

Transmission Type:

Automatic transmission is standard for most forklift applications of this size.

Optional

Optional Transmission:

Less common in forklifts, but manual transmission variants might exist for specific markets or older models.

Features

Transmission Fluid Type:

Specific ATF (Automatic Transmission Fluid) type will be detailed in the manual, critical for longevity.

Torque Converter:

Standard component in automatic transmissions, responsible for torque multiplication.

📐 Dimensions

Exterior

Lift Capacity Fg35A:

Approximately 3500 kg (7700 lbs) - '35' often denotes 3.5 metric tons.

Mast Height Variable:

The manual will cover various mast configurations (e.g., Duplex, Triplex) and their extended/lowered heights.

Weights

Operating Weight:

Specific to FG35A model, likely in the 4500-5500 kg range, including battery/operator.

🛡️ Safety Features

Ratings

Safety Standards Compliance:

The manual will align with relevant industrial safety standards (e.g., ANSI, ISO).

Active Features

Safety Interlocks:

Procedures for checking and maintaining seat-actuated operator presence systems, parking brake engagement.

Passive Features

Operator Protection:

Information on overhead guards, seat belts, and chassis integrity.

💡 Technology Features

Infotainment

Instrument Panel:

Basic instrumentation for engine status (oil pressure, temperature, battery charge), fuel level, and hour meter. Manual will detail gauge functions.

Driver Assistance

Operator Safety Features:

Features like seat interlocks, audible reverse alarms, warning lights.

Connectivity

Diagnostic Ports:

OBD-II or proprietary diagnostic connectors for engine and system diagnostics, covered in the manual.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 250-500 operating hours, or annually. Manual will specify exact interval.

Air Filter Replacement:

Dependent on operating environment, but recommended at regular intervals or when visually inspected as dirty.

Spark Plug Replacement:

Typically every 500-1000 operating hours, or as per manual recommendation.

Fluid Specifications

Engine Oil Spec:

Likely SAE 10W-30 or 10W-40 API SG/SH or higher. Manual will provide exact specification (e.g., Mitsubishi Genuine Oil).

Coolant Spec:

Ethylene Glycol based antifreeze, mixed 50/50 with distilled water. Manual will confirm capacity and type.

Hydraulic Fluid Spec:

ISO VG 32 or 46 hydraulic oil is common. Manual will specify type and capacity for the FG35A's hydraulic system.

Known Issues

Engine 4G6X Common Issues:

Head gasket leaks, oil consumption in higher mileage engines, timing belt (if belt-driven) wear, ignition component failures.

Forklift Fg35A Common Issues:

Hydraulic system leaks, mast chain adjustments, brake wear, wear on lift mechanism components.

📚 Vehicle History

Brand Heritage

Mitsubishi Heavy Industries:

Mitsubishi Heavy Industries has a long history of manufacturing industrial equipment, including forklifts.

Model Evolution

Fg Series Evolution:

The FG series represents a line of reliable gasoline/LPG powered forklifts from Mitsubishi, with continuous development in efficiency and ergonomics.

Production

Production Years Fg35A:

Specific production years would require further model identification, but this engine/chassis combination has been popular over several decades.

🏆 Awards & Recognition

Recognitions

Mitsubishi Engines Reputation:

Mitsubishi 4G series engines are generally recognized for their durability and reliability in demanding applications.

Ratings

Forklift Durability Reputation:

Mitsubishi forklifts are known for robust construction and longevity, reflecting good engineering and build quality.