Mitsubishi K21 Manual de usuario

K21

K25

Service Manual

K21, K25 Gasoline Engine

For use with FG15N-FG35N

Chassis Service Manual. 99789-57100

FOREWORD

This service manual covers K21 and K25 Gasoline Engine of Mitsubishi Forklift Trucks and

gives detailed maintenance and repair information. The instructions are grouped by systems to be

a convenient reference.

Long productive life of your forklift trucks depends to a great extent on correct servicing – the

servicing consistent with what you will learn from this service manual. Read the respective

sections of this manual carefully and become familiar with all the truck components before

attempting any work.

All descriptions, illustrations, specifications, and serial numbers in this manual are effective as of

the printed date of this manual. Mitsubishi reserves the right to change specifications or designs

without notice and without incurring obligations.

Pub. No. 99789-57100

GROUP INDEX Items

GENERAL INFORMATION

HOW TO USE THIS MANUAL, PRECAUTIONS FOR SAFETY AND

QUALITY, PRECAUTIONS, TIGHTENING TORQUE,

SPECIAL SERVICE TOOLS, ENGINE OUTSIDE DRAWINGS, MAIN

SPECIFICATIONS, STANDARD AND REPAIR LIMIT, STAMPED LOCA-

TION OF ENGINE NO., TROUBLE DIAGNOSIS

MAINTENANCE

ENGINE MAINTENANCE

ENGINE TUNE-UP

SPECIFICATIONS, TIGHTENING TORQUE, TROUBLE DIAGNO-

SIS, ENGINE INSPECTION AND ADJUSTMENT

ENGINE MECHANICAL

PRECAUTIONS, ENGINE OUTSIDE DRAWINGS, MAIN SPECI-

FICATIONS, ADJUSTMENT VALUE, TIGHTENING TORQUE,

TROUBLEDIAGNOSIS,SPECIALSERVICE TOOLS,REMOVAL

AND INSTALLATION OF ENGINE, ENGINE SERVICE

ENGINE CONTROL

PRECAUTIONS, PREPARATION, DESCRIPTION, TROUBLE

DIAGNOSIS, BASIC INSPECTION, COMPONENT PARTS

INSPECTION, PCV GAS RECIRCULATION DEVICE, ECM COM-

PONENTS

ENGINE LUBRICATION

& COOLING SYSTEM

LUBRICATION SYSTEM, ENGINE COOLANT SYSTEM

ENGINE FUEL

EMISSION CONTROL SYSTEM, ENGINE OUTSIDE DRAW-

INGS,SYSTEMDIAGRAM,UNITLAYOUT,SERVICEDATA AND

SPECIFICATIONS (SDS), LPG FUEL SYSTEM TROUBLE DIAG-

NOSIS, DISASSEMBLY AND ASSEMBLY OF FUEL SYSTEM,

DISASSEMBLY AND ASSEMBLY OF VAPORIZER

ENGINE ELECTRICAL

ADJUSTMENT VALUE, TROUBLE DIAGNOSIS, STARTER

MOTOR, ALTERNATOR

GROUP INDEX

CONTENTS

HOW TO USE THIS MANUAL ............................. GI-2

Description ...................................................... GI-2

Definition of Terms ..........................................GI-2

Definition of Units ............................................GI-2

Description ...................................................... GI-2

PRECAUTIONS FOR SAFETY AND QUALITY ..GI-3

Safe Operation ................................................GI-3

Correct Operation ............................................GI-4

Precautions for Radio Equipment Installation .GI-4

PRECAUTIONS ................................................... GI-5

Precautions in Draining Engine Coolant ..........GI-5

Precautions for Disconnecting Fuel Piping ...... GI-5

Precautions for Removing and Disassembling GI-5

Precautions for Inspection, Correction, and

Replacement ................................................... GI-5

Precautions for Assembly and Installation ...... GI-5

Parts Requiring Angle Tightening .................... GI-6

Caution with Use of Power Tools .................... GI-6

Precautions for Liquid Gasket Application ....... GI-6

TIGHTENING TORQUE ....................................... GI-7

Standard Bolt Tightening Torque .................... GI-7

Engine Part Tightening Torque ....................... GI-8

SPECIAL SERVICE TOOLS .............................. GI-10

ENGINE OUTSIDE DRAWINGS ........................ GI-11

MAIN SPECIFICATIONS ................................... GI-12

STANDARD AND REPAIR LIMIT ..................... GI-15

STAMPED LOCATION OF ENGINE NO. .......... GI-19

TROUBLE DIAGNOSIS ..................................... GI-20

Engine Adjustment ........................................ GI-21

Engine LPG Fuel System .............................. GI-26

GENERAL INFORMATION

SECTION

GI GI

HOW TO USE THIS MANUAL

Description

This manual explains how to use “removal, installation, disassembly,

assembly, inspection and adjustment” and “diagnosis.”

Definition of Terms

WARNING: Instructions and precautions that may lead to fatal

hazards and/or serious injuries if not observed properly.

CAUTION: Instructions and precautions that require special

attention and may lead to problems and/or accidents as

well as damages to the vehicle and/or components.

NOTE: Provides additional information that facilitates

operation.

Standard: Indicates tolerances for inspection and adjustment.

Repair limit: Indicates maximum or minimum values allowed for

inspection and adjustment.

Definition of Units

The units and numerical values in this Standard are SI units, and

those given in ( ) in this Standard are based on the conventional unit

system and are appended for informative reference.

Example: Tightening torque 59 - 78 N·m (6.0 - 8.0 kgf-m)

SI (Metric system)

Main unit changes

* The conventional unit can be used for SI.

Description

Caution: At the beginning of each section, the precautions

exclusive to the section are described.

Preparation: At the beginning of each section and during the trouble

diagnosis items, the Special Tools (STs), gauges, and

other tools to be prepared before operation are

described. Some commercial service tools, assumed to

be available in any workshop, are omitted.

Description: To perform correct operations, operational procedures,

notes, STs, and other service information are

described.

CAUTION: Descriptions of visual inspections and cleaning of

removed parts are generally omitted. Please remember

that actual operations require these processes.

Measure SI Conventional unit Conversion factor to SI

Acceleration m/s2G 9.80665

Torque, moment N•m kgf-m 9.80665

Force N kgf 9.80665

Pressure MPa kgf/cm20.0980665

kPa mmHg 0.133322

Power efficiency kW PS 0.735499

W kcal/h 1.16279

Volume cm3cc 1

Spring constant N/mm kgf/mm 9.80665

Fuel consumption *g/kW•h g/PS•h 1.3596

GI-2

HOW TO USE THIS MANUAL

PRECAUTIONS FOR SAFETY AND QUALITY

• The following precautions must be carefully observed for safe

and appropriate service work.

• Only qualified and designated personnel must perform

inspections, repairs and adjustments.

• Always keep the workplace clean, and store tools neatly in

specified places.

Safe Operation

• Do not run engines inside the workshop without proper

ventilation (ex. no ventilation ducts).

• Keep the workshop well ventilated and free of any flammable

materials. Special care should be taken when flammable or

poisonous materials such as gasoline are handled.

• Discard waste oil after oil changes or parts treatment in

accordance with local laws and regulations.

• Be careful of burns and injury when working on high-

temperature parts, rotating parts, or sliding portions.

• When working in a pit or enclosed area, ensure that adequate

ventilation is provided for discharging any hazardous emissions.

• Do not work underneath a vehicle supported only by a jack.

Always use rectangular wood blocks at the prescribed points to

support the vehicle.

• Support it at the prescribed points and lock it in position with

safety devices before lifting the vehicle.

• When removing a heavy component such as the engine and

vehicle side, be careful the vehicle body does not become off-

balance and fall.

• Do not smoke during service work.

• Do not wear any rings and necklaces when working. These

objects may cause electric short.

• Before starting repair work that requires no battery power,

always turn OFF the ignition switch, and disconnect the

negative battery cable.

• Do not touch any metal portions immediately after the engine is

stopped. Otherwise the heated metals may cause burns. Do not

attempt to remove any cooling system parts such as the radiator

cap while the engine is hot.

• To perform repair work safely and efficiently, always use

appropriate commercial service tools and specified STs

wherever required.

GIM0057

GIM0058

GIM0059

GIM0060

GI-3

PRECAUTIONS FOR SAFETY AND QUALITY

Correct Operation

• Make sure that you understand the symptoms before starting

trouble diagnosis.

• Check correct installation status prior to removal or

disassembly. Make sure that they do not interfere with the

function of the parts they are applied to if matching marks are

required.

• Once they are removed, always replace parts indicated as “do

not reuse” with new ones. This includes: oil seals, gaskets,

packings, O-rings, lock washers, cotter pins, and self-locking

nuts.

• Replace inner and outer races of tapered or needle roller

bearings as a set.

• Arrange disassembled parts in order and prevent them from

being mixed-up.

• Clean or flush disassembled parts prior to inspection or

assembly.

• Use Genuine MITSUBISHI parts for replacement.

• Use authorized grease and sealer.

• Release the pressure before disconnecting pressurized piping

or hoses.

• Be sure to check for leakage after repairing fuel, oil, coolant,

exhaust, or vacuum systems.

Precautions for Radio Equipment Installation

Check the following when installing a commercial/ham radio or

mobile phone. If mounting position is not chosen carefully, the unit

may interfere with the electric control system.

• Separate the antenna as far from the Engine Control System as

possible.

• Route an antenna feeder line at least 20 cm apart from the

control unit harness.

• Adjust antenna and feeder line to eliminate radio wave

interference.

GI-4

PRECAUTIONS FOR SAFETY AND QUALITY

PRECAUTIONS

Precautions in Draining Engine Coolant

• Drain coolant only after the engine has cooled down.

Precautions for Disconnecting Fuel Piping

• Operation should be done in a place free from fire.

• Release fuel pressure before operation. (Electric controlled

specifications): Refer to “Release of Fuel Pressure” in EC

section.

• After disconnecting, plug the pipe to prevent fuel from draining.

Precautions for Removing and

Disassembling

• Use correct STs in the specified position. Always pay attention

to safety.

• Be careful not to lose surface accuracy of mating or sliding

surfaces.

• To prevent foreign material from entering the engine, close

openings with appropriate tape as necessary.

• Arrange disassembled parts in their normal positions in order to

simplify locating the cause of damage or excessive wear and to

ensure correct reassembly.

• As a rule, nuts and bolts must be untightened in a diagonal

manner starting from an outer one. If a particular untightening

sequence is provided separately, follow the sequence.

Precautions for Inspection, Correction, and

Replacement

• Following the inspection procedure, inspect the parts

adequately and repair or replace as necessary. Perform the

same inspections even for new parts and replace them if

necessary.

Precautions for Assembly and Installation

• Always use a torque wrench when tightening bolts and nuts.

• Unless otherwise specified, tighten nuts and bolts from inside to

outside in a crisscross pattern. Tighten them gradually and

evenly in 2 to 3 steps.

• Always replace gasket, packing, oil seals, and O-rings with new

ones.

• For each part, perform adequate cleaning/washing and drying

with a dryer. In particular, ensure that the oil and coolant

passages are free from plugging and clogging.

• Remove any dirt and lint on sliding and mating surfaces. Before

assembly, apply ample amount of engine oil to sliding surfaces.

• If coolant was drained, bleed air from the system.

• After assembly, start engine and increase the engine speed,

then check coolant, fuel, oil, grease, and exhaust gas for

leakage.

GI-5

PRECAUTIONS

Parts Requiring Angle Tightening

• When tightening the following parts, use an angle wrench (ST).

• Cylinder head bolt

Before assembly, verify that no grease/oil and dust are present

on the cylinder head, cylinder block mounting face, and head

gasket. Then apply antirust oil or engine oil to the threads and

head bottoms of the head bolts.

Caution with Use of Power Tools

• The use of power tools such as pneumatic air tools is only

allowed for disassembly. Do not use them for assembly.

Precautions for Liquid Gasket Application

REMOVING PARTS ATTACHED WITH LIQUID GASKET

• Remove mounting nuts and bolts. Remove liquid gasket using a

seal cutter (ST).

CAUTION:

Be careful not to damage the mating surfaces.

• In positions where a seal cutter is difficult to use, lightly tap with

a plastic hammer, and remove.

CAUTION:

Be careful not to scratch the mating surfaces when using a

screwdriver.

LIQUID GASKET APPLICATION INSTRUCTION

1. Remove any old liquid gasket remaining on the gasket

application surface and its mating surface using a scraper.

• Remove any old liquid gasket remaining in the gasket

application groove and on the threads of bolts and bolt

holes.

2. Wipe the gasket application surface and its mating surface

using Isozole or any equivalent thinner to remove any moisture,

oil, and foreign material.

3. Set genuine liquid gasket to tube presser (commercial service

tool).

4. Apply a continuous bead of liquid gasket to the specified

position at the specified diameter.

• Apply liquid gasket in the application groove.

• Apply liquid gasket inside bolt holes as a rule. Make sure to

carefully read the relevant instructions.

• Attaching should be done within 5 minutes after gasket

application.

• Immediately wipe off any protruding liquid gasket.

• Do not retighten nuts and bolts after installation.

• After finishing work, wait at least 30 minutes before refilling

engine oil and coolant.

CAUTION:

Follow any directions specified in the text on the following

pages.

GIM0061

GIM0062

GIM0063

GI-6

PRECAUTIONS

TIGHTENING TORQUE

Standard Bolt Tightening Torque

Upper: Lubricated (Antirust oil is applied to abrasive faces of

threads and seating faces)

Lower: No lubrication (Threads and seating faces are

completely degreased)

CAUTION:

• Except special nuts and bolts.

• The bolts applicable to this table have one of the following

marks embossed on their heads.

4T......4

7T......7

9T......9

Thread size Unit 4T (Bolt) 7T (Bolt) 9T (Bolt)

Diameter Pitch

Hexagon head bolt and nut

M6 1

N·m 3.82 - 4.41 6.37 - 7.45 9.22 - 10.8

(kgf-m) (0.39 - 0.45) (0.65 - 0.76) (0.94 - 1.1)

N·m 5.00 - 6.47 8.43 - 10.8 11.8 - 15.7

(kgf-m) (0.51 - 0.66) (0.86 - 1.1) (1.2 - 1.6)

M8 1.25

N·m 9.32 - 10.8 15.7 - 17.7 22.6 - 25.5

(kgf-m) (0.95 - 1.1) (1.6 - 1.8) (2.3 - 2.6)

N·m 12.7 - 15.7 20.6 - 26.5 29.4 - 37.3

(kgf-m) (1.3 - 1.6) (2.1 - 2.7) (3.0 - 3.8)

M10

1.25

N·m 19.6 - 22.6 32.4 - 38.2 47.1 - 53.9

(kgf-m) (2.0 - 2.3) (3.3 - 3.9) (4.8 - 5.5)

N·m 25.5 - 33.3 43.1 - 54.9 61.8 - 78.5

(kgf-m) (2.6 - 3.4) (4.4 - 5.6) (6.3 - 8.0)

1.5

N·m 18.6 - 21.6 30.4 - 36.3 44.1 - 52

(kgf-m) (1.9 - 2.2) (3.1 - 3.7) (4.5 - 5.3)

N·m 24.5 - 31.4 41.2 - 52 58.8 - 74.5

(kgf-m) (2.5 - 3.2) (4.2 - 5.3) (6.0 - 7.6)

Flanged bolt

M6 1

N·m 4.9 - 5.69 8.14 - 9.51 11.8 - 13.7

(kgf-m) (0.5 - 0.58) (0.83 - 0.97) (1.2 - 1.4)

N·m 5.98 - 7.65 9.81 - 12.7 14.7 - 18.6

(kgf-m) (0.61 - 0.78) (1.0 - 1.3) (1.5 - 1.9)

M8 1.25

N·m 11.8 - 13.7 19.6 - 23.5 28.4 - 33.3

(kgf-m) (1.2 - 1.4) (2.0 - 2.4) (2.9 - 3.4)

N·m 14.7 - 18.6 24.5 - 31.4 35.3 - 45.1

(kgf-m) (1.5 - 1.9) (2.5 - 3.2) (3.6 - 4.6)

M10

1.25

N·m 24.5 - 29.4 41.2 - 48.1 59.8 - 69.6

(kgf-m) (2.5 - 3.0) (4.2 - 4.9) (6.1 - 7.1)

N·m 30.4 - 39.2 51.0 - 64.7 73.6 - 93.2

(kgf-m) (3.1 - 4.0) (5.2 - 6.6) (7.5 - 9.5)

1.5

N·m 23.5 - 27.5 39.2 - 46.1 56.9 - 65.7

(kgf-m) (2.4 - 2.8) (4.0 - 4.7) (5.8 - 6.7)

N·m 29.4 - 37.3 49.0 - 61.8 69.6 - 89.2

(kgf-m) (3.0 - 3.8) (5.0 - 6.3) (7.1 - 9.1)

GI-7

TIGHTENING TORQUE

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