🏷️ Basic Information

Make:

Mitsubishi

Model:

Forklift Truck

Engine Type:

Gasoline

Engine Model Designations:

K21, K25

Manual Product Name:

Mitsubishi K21 & K25 Gasoline Engine Forklift Truck Complete Workshop Service Repair Manual

👋 Introduction

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.

Value Proposition:

Offers a cost-effective and efficient solution for in-house or external repair and maintenance, reducing reliance on expensive dealer services.

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

General Coverage:

Complete Service & Repair Procedures

Estimated Page Count:

Variable (Estimate: 500-1000+ pages depending on specific forklift models covered)

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (e.g., PDF)

📖 Manual Coverage

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.

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.

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:

PDF

Searchability:

Searchable text for quick information retrieval.

Print Quality:

High-resolution scans suitable for clear printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Series:

Mitsubishi K Series Gasoline

Engine Model K21 Displacement:

2.1 Liters (Approximate)

Engine Model K25 Displacement:

2.5 Liters (Approximate)

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 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

Transmission Type:

Typically a 1 or 2-speed automatic transmission specifically designed for forklift applications (e.g., hydrostatic or torque converter based).

Optional Transmission:

Manual transmission (less common in modern forklifts of this engine class).

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

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).

Operating Weight:

Variable, typically between 5,000 - 9,000 lbs depending on configuration.

🛡️ Safety Features

Operator Protection:

Operator overhead guard (OHG) is standard. Rollover protection (ROPS) may be present on some models/configurations.

Braking System Type:

Typically hydraulic drum brakes or disc brakes for service brakes, parking brake often mechanical.

Seatbelt:

Operator seatbelt is crucial safety equipment.

💡 Technology Features

Infotainment Features:

Basic instrumentation (hour meter, fuel gauge, warning lights). No complex infotainment systems typical of passenger vehicles.

Driver Assistance Features:

Minimal. Focus is on functional operator controls for lift, tilt, steering, and drive.

Connectivity Features:

N/A. No telematics or connectivity typically found on forklifts of this era/class.

🔧 Maintenance

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.

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.

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

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.

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.

Typical Production Years:

These engines have been utilized in forklift models produced from the late 1990s through the 2010s, with variations and updates.

🏆 Awards & Recognition

Industry Recognition:

Mitsubishi engines are generally recognized for their durability and suitability for demanding industrial applications.

Reliability Rating:

Known for robust construction and reliable performance when properly maintained.

Emission Standards:

Compliance with relevant emission standards for internal combustion engines applicable during their production years.