1997-up Mitsubishi FG10-FG35A & FD10-FD35A Forklift Chassis & Mast Service Manual (P/N 99719-11400)

Mitsubishi’s Chassis & Mast Service Manual, publication 99719-11400, covers the listed 1997–up FG10–FG35A and FD10–FD35A forklifts within the serial-number ranges above. It provides service and repair procedures for the chassis, mast, drivetrain, hydraulics, and electrical systems.

PDF Bookmarks, Diagram Detail, and Page Count

Search and schematic access: Text search is unavailable in the manual pages; only the feedback form has searchable text. Embedded bookmarks use file-code labels and link to the main sections and electrical schematics. Small connector numbers and wire codes in the gasoline and diesel wiring diagrams require zooming.

One printable PDF contains 377 pages total, including 17 blank pages and a one-page technical-publications feedback form.

Transmission, Hydraulic, and Mast Repair Coverage

• Clutches and manual transmission: Dry- and wet-type clutch service, pressure-plate inspection, hydraulic bleeding, synchronizer inspection, and transmission shim adjustment.

• Powershift transmission: Clutch-pack, pump, and control-valve overhaul, hydraulic pressure testing, inching adjustment, stall-speed testing, and start-acceleration checks.

• Axles and steering: Front and rear axle service, differential tooth-contact adjustment, bearing preload checks, steering-gear overhaul, and power-cylinder repair.

• Brake system: Master- and wheel-cylinder overhaul, automatic adjuster inspection, drum-to-lining adjustment, pedal setup, bleeding, and brake testing.

• Hydraulic system: Gear-pump and control-valve service, lift- and tilt-cylinder rebuilding, relief-valve adjustment, flow-regulator inspection, and load-drift testing.

• Mast and forks: Simplex, duplex, and triplex mast disassembly, chain-tension adjustment, roller selection, shim replacement, fork inspection, and cylinder-stroke matching.

• Electrical troubleshooting: Gasoline and diesel wiring diagrams, switch connection charts, console and combination-meter service, and starter, lighting, gauge, and battery fault tables.

Suited to forklift technicians familiar with drivetrain overhaul, hydraulic testing, and the use of lifting equipment and special service tools.

Powertrain Repair and Transmission Diagnosis

Step-by-step procedures cover engine-and-transmission removal and installation, with separate details for gasoline, diesel, manual-transmission, and powershift configurations. The split input-shaft design also permits clutch-disc and release-bearing service without removing the complete powertrain; clutch-shaft removal requires the assembly to be dismounted.

Engine and attachment scope: Internal engine service and attachment repair require separate manuals. The foreword identifies companion manuals for the 4G15, 4G63/4G64, S4Q2, and S4S engines; these publications are not included.

The powershift troubleshooting chart connects pressure readings, stall speed, and the 10-m start-acceleration test to likely faults. It distinguishes checks that can be made with the transmission installed from faults requiring removal, supporting repair planning before disassembly.

For the wet-type clutch, insufficient pedal free play can keep the master-cylinder return port covered, causing clutch slip and premature facing wear. The powershift section separately explains how incorrect inching linkage adjustment can cause poor braking, overheating, or clutch-disc seizure.

Axle, Brake, and Steering Service

Differential instructions distinguish the one-piece cases used in the smaller trucks from the two-piece cases in FG/FD30 and 35A models. Tooth Contact Patterns and Adjustment illustrates how gear-contact location relates to pinion shimming and backlash.

Brake coverage includes primary and secondary shoes, parking-brake cables, and side-specific automatic adjusters. Steering procedures extend to the recirculating-ball gear, control valve, power cylinder, and post-assembly checks.

Hydraulic and Mast Service

The Hydraulic Circuit Diagram shows the steering-priority flow divider, lift and tilt circuits, flow regulator, and down safety valve. Cylinder drawings identify seal-kit parts and distinguish the first and second cylinders used in full-free-lift masts.

Mast instructions address lift-bracket and mast clearances, roller sizes, chain anchors, and matching cylinder strokes. Duplex second lift cylinders have bleeding valves; the other described internal-drain lift cylinders are treated differently.

Always properly block the mast and relieve hydraulic pressure before opening lines or performing system tests.

Electrical Diagrams and Workshop References

Separate Electrical System Schematics cover gasoline and diesel trucks, with Lighting Switch Connection Charts and F-N-R Lever Switch Connection Charts. Exploded console, steering, and mast drawings support component identification alongside disassembly-sequence illustrations.

Cooling coverage includes fan-belt removal, inspection, and tension adjustment. Service references provide maintenance and lubrication charts, engine-oil capacities, component-specific tightening torques, cylinder clearances, and clutch wear limits. The special-tool section identifies equipment such as clutch gauge 91268-02200 and pressure gauge kit 64309-17701.

Selected Valve-Clearance and Hydraulic Specifications

The 4G15 specification table lists intake-valve clearance at 0.20 mm with the engine hot. This is reference data; internal engine procedures belong to the companion engine manual.

For the powershift pressure test, main and clutch pressure are specified at 883–1,079 kPa with engine speed at 1,500 ±100 rpm.

The FG35A hydraulic-tank table gives approximate capacities of 40.1 liters at the N mark and 45.1 liters at the H mark, distinguishing the two gauge levels.