Komatsu TB45E Series Forklift Trucks Engine Service Manual SM127 – PDF DOWNLOAD

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Komatsu TB45E Series Forklift Trucks Engine Service Manual SM127 – PDF DOWNLOAD

FILE DETAILS:

Komatsu TB45E Series Forklift Trucks Engine Service Manual SM127 – PDF DOWNLOAD

Language : English
Pages : 228
Downloadable : Yes
File Type : PDF
Size: 4.48 MB

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TABLE OF CONTENTS:

Komatsu TB45E Series Forklift Trucks Engine Service Manual SM127 – PDF DOWNLOAD

TB45E: ENGINE SERIAL NUMBERS 064005-

TABLE OF CONTENTS 1
FEDERAL EPA EMISSIONS CONTROL STATEMENT FOR OFF-ROAD LSI
NON-DIESEL ENGINES (TB45E) 7
1 Labels Required and Label Locations 7
2 Warranty 8
CHAPTER EG ENGINE GENERAL
Precautions for Safety and Quality
Safeoperation
Correctoperation
Precautions for Radio Equipment Installation
HowtoUseThisManual
Description
DefinitionofTerms
Definition of Units
Description C aution
ComponentPartsLocation
ComponentSymbols
Troubleshooting
ECCSTroubleshooting
SymbolsChart
Symbols for Harness Connector
ECCS Abbreviations List
Connector Terminal Inspection
ECM General Service Information
Inspection for Electrical System
Control Unit and Electronic Component
ServiceTool
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
SpecialServiceTools
ServiceParts
ServiceData
Periodiclnspection
Standard RepairLimit
TighteningTorque
Caution for Use of Power Tools
CHAPTER ET ENGINE TUNE-UP ET-1
Valveclearance ET 2
Inspection E T 2
Adjustment E T 3
EngineDriveBelt
lnspection
Belt Tension Adjustment
Engineoil
EngineOillnspection
EngineOilReplacement
Oil Filter Replacement
CompressionPressure
Sparkplug
CHAPTER EM ENGINE MECHANICAL
IntakeManifold
Component Parts Location Diagram
Removal and Installation of Intake Manifold
Removal and Installation of Air Horn Bolt
Inspection
ExhaustManifold
Component Parts LocationDiagram
Removal and lnstallation
OilPanandOilStrainer
Component Parts Location Diagram
Removal and Installation
Rockercover
Component Parts Location Diagram
Removal and lnstallation
Rocker Arm and Rocker Shaft Assembly
Component Parts Location Diagram
Removal and Installation
Disassembly and Assembly
Inspection
CylinderHead
Component Parts Location Diagram
Removal and Installation of Cylinder Head
Cylinder Head Assembly
Timingchain
Component Parts Location Diagram
Removal
Installation
Removal and Installation of Engine
Removal
Installation
Inspection
CylinderBlock
Component Parts Location Diagram
Disassembly
Selective-Fit Service Parts
Inspection After Disassembly
Assembly
CHAPTER LU ENGINE LUBRICATION LU-1
OilPump LU 2
ComponentPartsLocation L U 2
Disassembly and Assembly L U-2
Inspection LU 3
CHAPTER CO COOLING SYSTEM
Changing Enginecoolant
Draining Engine Coolant
Refilling Engine Coolant
Waterpump
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
SpecialTools
Engine Control System
Description
System Diagram Gasoline
System Diagram LPG
System Diagram Dual-Fuel
Sensors and Actuators Control Items Chart
Basiclnspection
lnspection of ldle Speed, Ignition Timing and Air-Fuel Ratio
Throttle Valve Closed Position Learning and ldle Air Volume Learning
FuelPressurelnspection
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 DuaLFuel
ECCS Terminal Layout Chart
ECCS Input I Output Signal Specifications
ServiceTool
Self-Diagnosis Function Without Service Tool
Service Tool Reference Value in Data Monitor
Fail-SafeFunction
Power Supply and Ground System
Control Unit Input I Output Signal Specifications
CircuitDiagram
Crankshaft Position Sensor I ” (POS)
Control Unit Input I Output Signal Specifications
CircuitDiagram
Component Parts Inspection
Crankshaft Position Sensor 120″ (REF) Signal Circuit
Control Unit Input I Output Signal Specifications
CircuitDiagram
Component Parts Inspection
Mass Air Flow Sensor System
Service Tool Data Monitor Display
Control Unit Input 1 Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Engine Coolant Temperature Sensor System
Service Tool Data Monitor Display
Control Unit Input 1 Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Heated Oxygen Sensor System
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Vehicle Speed Sensor System
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
Throttle Position Sensor System
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Accelerator Pedal Position Sensor System
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Intake Air Temperature Sensor
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
PNP Switch System
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Stop Lamp Switch System
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Electric Load Switch System
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Ignitionsystem
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts lnspection
Fuel Injector System
Service Tool Data Monitor Display
Control Unit Input 1 Output Signal Specifications
CircuitDiagram
Component Parts lnspection
FuelPumpSystem
Service Tool Data Monitor Display
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts Inspection
Engine Warning Light System
Control Unit Input / Output Signal Specifications
CircuitDiagram
Heated Oxygen Sensor Heater System
Service Tool Data Monitor Display
Control Unit Input 1 Output Signal Specifications
CircuitDiagram
ComponentPartslnspection
LPG lnjector System
Control Unit Input / Output Signal Specifications
CircuitDiagram
Throttle Control Motor System
Control Unit Input / Output Signal Specifications
CircuitDiagram
Component Parts lnspection
LPG Fuel Pressure Sensor System
Control Unit Input / Output Signal Specifications
CircuitDiagram
LPG Assistance Injector System
Control Unit Input I Output Signal Specifications
CircuitDiagram
Component Parts Inspection
Blow-by Gas Restoration Device
SystemDiagram
Removal and Installation of PCV (Blow-by Control) Valve
Blow-by Control Valve Inspection
FuelCutFunction
InspectionProcedure
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 (w/ Heater)
Removal and Installation of Throttle Position Sensor (ETCA)
Removal and Installation of Accelerator Pedal Position Sensor (Pedal Assy)
Removal and Installation of Air Temperature Sensor (w/ 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 lnjector Drive Unit
Service Data and Specifications (SDS)
Standard, RepairLimit
CHAPTER FL ENGINE FUEL SYSTEM FL-1
Description FL-2
Gasoline Specification F L -2
LPGSpecification F L 2
Dual-Fuel Specification F L -3
Removal and Installation of Fuel Injector(Gasoline & Duel-Fuel trucks) FL-4
Preparation FL-4
Removal and Installation of Fuel Hose F L -4
Removal and Installation of Fuel Tube and Fuel Injector FL-4
Check for Fuel Leakage After Installation F L -6
Disassembly and Reassembly of LPG System F L -7
Description of LPG System (Gasoline & Dual-Fuel) F L-7
LPG Injection SystemDiagram FL-8
Removal and Installation of Injector Holder FL-9
Removal and Installation of Vaporizer FL-12
Maintenance of Vaporizer F L -14
CHAPTER EL ENGINE ELECTRICAL SYSTEM EL-1
Starting System E L-2
Component Parts Location Diagram E L-2
Starter Motor Removal and Installation E L -2
ChargingSystem EL -3
Component Parts Location Diagram E L -3
Alternator Exploded View E L -4
Components of Alternator E L-5
Alternator Removal and Installation E L -5
Alternator Disassembly and Reassembly E L-6
Assembly of High-Tension Cables (Ignition Wires) – Diagram E L-12
APPENDIX I MAINTENANCE SCHEDULE CHART APP 1-1
First Month or Initial 200 Hours Service A PP 1-1
Every 2 Weeks or 100 Hours Service A P P 1-1
Every Month or 200 Hours Service A PP 1-1
Every 3 Months or GOO Hours Service A P P 1-3
Every 6 Months or 1 2 00 Hours Service A PP 1-3
Every 2 000 Hours Service A P P 1-3
Every 12 Months or 2 4 00 Hours Service A PP 1-3
Every 18 Months or 3 6 00 Hours Service A PP 1-

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