Komatsu K21, K25 Series Engine Forklift Truck Service Manual SM301

Description

• Model List:
  • K21 Series Engine Forklift Truck
  • K25 Series Engine Forklift Truck

• 1. INTRODUCTION
• 2. AN OVERVIEW OF MAJOR IMPROVEMENTS FROM CURRENT HTYPE ENGINES TO THE NEW KENGINES
• 3. APPLICABLE EPA LIFT TRUCK MODELS
• 4. KENGINE SERIAL NUMBER BREAKS BY MODEL YEAR
• 5. Precautions
• 5.1. Draining Engine Coolant
• 5.2. Disconnecting Fuel Piping
• 5.3. Removing and Disassembling
• 5.4. Inspection, Correction, and Replacement
• 5.5. Assembly and Installation
• 5.6. Parts Requiring Angle Tightening
• 5.7. Use of Power Tools
• 5.8. Liquid Gasket Application
• 6. Engine Outside Drawings
• 7. Main Specifications
• 8. Adjustment Value
• 9. Tightening Torque
• 9.1. Standard Bolt Tightening Torque
• 9.2. Engine Part Tightening Torque
• 10. Trouble Shooting
• 11. Special Service Tools
• 12. Removal And Installation Of Engine
• 12.1. Removal
• 12.2. Installation
• 12.3. Inspection
• 13. Engine Service
• 13.1. Engine Disassembly
• 13.2. Inspection and Correction
• 13.3. Engine Assembly
• 14. Engine Types
• 15. Engine Outside Drawings
• 16. System Diagram
• 17. Unit Layout
• 18. Service Data And Specifications (SDS)
• 18.1. LPG Fuel System Trouble Diagnosis
• 19. Disassembly And Assembly Of Fuel System
• 19.1. Removal and Installation of LPG Injector Drive Unit Connector
• 19.2. Removal and Installation of Electronic Control Throttle Assembly
• 19.3. Removal and Installation of Gasoline Fuel Injector (Electronic Controlled Gasoline and Combined Use)
• 19.4. LPG device (Specifications for LPG and Combined Use)
• 19.5. Holder Assembly
• 19.6. LPG Fuel Injector
• 19.7. LPG Assist Fuel Injector
• 19.8. LPG Fuel Pressure Sensor
• 19.9. Vaporizer Mechanism and Operation
• 20. Disassembly And Assembly Of Injector Holder
• 20.1. LPG Fuel Injector
• 20.2. LPG Assist Fuel Injector
• 20.3. LPG Fuel Pressure Sensor
• 20.4. Relief Valve (2 Relief Valves)
• 21. Disassembly And Assembly Of Vaporizer
• 22. Lubrication System
• 22.1. Specifications
• 22.2. Adjustment Value
• 22.3. Oil Pressure
• 22.4. Tightening Torque
• 22.5. Trouble Shooting
• 22.6. Lubrication Schematic Diagram
• 22.7. Oil Pump
• 23. Engine Coolant System
• 23.1. Specifications
• 23.2. Adjustment Value
• 23.3. Tightening Torque
• 23.4. Trouble Shooting
• 23.5. Cooling System Configuration
• 23.6. Water Pump
• 23.7. Thermostat
• 24. LUBRICATION SYSTEM
• 25. ENGINE COOLANT SYSTEM
• 26. Engine And Main Body
• 26.1. Description
• 26.2. Main Engine System
• 26.3. Cylinder Block
• 26.4. Cylinder Head
• 26.5. Cylinder Head Gasket
• 26.6. Cylinder Head Bolt
• 26.7. Piston, Piston Pin and Piston Rings
• 26.8. Connecting Rod and Connecting Rod Bearing
• 26.9. Crankshaft
• 26.10. Main Bearing and Bearing Cap Bolts
• 26.11. Oil Seal
• 26.12. Crankshaft Pulley Bushing
• 26.13. Crankshaft Pulley and Pulley Bolt
• 26.14. PTO (Power TakeOff)
• 26.15. Oil Pan
• 26.16. Rocker Cover and Gasket
• 27. Valves
• 27.1. Description
• 27.2. Camshaft
• 27.3. Timing Chain and Sprocket
• 27.4. Valve Related Parts
• 28. Lubrication System
• 28.1. Description
• 28.2. Oil Pump
• 28.3. Oil Strainer
• 28.4. Oil Filter
• 28.5. Engine Oil and Oil Level Gauge (Dipstick)
• 29. Intake / Exhaust
• 29.1. Description
• 29.2. Manifold Component Parts Location
• 29.3. Engine Intake System Component Parts Location
• 29.4. Electric Throttle Control Actuator (ETCA)
• 29.5. Intake Manifold
• 29.6. Exhaust Manifold
• 30. Engine Control System
• 31. Circuit Diagrams of Engine Control Module
• 31.1. Gasoline
• 31.3. Dual Fuel
• 31.4. Dual Fuel EPA Tier 2 (2007)
• 32. Engine Control System
• 32.1. Fuel System Diagrams
• 32.1.1. Gasoline
• 32.1.3. Dual Fuel
• 32.1.4. Gasoline EPA Tier 2 (2007)
• 32.1.5. LPG EPA Tier 2 (2007)
• 32.1.6. Dual Fuel EPA Tier 2 (2007)
• 32.2. ECM Terminal Layout
• 32.2.1. Fuel Injection Control
• 32.2.2. PCV Gas Recirculation Device
• 32.3. Coolant System
• 32.3.1. Description of Coolant System
• 32.3.2. Specifications
• 32.3.3. Construction
• 32.4. Fuel System Description
• 33. Engine Control System
• 33.1. APPENDIX 1. Theory of Fuel Injection Pulse Width Indication
• 33.2. APPENDIX 2. Service Support Tool Exercise Program
• 33.3. APPENDIX 3. Error Code List
• 34. Engine Control System
• 34.1. APPENDIX 4. Diagnostic Monitor Service Support Tool (SST)