Professional Documents
Culture Documents
Shop Manual
Shop Manual
Shop Manual
fm 1 ページ 2008年7月2日 水曜日 午後12時30分
TB45E-BE1
TB45E ENGINE
TB45E
GASOLINE ENGINE (ECU)
TB45E ENGINE
TB45E
GASOLINE ENGINE (ECU)
Page No.
ENGINE GENERAL
PRECAUTIONS FOR SAFETY AND QUALITY ..................................................................EG-2
Description .....................................................................................................................................................EG-2
Safe Work ......................................................................................................................................................EG-2
Correct Work ..................................................................................................................................................EG-3
Precautions for Radio Equipment Installation ................................................................................................EG-3
PREPARATION .................................................................................................................EG-18
Special Service Tools ..................................................................................................................................EG-18
Service Parts ................................................................................................................................................EG-20
ENGINE MECHANICAL
INTAKE MANIFOLD ............................................................................................................EM-2
Component Parts Location ........................................................................................................................... EM-2
Removal and Installation of Intake Manifold ................................................................................................. EM-3
Removal and Installation of Air Horn Bolt ..................................................................................................... EM-3
Inspection ...................................................................................................................................................... EM-3
1
OIL PAN AND OIL STRAINER ........................................................................................... EM-6
Component Parts Location ............................................................................................................................EM-6
Removal and Installation ...............................................................................................................................EM-6
ENGINE LUBRICATION
OIL PUMP ............................................................................................................................ LU-2
Component Parts Location .............................................................................................................................LU-2
Disassembly and Assembly ............................................................................................................................LU-2
Inspection .......................................................................................................................................................LU-3
2
THERMOSTAT ..................................................................................................................... LU-4
Component Parts Location ............................................................................................................................ LU-4
Removal and Installation ................................................................................................................................ LU-4
ENGINE CONTROL
PRECAUTIONS ................................................................................................................... EC-3
General Precautions for Service Operations .................................................................................................EC-3
On Board Diagnostic (OBD) System of Engine .............................................................................................EC-4
Precaution ......................................................................................................................................................EC-4
Special Service Tools ....................................................................................................................................EC-7
3
THROTTLE POSITION SENSOR SYSTEM ......................................................................EC-59
SST Data Monitor Display ........................................................................................................................... EC-59
ECM Input/Output Signal Specifications ...................................................................................................... EC-59
Circuit Diagram ............................................................................................................................................ EC-59
Component Parts Inspection ....................................................................................................................... EC-59
4
FUEL CHANGING SWITCH SYSTEM ............................................................................... EC-71
SST Data Monitor Display ............................................................................................................................EC-71
ECM Input/Output Signal Specifications ...................................................................................................... EC-71
Circuit Diagram ............................................................................................................................................ EC-71
5
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR ............. EL-6
Component Parts Location .............................................................................................................................EL-6
Disassembly ...................................................................................................................................................EL-7
Inspection .......................................................................................................................................................EL-9
ENGINE TUNE-UP
VALVE CLEARANCE .......................................................................................................... ET-2
Description ......................................................................................................................................................ET-2
Inspection .......................................................................................................................................................ET-2
Adjustment ......................................................................................................................................................ET-3
6
KOMATSU TB45 ENGINE GENERAL
SECTION EG
CONTENTS
PRECAUTIONS FOR SAFETY AND QUALITY ... EG-2 PRECAUTIONS FOR WORK ........................... EG-15
Description ..................................................... EG-2 Precautions for Draining Coolant ................. EG-15
Safe Work ...................................................... EG-2 Precautions for Separating Fuel Piping ....... EG-15
Correct Work .................................................. EG-3 Precautions for Removal and Disassembly . EG-15
Precautions for Radio Equipment Installation .. EG-3 Precautions for Checking, Repairing, and
HOW TO READ THIS MANUAL ........................ EG-4 Replacing Parts ........................................... EG-15
Outline ............................................................ EG-4 Precautions for Assembling and
Definition of Terms ......................................... EG-4 Installing Parts ............................................. EG-15
Definition of Units ........................................... EG-4 Precautions for Using Power Tools ............. EG-16
Description ..................................................... EG-5 Precautions for Applying Gasket Sealent .... EG-16
Component Parts Location ............................ EG-5 Parts Which Need to be Tightened by Angle
TROUBLE DIAGNOSIS ...................................... EG-7 Tightening Method ....................................... EG-17
ECM Trouble Diagnosis ................................. EG-7 PREPARATION ................................................ EG-18
ECM Abbreviations List ................................ EG-10 Special Service Tools .................................. EG-18
ECM GENERAL SERVICE INFORMATION .... EG-11 Service Parts ............................................... EG-20
Connector Terminal Inspection .................... EG-11 SERVICE DATA ............................................... EG-21
Inspection for Electrical System ................... EG-12 Periodical Inspection .................................... EG-21
Control Unit and Electronic Component ....... EG-13 Standard, Repair Limit ................................. EG-23
SST .............................................................. EG-14 Tightening Torque ........................................ EG-24
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.
EGM0044
• Before starting repair which does not need the battery power,
turn the key switch OFF and disconnect the negative (–)
terminal of the battery.
EGM0045
• 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.
EGM0046
EG-2
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.
EG-3
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.
• 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.
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}
EG-4
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.
EGM0097
EG-5
HOW TO READ THIS MANUAL
EG-6
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
EG-7
TROUBLE DIAGNOSIS
EG-8
TROUBLE DIAGNOSIS
EGM0050
EGM0051
MALE CONNECTOR
The illustration method is the same as that for a female connector,
the black guide box, however, indicates a male connector (the white
guide box a female connector).
EGM0052
EGM0053
EG-9
TROUBLE DIAGNOSIS
EG-10
ECM GENERAL SERVICE INFORMATION
ECM GENERAL SERVICE INFORMATION
EGM0054
EGM0055
EGM0056
EG-11
ECM GENERAL SERVICE INFORMATION
EGM0057
EGM0058
EGM0059
EG-12
ECM GENERAL SERVICE INFORMATION
EGM0062
EGM0063
EG-13
ECM GENERAL SERVICE INFORMATION
SST
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.
Items Function
WORK SUPPORT Sends command to control unit to set status suitable for inspection and service.
FUNCTION SYSTEM Checks each system as ECM basic inspection.
SELF-DIAG RESULTS Receives self-diagnostic results from control unit and indicates DTCs and number of occurrences.
SELF-DIAG RESULTS DTCs (Diagnostic Trouble Codes) recorded in control unit's memory are displayed.
[MEMORY]
DATA MONITOR Receives input/output signals from control unit and indicates and stores them to facilitate locating cause of
malfunctions.
DATA MONITOR [SPEC]
Active test Sends command to control unit to change output signals and check operation of output system.
DTC RECORD DISPLAY Indicates self-diagnostic results stored in ECM prior to the most recent "ERASE MEMORY".
Control unit part No. Displays control unit part number.
Control unit identification No. Displays control unit identification number.
WORK SUPPORT {
SELF-DIAG RESULTS {
SELF-DIAG RESULTS [MEMORY]
DATA MONITOR {
DATA MONITOR [SPEC] {
Active test {
DTC RECORD DISPLAY
Control unit part No. {
Control unit identification No.
EG-14
PRECAUTIONS FOR WORK
PRECAUTIONS FOR WORK
EG-15
PRECAUTIONS FOR WORK
EGM0067
EG-16
PRECAUTIONS FOR WORK
EG-17
PREPARATION
PREPARATION
EGM0069
EGM0071
Already established
EGM0072
EGM0073
EGM0074
EGM0075
EG-18
PREPARATION
EGM0076
Engine attachment
KV101 06500
EGM0077
Engine sub-attachment
KV111 04800 Already established
EGM0078
EGM0080
EGM0081
EGM0082
EG-19
PREPARATION
EGM0083
EGM0084
Harness adapter
EG1755 0200
(150-pin to 121-pin conversion adapter)
EGM0085
EGM0086
Service Parts
Piston oversize
0.5 mm (0.020 in) OS [0.5 mm (0.020 in) oversize]
1.0 mm (0.039 in) OS [1.0 mm (0.039 in) oversize]
Main bearing undersize
Unit: mm (in)
Size Thickness
EG-20
SERVICE DATA
SERVICE DATA
Periodical Inspection
To maintain the initial performance of the NISSAN 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.
Months of
1 2 3 4 5 6 7 8 9 10 11 12 ... 18
Applicab use
No. nspection items le control
Operation
system hours 2 4 6 8 10 12 14 16 18 20 22 24 ... 36
(x 100 hours)
EG-21
SERVICE DATA
CAUTION:
• If the vehicle is being used in dusty and dirty environments, the maintenance work should be performed
more frequently.
• After replacing the LPG tank, apply soapsuds to the piping joints to check for any gas leakage.
Meanings of symbols: I = Inspection. Repair or replace if necessary.
R = Replacement
A = Adjustment
C = Cleaning
D = Draining
T = Tightening (Retightening)
EG-22
SERVICE DATA
EGM0098
EG-23
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)*
4T 7T 9T
Normal size Pitch
d P Non-flanged Non-flanged
Flanged bolt Non-flanged bolt Flanged bolt Flanged bolt
bolt bolt
CAUTION:
• Except special parts.
• The bolt applicable to the list has the following number embossed on the head.
Model Number
4T ... 4 or none
7T ... 7
9T ... 9
EG-24
SERVICE DATA
EG-25
KOMATSU TB45 ENGINE MECHANICAL
SECTION EM
CONTENTS
INTAKE MANIFOLD ........................................... EM-2 CYLINDER HEAD ............................................ EM-12
Component Parts Location ............................ EM-2 Component Parts Location .......................... EM-12
Removal and Installation of Intake Manifold .. EM-3 Preparation .................................................. EM-12
Removal and Installation of Air Horn Bolt ...... EM-3 Cylinder Head Auxiliary Bolt ........................ EM-13
Inspection ....................................................... EM-3 Cylinder Head Bolt ....................................... EM-13
EXHAUST MANIFOLD ....................................... EM-4 Cylinder Head Bolt Washer ......................... EM-14
Component Parts Location ............................ EM-4 Cylinder Head Gasket .................................. EM-14
Removal and Installation ................................ EM-4 Cylinder Head Assembly ............................. EM-15
OIL PAN AND OIL STRAINER .......................... EM-6 TIMING CHAIN ................................................. EM-20
Component Parts Location ............................ EM-6 Component Parts Location .......................... EM-20
Removal and Installation ................................ EM-6 Removal ....................................................... EM-20
ROCKER COVER ............................................... EM-8 CYLINDER BLOCK .......................................... EM-27
Component Parts Location ............................ EM-8 Component Parts Location .......................... EM-27
Preparation .................................................... EM-8 Disassembly ................................................ EM-27
Removal ......................................................... EM-8 Selective-Fit Service Parts ........................... EM-31
Installation ...................................................... EM-8 Inspection After Disassembly ...................... EM-31
ROCKER ARM AND ROCKER SHAFT Assembly ..................................................... EM-44
ASSEMBLY ........................................................ EM-9
Component Parts Location ............................ EM-9
Preparation .................................................... EM-9
Removal ......................................................... EM-9
Installation .................................................... EM-10
Disassembly and Assembly ......................... EM-10
Inspection ..................................................... EM-10
INTAKE MANIFOLD
INTAKE MANIFOLD
Screw
Bolt (4)
1.0 - 2.0 (0.1 - 0.2, 9 - 17)
22 - 37
(2.2 - 3.8, 16 - 27)
: Liquid gasket
: Not reusable
Gasket
Plug
(Gasoline)
Electric throttle
control actuator Water
connector
(LPG)
Gasket (3)
Plug
Water
connector
EMM0723
EM-2
INTAKE MANIFOLD
INSTALLATION
Tighten bolts evenly in two steps.
: 1st: 9 - 10 N•m (0.9 - 1.1 kg-m, 6.5 - 7.9 ft-lb)
2nd: 22 - 37 N•m (2.2 - 3.8 kg-m, 16 - 27 ft-lb)
EMM0724
Inspection
CHECK INTAKE MANIFOLD DISTORTION.
Check distortion of mounting surface in 6 directions using
straightedge and feeler gauge.
Limit: 0.2 mm (0.008 in)
EM-3
EXHAUST MANIFOLD
EXHAUST MANIFOLD
EMM0725
EMM0397
EM-4
EXHAUST MANIFOLD
INSPECTION
O2 sensor EMM0398
1. Exhaust manifold distortion
• Check distortion of mounting surface in 4 directions using
straightedge and feeler gauge.
Limit: 0.3 mm (0.012 in)
CAUTION:
If value is over limit, change new exhaust manifold.
EM-5
OIL PAN AND OIL STRAINER
OIL PAN AND OIL STRAINER
EMM0552
EMM0400
EM-6
OIL PAN AND OIL STRAINER
EMM0531
EM-7
ROCKER COVER
ROCKER COVER
EMM0532
Preparation
• Move high-tension core
• Wiring, disconnecting lines, moving
Removal
Loosen screws in the reverse of the order shown in the figure.
Installation
• Make sure that gasket is not missing from rocker cover
mounting groove.
• Tighten screws in the numerical order shown in the figure.
CAUTION:
Tightening torque of the first screw may decrease after
tightening all screws. Retighten all screws.
EMM0403
EM-8
ROCKER ARM AND ROCKER SHAFT ASSEMBLY
ROCKER ARM AND ROCKER SHAFT ASSEMBLY
EMM0533
CAUTION:
Apply new engine oil to the parts marked in the figure before
installation.
Preparation
• Rocker cover
• Adjusting valve clearance (after installation)
Removal
• Loosen lock nut, and then fully loosen valve clearance adjusting
screw.
• Loosen bolts evenly in several setps from outside to center.
• Carry each bracket with mounting bolts.
CAUTION:
Hold No. 8 bracket (end) only so as not to drop it when carrying.
EMM0405
EM-9
ROCKER ARM AND ROCKER SHAFT ASSEMBLY
Installation
ROCKER ARM AND ROCKER SHAFT ASSEMBLY
Tighten bolts evenly in several steps from center to outer side in this
order.
CAUTION:
• Make sure that valve clearance adjusting screw is securely
inserted to push rod head.
• Perform installation with valve clearance adjusting screw
fully loosened so as not to be affected by valve spring
tension.
• Adjust valve clearance after installation.
Refer to "Inspection and adjustment of valve clearance" in
EMM0406
ET section.
PUSH ROD
Rotate push rod after inserting, and then make sure that push rod tip
is securely inserted into valve lifter sphere surface.
EMM0407
SPRING WASHER
Install with each convex surface facing flat washer side. (Refer to
"Component Parts Location".)
ROCKER ARM
Assemble rocker shaft with bolt hole side facing engine front side
and oil hole facing downward. (Refer to "Component Parts
Location".)
Inspection
ROCKER SHAFT BEND
• Hold both ends of rocker shaft with V-blocks, and then set dial
indicator on the center.
• Rotate the rocker shaft in one direction by hand and read
indication on the dial indicator.
• Half of the reading is the rocker shaft bend.
Standard:
0.15 mm (0.0059 in) or less
Limit:
0.3 mm (0.012 in)
ECM0408
EM-10
ROCKER ARM AND ROCKER SHAFT ASSEMBLY
Inspection (Cont'd)
ROCKER ARM OIL CLEARANCE
1. Rocker shaft outer diameter
• Measure outer diameter around rocker arm mounting using a
micrometer.
Standard:
19.988 - 20.000 mm (0.7869 - 0.7874 in) dia.
EMM0409
EMM0410
EMM0411
EM-11
CYLINDER HEAD
CYLINDER HEAD
EMM0550
CAUTION:
Apply new engine oil to the parts marked in the figure before
installation.
Preparation
• Drain engine coolant
• Exhaust manifold
• Intake manifold
• High tension core
• Rocker cover
• Rocker arm and rocker shaft assembly
• Push rod
• Wiring, disconnecting lines, moving
• Alternator adjusting bar
EM-12
CYLINDER HEAD
INSTALLATION
Install after tightening cylinder head bolt.
EMM0413
INSTALLATION
• Lubricate threads and seat surface of each cylinder head bolt
with new engine oil.
• Tighten bolts in the numerical order shown in the figure with the
following steps.
CAUTION:
In step 3), loosen all bolts in the reverse of the order shown in
the figure.
1) Tighten to 29.4 N•m (3.0 kg-m, 22 ft-lb)
2) Tighten to 61.8 N•m (6.3 kg-m, 46 ft-lb).
3) Fully loosen to 0 N•m (0 kg-m, 0 in-lb).
4) Tighten to 29.4 N•m (3.0 kg-m, 22 ft-lb).
5) Tighten to 69° to 74°
EMM0414
EMM0415
EM-13
CYLINDER HEAD
EMM0416
EMM0417
EM-14
CYLINDER HEAD
EMM0535
CAUTION:
Apply new engine oil to the parts marked in the figure before
installation.
DISASSEMBLY
1. Compress the valve spring with a valve spring compressor
(SST), and remove the valve collet with a magnetic driver.
2. Remove valve spring retainer.
3. Remove valve spring.
4. Push the valve stem toward the combustion chamber side and
remove valve.
• Check valve guide clearance before removal.
• Check the location, and store individually.
EMM0419
EM-15
CYLINDER HEAD
EMM0420
INSPECTION
1. Cylinder head distortion
• Remove oil, scale, gasket, sealant, and carbon deposits from
surface of cylinder head using a scraper.
CAUTION:
• Do not allow gasket fragments to enter oil or engine
coolant passages.
• Check flatness of cylinder head lower surface. Measure
distortion in 6 directions shown in the figure, at several
points in each direction.
Limit: 0.2 mm (0.008 in)
EMM0421
2. Bulb Dimensions
• Measure dimensions at the points shown in the figure using a
micrometer.
Standard Unit: mm (in)
Intake Exhaust
a :118.15 (4.65) 118.8 (4.677)
b :3.1 - 3.5 (0.122 - 0.138) 3.1 - 3.5 (0.122 - 0.138)
c :1.15 - 1.45 (0.0453 - 0.0571) 1.35 - 1.65 (0.0531 - 0.0650)
D (diameter) :46.95 - 47.25 (1.848 - 1.860) 37.95 - 38.25 (1.4941 - 1.5059)
d (diameter) :7.965 - 7.980 (0.3136 - 0.3142) 7.945 - 7.960 (0.3128 - 0.3134)
α (degree) :45°15' - 45°45' 45°15' - 45°45'
EMM0422
EMM0423
EM-16
CYLINDER HEAD
EMM0424
EM-17
CYLINDER HEAD
EMM0428
ASSEMBLY
1. Install valve spring seats.
• Install valve spring seat (outer) with rounded side facing
upward.
2. Install valve oil seals.
• Install valve oil seal to the dimensions specified in the figure
using a valve oil seal drift (SST).
EMM0430
EM-18
CYLINDER HEAD
EMM0432
EM-19
TIMING CHAIN
TIMING CHAIN
EMM0726
CAUTION:
Apply new engine oil to the parts marked in the figure prior to
installation.
Removal
1. Remove the following parts. (Refer to the appropriate section
for each preparation.)
• Engine drive belt
• Water pump pulley
• Oil pan
• Rocker cover
• Rocker arm
• Rocker shaft assembly
• Push rod
• Cylinder head
EM-20
TIMING CHAIN
Removal (Cont'd)
2. Make sure that No. 1 cylinder is at TDC on its compression
stroke with the following procedure:
1) Rotate the crankshaft pulley clockwise (as viewed from the
front) and align orange notch with the timing indicator
(protrusion) on the front cover.
2) Make sure that distributor rotor is facing the direction (front side)
as shown in the figure.
• Turn crankshaft pulley 360 degrees in the direction shown
in the figure if the rotor is facing rear side.
3. Remove distributor.
4. Remove crankshaft pulley with the following procedure.
1) Remove starter motor.
2) Secure crankshaft by installing a ring gear stopper (SST) to
starter mounting hole.
• Use approximately 10 mm spacer between plate and
stopper.
3) Loosen crankshaft pulley bolts, and then remove crankshaft
pulley washer.
4) Screw crankshaft bolt by hand until it stops, and then rotate it 2
or 3 turns back.
5) Position a pulley puller (SST) to crankshaft pulley with M8 bolts
(2).
6) Set puller bolt to a pulley puller, and then tighten it until it
contacts with crankshaft pulley bolt.
7) Tighten M8 bolts (2) temporarily installed.
8) Tighten puller bolt approximately 2 turns after feeling that
EMM0437
sticking of crankshaft pulley is released.
9) Remove the pulley puller, place it to front surface of crankshaft
pulley, and tap it with a hammer. Release sticking of cone
bushing.
10) Remove cone bushing using long-nose pliers.
11) Remove crankshaft pulley.
12) Remove key for cone bushing.
5. Remove front cover bolt in the reverse of the order on EM
section, and then remove front cover using a seal cutter (SST).
CAUTION:
Be careful not to damage mounting surface.
EM-21
TIMING CHAIN
Removal (Cont'd)
12. Remove camshaft sprocket bolt.
• Insert a screwdriver wrapped in a shop cloth to the hole on
camshaft sprocket, secure camshaft sprocket by attaching the
tip of screwdriver to camshaft locating plate bolt, and then
loosen the bolt.
EMM0439
EMM0438
EM-22
TIMING CHAIN
Installation
NOTE:
Installing condition and matching mark location of each part are
shown in the figure.
1. Install the key for crankshaft sprocket after making sure that
crankshaft key groove and camshaft key point straight up.
EMM0440
EMM0441
EM-23
TIMING CHAIN
Installation (Cont'd)
4. Install camshaft sprocket bolt.
• Install washer with flat side facing camshaft sprocket side.
(Refer to "Component Parts Location".)
• Secure camshaft sprocket in the same procedure as removal,
and tighten bolts.
EMM0443
8. Install front oil seal to front cover when replacing front oil seal.
• Install with the arrow facing outside.
• Press oil seal in until it is flush with the end surface of front
cover using an oil seal drift (SST) or 78 mm (3.07 in) dia. drift.
CAUTION:
Make sure that the circumference of oil seal is not damaged
and there is no burr.
EMM0444
EM-24
TIMING CHAIN
Installation (Cont'd)
• Refer to the figure for location and tightening order of bolts.
A: M8 X Length under head: 35 mm (1.38 in) (4)
B: M8 X Length under head: 65mm (2.56 in) (8)
C: M8 X Length under head: 80mm (3.15 in) (1)
EMM0551
EMM0447
EM-25
TIMING CHAIN
Installation (Cont'd)
14. Install distributor.
• Check TDC on compression stroke with matching mark on
crankshaft pulley.
• Insert distributor shaft to front cover aligning distributor shaft
matching mark (circle stamp mark) with unit side matching mark
(short stamp line).
NOTE:
Matching mark on shaft is aligned with unit side matching mark (long
stamp line) by engagement of helical gear after inserting.
EMM0448
EM-26
CYLINDER BLOCK
CYLINDER BLOCK
EMM0538
CAUTION:
Apply new engine oil to the parts marked in the figure prior to
installation.
Disassembly
1. Remove engine assembly from the vehicle.
2. Keep the position using a hoist so as not to tilt engine.
3. Remove engine mount bracket.
4. Install engine assembly to engine stand (SST) with the following
procedure:
EM-27
CYLINDER BLOCK
Disassembly (Cont'd)
1) Install engine sub-attachment (SST, A shown in the figure) to
engine mount bracket mounting hole on exhaust manifold side.
2) Install engine attachment (SST, B shown in the figure) to engine
sub-attachment.
EMM0546
EMM0453
8. Remove flywheel.
• Secure crankshaft using a stopper plate (SST), and then
remove bolts.
CAUTION:
• Place a shop cloth on flywheel surface to prevent damage.
• Loosen bolts diagonally and remove them.
EMM0454 NOTE:
Oil seal is integrated with retainer.
EM-28
CYLINDER BLOCK
Disassembly (Cont'd)
11. Remove valve lifter.
• Pull out from block upper surface with a finger and remove it.
• Remove camshaft with valve lifter in non-contact condition if
removal is difficult, and then remove valve lifter after tapping
from crankshaft side hole.
• Check the location, and store individually.
EMM0455
EMM0456
EMM0457
EMM0458
EM-29
CYLINDER BLOCK
Disassembly (Cont'd)
15. Remove connecting rod from piston.
1) Remove snap ring using snap ring pliers.
EMM0459
EMM0460
3) Push out piston pin from piston using a round bar with outer
diameter of approximately 20 mm (0.79 in).
CAUTION:
Do not remove connecting rod bolt from connecting rod.
EMM0523
EMM0462
EM-30
CYLINDER BLOCK
Disassembly (Cont'd)
2) Remove main bearing cap while shaking it left/right using main
bearing bolts.
17. Remove crankshaft.
18. Remove main bearing from main bearing cap and cylinder
block.
CAUTION:
• Check installation position of each part. Arrange removed
parts to prevent mixing them up.
• Before loosening main bearing cap bolts, check crankshaft
side clearance.
EMM0463
(Refer to EM section, "Inspection of crankshaft side
clearance".)
Cylinder block to piston Piston and piston pin assembly Piston grade Piston grade = Cylinder bore grade (Bore
NOTE: Piston and piston pin are a (Piston outer diameter) inner diameter)
matched set. They make up one
part as an assembly.
EM-31
CYLINDER BLOCK
EMM0466
EM-32
CYLINDER BLOCK
EMM0470
EMM0471
EMM0472
EM-33
CYLINDER BLOCK
EMM0473
EMM0474
EMM0475
EM-34
CYLINDER BLOCK
EMM0477
EMM0479
EM-35
CYLINDER BLOCK
Grade
number 1 2 3 4 5
EMM0480
(stamping)
99.510 99.520 99.530 99.540 99.550
Cylinder bore (3.9117) (3.9181) (3.9185) (3.9189) (3.9193)
inner
diameter 99.500 99.510 99.520 99.530 99.540
(3.9173) (3.9177) (3.9181) (3.9185) (3.9189)
99.470 99.480 99.490 99.500 99.510
Piston outer (3.9161) (3.9165) (3.9169) (3.9173) (3.9177)
diameter 99.460 99.470 99.480 99.490 99.500
(3.9157) (3.9161) (3.9165) (3.9169) (3.9173)
CRANKSHAFT BEND
• Set a pair of V-blocks on a level surface and support journals 1
and 7 of crankshaft.
• Set a dial indicator vertically onto journal 4.
• Rotate crankshaft and read indication on the indicator.
• Half of the reading is the bend.
Repair limit:
0.2 mm (0.008 in)
EMM0483
EM-36
CYLINDER BLOCK
EMM0485
• Remove connecting rod cap and bearing. Measure width of the
plastigage using scale printed on its bag.
CAUTION:
Follow the method outlined in "By measuring" if clearance is
standard and repair limit, and if clearance exceeds repair limit,
but remeasure if clearance is less than standard.
EM-37
CYLINDER BLOCK
Size Thickness
STD 2.000 (0.0787)
US0.25 (0.0098) 2.125 (0.0837)
US0.50 (0.0197) 2.250 (0.0886)
US0.75 (0.0295) 2.375 (0.0935)
US1.00 (0.0394) 2.500 (0.0984)
EMM0547
NOTE:
Each tolerance is +0.008 to +0.012 (+0.0003 to +0.0005).
CAUTION:
Be careful not to damage fillet-roll area when grinding
crankshaft journal in order to use undersize bearing.
EMM0489
EM-38
CYLINDER BLOCK
EMM0491
EMM0492
EM-39
CYLINDER BLOCK
EMM0495
EM-40
CYLINDER BLOCK
EMM0496
EMM0497
EMM0498
EMM0499
EM-41
CYLINDER BLOCK
EMM0500
EMM0501
EM-42
CYLINDER BLOCK
EMM0502
• Make sure that oil holes in each journal and cylinder block oil
holes are aligned after installing each journal.
4. Install camshaft bushing (journal 1).
• Align journal oil hole with cylinder block oil hole.
• Press-fit until journal front end is 0.5 mm (0.020 in) inside from
cylinder block front end surface using a drift (SST).
• Make sure that journal oil hole and cylinder block oil hole are
aligned after installing journal.
EMM0503
EMM0504
EM-43
CYLINDER BLOCK
EMM0505
EMM0506
Assembly
1. Thoroughly clean engine coolant and oil passages in cylinder
block, as well as inside of crank case and cylinder bores using
compressed air.
EM-44
CYLINDER BLOCK
Assembly (Cont'd)
2. Install main bearing.
1) Clean bearing mounting surfaces on cylinder block and main
bearing cap to remove any foreign material, dust, and oil.
2) Install main bearing in the correct direction.
• Install main bearing half with oil groove and oil hole to
cylinder block, and the half without oil groove and oil hole to
main bearing cap.
• Install integrated thrust bearing to journal 6.
• Apply engine oil to bearing surface (inside) and thrust
outside when installing bearing. Do not apply engine oil to
reverse side of bearing, but thoroughly clean it.
• Install by aligning main bearing detent with the notch.
• Make sure the oil holes in cylinder block and main bearing
are aligned.
3. Install crankshaft to cylinder block.
• Make sure that it turns smoothly by hand.
EMM0508
EMM0509
EM-45
CYLINDER BLOCK
Assembly (Cont'd)
2) Install piston to connecting rod.
• Heat piston [to between 60 and 70°C (140 and 178°F)]
using a dryer so that piston pin can be easily inserted by
hand. Insert piston pin in piston and connecting rod from
front side of piston.
• Assemble so that front mark on position head, oil hole in
connecting rod, and cylinder No. stamped on connecting
rod are positioned as shown in the figure.
3) Install snap ring onto piston front side.
• Make sure that the connecting rod swings freely after
EMM0511
completing work.
7. Install piston rings with piston ring expander (commercial
service tool).
CAUTION:
Be careful not to damage piston.
• Install top and second rings with stamp marks on end gaps
facing up.
EMM0512
• Install oil ring with ring end gap as shown in the figure.
EMM0513
EMM0514
EM-46
CYLINDER BLOCK
Assembly (Cont'd)
8. Install connecting rod bearing to connecting rod and connecting
rod cap.
• Apply engine oil to bearing surface (inside) when installing
connecting rod bearing. Do not apply engine oil to reverse side
of bearing, but thoroughly clean it.
• Install connecting rod bearing by aligning the projection with
detent notch on connecting rod.
EMM0515
EMM0518
EM-47
CYLINDER BLOCK
Assembly (Cont'd)
15. Install rear oil seal and retainer assembly.
• Apply a continuous bead of Three Bond 1207C (KP51000150)
to the positions shown in the figure.
EMM0519
EMM0520
EM-48
KOMATSU TB45 ENGINE LUBRICATION
SECTION LU
CONTENTS
OIL PUMP ............................................................LU-2 Disassembly and Assembly ............................ LU-2
Component Parts Location ............................ LU-2 Inspection ....................................................... LU-3
OIL PUMP
OIL PUMP
LUM0008
CAUTION:
Apply new engine oil to the parts marked in the figure prior to
installation.
LU-2
OIL PUMP
Inspection
OIL PUMP COMPONENTS INSPECTION
• Measure each clearance using a feeler gauge.
Outer rotor to housing clearance (1 in the figure)
Standard:
0.114 - 0.260 mm (0.0045 - 0.0102 in)
Outer rotor to inner rotor tip clearance (2 in the figure)
Standard:
0.180 mm (0.0071 in) or less
LUM0009
LUM0004
LU-3
KOMATSU TB45 ENGINE COOLING SYSTEM
SECTION CO
CONTENTS
CHANGING ENGINE COOLANT ....................... CO-2 Removal and Installation ............................... CO-3
Draining Engine Coolant ............................... CO-2 Water Pump Inspection ................................. CO-3
Refilling Engine Coolant ................................. CO-2 THERMOSTAT ................................................... CO-4
WATER PUMP ................................................... CO-3 Component Parts Location ........................... CO-4
Component Parts Location ........................... CO-3 Removal and Installation ............................... CO-4
CHANGING ENGINE COOLANT
CHANGING ENGINE COOLANT
Remove exhaust manifold side drain plug of cylinder block and drain
the coolant in cylinder block.
Engine coolant level [including the reservoir tank (MAX level) volume]
Unit: l (US qt, Imp qt)
CO-2
WATER PUMP
WATER PUMP
COM0017
CO-3
THERMOSTAT
THERMOSTAT
COM0016
INSTALLATION OF THERMOSTAT
• Install thermostat with jiggle valve facing upward.
• Make sure that thermostat flange is securely inserted to seal
ring.
COM0014
CO-4
THERMOSTAT
CO-5
KOMATSU TB45 ENGINE CONTROL
SECTION EC
CONTENTS
PRECAUTIONS .................................................. EC-3 CRANK ANGLE SENSOR 120° (REF)
General Precautions for Service Operations .... EC-3 SIGNAL SYSTEM ..............................................EC-55
On Board Diagnostic (OBD) ECM Input/Output Signal Specifications .......EC-55
System of Engine ........................................... EC-4 Circuit Diagram .............................................EC-55
Precaution ...................................................... EC-4 Component Parts Inspection ........................EC-55
Special Service Tools .................................... EC-7 MASS AIR FLOW SENSOR SYSTEM ..............EC-56
ENGINE CONTROL SYSTEM ............................ EC-8 SST Data Monitor Display ............................EC-56
Description ..................................................... EC-8 ECM Input/Output Signal Specifications .......EC-56
System Diagram ............................................ EC-9 Circuit Diagram .............................................EC-56
Sensors and Actuators Control Items .......... EC-12 Component Parts Inspection ........................EC-56
TROUBLE DIAGNOSIS .................................... EC-13 HEATED OXYGEN SENSOR SYSTEM ............EC-57
Trouble Diagnosis Procedure ...................... EC-13 SST Data Monitor Display ............................EC-57
Diagnosis Chart by Symptom ...................... EC-17 ECM Input/Output Signal Specifications .......EC-57
Locations of components ............................. EC-28 Circuit Diagram .............................................EC-57
Circult Diagram ............................................ EC-32 VEHICLE SPEED SENSOR SYSTEM ..............EC-58
ECM Terminal Layout .................................. EC-33 SST Data Monitor Display ............................EC-58
ECM Input/Output Signal Specifications ...... EC-36 ECM Input/Output Signal Specifications .......EC-58
SST .............................................................. EC-42 Circuit Diagram .............................................EC-58
Self-diagnosis Function (without SST) ......... EC-46 THROTTLE POSITION SENSOR SYSTEM ......EC-59
Service Tool ................................................. EC-48 SST Data Monitor Display ............................EC-59
Method of indicating failure code ECM Input/Output Signal Specifications .......EC-59
with troubleshooting tool .............................. EC-49 Circuit Diagram .............................................EC-59
Example of indication of failure code ........... EC-50 Component Parts Inspection ........................EC-59
Method of indicating failure code with ACCELERATOR PEDAL POSITION
meter panel .................................................. EC-50 SENSOR SYSTEM ............................................EC-60
SST Reference Value in Data Monitor ......... EC-51 SST Data Monitor Display ............................EC-60
Fail-Safe Function ........................................ EC-52 ECM Input/Output Signal Specifications .......EC-60
ECM Input/Output Signal Specifications ...... EC-53 Circuit Diagram .............................................EC-60
Circuit Diagram ............................................ EC-53 INTAKE AIR TEMPERATURE
CRANKSHAFT POSITION SENSOR 1° (POS) .. EC-54 SENSOR SYSTEM ............................................EC-61
ECM Input/Output Signal Specifications ...... EC-54 SST Data Monitor Display ............................EC-61
Circuit Diagram ............................................ EC-54 ECM Input/Output Signal Specifications .......EC-61
Circuit Diagram .............................................EC-61
Component Parts Inspection ........................EC-61
IGNITION SYSTEM ...........................................EC-62 FUEL CUT FUNCTION ..................................... EC-69
SST Data Monitor Display ............................EC-62 Inspection Procedure .................................... EC-69
ECM Input/Output Signal Specifications .......EC-62 INTERCEPTION VALVE SYSTEM ................... EC-70
Circuit Diagram .............................................EC-62 SST Data Monitor Display ............................ EC-70
Component Parts Inspection ........................EC-62 ECM Input/Output Signal Specifications ....... EC-70
FUEL INJECTOR SYSTEM (GASOLINE) ........EC-63 Circuit Diagram ............................................. EC-70
SST Data Monitor Display ............................EC-63 FUEL CHANGING SWITCH SYSTEM .............. EC-71
ECM Input/Output Signal Specifications .......EC-63 SST Data Monitor Display ............................ EC-71
Circuit Diagram .............................................EC-63 ECM Input/Output Signal Specifications ....... EC-71
Component Parts Inspection ........................EC-63 Circuit Diagram ............................................. EC-71
THROTTLE CONTROL MOTOR SYSTEM .......EC-64 BLOW-BY GAS REDUCING DEVICE .............. EC-72
ECM Input/Output Signal Specifications .......EC-64 System Chart ................................................ EC-72
Circuit Diagram .............................................EC-64 Removal and Installation of
Component Parts Inspection ........................EC-64 Blow-by Control Valve .................................. EC-72
HEATED OXYGEN SENSOR Inspection of Blow-by Control Valve ............. EC-72
HEATER SYSTEM ............................................EC-65 ECM COPMONENTS ........................................ EC-73
SST Data Monitor Display ............................EC-65 ECM .............................................................. EC-73
ECM Input/Output Signal Specifications .......EC-65 Crankshaft Position Sensor
Circuit Diagram .............................................EC-65 (Integrated Into the Distributor) ..................... EC-73
Component Parts Inspection ........................EC-65 Mass Air Flow Sensor ................................... EC-73
LPG INJECTOR SYSTEM ................................EC-66 Engine Coolant Temperature Sensor ........... EC-73
ECM Input/Output Signal Specifications .......EC-66 Heated Oxygen Sensor
Inspection .....................................................EC-66 (With Heated Oxygen Sensor Heater) .......... EC-74
LPG ASSISTANCE INJECTOR SYSTEM ........EC-67 Throttle Position Sensor (Electric Throttle
ECM Input/Output Signal Specifications .......EC-67 Control Actuator Assembly) .......................... EC-74
Circuit Diagram .............................................EC-67 LPG Injector Holder ...................................... EC-75
Component Parts Inspection ........................EC-67 SERVICE DATA AND SPECIFICATIONS
LPG FUEL PRESSURE SENSOR SYSTEM ....EC-68 (SDS) ................................................................. EC-76
ECM Input/Output Signal Specifications .......EC-68 Standard, Repair Limit .................................. EC-76
Circuit Diagram .............................................EC-68
PRECAUTIONS
PRECAUTIONS
ECM0215
ECM0216
EGM0063
EC-3
PRECAUTIONS
CAUTION:
• Be sure to turn the ignition switch OFF and disconnect the
negative battery cable before any repair or inspection work.
The open/short circuit of related switches, sensors,
solenoid valves, etc. will cause the MIL to light up.
• Be sure to connect and lock the connectors securely after
work. A loose (unlocked) connector will cause the MIL to
light up due to the open circuit. (Be sure the connector is
free from water, grease, dirt, bent terminals, etc.)
• Certain systems and components, especially those related
to OBD, may use a new style slide-locking type harness
connector.
• Be sure to route and secure the harnesses properly after
work. The interference of the harness with a bracket, etc.
may cause the MIL to light up due to the short circuit.
• Be sure to connect rubber tubes properly after work. A
misconnected or disconnected rubber tube may cause the
MIL to light up due to the malfunction of fuel injection
system, etc.
• Be sure to erase the unnecessary malfunction information
(repairs completed) from the ECM before returning the
vehicle to the customer.
Precaution
• Always use a 12 volt battery as power source.
• Do not attempt to disconnect battery cables while engine is
running.
• Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect battery
ground cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
• Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF0289H
EC-4
PRECAUTIONS
Precaution (Cont’d)
• When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown in the
figure.
EC-5
PRECAUTIONS
Precaution (Cont’d)
• When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact. Accidental contact
of probes will cause a short circuit and damage the ECM
power transistor.
• Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the
ECM's transistor. Use a ground other than ECM terminals,
such as the ground.
SEF348N
SEF709Y
EC-6
PRECAUTIONS
ECM0013
Heated oxygen sensor wrench Removing and installing heated oxygen sensor
KV10113700
ECM0014
ECM0016
Harness adapter
EG17550200
(150-pin to 121-pin conversion adapter)
ECM0017
ZZA1165D
EC-7
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Description
• Adopts Electronic Concentrated Engine Control System
(ECCS). Fuel injection control, ignition timing control, idle speed
control, and electronically controlled governor control etc. are all
performed by a single control unit.
• Adopts electric throttle control actuator system to control
electronically controlled governor.
Item Description
Electric throttle control • Adopts electronic throttle control actuator with integrated throttle control motor to adjust throttle valve opening
optimally according to driving conditions or to improve safety and operability by electronically controlled governor.
Fuel injection control • With SOFIS control, amounts of injected fuel are optimized to improve exhaust performance and response.
• Using feedback control through learning of air-fuel ratio compensation, the system corrects the ratio during
transitional conditions, such as sudden sharp changes in the ratio, in order to improve drivability.
Ignition timing control • Controls ignition timing depending on driving conditions on basis of the ignition timing map stored in the ECM.
• Performs knock control, in which ignition timing is retarded or advanced according to the presence of knocking, so
that optimum ignition timing is selected according to operating conditions and fuel in use.
Idle speed control • Adopts electronic throttle control actuator that continuously regulates intake air amount required for idling.
Governor speed control • Performs maximum regulation of engine speed for oil pressure pump protection by engine speed signal.
Maximum speed • Performs maximum speed regulation by vehicle speed sensor signal. Also, performs variable control of maximum
regulation control speed by changeover switch as an option.
Idling area torque up • Performs torque up control in idling area by engine speed signal in order to also enable cargo work at idling.
control
Overheat prevention • Reduces engine heat generation by reducing maximum engine speed and regulating maximum throttle opening
control when engine coolant temperature reaches approximately 110°C (230°F).
• Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or more when engine
coolant temperature reaches approximately 135°C (275°F).
Fuel pump control • Turns fuel pump relay ON/OFF depending on engine speed signal.
(gasoline)
LPG interception valve • Turns interception valve relay ON/OFF depending on engine speed signal and fuel pressure sensor signal.
control
Fail-safe function • Ensures vehicle's safe operation and enables vehicle to be driven in an emergency when any of the major system
components (mass air flow sensor, engine coolant temperature sensor, etc.) have malfunctioned.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.
EC-8
Battery voltage
Electric load switch signal
EGI relay control output
Ignition key switch signal
KLINE
Accelerator pedal position sensor signal (2 systems)
A/C relay control output
Monitor lamp output
A/C SW signal
Vehicle speed sensor signal
Vehicle speed selector switch (resistor) Neutral switch signal
O2 sensor heater control output Brake switch signal
O2 sensor signal Fuel control changing switch signal (2)
Throttle position sensor signal (2 systems) E.C.M Fuel pump relay output
Electric throttle control actuator control output Engine coolant temperature sensor signal
Cylinder discrimination signal
Crank angle sensor signal
Ignition signal output
Fuel injection (gasoline) control output (6)
Air flow meter signal
Intake air temperature
sensor signal
Gasoline
injector (6)
DIST
EC-9
GASOLINE
Engine coolant
temperature
sensor
O2 sensor
ENGINE CONTROL SYSTEM
Fuel pump
(gasoline)
ECM0511
Battery voltage
Electric load switch signal
EGI relay control output
Ignition key switch signal
KLINE
Accelerator pedal position sensor signal (2 systems)
A/C relay control output
Monitor lamp output
A/C SW signal
Vehicle speed sensor signal
Vehicle speed selector switch (resistor) Neutral switch signal
O2 sensor heater control output Brake switch signal
O2 sensor signal Fuel control changing switch signal (2)
Throttle position sensor signal (2 systems) E.C.M
Electric throttle control actuator control output Engine coolant temperature sensor signal
LPG interception valve control output Cylinder discrimination signal
LPG PTC heater relay control output Crank angle sensor signal
Fuel injection (LPG) control output (2) Ignition signal output
Assistance fuel injector Air flow meter signal
control output Intake air temperature
Fuel pressure sensor signal sensor signal
EC-10
W/coil optical crank
Air cleaner
angle sensor
Relay
Muffler Catalyzer
ECM0512
Battery voltage
Electric load switch signal
EGI relay control output
Ignition key switch signal
KLINE
Accelerator pedal position sensor signal (2 systems)
A/C relay control output
Monitor lamp output
A/C SW signal
Vehicle speed sensor signal
Vehicle speed selector switch (resistor) Neutral switch signal
O2 sensor heater control output Brake switch signal
O2 sensor signal Fuel control changing switch signal (2)
Throttle position sensor signal (2 systems) E.C.M Fuel pump relay output
Electric throttle control actuator control output Engine coolant temperature sensor signal
LPG interception valve control output Cylinder discrimination signal
LPG PTC heater relay control output Crank angle sensor signal
Fuel injection (LPG) control output (2) Ignition signal output
Assistance fuel injector Fuel injection (gasoline) control output (6)
control output Air flow meter signal
Fuel pressure sensor signal Intake air temperature
sensor signal
EC-11
W/coil optical crank
Air cleaner
angle sensor
Relay
Fuel pump
(gasoline)
ECM0513
ENGINE CONTROL SYSTEM
Gasoline std std std std std std std std Combined std std
Fuel
LPG std std std – std std std std Combined std std
Fail-safe
Ignition timing control
Self-diagnosis
A/F feedback control
EC-12
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
ECM0233
CAUTION:
Customers are not professionals. It can be dangerous to easily
interpreting their explanations assuming that "the customer may
ECM0234
mean this" or "the customer may refer to this phenomenon."
EC-13
TROUBLE DIAGNOSIS
5) To judge whether the I/O signals of the ECCS C/U are normal,
use the reference values (yardstick) of the I/O data stated in this
manual. If it is hard to make judgment, one of effective means
will be comparison of the data on the vehicle under trouble
diagnosis with data obtained by measuring another vehicle of
the same model under the same conditions. In that sense, a
shortcut to correct trouble diagnosis is personally accumulating
lots pieces of data on the vehicle under the normal state.
ECM0236
ECM0237
EC-14
TROUBLE DIAGNOSIS
2. Interview sheet
1) General
• To confirm a phenomenon of malfunction, it is necessary to
obtain information about what phenomenon of the vehicle the
customer complains through an interview with the customer.
• Important information on a phenomenon of malfunction includes
what phenomenon occurs under what conditions and that no
such a phenomenon occurs under what conditions.
• To ensure that complete information can be obtained with no
missing piece, it is recommended to use the interview sheet.
ECM0238
EC-15
TROUBLE DIAGNOSIS
ECM0393
EC-16
TROUBLE DIAGNOSIS
Poor fuel
Fast idle is not effective
Backfire
Inconsistent idle when engine is cold.
Inconsistent idle when warming up
Poor power output
Poor acceleration
After-burn
Overheat
Engine rpm does not increase smoothly.
During surge and acceleration
Knocking
At Idle
Driving
During deceleration
During a heavy load
No initial combustion
Initial combustion
Actuator malfunction
O : Highly possible
O : Possible
Crank angle sensor (POS, OPEN • The REF signal wire or POS signal
PHASE) wire, whichever has a break, the
vehicle cannot be started.
O O O O O O
• The sensor signals are not output
both to the fuel system nor ignition
system.
Electric OPEN
• The fail-safe device is actuated to
power O O O O O O O O O O O O
allow operation at 800 rpm or less.
supply
EC-17
TROUBLE DIAGNOSIS
Poor acceleration
Engine rpm does not increase smoothly.
When engine is cold
Knocking
Overheat
During surge and constant speed drive
Backfire
After-burn
Driving
During deceleration
During a heavy load
When engine is warming up
At Idle
Poor fuel
Description/notable characteristics of
the symptom
Actuator malfunction
O : Highly possible
O : Possible
Output
O O O O O O O O
fluctuation
Power supply for control unit OPEN • Impossible to start without outputs
O O O O O O
for fuel and ignition systems.
EC-18
TROUBLE DIAGNOSIS
Poor acceleration
Backfire
Knocking
After-burn
At Idle
Driving
During deceleration
During a heavy load
When engine is cold
Poor fuel
Inconsistent idle when engine is cold.
Overheat
Description/notable characteristics of
the symptom
Actuator malfunction
O : Highly possible
O : Possible
Instanta-
neous O O O O
interruption
Drive OPEN O O O O O O O O O O O O O O O
circuit
(C/U Instanta-
unit) neous O
interruption
Ground- OPEN O O O O
ing cir-
cuit (C/U Instanta-
unit) neous O O O O O O O O
interruption
Ground- OPEN O O O O O O O
ing cir-
cuit Instanta-
neous O O O O O O O O O O O O O O O
interruption
EC-19
TROUBLE DIAGNOSIS
Backfire
Inconsistent idle when engine is cold.
After-burn
At Idle
Driving
During deceleration
During a heavy load
When engine is cold
When engine is warming up
Poor acceleration
Poor fuel
Poor power output
Overheat
Description/notable characteristics of
the symptom
Actuator malfunction
O : Highly possible
O : Possible
Throttle control motor relay OPEN • The same troubles as those occur
circuit when the power cable of the throttle
O O O O O O O O O O O O O
motor and throttle sensor has a
disconnection can occur.
Coil OPEN O O O O O O O
Lo side OPEN O O O O O O O
circuit
SHORT O O O O O O O
Control
unit side O O O O O O
SHORT
Control
unit side
SHORT
EC-20
TROUBLE DIAGNOSIS
Poor fuel
Fast idle is not effective
During deceleration
No initial combustion
Poor acceleration
Initial combustion
Knocking
Backfire
After-burn
Actuator malfunction
O : Highly possible
O : Possible
U : Rarely possible
Air-fuel mixture
Air is sucked from the oil level • Air-fuel ratio becomes lean.
O U O O U U U
gauge section • Compensation value for the air-fuel ratio
increases.
Air is sucked from the oil filler cap • Negative suction pressure of the intake
O U O O U U U manifold increases.
section
* Inspect with a negative suction pressure
Air is sucked from the blow-by hose gauge.
O U O U O O O O O U U O O O U * Common to air suction from the suction
(PCV downstream)
system in general.
Air is sucked from the intake
O U O U O O O O O U U O O O U
manifold and gasket sections
LPG fuel is not suited (in cold • Start-up performance in the cold season
season, propane ratio) differs depending on the propane ratio.
O O O O O O O O O O U O O O O
• LPG with a specified propane ratio should
be used.
LPG interception valve section filter • In general, malfunctions are likely to occur
is clogged O U O U O O O O O O O U O O at a high speed or under a high load, though
depending on how the filter is clogged.
EC-21
TROUBLE DIAGNOSIS
Poor acceleration
Inconsistent idle when warming up
Knocking
During surge and constant speed drive
Backfire
After-burn
Driving
During deceleration
Overheat
During a heavy load
When engine is warming up
At Idle
Poor fuel
Description/notable characteristics of the
symptom
Actuator malfunction
O : Highly possible
O : Possible
U : Rarely possible
Sparks
Spark plug is defective • Is the gap adequate? Does the plug have
O O O O O O O O O U U U
stains (by smoke, etc.)?
Piston ring has worn out • Phenomena which may occur vary
U O O O O O O O O O O O O O O depending on the degree of wear and the
number of cylinders.
Others
HYD PUMP load is high (PS, • Hydraulic pressure relief valve is defective
material handling) or the oil specifications are not suited (the
U U U O O U
overload phenomenon occurs in particular
in cold season).
EC-22
TROUBLE DIAGNOSIS
Knocking
During surge and constant speed drive
Backfire
After-burn
Driving
During deceleration
Overheat
When engine is warming up
At Idle
Overcooling
Poor fuel
Description/notable
characteristics of the symptom
Actuator malfunction
O : Highly possible
O : Possible
U : Rarely possible
Air-fuel mixture
• In general, malfunctions
Fuel strainer is clogged O U O U O O O O O O O U O O are likely to occur at a high
speed or under a high
load, though depending on
Air cleaner element is clogged how the strainer or
O O O O O O
element is clogged.
EC-23
TROUBLE DIAGNOSIS
Knocking
During surge and constant speed drive
Backfire
After-burn
Overheat
Driving
During deceleration
During a heavy load
Overcooling
When engine is warming up
At Idle
Actuator malfunction
O : Highly possible
O : Possible
U : Rarely possible
Air-fuel mixture
EC-24
TROUBLE DIAGNOSIS
Overheat
Overcooling
During deceleration
During a heavy load
During surge and acceleration
Knocking
Backfire
At Idle
Driving
Poor fuel
Actuator malfunction
O : Highly possible
O : Possible
U : Rarely possible
Others
O
Water leakage
EC-25
TROUBLE DIAGNOSIS
Overheat
Initial combustion
When engine is cold
When engine is warming up
Knocking
Backfire
During deceleration
During a heavy load
Overcooling
At Idle
Driving
After-burn
Poor fuel
Actuator malfunction
O : Highly possible
O : Possible
U : Rarely possible
Others
Chain system
EC-26
TROUBLE DIAGNOSIS
Backfire
Initial combustion
After-burn
At Idle
Driving
During deceleration
Overcooling
When engine is cold
When engine is warming up
Overheat
Description/notable
characteristics of the symptom
Actuator malfunction
O : Highly possible
O : Possible
U : Rarely possible
Cooling system
Others
Thermostat failure O O
EC-27
TROUBLE DIAGNOSIS
Locations of components
Applicable specification
Major components Type Location
Combination
Gasoline LPG
use
Actuators
Throttle control motor Direct-current electric motor type (DC motor) Built in the electronic control throttle O O O
Ignition coil Mold type (with a built-in power transistor) Built in the distributor O O O
Accelerator pedal position sensor 1, 2 Variable-resistor type Built in the accelerator work unit
O O O
(accelerator pedal assembly.)
Intake air temperature sensor Integral with the air flow meter O O O
Vehicle speed sensor Electromagnetic power-generation type (On the vehicle side) O O O
EC-28
TROUBLE DIAGNOSIS
Power transistor O O O O
Intake air temperature sensor Integral with the air flow meter O O O O
Pressure regulator O O O
EC-29
TROUBLE DIAGNOSIS
ECM
Mass air flow sensor Accelerator pedal assembly
Engine coolant temperature sensor Accelerator pedal position sensor
Mass air flow sensor Accelerator pedal
assembly
ECM
Air horn
Engine coolant
temperature sensor
Thermostat
housing
Distributor
Distributor
ECM0240
EC-30
TROUBLE DIAGNOSIS
Fuel tube
O2 sensor Injector
Fuel tube
Exhaust manifold
cover
O2 sensor Injector
Intake manifold
Main injector
Assistance injector
Fuel pressure sensor
Main injector
Harness connector
for assistance injector
Fuel pressure sensor
Harness connector
for main injector
Assistance injector
Holder
ECM0241
EC-31
Notes
1) This diagram indicates the schematic for the gasoline/LPG
combination-use type engine. For the gasoline exclusive type
engine and LPG exclusive type engine, refer to the following:
1. Fuel changing switch
Instructions given in the diagram
* Point B * Point E should be followed.
2. Gasoline exclusive type
110 RATT IGN 62 8 2 The parts and circuits marked with ★ should be deleted
REF 14 4 6 (N.C.).
1.25sq or more DIST
118 VR POS 13 3 7 3. LPG exclusive type
Common caulking or joint is necessary 1.25sq or more 121 VR 5 1 The parts and circuits marked with ▲ should be deleted
(N.C.).
B 2) INJ number and IGN number indicated in the diagram are
111 SSOFF same with the cylinder number.
(The engine cylinder numbers are 1-2-3-4-5-6 from the FAN
EGI RLY side.)
1.25sq or more FUEL CHANGING SW 3) Joint of each sensor to GND-A line should be located as
★ LPG INJ 1 119 LPGINIVP#1 close as possible to the ECM.
For combination use type For gasoline exclusive type
#1 2 120 LPGINI-#1 • Within 150 mm from ECM CONN.
1.25sq or more LPG 70 FUELSW#1
FUELSW#1 70 • GND system of AWU is to be the trunk line.
32 FUELSW#2 • Sensors should be joined to the trunk line in sequence.
NUTE
1.25sq or more 49 AVCC The distance from one joint to another should be within
★ LPG INJ 1 117 LPGINIVR#2 150 mm.
Gasoline
#2 2 114 LPGINI-#2 FUELSW#2 32 • Joint of the pressure-sensor system GND should be
1.25sq or more For LPG exclusive type preferentially taken as the ECM side.
AVCC 49
ETC MOTOR RLY 70 FUELSW#1 • Total resistance between each sensor and GND should
1.25sq or more 1.25sq or more 32 FUELSW#2 be 50 mΩ or less.
3 VMOT 4) • * Length of harness from *point A to *point E should be
49 AVCC
7000 mm or less
104 MOTRLV • * Length of harness from *point D to *point F should be
2000 mm or less
6 5 MOTOR1
• * Length of harness from *point J to *point F should be
3 4 MOTOR2 2000 mm or less
THROT 5 66 GND-A2 • * Length of harness from *point G to *point C should be
A CHAMBER 1000 mm or less (15 or more)
(ETC) 4 50 TPS1 6 4 + SPEED SEN
(PICK UP) • * Length of harness from *point K to *point J should be
(▲) ▲ 2 69 TPS2 VSPB 33 5 SPEED SEN UNIT 1 -
150 mm or less
ICN RELAY F/PUMP RLY 1 47 AVCC2 2 3
▲ F/PUMP • * Composite resistance of harness from *point A to *point B
should be 30 mΩ or less including a possible deterioration.
• * Composite resistance of harness from *point D to *point F
B (totally two systems) and from *point J to *point F should
be 30 mΩ or less including a possible deterioration.
• * Any load which is not instructed should not be connected
on the harness from *point D to *point F.
APS1 106 5 • *Any load which is not instructed should not be connected
on the harness from *point J to *point F.
AVCC 90 6 ACCEL 5) • * BODY EARTH 2 should be commonly caulked with ECM
113 FRR GND-A 82 3 WORK GND.
85 KLINE APS2 98 2 LIMIT • * To connect the above with other device GND together,
AVCC2 91 4 (APS) caulking should be done using one terminal instead of
two or more terminals.
CONSULT GND-A2 83 1 • * BODY EARTH 3 can be commonly caulked with a general
EARTH.
TROUBLE DIAGNOSIS
★
1 2 3 4 5 6 7 8 SLOW INJ 11 2 LPG ASSIST INJ 1 • * Both should be tightened at such a location that can be
9 10 11 12 13 14 15 16 electrically ensured in such a way as to electrically ensure
★ LPG FUEL ★ the connection. (It is recommended to tighten with an FT
SAE JI962 1 2 bolt.)
INTERCEPTION VALVE#
CONNECTOR 6) : It is required to shield the part from the
MAIN/C RLY 112 sensor or actuator to the proximity of ECM.
EC-32
PTC/H 27
Load resistance kΩ Regulatory speed
Normal N.C. (open) Up to rated revolution
STEP1 25.0<R1 30.0±5% <m/h
STEP2 16.3<R1 18.5±5% <m/h
STEP3 11.0<R1 12.3±5% <m/h
103 IGNSW STEP4 7.4<R1 8.3±5% <m/h
STEP5 4.9<R1 5.6±5% <m/h
▲ STEP6 2.9<R1 3.5±5% <m/h
OFF ON ST 1 GAS INJ:#1 2 23 IN#1
Circult Diagram
1 GAS INJ:#6 2 40 IN#6 8) For the case where CAN communication is not performed
AVCC 48 Burn-out bulb in ENG CHECK LAMP should be checked with
24 O2HFR GND-A 67 ECM. It should not be checked with a meter.
3
35 O2SFR
2 O2 SEN 1
GA+ 51 AIR FLOW 4
4 3
78 GND-A METER 5
8 5 1 CHARGING TA 34 2 AIR/TEMP SEN 1
WARNING LAMP BRAKE LAMP
ALTERNATOR (12V - 34W)
101 BRAKE TW 73 1 W/TEMP SEN 2
FROM BRAKE LAMP SW
LFGPRES 31 FUEL 2
H/LAMP 3
PRESS SEN 1
INHIBITTER RLY ★
23~63.7Ω 84 H/LMP
FROM H/LAMP SW For max. vehicle RESISTANCE R1
speed control (When unused is N.C.)
102 NEUT VARI VSP 54
ENGINE COOLANT TEMPERATURE SENSOR
1
* Point A THERMO THENDER
STARTER MOTOR For idle air RESISTANCE R2
+
OIL PRESSURE WARNING LAMP volume leaning (When normal is N.C.)
INHIBIT SW (12V - 34W)
(NUTE SW) 1 S TAS SW 52
BATTERY SW-OIL PRESS
12V At N:ON
ECM0514
TROUBLE DIAGNOSIS
ECM0246
EC-33
TROUBLE DIAGNOSIS
EC-34
TROUBLE DIAGNOSIS
EC-35
TROUBLE DIAGNOSIS
ECM0247
ECM0248
EC-36
TROUBLE DIAGNOSIS
ECM0249
ECM0250
ECM0251
EC-37
TROUBLE DIAGNOSIS
ECM0252
ECM0253
ECM0254
91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 5V
power supply
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
110 BATT Always Battery voltage
47 Electric throttle control actuator sensor Ignition switch ON, engine running Approx. 5V
power supply
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply
27 PTC heater relay At idle after warming up Approx. 0V
(Except north america)
Ignition switch ON when the engine Battery voltage
coolant temperature is 30°C (86°F) or
less (except for cranking)
EC-38
TROUBLE DIAGNOSIS
ECM0255
ECM0256
ECM0257
EC-39
TROUBLE DIAGNOSIS
34 Intake air temperature sensor Intake air temperature is approx. 20°C Approx. 3.5V
(68°F).
Intake air temperature is approx. 80°C Approx. 1.2V
(176°F).
83 Accelerator pedal position sensor 2 Always Approx. 0V
ground
35 Heated oxygen sensor At idle after warming up Changes between approx. 0.1 - 0.4V
approx. 0.6 - 0.9V
ECM0258
ECM0259
ECM0260
ECM0261
ECM0262
118 Power supply for ECM Ignition switch ON, engine running Battery voltage
121
EC-40
TROUBLE DIAGNOSIS
104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
3 Throttle control motor relay power Always Battery voltage
supply
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 to 0.15V
At approx. 2000 rpm
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
At approx. 2000 rpm
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch OFF (At neutral) Approx. 0V
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch OFF (At LPG side or Approx. 0V
neutral)
112 LPG interception valve relay When ignition switch is ON (Approx. 1 Battery voltage
second) and for approximately 10
seconds after ignition switch is OFF
Ignition switch OFF Approx. 0V
52 Idle air volume learning operation When connecting tools for idle air Approx. 1.5V (Usually learning)
volume learning Approx. 2.5V (Factory learning)
When not connecting tools for idle air Approx. 0V
volume learning
54 Maximum speed shifting It varies depending on setting
condition.
33 Vehicle speed sensor signal Vehicle stopped Approx. 11V or approx. 1V
EC-41
TROUBLE DIAGNOSIS
SST
DISPLAY ITEM LIST
HDM2000
Diagnosis item Malfunction Return Condition MIL Trip
Error display
EC-42
TROUBLE DIAGNOSIS
SST (Cont'd)
HDM2000
Diagnosis item Malfunction Return Condition MIL Trip
Error display
Throttle control motor ETC MOT BACK UP/ • Throttle control motor power supply circuit is open. ON* 1
power supply circuit CIRC [P1126]
Throttle motor control sig- Throttle control motor • When throttle motor signal circuit has short-circuited ON* 1
nal circuit [P1128]
Engine over temperature Overheat [P1217] • Engine coolant temperature sensor output voltage has been ON 1
(Overheat) approximately 0.35V or lower for predetermined period
(with the coolant temperature sensor normal).
Overheat (STEP 1) OVERHEAT STEP-1 • Engine coolant temperature sensor output voltage has been ON 1
[P1218] approximately 0.6V or lower for predetermined period. (MIL light up)
Throttle valve closed posi- Throttle valve closed • Throttle valve closed position learning value is excessively low. ON 2
tion learning value (low) position learning
[P1225]
Throttle valve closed posi- Throttle valve closed • Throttle valve closed position learning cannot be performed. ON 2
tion learning value (mal- position learning
function) [P1226]
Sensor power supply cir- TP/APP SE BACK UP/ • Sensor power supply voltage has been 5.6V or more or less ON* 1
cuit CIRC [P1229] than 4.6V for predetermined period.
LPG injector 1 malfunction LPG F/INJ 1 malfunc- • Over current flows into LPG injector. ON* 1
(Injection area) tion (Injection) [P1240]
LPG injector 1 malfunction LPG F/INJ 1 malfunc- • Over current flows into LPG injector. ON* 1
(No injection area) tion (No injection)
[P1241]
LPG injector 2 malfunction LPG F/INJ 2 malfunc- • Over current flows into LPG injector. ON* 1
(Injection area) tion (Injection) [P1242]
LPG injector 2 malfunction LPG F/INJ 2 malfunc- • Over current flows into LPG injector. ON* 1
(No injection area) tion (No injection)
[P1243]
LPG fuel pressure sensor LPG fuel pressure • LPG fuel pressure sensor circuit is shorted. ON 1
signal circuit low input sensor short [P1245]
LPG fuel pressure sensor LPG malfunctioning • LPG fuel pressure sensor circuit is open. ON 1
signal circuit high input fuel pressure is • Fuel pressure in fuel piping from LPG VIPO to injector has been
detected and fuel excessively increased for predetermined period.
pressure is exces-
sively high. [P1249]
Stop lamp switch signal BRAKE SW/CIRCUIT • While driving, stop lamp switch is stuck at OFF for a long time. ON 1
system [P1805] (MIL light up)
Accelerator pedal position APP SEN 1/CIRC • Accelerator pedal position sensor output voltage has been ON* 1
sensor 1 circuit [P2122] 0.15V or less (open) for predetermined period.
Accelerator pedal position APP SEN 1/CIRC • Accelerator pedal position sensor output voltage has been 5V ON* 1
sensor 1 circuit [P2123] or more (short) for predetermined period.
Accelerator pedal position APP SEN 2/CIRC • Accelerator pedal position sensor output voltage has been ON* 1
sensor 2 circuit [P2127] 0.15V or less (open) for predetermined period.
Accelerator pedal position APP SEN 2/CIRC • Accelerator pedal position sensor output voltage has been 5V ON* 1
sensor 2 circuit [P2128] or more (short) for predetermined period.
Throttle position sensor TP SENSOR • A malfunction occurs in relation between throttle position ON* 1
signal (nonconformance) [P2135] sensors 1 and 2.
system
Accelerator pedal position APP SENSOR • A malfunction occurs in relation between accelerator pedal ON* 1
sensor signal (nonconfor- [P2138] position sensors 1 and 2.
mance) system
NOTE:
Number of trips varies depending on diagnosis content.
CAUTION:
Some DTCs specified above may detect a malfunction in the self-diagnosis, excluding the engine system, when the DTC detects some
malfunctions. Check the self-diagnosis excluding the engine at this time
EC-43
TROUBLE DIAGNOSIS
SST (Cont'd)
DATA MONITOR
• Allows determination and identification of the possible source of
a malfunction based on self-diagnosis test results.
• Displays ECM input/output signal data in real time.
• Records and prints out the data before and after the engine
malfunction or stall, either automatically or manually.
ENG SPEED rpm Engine speed computed from crankshaft angle sensor signal
MAS A/F SE-B1 V Mass air flow sensor output voltage
B/FUEL SCHDL msec Value calculated by ECM
A/F ALPHA % Average of cycles for air-fuel ratio feedback correction coefficient
COOLANT TEMP/S °C Value converted into temperature from the output voltage of the engine coolant
temperature sensor.
HO2S1 V Output voltage of heated oxygen sensor
HO2S1 MNTR RICH/LEAN Air-fuel ratio is given as heated oxygen sensor output signal during air-fuel ratio
feedback control.
RICH: Heated oxygen sensor output is high. Controlling to lower the value for
leaner ratio.
LEAN: Heated oxygen sensor output is low. Controlling to raise the value for
richer ratio.
VHCL SPEED SE km/h Value computed from vehicle speed sensor
BATTERY VOLT V ECM battery voltage
ACCEL SEN 1 Accelerator pedal position sensor 1 output voltage
ACCEL SEN 2 Accelerator pedal position sensor 2 output voltage
THRTL SEN 1 Throttle position sensor 1 output voltage
THRTL SEN 2 Throttle position sensor 2 output voltage
START SIGNAL ON/OFF ON/OFF status as judged by each input signal
P/N POSI SW
IGNITION SW
BRAKE SW
INJ PULSE msec Value calculated by ECM
IGN TIMING °BTDC
Incalculable % Value is calculated engine load based on the fuel injection amount.
FUEL PUMP RLY ON/OFF Status of each control as calculated by ECM.
THRTL RELAY
HO2S1 HTR
Battery voltage Displays values measured by voltage probe.
Vehicle speed maximum limit km/h Vehicle speed maximum value
LPG fuel injection width ms Value calculated by ECM
LPG basic fuel injection
Air-fuel ratio correction (Gasoline) %
Air-fuel ratio correction (LPG) %
Fuel type GASOLINE/ Fuel changing switch connecting condition
LPG/NEUTRAL
LPG fuel pressure kg/cm2 Value converted into pressure from the output voltage of LPG fuel pressure
sensor.
EC-44
TROUBLE DIAGNOSIS
SST (Cont'd)
Monitor item Unit Description
Fuel changing switch 1 ON/OFF ON/OFF status as judged by each input signal
Fuel changing switch 2
LPG interception valve relay
Specification
COOLANT TEMP
Condition Condition
VHCL SPEED SE
Normal (1) Supported by support data.
(2) Graph is supported.
Battery voltage
Data value that is not applied to communication in
RUN mode is displayed as "- - -".
FUEL TEMP SE
Selection narrowing (1) Supported by support data.
(2) Graph is supported.
(3) Selected.
SAVE SELECT RANGE START
Data value that is not applied to communication in
ECM0372 RUN mode is displayed as "- - -".
Normal (LOAD) (1) Saved.
Selection narrowing (LOAD) (1) Saved.
(2) Selected.
ACTIVE TEST
Use this mode to determine and identify the details of a malfunction,
based on self-diagnosis test results and data obtained from DATA
MONITOR mode. SST, instead of the ECM on the vehicle, sends a
drive signal to actuators to check their operation.
Fuel injection test • Can increase or decrease the amount of fuel injection (±25%).
LPG fuel injection test • Can reproduce conditions resulting from air-fuel ratio related malfunctions (e.g. hesitation, poor
acceleration, poor racing, etc.) and help solve these malfunctions by pinpointing the causes.
Ignition timing test • Allows setting a correction coefficient for retarding (-10 - 0°)
POWER BALANCE (Gasoline) • Stops operation of specified injector. Also, displays engine speed at that time.
(LPG, Neutral) • Mainly used to inspect for misfiring cylinders.
EC-45
TROUBLE DIAGNOSIS
0340 Crankshaft position sensor • At start-up, no camshaft position sensor signals (POS, REF) have been ON 2
signal circuit detected for more than a predetermined period.
• During engine running, no camshaft position sensor signal (POS or REF)
has been detected for more than a predetermined period.
• During engine running, crankshaft position sensor signal (POS or REF)
irregular waveform is detected for more than a predetermined period.
0500 Vehicle speed sensor • Vehicle sensor signal has not been input under some condition for a ON 2
predetermined time during driving after warming up. (MIL light
up)
1065 ECM power supply circuit • Power is not supplied to ECM for some time. ON 2
1121 Electric throttle control • Because of mechanical malfunction of electric throttle control actuator, ON* 1
actuator electric throttle control actuator does not operate normally. Ignition ON
cannot be
erased.
1122 Electric throttle control • When a malfunction occurred due to the correlation between the target ON* 1
function throttle position and the actual throttle position.
• Over current flows into throttle motor control circuit.
1124 Throttle control motor power • Throttle control motor power supply circuit is shorted ON* 1
supply circuit
1126 Throttle control motor power • Throttle control motor power supply circuit is open. ON* 1
supply circuit
1128 Throttle motor control signal • When throttle motor signal circuit has short-circuited ON* 1
circuit
1217 Engine over temperature • Engine coolant temperature sensor output voltage has been ON 1
(Overheat) approximately 0.35V or lower for predetermined period
(with the coolant temperature sensor normal).
1218 Overheat (STEP 1) • Engine coolant temperature sensor output voltage has been ON 1
approximately 0.6V or lower for predetermined period. (MIL light
up)
1225 Throttle valve closed • Throttle valve closed position learning value is excessively low. ON 2
position learning value (low)
1226 Throttle valve closed • Throttle valve closed position learning cannot be performed. ON 2
position learning value
(malfunction)
1229 Sensor power supply circuit • Sensor power supply voltage has been 5.6V or more or less than 4.6V for ON* 1
predetermined period.
1240 LPG injector 1 malfunction • Over current flows into LPG injector. ON* 1
(Injection area)
1241 LPG injector 1 malfunction • Over current flows into LPG injector. ON* 1
(No injection area)
1242 LPG injector 2 malfunction • Over current flows into LPG injector. ON* 1
(Injection area)
EC-46
TROUBLE DIAGNOSIS
1243 LPG injector 2 malfunction • Over current flows into LPG injector. ON* 1
(No injection area)
1245 LPG fuel pressure sensor • LPG fuel pressure sensor circuit is shorted. ON 1
signal circuit low input
1249 LPG fuel pressure sensor • LPG fuel pressure sensor circuit is open. ON 1
signal circuit high input • Fuel pressure in fuel piping from LPG VIPO to injector has been
excessively increased for predetermined period.
1805 Stop lamp switch signal • While driving, stop lamp switch is stuck at OFF for a long time. ON 1
system (MIL light
up)
1814 Air-fuel ratio does not cross • After engine warmed with gasoline fuel, when oxygen sensor signal is - 1
stoichiometry for a long time sticked and does not reverse at a condition of A/F ratio is excessively lean
during intended closed-loop or rich.
operation. (written in 40CFR
1148 Parts 1048.110.) • After engine is started with gasoline fuel, when closed-loop control does
not start within a predetermined period.
1815 Air-fuel ratio does not cross • After engine warmed with LPG fuel, when oxygen sensor signal is sticked - 1
stoichiometry for a long time and does not reverse at a condition of A/F ratio is excessively lean or rich.
during intended closed-loop
1817 operation. (written in 40CFR • After engine is started with LPG fuel, when closed-loop control does not
Parts 1048.110.) start within a predetermined period.
2122 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 0.15V or less ON* 1
sensor 1 circuit (open) for predetermined period.
2123 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 5V or more ON* 1
sensor 1 circuit (short) for predetermined period.
2127 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 0.15V or less ON* 1
sensor 2 circuit (open) for predetermined period.
2128 Accelerator pedal position • Accelerator pedal position sensor output voltage has been 5V or more ON* 1
sensor 2 circuit (short) for predetermined period.
2135 Throttle position sensor • A malfunction occurs in relation between throttle position sensors 1 and 2. ON* 1
signal (nonconformance)
system
2138 Accelerator pedal position • A malfunction occurs in relation between accelerator pedal position ON* 1
sensor signal sensors 1 and 2.
(nonconformance) system
NOTE:
Number of trips varies depending on diagnosis content.
CAUTION:
Some DTCs specified above may detect a malfunction in the self-diagnosis, excluding the engine system, when the DTC detects some
malfunctions. Check the self-diagnosis excluding the engine at this time.
EC-47
TROUBLE DIAGNOSIS
Service Tool
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as “trip”), Engine Warning lamp is lit. The
corresponding DTC is recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), Engine Warning lamp is lit and the corresponding final
DTC is recorded.
EC-48
TROUBLE DIAGNOSIS
1A 1
EC-49
TROUBLE DIAGNOSIS
EC-50
TROUBLE DIAGNOSIS
EC-51
TROUBLE DIAGNOSIS
Fail-Safe Function
When any of the critical sensors or systems sends a malfunction
message, the fail-safe function estimates the driving conditions with
other input signals and selects safer conditions for engine (vehicle)
control, based on data previously stored in ECM.
Malfunction
Related sensors Fail-safe MIL
condition
Mass air flow sensor Same as self- • Selects fuel injection pulse width depending on engine speed ON
diagnosis and throttle position so the vehicle can be driven. However, fuel
malfunction detection injection will be inhibited (fuel cut-off) when engine speed
conditions. exceeds approximately 800 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with ON
temperature sensor elapsed time after start) to perform controls so the vehicle can
be driven.
Accelerator pedal • Fuel injection will be inhibited when 1 circuit is opened. Release ON
position sensor valve mechanically until it can drive at low speed when
disconnecting connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. ON
However, fuel injection will be inhibited (fuel cut-off) when
engine speed exceeds approximately 2,500 rpm.
MIL • Engine speed will be inhibited at approximately 1,300 rpm to -
prevent MIL malfunction if exhaust performance and driving
performance malfunctions are occurring.
EC-52
TROUBLE DIAGNOSIS
111 Self shut off Ignition switch ON and engine running Approx. 1V
Ignition switch OFF Battery voltage
109 (IGN) Ignition switch Ignition switch ON and engine running
118 Power supply for ECM
121
110 BATT Always
1 Ground Approx. 0V
2
115
116
Circuit Diagram
EC-53
CRANKSHAFT POSITION SENSOR 1° (POS)
CRANKSHAFT POSITION SENSOR 1° (POS)
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
13 Crankshaft position At cranking: Approx. 2.6V At idling: Approx. 2.5V Approx. 2.5V
sensor 1° (POS)
Circuit Diagram
EC-54
CRANK ANGLE SENSOR 120° (REF) SIGNAL SYSTEM
CRANK ANGLE SENSOR 120° (REF) SIGNAL SYSTEM
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
14 Crankshaft position At cranking: Approx. 0.5V At idling: Approx. 0.5V Approx. 0.5V
sensor 120° (REF)
signal
Circuit Diagram
ECCS & IGN
coil relay
118
121
ECCS
control
unit
ECM0295
CAUTION:
Check voltage after disconnecting the injector fuse to inhibit
injector operation.
ECM0291
Malfunctions may or may not be accurately detected by self-
diagnosis depending on how the shaft is turned. Note that there
is no malfunction in this case.
EC-55
MASS AIR FLOW SENSOR SYSTEM
MASS AIR FLOW SENSOR SYSTEM
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
Circuit Diagram
EC-56
HEATED OXYGEN SENSOR SYSTEM
HEATED OXYGEN SENSOR SYSTEM
35 Heated oxygen sensor Changes between approx. 0.1 - 0.4V Changes between approx. 0.1 - 0.4V
approx. 0.6 - 0.9V approx. 0.6 - 0.9V
(V) (V)
1.5 1.5
1.0 1.0
0.5 0.5
0 0
1s 1s
PBIA0529J PBIA0530J
Circuit Diagram
ECM0304
EC-57
VEHICLE SPEED SENSOR SYSTEM
VEHICLE SPEED SENSOR SYSTEM
Terminal Signal name Vehicle stopped Vehicle running at approx. 40 km/h (25 MPH)
ECM0399
Circuit Diagram
EC-58
THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM
* Throttle position sensor 2 signal (terminal 69) voltage is different from DATA MONITOR display of SST because it is converted in ECM.
Circuit Diagram
ECM0307
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. If there are any water drops, completely wipe
ECM0308
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform "Throttle Valve Closed Position Learning" if
disconnecting connector.
• Do not disassemble electric throttle control actuator.
EC-59
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
When the accelerator pedal is depressed slowly from the fully-closed position, the voltage must increase in proportion to the opening of the
throttle. [Ignition switch ON (engine stopped)]
* Accelerator pedal position sensor 2 signal (terminal 98) voltage is different from DATA MONITOR display of SST because it is converted in ECM.
Circuit Diagram
ECM0309
EC-60
INTAKE AIR TEMPERATURE SENSOR SYSTEM
INTAKE AIR TEMPERATURE SENSOR SYSTEM
34 Intake air temperature sensor signal Intake air temperature at 20°C (68°F): approx. 3.5V
Intake air temperature at 80°C (176°F): approx. 1.2V
Circuit Diagram
ECM0312
EC-61
IGNITION SYSTEM
IGNITION SYSTEM
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
Circuit Diagram
CAUTION:
• Check terminals for looseness.
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
ECM0321
Spark plug gap:
0.8 - 0.9 mm (0.031 - 0.035 in)
EC-62
FUEL INJECTOR SYSTEM (GASOLINE)
FUEL INJECTOR SYSTEM (GASOLINE)
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
21 Injector drive signal Approx. 10.5V Battery voltage Relatively lower than battery
22 voltage
23
40
41
42
ECM0324 ECM0325
ECM0326
Circuit Diagram
ECM0327
ECM0328
EC-63
THROTTLE CONTROL MOTOR SYSTEM
THROTTLE CONTROL MOTOR SYSTEM
Circuit Diagram
ECM0330
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
ECM0332 connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to electric throttle control motor
terminal.
• Perform "Throttle Valve Closed Position Learning" if
disconnecting connector.
• Do not disassemble electric throttle control actuator.
EC-64
HEATED OXYGEN SENSOR HEATER SYSTEM
HEATED OXYGEN SENSOR HEATER SYSTEM
HO2S1 MTR ON
Circuit Diagram
ECM0334
EC-65
LPG INJECTOR SYSTEM
LPG INJECTOR SYSTEM
Inspection
LPG INJECTOR
• Check resistance between terminals 1 and 2.
Resistance:
Approx. 1Ω (at room temperature)
• Remove fuse cover, and then check fuse for open.
CAUTION:
Do not apply voltage to LPG injector.
EC-66
LPG ASSISTANCE INJECTOR SYSTEM
LPG ASSISTANCE INJECTOR SYSTEM
Circuit Diagram
EGI1 118
30 87
BAT 121
86 88
111
EGI2
30 87 To Crank angle ECM
sensor ignition
86 88
1
1 2 LPG assistance injector
2 11
ECM0524
ECM0123
EC-67
LPG FUEL PRESSURE SENSOR SYSTEM
LPG FUEL PRESSURE SENSOR SYSTEM
Circuit Diagram
ECM0419
EC-68
FUEL CUT FUNCTION
FUEL CUT FUNCTION
Inspection Procedure
WITH SST
1. Check "INJ PULSE-B1" (gasoline) or "LPG INJ PULSE" (LPG)
in DATA MONITOR menu, and increase the engine speed to
approximately 2,400 rpm after warming up engine.
2. Make sure that when the acceleration pedal is released, "INJ
PULSE-B1" (gasoline) or "LPG INJ PULSE" (LPG)
instantaneously drops.
Without SST
1. Warm up the engine sufficiently.
2. Disconnect harness connector of the injector and connect a test
lamp.
3. Release the accelerator pedal at the engine speed of
approximately 2,400 rpm, and confirm test lamp goes out for a
moment.
ECM0355
EC-69
INTERCEPTION VALVE SYSTEM
INTERCEPTION VALVE SYSTEM
Terminal Signal name When stopping the engine During engine rotation
Circuit Diagram
EGI1 118
30 87
BAT 121
86 88
111
EGI2
30 87 To Crank angle
sensor ignition
86 88 ECCS
contorl
unit
1 2
LPG interception valve
112
ECM0356
EC-70
FUEL CHANGING SWITCH SYSTEM
FUEL CHANGING SWITCH SYSTEM
Circuit Diagram
Fuel changing SW
LPG
70
Neutral
ECCS
Gasoline
32 contorl
unit
49
ECM0109
EC-71
BLOW-BY GAS REDUCING DEVICE
BLOW-BY GAS REDUCING DEVICE
System Chart
Blow-by hose Blow-by control valve
Fuel gallery
Blow-by passage
(also used for slots for the engine
front part and 12 bushing rods)
Fresh air
Blow-by gas
ECM0353
EC-72
ECM COPMONENTS
ECM COPMONENTS
ECM
REMOVAL AND INSTALLATION
1. Disconnect ECM connector.
2. Remove ECM.
3. Install in the reverse order of removal.
CAUTION:
Perform "Throttle Valve Closed Position Learning and Idle Air
Volume Learning" after installation if replacing ECM.
Check pin for bend and damage when installing ECM.
ECM0390
Air horn
ECM0391
CAUTION:
Make sure to drain when the coolant temperature is cold.
ECM0392
EC-73
ECM COPMONENTS
CAUTION:
Handle it carefully and avoid impacts.
CAUTION:
Also, remove harness connectors of mass air flow sensor, LPG
Air horn
injector, and LPG fuel pressure sensor so that when removing
Screw
and installing air horn, LPG injection holder (LPG and
Combined) is performed at the same time.
Electric throttle
control actuator
ECM0374
INSTALLATION
Caution for installation
Uniformly tighten bolts diagonally in several steps.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform "Throttle Valve Closed Position Learning" if
disconnecting connector.
• Do not disassemble electric throttle control actuator.
EC-74
ECM COPMONENTS
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing each connector. If there are
any water drops, completely wipe them off.
LPG injector holder • Do not apply voltage to each terminal.
(LPG and combined use)
Electric throttle
control actuator
EC-75
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
EC-76
KOMATSU TB45 ENGINE FUEL SYSTEM
SECTION FL
CONTENTS
FUEL SYSTEM ................................................... FL-2 LPG PARTS ....................................................... FL-7
Description ..................................................... FL-2 LPG Device (Specifications for LPG and
Gasoline Specification ................................... FL-2 Gasoline/LPG) ............................................... FL-7
LPG Specification .......................................... FL-3 Injector Holder ............................................... FL-9
Specification for Combined Vaporizer ..................................................... FL-12
Gasoline and LPG .......................................... FL-3
FUEL INJECTOR (GASOLINE AND
COMBINED USE) ............................................... FL-4
Preparation .................................................... FL-4
Fuel Hose ....................................................... FL-4
Fuel Tube and Fuel Injector ........................... FL-4
Inspection ....................................................... FL-6
FUEL SYSTEM
FUEL SYSTEM
Description
Three fuel system specifications ("Gasoline", "LPG", "Combined
gasoline and LPG") have been applied.
Gasoline Specification
Fuel pump type integrated with fuel tank has been adopted.
Complete pump is composed of fuel pump, fuel filter, pressure
regulator, and fuel gauge. All of them together are called returnless
fuel supply system.
FLM0001
FLM0046
CAUTION:
Apply new engine oil to the parts marked in the figure before
installation.
FL-2
FUEL SYSTEM
LPG Specification
• LPG gas injection system has been adopted.
• LPG injector holder is equipped with injector, assistance
injector, fuel pressure sensor, and relief valve, and they are
composed as an assembly. All of them are installed on
electronic throttle control actuator.
FLM0001
FL-3
FUEL INJECTOR (GASOLINE AND COMBINED USE)
Preparation
• Air hose
• Moving engine harness connector
Fuel Hose
REMOVAL
Release the fuel pressure.
CAUTION:
Plug the fuel hose to prevent the fuel from draining after
removal.
INSTALLATION
• Insert hose until its end reaches 25 mm (0.98 in) or more from
fuel tube end. Install a clamp and securely tighten it. Do not
install the clamp on top of the bulge.
• Start engine, increase the engine speed, and make sure that
there is no fuel leakage after repairing.
INSTALLATION
Fuel Injector
1. Install fuel injector to fuel tube as shown in figure 1.
FL-4
FUEL INJECTOR (GASOLINE AND COMBINED USE)
FLM0003
FL-5
FUEL INJECTOR (GASOLINE AND COMBINED USE)
FLM0004
Inspection
FUEL LEAKAGE AFTER INSTALLATION
Check for fuel leakage by racing several times after idling for 5 to 10
minutes.
FL-6
LPG PARTS
LPG PARTS
FLM0045
FL-7
LPG PARTS
FLM0043
FL-8
LPG PARTS
Injector Holder
Inject a proper amount of fuel supplied from vaporizer based on
ECM command.
NOTE:
Repair each component specified in (1), (2), and (3) as an assembly
if a malfunction is detected in above components. Repair holder
assembly specified in (4). Refer to EC section for inspection
procedure.
HOLDER ASSEMBLY
Main injector
Harness connector
for assistance injector
Harness connector
Assistance injector for main injector
Holder
FLM0009
FL-9
LPG PARTS
FLM0012
Check and Cleaning
If foreign materials such as tars are applied or collected on plunger
or its inside, remove them with compressed air.
FL-10
LPG PARTS
FLM0015
FL-11
LPG PARTS
Vaporizer
DESCRIPTION
This is decompressed and carbureted high-pressure fuel flow from
LPG tank to approximately 29 kpa (0.3 kg/cm2, 4 psi).
FLM0016
Fuel is supplied from LPG tank to vaporizer via LPG solenoid valve.
Fuel from solenoid valve is supplied to primary decompression room
through between primary side valve (1) and primary side valve seat
(2).
Fuel pressure supplied to primary room is 29 kpa (0.3 kg/cm2, 4 psi)
or more. Primary diaphragm (4) pushes up diaphragm spring (5),
and hook (6) is working together. It becomes the operation that one
side of primary valve lever (7) is lifted up. Therefore, the power that
pushes primary valve (1) toward valve seat side (2) is increased,
and fuel flow is cut off.
Primary diaphragm is pushed down by increasing the tension of
diaphragm spring (5) higher than the fuel pressure when the fuel of
primary room is consumed and the pressure of primary room inside
is decreased to 29 kpa (0.3 kg/cm2, 4 psi) or less, and hook (6) is
working together to push primary valve lever (7) down. Therefore,
open primary valve (1) and flow fuel in.
Repeat above operations to keep primary room pressure
approximately 29 kpa (0.3 kg/cm2, 4 psi).
Variation of pressurization can be suppressed by balance
diaphragm (8) even if pressure in LPG tank changes.
FL-12
LPG PARTS
Vaporizer (Cont’d)
Set primary valve lever as shown in the figure.
EFM0044
Pressure Inspection
Check primary room pressure with the following procedure:
1. Remove primary room test hole plug, and install pressure gage
using appropriate connector.
2. Start engine, and check for primary room fuel leakage at idle
after warming up.
Standard:
30.7 - 33.1 kpa (0.313 - 0.338 kg/cm2, 4.45 - 4.81 psi)
3. Rotate pressure adjusting screw if measured pressure is
outside the standard.
CAUTION:
Apply sealant and keep air tightness when reinstalling test hole
plug.
Removal of Impurity
LPG includes incombustible materials (e.g. tar).
These materials will be collected in vaporizer if they are continued to
be included. This may cause operating malfunction of fuel system.
It is necessary to release and drain periodically with engine warmed
up.
FL-13
LPG PARTS
Vaporizer (Cont’d)
COMPONENT OF VAPORIZER
Fuel connector
(Outlet side)
Vacuum connector
Tamper screw
FLM0017
TAR REMOVING
• Take the warmth of the engine with LPG.
• Close tank cock, and then consume LPG in fuel line.
• Remove drain plug, and then drain tar from vaporizer.
*Put the tray below so as not to make engine room dirty.
• Apply sealant to drain plug and assemble after finishing work.
• Install LPG fuel injector and check LPG leakage using soapy
water after assembly.
Drain plug
FLM0018
REMOVAL
• Close tank cock, and then consume LPG in fuel line.
• Disconnect battery cable at negative terminal.
• Drain engine coolant from radiator drain plug.
• Disconnect hot water hose. Use shop cloth and tray because
water may come out.
• Disconnect vacuum hose.
• Disconnect fuel hose and fuel tube.
*Treat each hose so that foreign materials should not enter the
inside.
Or, be careful to prevent each tube insertion part from being
damaged.
• Remove mounting bolt to bracket of vaporizer.
FL-14
LPG PARTS
Vaporizer (Cont’d)
INSTALLATION
• Install in the reverse order of removal.
• Install vaporizer bracket.
Standard:
16 - 21 N•m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
• Connect each hose and tube.
*Securely tighten each clamp.
• Connect battery cable at negative.
• Check LPG leakage.
Start the engine and apply soapy water to each connection of
fuel hose, fuel pipe, hot water hose vacuum hose, and drain
plug. Check for LPG leakage.
Apply soapy water to mating surface of case and cover. Check
for LPG leakage.
CAUTION:
• Flush and clean vaporizer with compressed air.
• *Do not use chemical cleaner because it negatively affects
rubber parts and Teflon coated parts.
DISASSEMBLY
Primary Side
Primary pressurization • Remove mounting screws (2) of bracket for tamperproof using
screw
SST.
• Remove primary adjusting screw lock nut {WAF: 23 mm (0.91
in)}.
Lock nut • Remove primary adjusting screw.
• Remove primary room cover screws (2) using SST.
• Remove other screws (8) using commercial service tool.
• Remove fuel connector (inlet side) screws (2) using commercial
service tool.
FLM0020
Sliding
Primary pressurization
spring
Primary diaphragm
FLM0021
FL-15
LPG PARTS
Vaporizer (Cont’d)
• The figure shows the condition that primary diaphragm is
Primary side valve removed.
Remove the diaphragm while sliding it in the arrow direction
shown in the figure.
• Check primary diaphragm for breakage or damage. Replace if
necessary.
Primary
diaphragm
Securing screw
FLM0022
• The figure shows the condition that lever and valve seat are
removed.
Balance diaphragm When removing lever mounting screws (2) shown in the above
figure, lever and valve seat can be removed as a set. Do not
lose the lever because it is fixed with only the pin.
FLM0023
FL-16
LPG PARTS
Vaporizer (Cont’d)
• The figure shows the condition that valve lever, valve seat, and
pin are removed. Furthermore, the figure below shows the
condition that valve is removed.
FLM0025
FLM0024
Rod
Plate
FLM0026
Secondary Side
Secondary room • Secondary room cover is fixed by 6 screws.
seal rubber
Secondary room cover can be removed by loosening each
screw.
• The figure shows the condition that secondary room cover is
removed.
FLM0027
FL-17
LPG PARTS
Vaporizer (Cont’d)
• The figure shows that secondary room side is assembled.
Secondary side
cover
FLM0028
FLM0029
INSPECTION
Primary Side Valve
• Check around primary side valve and valve seat.
• Check valve lever for smooth operation.
• Replace valve and lever assembly if necessary.
Each Diaphragm
• Check for cracks, damage, and hardening.
• Replace each diaphragm if necessary.
FLM0030
FL-18
LPG PARTS
Vaporizer (Cont’d)
ASSEMBLY
High-pressure Side Cover
• Clean disassembled parts completely.
• Clean filter from inside with compressed air.
• Replace O-ring with a new one.
• Tighten mounting bolts (6) evenly.
Standard:
: 6.3 - 8.3 N•m (0.64 - 0.85 kg-m, 4.6 - 6.1 ft-lb)
High-pressure side cover
FLM0031
Secondary Side
Secondary room • Clean disassembled parts other than seal rubber completely.
seal rubber
• Replace seal rubber with a new one.
Securely insert circumference O-ring of seal rubber into groove.
• Gently place primary room cover (steel), and then install with
securing screws (6).
Standard:
: 3.8 - 5.1 N•m (0.39 - 0.52 kg-m, 2.8 - 3.8 ft-lb)
FLM0032
Primary Side
• Clean disassembled parts other than diaphragm completely.
Balance • Set balance diaphragm and plate in this order, and then secure
diaphragm
them using screws.
Standard:
Rod
: 1.0 - 2.9 N•m (0.1 - 0.3 kg-m, 0.7 - 2.2 ft-lb)
Plate • Lastly, put the rod on center.
Top convex side faces to lever side.
FLM0033
FLM0034
FL-19
LPG PARTS
Vaporizer (Cont’d)
• Assemble primary side lever.
• Replace O-ring with a new one.
Standard:
: 1.0 - 2.9 N•m (0.1 - 0.3 kg-m, 0.7 - 2.2 ft-lb)
• Measure dimension H of lever.
FLM0035
Balance diaphragm
FLM0036
FLM0037
FL-20
LPG PARTS
Vaporizer (Cont’d)
• If it is outside the standard, insert both end grooves of vaporizer
height gauge (SST) into lever, and then bend and adjust the
lever.
CAUTION:
Be careful not to damage valve.
FLM0038
FLM0039
FL-21
LPG PARTS
Vaporizer (Cont’d)
• If the value is outside the standard, adjust it as described
below.
*Vaporizer primary pressure setting value is different
between the unit condition and the condition of installing
vaporizer to engine and having hot water flowing
(approximately 80°C (176°F)).
FL-22
KOMATSU TB45 ENGINE ELECTRICAL SYSTEM
SECTION EL
CONTENTS
STARTING SYSTEM ...........................................EL-2 CHARGING SYSTEM .......................................... EL-5
Component Parts Location ............................. EL-2 Component Parts Location ............................. EL-5
Starter Motor ................................................... EL-2 PROCEDURE FOR DISASSEMBLING AND
STARTING MOTOR EXPRODED ....................... EL-3 INSPECTING THE ALTERNATOR ..................... EL-6
MAINTENANCE OF STARTER ...........................EL-4 Component Parts Location ............................. EL-6
Starter Motor ................................................... EL-4 Disassembly ................................................... EL-7
Armature Coil .................................................. EL-4 Inspection ....................................................... EL-9
Data related to brush commutators ................. EL-4 HIGH-TENSION CABLE ................................... EL-13
Assembly ...................................................... EL-13
STARTING SYSTEM
STARTING SYSTEM
ELM0247
CAUTION:
Be sure to disconnect negative battery cable before operation.
Starter Motor
REMOVAL
1. Disconnect terminals S and B.
2. Remove bolts (2).
3. Remove starter motor.
INSTALLATION
Install in the reverse order of removal.
EL-2
STARTING MOTOR EXPRODED
STARTING MOTOR EXPRODED
23 17 20
18
19 24
22
15 14
12 13 16
21 11
9 10 3 2 6 5
8 1 4 7 ELM0249
Manufacturer's part
No. Tree Parts name Quantity Hitachi part number Product name code
number
STARTING MOTOR S114-482 23300 52H00 70443222
EL-3
MAINTENANCE OF STARTER
MAINTENANCE OF STARTER
Starter Motor
• Inspect for continuity between the field coil and the ground.
Judgment
If there is continuity between the coil and the ground, the starter
motor has a short circuit. In this case, change the starter motor
with a new one.
When there is no continuity between the coil and the ground,
the starter motor is normal.
CAUTION:
Field coil assembly Carefully carry out the inspection since a compound motor is
EEM0127
structurally grounded even when continuity between the field
coil and the ground is checked with a tester.
Armature Coil
• Inspect for continuity between commutators.
Judgment
Commutators
When there is continuity between the commutators, the starter
motor is normal.
When there is no continuity between the commutators, the
starter motor has a break. In this case, change the starter motor
with a new one.
Armature coil Assembly • Inspect for continuity between the armature coil and the ground.
Judgment
If there is continuity between the coil and the ground, the starter
motor has a short circuit. In this case, change the starter motor
with a new one.
When there is no continuity between the coil and the ground,
the starter motor is normal.
EEM0129
EEM0130
EL-4
CHARGING SYSTEM
CHARGING SYSTEM
ELM0248
EL-5
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
Rear bearing
Rotor
12.7-18.6 N • m
2.9-4.9 N • m
Rectifier
Brush
2.9-4.9 N • m
Pulley
Regulator assembly
Stator
ELM0250
5.9-9.8 N • m
Front braket
Retainer
3.4-5.4 N • m Front
bearing
2.9-4.9 N • m
98-137 N • m
Rear bracket
Rectifier
Brush
2.9-4.9 N • m
Pulley
Regulator assembly
Stator
ELM0251
EL-6
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
Disassembly
Through-bolt 1. Remove four through-bolts from the front assembly and rear
Through-bolt assembly.
Through-bolt
Through-bolt
Front assembly ELM0252
Slotted screwdriver
2. Separating the front assembly and rear assembly.
Slotted screwdriver Inserting the tip of a slotted screwdriver into the clearance
between stator and front bracket, separate the front assembly
and rear assembly.
NOTE:
Take care not to damage the stator coil or peel laminations from the
stator core with a screwdriver.
EL-7
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
Disassembly (Cont’d)
5. Detaching the rear bearing
Rear bearing Rotor Detach the rear bearing with a commercially available bearing
puller.
NOTE:
• The clearance provided between the bearing and slip ring is
small. Take care not to damage the mold part of the slip ring
with the bearing-puller claw.
• The rear bearing which is once removed is not reusable.
Bearing-puller
ELM0256
ELM0257
Regulator assembly b) Separate soldered joints (at two locations) of the regulator
Stator
assembly to raise the stator. Then, detach the regulator assembly.
NOTE:
It is suggested to remove plate R first and lightly push the connector
part for easy removal of the regulator assembly Since the soldered
joints are caulked, try to widen an opening of the caulked part for
easy separation of the joints.
EL-8
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
Disassembly (Cont’d)
Eectifier assembly 8. Detaching the rectifier assembly
a) Remove the tightening screw from the rectifier.
b) Detaching B terminal
Example (1): For press-fitted side-removal B terminal
Detach the round cover and nut. Pressurize the
top of B terminal bolt from the rear side to detach
the press-fitted B terminal.
Example (2): Rear-removal B terminal
Detach the nut and mold from B terminal.
Inspection
1. Inspecting the stator coil
a) Inspection of coil for continuity (circuit tester)
Inspect two coil lead wires for mutual continuity.
N lead wires Check for continuity between N lead wires (bundled wire) and
Stator
each phase (for all of the three phases).
Judgment criteria:
Resistance between lead wires 0.05 to 0.5 (Ω)
Coil lead wires
ELM0261
Core
ELM0262
EL-9
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
Inspection (Cont’d)
b) Inspection of the rotor for insulation (insulation resistance tester
of 500 V/M)
Check for insulation between the slip ring and the fan.
Fan
Judgment criteria:
Rotor
1MΩ or more
Rotor
ELM0264
EL-10
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
Inspection (Cont’d)
b) Inspection of the minus diode (circuit tester)
Rectifier assembly
Functional check of the diode
Diode
Check for continuity between the minus heat sink and each
diode terminal.
Judgment criteria:
There should be continuity in the forward direction.
There should be no continuity in the reverse direction.
Minus heat sink • If there is continuity in both directions, the diode has a
short-circuit error.
• If there is no continuity in both directions, the diode
Tester: Example of measurement in forward direction
has an open-circuit error.
under DI mode
ELM0266
Judgment criteria:
50
EL-11
PROCEDURE FOR DISASSEMBLING AND INSPECTING THE ALTERNATOR
Inspection (Cont’d)
6. Inspecting the regulator (verification of the completed alternator
+ -
Fuse on the vehicle)
B A
Alternator S
ON a) Inspection of the adjusted voltage
Starting
E
ST Switch
+
(1)Turn off all electrical loads.
V Battery
- (2)Check to be sure that the voltmeter indicates a voltage which
To Starting motor
is equal to or lower than the overcharge voltage (15V) during
ELM0268
idling. Then, gradually increase the engine revolutions.
(3)Continuously checking that the voltmeter gives a value below
the overcharge voltage, read the voltage (adjusted voltage)
when the engine revolutions reach 2500 rpm.
Judgment criteria:
14.5 ± 0.3V
NOTE:
In this case, the ammeter should give a current which is equal to or
lower than the specified electric current (10A). If the electric current
exceeds the specified value, continue charging for a while until the
electric current becomes equal to or lower than the specified value.
EL-12
HIGH-TENSION CABLE
HIGH-TENSION CABLE
Assembly
ELM0322
EL-13
KOMATSU TB45 ENGINE TUNE-UP
SECTION ET
CONTENTS
VALVE CLEARANCE .......................................... ET-2 ENGINE OIL ........................................................ ET-6
Description ...................................................... ET-2 Inspection ....................................................... ET-6
Inspection ........................................................ET-2 Replacement ................................................... ET-7
Adjustment ...................................................... ET-3 Oil Filter Replacement .................................... ET-8
ENGINE DRIVE BELT ......................................... ET-4 COMPRESSION PRESSURE ........................... ET-10
Inspection ........................................................ET-4 Inspection ..................................................... ET-10
Belt Tension Adjustment ................................. ET-5 SPARK PLUG ................................................... ET-11
Removal and Installation .............................. ET-11
Inspection After Removal .............................. ET-11
VALVE CLEARANCE
VALVE CLEARANCE
Description
Whenever rocker arm and rocker shaft assembly are removed and
installed, or symptoms due to changes in valve clearance as a result
of aging (poor starting, rough idle, unusual noise) are obvious, check
and adjust valve clearance with the following procedure:
Inspection
1. Stop the engine after warming up.
2. Remove rocker cover.
3. Rotate the crankshaft pulley clockwise (as viewed from
crankshaft pulley side) and align orange notch with the timing
indicator (protrusion) on the front cover.
4. Make sure that there is valve clearance in intake/exhaust side of
No. 1 cylinder. (No. 1 cylinder is at TDC on its compression
stroke.)
• If not, rotate the crankshaft pulley one more turn.
ETM0065
5. Refer to the figure, and measure valve clearance for the table
item below with a circle using a feeler gauge.
Standard:
0.35 mm (0.0138 in) (Hot, intake/exhaust)
CAUTION:
Make sure that the standard under hot condition is appropriate
if adjustment is made under cold condition.
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
1 cylinder at TDC of
its compression { { { { { {
stroke
NOTE:
Firing order: 1 - 5 - 3 - 6 - 2 - 4
ET-2
VALVE CLEARANCE
Inspection (Cont'd)
7. Measure valve clearance at points marked with { in the
following table.
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
6 cylinder at TDC of
its compression { { { { { {
stroke
NOTE:
If No. 1 cylinder is not at TDC on its compression stroke in step 4, it
is acceptable to measure the item with No. 6 cylinder at TDC on its
compression stroke (step 7) without rotating crankshaft pulley.
8. Adjust with the following if outside the standard value.
Adjustment
NOTE:
Adjust the same measuring points in the same condition of
"Inspection" with the following procedure:
1. Loosen valve clearance adjusting screw lock nut.
2. Turn adjusting screw in the loosening direction using a
screwdriver.
3. Insert a standard feeler gauge in between rocker arm and valve
stem end surface, and then tighten until it contacts with
adjusting screw.
4. Tighten lock nut while securing it using a screwdriver so as not
to rotate adjusting screw.
: 16 - 21 N•m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)
5. Crank engine several times, check valve clearance again, and
make sure that it is within the standard.
ETM0066
ET-3
ENGINE DRIVE BELT
ENGINE DRIVE BELT
Inspection
• Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
• Measure the belt deflection by applying load of 98 N (10 kg, 22
lb) to T as shown in the figure.
CAUTION:
• First set the tension to the standard when measuring belt
tension immediately after the belt is installed. Rotate the
crankshaft more than two turns in order to eliminate
variance in the belt deflection between pulleys. Then
measure and adjust tension to the standard.
• Visually check belts for wear, damage, and cracks on inside
and edges.
ETM0136
• Retighten if belt deflection is too low (excessive tension)
and too high (outside retightening limit).
Unit: mm (in)
ETM0135
CAUTION:
• Tighten slightly stronger than used belt when belt is
replaced with new one, because new belt will not fully seat
in the pulley groove.
• Adjust the tension to the value after adjustment when used
belt tension exceeds retightening limit.
• Make sure that belt is correctly engaged with the pulley
groove when installing.
• Adjust the belt by applying tension, but do not rotate pulley
in each pulley stop condition.
• Do not tighten with excessive tension.
• Do not allow oil or water to get on the belt.
• Do not twist or bend the belt strongly.
ET-4
ENGINE DRIVE BELT
FAN BELT
• Loosen lock nut and two nuts for fan pulley, and adjust fan belt
with adjust bolt.
• Tightening lock nut and nut for fan pulley.
Lock nut:
: 9 - 13 N•m (0.9 - 1.3 kg-m, 7 - 10 ft-lb)
Nut for fan pulley:
: 9 - 13 N•m (0.9 - 1.3 kg-m, 7 - 10 ft-lb)
ET-5
ENGINE OIL
ENGINE OIL
Inspection
OIL LEVEL AND CONTAMINATION
CAUTION:
Forklift must be level when checking oil level.
• Check oil level before starting engine. Stop engine and leave it
at least 10 minutes if engine has been started. Then check
level.
• Check if the oil level is within the range shown on the left.
• Check engine oil for white contamination or considerable dirt.
• If oil has white or pale contamination, it may be caused by
mixing with engine coolant. Repair the suspect parts.
• Adjust oil level if it is outside the range.
ETM0068
OIL LEAKAGE
Check the following parts for engine oil leakage.
• Oil pan
• Oil pan drain plug
• Oil pressure switch
• Oil filter bracket
• Oil filter
• Lower side of cylinder block back
• Mating surfaces of cylinder block and cylinder head
• Mating surfaces of cylinder head and rocker cover
• Front cover
• Around crankshaft pulley
OIL PRESSURE
1. Check oil level.
2. Remove oil pressure switch and connect an oil pressure gauge.
3. Make sure that the proper oil pressure corresponding to engine
speed is obtained after warming up the engine.
NOTE:
Oil pressure is displayed highish when low oil temperature.
kPa (bar, kg/cm 2, psi) Approx. 49 (0.49, 0.5, 7) Approx. 118 (1.18,1.2, 17)
or more or more
4. Install oil pressure switch after checking the oil pressure with the
following procedure.
1) Remove old sealant on the switch and engine.
2) Apply Three Bond 1201 or equivalent to the threads and then
tighten.
: 13 - 17 N•m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)
CAUTION:
Be careful not to get burned when engine or engine oil is
heated.
ET-6
ENGINE OIL
Replacement
NOTE:
Perform inspection "after refilling oil and after replacing oil" after
replacing oil filter if engine oil and oil filter have been replaced.
REPLACEMENT PROCEDURE
CAUTION:
Be careful not to get burned when engine or engine oil is
heated.
1. Warm up engine, and check that there is no oil leakage.
2. Stop the engine. Leave it for 10 minutes.
3. Remove oil filler cap, and remove drain plug of oil pan.
4. Drain engine oil.
5. Install drain plug. Refill with new engine oil.
Drain plug tightening torque:
: 54 - 59 N•m (5.5 - 6.0 kg-m, 40 - 43 ft-lb)
ETM0070
OIL LEVEL
Unitt: (US qt, lmp qt)
H-level Approx. 8.7 (9-1/4, 7-5/8)
L-level Approx. 7.6 (8, 6-3/4)
Only refill level when changing oil
Approx. 8.3 (8-3/4, 7-1/4)
(When drained from drain plug)
Refill level when changing both oil lifter and oil
Approx. 8.6 (9-1/8, 7-5/8)
(When drained from drain plug)
ET-7
ENGINE OIL
ETM0071
REMOVAL
Remove oil filter using an oil filter wrench (SST).
CAUTION:
• Be careful not to get burned when engine or engine oil is
heated.
• Use a shop cloth to absorb engine oil leakage when
removing.
• Be careful not to spill engine oil on the engine drive belt.
• Completely wipe off any engine oil spilled on the engine
and vehicle.
ET-8
ENGINE OIL
ET-9
COMPRESSION PRESSURE
COMPRESSION PRESSURE
Inspection
1. Warm up the engine sufficiently.
2. Release the fuel pressure.
3. Turn ignition switch OFF.
4. Disconnect air hose from throttle body and move it out of
position.
5. Remove all spark plugs.
CAUTION:
Blow spark plug clean with compressed air when removing it.
6. Install a rev counter or electronic system diagnosis tester (SST).
7. Remove injector harness connector.
8. Attach an adapter to Allen compression gauge (commercial
service tool) and set it to the engine.
9. Depress accelerator pedal fully. Turn ignition switch to "START"
and crank the engine. Record the compression pressure and
the engine speed after the gauge indication stabilizes. Repeat
the measurement on each cylinder.
Compression pressure kPa (bar, kg/cm2, psi)/rpm
Standard:
1,187 (11.87, 12.1, 172)/200
Repair limit:
892 (8.92, 9.1, 129)/200
Difference limit among cylinders:
98 (0.98, 1.0, 14)/200
• Check battery for the specific gravity if engine speed is not
within the standard, and measure again under normal
conditions.
• Check valve clearance and components around the
combustion chamber (valve, valve seat, pistons, piston
rings, cylinder bore, cylinder head, cylinder head gasket) if
compression pressure is not within the standard, and
measure again.
• Add a small amount of engine oil from spark plug hole if
compression pressure of some cylinders is low, and
measure again.
• It is possible that piston ring is worn or damaged if
compression pressure is improved by adding engine oil.
Check piston ring, and replace it if necessary.
• There may be a valve malfunction if compression pressure
is not improved by adding engine oil. Check valve, and then
replace valve or cylinder head if necessary.
• If compression pressures of adjacent two cylinders are low,
and if pressures cannot be improved by adding engine oil,
gasket is leaking. Replace cylinder head gasket.
10. Install removed parts.
ET-10
SPARK PLUG
SPARK PLUG
ETM0075
ET-11