TB45 GASOLINE ENGINE (ECU)
Contents
1. such as ECM connectors remove the rear cover before the inspection e For a waterproof connector do not probe the terminals from the harness side Doing so may damage the seal INSPECTION FROM TERMINAL SIDE 1 Female terminal Female connector terminals have a small notch difference inside Insert a T pin along the step to inspect A CAUTION Do not insert any objects to a female connector terminal other than the corresponding male connector terminal e In case of a female connector terminal without any notches remove the retainer before probing EG 11 Male terminal ECM GENERAL SERVICE INFORMATION EGM0057 EGM0058 EGM0059 Connector Terminal Inspection Cont d 2 Male terminal For a male connector terminal apply a T pin to the surface of the terminal A CAUTION Do not bend terminals Inspection for Electrical System DESCRIPTION If the malfunction can be traced directly to the electrical system first check for items such as burned out fuses and fusible links broken wires or loose connectors pulled out terminals and improper connections If a fuse or a fusible link is blown out determine the possible cause and restore it Always replace it with a new fuse or fusible link of the specified capacity When removing a connector do not apply excessive force to the main body by grasping and twisting Do not pull a connector off by tugging on the harness For a lock type connector dis2. 46 1 55 9 77 5 92 2 108 4 7 34 5 7 41 7 9 57 9 4 68 11 80 M14 1 5 73 6 87 3 127 147 177 7 5 54 8 9 64 13 94 15 108 18 130 M16 108 137 186 226 265 11 80 14 101 19 137 23 166 27 195 M18 167 196 275 324 392 17 123 20 145 28 203 33 239 40 289 M20 226 275 382 451 549 23 166 28 203 39 282 46 333 56 405 M22 1 5 304 363 510 608 736 31 224 37 268 52 376 62 448 75 542 A CAUTION e Except special parts e The bolt applicable to the list has the following number embossed on the head Model Number 4T 7T 9T 4 or none 7 9 CAUTION FOR USE OF POWER TOOLS Do not use any power tools e g air ratchet impact wrench to tighten the bolts and nuts Use these tools only for loosening the bolts and nuts However do not use power tools in any event and for any purposes on the parts subject to heat catalyst muffler and other exhaust parts and the tapping screws These parts may also be damaged when loosened with a power tool EG 24 eee 2 8 0 29 25 4 2 0 43 37 8 5 0 87 76 14 7 1 5 10 8 35 3 3 6 26 37 3 3 8 27 69 6 7 1 51 73 6 7 5 54 118 12 87 137 14 101 206 21 152 324 33 239 471 48 34 657 67 485 883 90 651 1 Unit Parts with tightening sequence Tighten separately in several turns Nem kg m ft lb Nem kg m in lb Parts name or locatio
3. 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 kgfem SI unit Metric unit CONVERSION OF MAJOR UNITS Quantity Conventional unit Coefficient of conversion into SI kgfem 9 80665 Torque and moment Force Pressure 0 735499 kcal h 1 16279 a Spring constant N mm kgf mm 9 80665 Fuel consumption g kWeh 1 g PSeh 1 3596 Power Power efficiency Volume 1 Conventional unit may be used in SI 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 Component Parts Location The Component Parts Location diagram refer to the figure includes information for removal installation disassembly and assembly tightening torque grease
4. is the same as that for a female connector Ean the black guide box however indicates a male connector the white prenon mark guide box a female connector A TS Guide is black Direction mark as EGM0052 SINGLE UNIT CONTROL UNIT A single control unit is viewed only from A and the illustration is as Control unit shown in the figure ae T Lo Male terminal al Direction mark i f2 3 4 5 6 7 8 9 Za Hopi tpi2 isfia is fie i7 t8 Connector symbol EGM0053 EG 9 TROUBLE DIAGNOSIS ECM Abbreviations List Abbreviations Description Abbreviations Description A T Automatic transmission Intake Left Light emitting diode ASSY Assembly INT Long life coolant i Rear F L Fusible link ae FR I P Idler pulley IGN Ignition Throttle adjust screw Transistor Undersize EG 10 ECM GENERAL SERVICE INFORMATION F EGM0054 emale terminal EGM0055 EGM0056 Connector Terminal Inspection CONNECTOR INSPECTION PROCEDURE In circuit inspection inappropriate connector probing will cause connector damages and or poor connection The probes provided with the circuit tester may be too large to probe connector terminals without damaging them Always use alligator clips and T pins according to following the procedure INSPECTION FROM HARNESS SIDE For a standard connector without any waterproofing use T pins from the harness side A CAUTION e For a connector with a rear cover
5. 74 7 9 35 11 0 95 1 1 82 95 5 6 8 4 0 57 0 86 49 5 74 7 146 167 15 17 108 123 162 172 16 5 17 5 119 127 1 38 40 3 9 4 1 28 30 2 40 45 Angle tightening 34 44 3 5 4 5 25 33 15 7 18 6 1 6 1 9 12 14 20 29 2 0 3 0 14 22 20292 0 30 14 22 1 9 3 20 6 0 9 2 1 78 182 2 20 6 26 5 2 1 2 7 15 20 41 2 52 4 2 5 3 30 38 40 60 4 1 6 1 30 44 EG 25
6. SM208 TB45E CARB2010 BE1 SERVICE MANUAL CX50 Forklift Truck EPA CARB 2010 Compliant Gasoline LPG FG40ZTU 40TU 45TU SOATU 10 S N 134756 FG402Z 35 40 45 50A 10 TB45 GASOLINE ENGINE ECU AA WARNING Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place KOMATSU Komatsu Forklift U S A LLC ISSUED JUNE 2011 PRECAUTIONS FOR SAFETY AND QUALITY EGM0043 EGM0044 EGM0045 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 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 sp
7. c 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 Diagnostic systems Engine WORK SUPPORT O SELF DIAG RESULTS O SELF DIAG RESULTS MEMORY DATA MONITOR O DATA MONITOR SPEC O Active test O DTC RECORD DISPLAY Control unit part No O Control unit identification No EG 14 PRECAUTIONS FOR WORK Precautions for Draining Coolant Drain the coolant after its temperature lowers sufficiently Precautions for Separating Fuel Piping Work in a place where there is nothing to start a fire Release the fuel pressure in advance After separating the fuel piping plug it to prevent the fuel from flowing out Precautions for Removal and Disassembly If specified use correct special tools and pay attention Do not apply an excessive force Take extreme care not to lower the accuracy of the mating faces sliding faces etc If necessary cover the openings with tapes etc to prevent foreign matter from entering the engine Make marks on the removed parts and arrange them for secure troubleshooting and assembly As a rule loosen the bolts and nuts from outside in the diagonal direction If the loosening order is specified observe it Precautions for Checking Repairing and Replacing Parts Before repairing or replacing parts check them sufficiently according to the check procedure C
8. clean them When replacing a part install a NISSAN genuine part Use the specified oil grease sealant etc Before removing a pressurized pipe hose etc release the pressure After repairing the fuel oil coolant exhaust or vacuum system check it for leakage securely Precautions for Radio Equipment Installation Check the following when installing a commercial hnam radio or mobile phone If mounting position is not chosen carefully the unit may interfere with the electronic control system Separate the antenna as far from the ECM as possible Route an antenna feeder line at least 20 cm 7 87 in apart from the control unit harness Adjust an antenna and feeder line to eliminate radio wave interference EG 3 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 A CAUTION e An item or a work procedure neglect of which can cause a death or a serious injury if neglected e An item or a work procedure to be observed especially among those neglect of which can cause an injury an accident or a damage of the vehicle or component parts Reference Supplementary explanation for the ease of work Standard value Permissible deviation of a value at inspection or adjustment Limit value The maximum or minimum which a value must not exceed at inspection or adjustment
9. e 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 Refer to the following notes for values in Engine system inspection except LPG fuel systems monast ie Ge a a a GG A 8 18 Applicable aa No Inspection items control Operation system hours 2 4 6 8 10 12 14 16 18 20 22 24 36 x 100 hours 1 Intake exhaust valve clearance Electronic A A A A A a A Electronic controls controls 2 Engine drive belt tension Electronic l l l l a controls 3 Engine oil Electronic 1 R R R R R R R R R R R R Oe R controls 4 Oil filter Electronic 1 R R R R R R controls 5 Engine coolant Electronic R controls 6 Air cleaner element Electronic C C C C C R C C C C C R Lees R controls 7 Ignition timing Electronic A A A A A A A A A A A A A controls 8 Spark plug Electronic es R controls 9 Distributor Electronic C controls 10 PCV valve Electronic 1 as controls 11 PCV hose Electronic l ae controls EG 21 SERVICE DATA Periodical Inspection Cont d No Engine system inspection LPG models 1 Gas leakage from piping and piping Electronic 2 l J joints controls 2 Damage to piping and piping joints Electronic ca al controls 3 Tar in vaporizer Elec
10. ecified 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 Before starting repair which does not need the battery power turn the key switch OFF and disconnect the negative terminal of the battery Take care not to touch the hot metal parts just after stopping the engine While the engine is still hot do not remove the radiator cap or another part of the coolant system Use the specified proper common tools or special tools for safe and efficient repair 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
11. engage its lock first then disconnect the connector by holding the main body of the connector Before connecting a connector check terminals for bends or breakage Connect it securely For a lock type connector press it until its lock is securely engaged When installing parts prevent harnesses from being snagged or overextended EG 12 Inspection component ECM GENERAL SERVICE INFORMATION EGM0063 Control Unit and Electronic Component PRECAUTIONS Never reverse polarity of battery terminals Install only parts specified for each model Before replacing a control unit check input and output signals to from the control unit and component functions When disconnecting a connector do not twist or apply excessive force For a bolt type connector loosen the bolt first then hold the main body of the connector to disconnect Before connecting a connector check terminals for bends or breakage Connect it securely For a bolt type connector screw in the bolt until the colored lug is flush with the surface to be sure it is securely connected Do not drop hit or subject control units to impact Be sure to protect control units from condensation caused by a sudden shift in temperature or from raindrops or splashes If any water drops adhere to the unit dry it well prior to installation Be sure to protect control unit connectors from oil Avoid cleaning control units with benzine Do not open a top or bottom cove
12. gine is warmed up sufficiently Voltage should be measured with a voltmeter Circuit resistance should be measured with an ohmmeter Current should be measured with an ammeter EG 8 Procedure with SST Procedure without SST A C switch is ON A C switch is OFF Connect to battery power supply directly Drive condition Disconnect battery negative terminal Brake pedal depressed Release brake pedal Depress accelerator pedal Release accelerator pedal Shows connector terminals of ECM or other control units that have several terminals Control unit connector 8 EGM0049 TROUBLE DIAGNOSIS ECM Trouble Diagnosis Cont d SYMBOLS FOR HARNESS CONNECTOR FEMALE CONNECTOR e When a harness connector is viewed from A terminal side the Connector symbol outer frame of the connector symbol is indicated with a single line In addition the direction indicator shows TS Terminal Side in description type font Single line Direction mark Female connector EGM0050 e When a harness connector is viewed from B harness side the outer frame of the connector symbol is indicated with double lines In addition the direction indicator shows HS Harness Side in description type font e Terminal assignments of a connector viewed from A and B are mirror images indicating just as they are seen Female connector Double line Direction mark Tan HS EGM0051 MALE CONNECTOR The illustration method
13. given in the manual observe it EG 16 PRECAUTIONS FOR WORK Parts Which Need to be Tightened by Angle Tightening Method Use angle wrenches special tools to tighten the following parts Cylinder head bolt Check that the cylinder head cylinder block mounting face and cylinder head gasket are free from oil and dirt and then coat the threads and stem of the cylinder head bolt and tighten it EG 17 PREPARATION Special Service Tools Description Seal cutter KV1011 11100 EGM0069 Ring gear stopper KVI101 05680 1 Adapter KV101 05630 2 Stopper plate KV101 05610 EGM0070 Oil seal drift KV101 04900 EGM0071 Angle wrench KV101 12100 EGM0072 1 Valve spring compressor KV101 09210 2 Adapter KV101 11200 EGM0073 Valve oil seal puller KV101 07901 EGM0074 Valve oil seal drift KV101 13000 EGM0075 EG 18 Application Remarks Removing parts attached with liquid gasket Removing and installing crankshaft pulley Installing front oil seal Checking tightening angle Already established Removing and installing valve collet Removing valve oil seal Installing valve oil seal PREPARATION Special Service Tools Cont d Description Application Remarks Overhauling engine Engine stand assembly ST0501 S000 EGM0076 Engine attachment KV101 06500 EGM0077 Engine sub attachment KV111 04800 Already established Camshaft bushing tool set Remo
14. heck the new parts similarly and replace them if necessary Precautions for Assembling and Installing Parts When tightening the bolts and nuts be sure to use torque wrenches As a rule tighten the bolts and nuts from inside to outside in the diagonal direction in 2 3 times If the tightening order is specified observe it Replace the gaskets packings oil seal and O rings with new ones Clean each part and dry it by blowing compressed air against it In particular take care that the oil passages and coolant passages will not be clogged Take care not to damage the sliding surfaces and mating faces and remove all dirt lint etc from them Apply sufficient oil to the sliding surface before assembling If the coolant is drained bleed air from the coolant system After repairing run the engine at high speed and check for leakage of the coolant fuel oil grease and exhaust gas EG 15 Scraper KV101 11100 ery Co a Slide PRECAUTIONS FOR WORK EGM0066 EGM0068 Precautions for Using Power Tools Use power tools such as an air runner for disassembly only Do not use them for assembly Precautions for Applying Gasket Sealant SEPARATION OF PARTS COATED WITH GASKET SEALANT e After removing the mounting bolts and mounting nuts cut and remove the gasket sealant with seal cutter special tool KV101 11100 according tothe following procedure 1 Drive in the seal cutter in the direct
15. ion of the arrow 2 Slide the seal cutter in the direction of the arrow 3 Slide the seal cutter in the direction of the arrow A CAUTION e Take care not to damage the mating faces e If it is difficult to use the seal cutter remove the gasket sealant by hitting it lightly with a plastic hammer A CAUTION If it is obliged to use a flat head screwdriver take extreme care not to damage the mating faces PROCEDURE FOR APPLYING GASKET SEALANT 1 Remove the old gasket sealant sticking to the mating faces with scraper e Remove all the gasket sealant from the grooves mounting bolts and bolt holes too 2 Wipe the mating faces with isoparaffin etc to remove water oil grease and foreign matter 3 Install the genuine gasket sealant to tube presser common tool 4 Apply the gasket sealant to the specified parts and dimensions without breaking it e Apply the gasket sealant to the grooves too if specified so e As a rule apply the gasket sealant to the inside of the bolt holes The outside of the bolt holes may need to be coated with the gasket sealant however Accordingly refer to the manual without fail e Install the parts within 5 minutes after applying the gasket sealant e Wipe off the projected gasket sealant immediately e Do not retighten the bolts after installing the parts e After installing the parts wait at least 30 minutes before supplying engine oil or coolant A CAUTION If a direction is
16. n Adjusting screw Lock nut AlternatorAdjusting bar side Bracket side Oil pan drain plug Spark plug Intake manifold Air horn Exhaust manifold cover Exhaust manifold Exhaust manifold connector Oil pan M6 M8 Oil strainer Rocker cover Rocker shaft bracket Cylinder head bolt Cylinder head additional bolt Crankshaft pulley Front cover Camshaft sprocket Chain tensioner Distributor Camshaft locating plate Flywheel Main bearing cap Connecting rod nut Engine coolant drain plug Water pump Engine coolant temperature sensor PCV valve Fuel tube Starter motor Heated oxygen sensor 1 SERVICE DATA Tightening Torque Cont d MAIN TIGHTENING TORQUE Tightening torque 16 22 1 6 2 2 12 16 175297 18 2413 17 50 0 67 6 5 1 6 9 37 50 54 59 5 5 6 0 40 43 20 29 2 04 2 96 14 22 15 7 18 6 1 6 1 9 12 14 20 6 26 5 2 1 2 7 16 27 6 37 7 45 0 65 0 76 56 66 97 31 28 3220293 59 78 6 0 8 0 43 58 6 3 8 3 0 64 0 85 56 74 15 7 20 6 1 6 2 1 12 15 16 19 1 6 1 9 12 14 1 0 2 9 0 1 0 3 9 26 15 6 21 6 1 6 2 2 12 16 1 29 4 3 22 2 61 7 6 3 46 3 0 0 0 4 29 4 3 22 5 69 74 Angle tightening 6 4 7 5 0 65 0 76 56 66 181 191 18 5 19 5 134 141 15 7 20 6 1 6 2 1 12 15 132 3 142 1 13 5 14 5 98 105 5 6 8 4 0 57 0 86 49 5
17. points non reusable parts as well as other information important for repair work Camshaft sprocket Distributor cap sia geal 7 with flat side facing sprocket side Distributor i 5 132 142 13 5 14 5 97 105 Chain tensioner O 6 4 7 5 0 65 0 76 5 Dy 3 e a O ring y Sa x Front cover Key for crankshaft sprocket Key for cone bushing Timing chain Chain guide 6 4 7 5 0 65 0 76 5 6 2 Crankshaft sprocket 4 X C haft ket sid gt pump drive spacer Be N R hor ela oA Stamp line O ring installing groove Granichanouley bak 69 Oil seal Q 15 7 20 6 1 6 2 1 12 15 l _ 0181 191 18 5 19 5 134 141 Engine oil 15 7 20 6 1 6 2 1 12 15 Crankshaft pulley washer Liquid gasket 4 Not reusable Nem kg m ft lb EGM0097 EG 5 HOW TO READ THIS MANUAL Component Parts Location Cont d COMPONENT SYMBOLS cs Tightening torque oo Not reusable Should be lubricated with oil eS Select proper thickness Searing point EGM0048 EG 6 TROUBLE DIAGNOSIS ECM Trouble Diagnosis A CAUTION The following trouble diagnosis procedures are designed to identify the trouble causes efficiently When performing diagnoses carefully observe the following instructions Before starting a trouble diagnosis carefully read and understand the contents in Basic Inspection Diagnosis Chart by Symptom and Trouble Diagnosis Flowchart Afte
18. r on a control unit When using a circuit tester ensure the appropriate distance between test probes A longer distance is recommended because if the distance is too short it may cause contact of the test probes resulting in a short circuit A short circuit allows battery voltage to be applied directly to the control unit resulting in damage to its internal power transistors Use the specified check adapter to check input and output signals to from control units 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 FUNCTION AND APPLIED SYSTEM 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 DATA MONITOR SPEC malluneyens Active test Sends command to control unit to change output signals and check operation of output system DTC RECORD DISPLAY Indicates self diagnosti
19. r the repair work always verify that the trouble is eliminated For the locations of the parts and harness connectors refer to Component Parts Location in the relevant section To perform a simple inspection utilize the circuit diagrams To inspect the circuit for continuity in details including the sub harnesses identify the relevant connectors and harness layouts referring to the Wiring Diagrams Before inspecting a circuit for continuity always turn the ignition switch to OFF Before measuring voltage at a connector always measure the battery voltage After finishing diagnoses or inspections always ensure that all removed harness connectors are reconnected correctly EG 7 DISCONNECT TROUBLE DIAGNOSIS ECM Trouble Diagnosis Cont d SYMBOLS Check after disconnecting the connector to be measured Check after connecting the connector to be measured Insert key into ignition switch Remove key from ignition switch Turn ignition switch to OFF position Turn ignition switch to ON position Turn ignition switch to START position Turn ignition switch from OFF to ACC position Turn ignition switch from ACC to OFF position Turn ignition switch from OFF to ON position Turn ignition switch from ON to OFF position Do not start engine or check with engine stopped Start engine or check with engine running CONNECT E A Apply parking brake Release parking brake Check after en
20. t idle speed ppm 0 1 or less 50 or less Ignition timing When feedback control is stopped BTDC rpm 10 2 750 Valve clearance mm in 0 35 0 0138 0 35 0 0138 Thermostat opening valve temperature Start Full open C F 82 95 180 203 Engine drive belt deflection New belt After adjustment Limit Measured by pressing 10 12 13 15 16 0 63 with 98 N 10 kg 22 Ib mm in 0 39 0 47 0 51 0 59 Alternator belt NV12 EGM0098 EG 23 SERVICE DATA Tightening Torque STANDARD BOLT TIGHTENING TORQUE lt Hexagon head gt lt No lubrication gt Unit Nem kg m ft lb Nem E in lb e Flanged bolt Non flanged bolt Flanged bolt nen a Flanged bolt 0 6 0 7 1 1 1 3 1 6 0 06 5 0 07 6 0 11 10 0 13 11 0 16 14 1 0 12 1 7 2 1 2 5 0 10 9 0 12 10 0 17 15 0 21 18 0 25 22 0 7 1 5 17 2 5 2 9 3 5 0 15 13 0 17 15 0 25 22 0 30 26 0 36 31 M5 2 9 3 5 5 0 5 9 72 0 30 26 0 36 31 0 51 44 0 6 52 0 73 63 M6 5 0 11 8 0 51 44 ee D ee ve 1 r 2 67 M8 12 7 14 7 20 6 24 5 29 4 1 3 9 4 1 5 10 8 2 1 15 2 5 18 3 0 22 13 7 15 7 21 6 26 5 31 4 1 4 10 1 6 12 2 2 16 2 7 20 3 2 23 M10 24 5 29 4 41 2 49 58 8 2 5 18 3 0 22 4 2 30 5 36 6 0 43 25 5 30 4 43 1 51 61 8 2 6 19 3 1 22 4 4 32 5 2 38 6 3 46 M12 1 75 42 2 51 70 6 84 3 98 1 4 3 31 5 2 38 7 2 52 8 6 62 10 72 1 25
21. tronic D D D D D D D D D D D D se D controls 4 Injection nozzle Electronic Sey al controls 5 LPG filter Electronic C C C R ae C controls A CAUTION e If the vehicle is being used in dusty and dirty environments the maintenance work should be performed more frequently e 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 Standard Repair Limit Fuel in use Lead free regular gasoline with an octane value of 91 or more Engine weight without water with oil kg Ib Approx GAS LPG 301 DUAL 302 Firing order 1 5 3 6 2 4 Compression pressure 1 187 11 87 12 1 172 200 kPa bar kgf cm psi rpm 892 8 92 9 1 129 200 98 0 98 1 0 14 200 Distortion limit mm in 0 2 0 008 02 0 005 0 0 008 Engine oil amount Imp qt Approx 8 3 7 1 4 ae Approx 86 6 578 Spark plug Manufacturer type gap mm in NGK BPR4ES D 0 8 0 9 0 031 0 035 Resistance on high tension cable kQ 1 Approx 2 7 2 Approx 2 8 3 Approx 4 4 Approx 5 5 Approx 5 2 6 Approx 6 1 Ignition advance device Electronically controlled ignition advance Onboard idle speed rom 750 50 Onboard idling pace speed When feedback control is stopped rpm 750 Density of CO at idle speed Density of HC a
22. ving and installing camshaft KV111 045S0 bushing 1 Bar KV111 04510 2 Guide plate KV111 04520 3 Adapter KV111 04530 4 Drift ST 1524 3000 EGM0079 Pulley puller Removing crankshaft pulley Already established KV111 03000 EGM0080 Oil filter wrench KV101 15801 Removing oil filter Already established EGM0081 EGI fuel pressure indicator For measuring fuel pressure ST1959 0000 gauge EGM0082 EG 19 PREPARATION Special Service Tools Cont d Description Application Remarks Heated oxygen sensor wrench Removing and installing heated KV101 13700 oxygen sensor EGM0083 Maintenance tool For system inspection and 1 DIAGNOSIS KIT diagnosis SKVEE GY010 2 SOFT WARE SKVEE GY100 Check adapter V For control unit input output signal EG1755 0000 inspection for SMJ 150 pin connector Harness adapter EG1755 0200 150 pin to 121 pin conversion adapter EGM0085 For molding coil Checking engine speed Adapter harness EG101 17500 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 STD 2 000 0 0787 US 0 25 0 0098 2 125 0 0837 US 0 50 0 0197 2 250 0 0886 US 0 75 0 0295 2 375 0 0935 US 1 00 0 0394 2 500 0 0984 EG 20 SERVICE DATA Periodical Inspection To maintain the initial performance of the KOMATSU FORKLIFT make sur
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