🏷️ Basic Information Identification Make: Mitsubishi Model: FGC Series Forklift Truck Covered Models: FGC15, FGC18, FGC20, FGC20HP, FGC25HP, FGC30 Product Type: Service Repair Workshop Manual Codes Engine Code: 4G63, 4G64 (Gasoline) 👋 Introduction Market Position Industry Segment: Internal Combustion Engine (ICE) Counterbalance Forklift Trucks Application Focus: Designed for material handling in warehouses, manufacturing, and logistics environments. Competitive Analysis Key Competitors: Toyota, Hyster, Yale, Komatsu, Caterpillar (in the forklift market). Key Features 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. 📋 Manual Details Coverage Areas Systems Covered: Engine, Drivetrain, Hydraulic System, Electrical System, Chassis, Steering, Braking System, Operator Compartment, Mast Assembly, Cooling System, Fuel System, Lubrication System, Troubleshooting, Maintenance Page Count Estimated Page Count: Estimated 800+ pages (typical for comprehensive service manuals) Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval. Print Quality Print Quality: High-resolution, suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Family: Mitsubishi 4G Series Engine Codes Covered: 4G63, 4G64 Engine Type: 4-cylinder, inline, gasoline, spark ignition Performance 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 System Fuel Delivery: Carbureted or Electronic Fuel Injection (EFI) depending on specific variant and year. Fuel Type: Unleaded Gasoline Lubrication 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 System Cooling Type: Water-cooled, pressurized system with thermostatic control. 🔧 Transmission Standard Transmission Type: Automatic (likely torque converter type) Optional Optional Transmission: Typically single-speed or two-speed forward/reverse for forklifts. Features Transmission Fluid: Automatic Transmission Fluid (ATF) - specific type like Dexron II/III or equivalent required (refer to manual). 📐 Dimensions Exterior 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). Weights Operating Weight: Typically ranges from 2500 kg to 4500 kg depending on model and configuration. 🛡️ Safety Features Ratings Rollover Protection: Includes operator overhead guard (OHG) and potentially integral rollover protective structure (ROPS) depending on configuration and standards. Active Features Braking System Type: Service brakes (hydraulic), parking brake. Passive Features Seatbelt: Standard operator seatbelt. Operator Presence System: Often equipped to prevent hydraulic functions when the operator is not seated. 💡 Technology Features Infotainment 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. Driver Assistance Instrumentation: Warning lights and gauges to monitor machine health. Connectivity Telematics: Generally not featured on models of this era, basic diagnostics rely on mechanical and electrical system inspection. 🔧 Maintenance Service Intervals 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). Fluid Specifications Engine Coolant: Ethylene glycol-based antifreeze mixed with distilled water, typically a...