Caterpillar K21, K25 Engine Service Manual 99789-65101

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Caterpillar K21, K25 Engine Service Manual 99789-65101

$50.00

Type Of Manual: Service Manual
Manual ID: 99789-65101
Number of Pages: 232
Size: 5.3MB
Format: PDF

Category: Caterpillar Service Manual PDF

Model List:
- K21 Engine, K25 Engine

1. How to use this manual
1.1. Description
1.2. Definition of Terms
1.3. Definition of Units
1.4. Description
2. Precautions for safety and quality
2.1. Reduction of Risk Operation
2.2. Correct Operation
2.3. Precautions for Radio Equipment Installation
3. Precautions
3.1. Precautions in Draining Engine Coolant
3.2. Precautions for Disconnecting Fuel Piping
3.3. Precautions for Removing and Disassembling
3.4. Precautions for Inspection, Correction, and Replacement
3.5. Precautions for Assembly and Installation
3.6. Parts Requiring Angle Tightening
3.7. Caution for Use of Power Tools
3.8. Precautions for Liquid Gasket Application
4. Tightening torque
4.1. Standard Bolt Tightening Torque
4.2. Engine Part Tightening Torque
5. Special Service Tools
6. Engine outside drawings
7. Standard and repair limit
8. Trouble diagnosis
8.1. Engine Adjustment
8.2. Engine LPG Fuel System
9. Engine maintenance
9.1. Specifications
9.2. Tightening Torque
9.3. Maintenance Schedule
9.4. Oil and Grease, and Capacity
9.5. On Board Inspection and Service
10. Specifications
11. Tightening torque
12. Trouble diagnosis
13. ENGINE INSPECTION AND ADJUSTMENT
13.1. Engine Body Related
13.2. Ignition and Fuel Systems
14. SERVICE DATA AND SPECI FICATIONS (SDS)
14.1. Electronic Control System Specifications
15. Precautions
15.1. Precautions for Draining Engine Coolant
15.2. Precautions for Disconnecting Fuel Piping
15.3. Precautions for Removing and Disassembling
15.4. Precautions for Inspection, Correction, and Replacement
15.5. Precautions for Assembly and Installation
15.6. Parts Requiring Angle Tightening
15.7. Caution for Use of Power Tools
15.8. Precautions for Liquid Gasket Application
16. Engine outside drawings
17. Adjustment value
18. Tightening torque
18.1. Standard Bolt Tightening Torque
18.2. Engine Part Tightening Torque
19. Trouble diagnosis
20. Special Service Tools
21. Removal and installation of engine
21.1. Removal
21.2. Installation
21.3. Inspection
22. Engine service
22.1. Engine Disassembly
22.2. Inspection and Correction
22.3. Engine Assembly
23. Precautions
23.1. General precautions for service operations
24. Preparation
24.1. Service Tools
25. Description
26. Basic inspection
26.1. Inspection of Idle Speed, Ignition Timing, and Air-fuel Ratio
26.2. Throttle Valve Closed Position Learning and Idle Air Volume Learning
26.3. Accelerator Pedal Released Position Learning
26.4. Fuel pressure inspection
27. Trouble Diagnosis
27.1. How to Proceed with Trouble Diagnosis
27.2. Diagnosis Chart by Symptom
27.3. Component Parts Location
27.4. ECM Component
27.5. Circuit Diagram
27.6. ECM Terminal Layout
27.7. ECM Input/Output Signal Specifications
27.8. Service Tool (ST)
27.9. Self-Diagnosis Function (without ST)
27.10. ST Reference Value in Data Monitor
27.11. Fail-Safe Function
28. Power supply and ground system
28.1. ECM Input/Output Signal Specifications
28.2. Circuit Diagram
29. Crankshaft position sensor (POS) sys tem
29.1. ECM Input/Output Signal Specifications
29.2. Circuit Diagram
29.3. Component Parts Inspection
30. Camshaft position sen sor (PHASE) system
30.1. ECM Input/Output Signal Specifications
30.2. Circuit Diagram
30.3. Component Parts Inspection
31. Mass air flow sensor system
31.1. ST Data Monitor Display
31.2. ECM Input/Output Signal Specifications
31.3. Circuit Diagram
31.4. Component Parts Inspection
32. Engine coolant tempera ture sensor system
32.1. ST Data Monitor Display
32.2. ECM Input/Output Signal Specifications
32.3. Circuit Diagram
32.4. Component Parts Inspection
33. Heated oxygen sensor system
33.1. ST Data Monitor Display
33.2. ECM Input/Output Signal Specifications
33.3. Circuit Diagram
34. Throttle position sensor system
34.1. ST Data Monitor Display
34.2. ECM Input/Output Signal Specifications
34.3. Circuit Diagram
34.4. Component Parts Inspection
35. Accelerator pedal position sensor system
35.1. ST Data Monitor Display
35.2. ECM Input/Output Signal Specifications
35.3. Circuit Diagram
35.4. Component Parts Inspection
36. Intake air temperature sensor
36.1. ST Data Monitor Display
36.2. ECM Input/Output Signal Specifications
36.3. Circuit Diagram
36.4. Component Parts Inspection
37. PNP switch system
37.1. ST Data Monitor Display
37.2. ECM Input/Output Signal Specifications
37.3. Circuit Diagram
38. Stop lamp switch system
38.1. ST Data Monitor Display
38.2. ECM Input/Output Signal Specifications
38.3. Circuit Diagram
38.4. Component Parts Inspection
39. Electric load switch system
39.1. ST Data Monitor Display
39.2. ECM Input/Output Signal Specifications
39.3. Circuit Diagram
40. CAN communication system
40.1. ECM Input/Output Signal Specifications
40.2. Circuit Diagram
41. Ignition system
41.1. ST Data Monitor Display
41.2. ECM Input/Output Signal Specifications
41.3. Circuit Diagram
41.4. Component Parts Inspection
42. Fuel injector system
42.1. ST Data Monitor Display
42.2. ECM Input/Output Signal Specifications
42.3. Circuit Diagram
42.4. Component Parts Inspection
43. Fuel pump system
43.1. ST Data Monitor Display
43.2. ECM Input/Output Signal Specifications
43.3. Circuit Diagram
43.4. Component Parts Inspection
44. Throttle control motor system
44.1. ECM Input/Output Signal Specifications
44.2. Circuit Diagram
44.3. Component Parts Inspection
45. Heated oxygen sensor heater system
45.1. ST Data Monitor Display
45.2. ECM Input/Output Signal Specifications
45.3. Circuit Diagram
45.4. Component Parts Inspection
46. PCV gas recirculation device
46.1. System Diagram
46.2. Component Parts Inspection
47. Fuel cut function
47.1. Inspection Procedure
48. Removal and installation of ECM components
48.1. Removal and Installation of ECM
48.2. Removal and Installation of Crankshaft Position Sensor (POS)
48.3. Removal and Installation of Camshaft Position Sensor (PHASE)
48.4. Removal and Installation of Mass Air Flow Sensor
48.5. Removal and Installation of Engine Coolant Temperature Sensor.
48.6. Removal and Installation of Heated Oxygen Sensor (with Heated Oxygen Sensor Heater)
48.7. Removal and Installation of Throttle Position Sensor (Electric Throttle Control Actuator Assembly)
48.8. Removal and Installation of Accelerator Pedal Position Sensor (Accelerator Pedal Assembly)
48.9. Removal and Installation of Intake Air Temperature Sensor (with Mass Air Flow Sensor)
48.10. Removal and Installation of Neutral Switch (M/T Model)
48.11. Removal and Installation of Ignition Coil (with Power Transistor)
48.12. Removal and Installation of Fuel Injector
48.13. Removal and Installation of Fuel Pump
48.14. Removal and Installation of Throttle Control Motor (Electric Throttle Control Actuator Assembly)
48.15. Removal and Installation of LPG Injector Holder
48.16. Removal and Installation of LPG Injector Drive Unit
49. SERVICE DATA AND SPECIFICATIONS (SDS)
49.1. Standard, Repair Limit
50. Lubrication system
50.1. Specifications
50.2. Adjustment Value
50.3. Oil Pressure
50.4. Tightening Torque
50.5. Trouble Diagnosis
50.6. Lubrication Schematic Diagram
50.7. Oil Pump
51. Engine coolant system
51.1. Specifications
51.2. Adjustment Value
51.3. Tightening Torque
51.4. Trouble Diagnosis
51.5. Cooling System Configuration
51.6. Water Pump
51.7. Thermostat
51.8. Thermostat
52. Emission control system (only for electronic controlled type)
53. Unit layout
54. LPG fuel system trouble diagnosis
55. Disassembly and assembly of fuel system
55.1. Removal and Installation of LPG Injector Drive Unit Connector
55.2. Removal and Installation of Electronic Control Throttle Assembly
55.3. Removal and Installation of Gasoline Fuel Injector (Electronic Controlled Gasoline and Combined Use)
55.4. Injector Holder
56. Vaporizer mechanism and operation
56.1. Primary (Decompression) Room
56.2. Description
57. Adjustment value
58. Trouble diagnosis
59. Starter motor
59.1. Starter Motor Specifications
59.2. Component Parts Location
59.3. Overhaul
59.4. Assembly Inspection
60. Alternator
60.1. Components of Alternator
60.2. Disassembly
60.3. Inspection

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