Komatsu TB45 Service Manual
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Komatsu TB45 Service Manual

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SERVICE MANUAL
CX50 Forklift Truck, EPA/CARB 2010 Compliant
Gasoline/LPG
TB45 GASOLINE
ENGINE (ECU)
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.
ISSUED: JUNE 2011
FG40ZTU/40TU/45TU/50ATU-10
FG40Z/35/40/45/50A-10
WARNING
SM208
TB45E(CARB2010)-BE1
S/N 134756~

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  • Page 1 SERVICE MANUAL CX50 Forklift Truck, EPA/CARB 2010 Compliant Gasoline/LPG FG40ZTU/40TU/45TU/50ATU-10 S/N 134756~ FG40Z/35/40/45/50A-10 TB45 GASOLINE ENGINE (ECU) WARNING Read and observe all warnings on this unit before operating it. DO NOT operate this equipment unless all factory-installed guards and shields are properly secured in place.

  • Page 2: Precautions For Safety And Quality

    PRECAUTIONS FOR SAFETY AND QUALITY PRECAUTIONS FOR SAFETY AND QUALITY Description • Observe the following precautions for safe and proper maintenance. • Only qualified and appointed persons shall inspect, repair, or adjust the vehicle. • Keep the workplace and tools clean. Safe Work •...
  • Page 3 PRECAUTIONS FOR SAFETY AND QUALITY Correct Work • Grasp the contents of each trouble, and then troubleshoot and work efficiently. • When removing and disassembling parts, check their normal assembly condition in advance. Make match marks on places which do not affect the function, if necessary. •...

  • Page 4: How To Read This Manual

    HOW TO READ THIS MANUAL HOW TO READ THIS MANUAL Outline This chapter explains how to read the procedures of "removal, disassembly, assembly, inspection, and adjustment" and "trouble- shooting". Definition of Terms CAUTION: • An item or a work procedure, neglect of which can cause a death or a serious injury if neglected.
  • Page 5 HOW TO READ THIS MANUAL Description CAUTION : At the beginning of each section, the precautions exclusive to the section are described. Preparation: At the beginning of each section and during the trouble diagnosis items, the SSTs, gauges, and other tools to be prepared before operation are described.
  • Page 6 HOW TO READ THIS MANUAL Component Parts Location (Cont'd) COMPONENT SYMBOLS EG-6...

  • Page 7: Trouble Diagnosis

    TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS ECM Trouble Diagnosis CAUTION: • The following trouble diagnosis procedures are designed to identify the trouble causes efficiently. When performing diagnoses, carefully observe the following instructions. • Before starting a trouble diagnosis, carefully read and understand the contents in "Basic Inspection", "Diagnosis Chart by Symptom"...
  • Page 8 TROUBLE DIAGNOSIS ECM Trouble Diagnosis (Cont'd) SYMBOLS EG-8...
  • Page 9 TROUBLE DIAGNOSIS ECM Trouble Diagnosis (Cont'd) SYMBOLS FOR HARNESS CONNECTOR FEMALE CONNECTOR • When a harness connector is viewed from A (terminal side), the outer frame of the connector symbol is indicated with a single line. In addition, the direction indicator shows "TS" (Terminal Side) in description type font.
  • Page 10 TROUBLE DIAGNOSIS ECM Abbreviations List Abbreviations Description Abbreviations Description Air conditioner Intake Automatic transmission Left Alternator Light emitting diode ASSY Assembly Long-life coolant Battery Manual transmission Crankshaft pulley Overhead valve Control unit Oversize Cylinder Power steering Engine Power take-off Exhaust Right Fusible link Rear...

  • Page 11: Ecm General Service Information

    ECM GENERAL SERVICE INFORMATION ECM GENERAL SERVICE INFORMATION Connector Terminal Inspection CONNECTOR INSPECTION PROCEDURE In circuit inspection, inappropriate connector probing will cause connector damages and/or poor connection. The probes provided with the circuit tester may be too large to probe connector terminals without damaging them.
  • Page 12 ECM GENERAL SERVICE INFORMATION Connector Terminal Inspection (Cont'd) Male terminal For a male connector terminal, apply a "T" pin to the surface of the terminal. CAUTION: Do not bend terminals. EGM0057 Inspection for Electrical System DESCRIPTION • If the malfunction can be traced directly to the electrical system, first check for items such as burned-out fuses and fusible links, broken wires or loose connectors, pulled-out terminals, and improper connections.
  • Page 13 ECM GENERAL SERVICE INFORMATION Control Unit and Electronic Component PRECAUTIONS • Never reverse polarity of battery terminals. • Install only parts specified for each model. • Before replacing a control unit, check input and output signals to/from the control unit, and component functions. •...
  • Page 14 ECM GENERAL SERVICE INFORMATION DESCRIPTION SST is a small, lightweight handheld tester. When connected to the vehicle-side data link connector, it communicates with control units installed on the vehicle and performs a variety of diagnostic tests. FUNCTION AND APPLIED SYSTEM Items Function WORK SUPPORT...

  • Page 15: Precautions For Work

    PRECAUTIONS FOR WORK PRECAUTIONS FOR WORK Precautions for Draining Coolant Drain the coolant after its temperature lowers sufficiently. Precautions for Separating Fuel Piping • Work in a place where there is nothing to start a fire. • Release the fuel pressure in advance. •...
  • Page 16 PRECAUTIONS FOR WORK Precautions for Using Power Tools Use power tools such as an air runner for disassembly only. Do not use them for assembly. Precautions for Applying Gasket Sealant SEPARATION OF PARTS COATED WITH GASKET SEALANT • After removing the mounting bolts and mounting nuts, cut and remove the gasket sealant with seal cutter (special tool KV101- 11100) according tothe following procedure.
  • Page 17 PRECAUTIONS FOR WORK Parts Which Need to be Tightened by Angle Tightening Method • Use angle wrenches (special tools) to tighten the following parts. • Cylinder head bolt Check that the cylinder head, cylinder block mounting face, and cylinder head gasket are free from oil and dirt, and then coat the threads and stem of the cylinder head bolt and tighten it.
  • Page 18 PREPARATION PREPARATION Special Service Tools Special Service Tools (Cont'd) Description Application Remarks Seal cutter Removing parts attached with KV1011 11100 liquid gasket EGM0069 Ring gear stopper Removing and installing KVl101 056S0 crankshaft pulley 1 Adapter KV101 05630 2 Stopper plate KV101 05610 EGM0070 Oil seal drift...
  • Page 19 PREPARATION Special Service Tools (Cont'd) Description Application Remarks Engine stand assembly Overhauling engine ST0501 S000 EGM0076 Engine attachment KV101 06500 EGM0077 Engine sub-attachment KV111 04800 Already established EGM0078 Camshaft bushing tool set Removing and installing camshaft KV111 045S0 bushing 1. Bar KV111 04510 2.

  • Page 20: Service Parts

    PREPARATION Special Service Tools (Cont'd) Description Application Remarks Heated oxygen sensor wrench Removing and installing heated KV101 13700 oxygen sensor EGM0083 Maintenance tool For system inspection and 1. DIAGNOSIS KIT diagnosis SKVEE GY010 2. SOFT WARE SKVEE GY100 Check adapter V For control unit input/output signal EG1755 0000 inspection...

  • Page 21: Service Data

    SERVICE DATA SERVICE DATA Periodical Inspection To maintain the initial performance of the KOMATSU FORKLIFT, make sure to perform appropriate maintenance and service work. PERFORM INSPECTION Make sure to perform the periodical inspections at the appropriate times, according to the month basis or the operating hour basis, whichever comes first.
  • Page 22 SERVICE DATA Periodical Inspection (Cont'd) Engine system inspection (LPG models) Gas leakage from piping and piping Electronic joints controls Damage to piping and piping joints Electronic controls Tar in vaporizer Electronic controls Injection nozzle Electronic controls LPG filter Electronic controls CAUTION: •...
  • Page 23 SERVICE DATA Standard, Repair Limit Fuel in use Gasoline specification Lead-free regular gasoline with an octane value of 91 or more LPG specification 20-100P Engine weight (without water, with oil) kg (lb) Approx. GAS, LPG:301’, DUAL:302’ Firing order 1 - 5 - 3 - 6 - 2 - 4 Compression pressure Standard 1,187 (11.87, 12.1, 172)/200...

  • Page 24: Tightening Torque

    SERVICE DATA Tightening Torque STANDARD BOLT TIGHTENING TORQUE <Hexagon head> <No lubrication> Unit: N•m (kg-m, ft-lb) N•m (kg-m, in-lb)* Normal size Pitch Non-flanged Non-flanged Flanged bolt Non-flanged bolt Flanged bolt Flanged bolt bolt bolt (0.06, 5)* (0.07, 6)* (0.11, 10)* (0.13, 11)* (0.16, 14)* (0.19, 16)*...
  • Page 25 SERVICE DATA Tightening Torque (Cont'd) MAIN TIGHTENING TORQUE : Parts with tightening sequence 1) - :Tighten separately in several turns. Unit :N•m (kg-m, ft-lb) N•m (kg-m, in-lb)* Parts name or location Tightening torque Adjusting screw Lock nut 16 - 22 (1.6 - 2.2, 12 - 16) AlternatorAdjusting bar side 17.5 - 23.7 (1.8 - 2.4, 13 - 17) Bracket side...

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