2The following modules do not cover all of the material in the manual 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.
16Cylinder Head Cylinder head is common with K15, k21and K25 Made of aluminum alloy material
17Rocker Cover Removal of rocker cover and gasket: 1. Remove the rocker cover retaining nuts.2. Remove rocker cover.
18Rocker Shaft Assembly 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.
19Assemble 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)
20Assemble Rocker Shaft Assembly Tighten the rocker shaft retaining bolts evenly from inside to outsideTorque: – N-m (1.8 – 2.2kgf·m)
21Adjusting Valve Clearance 1. Start the engine and fully warm it up. Then stop engine.2. Remove rocker cover3. 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
22Adjusting Valve Clearance Intake and Exhaust: 0.38 mmAdjust Valve Clearance when Engine is Hot
25Piston 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.
26Assembly 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.
27Assembly of Camshaft1. Gently put the camshaft into the camshaft hole so that the bearing bushings are no damaged.2. Tighten locating plate to the specified torque – 10.8 Nm (0.86 – 1.1 kgf.m)
29Assembly of Timing chain/Sprocket 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.
30Assembly 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
31Installation of Crankshaft Pulley Set the crankshaft pulley by aligning the pulley claws to the groove of the bushing.
38Remove Water Pump1. 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 pulley6. Remove water pump together with the gasket.
39Water Pump Inspection Do not disassemble water pump Check the water pump vanes for rust and pitching.Do not disassemble water pump
40Water Pump Inspection Do not disassemble water pump Check the water pump bearing for proper end play and smooth operation.Do not disassemble water pump
41Fan Belt TensionBelt Deflection: 11 – 13 mmForce: 98 N (10 kgf)
55Engine Speed Measurement 1. Remove the distribution connector from the coupling as shown.
56Engine 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
57Engine 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 rpmCaution: The idling and maximum speed are preset at factory. Do not adjust unless necessary.
58Engine Speed Adjustment 4. Adjust the ignition timing for idling.Ignition timing: BTDC:K15 : 0oK21 : 2oK25 : 0oCaution: The idling and maximum speed are preset at factory. Do not adjust unless necessary.
59Engine 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.
60Governor 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 loadK15 : 3,600 rpmK21 : 3,600 rpmK25 : 3,600 rpm3. 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.
61Governor 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 loadK15 : 3,000 rpmK21 : 3,000 rpmK25 : 3,000 rpm4. 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.
62Testing 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)K151.27 (13.0), 250 rpmK211.23 (12.5), 250 rpmK25Note: Keep engine speed at approx. 250 rpmTake reading in a short time as possible