KOMATSU TB45E SERIES FORKLIFT TRUCK ENGINES SERVICE REPAIR MANUAL
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KOMATSU TB45E SERIES FORKLIFT TRUCK ENGINES SERVICE REPAIR MANUAL
KOMATSU TB45E SERIES FORKLIFT TRUCK ENGINES SERVICE REPAIR MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 228
FILE SIZE: 4.48MB
MODEL COVERED:
KOMATSU TB45E SERIES
SERIAL NO: 064005 AND UP
PART NO:
SM127
ISSUED:
OCTOBER, 2004
CONTENTS:
- Table of Contents
- Federal EPA Emissions Control Statement for Off-Road LSI Non-Diesel Engines (TB45E)
- Labels Required and Label Locations
- Warranty
CHAPTER EG – ENGINE GENERAL
- Precautions for Safety and Quality
- Safe Operation
- Correct Operation
- Precautions for Radio Equipment Installation
- How to Use This Manual
- Description
- Definition of Terms
- Definition of Units
- Description – Caution
- Component Parts Location
- Component Symbols
- Troubleshooting
- ECCS Troubleshooting
- Symbols Chart
- Symbols for Harness Connector
- ECCS Abbreviations List
- Connector Terminal Inspection
- ECM General Service Information
- Inspection for Electrical System
- Control Unit and Electronic Component
- Service Tool
- Precautions
- Precautions in Draining Engine Coolant
- Precautions for Disconnecting Fuel Piping
- Precautions for Removing and Disassembling
- Precautions for Inspection, Correction and Replacement
- Precautions for Assembly and Installation
- Caution for Use of Power Tools
- Precautions for Liquid Gasket Application
- Parts Requiring Angle Tightening
- Preparation
- Special Service Tools
- Service Parts
- Service Data
- Periodic Inspection
- Standard Repair Limit
- Tightening Torque
- Caution for Use of Power Tools
CHAPTER ET – ENGINE TUNE-UP
- Valve Clearance
- Inspection
- Adjustment
- Engine Drive Belt
- Inspection
- Belt Tension Adjustment
- Engine Oil
- Engine Oil Inspection
- Engine Oil Replacement
- Oil Filter Replacement
- Compression Pressure
- Spark Plug
CHAPTER EM – ENGINE MECHANICAL
- Intake Manifold
- Component Parts Location Diagram
- Removal and Installation of Intake Manifold
- Removal and Installation of Air Horn Bolt
- Inspection
- Exhaust Manifold
- Component Parts Location Diagram
- Removal and Installation
- Oil Pan and Oil Strainer
- Component Parts Location Diagram
- Removal and Installation
- Rocker Cover
- Component Parts Location Diagram
- Removal and Installation
- Rocker Arm and Rocker Shaft Assembly
- Component Parts Location Diagram
- Removal and Installation
- Disassembly and Assembly
- Inspection
- Cylinder Head
- Component Parts Location Diagram
- Removal and Installation of Cylinder Head
- Cylinder Head Assembly
- Timing Chain
- Component Parts Location Diagram
- Removal
- Installation
- Removal and Installation of Engine
- Removal
- Installation
- Inspection
- Cylinder Block
- Component Parts Location Diagram
- Disassembly
- Selective-Fit Service Parts
- Inspection After Disassembly
- Assembly
CHAPTER LU – ENGINE LUBRICATION
- Oil Pump
- Component Parts Location
- Disassembly and Assembly
- Inspection
CHAPTER CO – COOLING SYSTEM
- Changing Engine Coolant
- Draining Engine Coolant
- Refilling Engine Coolant
- Water Pump
- Component Parts Location Diagram
- Removal and Installation
- Water Pump Inspection
- Thermostat
- Component Parts Location Diagram
- Removal and Installation
CHAPTER EC – TB45 ENGINE CONTROL
- Precautions
- General Precautions for Service Operations
- Preparation
- Special Tools
- Engine Control System
- Description
- System Diagram – Gasoline
- System Diagram – LPG
- System Diagram – Dual-Fuel
- Sensors and Actuators Control Items Chart
- Basic Inspection
- Inspection of Idle Speed, Ignition Timing and Air-Fuel Ratio
- Throttle Valve Closed Position Learning and Idle Air Volume Learning
- Fuel Pressure Inspection
- Troubleshooting
- How to Proceed with Trouble Diagnosis
- Diagnosis Chart by Symptom
- Component Parts Location Chart
- Circuit Diagram – ECCS – Gasoline
- Circuit Diagram – ECCS – LPG
- Circuit Diagram – ECCS – Dual-Fuel
- ECCS Terminal Layout Chart
- ECCS Input/Output Signal Specifications
- Service Tool
- Self-Diagnosis Function – Without Service Tool
- Service Tool Reference Value in Data Monitor
- Fail-Safe Function
- Power Supply and Ground System
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Crankshaft Position Sensor 1° (POS)
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Crankshaft Position Sensor 120° (REF) Signal Circuit
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Mass Air Flow Sensor System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Engine Coolant Temperature Sensor System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Heated Oxygen Sensor System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Vehicle Speed Sensor System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Throttle Position Sensor System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Accelerator Pedal Position Sensor System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Intake Air Temperature Sensor
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- PNP Switch System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Stop Lamp Switch System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Electric Load Switch System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Ignition System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Fuel Injector System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Fuel Pump System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Engine Warning Light System
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Heated Oxygen Sensor Heater System
- Service Tool Data Monitor Display
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- LPG Injector System
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Throttle Control Motor System
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- LPG Fuel Pressure Sensor System
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- LPG Assistance Injector System
- Control Unit Input/Output Signal Specifications
- Circuit Diagram
- Component Parts Inspection
- Blow-by Gas Restoration Device
- System Diagram
- Removal and Installation of PCV (Blow-by Control) Valve
- Blow-by Control Valve Inspection
- Fuel Cut Function
- Inspection Procedure
- Removal and Inspection of ECCS (ECM) Components
- Removal and Installation of ECM
- Removal and Installation of Crankshaft Position Sensor
- Removal and Installation of Mass Air Flow Sensor
- Removal and Installation of Engine Coolant Temperature Sensor
- Removal and Installation of Heated Oxygen Sensor (with Heater)
- Removal and Installation of Throttle Position Sensor (ETCA)
- Removal and Installation of Accelerator Pedal Position Sensor (Pedal Assembly)
- Removal and Installation of Air Temperature Sensor (with Mass Air Flow Sensor)
- Removal and Installation of Ignition Coil (in Distributor)
- Removal and Installation of Fuel Injector
- Removal and Installation of Fuel Pump
- Removal and Installation of Throttle Control Motor (ETCA Assembly)
- Removal and Installation of Injector Holder
- LPG Injector Drive Unit
- Service Data and Specifications (SDS)
- Standard Repair Limit
CHAPTER FL – ENGINE FUEL SYSTEM
- Description
- Gasoline Specification
- LPG Specification
- Dual-Fuel Specification
- Removal and Installation of Fuel Injector (Gasoline and Dual-Fuel Trucks)
- Preparation
- Removal and Installation of Fuel Hose
- Removal and Installation of Fuel Tube and Fuel Injector
- Check for Fuel Leakage After Installation
- Disassembly and Reassembly of LPG System
- Description of LPG System (Gasoline and Dual-Fuel)
- LPG Injection System Diagram
- Removal and Installation of Injector Holder
- Removal and Installation of Vaporizer
- Maintenance of Vaporizer
CHAPTER EL – ENGINE ELECTRICAL SYSTEM
- Starting System
- Component Parts Location Diagram
- Starter Motor Removal and Installation
- Charging System
- Component Parts Location Diagram
- Alternator Exploded View
- Components of Alternator
- Alternator Removal and Installation
- Alternator Disassembly and Reassembly
- Assembly of High-Tension Cables (Ignition Wires) – Diagram
APPENDIX 1 – MAINTENANCE SCHEDULE CHART
- First Month or Initial 200 Hours Service
- Every 2 Weeks or 100 Hours Service
- Every Month or 200 Hours Service
- Every 3 Months or 600 Hours Service
- Every 6 Months or 1,200 Hours Service
- Every 2,000 Hours Service
- Every 12 Months or 2,400 Hours Service
- Every 18 Months or 3,600 Hours Service
The Komatsu TB45E Series Forklift Truck Engine Service Manual is a comprehensive technical workshop reference designed to assist with engine servicing, routine maintenance, inspection, troubleshooting, testing, adjustment, component removal, repair and reassembly. Covering the TB45E engine series, this manual provides detailed service information for engine general procedures, engine tune-up, mechanical components, lubrication, cooling, engine control, fuel delivery and electrical systems. It includes essential guidance on safety precautions, service specifications, periodic inspections, standard repair limits, tightening torque values, special service tools and maintenance procedures. The engine mechanical section covers the intake and exhaust manifolds, oil pan, oil strainer, rocker cover, rocker arm and shaft assembly, cylinder head, timing chain and cylinder block, with instructions for removal, installation, inspection, disassembly and assembly. The engine control section provides information on gasoline, LPG and dual-fuel configurations, electronic control systems, sensors, actuators, circuit diagrams, input and output signal specifications, service tool functions and diagnostic procedures. Additional coverage includes fuel injectors, fuel pumps, fuel hoses, LPG injection components, vaporizer maintenance, starter motor servicing, alternator inspection and repair. The manual also features troubleshooting charts, electrical system diagnosis, component inspection procedures and a maintenance schedule covering initial 200-hour servicing, regular 100-hour and 200-hour intervals, and longer-term 600-hour, 1,200-hour, 2,000-hour, 2,400-hour and 3,600-hour maintenance intervals. An essential reference for Komatsu forklift technicians, engine mechanics, diesel and industrial engine specialists, service workshops and equipment maintenance professionals involved in keeping TB45E series forklift truck engines operating reliably.
