Komatsu TB45 Service Manual

SERVICE MANUAL

SM208

TB45E(CARB2010)-BE1

CX50 Forklift Truck, EPA/CARB 2010 Compliant

Gasoline/LPG FG40ZTU/40TU/45TU/50ATU-10

FG40Z/35/40/45/50A-10

S/N 134756~

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.

ISSUED: JUNE 2011

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

• Do not run the engine in a place which has no exhaust ducts
and which is poorly ventilated.

• Ventilate the workplace well and do not place a combustible
thing there. Take extreme care when handling a combustible
thing or a hazardous material such as gasoline.

• Dispose of the replaced oil, parts washing oil, etc. according to
laws.

• When working on parts which become hot, rotary parts, or
sliding parts, take care not to burn or injure yourself.

• When working in a pit or a closed place, ventilate it to discharge

EGM0043

harmful materials in advance.

• Do not work on the vehicle jacked up. When working on it,
support it by the specified parts on wood blocks, etc.

• When lifting up the vehicle, support it by the specified parts and
apply a safety device.

• When removing a heavy part such as the engine, vehicle body,
etc. take care not to drop it by unbalancing it.

• Do not smoke while maintaining the vehicle.

• When maintaining the vehicle, take off rings and necklace to
prevent a short circuit in the electrical system.

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• Before starting repair which does not need the battery power,
turn the key switch OFF and disconnect the negative (–)
terminal of the battery.

• Take care not to touch the hot metal parts just after stopping the
engine. While the engine is still hot, do not remove the radiator
cap or another part of the coolant system.

• Use the specified proper common tools or special tools for safe
and efficient repair.

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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.

• If an oil seal, gasket, packing, O-ring, lock washer, cotter pin,
self-lock nut, etc. are removed, replace them according to the
directions in their sections (Parts which must not be reused).

• When a tapered roller bearing or a needle roller bearing needs
to be replaced, replace its inner race and outer race as a set.

• Arrange the removed parts in order so that they will not be
mixed up.

• Before checking or assembling the disassembled parts, clean
them.

• When replacing a part, install a NISSAN genuine part.

• Use the specified oil, grease, sealant, etc.

• Before removing a pressurized pipe, hose, etc., release the
pressure.

• After repairing the fuel, oil, coolant, exhaust, or vacuum system,
check it for leakage securely.

Precautions for Radio Equipment Installation

Check the following when installing a commercial/ham radio or
mobile phone. If mounting position is not chosen carefully, the unit
may interfere with the electronic control system.

• Separate the antenna as far from the ECM as possible.

• Route an antenna feeder line at least 20 cm (7.87 in) apart from
the control unit harness.

• Adjust an antenna and feeder line to eliminate radio wave
interference.

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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 "trouble­shooting".

Definition of Terms

CAUTION:

• An item or a work procedure, neglect of which can cause a
death or a serious injury if neglected.

• An item or a work procedure to be observed especially
among those, neglect of which can cause an injury, an
accident, or a damage of the vehicle or component parts.

Reference : Supplementary explanation for the ease of work.
Standard value : Permissible deviation of a value at inspection or

adjustment.

Limit value : The maximum or minimum which a value must not

exceed at inspection or adjustment.

Definition of Units

In this manual, tightening torque, pressure, etc. are indicated by the
"SI unit" (International unit) first, then by the "metric unit) in { }.
Example) Tightening torque: 59 - 78 Nm {6.0 - 8.0 kgf•m}

SI unit {Metric unit}

CONVERSION OF MAJOR UNITS

Quantity SI unit Conventional unit Coefficient of conversion into SI

Acceleration

Torque and moment Nm kgf•m 9.80665

Force N kgf 9.80665

Pressure MPa

Power/Power efficiency kW PS 0.735499

Vol um e

Spring constant N/mm kgf/mm 9.80665

Fuel consumption g/kW•h(*1) g/PS•h 1.3596

2

m/s

kPa mmHg 0.133322

W kcal/h 1.16279

3

cm

G 9.80665

2

kgf/cm

cc 1

*1. Conventional unit may be used in SI.

0.09809665

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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. Some
commercial service tools, assumed to be available in
any workshop, are omitted.

Description : To perform correct operations, operational procedures,

notes, SSTs, and other service information are
described.

CAUTION : Descriptions of visual inspections and cleaning of

removed parts are generally omitted. Please
remember that actual operations require these
processes.

Component Parts Location

The "Component Parts Location" diagram (refer to the figure)
includes information for removal, installation, disassembly, and
assembly (tightening torque, grease points, non-reusable parts) as
well as other information important for repair work.

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HOW TO READ THIS MANUAL

Component Parts Location (Cont'd)

COMPONENT SYMBOLS

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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" and "Trouble Diagnosis Flowchart".

• After the repair work, always verify that the trouble is
eliminated.

• For the locations of the parts and harness connectors,
refer to "Component Parts Location" in the relevant
section.

• To perform a simple inspection, utilize the circuit diagrams.
To inspect the circuit for continuity in details including the
sub-harnesses, identify the relevant connectors and
harness layouts referring to the "Wiring Diagrams".

• Before inspecting a circuit for continuity, always turn the
ignition switch to OFF.

• Before measuring voltage at a connector, always measure
the battery voltage.

• After finishing diagnoses or inspections, always ensure
that all removed harness connectors are reconnected
correctly.

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TROUBLE DIAGNOSIS

ECM Trouble Diagnosis (Cont'd)

SYMBOLS

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