CX50DX50 Training

CX50 DX50
CX50/DX50
CX50 DX50
Diesel STD Model

Non Emission Control Emission Control
CX DX CX DX
FD35YT-10 FD50-8 FD35T-10 No production
FD40YT-10 FD60-8 FD40T-10 FD60-10
FD45YT-10 FD70-8 FD45T-10 FD70-10
FD50AYT-10 FD80-10 FD50A-10 FD80-10

CX50 DX50
Compact Model
Non Emission Emission Control

Control Area Area
FG40Z-10 FG40Z-10
FD40ZYT-10 FD40Z-10
Note: Not Available 3.5 ton Compact Model.

CX50 DX50
Gasoline/LPG Engine
Non Emission Emission Control
Control Area Area
CX 50 DX50 CX50 DX50

FG35T-10 Na FG35T-10 Na
FG50AT-10 Na FG50AT-10 (FG70-8)##
Note 1: DX Model of Gas/LPG are not available.

Note 2: All Gas/LPG Engine is Electric Control and
meet 2007 EPA III Emission control.
(No regulation on Euro)
##: Only USA Market
1-5. Emission Standard History
82% reduction
of NOx
Oxides of Nitrogen (g/bhp-hr)
Unregulated level 54% (1996-2006)

15
10 35%
40%
Tier 1
5 ?
Tier 2 ?
Tier 3
0 Tier 4
1980 1985 1990 1995 2000 2005 2010 2015 2020

PM g/kwh
0.8
Emission Regulations
0.7
U.S.EPA(225kw - 560kw/306ps - 762ps)
0.6 1-6. EPA Medium Range
0.5 Tier 1
0.4 EGR / In-cylinder Air to Air
& &
0.3 HPCR(160MPa) HPCR(120MPa)
0.2
Tier 3
0.1
0.027 (Tier 4) Aftertreatment Tier 2
0.0
00.55 1 2 3 4 5 6 7 8 9 10
NOx + NMHC g/kwh
(*Tier1: NOx only)
Weighting 10%
Torque 100%
15%
10%
1-7. 8-Mode Test 75%
Cycle15%- ISO
Tier 3
8178 50%
10% Design Limits
3.0 gr/hp--hr
15%
(NOx+NMHC)
Torque (%)
0.15 g/hp-hr PM
10%
15%
Engine
Speed
Idle Peak Torque Rated
FEATURES OF CX50
CX Model
Non Emission Emission
Control Area Control Area
Engine S4D95LE /TB45 SAA4D95LE/TB45

Torque Converter Same as CX20 Same as CX20
Transmission F1/R1, F2/R1 (50A)
Front Axle New Design
Brake Wet Brake
Hydraulic New System
Steering Without OPS (D) With OPS
With OPS (G)
FEATURES OF CX50
• Vibration reduction by dual floating structure

• Conformance with ISO3691 （ＯＰ）
Improvement of fuel
consumption by up to 20%
Excellent fine control work
• Improvement of Komatsu
new hydraulic system
Variable displacement
pump + CLSS
• Wet-type brake as standard • Improvement of the electronic

control Komatsu engine in
equipment conformance with emission
10000H durability level regulations (Diesel forklift truck)
　　 (Emission Control Area)
FEATURES OF CX50
Comparison of current and new CX models
Item Precautions
CX-10 CX-8
1 Idle lift function  CLSS makes idle lifting possible. Do  Idle lifting is impossible.
public relations widely on this feature. – Idle lifting speed: 0mm/s
– Idle lifting speed: 160 mm/s
2 Wet-type brake  The brake has in-board structure,  Drum type

which is different from DX. Lining needs to be replaced
The brake valve is actuated with at intervals of about 1,000 H.
hydraulic oil and cooled with differential
oil. (SAE 80 GL-5 Gear Oil)
– Differential oil: 8, 5L : SAE J306 80
Replacement interval: 1,200 H
3 Brake-interlocked start  Similarly to an automatic transmission  Without brake-interlocked
system car engine, the engine does not start start system
unless the brake pedal is depressed.
(See Technology)
4 Interchangeability of  Number of bolts: 8  Number of bolts: 6
rims The number of front wheel hub bolts
(Front wheels) and their pitch are changed to prevent
them from loosening. Accordingly, the
tire assemblies are not
interchangeable.
FEATURES OF CX50
Precautions for sale/Body
Item Precautions
CX-10 CX-8
1 Fork The notch position of the board is changed to meet JIS.
The current fork can be installed to the new model from the side after
removing the backrest.
2 Coarse mesh radiator  Not set.  Not set.

The radiator screen is prepared.
FEATURES OF CX50
Quality improvement activities <1>
Component No Quality item Measures taken for Model 8 Application to Model 10
Brake 1 Breakage/Wear of Improvement of finned drum
lining
As the remedy, the wet-type
2 Squeal/Insufficient Selection of individual lining
brake is employed as the
working of brake
standard equipment.
3 Overheat Improvement of finned drum
4 Oil leakage from Replacement at each trouble

booster or master
cylinder
Cooling 1 Overheat Increase of fan speed and Improvement of hydraulic oil
remedy against each trouble temperature with variable-
displacement pump and heat
shield structure
2 Water leakage from Addition of reinforcement plate Improvement of floating structure,
radiator etc. change of hose clamp method
and change of hose material
Engine 1 Starting trouble Change of preheating method Improvement of electronic control
(Starting motor trouble)
2 Large oil Remedy against each trouble CPU controls electronically

consumption/White controlled engine to maintain the
exhaust gas best condition.
3 TB42 starting trouble Change of starting procedure Improvement of electronic control
Easy/Efficient work
FEATURES OF CX50
Front axle 1 Breakage of needle roller Remedy against each trouble Increase of king pin size (35  40ø)
bearing Change of bearing outer race
material (SPC  SCM)
2 Play of PS cylinder Caulking 2  4 places Head tie rod fixed type
3 Play of link Bushing with seal Bushing with seal
4 Looseness of hub nut Reduction of tolerance Change of bolt pitch and change of number of
bolts (6  8)
Power train 1 Torque converter overheat Remedy for individual cooler Installation of air after cooler as standard
equipment
2 Disconnection of torque Change to taper seal type Change to face seal type
converter piping
3 Oil leakage from deferential Reinforcement of gasket Separation of differential and transmission by
joint employing full float structure
Hydraulic 1 Oil leakage from control Remedy against each trouble New development in Komatsu
system valve
2 Hydraulic drift and forward Measures against complaint Resolution by conforming with ISO
slant
3 Oil leakage from hydraulic Improvement of hose with adapter Improvement of cooler-less system
cooler
4 Oil leakage from each part Replacement at each trouble Improvement of heat balance and use of face
seals for high-pressure portions
5 Oil leakage from hydraulic Replacement at each trouble Optimization by employing variable-
pump displacement pump
6 Oil leakage from tilt cylinder Replacement at each trouble Increase of cleanliness of oil and parts
7 Breakage of pump drive Reinforcement of shaft Improvement of torque converter PTO

shaft
FEATURES OF CX50
Steering 1 Large steering effort or Replacement of parts at Installation of FHPS and priority valve
system hitch each trouble
2 Fixing of steering joint Change of greasing interval Improvement of joint-less system
3 Fluctuation No remedy Improvement of FHPS
Machine 1 Much heat radiation Lagging individual part Change of exhaust pipe layout
cover etc. from hood
2 Fogging of meter panel Repair seal against Use of NXT-V
individual trouble
3 Slight fluttering of No remedy Improvement by employing electronic
accelerator pedal control
Electric 1 Short circuit in wiring Addition of clamp Centralization of wiring and disuse of
parts etc. harness tie wrap
2 Flaking of rolling Improvement of mild steel Improvement of mild steel for 3.5 – 4
surface of inner mast roller ton models
3 Damage of chain Addition of prevention panel Taken over
(Catching)
FEATURES OF CX50
New Komatsu engines <1>
Komatsu SAA4D95LE engine
--- 2-valve, common rail, electronic control ---
The goal is clearing

the 3rd emission regulations
+ improving fuel consumption.
When mounted on CX
33%
Particle matter: Reduction by Displacement: 3,260cc
62.5kw/2400rpm
Black smoke: Reduction by 25% 85PS/2400rpm
33kg-m/1600rpm
Environmental measures
FEATURES OF CX50
High-output engine
2 valves/cylinder High output is attained by setting
optimum displacement and employing
shaker piston.
Low-speed torque is increased by
employing high-pressure common rail.
Common rail
Engine-mounted engine controller (ECM)
Noise is lowered
Noise is lowered by employing highly-rigid cylinder block, front
gear train and electronically controlled multi-injection
FEATURES OF CX50
Gasoline engines that meet the regulations
Gasoline engine
Mounted with engines that meet 2007 regulations (manufactured by Nissan)
• EBT-TB45-1A Gasoline engine
• EBT-TB45-1B Gasoline/LPG engine
• EBT-TB45-1C LPG engine
3-way catalyst
FEATURES OF CX50
TB45/K25 Electric Fuel Control System Gasoline: MPI
Dual Fuel
K-LINE (Troubleshooting) LPG: Gas Jet SPI
Accelerator
Travel speed signal
E.C.M.
Air flow meter
Injector x 1
(LPG) Injector (Gasoline) x 4 Air cleaner
Nozzle
0.3k OHV Ignition coil
PTC heater Intake (Low-voltage distribution system)
Electronically manifold Ignition plug
Vaporizer controlled throttle
Exhaust Coolant Fuel pump
manifold temperature
LPG cylinder 3.5k Relay
O2 sensor sensor
LPG fuel cut solenoid
(Gasoline, Outside Installation)
Crankshaft Cam angle sensor

Muffler Catalyst angle sensor
Fuel pump
Fuel tank (Gasoline)

FEATURES OF CX50
Explanation of electronically controlled engine of machine with 3-way catalyst in Japan (1)
LPG fuel cut solenoid
Model K engine
Vaporizer PTC with heater
Crankshaft angle sensor, for electronic control
cam angle sensor Gasoline fuel pump
(Front gear case cover) (in tank)
Travel speed signal

O2 sensor
converter
(under relay box)
Air flow meter
ECM
Ignition coil x 4
Electronically
Gasoline injector x 4
controlled throttle
LPG injector (main)
LPG fuel pressure sensor
LPG injector (sub)
Accelerator
pedal sensor
3-way catalyst
FEATURES OF CX50
Function outline of electronically controlled engine
Contents
Category Diesel (Cummins ECU) Gasoline/LPG (Hitachi Automotive ECM)
Contents of control Control boundary Contents of control Control boundary
When Idle learning No function (No processing is necessary) *** Initialization of idle throttle valve opening ***
normal degree for each forklift truck (Quick TAS
learning)
Cold starting When temperature is low, intake air heater is Intake air temperature is PTC heater in LPG vaporizer is controlled ON: Coolant temperature
aids turned ON to preheat for up to 30 seconds 5°C or below is 30°C or below
OFF: Coolant temperature
is 40°C or above
Automatic After engine is started, its low idle speed is ON: Coolant temperature After engine is started, its low idle speed is ON: Coolant temperature
warming up increased to 1,000 rpm to warm it up is 45°C or below increased to 1,000 rpm to warm it up is 40°C or below
OFF: Coolant temperature OFF: Coolant temperature
is 50°C or above is 50°C or above
Turbo protect After the engine is started, the throttle Engine speed is limited Non-turbocharging only
function opening degree is limited to 1,000 rpm to for up to 20 sec when
prevent breakage of the turbocharger coolant temperature is
caused by insufficient lubrication. below 10°C
Normal Fuel injection rate is decided according to Open control Lean/Rich air-fuel ratio of O 2 sensor is fed Closed control
operation accelerator opening degree and quantity and back and fuel injection rate is decided
temperature of intake air. according to accelerator opening degree,
engine speed and quantity and temperature
of intake air.
When Self-diagnosis Measured values (Outputs) of various CANBUS method Same as left. Number of kinds of warning K-LINE method
abnormal function sensors are monitored constantly and depending on failure lamp is only 1, however. depending on failure
following are output when abnormality is mode mode
detected.
<1> Lighting of warning lamp (2 kinds)
<2> Saving of failure code in ECU
Output/Speed When trouble occurs, engine torque and/or See each failure mode When trouble occurs, engine torque and/or See each failure mode
derate speed is decreased to prevent fatal damage speed is decreased to prevent fatal damage
of engine, according to that trouble of engine, according to that trouble
FEATURES OF CX50
Examples of engine derate when electronically controlled engine is
abnormal
Diesel Gasoline/LPG
Derate category Torque Speed Derate category Torque Speed
Overheat
Overheat    Output reduction to half  Near idle speed
(There are 2 levels)
Low oil pressure   Low oil pressure
Too high/low common

 Too high LPG pressure  
rail fuel pressure
Crankshaft sensor
Engine speed sensor    Output reduction to half/Near 1,800 rpm
abnormality
IMV/PCV1 short Warning lamp bulb

  
circuit/disconnection breakage
Injectors Drive Circuit Electronically controlled

  Reduction to near 1,000 rpm
Error throttle abnormality
Accelerator sensor Accelerator sensor

 
abnormality abnormality
FEATURES OF CX50
SAA4D95LE-5
FEATURES OF CX50
SAA4D95 Engine
FEATURES OF CX50
Engine Performance
Isochronous Engine Speed Control
Any load condition of Engine ,
Engine speed maintain constant
by soft ware of engine controller at
Low idling and rated engine speed.
1, Merit
(a) To avoid engine stop at low idling
due to high load.
(b) Reduce High Idle engine speed
for reduce engine noise.
Note: This function are only effect

at engine Low/High idle speed.
On DX model,
Only effect at low engine Idle speed.
FEATURES OF CX50
Features of Electric Fuel Control

Diesel
Engine
Controller
FEATURES OF CX50
SAA4D95LE-5-A Failure code list
Failure code of Failure code of
Failure phenomenon Failure phenomenon
troubleshooting tool troubleshooting tool
111 ECM Critical Internal Failure 352 Sensor Sup. 1 Volt. Low Error
115 Eng. Ne and Bkup Speed Sensor Error 386 Sensor Sup. 1 Volt. High Error
122 Charge Air Press Sensor High Error 415 Rotation derating by low engine oil pressure
123 Charge Air Press Sensor Low Error 431 Idle Validation SW Low error
131 Throttle Sensor High Error 432 Idle Validation Process error
132 Throttle Sensor Low Error 435 Abnormality in engine oil pressure switch
144 Coolant Temp. Sensor High Error 441 Battery voltage low error
145 Coolant Temp. Sensor Low Error 442 Battery voltage high error
153 Charge Air Temp. Sensor High Error 449 Rail Press. Very High Error
154 Charge Air Temp. Sensor Low Error 451 Rail Press. Sensor High Error
187 Sensor Sup. 2 Volt. Low Error 452 Rail Press. Sensor Low Error
221 Ambient Air Press. Sensor High Error 553 Rail Press. High Error
222 Ambient Air Press. Sensor Low Error 559 Rail Press. Low Error
227 Sensor Sup. 2 Volt. High Error 689 Eng. Ne Speed Sensor Error
234 Eng. Overspeed 731 Eng. Bkup Speed Sensor Phase Error
238 Ne Speed Sensor Sup. Volt. Error 757 All Persistent Data Lost Error
271 IMV Short Error 778 Eng. Bkup Speed Sensor Error
272 IMV Open Error 2185 Throttle Sens. Sup. Volt. High Error
322 Injector #1 (L/B #1) System Open/Short Error 2186 Throttle Sens. Sup. Volt. Low Error
324 Injector #3 (L/B #3) System Open/Short Error 2249 Rail Press. Very Low Error
331 Injector #2 (L/B #2) System Open/Short Error 2311 Abnormality in IMV solenoid
332 Injector #4 (L/B #4) System Open/Short Error 2555 Grid Heater Relay Volt. Low Error
351 INJ. Drive Circuit Error 2556 Grid Heater Relay Volt. High Error
 A failure code of troubleshooting tool is a 3 or 4-digit failure code displayed on the troubleshooting tool when the
trouble occurrence condition is checked with the troubleshooting tool.
FEATURES OF CX50
Explanation of engine controller function - 1
Torque reduction by 30%

Torque curve at max. torque speed
Troubles notified by Engine Engine at full throttle
Engine torque
engine controller torque drop speed drop
Eng Overspeed 
Engine oil pressure Torque

 
drop reduction
by 30%
Common rail high

pressure
Engine torque
Common rail low lowers 3 seconds
 later
pressure
IMV short circuit 
IMV disconnection  Engine speed

lowers 30 seconds
Injector system later

abnormality 0 Engine speed
Engine speed lowers to

near max. torque speed
FEATURES OF CX50
Explanation of engine controller function - 2
Turbo protect function
The turbo-protect function restricts the throttle opening degree recognition for several seconds after the engine is
started so that the engine speed will not exceed 1,000 rpm.
This function senses the engine coolant temperature and engine oil pressure switch signal rising time after the
engine is started and sets the engine speed hold timer.
 Engine speed hold time
• When coolant temperature is 10°C or above: 0 sec
• When coolant temperature is below 10°C: Max. 20 sec (varies from 0 to 20 seconds, depending on oil
pressure rise)
Automatic warm-up function

If the engine is started when the engine coolant temperature is 50°C or below, the low idle speed is set to about 1,
000 rpm. The automatic warm-up function is reset under one of the following conditions.
1) Engine coolant temperature has risen
2) Throttle opening degree has been kept 70% or above for 3 seconds
3) Engine has been operated for continuous 30 minutes
Automatic preheat function

When the engine is started at low temperature, the engine intake manifold temperature (boost temperature) is
sensed and the engine is preheated with the intake air heater automatically.
1) When the key switch is turned to (ACC) ON position, the engine controller outputs the signal to the heater rela
y at the intake air manifold temperature and time shown in the above figure, and then the intake air heater is tu
rned ON.
2) At the same time as 1) above, the "Preheat" lamp is lighted by the signal from the engine controller.
(When the heater relay is turned OFF, the lamp goes off)
3) The operator shall start the engine after the "preheat" lamp goes off. If the engine is started before the lamp g
oes off, the signal to the heater relay is turned OFF.
FEATURES OF CX50
SAA4D95LE Engine
For CX50 For DX50
FEATURES OF CX50
FEATURES OF CX50
FEATURES OF CX50
Fuel Circuit for SAA4D95LE

9
10
6 7 8
5
11
1. Fuel Tank
2. Priming Pump
3. Fuel Filter with Water
4 Separator
4. Main Fuel Filter
3 5. Feed Pump
6. IMV (Inlet Metering Valve)
7. Over flow Valve
2
8. Common Rail
9. Injector
1 10. Safety Valve
11. High Pressure pump
Poor Fuel Area Specification (Asia.Middle East, Israel )
Additional
6271-71-
6500
Water
Sepalator
6738-71-
9110
Pre-Filter
6271-71-
6200
FEATURES OF CX50
Fuel Supply Pump
1 2
1. High pressure Valve
3
2. Inlet Valve
3. Piston
4. Cam
4 5. MPROP
(Solenoid Valve for Fuel Volume Control)
6. Gear Pump
6 Specification:
Supply Pump
Type: CP1H-OHW made by Boche
5 Lub: Fuel Lubrication
Governor: Electric Control
FEATURES OF CX50
SAA6D95LS-5
FEATURES OF CX50
Fuel Circuit
1. Drive Shaft
2. Gear for Supply Pump Drive
(Teeth: 31)
3. Pump Holder
4. Supply Pump
5. High pressure pipe (Pump to Rail)
6. Fuel Main Filter
7. Fuel Injection Pipe(No.1)
6 13 8. Fuel Injection pipe(No.2)
12
9. Fuel Injection pipe(No.3)
11. Spill Tube
12. Common Rail
13. Injector
A: Fuel gate (From Fuel

Filter)
A B: From Supply pump to Rail
C: From Rail to Injector
D: To Spill
E: To Fuel tank
FEATURES OF CX50
Supply pump mounting

1. Drive Shaft
2. Gear for Supply Pump Drive
(Teeth: 31)
3. Pump Holder
4. Supply Pump
5. High pressure pipe (Pump to Rail)
6. Fuel Main Filter
6 13 8. Fuel Injection pipe(No.2)
12
9. Fuel Injection pipe(No.3)
11. Spill Tube
12. Common Rail
13. Injector
A: Fuel gate (From Fuel

Filter)
A B: From Supply pump to Rail
C: From Rail to Injector
D: To Spill
E: To Fuel tank
FEATURES OF CX50
Oil Filter mounting

1. Oil Cooler
2. Cartridge
3. Bracket
2 3
1
FEATURES OF CX50
Oil Filter mounting

1. Oil Cooler
2. Cartridge
3. Bracket
2 3
1
FEATURES OF CX50
Supply pump mounting

A: Fuel inlet (From fuel filter)
B: From supply pump to rail
C: From rail to injector
D: To spill
E: To fuel tank
1. Drive shaft
2. Supply pump drive gear
(Number of teeth: 31)
3. Pump holder
4. Supply pump
5. High-pressure pipe
(Between pump and rail)
6. Fuel filter
7. Fuel injection pipe (No. 1)
11. Spill tube
12. Rail
13. Injector
FEATURES OF CX50
Fuel injection nozzle

A: Fuel inlet (From supply pump)
B: Fuel return opening (To fuel tank)
1. Backup ring
2. 2-way valve
3. Armature
4. Lock sleeve
5. Valve spring
6. Magnet
7. Inlet connector
8. Valve
9. Injector body
10. Nozzle
Specifications
Model: Bosch CR12.0 Injector
Fuel injection pressure:
25.4 – 108MPa {250 – 1,100kg/cm2}
FEATURES OF CX50
Common rail
A: From supply pump
B: To No. 1 injector
C: To No. 2 injector
D: To No. 3 injector
E: To No. 4 injector
F: Fuel outlet when limiter is open
1. Common rail
2. Pressure limiter
3. Fuel pressure sensor
4. HP connection
FEATURES OF CX50
Various sensors
1. Cam speed sensor

2. Crankshaft speed sensor
3. Coolant temperature sensor
4. Boost pressure/temperature sensor
FEATURES OF CX50
Various sensors
5. Oil pressure switch
6. Common rail pressure sensor
7. Ambient pressure sensor
FEATURES OF CX50
Cooling system diagram

1. Radiator
2. Thermostat
3. Coolant temperature gauge
4. Water pump
5. Water manifold
6. Cylinder head
7. Piston
8. Cylinder block
FEATURES OF CX50
Water pump
(Bearing, shaft-rotor unit type, with split seal)
1. Pump cover
A: Water inlet (From radiator) 2. Impeller
B: Water inlet (From thermostat) 3. Water seal
C: Water outlet (To each part of engine) 4. Pump body
D: Water outlet (To radiator) 5. Boss
6. Drive shaft
FEATURES OF CX50
Cooling fan drive and thermostat

A: Air flow direction
B: To radiator (Coolant)
C: From each part of engine (Coolant)
a,b,c: Pulley outside diameter
d: Heater pickup port
e: Thermosensor
f: Coolant temperature pickup port
1. Fan
2. Fan belt
3. Water pump
4. Fan spacer
5. Fan pulley
6. Crankshaft pulley
7. Crankshaft
8. Thermostat case cover
9. Thermostat
10. Thermostat case
11. Alternator
FEATURES OF CX50
Cooling fan drive
12
FEATURES OF CX50
Thermostat (With jiggle valve)

1. Piston
2. Case
3. Pellet
4. Seat
5. Valve
6. Case
7. Spring
8. Bypass spring
9. Bypass valve
10. Bypass seat
11. E-ring
12. Jiggle valve
Jiggle valve (12) allows air

pass through the
12 thermostat top but does not
allow water to increase the
engine coolant temperature
quickly.
FEATURES OF CX50
Engine controller
1. Controller body
2 3 4 2. Engine wiring harness connector
3. Machine wiring harness connector
4. Power supply
1
FEATURES OF CX50
Valve clearance adjustment

2. Rotate the crankshaft forward (cw seeing from
the front) and set wide notch (a) (Width: 25 mm)
of signal plate (1) at the rear of the crank pulley
to embossed "1.4TOP" (b) of front cover (2).
Reference: All of the other notches of the signal
plate are 5 mm in width.
 Rotate the crankshaft by turning the crank pulley
bolt (3) (Width across flats: 27mm).
 Be sure to rotate the crank pulley bolt forward to
prevent it from being loosened.
[Reference information for mounting onto machine]

If plug (c) of the flywheel housing is removed, the
top dead center mark (white paint) of the No. 1
cylinder on the flywheel side can be checked.
Remove flywheel housing cover (d), and you can
install the barring tool to rotate the crankshaft.
For detail, see the Shop Manual of the applicable
machine.
FEATURES OF CX50
Engine cranking
FEATURES OF CX50
Valve clearance adjustment
3. Adjust the clearances of the valves marked
with  in the valve arrangement drawing in the
following procedure.
4. Rotate the crankshaft 1 turn to set the piston of
the No. 4 cylinder to the compression top dead
center and adjust the clearances of the valves
marked with  similarly to those marked with
.
Reference: You may rotate the crank pulley 180
degrees and adjust the clearance of the valve
of the cylinder, the piston of which is at the
compression top dead center. (Firing order: 1-
2-4-3)
Valve clearance
Intake valve: 0.35 ± 0.02mm
Exhaust valve: 0.50 ± 0.02mm
Locknut: 39.2 – 49Nm {4 – 5kgm}
Cylinder head cover mounting nut:

8.82 ± 0.98Nm {0.9 ± 0.1kgm}
FEATURES OF CX50
FEATURES OF CX50
FEATURES OF CX50
Check of compression pressure (Removal of injector)
 Measurement of No. 1 cylinder is shown as an
example.
1) Remove wiring harness connector (2) from injector
(1).
2) Move fuel splash prevention cover (3) from the
connecting portion.
3) Remove clamp (4) and high-pressure pipe (5).
4) Pull out spill hose connector (6) from injector (1).
5) Remove holder (7) and injector (1).
If the injector is stuck and cannot be removed easily,
pass a wire under the fuel inlet and pull up the
injector to remove.Do not apply an external force to
the injector top terminal.
Symbol Part No. Part name

1 795-502-1590 Compression gauge
C 795-471-1420 Adapter
2
6271-11-3880 Gasket
FEATURES OF CX50
Check of compression pressure (Removal of injector)
2. Insert adapter C2 in the injector mounting hole
and fix it with holder (7).
 Fit the gasket to the adapter end.
Holder mount bolt:
27 – 30Nm {2.8 – 3.1kgm}
 While the fulcrum of the holder is seated
perfectly, tighten the mounting bolt.
3. Connect compression gauge C1 to adapter C2.
4. Connect the INSITE (Bench test device) to the

engine controller and set it to the no injection
position.Or, disconnect the wiring harness
connectors from all the injectors to set the
injectors in the no injection state.
If the engine starts, it is dangerous. Be sure to
check while the injectors are in the no
injection state.
FEATURES OF CX50
Check of compression pressure (Installation of injector)
6. After finishing check, remove the check

devices and return the removed parts
according to the following procedure.
1) Fit O-ring (8) and gasket (9) to injector (1).
Do not fit O-ring (8) to groove "a".
2) Insert injector (1) in the cylinder head and

fix it with holder (7).
Holder mount bolt:
27 – 30Nm {2.8 – 3.1kgm}
While the fulcrum of the holder is seated
perfectly, tighten the mounting bolt.
FEATURES OF CX50
FEATURES OF CX50
Check of engine oil pressure
The check point may different from the following, depending on the applicable
machine.
1. Remove 1 oil pressure pickup plug (1) on the right side of the cylinder
block.
You may remove any 1 of the 3 oil pressure pickup plugs.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
E 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
FEATURES OF CX50
Measurement of fuel pressure (low pressure side)
Remove plug (1) from the main fuel filter head.
2. Install adapter F3 and nipple [1] of hydraulic

tester F1 and connect to gauge [2] of boost
gauge kit F2.
3. While running the engine at high idle,

measure the fuel pressure.
 If the fuel pressure is as follows, it is
normal.
Reference: The fuel pressure is negative.
Plug: 7.8 – 9.8Nm {0.8 – 1.0kgm}

FEATURES OF CX50
Check of fuel return rate/leakage (common rail)
1. Preparation
1) Remove spill hose (2) between the 3) Insert spacer G1 on return block (3) side
common rail and injector. and reinstall the removed joint bolt.
2) Remove tube (4) between common rail  Be sure to fit the gaskets to both ends of
(1) and return block (3). the spacer.
FEATURES OF CX50
4) Install joint G2 on common rail (1) side and reinstall the removed joint.
 Fit the gaskets to both ends of the joint securely.
5) Remove spill hose connector joint (5) and install plug G3.
Plug G3: 3.9 – 6.9Nm {0.4 – 0.7kgm}
FEATURES OF CX50
6) Connect hose G4 to joint G2.
 Fix the test hose with a wire so that it will not come off.
7) Connect test hose G5 and return connector (6) from the injector.
 Fix the test hose with a wire so that it will not come off.
 Measuring tools for fuel leakage

from common rail and injector
FEATURES OF CX50
Use the real-time monitoring function

of the service mode to set the engine
rated speed.
Standard leakage per minute
Reference: Although the standard value is 20cc/min as shown

above, fuel does not leakage at all actually.
Joint (5): 3.9 – 6.9Nm {0.4 – 0.7kgm}

FEATURES OF CX50
Check of fuel return rate/leakage (injector)
1) Secure hose G5 and put it in a measuring cylinder.
2) While watching the real-time monitor in the service mode, set the engine to
the rated speed.
3) After the engine speed is stabilized, measure the fuel leakage per minute.
 You may measure for 20 seconds and multiply the result by 3.

 If the fuel pump does not supply fuel and the fuel pressure does not rise, the engine
speed does not increase. In that case, record the engine speed.
 If the fuel return rate from the injector is as follows, the injector is normal.
FEATURES OF CX50
Check of return rate from injector

FEATURES OF CX50
Bleeding air from fuel circuit
If fuel is used up or any fuel circuit device is removed and installed, bleed air
according to the following procedure. The installed positions of the fuel
system devices may different from the following, depending on the applicable
machine.
Fuel pre-filter (1), priming pump (2) and air bleeding plug (3) on the pre-filter
side are installed to the machine.
FEATURES OF CX50
1. Remove fuel pre-filter (1) and fill it with fuel.
Fill the pre-filter with clean fuel and take care that dirt will not enter.
Check that the cap is fitted to part (a) (center hole) of the fuel pre-filter and
pour fuel in part (b) (peripheral holes). When the pre-filter becomes full of
fuel, remove the cap from part (a).
If clean fuel is not available, fill the fuel pre-filter with fuel by operating
priming pump (2) without removing the fuel pre-filter.
Do not pour fuel in fuel main filter (4) from outside.
2. Install fuel pre-filter (1) to the filter head.
Apply engine oil thinly to the packing
surface on the fuel pre-filter side.
After the pre-filter packing surface
reaches the sealing surface of the filter
head, tighten 3/4 turns.
FEATURES OF CX50
3. Remove air bleeding plug(3) of the fuel pre-filter bracket
and operate priming pump (2).
Operate the priming pump until fuel flows out of the plug
hole and then install the plug.
4. Remove air bleeding plug(5) of the fuel main filter (4) and
operate priming pump (2).
Operate the priming pump until fuel flows out of the plug
hole and then install the plug.
Air bleeding plug: 7.8 – 9.8Nm {0.8 – 1.0kgm}
5. Star the engine with the starting motor.
Air in the high-pressure circuit is bled automatically if the
engine starts.
If the engine does not start, air may not be bled from the
low-pressure circuit. In that case, repeat the above
procedure from step 3.
FEATURES OF CX50
TB45 (GAS/LPG )
FEATURES OF CX50
Explanation of electronically controlled engine of machine with 3-way catalyst in
Model TB45 engine LPG fuel cut solenoid
Air flow meter Travel speed signal converter

(under relay box)
Gasoline fuel pump

(in tank)
Vaporizer PTC with heater

for electronic control
ECM
Electronically controlled throttle
Distributor with speed sensor Gasoline injector x 6
LPG injector (main) x 2
LPG injector (sub)
LPG fuel pressure sensor
O2 sensor 3-way catalyst

FEATURES OF CX50
Nissan gasoline engine Electronic controller failure code list
Failure
No. Contents of trouble Phenomenon when trouble occurs Warning lamp
code
1 P0031 O2 sensor heater sy st em disconnection or short circuit None in particular. ON
2 P0032 O2 sensor heater sy st em short circuit Same as abov e ON
Air f lowmeter sy stem disconnection or short circuit (while
3 P0102 Idle speed is high. Speed is limited to 1,600 rpm. Or engine cannot start or it stalls. ON
engine is running)
4 P0103 Engine may not be able to start. ON
engine is stopped and key is ON)
Coolant temperature sensor sy stem disconnection or Idle speed is high when engine is started in cold state. Engine condition lowers easily when engine is
5 P0117 ON
short circuit (low v oltage side) warm.
Coolant temperature sensor sy stem disconnection or
6 P0118 Engine condition lowers easily when engine is cold. ON
short circuit (high v oltage side)
7 P0122 Throttle sensor 2 sy stem disconnection Accelerator is set to base opening degree and cannot be controlled. Engine can be started and stopped. ON
8 P0123 Throttle sensor 2 sy stem short circuit Same as abov e ON
9 P0132 O2 sensor output v oltage too high No phenomenon is f elt. Base air-f uel ratio control is started and f eedback control is not executed. ON
10 P0134 O2 sensor sy stem disconnection Same as abov e ON
11 P0222 Throttle sensor 1 sy stem disconnection Accelerator is set to base opening degree and cannot be controlled. Engine can be started and stopped. ON
12 P0223 Throttle sensor 1 sy stem short circuit Same as abov e ON
Speed sensor (pos) sy stem disconnection/wav ef orm
13 P0335 Starting takes time more than usual. Engine may stall ON
abnormality
Crank angle sensor (phase) sy stem
14 P0340 Engine cannot be start ed. LPG injector does not operate. Spark plug does not spark. ON
disconnection/wav ef orm abnormality
15 P0350 Ignition primary signal sy stem disconnection Engine cannot start. Spark plug does not spark. ON
Disconnection or short circuit between trav el speed
16 P0500 ECM controls at def ault trav el speed. ON
sensor and sensor conv erter
Engine cannot be start ed. GAS/LPG injector does not operate. Spark plug does not spark. LPG solenoid
17 P0605 ECM trouble ON
and GAS pump do not operate.
18 P0650 Engine warning lamp bulb breakage or circuit abnormality Fuel is cut if engine speed rises to 2,500 rpm (reset at 2,000 rpm) ON
Backup power supply sy stem to learning RAM is disconnected. This occurs when learning RAM has
19 P1065 No power to ECM ON
trouble. 04MY =No. 121/07MY =No. 110 wiring.
20 P1121 Malf unction of throttle actuator ON
21 P1122 Throttle opening degree response abnormality ON
22 P1124 Throttle motor power supply sy stem short circuit ON
23 P1126 Throttle motor power supply sy stem disconnection ON
24 P1128 Throttle motor control sy stem short circuit ON
25 P1217 Ov erheat If coolant temperature reaches 135ºC, f uel is cut when engine speed reaches 1,000 rpm ON
26 P1218 Light ov erheat When coolant t emperature reaches 110ºC, Throttle is limited until Hi – 1, 100 rpm = 1,600 rpm (25º) ON
27 P1225 Throttle sensor f ull close learning v alue abnormality ON
28 P1226 Throttle sensor f ull close learning cannot be executed ON
29 P1229 Throttle/Accelerator sensor source v oltage abnormality ON
30 P1240 Def ectiv e LPG injector (Inject ing range) Engine cannot be start ed or is not in good condition. ON
31 P1241 Def ectiv e LPG injector (Non-injecting range) Same as abov e ON
32 P1242 Def ectiv e LPG injector 2 (Injecting range) Same as abov e ON
33 P1243 Def ectiv e LPG injector 2 (Non-injecting range) Same as abov e ON
34 P1245 LPG f uel pressure sensor sy stem short circuit LPG stop v alv e OFF. Engine cannot be started. ON
LPG f uel pressure sensor sy stem disconnection or
35 P1249 ON
abnormally high
36 P1805 Brake switch output OFF sticking ON
37 P2122 Accelerator sensor 1 sy stem disconnection ON
38 P2123 Accelerator sensor 1 sy stem short circuit ON
39 P2127 Accelerator sensor 2 sy stem disconnection ON
40 P2128 Accelerator sensor 2 sy stem short circuit ON
41 P2135 Throttle sensor 1/2 out put signal relation abnormality ON
42 P2138 Accelerator sensor 1/2 output signal relation abnormality ON
FEATURES OF CX50
Improvement of Komatsu new hydraulic system
Waste horsepower is eliminated by reducing (optimizing) the
hydraulic load = The engine displacement is "reduced" and fuel
consumption is improved greatly.
Control valve Down control valve
Priority valve
Load sensing valve

Down control valve and
control valve are made
one
Independent brake
circuit is installed to
increase reliability
largely
Brake circuit pump Variable-displacement pump

FEATURES OF CX50
Explanation of CLSS <1>
1. Features and composition of CLSS
Actuator
<Features>
CLSS is
an abbreviation for Closed center Load
Sensing System, which has the
following features. Control valve
• Fine control performance that is not

affected by load
• Energy saving by controlling

variable-displacement pump
<Composition> LS valve
• The CLSS consists of the variable-
displacement piston pump, control
valve and each actuator.
• The pump unit consists of the main Servo

piston
pump and LS valve.
FEATURES OF CX50
Explanation of CLSS <2> Actuator
2. Basic principle of CLSS
<Control of pump swash plate angle>
The pump swash plate angle (pump delivery) is so controlled that the LS
differential (PLS) pressure which is the differential pressure between Control valve
pump discharge pressure PP and LS pressure (PLS) at the control valve
outlet (actuator load pressure) will be constant.
(LS differential pressure (PLS) =

LS passage
pump discharge pressure (PP) – LS pressure (PLS) Pump passage
If LS differential pressure PLS decreases below the LS valve set

pressure, the pump swash plate angle changes to increase the delivery. Main pump
If the former increases, the latter changes to decrease the delivery.
LS differential pressure PLS

and pump swash plate angle
Max. Servo
piston
Swash plate angle Q
LS valve
LS valve
set pressure
Min. Differential Differential
pressure: High pressure: Low
LS differential pressure PLS

FEATURES OF CX50
S4D95LE-3 Engine
For No Emission control

Area's CX50
FEATURES OF CX50
S4D95LE Engine
FEATURES OF CX50
FEATURES OF CX50
S4D95LE-3 Engine
Normal
Fuel
Injection Pump
FEATURES OF CX50
S4D95LE
FEATURES OF CX50
POWER TRAIN of CX50
Non Emission control models and Emission Control

Models are same Power train.
FEATURES OF CX50
Ｐｏｗｅｒ　Ｔｒａｉｎ
FEATURES OF CX50
Transmission and torque converter <1> <Outline>
[General view] The transmissions is made by
Oil filler Oil level gauge combining the counter-shaft
type constant mesh gear
mechanism and the disc
clutch. It has 2 forward gear
speeds and 1 reverse gear
speed (FG, D45/50A) or 1
Torque forward gear speed and 1
converter reverse gear speed (FG,
inlet relief D35/40A).
valve
The rotation direction of the
F/R solenoid 1st gear speed and 1st or 2nd
valve gear speed are selected by
F2 solenoid F/R valve Work equipment fixing 1 clutch hydraulically
pump mounting
valve assembly opening through the control valve.
Breather
Oil filter
Oil
temperature
sensor
Brake cooling pump Drain plug

mounting opening
FEATURES OF CX50
Transmission and torque converter <2>
[Sectional view of torque converter]
Turbine
Pump (Impeller)
Input guide
Stator support
Turbine hub
Impeller gear
Idler gear
Input plate
Gear pump
Torque converter housing
Gear pump
FEATURES OF CX50
[Sectional view of transmission – Forward 2nd clutch specification (FG, D45/50A)]
Forward 2nd clutch
(FG, D45/50A)
Forward clutch Input shaft
Reverse clutch
Transmission case
Torque converter inlet

FEATURES OF CX50
[Transmission and torque converter hydraulic port locations]
Torque converter relief pressure pickup port (RC1/8) Main relief pressure pickup port (RC1/8)
 0.5 – 0.7Mpa {5.1 – 7.1kg/cm2}  1.13 ± 0.12Mpa {11.5 ± 1.2kg/cm2}
Torque converter outlet

hose mounting elbow
Lubricating oil inlet

pipe mounting elbow
Forward clutch pressure Reverse clutch pressure
pickup port (RC1/8) pickup port (RC1/8)
Forward 2nd clutch pressure

pickup port (RC1/8)
FEATURES OF CX50
Operation of clutch
Piston Plate Disc Clutch gear
 When clutch is "engaged"
• The oil sent from the control valve is sent
through the oil passage of the shaft to the Shaft
back of the piston to press the piston
toward the right.
• The piston fits the plates and discs to each
other and stops the rotation of the disc
with the friction force.
• Since the internal teeth of the discs are
meshed with the clutch gear, the shaft and
clutch gear transmit the power together.
 When clutch is "disengaged" Piston Plate Disc Spring

• If the oil sent from the control valve is cut
off, the back pressure applied to the piston
decreases. Shaft
• The piston is returned toward the left by
the reaction force of the spring.
• The plates and discs are released and the
shaft and clutch gear are disengaged.
FEATURES OF CX50
2. Transmission and Special for FG(D)45/50A
torque converter
hydraulic circuit
Oil cooler
Transmission
lubrication
FEATURES OF CX50
Wet-type disc brake <1>
Tough & Economy
Komatsu's newly developed wet-type brake is employed as standard for
long, easy and safe work
Parking Brake
Wet-type disc
Differential gear Service brake
1. Since this brake does not have self-boosting function, pedal depressing force is applied to the brake
linearly. In addition, when the brake is applied, less shocks are generated and the machine stops
smoothly.
2. When the disc is worn, it does not need clearance adjustment.
3. The brake disc is cooled forcibly with the special cooler which is also used for the differential oil,
improving its reliability.
4. Wear of the disc can be measured from outside for easier maintenance.
FEATURES OF CX50
Wet-type brake cooling system Special cooling pump
Special pump is installed to cool the brake. (Torque converter PTO)

The brake oil is cooled by the radiator of the engine.
FEATURES OF CX50
Enclosed wet-type multi-disc brake
The technology of the "Komatsu WA" front axles that have been used widely in severer
jobsites is employed.
Since the brake unit is filled with oil and enclosed, dirt does not enter, thus it has high
reliability, high water resistance and high fade resistance and always generates stable
braking power.
This brake does not need shoe replacement which the drum brake needs.
FEATURES OF CX50
[Sectional view] FG, D45/50A FG, D35/40A
: 4 discs : 3 discs
Sun gear shaft
Spring Bearing Differential Axle housing

carrier
Plate Disc Piston Outer plate

<Function>
• The service brake has a wet-type multi-disc structure, which consists of the piston, plate, disc, outer plate and
spring.
• The brake cylinder consists of the differential housing and bearing carrier and has the piston in it.
• The plate and outer plate are jointed to the differential housing groove with lugs.
• The both sides of the disc are stuck with the lining and the disc is installed between the plate and outer plate
and connected by the sun gear shaft spline.
FEATURES OF CX50
Operation of brake Slack adjuster
 When applied
• If the brake pedal is depressed, oil Piston
pressure (P) is sent from the hydraulic tank
through the pump, brake charge valve and
slack adjuster to the brake cylinder, where
it slides piston (1).
 When released Plate

• If the oil pressure is released, the piston is Disc
Spring
Piston
returned by the reaction force of the
spring. As a result, clearance is made
Outer plate
between the plate and outer plate and the
disc is set free.
FEATURES OF CX50
Komatsu wet-type disc brake <6>
Wear measurement of brake [Detail of gauge]
Disc wear Oil filler plug/ Disc wear
check port Oil level gauge/ check port
Disc wear gauge
Gauge
 When released
1) Take out the plug from the disc wear check port.
2) Remove disc wear gauge.
3) Insert the disc wear gauge between the brake housing and back of the piston and rotate it. If
it rotates 1 turn, the disc is worn to the wear limit. Accordingly, replace the disc.
FEATURES OF CX50
Brake parts (Slack adjuster) <1>
[Sectional view]
S/A piston
2-ø0.7 Check valve

orifices
C/V cylinder
C/V spool 4-ø4 main oil passages

Axle
<Function>
• The slack adjuster is installed to the brake oil line between the brake valve and brake piston. It evens the brake
operation time lag.
• The slack adjuster cannot be disassembled.
<Cushioning function>
• If the brake pedal is depressed sharply, the generated peak pressure causes "stepped braking", "backlash
sound", etc. Generally, the peak pressure is restricted by installing an orifice or damping part (ACC etc.) in the
hydraulic piping after the brake valve so that hydraulic oil will be supplied to the brake chamber gently. If this
method is applied, the response is lowered more or less, however.
Accordingly, the throttling rate is decided from the balance between the response required by the machine and
the peak pressure restriction effect. However, it is difficult to attain both peak pressure restriction and high
response for medium and small-sized forklift trucks, since high brake response is required.
To solve this problem, the response reduction is minimized and the peak pressure (backlash sound) is restricted
by staring oil flow control just before the brake discs contact each other while maintaining the slack adjuster
mechanism.
FEATURES OF CX50
Operation of slack adjuster - 1
S/A piston
• The hydraulic oil sent from the brake valve
pushes the SA piston toward the OUT port (B),
and the CV spool moves inside the CV
cylinder, following the SA piston. C/V spool
This hydraulic oil is sent through 4-ø4 main oil
passages to the OUT port.
C/V cylinder
4-ø4 main
oil passages
• The 4-ø4 main oil passages are shut off by the

CV spool at 3 mm before the stroke end of the S/A piston
SA piston, and then the oil is sent through
only the ø0.7 orifice to the OUT port (B) to 2-ø0.7
C/V spool orifices
operate the brake.
(Cushioning function)
4-ø4 main
oil passages
FEATURES OF CX50
Operation of slack adjuster - 2
• If the pressure in the C/V cylinder increases to the S/A piston
check valve cracking pressure, the pressure in
the line between the IN and OUT ports becomes
constant.
At this time, if the oil quantity is insufficient for
C/V spool
brake operation because of wear of the discs, the
hydraulic oil is supplied from the check valve oil
passage to the OUT port (B) side.
(Slack adjuster mechanism)
• If the brake is released and the check valve C/V cylinder
closes, the SA piston is returned by the force of
the return spring in the axle and the residual
pressure on the OUT port (B) side, while 4-ø4 main
oil passages
compressing the spring, thus oil necessary for
brake operation (refill capacity) is stored in the CV
cylinder.
(Slack adjuster mechanism)
Return spring
S/A piston
C/V cylinder
FEATURES OF CX50
ALIGNMENT OF POWER TRAIN
FEATURES OF CX50
CX50 Hydraulic circuit diagram
FEATURES OF CX50
Explanation of CLSS <6> - Work equipment pump (LPV45-41cc specification)
Unload valve
Return rate to tank (QD)

Pump delivery (Q)
LS differential pressure (PLS)

<Function>
• The unload valve is built in the LS valve. When the LS differential pressure (PLS) exceeds the
unload set differential pressure, the unload valve releases the oil in the main pump discharge
pressure circuit to the tank circuit.
• The unload set differential pressure is set higher than the LS set differential pressure controlled by
the LS valve.
• When the actuator stops suddenly because of control valve spool operation and the pump circuit
pressure increases, the unload valve releases the oil in the pump circuit to the tank circuit to
prevent generation of abnormally high pressure.
FEATURES OF CX50
Explanation of CLSS <10> - Control valve
[Control valve hydraulic circuit diagram and item names]
LS shuttle LS relief valve set pressure

valve 17.15MPa {175kg/cm2}
Suction safety valve set pressure

17.64MPa {180kg/cm2}
Attachment
LS shuttle
valve
Tilt
Load check
LS shuttle valve
valve
Tilt lock valve
Lift
Load check valve

ON-OFF
solenoid
Lift lock
valve
Load check Down control

valve valve
ON-OFF
solenoid
Priority valve
FEATURES OF CX50
[General view] * This piston pump is LPV45 of the 41cc/rev specification.
Discharge
P1: Pump discharge port
P1C: Pump pressure pickup plug
 17.2Mpa {175kg/cm2}
P2: Gear pump discharge port
PD1: Drain plug
PD2: Drain plug
Suction PEN: Control pressure pickup plug
Pump body Gear pump
PLS: LS pressure input port
PP: Pump pressure input port
PS: Pump suction port
LS valve
FEATURES OF CX50
[Sectional view] Servo piston Piston Cylinder block
Case Rocker cam Valve plate
Shaft Shoe End cap
Oil seal Shoe retainer

Bearing Ball Bearing
LS valve
FEATURES OF CX50
LS valve
Spool Retainer Screw
Sleeve Spring Nut
P1: Pump discharge port

PP: Pump pressure input port
PLS: LS pressure input port
PEN: Control piston
pressure pickup port
PD2: Drain port
<Function>
• The LS valve controls the pump delivery according to the control lever stroke, or the actuator demand flow rate.
• The LS valve controls main pump delivery (Q) by judging the actuator demand flow rate from differential pressure
(PLS) between control valve inlet pressure (PPLS) and control valve outlet pressure (PLS).
(PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (PLS) the LS differential pressure.
• That is, pressure loss made when the pump oil flows through the open area of the control valve spool (= LS
differential pressure PLS) is detected and pump delivery (Q) is so controlled that the pressure loss will be
constant. By this control, the pump delivery is controlled according to the actuator demand.
• Main pump discharge pressure (PP), LS pump pressure (PPLS) and LS pressure (PLS) are supplied to the LS valve.
The relationship between LS differential pressure (PLS) and pump delivery (Q) changes as shown in the following
figure.
FEATURES OF CX50
Explanation of CLSS <7> - Control valve A1: To lift cylinder
A2: To tilt cylinder
[General view]
A3: To attachment actuator
B2: To tilt cylinder
B3: To attachment actuator
C1: From machine wiring
C2: From machine wiring
LS: To work equipment and steering pump
P: From work equipment and steering pump
PP: To work equipment and steering pump
Cover
STLS: From orbit roll valve
STP: To orbit roll valve
Servic
e T: To tank
valve TS: To tank
Valve
block
FEATURES OF CX50
[Sectional view - 1]
Spool Load check valve
(Attachment) (Attachment)
Down control
Spool valve
(Tilt)
Load check
valve (Tilt)
Spool
(Lift)
Load check
valve (Lift)
Emergency
lower valve
LS shuttle valve
(Steering)
LS shuttle valve
(Attachment)
LS shuttle valve
(Lift/Tilt)
FEATURES OF CX50
[Sectional view - 2]
LS shuttle valve
Suction safety valve
ON-OFF solenoid Suction safety valve (Attachment)
(Attachment)
(Work equipment lock) (Attachment)
Priority valve Load check valve
(Attachment)
Down control
valve
Lift lock
valve
Spool (Lift) Spool
ON-OFF solenoid
(Lift lock)
LS shuttle valve
(Steering) LS relief valve
LS shuttle valve Load check valve
(Lift/Tilt) (Tilt)
Spool (Tilt) Tilt lock valve

FEATURES OF CX50
Introduction of LS pressure
 The figure shows the condition
when the mast is tilted forward.
LS shuttle
valve
Load check
valve
Spool
<Function> Pump
• The LS pressure means the actuator
load pressure on the control valve
outlet side.
• The downstream pressure of control
notch C of the spool is introduced as
LS pressure (PLS) to the LS shuttle
valve.
• The highest LS pressure in the Passage E
Spool Spool
introduced LS pressure (PLS) is notch D notch C
selected and introduced by the LS
shuttle valve to the pump LS valve.
<Operation>
• If the spool is operated, pump pressure (PP) flows through the load check valve and spool notches C and D to
actuator circuit B.
• The pressure decreased by spool notch C is introduced as LS pressure (PLS) through passage E to the LS shuttle
valve.
• Since the open area of spool notch D is wide and does not cause much pressure loss, the LS pressure is almost
equal to the actuator load pressure.
FEATURES OF CX50
LS relief valve
Poppet in LS
relief valve
Spring
Throttle in LS shuttle valve
<Function>
• This valve sets the maximum LS
pressure.
• When oil is relieved, differential
pressure is generated between pump
pressure (PP) and LS pressure (PLS)
by the throttle in the LS shuttle valve. LS valve
• The maximum pump pressure is set
by controlling pump LS valve with the
differential pressure and minimizing
the pump swash plate angle ( ≈ 0
degrees). Work equipment
Servo piston and steering pump
<Operation>
• If the work equipment control lever is operated to move the work equipment cylinder to the stroke end, pump
pressure (PP) increases.
• Since pressurized oil does not flow in the actuator circuit, LS pressure (PLS) becomes the same as pump
pressure (PP).
• LS pressure (PLS) at the same level as increased pump pressure (PP) act on the LS relief valve poppet. If they
reach the spring load, LS pressure (PLS) is relieved to tank circuit (T).
• Since there is the throttle on the upstream side of the LS relief valve, pump pressure (PP) increases further and a
differential pressure is generated between it and LS pressure (PLS).
• The differential pressure acts on the pump LS valve. If it reaches a certain pressure, pump pressure (PP) is
balanced when the swash plate angle is minimized ( ≈ 0 degrees).
FEATURES OF CX50
Priority valve - 1
 When work equipment is operated singly
Pump
Spool
Chamber F
Steering
wheel
Spool notch
To work equipment
Orbit cylinder
roll
• Pump pressure (PP) acts on the right end of the spool and steering LS pressure (STLS) acts on the left end [spring
chamber F].
• Since the steering is not operated, steering LS pressure (STLS) is ≈ 0MPa {0kg/cm 2}.
• The spool is moved to the left stroke end by pump pressure (PP) which acts on the right end of the spool.
• If the work equipment control lever is operated, pump circuit (PP) and work equipment circuit (W) are connected
by the spool notch and pump pressure (PP) flows to the work equipment cylinder.
FEATURES OF CX50
Priority valve - 2
 When steering is operated singly
Pump
Chamber F
Spool
Steering wheel
Spool notch
To work equipment cylinder

Orbit roll
• Pump pressure (PP) acts on the right end of the spool and steering cylinder load pressure acts on the left end
[spring chamber F].
• The spool is balanced by the differential pressure and the spring force applied to its both sides at the notch
opening position necessary for supplying steering demand flow.
• If the steering wheel is operated, pump circuit (PP) and steering circuit (S) are connected by the spool notch and
pump pressure (PP) flows to the orbit roll valve.
FEATURES OF CX50
Priority valve - 3
 When steering and work equipment are
operated simultaneously Pump
Chamber F
Spool
Steering wheel
Spool notch
To work equipment cylinder

Orbit roll
• Pump pressure (PP) acts on the right end of the spool and steering LS pressure (STLS) acts on the left end [spring
chamber F].
• Since the steering is operated, steering LS pressure (STLS) becomes the steering cylinder load pressure.
• The spool is balanced by the differential pressure and the spring force applied to its both sides at the opening
position necessary for supplying steering demand flow and work equipment demand flow.
• If the steering and work equipment are operated simultaneously, pump circuit (PP) and steering circuit (S) are
connected by the spool notch and pump pressure (PP) flows to the orbit roll. Since pump circuit (PP) and work
equipment circuit (W) are also connected, pump pressure (PP) flows to the work equipment cylinder, too.
FEATURES OF CX50
Down control valve
Lift cylinder
 When lift spool is lowered Down control spool
Lift spool
Spring
Down control
Lift spool notch spool notch Spring
Throttle
<Function>
• This valve controls the cylinder circuit return flow according to the load pressure when the lift is lowered.
<Operation>
• If the lift spool is operated, the down control spool is moved by springs A and B in the same direction as the lift
spool.
• The down control spool stroke is controlled by the differential pressure between front and rear of the throttle and
the balance of springs A and B.
• Return flow (Q) from the lift cylinder is the total of lift spool notch flow (QL) and down control spool notch flow
(QD).
FEATURES OF CX50
Work equipment lock function (Priority valve) - 1
Pump
 When solenoid is energized
Chamber F Spool
Spool notch
To work
equipment
cylinder
• If the signal to the solenoid valve is turned ON, pump pressure (PP) acts on the right end of the spool and steering
LS pressure (STLS) acts on the left end [spring chamber F].
• Since the steering is not operated, steering LS pressure is (STLS) 0MPa {0kg/cm 2}.
• The spool is moved to the left stroke end by pump pressure (PP) which acts on the right end of the spool.
• If the work equipment control lever is operated, pump circuit (PP) and work equipment circuit (W) are connected
by the spool notch and pump pressure (PP) flows to the work equipment cylinder.
FEATURES OF CX50
Work equipment lock function (Priority valve) - 2
 When solenoid is deenergized Pump
Chamber F Spool
Spool notch
To work
equipment
cylinder
• If the signal to the solenoid valve is turned OFF, pump pressure (PP) on the right end of the spool is also applied
to the left end [spring chamber F].
• The spool is moved to the right by the spring.
• Since the spool notch is closed, pump pressure (PP) does not flow into the work equipment circuit (W) even if the
work equipment control lever is operated.
FEATURES OF CX50
Lift lock function (Lift lock valve) - 1
 Lift spool lowering operation
 When solenoid valve is
energized
Lift cylinder
Lift spool
Check valve
throttle
<Energized>
Check valve
Lift spool
Spring
Solenoid valve
<Function>
This valve locks lift cylinder (2) when solenoid valve (6) is deenergized.
<Operation>
• When the solenoid valve is energized, if the lift spool is operated, the cylinder pressure is drained into the tank
through the check valve throttle and solenoid valve lift spool notch.
• Differential pressure is generated between front and rear of the check valve by the above flow.
• If the differential pressure reaches the spring load, the check valve opens and the lift cylinder operates.
FEATURES OF CX50
Lift lock function (Lift lock valve) - 2
 Lift spool lowering operation
 When solenoid valve is deenergized
Lift cylinder
Lift spool
Check valve throttle
<Deenergized>
Check valve
Lift spool notch

Spring
Solenoid valve
<Operation>
If the solenoid valve is deenergized, the cylinder pressure is applied to the check valve spring chamber to close the
check valve.
Even if the lift spool is operated, the check valve does not open, thus the lift cylinder does not operate.
FEATURES OF CX50
Tilt lock function (Tilt lock valve) - 1 Tilt cylinder
 Tilt spool forward tilt operation

 When solenoid valve is energized
Orbit roll
Load check valve
<Energized>
Solenoid
valve
Tilt spool
Priority
valve
Pump
Tilt lock Spring

Tilt spool valve
notch A Tilt spool Tilt spool
notch C notch B
<Function>
• This valve locks the tilt cylinder when the solenoid valve is deenergized.
<Operation>
• When the tilt spool is operated for forward tilting, pump pressure (PP) is applied to tilt spool notch B through the
load check valve, tilt spool notch A and tilt cylinder.
• Since pump pressure (PP) is applied to the left end of the tilt lock valve through tilt spool hole C, the tilt lock valve
pushes the spring.
• If the tilt lock valve moves, tilt spool notch B is connected to the tank, and the tilt cylinder operates for tilting
forward.
FEATURES OF CX50
Tilt lock function (Tilt lock valve) - 2 Tilt cylinder
 Tilt spool forward tilt operation

 When solenoid valve is deenergized
Orbit roll
<Energized>
Solenoid
valve
Priority
valve
Pump
Tilt spool Tilt lock Spring

notch B valve
<Operation>
• When the solenoid valve is deenergized, pump pressure (PP) is cut off by the priority valve and the pump
pressure is not applied to the left end of the tilt lock valve.
• Since the tilt lock valve is pressed with the spring, tilt spool notch B is not connected to the tank. Accordingly, the
tilt cylinder does not operate even if the tilt spool is moved for tilting forward.
FEATURES OF CX50
Emergency lower valve
Lift cylinder
Check valve
throttle
Solenoid
valve
Check
Spring
Lift spool Emergency lower valve
<Function>
• When the solenoid valve or electric circuit has a trouble, the lift cylinder can be lowered manually by operating
this valve.
<Operation>
• While the solenoid valve is deenergized, even if the lift spool is operated for lowering, the check valve does not
open and the lift cylinder does not operate. (Lift lock function)
• If the emergency lower valve is opened slowly under this condition, the oil in the check valve spring chamber is
drained into the tank and differential pressure is generated between front and rear of the check valve.
• If the differential pressure reaches the installed spring load, the check valve opens and the lift cylinder lowers.
FEATURES OF CX50
Cooling system [Condition after engine, fan and shroud are
Cooling system (Diesel engine lift truck) removed]
Radiator
Oil cooler Aftercooler
(Brake cooling) Radiator
Aftercooler
Reservoir
Tank
Fan Torque
converter
cooler
[Brake cooling system diagram]

Water-cooled cooler
Enclosed wet-type brake
Oil pump
FD60-10
FD70-10
FD80-10
FEATURES OF DX50
DX Model
Non Emission Emission
Control Area Control Area
Engine S6D102 SAA4D95LE

Torque Converter Same as Current Same as Current
Transmission Same as Current Same as Current
Brake Drum Brake Wet Brake
Hydraulic System Same as Current New Hydraulic System
OPS --- STD
FEATURES OF DX50
Features of DX-10 <1>
• Vibration reduction by dual floating structure
• Conformance with ISO3691
Improvement of fuel
consumption by up to 20%
Excellent fine control work
• Improvement of Komatsu
new hydraulic system
pump + OLMS
• Wet-type brake as standard • Improvement of the electronic

equipment control Komatsu engine in
10000H durability level conformance with emission
regulations (Diesel forklift truck)
FEATURES OF DX50
Features of DX-10 <2>
DX Remarks
Structure Equipped with variable displacement pump
 The maximum delivery is the same with Model 8 and
the performance is not lowered by simultaneous
operation of the travel system and attachments.
(6 – 8 ton model)
Function Variable displacement pump + OLMS
The mechanism of DX senses the engine load (speed)
and supplies necessary flow.
 The point of performance maintenance is oil control

since the variable displacement pump is employed.
Replacement period: 1,200H
6 – 8 ton model: 100L
Engine SAA4D95LE
24V specification
24V is required for the converter capacity and auxiliary
devices (weight).
Braking Wet-type brake Selection for reason of structure
Outboard type
FEATURES OF DX50
Comparison between current and new DX models
Item Precautions
DX-10 DX-8
1 Coarse mesh radiator  Not set.  Not set.
The radiator screen is prepared.
2 Front wheel rim  Changed to wedge band type.  Hub nut type
(8 ton model) (Tightening method is same with EX)
3 Tire size  8.25-15-18PR  9.00-12-18PR

FEATURES OF DX50
Brake 1 Breakage/Wear of Improvement of finned drum
lining
As the remedy, the
2 Squeal/Insufficient Selection of individual lining
wet-type brake is
working of brake
employed as the
3 Overheat Improvement of finned drum standard equipment.
4 Oil leakage from brake Remedy against each trouble
piping
Cooling 1 Water leakage from Fixing with band, increase of Taken over
hose reinforcement layer, change of
interference
2 Water leakage from Addition of reinforcement plate Improvement of aluminum
radiator etc. radiator, Improvement of floating
structure, change of hose clamp
method and change of hose
material
3 Overheat Increase of fan speed Addition of separate torque
converter cooler
Engine 1 Starting trouble Change of preheating method Improvement of electronic control
(Starting motor trouble)
2 Large oil CPU controls electronically
consumption/White controlled engine to maintain the
exhaust gas best condition.
FEATURES OF DX50
Front axle 1 Breakage of needle roller Remedy against each trouble Increase of bearing capacity
bearing
2 Breakage of PS cylinder rod Positioning with stopper at stationary Fixing at cylinder stroke end
steering end
3 Looseness of hub nut Wedge band type (8 ton)
Power train 1 Torque converter overheat Remedy against each trouble Installation of cooler as standard
equipment
2 Breakage of final gear Strengthening of planetary gear, Taken over

increase of carrier rigidity,
improvement of lubrication
Hydraulic 1 Cracking of hydraulic oil Addition of relief valve Taken over

system cooler
2 Hydraulic drift and forward Measures against complaint Resolution by conforming with ISO
slant
3 Breakage of hydraulic oil Improvement of pressure resistance of Taken over

cooler hose filter and circuit
4 Oil leakage from each part Replacement at each trouble Improvement of heat balance and use of
face seals for high-pressure portions
5 Oil leakage from hydraulic Replacement at each trouble Optimization by employing variable-
pump displacement pump
6 Oil leakage from tilt cylinder Replacement at each trouble Increase of cleanliness of oil and parts
FEATURES OF DX50
Steering 1 Large steering effort, Replacement of parts at New FHPS
abnormal sound each trouble
2 Fixing of steering joint Change of greasing interval Taken over
3 Shifting of knob Remedy against each Standard equipment

trouble (Setting of option)
Machine 1 Cracking of hood Addition of reinforcement Use of hood for CX10 for higher
cover etc. plate durability
Others 1 Malfunction of backup Remedy against each Redesign of whole system including
buzzer and backup trouble ground circuit
lamp
2 Short circuit, rubbing Remedy against each Redesign of wiring

of wiring harness trouble
FEATURES OF DX50
Komatsu SAA4D95LE engine
--- 2-valve, common rail, electronic control ---
The goal is clearing

the 3rd emission regulations
+ improving fuel consumption.
When mounted on DX
33%
Particle matter: Reduction by Displacement: 3,260cc
71.7kw/2250rpm
Black smoke: Reduction by 25% 97.5PS/2250rpm
35.4Kg-m/1600rpm
FEATURES OF DX50
High-output engine
2 valves/cylinder High output is attained by setting
optimum displacement and employing
shaker piston.
Low-speed torque is increased by
employing high-pressure common rail.
Common rail
Engine-mounted engine controller (ECM)
Noise is lowered
Noise is lowered by employing highly-rigid cylinder block, front
gear train and electronically controlled multi-injection
FEATURES OF DX50
SAA4D95LE-5-A Failure code list
Failure code of Failure code of
Failure phenomenon Failure phenomenon
troubleshooting tool troubleshooting tool
111 ECM Critical Internal Failure 352 Sensor Sup. 1 Volt. Low Error
115 Eng. Ne and Bkup Speed Sensor Error 386 Sensor Sup. 1 Volt. High Error
122 Charge Air Press Sensor High Error 415 Rotation derating by low engine oil pressure
123 Charge Air Press Sensor Low Error 431 Idle Validation SW Low error
131 Throttle Sensor High Error 432 Idle Validation Process error
132 Throttle Sensor Low Error 435 Abnormality in engine oil pressure switch
144 Coolant Temp. Sensor High Error 441 Battery voltage low error
145 Coolant Temp. Sensor Low Error 442 Battery voltage high error
153 Charge Air Temp. Sensor High Error 449 Rail Press. Very High Error
154 Charge Air Temp. Sensor Low Error 451 Rail Press. Sensor High Error
187 Sensor Sup. 2 Volt. Low Error 452 Rail Press. Sensor Low Error
221 Ambient Air Press. Sensor High Error 553 Rail Press. High Error
222 Ambient Air Press. Sensor Low Error 559 Rail Press. Low Error
227 Sensor Sup. 2 Volt. High Error 689 Eng. Ne Speed Sensor Error
234 Eng. Overspeed 731 Eng. Bkup Speed Sensor Phase Error
238 Ne Speed Sensor Sup. Volt. Error 757 All Persistent Data Lost Error
271 IMV Short Error 778 Eng. Bkup Speed Sensor Error
272 IMV Open Error 2185 Throttle Sens. Sup. Volt. High Error
322 Injector #1 (L/B #1) System Open/Short Error 2186 Throttle Sens. Sup. Volt. Low Error
324 Injector #3 (L/B #3) System Open/Short Error 2249 Rail Press. Very Low Error
331 Injector #2 (L/B #2) System Open/Short Error 2311 Abnormality in IMV solenoid
332 Injector #4 (L/B #4) System Open/Short Error 2555 Grid Heater Relay Volt. Low Error
351 INJ. Drive Circuit Error 2556 Grid Heater Relay Volt. High Error
 A failure code of troubleshooting tool is a 3 or 4-digit failure code displayed on the troubleshooting tool when the
trouble occurrence condition is checked with the troubleshooting tool.
FEATURES OF DX50
Long, easy and safe work are possible
Komatsu's newly developed wet-type brake is employed as standard
Since the wet-type brake is enclosed, it is protected from salt water, rusting and
corrosion. In addition, this brake is cooled forcibly, the operator can work stably
for a long period.
Wet-type disc
Since the structure of the

wet-type brake does not
produce lining dust, jobsites
are not polluted.
Easy/Efficient work
The brake disc is cooled forcibly with the oil which is also used for the torque converter,
improving its reliability.
FEATURES OF DX50
Wet-type brake cooling system
The same oil is used for the brake and torque converter and cooled in the
brake/torque converter oil cooler.
FEATURES OF DX50
The technology of the "Komatsu WA" front axles that have been used widely in
severe jobsites is employed.
Since the brake unit is filled with oil and enclosed, dirt does not enter, thus it has
high reliability, high water resistance and high fade resistance and always
generates stable braking power.
This brake does not need shoe replacement which the drum brake needs.
FEATURES OF DX50
[Sectional view] Cylinder Piston Outer gear
Plate Disc Hub gear

<Function>
• The service brake has a wet-type multi-disc structure, which consists of the piston, plate, disc, outer gear and
spring.
• The both sides of the disc are stuck with the lining and the disc is installed between the plates and connected by
the hub gear shaft spline.
FEATURES OF DX50
Wear measurement of brake
Cylinder
Disc wear
sensor
Piston
Plug
Cap nut
1) Start the engine and increase the brake accumulator pressure with the directional lever in neutral.
2) Stop the engine.
3) Check that no brake other than the parking brake is applied.
4) Depress the brake pedal.
5) Remove the disc wear sensor cap nut.
6) Push in the disc wear sensor until it reaches the piston and measure the wear.
 When the truck is new, the rod end is projected from the plug. Loosen the plug only when checking the disc.
 When the disc wear sensor end is blow the housing level of the plug, the disc has been worn to the wear limit.
Replace the brake disc set at this time.
7) Install the disc wear sensor cap nut.
FEATURES OF DX50
DX hydraulic circuit diagram
FEATURES OF DX50
Explanation of OLMS <1>
OLMS
Open center Load Moderating System
Engine OFF
Control valve lever in neutral
pump for work equipment
(45cc/rev)
Gear pump for steering
and work equipment
(27.8cc/rev)
Gear pump for

sensing engine speed
(4cc/rev)
To steering
The engine is stopped now.

The hydraulic circuit is indicated with black line. Hydraulic oil tank
Since the engine is not running, the gear pump and variable displacement pump are
not running either and the oil is not circulated.
FEATURES OF DX50
Engine ON  Idle run
Steering operation only
To steering
If the engine starts and run at idle, the 2 gear pumps on the right and left sides run to circulate the oil.
The right smaller gear pump for sensing the engine speed draws up oil from the hydraulic tank and drains it to the tank.
The left large gear pump also runs to supply oil to the steering.
The excessive oil is sent to the control valve. Since the control valve lever is not pulled, however, the oil is drained to the tank.
FEATURES OF DX50
Engine ON  Idle run
Steering operation only
To steering
If the engine starts and run at idle, the 2 gear pumps on the right and left sides run to circulate the oil.
The right smaller gear pump for sensing the engine speed draws up oil from the hydraulic tank and drains it to the tank.
The left large gear pump also runs to supply oil to the steering.
The excessive oil is sent to the control valve. Since the control valve lever is not pulled, however, the oil is drained to the tank.
FEATURES OF DX50
(Point)
The variable displacement pump
of DX does not control the swash
Engine idling  1,400 rpm plate angle according to the oil
flow necessary for the work
equipment circuit but increases
Accelerator pedal depressed a little the swash plate angle to increase
the delivery in proportion to the
engine speed in the range from the
idle speed to 1,400 rpm.
There is an orifice in this circuit to

sense the engine speed. The swash
plate angle is controlled by sensing
the pressure difference between the
inlet and outlet of the orifice.
If the engine speed increases, the oil
flow increases and the inlet pressure
rises.
To steering
If the accelerator pedal is depressed to increase the engine speed at this time,
the engine speed sensor gear pump senses the increase of the engine speed
and slants the swash plate of the variable displacement pump to increase the
oil supplied to the work equipment circuit.
FEATURES OF DX50
(Point)
If the engine speed increases above
Engine speed high (above 1,400rpm) the idle speed for travel etc., the
variable displacement pump
Accelerator pedal depressed fully discharges oil since it is running
automatically. If the discharge oil is
not required by the work equipment
circuit at this time, it is drained to the
tank.
To steering
If the engine speed exceeds 1,400 rpm, the swash plate of the variable displacement
pump is slanted to the maximum of 14 degrees and the delivery is kept at maximum.
FEATURES OF DX50
(L/min)
Comparison of work equipment pump delivery
200
196
190
Current DX
gear pump
150
New DX
variable displacement pump + gear pump
112 110
109
100
80
60
63
50
New DX variable displacement pump
46
26
New DX gear pump
0
0
750
Engine speed 1400 2450 (rpm)
800
FEATURES OF DX50
Explanation of OLMS <7> - work equipment pump (LPV45)
[General view]
Discharge P1: Pump discharge port
P1C: Pump pressure pickup plug
 18.1 {185kg/cm2}
P2: Gear pump discharge port
PD1: Drain plug
PD2: Drain plug
Suction PEN: Control pressure pickup plug
Pump body Gear pump
ES valve
FEATURES OF DX50
[Sectional view] Servo piston Piston Cylinder block
Case Rocker cam Valve plate
Shaft Shoe End cap
Oil seal Shoe retainer

Bearing Ball Bearing
ES valve
FEATURES OF DX50
ES valve - 1
Spool Retainer Screw
Sleeve Spring Nut
<Function>
• The ES valve controls the pump delivery according to the engine speed.
• The ES valve controls work equipment pump delivery (Q) by judging the
PD1: Drain port
demand flow rate from gear pump discharge pressure (PSIG). [(PSIG) is
DDP: Drain port called the signal pressure]
• Since the gear pump capacity is fixed, its delivery (QGP) changes in
PLP: Control pressure output port proportion to engine speed (N).
PP: Pump pressure port • The gear pump discharge circuit has an orifice so that signal pressure
(PSIG) will increase or decrease according to gear pump delivery (QGP).
PSIG: Signal pressure input port • Engine speed (N) is sensed by signal pressure (PSIG) and work equipment
pump delivery (Q) is controlled according to that signal pressure.
FEATURES OF DX50
ES valve - 2
• The relationship between engine speed and work equipment pump delivery (Q)
changes as shown in the following figure.
Pump delivery (Q)
Engine speed (S)

SAA4D95/ TB45
Trouble Shooting on Control system
SAA4D94LE TB45
SAA4D95LE/TB45
Accelerator pedal sensor <1>
[SAA4D95LE-5A Diesel engine forklift truck]
Pedal
Sensor
Connector
<Function>
• The accelerator pedal sensor is installed the floor top and outputs the accelerator signal and idle validation
signal according to the depressing angle of the accelerator pedal.
Accelerator signal
• The sensor senses the displacement of the accelerator pedal and outputs a variable voltage through the pin
No. 2.
Idle validation signal
• When the sensor senses the accelerator pedal operation condition, if the accelerator pedal is released, the
signal input to pin No. 5 is output through pin No. 4. If the accelerator pedal is depressed, the signal input to
pin No. 6 is output through pin No. 4.
[EBT-TB45-1 Gasoline (LPG) engine forklift truck]

Pedal
Sensor
SAA4D95LE/TB45
1/7
SAA4D5LE/TB45
2/7
SAA4D95LE/TB45
3/7
SAA4D95LE
KOMATSU Diesel engine CM850/CM2150C engine controller failure code list
For display of Komatsu Utility Simple Service tool 1/2
Applicable Error when Remedy
Failure Engine
No model Contents of trouble Phenomenon Action of ECU Contents of remedy disconnection Reduction
code warning lamp
4D95 6D107 is made Torque Speed
1 111   ECM Critical Internal Failure Engine cannot be started Cannot start engine Replace ECU Stop (Lighting)
Check and replace both sensor
2 115   Eng. Ne and Bkup Speed Sensor Error Engine cannot start or engine stops Cannot start engine Stop (Lighting)
sy stems
Operation can be continued at medium
3 122   Charge Air Press Sensor High Error Replace charge pressure sensor Warning (Lighting)
speed
Operates with def ault v alue
4 123   Charge Air Press Sensor Low Error Replace charge pressure sensor Warning (Lighting) 
speed
5 131   Throttle Sensor High Error Changes to low speed run of 30% with Changes to def ault of 30% with Replace Throttle Sensor Stop (Lighting)
6 132   Throttle Sensor Low Error modulation of 10%/sec. modulation of 10%/sec. Replace Throttle Sensor Stop (Lighting) 
7 143   Eng Oil Press Low Speed Derate Operation can be continued at low speed Derates speed Remov e cause of oil pressure drop Warning (Lighting) 
8 144   Coolant Temp. Sensor High Error Replace coolant temperature sensor Warning (Lighting) 
speed
9 145   Coolant Temp. Sensor Low Error Replace coolant temperature sensor Warning (Lighting)
speed
Operation can be continued with injection
10 146   Engine ov erheat Derates torque Remov e cause of ov erheat Warning stop (Lighting) 
rate reduced by 20%
11 153   Charge Air Temp. Sensor High Error Warning (Lighting) 
speed
12 154   Charge Air Temp. Sensor Low Error Warning (Lighting)
speed
Check and repair sensor power
13 187   Sensor Sup. 2 Volt. Low Error Engine cannot start or engine stops Warning (Lighting)
supply wiring
14 221   Ambient Air Press. Sensor High Error Warning (Lighting)
speed
15 222   Ambient Air Press. Sensor Low Error Warning (Lighting) 
speed
16 227   Sensor Sup. 2 Volt. High Error Engine cannot start or engine stops Replace ECU? Warning (Lighting)
(Zero is indicated as gov ernor
17 234   Eng. Ov erspeed Operation can be continued at ov erspeed Replace ECU Stop (Lighting)
calculation f uel injection)
18 238   Ne Speed Sensor Sup. Volt. Error Engine cannot start or engine stops Replace ECU? Warning (Lighting)
19 271   IMV Short Error Derate torque Unknown Warning (Lighting) 
rate reduced by 20%
20 272   IMV Open Error Derate torque Unknown Warning (Lighting) 
rate reduced by 20%
Check and repair #1 injector driv e
21 322   Injector #1 (L/B #1) Sy stem Open/Short Error Fuel is not injected in #1 cy linder Warning (Lighting)
wiring
22 323 –—  Injector #5 (L/B #5) Sy stem Open/Short Error Fuel is not injected in #5 cy linder Warning (Lighting)
wiring
wiring
24 325 –—  Injector #6 (L/B #6) Sy stem Open/Short Error Fuel is not injected in #6 cy linder Warning (Lighting)
wiring
Takes no remedy and cannot wiring
inject f uel Check and repair #4 injector driv e
wiring
Check wiring and take remedies f or
Only alarm is turned ON. Operation can be
27 342   Engine controller data mismatching Operates normally other display ed f ailure codes. Stop (Lighting)
continued in normal mode.
Replace ECU in worst case.
Derates torque (Cannot inject in
28 351   INJ. Driv e Circuit Error rate reduced by 20%. Fuel is not injected Check and repair injector driv e wiring Warning (Lighting) 
abnormal cy linder)
in abnormal cy linder.
Only alarm is turned ON. Operation can be Check and repair sensor power
29 352   Sensor Sup. 1 Volt. Low Error Warning (Lighting)
continued in normal mode. Takes remedy against high/low supply wiring
Only alarm is turned ON. Operation can be error of each connected sensor
30 386   Sensor Sup. 1 Volt. High Error Replace ECU? Warning (Lighting)
31 415   Rotation derating by low engine oil pressure Derates torque Remov e cause of oil pressure drop Stop (Lighting) 
rate reduced by 20%
32 418 –—  Water in f uel error Only alarm is turned ON. Warning (Blinking)
SAA4D95LE
2/2
Applicable Error when Remedy
Failure Engine
No model Contents of trouble Phenomenon Action of ECU Contents of remedy disconnection Reduction
code warning lamp
4D95 6D107 is made Torque Speed
33 428 –—  Water sensor high error Operates normally Warning (Lighting) 
34 429 –—  Water sensor low error Warning (Lighting)
35 431   Idle Validation SW Low error Warning (Lighting)
36 432   Idle Validation Process error Warning (Lighting)
Continues operation on
Operation is continued on assumption that
37 435   Abnormality in engine oil pressure switch assumption that oil pressure is Replace oil pressure switch Warning (Lighting)
oil pressure is normal
normal
38 441   Battery v oltage low error Operates with def ault v alue Check alternator charge sy stem Warning (Lighting)
speed
39 442   Battery v oltage high error Operates with def ault v alue Check alternator regulator Warning (Lighting)
speed
40 449   Rail Press. Very High Error Derates torque Replace pressure sensor Warning (Lighting) 
rate reduced by 20%
Operation is continued with open control +
41 451   Rail Press. Sensor High Error Replace pressure sensor Warning (Lighting)  
injection rate reduced by 20% Continues open control + derate
Operation is continued with open control + torque
42 452   Rail Press. Sensor Low Error Check and repair sensor wiring Warning (Lighting) 
injection rate reduced by 21%
Operation can be continued with injection Check and repair turbocharger
43 488 –—  Charge temperature high error torque derate Derates torque Stop (Lighting) 
rate reduced by 20% wastegate
44 553   Rail Press. High Error Only alarm is turned ON. Check and repair sensor wiring Warning (Lighting)
Only alarm is turned ON. Operation can be Check and replace f uel f ilter and
45 559   Rail Press. Low Error Only alarm is turned ON. Warning (Lighting)
continued in normal mode. pump
Normal operation (Backup sensor Continues normal operation (Bkup
46 689   Eng. Ne Speed Sensor Error Replace engine speed sensor Warning (Lighting) 
independent control) sensor independent control)
Controls Ne sensor independently
47 731   Eng. Bkup Speed Sensor Phase Error Engine cannot start or engine stops Replace engine backup speed sensor Warning (Lighting)
and cannot start engine
Only alarm is turned ON. Can not Re-Start Operates normally if Failure
48 757   All Persistent Data Lost Error Stop (Lighting)
Enine. occure during Engine running
Normal operation (Ne sensor independent Continues normal operation (Ne
49 778   Eng. Bkup Speed Sensor Error Replace engine backup speed sensor Warning (Lighting) 
control) sensor independent control)
Sort Cercuit or Replace ECU if There
50 2185   Throttle Sens. Sup. Volt. High Error Engine cannot start or engine stops Warning (Lighting)
no Short cercuit
Check and repair throttle sensor
51 2186   Throttle Sens. Sup. Volt. Low Error Engine cannot start or engine stops Warning (Lighting)
power supply wiring
Operation can be continued with injection Check and replace f uel f ilter and
52 2249   Supply pump pressure abnormality 2 Derates torque Warning (Lighting) 
rate reduced by 20% pump
IMV solenoid abnormality (Fuel supply pump
53 2311   Engine cannot start or engine stops Takes no remedy Unknown Warning (Lighting)
actuator resistance abnormality )
54 2555   Grid Htr Relay Disconnection Error (Cannot driv e heater relay ) Warning (Lighting) 
55 2556   Grid Htr Relay Short Circuit Error Operates normally Warning (Lighting)
TB45
SAA4D95LE/TB45
TB45
TB45
Remedy procedure against electronically controlled gasoline engine trouble
<When self-diagnosis function of electronically controlled engine can be used>
(1) User notifies abnormality.
• Engine warning lamp is lighting.
• Engine operation is abnormal.
• Engine cannot be started. (Power can be turned ON)
Operation and Maintenance Manual
(2) Remedy against usual trouble  PC simple service tool
HELP button in software
Use the PC simple tool or HDM2000.
<1> Communicate with ECM and display the failure code.  HDM2000
Outline is shown in separate sheet.
Repair the portion indicated by the failure code. For details, see attached booklet.
• Disconnection or defective contact of terminal

Priority • Disconnection/Short circuit, particularly ground cable
• Parts replacement
<2> If the trouble is judged to be repaired, communicate with ECM and "delete" the failure code temporarily.
<3> Start and warm up the engine and display the failure code again.
Failure code is not displayed   Repair is completed
Failure code is displayed  Perform repair again from <1>
(3) When HDM2000 must be used
<1> Electronically controlled throttle is broken.

<2> ECM is broken.
After the parts are replaced, ECM must be initialized.
Initialize with the function of HDM2000.
Initialization: Have the delicate base load of each
machine saved and operate the engine smoothly.
<3> Accelerator pedal sensor is broken or accelerator sensor output is out of the normal range.
After the parts are replaced or repaired, the operation

range of the accelerator pedal sensor must be adjusted.
Use the parameter display function of HDM2000
<4> No failure code is displayed but engine condition is bad.
Using the parameter display function/active test function

of HDM2000, find out the cause of the trouble.
When notifying to Product Support Department, check
the displayed parameter.
TB45
Self-diagnosis function and fail-safe function of electronically controlled gasoline engine
<Nissan K21 engine>
(1) Self-diagnosis function
The ECM (Engine Control Module) monitors each sensor constantly for abnormality.
Accelerator pedal, throttle, O 2 sensor, engine speed, coolant temperature, fuel pressure (LPG), etc.
If abnormality is detected, the engine turns the warning lamp ON and the fail-safe function
is turned ON to prevent abnormal operation and protect the engine in most cases.
(2) Fail-safe function

(1) Output does not reach the maximum. : Speed is limited to 1,600 rpm – 2,000 rpm and
output is lowered to half
• Crankshaft angle sensor abnormality
• Overheat
• Warning lamp bulb breakage
• LPG fuel pressure abnormality, etc.
(2) Engine speed becomes constant. : Approx. 1,000 rpm

• Electronically controlled throttle abnormality
• Accelerator pedal abnormality, etc.
TB45
Electronically controlled TB45 engine
Off-line check and Initialization
 After each machine is completed, perform the following.
* Prepare the Hitachi Service Tool.
<1> Throttle full close position learning

Key ON for 4 sec, Key OFF for 6 sec x 3 times (Do not turn the key to ST)
<2> Execution of troubleshooting and resolution
Page 2
Use the Hitachi Service Tool.
Turn the key ON. (The engine does not need to run)
Perform troubleshooting with the service tool.
If a failure code is displayed, repair the machine according to its contents.
 Check the connectors and wirings for defective contact first.
* If the key is turned ON while the wiring is not complete, it is judged to be a trouble.
Delete the failure code temporarily.
Start the engine once. (Have the engine perform self-diagnosis)
Perform troubleshooting again with the service tool.
Ensure that no failure code is displayed and then finish.
failure code table: Page 5
<3> Warming up machine sufficiently
Hydraulic oil and torque converter oil: 50(Min. 50°C)
<4> Initialization of ECM (engine controller) (Quick TAS learning)
Use Page 4
the Hitachi Service Tool.
Run the engine at low idle.
Perform quick TAS learning. (Finished in 30 seconds)
If leaning is not completed, check the condition in page 4 which may not be satisfied.
(When learning is not finished in 1 minute)
<5> The engine warning lamp must not light in the machine instrument panel.
If the engine warning lamp lights, a failure code has occurred.
Perform <2> again.
 How to connect the Hitachi Service Tool (HDM2000)

• The engine wiring harness has the service connector.
• Service connector  Adapter wiring harness  HDM2000 cable  HDM2000
TB45
Examples of trouble detection in K21/25 Series engine (Source; KFI Production BX Quality Report 2006 2nd edition)
Failure Occurrence f requency Failure Occurrence f requency

No. Total Contents of trouble No. Total Contents of trouble
code 2005 2006 code 2005 2006
1 P1245 13 2 15 LPG f uel pressure sensor sy stem short circuit 23 P1128 1 1 2 Throttle motor control sy stem short circuit
2 P1241 9 4 13 Def ectiv e LPG injector (Non-injecting range) 24 P0223 2 2 Throttle sensor 1 sy stem short circuit
3 P1122 7 4 11 Throttle opening degree response abnormality Coolant temperature sensor sy stem disconnection or
25 P0117 1 1
4 P2138 8 2 10 Accelerator sensor 1/2 output signal relation abnormality short circuit (low v oltage side)
5 P1126 4 3 7 Throttle motor power supply sy stem disconnection 26 P0122 1 1 Throttle sensor 2 sy stem disconnection
6 P1805 6 6 Brake switch output OFF sticking 27 P0132 1 1 O2 sensor output v oltage too high
7 P0350 4 1 5 Ignition primary signal sy stem disconnection 28 P0134 1 1 O2 sensor sy stem disconnection
LPG f uel pressure sensor sy stem disconnection or 29 P1217 1 1 Ov erheat
8 P1249 4 1 5
abnormally high 30 P1218 1 1 Light ov erheat
9 P0031 3 1 4 O2 sensor heater sy stem disconnection or short circuit 31 P1229 1 1 Throttle/Accelerator sensor source v oltage abnormality
Speed sensor (pos) sy stem disconnection/wav ef orm 32 P2123 1 1 Accelerator sensor 1 sy stem short circuit
10 P0335 4 4
abnormality 33 P2135 1 1 Throttle sensor 1/2 output signal relation abnormality
Disconnection or short circuit between trav el speed 34 P1121 1 1 Malf unction of throttle actuator
11 P0500 4 4
sensor and sensor conv erter 35 P0032 0 O2 sensor heater sy stem short circuit
12 P0650 4 4 Engine warning lamp bulb breakage or circuit abnormality 36 P0222 0 Throttle sensor 1 sy stem disconnection
13 P2122 4 4 Accelerator sensor 1 sy stem disconnection Crank angle sensor (phase) sy stem
37 P0340 0
14 P2127 4 4 Accelerator sensor 2 sy stem disconnection disconnection/wav ef orm abnormality
15 P2128 4 4 Accelerator sensor 2 sy stem short circuit 38 P1065 0 No power to ECM
16 P0123 1 2 3 Throttle sensor 2 sy stem short circuit 39 P1225 0 Throttle sensor f ull close learning v alue abnormality
17 P1124 1 2 3 Throttle motor power supply sy stem short circuit 40 P1126 0 Throttle sensor f ull close learning cannot be executed
18 P0605 2 1 3 ECM trouble 41 P1242 0 Def ectiv e LPG injector 2 (Injecting range)
Coolant temperature sensor sy stem disconnection or 42 P1243 0 Def ectiv e LPG injector 2 (Non-injecting range)
19 P0118 3 3
short circuit (high v oltage side) Total 104 29
20 P1240 3 3 Def ectiv e LPG injector (Injecting range)
21 P0102 1 1 2
engine is running)
22 P0103 1 1 2
engine is stopped and key is ON)
TB45
Introduction of high-function type service tool P1
For electronically controlled gasoline engines K21/K25/TB45 2008/7/15
Development Division, Business Department
[Important service items] [Reference]
<1> How to read error code <4> Explanation of each function
Page 2 Page 7
<2> How to perform quick TAS learning <5> Language setting
Page 3 Page 9
<3> How to work]
[Common read engine parameter <6> Body
Page 5 Page 10
Opening screen
Connect the service tool and turn the service tool ON.
It is recommended to keep the machine key switch OFF.
Main menu
Turn the key switch ON and answer YES
to 1. Perform machine troubleshooting.
YES key Go
C key Back
NO key Cancel (Displayed on screen)
Be sure to perform with the key ON.

Turn the key ON (to turn ECM ON), and
communication can be started.
If the communication fails, check that the

cables are connected and the key is ON, and
then follow the instructions on the screen.
This screen is the start screen of each work.
P1
TB45
[<1> How to read error code] P2
1. Self-diagnosis result display

When error code is displayed • DTC: Diagnosis trouble code
• Time: How many times the engine has been
started and stopped since the error code
occurred is displayed. *
* The coolant temperature must increase from low to above 70°C.
0: Trouble occurred during runoff this time
1: Previous time (Trouble did not occur this time)
2: 2 times before (Trouble did not occur this time)
•••
When error code is not displayed This number is updated if trouble occurs multiple times.
No problem.
However, since all troubles are not indicated
by error codes, check the phenomena of the
machine carefully.
2. How to delete self-diagnosis data
Be sure to perform this step after repairing.
Check again that the repair is successful

and the error code is not displayed.
P2
TB45
[Conditions for permitting quick TAS learning] P4
1) 70°C <= Engine coolant temperature <= 100°C

2) The engine is idling (750 ± 100 rpm).
3) The idling switch signal input is ON.
 The accelerator pedal sensor is adjusted normally and the accelerator is open full.
4) All of the power steering, tilt, lift and headlight are turned OFF.
 The engine is not loaded at all.
5) The neutral switch is ON.
 The FR lever is in neutral.
6) Battery voltage signal >= 12.88V
7) The travel speed is 0 km/h.
8) The coolant temperature sensor is normal.
9) The throttle full close position learning is finished.
[Throttle full close position learning]

Key ON for 4 sec, Key OFF for 6 sec x 3 times
Have the ECM learn the full close position of the electronically controlled throttle.
Do not crank the engine. Turn the key to the ON position.
If the ECM or electronically controlled throttle chamber parts were replaced, perform
this step before starting the engine.
If you noticed after starting the engine that this step has not been performed,
stop the engine and then perform this step.
P4
TB45
[<2> How to perform quick TAS learning] P3
 Be sure to perform this step when the ECM or electronically controlled throttle chamber
(ETC) parts were replaced.
Press the YES key to perform quick TAS learning.
* Check in advance that the machine has satisfied

the condition for the quick TAS learning.
Conditions: See the next page.
* In particular, warm up the hydraulic oil and torque
converter oil (above 60°C) before performing.
Normally, this step is finished in about 15 seconds.

If it takes 30 seconds or more to finish, check the conditions
that may not be satisfied.
* In this case, the result is not displayed as failure.
The process is not completed for ever.
If "Failure" is displayed
Perform the throttle full close position learning.
See the separate sheet.
P3
TB45
[<3> How to read engine parameters] P5
 This step is necessary for initial setting of the accelerator pedal.
 This step is also used as a means to find out the causes of troubles.
Display example of 12 data
The current condition of the engine is indicated.
There are 40 items, which can be displayed by scrolling

with the  and  keys.
The item list is on the next page.
[Accelerator pedal sensor initial setting]

Set ETC accelerator sensor 1 to the following values.
Target Range
Accelerator pedal sensor When closed fully 0.77V 0.67 – 0.86V
When open fully 4.55V 4.46 – 4.65V
If the values of ECT accelerator sensor 2 are almost the

same with 1, they are normal.
If they are very different, an error code is displayed
and either of sensors 1 and 2 may be broken.
For the sensor position adjustment method, see the

Shop Manual of the machine.
(Display example of 1 data)
P5
TB45
[Engine parameter check] P6
These values shows the recognition condition of the ECM. Important
For the normal values of these items, see the Shop Manual. All the values are not shown, however.
No. Item name Unit Contents/Meaning

1 Engine speed rpm
2 Coolant temperature sensor °C
3 Trav el speed sensor km/h Indicated by integers. See No. 22 “Accurate trav el speed”.
4 Battery v oltage V Is battery f atigued?
5 Intake air temperature sensor °C Is indicated temperature dif f erent f rom ambient temperature?
6 Ignition timing BTDC
7 O2 sensor bank 1 V O2 sensor output v oltage
8 Air-f uel ratio correction bank 1 % Dif f erence f rom base air-f uel ratio. A little dif f erence is OK.
9 O2 sensor heater % Power output condition to O2 sensor heater
10 Charge ef f iciency % Ef f iciency to cy linder displacement when GAS is used
11 LPG charge ef f iciency % Ef f iciency to cy linder displacement when LPG is used
12 LPG air-f uel ratio correction bank 1 % Same as abov e
13 Fuel ty pe Selection recognition condition of GAS or LPG
14 Air f lowmeter bank 1 V Air f lowmeter output v oltage
15 Injection pulse width bank 1 ms GAS f uel injection calculation parameter
16 Basic injection rate ms Gasoline f uel injection width (quantity )
17 Real-time DTC Existence of currently display ed error code
18 ETC accelerator sensor 1 V Accelerator pedal sensor 1 output v oltage
19 ETC accelerator sensor 2 V (Twice) Output v oltage of abov e sensor 2
20 ETC throttle sensor 1 V Throttle position sensor 1 output v oltage
21 ETC throttle sensor 2 V (Twice) Output v oltage of abov e sensor 2
22 Accurate trav el speed km/h Calculated to 0.1 km/h
23 LPG f uel injection width ms LPG f uel injection calculation parameter
24 LPG f uel pressure sensor mmHg
25 LPG basic f uel injection rate ms LPG f uel injection width (quantity )
26 Snow mode switch Must be eco mode switch. Must be kept ON on AX.
27 Electric load signal Turned ON when light is turned ON
28 Neutral switch Turned ON when FR lev er is in neutral
29 Starting motor signal During cranking
30 Idle switch Turned ON while accelerator pedal is released
31 O2 sensor monitor bank 1 Rich and lean are repeated if normal
32 Ignition switch Turned ON when key is turned ON
33 TAS learning history Quick TAS learning. Finished once perf ormed.
34 Brake switch Turned ON when brake pedal is depressed
35 Fuel pump relay Turned ON when GAS is used
36 Throttle relay For ETC throttle
37 O2 sensor heater bank 1 For warming up O2 sensor
38 Fuel selector switch 1 Recognition condition of GAS/LPG selector switch
39 Fuel selector switch 2 Same as abov e
40 LPG stop v alv e relay Driv e of f uel cut solenoid when LPG is used
P6
TB45
 Reference P7
[<4> Explanation of each function]
[Work support]
Ignition timing Use this function to stop the electronic control feedback when
adjustment setting the mechanical ignition timing.
The gasoline fuel pump can be stopped while the engine is
running. When disassembling the gasoline fuel piping, you
Fuel pressure release can release the pressure by using the gasoline in the piping
until the engine stalls to prevent the danger of fuel splashed
by the fuel pressure. This function is ineffective during LPG
operation.
Idle adjustment menu
Target ignition timing When changing the ignition timing temporarily, use the
adjustment ignition timing test of the active test menu.
Target idle speed Use this function to increase the idle speed temporarily.
adjustment (Limit: 250 rpm) Return to original speed with the service tool
after repairing.
Use this function to perform the air-fuel ratio learning forcibly
Air-fuel learning in the gasoline mode. When the gasoline injector or fuel pump
clearing is replaced, the condition may lower since the learning values
have been increased. In that case, the learning values can be
increased largely which are increased little by little usually.
This function is for releasing fuel pressure in the LPG mode.
LPG fuel pressure The LPG in the piping and vaporizer can be used until the
release engine stalls by closing the fuel cut solenoid during operation.
(This operation is equivalent to closing the gas cylinder
valve). This function is ineffective while GAS is used.
Use this function to perform the air-fuel ratio learning forcibly
LPG air-fuel ratio in the LPG mode. When the LPG injector or vaporizer is
learning clearing replaced with new one, if the condition lowers, the cause may
be the learning values. In that case, the learning of the new
part can be advanced largely with this function.
P7
TB45
[Active test] P8
With this function, the gasoline fuel injection rate can be

increased or decreased forcibly in the range of ±25%. This
Fuel injection rate test function is used to check discharge pressure of the electric
fuel pump, injection rate of the injector, etc. for mechanical
abnormalities.
With this function, the LPG fuel injection rate can be
LPG fuel injection rate increased or decreased forcibly in the range of ±25%. The
test LPG fuel is injected while its pressure is sensed, unlike the
gasoline. This function is used to check the injector for wear,
sticking and other mechanical abnormalities.
This function is used to change the ignition timing temporarily
Ignition timing test to judge the change of the operating condition and the effects
of the change of the ignition timing.
This test is the so-called reduced cylinder operation test.
Power balance test Gasoline injection in any cylinder can be stopped. This test
cannot be performed in the LPG mode, however.
P8
TB45
 Reference P9
[<5> Language setting]
If the backup battery is dead, the service tool starts with the following screen.
Language setting screen

If Japanese is not selected by mistake,
select it again in the following menu.
Return to the language setting screen and select Japanese. P9

TB45
[<6> Name of parts on body] P10
The name of each part on the body and their main functions are shown in
the following front view, rear view and bottom view.
Front view
<1> Power switch: Push/Push type <11> Diagnosis communication connector

<2> Direction keys: Used to move the cursor <12> Measurement connector CH1 (V/ohm/Hz mark)
(outline character item) on the screen up, <13> Measurement connector COM (COM mark)
down, to the right and to the left. (COM is the negative terminal common to CH1
<3> YES key: Affirm/Execute and CH2.)
NO key: Deny/Stop <14> Measurement connector CH2 (V mark)
<4> C key: Cancel. Return to previous screen. When measuring with CH1, use CH1 and
<5> S key: Special operation, shifting. COM.
<6> Function keys: F1, F2, F3, F4 When measuring with CH2, use CH2 and
<7> LCD screen COM.
<8> LED display unit <15> Power connector: Center pole is "+".
<9> Power supply monitor lamp <16> RS232C connector
<10> Cartridge slot <17> Optical communication port
<18> Wrist strap hook
Rear view
<19> LCD contrast control dial <22> Tripod adapter screw hole
<20> Ejector <23> Suction cup set mounting screw hole (3 places)
<21> Power supply cover <24> Hook fixing screw hole (2 places)
P10

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What are the main components mentioned in the document?

What are the main components mentioned in the document?

What are some of the features described for the CX50 model?

What are some of the features described for the CX50 model?

CX50 DX50

Diesel STD Model

FD35YT-10 FD50-8 FD35T-10 No production

FD40YT-10 FD60-8 FD40T-10 FD60-10

FD45YT-10 FD70-8 FD45T-10 FD70-10

FD50AYT-10 FD80-10 FD50A-10 FD80-10

Non Emission Emission Control

Note: Not Available 3.5 ton Compact Model.

CX 50 DX50 CX50 DX50

Note 1: DX Model of Gas/LPG are not available.

Unregulated level 54% (1996-2006)

1980 1985 1990 1995 2000 2005 2010 2015 2020

Engine S4D95LE /TB45 SAA4D95LE/TB45

• Vibration reduction by dual floating structure

• Wet-type brake as standard • Improvement of the electronic

2 Wet-type brake  The brake has in-board structure,  Drum type

2 Coarse mesh radiator  Not set.  Not set.

4 Oil leakage from Replacement at each trouble

2 Large oil Remedy against each trouble CPU controls electronically

3 TB42 starting trouble Change of starting procedure Improvement of electronic control

2 Play of PS cylinder Caulking 2  4 places Head tie rod fixed type

3 Play of link Bushing with seal Bushing with seal

7 Breakage of pump drive Reinforcement of shaft Improvement of torque converter PTO

3 Fluctuation No remedy Improvement of FHPS

The goal is clearing

Engine-mounted engine controller (ECM)

Air flow meter

(Gasoline, Outside Installation)

Crankshaft Cam angle sensor

Fuel tank (Gasoline)

Travel speed signal

LPG injector (main)

LPG fuel pressure sensor

LPG injector (sub)

Low oil pressure   Low oil pressure

Too high/low common

IMV/PCV1 short Warning lamp bulb

Injectors Drive Circuit Electronically controlled

Accelerator sensor Accelerator sensor

Note: This function are only effect

Features of Electric Fuel Control

Torque reduction by 30%

Engine oil pressure Torque

IMV short circuit 

IMV disconnection  Engine speed

Engine speed lowers to

Automatic warm-up function

Automatic preheat function

Fuel Circuit for SAA4D95LE

A: Fuel gate (From Fuel

Supply pump mounting

A: Fuel gate (From Fuel

Oil Filter mounting

Oil Filter mounting

Supply pump mounting

Fuel injection nozzle