The document provides specifications and service information for K15/21/25 gasoline engines, including:
1) It outlines the key engine models, fuel types, specifications, and control systems.
2) It describes the external views and main engine parts like the cylinder heads, valves, pistons, crankshaft, and camshaft.
3) It provides instructions for maintenance procedures like adjusting valve clearance, assembling pistons and camshafts, and setting the timing chain.
The document provides specifications and service information for K15/21/25 gasoline engines, including:
1) It outlines the key engine models, fuel types, specifications, and control systems.
2) It describes the external views and main engine parts like the cylinder heads, valves, pistons, crankshaft, and camshaft.
3) It provides instructions for maintenance procedures like adjusting valve clearance, assembling pistons and camshafts, and setting the timing chain.
The document provides specifications and service information for K15/21/25 gasoline engines, including:
1) It outlines the key engine models, fuel types, specifications, and control systems.
2) It describes the external views and main engine parts like the cylinder heads, valves, pistons, crankshaft, and camshaft.
3) It provides instructions for maintenance procedures like adjusting valve clearance, assembling pistons and camshafts, and setting the timing chain.
The document provides specifications and service information for K15/21/25 gasoline engines, including:
1) It outlines the key engine models, fuel types, specifications, and control systems.
2) It describes the external views and main engine parts like the cylinder heads, valves, pistons, crankshaft, and camshaft.
3) It provides instructions for maintenance procedures like adjusting valve clearance, assembling pistons and camshafts, and setting the timing chain.
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K15/21/25 Gasoline Engine
Service Manual # 99789-75100
The following modules do not cover all of the material in the manual. We have identified and chosen some of the more important key points. To fully understand the engine in more depth you will need to read the manual. More hands on work with the lift truck, and real life work will improve your overall knowledge of this equipment. Introduction Engine Models and Fuel Type
Engine Type Engine Control System
Carburetor Specification (Gas/LPG)
K15 Electronic Controlled (Gas/LPG)
Carburetor Specification (Gas/LPG)
K21 Electronic Controlled (Gas/LPG)
Carburetor Specification (Gas/LPG)
K25 Electronic Controlled (Gas/LPG) External View (Carburetor type) External View (Electronic Type) Indication of Model and Number K15 Engine Specification
New Current Engine Model Ｋ１５ ４Ｇ１５ Engine Control Electronic Control Carburetor Carburetor Fuel Type Gasoline Dual Gasoline Dual Dual Total Displacement (cc) 1486 1468
with K15, k21and K25 Made of aluminum alloy material Rocker Cover
Removal of rocker cover and gasket: 1. Remove the rocker cover retaining nuts. 2. Remove rocker cover. Rocker Shaft Assembly
Removal of rocker shaft assembly.
1. Loosen the eight valve rocket adjusting nuts and screws to remove the valve rocker shaft. 2. Pull off the push rod. 3. When removing the valve rocker shaft, compress the coil spring slightly and tie the spring with a metal wire, as shown in the figure, before loosening the bolts. This will facilitate the reassembly work later. Assemble Cylinder Head
Retighten the bolts in the
sequence shown in the figure while the engine is cold.
Torque: 68.6 N-m
(7.0kgf·m) Assemble Rocker Shaft Assembly
Tighten the rocker shaft
retaining bolts evenly from inside to outside Torque: 17.64 – 21.56 N- m (1.8 – 2.2kgf·m) Adjusting Valve Clearance
1. Start the engine and fully
warm it up. Then stop engine. 2. Remove rocker cover 3. Turn crankshaft – Set piston for No. 1 cylinder to the compression TDC and adjust valve clearance for (1) (2) (3) (5) in step 1. 4. Set piston fro No. 4 cylinder to the compression TDC and adjust valve clearance for (4) (6) (7) (8) in step 2. Adjust Valve Clearance when Engine is Hot Adjusting Valve Clearance
Intake and Exhaust: 0.38 mm
Adjust Valve Clearance when Engine is Hot
Pistons, Crankshaft & Crankcase PTO Device Piston And Connecting Rod
The front of the
connecting rod is determined as follow: When installed to the piston and view from the front, the projection should come to the right. Assembly of Piston Ring
1. Securely assemble the
top ring, second ring and oil ring to their relevant positions. 2. Make sure to assemble these parts in the following order: oil ring, second ring, top ring. Assembly of Camshaft
1. Gently put the camshaft
into the camshaft hole so that the bearing bushings are no damaged. 2. Tighten locating plate to the specified torque. 8.43 – 10.8 Nm (0.86 – 1.1 kgf.m) Assembly of Timing chain/Sprocket
shaft gear and crankshaft gear end faces, adjust the height by adding shims to the crankshaft side as necessary. Assembly of Timing chain/Sprocket
Assemble chain tensioner.
When installing the chain tensioner, align the oil holes of the tensioner body to those of the cylinder block to ensure that the tensioner spindle shoe (synthetic rubber) is held parallel with the chain.
CAUTION: Assemble shoe correctly
Installation of Crankshaft Pulley
Set the crankshaft pulley
by aligning the pulley claws to the groove of the bushing. Inlet and Exhaust System Inlet and Exhaust Cooling System Coolant Block Diagram Water Pump, Fan & Thermostat Engine Coolant Sensor & Transmitter Remove Water Pump
1. Open the drain of the
radiator and extract coolant. 2. Remove the radiator shroud. 3. Loosen the alternator adjusting bolt. 4. Fully put aside the alternator toward the engine. 5. Remove fan and fan pulley 6. Remove water pump together with the gasket. Water Pump Inspection
Check the water pump
vanes for rust and pitching.
Do not disassemble water pump
Water Pump Inspection
Check the water pump
bearing for proper end play and smooth operation.
Do not disassemble water pump
Fan Belt Tension
Belt Deflection: 11 – 13 mm Force: 98 N (10 kgf) Fuel System Fuel System Diagram Fuel Pump & Fuel Filter
Periodically inspect, clean
and replace fuel filter. Clean fuel filter every 3 months. Vacuum Piping Diagram Carburetor and Governor Carburetor Assembly Spark Plug Gap
Standard (mm) : 9 Lubrication System Engine oil Lubricating system Engine oil Lubricating Flowchart Oil Filter Oil Pump Oil Pressure At idle, 98 kPa (1.0 kgf/cm2) At 2000 rpm, 274-313 kPa (2.8-3.2 kgf/cm2)
No service parts. Replace drive shaft assembly or oil pump assembly
connector from the coupling as shown. Engine Speed Measurement
2. Connect the ignition coil
adapter harness between the distributor connector and coupling. Connect the tachometer power supply terminal (red) to the battery positive terminal and the black terminal to the battery negative terminal. Connect the measurement terminal (green) to the measurement wire in the middle of the adapter harness Engine Speed Adjustment
1. Start and warm up engine
sufficiently. 2. Check that FICD (fast idle control device) does not contact the carburetor throttle lever. 3. Adjust the idle speed by using the throttle adjusting screw and idling adjusting screw. Idle speed :700 ± 50 rpm
Caution: The idling and maximum speed are preset at
factory. Do not adjust unless necessary. Engine Speed Adjustment
Caution: The idling and maximum speed are preset at
factory. Do not adjust unless necessary. Engine Speed Adjustment
6. Remove the vacuum piping
from FICD and plug the pipe openings to prevent air leakage. 7. In this state, the FICD pushrod is pushing the carburetor throttle lever. Adjust engine speed to 1200 – 1500 rpm with the throttle lever adjusting screw. 8. After adjustment, connect the vacuum piping and verify that an appropriate engine idle speed is obtained.
Caution: The idling and maximum speed are preset at
factory. Do not adjust unless necessary. Governor Adjustment (No Load) 1. Set the directional lever to neutral position. 2. Start engine and fully open the throttle. Monitor the engine speed.
Maximum speed with no load
K15 : 3,600 rpm K21 : 3,600 rpm K25 : 3,600 rpm
3. If the engine speed does not fall in
the specified range, adjust by turning the governor adjusting handle.
Caution: The governor is preset at factory. Do not adjust
unless necessary. Governor Adjustment (With Load) 1. Set the directional lever to neutral position. 2. Start engine and fully tilt the mast rearward with the tile lever. 3. Fully open the throttle and monitor the engine speed. Maximum speed with load K15 : 3,000 rpm K21 : 3,000 rpm K25 : 3,000 rpm 4. If the engine speed does not fall in the specified range, adjust by turning the governor adjusting handle. In addition, adjust the maximum engine speed with no load.
Caution: The governor is preset at factory. Do not adjust
unless necessary. Testing Compression Pressure
1. Warn up engine and then stop.
2. Remove the spark plug. 3. Connect compression gauge correctly to the cylinder plug hole to be measure. 4. Set throttle valve to the fully open position. Depress the throttle pedal to the fully open- open position. 5. Crank the engine and read gauge. Unit: MPa (kgf/cm2)
K15 1.27 (13.0), 250 rpm
Note: Keep engine speed at approx. 250 rpm K21 1.23 (12.5), 250 rpm Take reading in a short time as possible K25 1.27 (13.0), 250 rpm Maintenance Schedule Maintenance Schedule
