K15 21 25 gasoline engine
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K15/21/25 Gasoline Engine. Service Manual # 99789-75100.

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K15 21 25 gasoline engine

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

Introduction 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.


Engine models and fuel type
Engine Models and Fuel Type 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.


External view carburetor type
External View (Carburetor type) 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.


External view electronic type
External View (Electronic Type) 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.


Indication of model and number
Indication of Model and Number 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.


K15 engine specification
K15 Engine Specification 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.


K15 engine specification1
K15 Engine Specification 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.


K21 engine specification
K21 Engine Specification 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.


K21 engine specification1
K21 Engine Specification 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.


K25 engine specification
K25 Engine Specification 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.


K25 engine specification1
K25 Engine Specification 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.


Engine main parts

Engine Main Parts 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.


Cylinder heads valve mechanism
Cylinder Heads & Valve Mechanism 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.


Cylinder head
Cylinder Head 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.

Cylinder head is common with K15, k21and K25

Made of aluminum alloy material


Rocker cover
Rocker Cover 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.

Removal of rocker cover and gasket:

1. Remove the rocker cover retaining nuts.

2. Remove rocker cover.


Rocker shaft assembly
Rocker Shaft Assembly 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.

  • Removal of rocker shaft assembly.

  • Loosen the eight valve rocket adjusting nuts and screws to remove the valve rocker shaft.

  • Pull off the push rod.

  • 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
Assemble Cylinder Head 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.

  • 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
Assemble Rocker Shaft Assembly 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.

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
Adjusting Valve Clearance 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.

  • 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 clearance1
Adjusting Valve Clearance 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.

Intake and Exhaust: 0.38 mm

Adjust Valve Clearance when Engine is Hot


Pistons crankshaft crankcase
Pistons, Crankshaft & Crankcase 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.


Pto device
PTO Device 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.


Piston and connecting rod
Piston And Connecting Rod 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.

  • 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
Assembly of Piston Ring 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.

  • 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
Assembly of Camshaft 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.

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
Assembly of Timing chain/Sprocket 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.

Tighten camshaft bolts. Tightening torque: 39.2 – 49 Nm (4.0 – 5.0 kgf.m)


Assembly of timing chain sprocket1
Assembly of Timing chain/Sprocket 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.

Check the height of the cam shaft gear and crankshaft gear end faces, adjust the height by adding shims to the crankshaft side as necessary.


Assembly of timing chain sprocket2
Assembly of Timing chain/Sprocket 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.

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
Installation of Crankshaft Pulley 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.

Set the crankshaft pulley by aligning the pulley claws to the groove of the bushing.


Inlet and exhaust system

Inlet and Exhaust System 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.


Inlet and exhaust
Inlet and Exhaust 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.


Cooling system

Cooling System 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.


Coolant block diagram
Coolant 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. Block Diagram


Water pump fan thermostat
Water Pump, Fan & Thermostat 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.


Engine coolant sensor transmitter
Engine Coolant Sensor & Transmitter 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.


Remove water pump
Remove Water Pump 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.

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
Water Pump Inspection 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.

Check the water pump vanes for rust and pitching.

Do not disassemble water pump


Water pump inspection1
Water Pump Inspection 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.

Check the water pump bearing for proper end play and smooth operation.

Do not disassemble water pump


Fan belt tension
Fan Belt Tension 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.

Belt Deflection: 11 – 13 mm

Force: 98 N (10 kgf)


Fuel system

Fuel System 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.


Fuel system diagram
Fuel System Diagram 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.


Fuel pump fuel filter
Fuel Pump & Fuel Filter 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.

Periodically inspect, clean and replace fuel filter.

Clean fuel filter every 3 months.


Vacuum piping diagram
Vacuum Piping Diagram 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.


Carburetor and governor
Carburetor and Governor 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.


Carburetor assembly
Carburetor Assembly 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.


Spark plug gap
Spark Plug Gap 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.

Standard (mm) : 9


Lubrication system

Lubrication System 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.


Engine oil lubricating system
Engine oil Lubricating system 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.


Engine oil lubricating flowchart
Engine oil Lubricating Flowchart 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.


Oil filter
Oil Filter 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.


Oil pump
Oil Pump 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.

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


Engine inspection adjustment

Engine Inspection & Adjustment 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.


Engine speed measurement
Engine Speed Measurement 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.

1. Remove the distribution connector from the coupling as shown.


Engine speed measurement1
Engine Speed Measurement 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.

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
Engine Speed Adjustment 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.

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 adjustment1
Engine Speed Adjustment 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.

4. Adjust the ignition timing for idling.

Ignition timing: BTDC:

K15 : 0o

K21 : 2o

K25 : 0o

Caution: The idling and maximum speed are preset at factory. Do not adjust unless necessary.


Engine speed adjustment2
Engine Speed Adjustment 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.

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
Governor Adjustment (No Load) 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.

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
Governor Adjustment (With Load) 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.

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. 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.

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.

Testing Compression Pressure

Unit: MPa (kgf/cm2)

Note: Keep engine speed at approx. 250 rpm

Take reading in a short time as possible


Maintenance schedule
Maintenance Schedule 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.


Maintenance schedule1
Maintenance Schedule 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.


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