Engine Mechanical:
Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system, ignition system, emissions control system.
Engine Electrical:
Starter system, charging system (alternator), ignition system diagnostics, wiring diagrams, sensor testing.
Transmission:
Service and repair of the forklift's transmission system (likely automatic or hydrostatic, specific details dependent on FG30 configuration).
Hydraulic System:
Operation, troubleshooting, and repair of the hydraulic lift and tilt mechanisms, steering hydraulics.
Chassis And Frame:
Frame inspection, maintenance, and repair, including mounting points for major components.
Steering System:
Components, operation, and service procedures for the steering mechanism.
Braking System:
Inspection, maintenance, and repair of the forklift's braking system (e.g., drum, disc, parking brake).
Electrical And Instrumentation:
Dashboard instrumentation, warning lights, battery system, lighting, and related wiring.
Cooling System:
Radiator, fan, water pump, thermostat, coolant specifications, and flushing procedures.
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor (if applicable), or fuel injection system diagnostics.
Lubrication System:
Oil pump, oil filter, oil pan, oil specifications, and lubrication points.
Exhaust System:
Muffler, exhaust pipes, and emissions control components.
Routine Maintenance:
Scheduled maintenance tasks, fluid checks and changes, filter replacements, greasing.
Troubleshooting:
Diagnostic charts, common problems and their solutions, symptom-based troubleshooting.
Repair And Overhaul:
Detailed step-by-step instructions for component disassembly, repair, and reassembly, including engine rebuilds.
Component Replacement:
Procedures for replacing major components like the engine, transmission, hydraulic pump, cylinders, etc.
Adjustment And Calibration:
Procedures for adjusting brakes, clutch (if applicable), engine timing, hydraulic pressures, etc.
Electrical Diagnostics:
Testing of electrical circuits, components, and troubleshooting using wiring diagrams.
Safety Precautions:
Essential safety guidelines for operating and servicing the forklift.
Diagnostic Capabilities:
Advanced diagnostics covering engine performance, hydraulic system operation, and electrical fault finding.
Rebuild Scope:
Comprehensive instructions for complete engine and major component rebuilds, including tolerances and specifications.
Troubleshooting Methodology:
Systematic approaches to identifying and resolving mechanical, hydraulic, and electrical issues.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Engine Model 1:
Mitsubishi 4G63
Engine Model 2:
Mitsubishi 4G64
Engine Configuration:
Inline 4-cylinder, SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific variant and application.
Bore X Stroke 4G63 Approx:
85.0 mm x 88.0 mm (varies slightly by specific 4G63 variant)
Bore X Stroke 4G64 Approx:
86.5 mm x 92.0 mm (varies slightly by specific 4G64 variant)
Displacement 4G63 Approx:
2.0 Liters (1997 cc)
Displacement 4G64 Approx:
2.4 Liters (2351 cc)
Fuel Type:
Gasoline (Unleaded)
Horsepower Rating:
Varies by specific engine tune and forklift model, typically in the range of 50-70 HP for industrial applications.
Torque Rating:
Varies by specific engine tune and forklift model, optimized for low-end torque for lifting applications.
Fuel Delivery:
Likely Carbureted or single-point/multi-point fuel injection, depending on the specific forklift model year and emission standards.
Ignition System:
Electronic ignition (distributorless or distributor-based).
Engine Oil Change:
Typically every 250-500 operating hours, or every 6-12 months, depending on operating conditions.
Air Filter Replacement:
Check every 250 hours, replace as needed or every 500-1000 hours.
Fuel Filter Replacement:
Typically every 500-1000 operating hours, or as per manual recommendation.
Transmission Fluid Change:
Refer to specific manual, usually around 1000-2000 operating hours.
Engine Oil Viscosity:
API SJ or SL, SAE 10W-30 or 15W-40 (confirm specific engine variant and operating temperature recommendations).
Engine Oil Capacity:
Approx. 4.0 - 4.5 Liters (4.2 - 4.8 Quarts) for 4G63/4G64 engines (confirm exact capacity in manual).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.
Transmission Fluid Type:
Dexron III or equivalent ATF (Automatic Transmission Fluid) for torque converter transmissions, or specific hydraulic fluid for hydrostatic systems.
Engine Wear:
Potential for piston ring wear, valve guide wear, and cylinder head gasket leaks in high-hour engines.
Cooling System:
Overheating issues due to radiator blockages, faulty thermostat, or worn water pump are common in heavy-duty applications.
Hydraulic System:
Leaks from hoses, seals, or the hydraulic pump; loss of lift/tilt power can indicate pump wear or pressure issues.
Electrical System:
Corrosion on electrical connectors, starter motor issues, and alternator failure can occur with age and exposure.
