🏷️ Basic Information

Make:

Mitsubishi

Model:

Forklift Truck (FG Series)

Engine Code:

4G63, 4G64

Specific Models Covered:

FG20, FG25, FG30, FG35A

Powertrain Type:

Gasoline Engine

👋 Introduction

Market Niche:

Essential for owners, operators, and maintenance technicians of Mitsubishi FG series forklifts equipped with 4G63 and 4G64 engines.

Value Proposition:

Provides comprehensive, in-depth technical information critical for maintaining and repairing these industrial vehicles, often scarce in general repair manuals.

Completeness:

Covers all aspects of service and repair for the specified forklift models and engines.

Technical Accuracy:

Based on factory specifications and procedures, ensuring accurate repairs.

📋 Manual Details

Manual Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable (implied PDF)

Page Count:

Estimated (Comprehensive Coverage)

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair of the 4G63 and 4G64 gasoline engines.

Fuel System:

Carburetor/injection system diagnosis, repair, and adjustment; fuel pump, fuel lines, and filter service.

Ignition System:

Spark plugs, ignition coils, distributor (if applicable), timing adjustment, and related components.

Cooling System:

Radiator, water pump, thermostat, hoses, fan, and coolant specifications.

Lubrication System:

Oil pump, oil pan, oil filter, oil pressure checks, and lubrication specifications.

Exhaust System:

Muffler, exhaust manifold, catalytic converter (if equipped), and emission control components.

Transmission Hydraulic System:

Torque converter, transmission fluid, filter replacement, and hydraulic circuit diagnosis.

Hydraulic Lift System:

Hydraulic pump, cylinders, control valves, hoses, and fluid maintenance for lifting operations.

Steering System:

Steering column, linkage, power steering pump (if equipped), and fluid specifications.

Braking System:

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

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting, wiring diagrams, and fuse/relay locations.

Chassis And Frame:

Frame inspection, suspension components, drive axle, and steering linkage.

Operator Compartment:

Dashboard, controls, seating, and safety features.

Preventive Maintenance:

Scheduled inspections, fluid changes, filter replacements, lubrication, and safety checks.

Troubleshooting Diagnostics:

Systematic fault finding and diagnostic procedures for common and complex issues.

Engine Overhaul:

Complete engine rebuild procedures, including component specifications and tolerances.

Transmission Repair:

Internal transmission component replacement and adjustment.

Hydraulic System Repair:

Leak diagnosis, component replacement, and pressure testing.

Brake System Overhaul:

Complete brake system servicing and replacement of wear items.

Electrical Component Replacement:

Alternator, starter motor, ignition system components, and sensors.

Wiring Diagram Interpretation:

Detailed schematics for electrical system troubleshooting.

Diagnostic Tools:

Mentions of necessary tools and equipment for diagnostics and repair.

Service Specifications:

Torque values, clearances, fluid capacities, and other critical specifications.

Rebuild Instructions:

Step-by-step instructions for major component overhauls.

Troubleshooting Charts:

Flowcharts and tables for diagnosing specific problems.

📊 Manual Specifications

File Format:

Digital Download (PDF)

Print Quality:

High-resolution, clear diagrams and text for easy reading and printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Model 1:

Mitsubishi 4G63

Engine Model 2:

Mitsubishi 4G64

Engine Type:

Inline 4-Cylinder, SOHC/DOHC (depending on specific variant, manual should clarify)

Bore Stroke 4G63:

Typically 85.0 mm x 88.0 mm (manual will provide exact specifications)

Displacement 4G63:

Approximately 2.0 Liters (1997 cc) (manual will confirm)

Bore Stroke 4G64:

Typically 86.5 mm x 92.0 mm (manual will provide exact specifications)

Displacement 4G64:

Approximately 2.4 Liters (2351 cc) (manual will confirm)

Compression Ratio:

Varies by specific engine variant and application (manual will specify)

Fuel Delivery:

Carbureted or Electronic Fuel Injection (EFI), depending on forklift model and year (manual will detail specific system).

Fuel Type:

Unleaded Gasoline

Octane Rating:

Refer to manual for recommended octane rating and any altitude adjustments.

🔧 Transmission

Transmission Type:

Automatic Transmission (Torque Converter type) specific to forklift applications.

Optional Transmission:

Not typically offered as an option on these specific forklift models; standard automatic transmission is expected.

Transmission Fluid Type:

Specific Automatic Transmission Fluid (ATF) type required (manual will specify exact specification and capacity).

Transmission Cooling:

Integrated transmission fluid cooler, likely part of the main radiator assembly.

📐 Dimensions

Lift Capacity Fg20:

Approx. 2000 kg (4,000 lbs)

Lift Capacity Fg25:

Approx. 2500 kg (5,000 lbs)

Lift Capacity Fg30:

Approx. 3000 kg (6,000 lbs)

Lift Capacity Fg35A:

Approx. 3500 kg (7,000 lbs)

Operating Weight:

Varies by model and configuration; manual will provide specific weights for each model.

🛡️ Safety Features

Safety Standards:

Designed to meet relevant industrial forklift safety standards (e.g., OSHA, ANSI B56.1); manual details specific safety procedures.

Operator Presence System:

Likely includes an operator presence system to prevent operation when the operator is not seated.

Parking Brake:

Mechanical parking brake system for secure immobilization.

Overhead Guard:

Standard overhead protective structure (OPS) for operator safety.

Seatbelt:

Operator seatbelt for restraint.

💡 Technology Features

Infotainment Features:

Basic operator instrumentation (engine temperature, oil pressure, fuel level, hour meter). No advanced infotainment systems expected.

Driver Assistance Features:

Limited to essential operational controls and safety indicators. No electronic driver-assistance systems like adaptive cruise control or lane keeping assist.

Connectivity Features:

None; these are industrial vehicles designed for core functionality.

🔧 Maintenance

Engine Oil Change Interval:

Typically 250-500 operating hours, or annually, whichever comes first (refer to manual for precise interval).

Transmission Fluid Filter Change:

Often coincides with engine service intervals or as recommended by the manufacturer (manual will specify).

Air Filter Replacement:

Inspect every 250 hours, replace as needed or annually.

Fuel Filter Replacement:

Inspect and replace as needed, often annually or per manufacturer recommendation.

Engine Oil Type:

API Service SG or higher, SAE 10W-30 or 10W-40 recommended for most ambient temperatures (manual will provide exact spec).

Engine Oil Capacity:

Approximately 4.0 - 4.5 Liters (refer to manual for exact capacity).

Coolant Type:

Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio recommended) (manual will specify approved types).

Common Engine Wear:

Potential for oil consumption due to worn piston rings or valve stem seals in higher mileage units; timing belt wear (if belt driven, manual confirms).

Hydraulic System Leaks:

Common in older forklifts due to seal wear in cylinders, pumps, or hoses.

Cooling System Overheating:

Can be caused by clogged radiator fins, faulty thermostat, or water pump failure.

Transmission Slipping:

May indicate low fluid level, worn clutch packs, or internal hydraulic issues.

📚 Vehicle History

Manufacturer Reputation:

Mitsubishi Forklift Trucks (now part of Mitsubishi Logisnext) has a long-standing reputation for durable and reliable material handling equipment.

Series Context:

The FG series represents a range of internal combustion engine (ICE) forklifts, popular for their robustness and adaptability in various industrial environments.

Production Period:

The 4G63/4G64 engines and FG series forklifts have been in production across multiple decades. Manual likely covers models from the late 1980s through the 2000s and potentially early 2010s.

🏆 Awards & Recognition

Industry Recognition:

While specific awards for these forklift models are not widely publicized, Mitsubishi Forklift Trucks consistently rank high in customer satisfaction and reliability surveys within the material handling industry.