🏷️ 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....