1t-3.5t R Series Internal Combustion Counterbalanced Forklift Truck. Manual - part 2

2.2K21/K25 Maintenance
2.2.1 Retighten cylinder head bolts
When the engine is cold, retighten
should be made in the sequence
shown.
·

T: 68.6 N·

In two steps.

2.2.2 Adjusting intake and exhaust
valve clearance

1）  Start engines and warm it up
sufficiently.
Then turn off engine.
2）  Remove valve rocker cover.
3）  Rotate crankshaft.

Set No.1 cylinder in top dead center on
its compression stroke and then adjust
valve clearance.
①      ②      ③    ⑤
Set NO.4 cylinder in top dead center on
its compression stroke, and adjust valve
clearance.
④      ⑥      ⑦    ⑧
Valve clearance (Hot)
Intake & exhaust: 0.38mm
2.2.3.  Checking  and  Adjusting  Fan

Belt for Tension

1） Visually inspect for cracks, fraying,

wear or lubricity.
The belt should not touch the bottom
of the pulley groove.

2） Check belt deflection by pushing

midway between pulleys.
Fan belt deflection:11mm～13mm
Pushing force:：98N

2.2.4. Changing engine oil and oil

filter

1) Start engine and warm up engine

sufficiently, then stop engine.

2) Remove oil filler cap and oil pan

drain plug, and allow oil to drain.

△

WARNING:

Be careful not to burn yourself, as

the engine oil may be hot.

·Milky oil indicates the presence of

cooling water and finds the cause,
takes corrective measure.

·Oil with extremely low viscosity

indicates dilution with gasoline.

3) Clean and install oil pan drain plug
with washer.
Oil pan drain plug: 29N·

m～39N·

4)  Using tool remove oil filter.
5)  Wipe oil filter mounting surface with
a clean rag.
6)  Smear a little engine oil on rubber
gasket of new oil filter.
7)  Install new oil filter. Hand-tighten
ONLY.

Don’t use a wrench to tighten the

filter.
8)  Refill engine with new
recommended engine oil, referring to
Recommended Lubricants.
Check oil level with dipstick.
Oil capacity: 3.6 L。
9)  Start engine, check area around
drain plug and oil filter for any sign of oil
leakage.
If any Leakage is evident, these parts
have not been properly installed.
10) Warm up engine sufficiently.
Then stop engine and wait a few
minutes. Check oil level. If necessary,
add engine oil.
When checking oil level, park the forklift
on a level surface.
2.2.5.  Changing Engine Coolant

△

! WARNING:

To avoid the danger of being scalded,
never attempt to change the coolant
when the engine is hot. When using
anti-freeze coolant, mix the anti-freeze
coolant with water.
2.2.6. Cleaning Radiator Outside
Clean outside of radiator with dry
compressed air.
2.2.7. Checking

cooling

System,

Hoses and Connections.

Check hoses and fittings for Lose
connections or deterioration.
Retighten or replace if necessary.

2.2.8. Checking

Engine

Compression Pressure
1） Warm up engine sufficiently, then

stop engine.

2） Remove all spark plugs.
3） Properly attach a compression

tester to spark plug hole in cylinder
being tested.

4） Set carburetor throttle valve at fully

open position.

5） Crank engine and red gauge

indication.

Run engine at about 250r/min

Engine

compression measurement

should be made as quickly as
possible.

Compression pressure:
K21 K25
Standard 1.23kPa 1.27kPa

6).Cylinder  compression  in  cylinders
should  not  be  less  than  80%  of  the
highest reading.
If  cylinder  compression  in  one  or  more
cylinders is low, pour a small quantity of
engine  oil  into  cylinders  through  the
spark

plug

holes

and

retest

compression.
·

If adding oil helps the compression

pressure, piston rings may be worn or
damaged.
·

If pressure stays low, valve may be

sticking or seating improperly.
·

If cylinder compression in any two

adjacent cylinders is low, and if adding
oil does not help the compression, there
is leakage pass on the gasket surface.

Oil and water in combustion

chambers can result from this problem.

2.2.9. Cleaning or Replacing Air
Cleaning Filter (Dry paper type)

It is necessary to clean the element

or replace it at the recommended
interval,

and

frequent

maintenance  should  do  in  other  dirty
operating conditions.
2.2.10.  Cleaning  or  Replacing  Fuel
Stained Element
  The  fuel  strainer  element  should  be
checked,

cleaned

replaced

periodically.
2.2.11. Checking Fuel lines

Check

fuel

lines

for

proper

attachment, leaks, cracks, damage,
loose

connections,

chaffing

and

deterioration. If necessary, replace any
damaged or defective parts.

2.2.12 Checking carburetor

1） Checking Linkage And Valve
·

Remove air horn. Visual check dirt and linkage of interior carburetor, visual check

wear or damage of connecting parts..
·

Check throttle valve shaft for wear by moving it by hand. It must not moved(no free

play).
·

Check operation (opening and closing) of throttle valve and choke valve.

Maintenance
·

If carburetor is excessively soiled, disassemble and clean.

If linkage is excessively worn, bent or damaged, replace with new one.

If throttle valve shaft is excessively bent, replace with new one.

2） Checking Auto-choke Mechanism
·

Visually check auto-choke mechanism for deformed linkage, etc.

Before starting engine, depress accelerator pedal one time.

After starting engine, ensure engine speed decreases to specified idle rpm.

Choke

valve

Throttle valve

Cam lever and fast idle cam

Ambient

temperature 20

Fully

closed

Fast idle

position

Differs with ambient temperature.
During engine starts:
1

or 2

ratchet position

afte1 warm-up:
3

or 4

rachet position

After warm-up

Fully open

Idle position

Clearance exists

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