Mitsubishi 4G63 4G64 Gasoline Engine FG20 Forklift

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🏷️ Basic Information Identification Make: Mitsubishi Model: FG20 Forklift Truck Engine Family: 4G63/4G64 Gasoline Product Type: Workshop Service Repair Manual Codes Engine Codes Covered: 4G63, 4G64, and their specific variants...

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类型: Forklift

斯库: 509918

标签: 4G63 4G64 Cars FG20 Forklift Misc Mitsubishi

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

FG20 Forklift Truck

Engine Family:

4G63/4G64 Gasoline

Product Type:

Workshop Service Repair Manual

Codes

Engine Codes Covered:

4G63, 4G64, and their specific variants as used in the FG20 forklift.

Model Designations:

👋 Introduction

Market Position

Target Audience:

Professional forklift technicians, mechanics, fleet maintenance managers, and skilled DIY users involved in Mitsubishi FG20 forklift repair.

Competitive Analysis

Manual Value Proposition:

Offers comprehensive, step-by-step guidance essential for maintaining and repairing the specific Mitsubishi FG20 model and its associated 4G63/4G64 engines, saving time and costly errors.

Key Features

Manual Highlight Features:

Detailed engine specifications, clear diagnostic procedures, extensive wiring diagrams, and complete torque values for all critical components.

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive service, repair, and maintenance for Mitsubishi FG20 Forklift Trucks equipped with 4G63 and 4G64 gasoline engines.

Page Count

Estimated Page Count:

Manual Type

Manual Classification:

Workshop Service Manual / Repair Manual

Language

Language Provided:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Powertrain Systems:

Engine (4G63, 4G64), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System.

Drivetrain Systems:

Transmission (Automatic/Torque Converter), Drive Axle, Differential, Wheels and Tires.

Chassis Systems:

Steering System, Braking System (Hydraulic), Suspension System (Front/Rear), Hydraulic Lift System, Mast Assembly.

Electrical Systems:

Starting System, Charging System, Lighting, Instrumentation, Wiring Diagrams, Electrical Component Troubleshooting.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, lubrication points, battery maintenance, tire pressure checks.

Repair Procedures:

Engine overhaul, component disassembly and reassembly, transmission repair, brake system overhaul, hydraulic system repair, steering system repair.

Troubleshooting Guides:

Diagnostic flowcharts, fault code interpretation, common problem diagnosis and solutions for engine, transmission, hydraulic, and electrical systems.

Fuel System Repair:

Carburetor adjustment and overhaul, fuel injector testing and replacement, fuel pump diagnosis, fuel filter replacement.

Ignition System Repair:

Ignition coil testing, spark plug replacement, distributor servicing (if applicable), ignition timing adjustment.

Hydraulic Lift System Repair:

Hydraulic pump inspection and repair, cylinder seals replacement, valve body troubleshooting, hydraulic hose and fitting inspection.

Mast Assembly Service:

Inspection and adjustment of mast chains, roller wear, tilt cylinder seals, and lubrication of mast channels.

Electrical System Troubleshooting:

Wiring diagram interpretation, fuse and relay testing, alternator and starter motor diagnosis, instrument cluster troubleshooting.

Technical Depth

Diagnostic Level:

Advanced diagnostic procedures, circuit analysis, component testing, and specifications for accurate fault identification.

Rebuild Depth:

Detailed instructions for complete engine rebuilds, transmission overhauls, and major component overhauls, including torque specifications and clearances.

📊 Manual Specifications

File Format

Digital File Quality:

High-resolution scans ensuring clarity of text and diagrams, searchable text for efficient navigation.

Searchability:

Full text search functionality enabled within the PDF document.

Print Quality

Print Ready Format:

Optimized for clear printing with professional layout and legible diagrams.

Binding Type

Physical Binding Style:

N/A (Digital PDF format)

Paper Type

Physical Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Model Variants:

Mitsubishi 4G63, Mitsubishi 4G64

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific 4G63/4G64 variant.

Performance

Estimated Horsepower Range:

Typically 50-70 HP (varies by specific engine tune and forklift model configuration).

Estimated Torque Range:

Varies by specific engine tune and forklift model configuration.

Fuel System

Fuel Delivery System:

Carbureted or Fuel Injection (EFI - Electronic Fuel Injection) depending on the specific engine variant and forklift model year.

Recommended Fuel Type:

Unleaded Gasoline (Octane rating as specified by Mitsubishi).

Ignition System

Ignition Type:

Distributor-based ignition or Electronic Ignition (EI) with coil-on-plug or coil-pack, depending on the engine variant.

Cooling System

Cooling Method:

Water-cooled, typically with a belt-driven fan and thermostat.

Lubrication System

Oil Pump Type:

Gear-driven oil pump.

Engine Codes

Common Engine Codes:

Specific engine codes may vary, but typically will be a variant of 4G63 or 4G64. Refer to vehicle data plate for exact code.

Engine Layout

Cylinder Arrangement:

Inline 4-cylinder

Engine Displacement

Displacement Cc:

4G63: ~2.0L; 4G64: ~2.4L (Refer to manual for precise cc of specific engine variant).

Engine Construction

Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

🔧 Transmission

Standard

Transmission Type:

Automatic transmission (Torque converter type).

Optional

Transmission Options:

N/A (Likely standard automatic for this forklift model).

Features

Transmission Control:

Hydraulic control system for gear shifting.

Fluid Specs

Transmission Fluid Type:

Refer to manual for specific ATF (Automatic Transmission Fluid) specification, e.g., Dexron III or equivalent.

Transmission Fluid Capacity:

Refer to manual for exact capacity, typically 5-8 liters.

📐 Dimensions

Exterior

Forklift Lift Capacity:

2000 kg (approximate, for FG20 designation).

Forklift Mast Height:

Varies based on mast type (e.g., Duplex, Triplex). Refer to manual for specific dimensions.

Weights

Forklift Operating Weight:

Typically 3,500 - 4,500 kg, depending on configuration.

🛡️ Safety Features

Ratings

Safety Standards Compliance:

Adherence to relevant industrial safety standards (e.g., ANSI B56.1, ISO 3691).

Active Features

Braking System Type:

Hydraulic drum brakes or disc brakes, depending on model configuration. Parking brake typically mechanically operated.

Passive Features

Operator Protection:

Overhead guard (OHG) as standard. Seat belt may be optional or standard depending on year and region.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic forklift instrumentation: hour meter, fuel gauge, warning lights).

Driver Assistance

Driver Assistance Features:

N/A (Focus is on mechanical and hydraulic operation).

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Typically every 250-500 operating hours, or as recommended by Mitsubishi for specific operating conditions. Refer to manual for precise intervals.

Air Filter Replacement Interval:

Replace as needed, based on operating environment (e.g., dusty conditions). Recommended inspection every 250 hours.

Transmission Fluid Change Interval:

Typically every 1000-2000 operating hours. Refer to manual for precise intervals and inspection criteria.

Spark Plug Replacement Interval:

Typically every 500-1000 operating hours, or as indicated by engine performance. Refer to manual for specific plug type and gap.

Fluid Specifications

Engine Oil Specification:

API SG or higher, SAE 10W-30 or 15W-40. Refer to manual for exact specification and viscosity based on ambient temperature.

Engine Coolant Type:

Ethylene Glycol based antifreeze/coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type and capacity.

Hydraulic Fluid Type:

ISO VG 32 or VG 46 Hydraulic Oil, or specific Type-C fluid. Refer to manual for exact specification and capacity.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (if hydraulic brakes are used). Refer to manual for exact specification.

Known Issues

Common Engine Issues:

Carbon buildup in combustion chambers, valve seal wear, timing belt wear (if applicable to specific 4G6 variant), carburetor/injector issues, cooling system leaks.

Common Transmission Issues:

Slipping gears, delayed engagement, torque converter issues, hydraulic fluid leaks.

Common Forklift Issues:

Hydraulic system pressure loss, mast chain wear, brake fade, tire wear, electrical harness degradation.

📚 Vehicle History

Brand Heritage

Mitsubishi Heavy Industries Context:

Mitsubishi Heavy Industries is a diversified manufacturing company with a long history in industrial equipment, including forklifts.

Model Evolution

Fg Series Evolution:

The FG series represents Mitsubishi's line of internal combustion engine (ICE) forklifts, often utilizing reliable automotive-derived engines like the 4G6 series for cost-effectiveness and parts availability.

Production

Estimated Production Years:

The 4G63/4G64 engines were widely used in Mitsubishi vehicles and industrial applications from the late 1980s through the 2000s. Specific FG20 forklift production years may vary.