Basic Information Identification Make: Mitsubishi Model: Forklift Truck Engine Type: Gasoline Engine Model Designations: K21, K25 Codes Manual Product Name: Mitsubishi K21 & K25 Gasoline Engine Forklift Truck Complete Workshop Service Repair Manual Introduction Market Position Target User: Forklift technicians, mechanics, service departments, equipment owners, maintenance personnel. Purpose: To provide comprehensive guidance for the maintenance, troubleshooting, and repair of Mitsubishi K21 and K25 engine forklift trucks. Competitive Analysis Value Proposition: Offers a cost-effective and efficient solution for in-house or external repair and maintenance, reducing reliance on expensive dealer services. Key Features Detail Level: In-depth technical information beyond basic owner's manuals. Coverage: Covers multiple forklift models and configurations utilizing the K21 and K25 gasoline engines. Manual Details Coverage Areas General Coverage: Complete Service & Repair Procedures Page Count Estimated Page Count: Variable (Estimate: 500-1000+ pages depending on specific forklift models covered) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (e.g., PDF) Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, disassembly, assembly, component testing, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (carburetor/injection), ignition system, timing system, exhaust system. Transmission Powertrain: Manual and automatic transmission (if applicable), torque converter, drive axle, differential, gearbox, clutch system, hydraulic transmission components, transmission fluid specifications and procedures. Hydraulic System: Hydraulic pump, control valve, cylinders (lift, tilt, side-shift), hydraulic fluid types and capacities, troubleshooting hydraulic leaks, pressure testing, hose and fitting specifications. Electrical System: Wiring diagrams, starter system, alternator/charging system, battery maintenance, lighting system, instrumentation, fuses, relays, ignition switch, sensors, troubleshooting electrical faults. Chassis And Frame: Frame inspection and repair, steering system, braking system (hydraulic, drum/disc), suspension components, tire and wheel specifications, lubrication points. Mast And Attachments: Mast assembly (inner, outer, intermediate masts), lift chains, rollers, mast tilt mechanism, side shift mechanism, fork care and inspection, mast lubrication. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), spark plug service, fluid level checks and top-ups, lubrication schedules, battery maintenance. Troubleshooting: Diagnostic charts, common problem identification, step-by-step troubleshooting guides for various systems (engine, hydraulic, electrical, transmission). Major Repairs: Engine rebuilds, transmission overhaul, hydraulic component replacement, brake system overhauls, steering system repair, mast component replacement. Component Disassembly And Assembly: Detailed instructions for taking apart and putting back together major components with torque specifications and procedures. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, fault code interpretation (if applicable), performance testing of key components. Rebuild Procedures: Comprehensive instructions for complete component rebuilding, including machining specifications and tolerances. Specifications And Tolerances: Exact torque values for fasteners, critical component clearances, material specifications, and testing parameters. Manual Specifications File Format File Format: PDF Searchability: Searchable text for quick information retrieval. Print Quality Print Quality: High-resolution scans suitable for clear printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Series: Mitsubishi K Series Gasoline Engine Model K21 Displacement: 2.1 Liters (Approximate) Engine Model K25 Displacement: 2.5 Liters (Approximate) Performance Horsepower Range: Variable based on specific forklift model and tuning, typically in the 40-60 HP range for these engines. Torque Range: Variable, designed for industrial torque delivery. Fuel System Fuel Type: Gasoline (Petrol) Induction System: Typically carbureted, but later models may utilize electronic fuel injection (EFI). Ignition System: Distributor-based or distributorless ignition system (DIS). Transmission Standard Transmission Type: Typically a 1 or 2-speed automatic transmission specifically designed for forklift applications (e.g., hydrostatic or torque converter based). Optional Optional Transmission: Manual transmission (less common in modern forklifts of this engine class). Features Transmission Fluid Type: Refer to manual for specific ATF type (e.g., DEXRON-III, MERCON, or manufacturer-specific). Transmission Cooling: Often integrated with the main vehicle cooling system or a separate transmission cooler. Dimensions Exterior Forklift Class: Class IV (Cushion Tire) or Class V (Solid Tire) Forklifts are common for these engines. Load Capacity: Highly variable depending on the forklift chassis and mast configuration (e.g., 3,000 lbs to 6,000 lbs). Weights Operating Weight: Variable, typically between 5,000 - 9,000 lbs depending on configuration. Safety Features Ratings Operator Protection: Operator overhead guard (OHG) is standard. Rollover protection (ROPS) may be present on some models/configurations. Active Features Braking System Type: Typically hydraulic drum brakes or disc brakes for service brakes, parking brake often mechanical. Passive Features Seatbelt: Operator seatbelt is crucial safety equipment. Technology Features Infotainment Infotainment Features: Basic instrumentation (hour meter, fuel gauge, warning lights). No complex infotainment systems typical of passenger vehicles. Driver Assistance Driver Assistance Features: Minimal. Focus is on functional operator controls for lift, tilt, steering, and drive. Connectivity Connectivity Features: N/A. No telematics or connectivity typically found on forklifts of this era/class. Maintenance Service Intervals Engine Oil Change: Typically every 250-500 operating hours or annually, refer to manual for exact intervals. Air Filter Replacement: Check regularly, replace as needed or at specified intervals (e.g., 500 hours). Fuel Filter Replacement: Replace as per manual recommendations, typically annually or every 1000 hours. Transmission Fluid Change: Refer to manual, typically every 1000-2000 operating hours. Fluid Specifications Engine Oil Viscosity: Commonly SAE 10W-30 or SAE 15W-40 API CD/CF or higher. Refer to manual for exact specification. Coolant Type: Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with water. Refer to manual for specific type and capacity. Known Issues Engine Overheating: Common in heavy-duty use; check cooling system, thermostat, water pump, and radiator. Hydraulic System Performance: Loss of lift speed or erratic operation can indicate pump wear, leaks, or low fluid levels. Brake Fade: Can occur with heavy use; requires inspection of brake pads/shoes, drums/rotors, and hydraulic system. Transmission Slipping: May indicate low fluid, worn clutches, or torque converter issues. Vehicle History Brand Heritage Manufacturer History: Mitsubishi Heavy Industries (MHI) and its subsidiary UniCarriers (formerly TCM and Nichiyu) are major players in the forklift industry, known for reliable industrial equipment. Model Evolution Engine Application: The K21 and K25 gasoline engines have been widely used in compact to medium-duty internal combustion engine (ICE) forklifts for various industrial and commercial applications. Production Typical Production Years: These engines have been utilized in forklift models produced from the late...