Model:
FGC Series Forklift Truck
Covered Models:
FGC15, FGC18, FGC20, FGC20HP, FGC25HP, FGC30
Product Type:
Service Repair Workshop Manual
Engine Code:
4G63, 4G64 (Gasoline)
Industry Segment:
Internal Combustion Engine (ICE) Counterbalance Forklift Trucks
Application Focus:
Designed for material handling in warehouses, manufacturing, and logistics environments.
Key Competitors:
Toyota, Hyster, Yale, Komatsu, Caterpillar (in the forklift market).
Engine Options:
Reliable 4G63 and 4G64 gasoline engines offering a balance of power and fuel efficiency for their class.
Durability:
Mitsubishi's reputation for robust construction and reliable components.
Operator Ergonomics:
Focus on operator comfort and control for extended use.
Systems Covered:
Engine, Drivetrain, Hydraulic System, Electrical System, Chassis, Steering, Braking System, Operator Compartment, Mast Assembly, Cooling System, Fuel System, Lubrication System, Troubleshooting, Maintenance
Estimated Page Count:
Estimated 800+ pages (typical for comprehensive service manuals)
Manual Type:
Service and Repair Workshop Manual
Format:
Digital Download (PDF)
Engine Service:
Detailed repair procedures, overhaul, diagnostics, specifications for 4G63 and 4G64 gasoline engines.
Transmission Service:
Coverage for automatic transmission systems, including torque converter, hydraulic controls, and overhaul.
Hydraulic System:
Detailed diagrams, troubleshooting, repair procedures for lift, tilt, and steering hydraulic circuits, pumps, valves, cylinders, and hoses.
Electrical System:
Wiring diagrams, component locations, troubleshooting guides for starting, charging, lighting, and instrument panel systems.
Chassis And Steering:
Front and rear axle, steering linkage, wheel alignment, steering column, and power steering system repair.
Braking System:
Drum or disc brake system overhaul, hydraulic lines, master cylinder, brake adjustments, and troubleshooting.
Mast And Forks:
Inspection, maintenance, and repair of mast channels, rollers, lift chains, forks, and related hardware.
Preventive Maintenance:
Scheduled maintenance, lubrication points, fluid change intervals, filter replacement procedures.
Diagnostic Procedures:
Systematic troubleshooting flowcharts and common fault diagnosis for all major components.
Disassembly And Assembly:
Step-by-step instructions for component removal, overhaul, and reassembly.
Component Rebuilds:
Detailed instructions for rebuilding engine, transmission, hydraulic pump, and cylinders.
Diagnostic Tools:
References to necessary special tools and equipment for servicing.
Torque Specifications:
Comprehensive list of all critical torque values for fasteners.
Clearances And Tolerances:
Precise specifications for critical component clearances and wear limits.
Wiring Diagrams:
High-quality, detailed electrical schematics for easy troubleshooting.
Engine Family:
Mitsubishi 4G Series
Engine Codes Covered:
4G63, 4G64
Engine Type:
4-cylinder, inline, gasoline, spark ignition
Estimated Horsepower Range:
Typically 45-70 HP depending on specific model and tuning (actual figures vary by forklift model).
Estimated Torque Range:
Typically 80-120 lb-ft (actual figures vary by forklift model).
Fuel Delivery:
Carbureted or Electronic Fuel Injection (EFI) depending on specific variant and year.
Fuel Type:
Unleaded Gasoline
Oil Type Specification:
API Service Classification SF, SG, SH, SJ or higher; viscosity grades such as 10W-30 or 15W-40 (refer to manual for specific recommendations).
Cooling Type:
Water-cooled, pressurized system with thermostatic control.
Lift Capacity Range:
1500 kg (FGC15) to 3000 kg (FGC30) (approximate, depends on specific model variant).
Lift Height:
Varies significantly by mast configuration (e.g., 3m, 4m, 5m, 6m duplex/triplex masts).
Operating Weight:
Typically ranges from 2500 kg to 4500 kg depending on model and configuration.
Rollover Protection:
Includes operator overhead guard (OHG) and potentially integral rollover protective structure (ROPS) depending on configuration and standards.
Braking System Type:
Service brakes (hydraulic), parking brake.
Seatbelt:
Standard operator seatbelt.
Operator Presence System:
Often equipped to prevent hydraulic functions when the operator is not seated.
Operator Controls:
Basic dashboard with essential indicators (fuel level, engine temp, oil pressure, battery charge), hour meter, and lever controls for lift, tilt, and direction.
Instrumentation:
Warning lights and gauges to monitor machine health.
Telematics:
Generally not featured on models of this era, basic diagnostics rely on mechanical and electrical system inspection.
Engine Oil Change:
Typically every 250-500 operating hours or annually, depending on operating conditions (refer to manual).
Hydraulic Fluid Change:
Typically every 1000-2000 operating hours or annually (refer to manual).
Air Filter Replacement:
Check and replace as needed, typically based on operating environment (e.g., dusty conditions require more frequent checks).
Engine Coolant:
Ethylene glycol-based antifreeze mixed with distilled water, typically a 50/50 ratio (refer to manual for specific type and capacity).
Transmission Fluid Capacity:
Varies by model, typically 6-10 liters (refer to manual for exact capacity and specification).
Hydraulic Fluid Type:
ISO VG 32 or 46 hydraulic oil, or equivalent (refer to manual for specific grade and capacity).
Common Wear Items:
Lift chains, mast rollers, fork wear, hydraulic hose degradation, brake pad/shoe wear.
Engine Related:
Spark plug fouling, carburetor adjustment (on older models), cooling system leaks, exhaust leaks.
Hydraulic Related:
Slow lift speeds, hydraulic leaks, noisy hydraulic pump.
Manufacturer Focus:
Mitsubishi Heavy Industries, renowned for heavy machinery and engineering.
Series Designation:
FGC series represents a line of internal combustion engine forklifts.
Production Period:
Models generally produced from the late 1990s through the 2000s, with updates and variations.
