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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
K15
Carburetor Specification (Gas/LPG)
Electronic Controlled (Gas/LPG)
K21
Carburetor Specification (Gas/LPG)
Electronic Controlled (Gas/LPG)
K25
Carburetor Specification (Gas/LPG)
Electronic Controlled (Gas/LPG)
External View (Carburetor type)
External View (Electronic Type)
Indication of Model and Number
K15 Engine Specification
Current
Engine Model 4G15
Engine Control Carburetor
Fuel Type Gasoline Dual Gasoline Dual Dual
Total Displacement (cc) 1468
Combustion Chamber Type Semi-spherical
Valve Mechanism OHC
Bore × Stroke (mm) 75.5×82
Compression Ratio 9.4
Compression Pressure (Mpa{kgf/c㎡} /rpm)
1.2{12.0} /250
K15
Electronic Control Carburetor
New
9.0
1.3{13.0} /250
1486
Bath tub
OHV
75.5×83
K15 Engine Specification
Current
4G15
Carburetor
Gasoline Dual Gasoline Dual Dual
Max Output (kW{PS} /rpm)24.9{33.8
} /260022.9{31.2
} /2600 (30) /2400
Max Torque N ‐ m{kgf‐ m} /rpm100.0{10.2} /1600
95.1{9.7}/1600
(9.7) /1600
600~650
2550~2600
Universal Joint
2800 2900
Fuel Type
Engine Control
New
On Vehicle Idle Speed ( rpm)
On Vehicle High-Idle Speed (rpm)
27.2{37}/ 2600
104.9{10.7} /1600
PTO Type
K15
Electronic Control Carburetor
Silent Chain Drive/Side PTO Method
700 700
Engine Model
K21 Engine Specification
Current
Engine Model 4G63
Engine Control Carburetor
Fuel Type Gasoline Dual Gasoline Dual Dual
Total Displacement (cc) 1997
Combustion Chamber Type Semi-spherical
Valve Mechanism OHC
Bore × Stroke (mm) 85×88
Compression Ratio 8.5
Compression Pressure (Mpa{kgf/c㎡} /rpm)
1.1{11.5} /300
8.7
1.2{12.5} /250
89×83
K21
Electronic Control Carburetor
New
2065
Bath Tub
OHV
K21 Engine Specification
Current
Engine Model 4G63
Engine Control Carburetor
Fuel Type Gasoline Dual Gasoline Dual Dual
Max Output (kW{PS} /rpm)34.2{46.5
} /260033.1{45.0
} /2600 (39) /2400
Max Torque N ‐ m{kgf‐ m} /rpm142.2{14.5
} /1600139.3{14.2
} /1600(13.7) /1600
On Vehicle Idle Speed ( rpm) 600~650On Vehicle High-Idle Speed
( rpm)2600~2650
PTO TypeUniversal
Joint
New
K21
Electronic Control Carburetor
Silent Chain Driven/Side PTO Method
2700 2750
38.2{51.9} /2600
151.0{15.4} /1600
700 700
K25 Engine Specification
Current
Engine Model 4G64
Engine Control Carburetor
Fuel Type Gasoline Dual Gasoline Dual Dual
Total Displacement (cc) 2350
Combustion Chamber Type Semi-spherical
Valve Mechanism OHC
Bore × Stroke (mm) 86.5×100
Compression Ratio 8.6
Compression Pressure (Mpa{kgf/c㎡} /rpm)
1.1{11.5} /300
89×100
8.7
1.2{12.5} /250
New
2488
Bath Tub
OHV
K25
Electronic Control Carburetor
K25 Engine Specification
Current
Engine Model 4G64
Engine Control Carburetor
Fuel Type Gasoline Dual Gasoline Dual Dual
Max Output (kW{PS} /rpm)38.5{52.3
} /240036.2{49.3
} /2400 (50) /2400
Max Torque N ‐ m{kgf‐ m} /rpm176.5{18.0} /1600
171.6{17.5} /1600
(17) /1600
On Vehicle Idle Speed
( rpm)600~650
On Vehicle High-Idle Speed
( rpm)2600~2650
PTO Type Universal Joint
41.4{56.3} /2400
K25
Electronic Control Carburetor
New
181.4{18.5} /1600
700 700
Silent Chain Drive/Side PTO Method
2700 2750
Engine Main Parts
Cylinder Heads & Valve Mechanism
Cylinder Head
Cylinder head is common 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
Adjust Valve Clearance when Engine is Hot
Intake and Exhaust: 0.38 mm
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
Tighten camshaft bolts. Tightening torque: 39.2 – 49 Nm (4.0 – 5.0 kgf.m)
Assembly 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.
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
No service parts. Replace drive shaft assembly or oil pump assembly
Oil PressureAt idle, 98 kPa (1.0 kgf/cm2)At 2000 rpm, 274-313 kPa (2.8-3.2 kgf/cm2)
Engine Inspection & Adjustment
Engine Speed Measurement
1. Remove the distribution 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
4. Adjust the ignition timing for idling.
Caution: The idling and maximum speed are preset at factory. Do not adjust unless necessary.
Ignition timing: BTDC:
K15 : 0o
K21 : 2o
K25 : 0o
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)
Caution: The governor is preset at factory. Do not adjust unless necessary.
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.
Governor Adjustment (With Load)
Caution: The governor is preset at factory. Do not adjust unless necessary.
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 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.
Testing Compression Pressure
Unit: MPa (kgf/cm2)
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.
K15 1.27 (13.0), 250 rpm
K21 1.23 (12.5), 250 rpm
K25 1.27 (13.0), 250 rpm
Note: Keep engine speed at approx. 250 rpm Take reading in a short time as possible
Maintenance Schedule
Maintenance Schedule