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WORKSHOP MANUAL

SKID STEER LOADER

SSV65

KiSC issued 12, 2015 A

CONTENTS TO THE READER TO THE READER I INFORMATION CONTENTS INFORMATION 1. SAFETY FIRST ............................................ I-1 2. SAFETY PRECAUTIONS FOR WORK......... I-2 3. SAFETY DECALS ........................................ I-8 4. MAIN SPECIFICATIONS............................ I-12 5. DIMENSIONS ............................................. I-13 G GENERAL CONTENTS GENERAL 1. ENGINE INDENTIFICATION.......................G-1 2. MUFFLER FULL ASSEMBLY IDENTIFICATION ........................................G-4 3. GENERAL PRECAUTIONS.........................G-6 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING.........G-10 5. TIGHTENING TORQUES..........................G-17 6. LUBRICANTS, FUEL AND COOLANT ......G-21 7. MAINTENANCE.........................................G-22

5. TERMINAL NAMES OF THE MAIN CONNECTOR.......................................... 4-S40 6. INSTRUMENT PANEL............................. 4-S41 7. TROUBLESHOOTING............................. 4-S61 8. FLOW CHART OF THE USER MODE AND SERVICE MODE SETTINGS............ 4-S1 5 CABIN CONTENTS MECHANISM 1. AIR CONDITIONING SYSTEM................. 5-M1 2. WIPER .................................................... 5-M19 SERVICING 1. TROUBLESHOOTING............................... 5-S1 2. MAINTENANCE AND SERVICE RELATED SPECIFICATIONS ................... 5-S4 3. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM ................. 5-S5 4. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM ....................... 5-S10 5. INSPECTION AND DISASSEMBLY ........ 5-S19

1 ENGINE CONTENTS GENERAL 1. SPECIFICATIONS.....................................1-G1 2. DIMENSIONS ............................................1-G2 3. PERFORMANCE CURVE .........................1-G3 SERVICING 1. ENGINE ..................................................... 1-S1 2 MACHINE BODY CONTENTS SERVICING 1. FRONT ...................................................... 2-S1 2. UPPER STRUCTURE ............................. 2-S18 3. LOWER CHASSIS LAYOUT ................... 2-S32 3 HYDRAULIC SYSTEM CONTENTS MECHANISM 1. HYDRAULIC CIRCUIT DIAGRAM............ 3-M1 2. HYDRAULIC EQUIPMENT LAYOUT ....... 3-M1 3. HYDRAULIC SYSTEM ............................. 3-M2 SERVICING 1. SERVICE DATA ........................................ 3-S1 2. PERFORMANCE CHECKS AND ADJUSTMENT METHODS........................ 3-S3 3. HYDRAULIC EQUIPMENT...................... 3-S13 4 ELECTRICAL SYSTEM CONTENTS SERVICING 1. DIAGNOSING MALFUNCTIONS .............. 4-S1 2. WIRING CIRCUIT...................................... 4-S4 3. ELECTRONIC EQUIPMENT LAYOUT...... 4-S5 4. ELECTRICAL CONNECTOR LAYOUT .................................................... 4-S6

KiSC issued 12, 2015 A

TO THE READER This Workshop Manual provides service personnel with information about the mechanisms, service and maintenance of the construction machine. The Manual is divided into three sections, General, Mechanisms and Service.  General This section contains information such as engine and equipment ID numbers, general precautions, maintenance schedules, inspections and maintenance items.  Mechanisms This section describes the structure of mechanisms and explains their functions. Be sure that you fully understand this Mechanisms section prior to performing any service work, such as troubleshooting or when performing any disassembly or assembly work.  Service This section contains information and procedures for performing maintenance on the machine, such as troubleshooting, service specification tables, torque specifications, items to be inspected and adjusted, disassembly and assembly procedures, as well as precautions, maintenance standard values and usage limits. All of the illustrations, specifications and other information in this manual were created based on the latest model at the time of publication. Please be aware that changes to the content may be made without prior notice.

NOTE • Applicable Models Model

Engine

SSV65

V2607-CR-TE4-SL1 V2607-CR-TE4-SL1-Q

IMPORTANT • Please refer to the "Workshop Manual" below for information about the engine. Workshop manual title: Diesel engine V2607-CR-E4B, V2607-CR-TE4B, V3307-CR-TE4B WEB PDF code: 9Y111-11043 Booklet print code: 9Y121-11043 CD-ROM code: 9Y131-11043 May 2015 © KUBOTA Corporation 2015

KiSC issued 12, 2015 A

Record of Revisions Last digit of the Code No.

Date

2015.06.30

Correction of the machine modification points. Correction of the wrong descriptions.

A. W

2015.12.18

Correction of the machine modification points. Correction of the wrong descriptions.

A. W

Main Revised Point and Corrective Measures

Remarks

KiSC issued 12, 2015 A

I INFORMATION

KiSC issued 12, 2015 A

INFORMATION CONTENTS 1. SAFETY FIRST .............................................................................................................................. I-1 2. SAFETY PRECAUTIONS FOR WORK .......................................................................................... I-2 [1] PRECAUTIONS BEFORE WORKING ..................................................................................... I-2 [2] PRECAUTIONS WHEN WORKING ......................................................................................... I-3 3. SAFETY DECALS .......................................................................................................................... I-8 [1] LOCATIONS ............................................................................................................................. I-8 [2] CARE OF LABELS ................................................................................................................. I-11 4. MAIN SPECIFICATIONS.............................................................................................................. I-12 5. DIMENSIONS ............................................................................................................................... I-13

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

1. SAFETY FIRST SAFETY FIRST • This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. • It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit. DANGER • Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING • Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION • Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT • Indicates that equipment or property damage could result if instructions are not followed. NOTE • Gives helpful information. RY9212007INI0001US0

I-1

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

2. SAFETY PRECAUTIONS FOR WORK [1] PRECAUTIONS BEFORE WORKING Before servicing and repairing • Be sure to read all of the instructions and safety precautions in this manual and the operator's manual, as well the various labels affixed to the machine. • Be sure to stop the engine when you are out of the driver's seat to clean and inspect the machine body and machine itself, or to check and adjust various parts. • Choose non-hazardous flat, firm ground for inspection. RY9212038INI0001US0

• When performing maintenance on the equipment, hang the DO NOT OPERATE sign where it will be obvious from and around the driver's seat. • When performing maintenance or repairs, always lower attachments to the ground, stop the engine and secure the tracks with blocks. • When performing maintenance on the equipment, always disconnect the negative battery cable. • Before using tools, make sure you understand how to use them correctly and use tools in good condition and of the right size for the job. RY9212038INI0002US0

Be Ready for an Emergency • Keep a first-aid kit and fire extinguisher close at hand so you can use it when needed. • Keep emergency contact information for doctors, hospitals and ERs handy. RY9212001INI0004US0

• Wear clothes appropriate for working on equipment. Do not wear loose-fitting clothes as they may catch on the machine controls. • When working on the equipment, use all safety gear, such as a helmet, safety glasses and shoes, that are required by law or regulation. • Never perform maintenance while drowsy or under the influence of alcohol or drugs. RY9212001INI0005US0

I-2

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

[2] PRECAUTIONS WHEN WORKING • Stop the machine on a hard and level location and make sure the area around the machine is free of obstacles and hazardous materials. When parking the machine indoors, select a spot that can be properly ventilated. • When performing work such as with a hammer, fragments may go flying, so make sure only authorized persons are around the machine. • Before servicing the machine, clean it off so there is no mud, debris, oil or the like sticking to it. RY9212001INI0006US0

• Before getting on/off of the machine, clean off around the steps so there is no mud on them. Always give yourself 3-point support when getting on/off the machine. CAUTION • 3-point support means using both legs and one hand or both hands and one leg as you climb up/down. RY9212038INI0003US0

• When you need to access the underside of the machine for maintenance purposes, but sure to support the machine with a safety stand. Getting under the machine while supporting the machine by machine's own hydraulic cylinder or using a hydraulic jack can be extremely dangerous in the event of a hydraulic fluid leakage or similar mishap. (1) Safety Stand RY9212332INI0001US0

• Make sure the lift arm stopper is properly engaged before performing any work beneath raised lift arms. Never attempt to do any work or move under the lift arms when they are not properly supported. • Keep in mind that the lift arms may fall whenever hydraulic lines are disconnected, loosened, or removed. Any malfunction or failure in the hydraulics can also cause lift arms to drop. • Always perform the necessary repairs or service whenever the lift arm stopper becomes damaged or malfunctioned, or part are missing. Damaged or malfunction the lift arm stopper may cause the lift arms to fall causing serious injury or death. (1) Lift Arm Stopper (2) Arm Cylinder Rod

(A) FIT RY9212332INI0002US0

I-3

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

• Do not raise or lower the cabin while the engine is running as it may move, cause the machine to become unstable, resulting in serious injury or death. Always lower the working parts of the machine to the ground and stop the engine before attempting to raise or lower the cabin. • Make sure the cabin is properly and securely supported with a stopper when tilted to prevent if from falling and causing serious injury. (See, "CAB TILT" page) (1) Cabin (2) Stopper (3) Stopper Lock

(a) RAISE (b) ENGAGE (c) LOCK RY9212332INI0003US0

I-4

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

• When opening the rear door to perform maintenance, be sure to insert the pin into the "LOCKED" position to hold the door in place. (3) Rear Door

(4) Pin RY9212332INI0004US0

Starting the Machine Safely • Before starting the engine, always sit in the driver's seat and make sure the area is safe and clear. • As it is dangerous, never start the engine from anywhere but the driver's seat. • Always check and make sure control lever(s) are not engaged before starting the engine. • Never start the engine by hot-wiring the starter circuit. This is not only dangerous, but may damage the machine. RY9212332INI0005US0

• Whenever it is necessary to open the engine covers or hood in order to service the machine, always prop them open. • If it is absolutely necessary to run the engine while working on the machine, make sure you are clear of all rotating or moving parts. Also take care not to leave anything, such as tools or rags, near any moving parts. RY9212001INI0009US0

I-5

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

• The engine, muffler, radiator, hydraulic line, etc., have parts that remain very hot even after the engine has been stopped. Be sure to avoid these parts, as touching them can result in burns. Radiator coolant, hydraulic fluid and oil also remain hot. Therefore, do not attempt to remove caps and plugs, etc., before these fluids have sufficiently cooled. • Make sure the coolant temperature has dropped sufficiently before opening the radiator cap. Also, since the inside of the radiator is pressurized, when removing the cap, first loosen it to release the pressure before removing the cap completely. RY9212001INI0016US0

• The pressure in the hydraulic circuit stays at pressure even after the engine stops. Before removing parts, such as hydraulic devices from the machine, first release the pressure. Please note that when releasing residual pressure, the machine itself and/or implements may move without warning, so be very careful when releasing the pressure. • Oil gushing out under pressure is extremely dangerous as it may pierce your skin or your eyes. Similarly, oil leaking out of pinholes is not visible. So when checking for oil leaks, always wear safety glasses and gloves and use a piece of cardboard or a wood block to shield yourself from oil. RY9212001INI0011US0

No Smoking or Open Flames while Fueling • Fuel is extremely flammable and dangerous. Never smoke near fuel. If fuel is spilled on the machine, its engine, or electrical parts, it may cause a fire. If fuel is spilled, wipe it all up immediately. • Never smoke while filling the machine with fuel. And always tighten the fuel cap securely and wipe up any spilled fuel. RY9212001INI0012US0

• Always wear safety glasses and gloves when handling the battery. • The gas generated by the battery is flammable. Never weld or use tools like a grinder near the battery. And never smoke near it. • When disconnecting the battery, always disconnect the negative cable first. When connecting the battery, always connect the positive cable first. RY9212001INI0013US0

I-6

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

Dispose of Waste Fluids Properly • Never dispose of waste fluids on the ground, in the gutter, a river, pond or lake. Always dispose of hazardous substances like waste oil, coolant and electrolytic fluid in accordance with the relevant environmental protection regulations. • Keep the safety plates clean so they can be read. If a safety plate is damaged and comes off or becomes illegible, put a plate with the same warnings back in its place. RY9212001INI0015US0

I-7

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

3. SAFETY DECALS [1] LOCATIONS

RY9212332INI0006US0

I-8

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

RY9212332INI0007US0

I-9

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

RY9212332INI0008US0

I-10

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

RY9212332INI0009US0

[2] CARE OF LABELS CARE OF DANGER, WARNING AND CAUTION LABELS 1. 2. 3. 4.

Keep danger, warning and caution labels clean and free from obstructing material. Clean danger, warning and caution labels with soap and water, dry with a soft cloth. Replace damaged or missing danger, warning and caution labels with new labels from your KUBOTA dealer. If a component with danger, warning and caution label(s) affixed is replace with new part, make sure new label(s) is (are) attached in the same locations(s) as the replace component. 5. Mount new danger, warning and caution labels by applying on a clean dry surface and pressure any bubbles to outside edge. RY9212007INI0015US0

I-11

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

4. MAIN SPECIFICATIONS KUBOTA SSL (Skid Steer Loader) Model name

SSV65

Type Operating weight (including operator's weight)

Closed Cab

3080 kg (6790 lbs)

3200 kg (7055 lbs)

Water cooled 4 cycle diesel engine with 4 cylinder EPA Tier 4

Type Model name

V2607-CR-TE4

Total displacement

2615 cc (159.7 cu.in)

Engine Engine power

Performance

Open Cab

SEA J1995 gross

47.7 kW (64.0 HP)

SAE J1349 net

47.0 kW (63.0 HP)

Rated speed

2700 rpm

Low idling speed

1250 rpm

Rated operating capacity

885 kg (1950 lbs)

Tipping load

1770 kg (3900 lbs)

Breakout force

Bucket

2195 kg (4839 lbs)

Lift arm

1750 kg (3858 lbs)

Fast

17.8 km/h (11.1 mph)

Slow

11.1 km/h (6.9 mph)

Travel speed

Battery capacity

Pressure connection for attachments

12 V RC: 160 min, CCA 900A Max. displacement (Theoretical)

Standard Flow

68 L/min (18.0 US gal/min)

High-Flow

106 L/min (28.0 US gal/min) 22.5 MPa (230 kgf/cm2) (3271 psi)

Max. pressure

96 L (25.4 US gal)

Fuel tank capacity NOTE • Specifications subject to change without notice.

RY9212332INI0011US0

I-12

KiSC issued 12, 2015 A

INFORMATION

SSV65, WSM

5. DIMENSIONS

SSV65 A

Length of track on ground

1125 mm (44.3 in.)

Turning radius from center-machine front w/bucket

2503 mm (98.5 in.)

Length w/o bucket

2700 mm (106.3 in.)

Length w/bucket on ground

3439 mm (135.4 in.)

Height to top of cab

2029 mm (79.9 in.)

Bucket hinge pin height at max. lift

3085 mm (121.5 in.)

Rollback angle at carry position

27 °

Reach at max. lift and dump

831 mm (32.7 in.)

Ground clearance

193 mm (7.6 in.)

Departure angle

23.9 °

Max. dump angle

Vehicle width

1689 mm (66.5 in.)

Width with bucket

1753 mm (69.0 in.)

Turning radius from center-machine rear

1364 mm (53.7 in.)

41 °

NOTE • Above dimensions are based on the machine with KUBOTA standard bucket. • Above dimensions are based on the machine with KUBOTA standard tire. • Specifications subject to change without notice. RY9212332INI0010US0

I-13

KiSC issued 12, 2015 A

G GENERAL

KiSC issued 12, 2015 A

GENERAL CONTENTS 1. ENGINE INDENTIFICATION........................................................................................................ G-1 [1] MODEL NAME AND SERIAL NUMBER ................................................................................ G-1 [2] E4B ENGINE .......................................................................................................................... G-3 [3] CYLINDER NUMBER ............................................................................................................. G-3 2. MUFFLER FULL ASSEMBLY IDENTIFICATION ......................................................................... G-4 [1] PART NUMBER AND SERIAL NUMBER .............................................................................. G-4 3. GENERAL PRECAUTIONS.......................................................................................................... G-6 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................. G-10 [1] WIRING ................................................................................................................................ G-10 [2] FUSES.................................................................................................................................. G-14 [3] CONNECTOR ...................................................................................................................... G-14 [4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER ..................................... G-16 5. TIGHTENING TORQUES........................................................................................................... G-17 [1] GENERAL USE SCREWS, BOLTS AND NUTS .................................................................. G-17 [2] STUD BOLTS ....................................................................................................................... G-17 [3] TORQUE FOR HYDRAULIC HOSE FITTINGS ................................................................... G-18 (1) Torque for Hydraulic Hose Fittings ................................................................................. G-18 (2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings (Straight Threads)........................................................................................................... G-19 (3) Torque for Tapering Adaptors ........................................................................................ G-19 [4] HOSE CLAMP SCREW TORQUE ....................................................................................... G-20 6. LUBRICANTS, FUEL AND COOLANT....................................................................................... G-21 7. MAINTENANCE.......................................................................................................................... G-22 [1] MAINTENANCE INTERVALS .............................................................................................. G-22 [2] OTHER ADJUSTMENTS AND REPLACEMENTS .............................................................. G-25 (1) Fuses.............................................................................................................................. G-25

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

1. ENGINE INDENTIFICATION [1] MODEL NAME AND SERIAL NUMBER Be sure to check the engine nameplate and serial number when you wish to consult about the engine. The model and serial number of the engine need to be checked prior to servicing the engine or replacing any of its parts.  Engine Serial No. The engine serial number is the numerical ID of the engine and is printed after the engine's model number. The year and month of manufacture are indicated as follows. Engine Series Number or Alphabet

Series

Number or Alphabet

Series

05 (include: WG)

GZ, OC, AC, EA, E

SM (include: WG)

EA, RK

Air Cooled Gasoline

03 (KET Production)

Alphabet or Number

Year

Alphabet or Number

Year

2001

2015

2002

2016

2003

2017

2004

2018

2005

2019

2006

2020

2007

2021

2008

2022

2009

2023

2010

2024

Production Year

2011

2025

2012

2026

2013

2027

2014

(1) Engine Model Name and Serial Number

(To be continued)

G-1

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

(Continued) Production Month and Lot Number Month

Engine Lot Number

January

A0001 to A9999

from B0001

February

C0001 to C9999

from D0001

March

E0001 to E9999

from F0001

April

G0001 to G9999

from H0001

May

J0001 to J9999

from K0001

June

L0001 to L9999

from M0001

July

N0001 to N9999

from P0001

August

Q0001 to Q9999

from R0001

September

S0001 to S9999

from T0001

October

U0001 to U9999

from V0001

November

W0001 to W9999

from X0001

December

Y0001 to Y9999

from Z0001

* Alphabetical letters "I" and "O" are not used. (a)

(b)(c)(d) (e)

e.g. V2607 - 8 F G A001 (a) (b) (c) (d) (e)

V2607: Engine Model Name 8: Engine Series (07 series) C: Production Year (2015) L: Production Month (April) A001: Lot Number: (0001 to 9999 or A001 to Z999) RY9212332GEG0001US0

G-2

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

[2] E4B ENGINE [Example: Engine Model Name V2607-CR-TE4-XXXX] The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission regulations depends on the engine output classification. Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the respective countries affected by Nonroad Emission regulations. For KUBOTA Engines, E4B will be the designation that identifies engine models affected by the next emission phase (See the table below). When servicing or repairing ###-E4B series engines, use only replacement parts for that specific E4B engine, designated by the appropriate E4B KUBOTA Parts List and perform all maintenance services listed in the appropriate KUBOTA Operator's Manual or in the appropriate E4B KUBOTA Workshop Manual. Use of incorrect replacement parts or replacement parts from other emission level engines (for example: E3B engines), may result in emission levels out of compliance with the original E4B design and EPA or other applicable regulations.Please refer to the emission label located on the engine head cover to identify Output classification and Emission Control Information. E4B engines are identified with "EF" at the end of the Model designation, on the US EPA label. Please note: E4B is not marked on the engine. Category (1)

Engine output classification

EU regulation

From 37 to less than 56 kW

STAGE IIIB

From 56 to less than 75 kW

STAGE IIIB

From 75 to less than 130 kW

STAGE IIIB

Category (2)

Engine output classification

EPA regulation

Less than 19 kW

Tier 4

From 19 to less than 56 kW

Interim Tier 4

From 56 to less than 75 kW

Interim Tier 4

From 75 to less than 130 kW

Interim Tier 4

(1) EU regulation engine output classification category (2) "E4B" engines are identified with "EF" at the end of the Model designation, on the US EPA label. "E4B" designates some Interim Tier 4 / Tier 4 models, depending on engine output classification. RY9212332GEG0002US0

[3] CYLINDER NUMBER You can see the cylinder numbers of KUBOTA diesel engine in the figure. The sequence of cylinder numbers is No.1, No.2, No.3 and No.4 and it starts from the gear case side. RY9212148GEG0013US0

G-3

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

2. MUFFLER FULL ASSEMBLY IDENTIFICATION [1] PART NUMBER AND SERIAL NUMBER Diesel Particulate Filter (hereinafter referred to as the "DPF") Muffler Full Assembly Serial Number The DPF muffler full assembly serial number is an identified number for the DPF muffler full assembly. It shows the month and year of manufacture as below. Year of manufacture Alphabet or Number

Year

Alphabet or Number

Year

2001

2015

2002

2016

2003

2017

2004

2018

2005

2019

2006

2020

2007

2021

2008

2022

2009

2023

2010

2024

2011

2025

2012

2026

2013

2027

2014

Month of manufacture Month

DPF Muffler Full Assembly Lot Number

January

A0001 to A9999

B0001 to BZ999

February

C0001 to C9999

D0001 to DZ999

March

E0001 to E9999

F0001 to FZ999

April

G0001 to G9999

H0001 to HZ999

May

J0001 to J9999

K0001 to KZ999

June

L0001 to L9999

M0001 to MZ999

July

N0001 to N9999

P0001 to PZ999

August

Q0001 to Q9999

R0001 to RZ999

September

S0001 to S9999

T0001 to TZ999

October

U0001 to U9999

V0001 to VZ999

November

W0001 to W9999

X0001 to XZ999

December

Y0001 to Y9999

Z0001 to ZZ999

* Alphabetical letters "I" and "O" are not used. (a)(b) (c)

e.g. F G 0019 (1) DPF Muffler Full Assembly Part Number and Serial Number (a) Year: F Indicates 2015 (b) Month: G or H Indicates April (c) Lot Number: (0001 to 9999 or A001 to Z999) RY9212332GEG0003US0

G-4

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Diesel Particulate Filter (hereinafter referred to as the "DPF") Muffler Full Assembly Serial Number You must keep the records of the filter comp (DPF) part number and serial number (3) and catalyst (DOC) part number and serial number (4) before you remove the DPF for cleaning. (1) DPF Muffler Assy Part Number and (A) V2607-CR-TE4 Serial Number V3307-CR-TE4 (2) DPF Muffler Full Assy Part Number and Serial Number (3) Filter Comp (DPF) Part Number and Serial Number (4) Catalyst (DOC) Part Number and Serial Number RY9212332GEG0004US0

G-5

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

3. GENERAL PRECAUTIONS Whenever performing maintenance on the machine, always read the Safety Precautions in this manual and the Operator's Manual carefully, become familiar with them and perform the work safely. Before performing any maintenance on the machine, make sure it is sufficiently clean and choose a sufficiently clean location to perform any disassembly. Before performing maintenance on the machine, always disconnect the negative battery cable first. Whenever a special tool is required, use the special tool that KUBOTA recommends. Make any special tools that are not used very frequently according to the diagrams in this manual. Always use genuine KUBOTA parts to maintain the performance and safety characteristics of the machine. RY9212001GEG0011US0

Plumber's Tape • Wrap plumber's tape on the threads before tightening taper couplings. After wrapping (2 wraps) the plumber's tape, tighten to the specified torque. Once the coupling is tightened, do not loosen it as this will cause an oil leak. (1) Plumber's Tape (2) External Thread (3) Internal Thread

(4) Gap (5) Leave 1 to 2 Threads RY9212001GEG0012US0

O-Ring • Clean the groove the O-ring goes in and remove any burrs. Apply grease on the O-ring when inserting it in the groove. (Except floating seals) • When putting the O-ring in the groove, be careful as it is easy at the very end to twist the O-ring against the inside of the groove. If it gets twisted, roll it gently with your fingertip to untwist it. (1) O-Ring Groove (2) O-Ring (3) Check for Burrs

(4) If the Ring Touches This Corner, It Will Twist RY9212001GEG0013US0

Oil Seal • Do not face the lip of the oil seal in the wrong direction. Face the main lip toward the material to be sealed. • After oil seals are replaced, apply grease to the moving parts around the lip to prevent the dry surfaces from wearing against each other when the engine is started. If the seal has a dust lip, fill the gap between the lips with grease. • As a general rule, use a press to insert the oil seal in place. If that is not possible, use an appropriate tool to gently and evenly tap it into place, taking care that it does not go in at a slant. Press the seal all the way so it seats in the boss. (1) (2) (3) (4) (5) (6)

Gasket Metal Ring Spring Main Lip Grease Dust Lip

A : Air (Outside) B : Hydraulic Chamber (Inside)

RY9212001GEG0014US0

G-6

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Floating Seal • Be sure to wipe off any oil from the O-ring or surfaces that touch the O-ring. (For wheel motors, apply a light film) • When putting an O-ring into a floating seal, make sure the O-ring does not twist. • Apply a light film of oil to surrounding surfaces when working to get the floating seal with O-ring in place; take care that the surrounding surfaces, O-ring and housing are parallel with each other. • After getting the seal in place, turn the engine over 2 or 3 revolutions, to both create a film of oil on surrounding surfaces and to properly seat the face of the seal. (1) Surrounding Surfaces

(2) O-Ring RY9212001GEG0015US0

Snap Ring Related • When installing external or internal snap rings, orient them as shown in the diagram so the angled side faces the direction of force. (1) Position so the Angled Part Receives the Force

(A) External (B) Internal RY9212001GEG0016US0

Spring Pins • When driving a spring pin, face the split in the direction that receives the force, as shown in the diagram. (1) With Lateral Movement

(2) With Rotational Movement RY9212001GEG0017US0

Adhesive • Clean and dry the area where adhesive will be applied with a solvent so it is free of moisture, oil and dirt. • Apply adhesive all around the threads of the bolt except the first set of threads at the tip and fill the grooves between the threads. If the threads or the grooves are large, adjust the amount of adhesive accordingly and apply it all around the bolt hole as well. (A) Bolt Through-Hole (Nut) (B) Pocket Bolt Hold (Capsule Shape, etc.)

(a) Apply Here (b) Do Not Apply (c) Drip On RY9212001GEG0018US0

G-7

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Tightening Bolts and Nuts • Tighten bolts and nuts to their specified torque. • Tighten nuts and bolts alternately top/bottom (a) (b), left/right so the torque is distributed evenly. (A) Top/Bottom Alternately (B) Across Diagonally

Assembling Hydraulic Hoses • Tighten to their specified torque. • Before assembling, wipe the inside of metal fittings clean of any dirt. • After assembly, put the fitting under normal pressure and check that it does not leak. RY9212001GEG0020US0

Elbow with Male Seat Assembly Procedure When assembling an elbow with male seat, adhere to the following procedures to prevent deformation of O-rings and leaks. 1. Connecting to Valves • Clean the blow with male seat and the surface of the seal opposite and mount with the lock-nut on top. • Finger tighten till it touches the washer.

2. Positioning • Turn the mouth of the elbow back so it faces the right direction. (not back over 1 turn)

3. Fasten • Tighten the lock-nut to the specified torque with a wrench. (1) Lock-Nut (2) Washer (3) Seal (O-Ring)

(4) Wrench for Holding (5) Hose (6) Torque Wrench for Tightening RY9212001GEG0021US0

G-8

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Installing and Removing Quick Couplings • To remove a quick hose coupling, push the fitting in the direction of the arrow and pull on the plastic part in the opposite direction. • To attach a quick coupler, push it in firmly in the direction of the arrow. Then check that it will not pull off. (1) Plastic Part

(2) Fitting RY9212001GEG0022US0

Connecting the face sealing (ORS) type hose 1. Remove the protective cap from the adapter and make sure the O-ring is installed in its groove. (If the O-ring is missing, fit the specified-size in position.) (1) Protective cap RY9212213GEG0005US0

2. Apply oil to the threads of the hose cap nut and the edge that touches the O-ring.

3. Make sure the mating surface on the hose side is in good contact with the O-ring on the joint side. Make sure it will not come off.

4. Be sure to tighten the cap nut to the specified torque. RY9212213GEG0007US0

G-9

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING Follow the precautions below for handling electrical parts and wiring to ensure safety and prevent damage to the machine and nearby equipment. IMPORTANT • Inspect electrical wiring for damage and/or loose connections. • Do not alter or rewire any electrical parts or wiring. • Always remove the negative battery cable first when disconnecting the battery and attach the positive cable first when connecting it. (1) Battery Cable (-) Side

(2) Battery Cable (+) Side RY9212001GEG0023US0

[1] WIRING • Tighten wiring terminals securely. (1) Correct (Tightened Securely)

(2) Incorrect (Poor Contact if Loose) RY9212001GEG0024US0

• Keep wiring away from hazards. (1) Hazardous Positioning (2) Wiring Position (Wrong)

(3) Wiring Position (Right) (4) Hazardous Position RY9212001GEG0025US0

• Immediately repair or replace old or damaged wiring. (1) Damaged (2) Torn

(3) Electrical Tape RY9212001GEG0026US0

G-10

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

• Insert grommet securely. (1) Grommet

(A) Correct (B) Incorrect RY9212001GEG0027US0

• Clamp wiring securely but do not damage wires with the clamp. (1) Clamp (Spiral Clamp Around Wire) (3) Clamp (2) Wire (4) Welding Mark RY9212001GEG0028US0

• Clamp wiring so it is not twisted, pulled too tight or sag too much. However, moving parts may require play in the wiring. (1) Wire (2) Clamp

(A) Correct (B) Incorrect RY9212001GEG0029US0

• Do not pinch or bind wiring when installing parts. (1) Wire

(A) Incorrect RY9212001GEG0030US0

• After wiring, double-check terminal protectors and clamps before connecting battery cables. (1) Cover (Install Covers Securely) RY9212001GEG0031US0

G-11

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

• Do not modify harnesses. The diameter of wires in each harness is determined after calculating its capacity. • Modifying harnesses may cause a malfunction or a fire. (A) Wiring Diagram (B) Diagram of Modification

(a) Standard Wiring (b) Modified Wiring RY9212038ELS0008US0

G-12

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Colors of Wiring Color of wiring

Color code

Color of wiring

Color code

Black

Blue / Green

L/G

Green

Blue / Orange

L/Or

Blue

Blue / Red

L/R

Pink

Blue / White

L/W

Red

Blue / Yellow

L/Y

White

Light Green / Blue

Lg/B

Yellow

Light Green / Red

Lg/R

Brown

Light Green / White

Lg/W

Gray

Light Green / Yellow

Lg/Y

Light Green

Orange / White

Or/W

Orange

Pink / White

P/W

Sky Blue

Pink / Blue

P/L

Black / Green

B/G

Red / Black

R/B

Black / Blue

B/L

Red / Green

R/G

Black / Pink

B/P

Red / Blue

R/L

Black / Violet

B/V

Red / White

R/W

Black / Red

B/R

Red / Yellow

R/Y

Black / White

B/W

Violet / White

V/W

Black / Yellow

B/Y

White / Black

B/W

Brown / Black

Br/B

White / Green

W/G

Brown / Yellow

Br/Y

White / Blue

W/L

Brown / Red

Br/R

White / Red

W/R

Green / Black

G/B

White / Yellow

W/Y

Green / Blue

G/L

Yellow / Black

Y/B

Green / Red

G/R

Yellow / Green

Y/G

Green / White

G/W

Yellow / Blue

Y/L

Green / Yellow

G/Y

Yellow / Red

Y/R

Blue / Black

L/B

(Ex.) 1.25-Y/R means : 1.25 : Wire size (mm2) Y : Base color (yellow) R : Stripe color (red) • Do not pull on or step on wires. Also, do not cut wires on burred edges or the like. • Do not twist or pinch wiring when installing it. (a) Wire Size (mm2) (b) Insulation Base Color

G-13

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

[2] FUSES • Always use fuses of the specified capacity. Never use over or undersized fuses. • Never use copper or steel wire in place of a fuse. • Do not install accessories such as work lights, radios, etc., if your machine does not have an auxiliary circuit. • Do not install accessories as they will exceed the capacity of fuses. (1) Fuse (2) Fusible Link

(3) Slow-Blow Fuse RY9212001GEG0032US0

[3] CONNECTOR Connectors The terminals of female connector are numbered from #1 on the top right when facing it. Male terminals are numbered from #1 on the top left. (A) Female connector terminals

(B) Male connector terminals RY9212038ELS0010US0

• Press the lock to disconnect locking connectors. (A) Push RY9212001GEG0033US0

• Hold the connectors when separating them. • Do not pull on the wire harness to separate the connectors. (A) Correct

(B) Incorrect RY9212001GEG0034US0

G-14

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Pull on the harness from the connector and make sure the harness does not come off. (Pull with 3 kgf (30 N, 7 lbf) or less of force) (A) Pull

(B) Loosened Crimping RY9212038ELS0011US0

• Straighten bent prongs and make sure none are sticking out or missing. • Remove corrosion from terminals with sandpaper. (1) Missing Terminal (2) Bent Prong

(3) Sandpaper (4) Corrosion RY9212001GEG0035US0

• Do not touch the terminals of connectors with bare hands. (A) Do not touch RY9212038ELS0012US0

• Female connectors must not be spread too far open (A) Correct

(B) Incorrect RY9212001GEG0036US0

• The plastic covers of connectors must cover them completely. (1) Cover

(A) Correct (B) Incorrect RY9212001GEG0037US0

G-15

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

[4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER Using a high-pressure washer incorrectly can lead to personal injury and/or damage, break or cause parts of the machine to fail, so use the power washer properly according to its operator's manual and labels. CAUTION • Stand at least 2.0 meters from the machine and adjust the nozzle for a wide spray so it does not cause any damage. If you blast the machine with water or wash it from too close a distance, 1. It may cause a fire due to damaged or cuts in the insulation of electrical wiring. 2. An injury may result if hydraulic oil gushes out under high pressure, due to damaged hydraulic hoses. 3. It may damage, break or cause parts of the machine to fail. (Ex.) (1) Stickers or labels may come off (2) Electrical parts or the engine may fail due to water in them. (3) Damage glass, resins, etc. or the rubber of oil seals. (4) Tear off paint or the film from plating (1) Do Not Blast with Water (2) Never Wash from Too Close

(A) (B) (C) (D)

Blasting Wide Spray Less Than 2.0 m (80 in.) Over 2.0 m (80 in.) RY9212001GEG0038US0

G-16

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of bolt

No-grade or 4T

Indication on top of nut

10.9

No-grade or 4T 6T

Material of opponent part

Steel

Unit

N·m kgf·m lbf·ft

7.9 to 9.3

0.8 to 0.95

5.8 to 6.8

7.9 to 8.8

0.8 to 0.9

5.8 to 6.5

9.81 to 11.2

1.0 to 1.15

7.24 to 8.31

7.9 to 8.8

0.8 to 0.9

5.8 to 6.5

12.3 to 14.2

1.25 to 1.45

9.05 to 10.4

–

18 to 20 40 to 45

1.8 to 2.1 4.0 to 4.6

13 to 15 29 to 33

17 to 19 32 to 34

1.7 to 2.0 3.2 to 3.5

13 to 14 24 to 25

24 to 27 48 to 55

2.4 to 2.8 4.9 to 5.7

18 to 20 36 to 41

18 to 20 40 to 44

1.8 to 2.1 4.0 to 4.5

13 to 15 29 to 32

30 to 34 61 to 70

3.0 to 3.5 6.2 to 7.2

22 to 25

–

45 to 52

–

63 to 72

6.4 to 7.4

47 to 53

–

78 to 90

6.4 to 7.4

47 to 53

–

124 to 147

–

76 to 86.7 123 to 144

–

10.5 to 12 17 to 20

–

79.6 to 92.5 123 to 141

103 to 117 167 to 196

–

11 to 12.8 17 to 19.5

58 to 66 91.2 to 108

63 to 72

108 to 125 167 to 191

7.9 to 9.2 12.6 to 15

–

197 to 225

20 to 23

145 to 166

–

260 to 304

26.5 to 31

192 to 224

–

M18

246 to 284

25 to 29

181 to 209

–

275 to 318

28 to 32.5

203 to 235

–

34 to 40

246 to 289

–

368 to 431

37.5 to 44

272 to 318

–

254 to 296 384 to 420

–

334 to 392

35 to 41 53.0 to 58.0

–

M20

344 to 402 520 to 569

–

M10

M12

M14

M16

Aluminum

Steel

Aluminum

Steel

RY9212332GEG0005US0

[2] STUD BOLTS Material of opponent part

Steel

Aluminum

Unit

N·m kgf·m lbf·ft

12 to 15

1.2 to 1.6

8.7 to 11

8.9 to 11

0.90 to 1.2

6.5 to 8.6

M10

25 to 31

2.5 to 3.2

18 to 23

20 to 25

2.0 to 2.6

15 to 18

M12

30 to 49

3.0 to 5.0

22 to 36

3.2

M14

62 to 73

6.3 to 7.5

46 to 54

–

M16

98.1 to 112

10.0 to 11.5

72.4 to 83.1

–

M18

172 to 201

17.5 to 20.5

127 to 148

–

– RY9212032GEG0002US0

G-17

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

[3] TORQUE FOR HYDRAULIC HOSE FITTINGS (1) Torque for Hydraulic Hose Fittings Union Nuts

Tightening torque

1/8

7.8 to 11.8 N·m 0.8 to 1.2 kgf·m 5.7 to 8.7 lbf·ft

1/4

24.5 to 29.2 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 lbf·ft

3/8

37.2 to 42.1 N·m 3.8 to 4.3 kgf·m 27.5 to 31.1 lbf·ft

1/2

58.8 to 63.7 N·m 6.0 to 6.5 kgf·m 43.4 to 47 lbf·ft

3/4

112 to 123 N·m 11.4 to 13 kgf·m 82.5 to 94 lbf·ft

(1) Nuts RY9212332GEG0006US0

Unify (UNF)

Tightening torque

7/16-20UNF

19 to 21 N·m 1.9 to 2.1 kgf·m

9/16-18UNF

32 to 36 N·m 3.3 to 3.7 kgf·m

3/4-16UNF

56 to 62 N·m 5.7 to 6.3 kgf·m

7/8-14UNF

74 to 82 N·m 7.5 to 8.4 kgf·m

1-1/16-12UNF

112 to 123 N·m 11.4 to 12.5 kgf·m RY9212332GEG0007US0

Fase Seal Type (ORS) Tightening torque

1 -3/16 -12UN

157 to 165 N·m 16 to 16.8 kgf·m 116 to 121 lbf·ft

(1) O-Ring RY9212332GEG0008US0

G-18

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

(2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings (Straight Threads) 1/4

24.5 to 29.4 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 lbf·ft

1/2

58.8 to 63.7 N·m 6.0 to 6.5 kgf·m 43.4 to 47.0 lbf·ft

3/4

117.6 to 127.4 N·m 12.0 to 13.0 kgf·m 86.8 to 94.0 lbf·ft

7/16-20UNF

19.0 to 21.0 N·m 1.9 to 2.1 kgf·m 14 to 15 lbf·ft

9/16-18UNF

32.0 to 36.0 N·m 3.3 to 3.7 kgf·m 24.1 to 27.0 lbf·ft

3/4-16UNF

56.0 to 62.0 N·m 5.7 to 6.3 kgf·m 42.1 to 46.5 lbf·ft

7/8-14UNF

74.0 to 82.0 N·m 7.6 to 8.4 kgf·m 55.5 to 61.6 lbf·ft

1.1/16-12UN

112.0 to 123.0 N·m 11.4 to 12.6 kgf·m 84.2 to 92.4 lbf·ft

Tightening torque

(1) Lock-Nut (2) Washer

(3) Seal (O-Ring) RY9212332GEG0009US0

(3) Torque for Tapering Adaptors

Tightening torque

1/8

19.6 to 29.4 N·m 2.0 to 3.0 kgf·m 14.5 to 21.7 lbf·ft

1/4

36.6 to 44.1 N·m 3.7 to 4.5 kgf·m 26.8 to 32.5 lbf·ft

3/8

68.6 to 73.5 N·m 7.0 to 7.5 kgf·m 50.6 to 54.2 lbf·ft

1/2

83.4 to 88.3 N·m 8.5 to 9.0 kgf·m 61.5 to 65.1 lbf·ft

3/4

166.6 to 181.3 N·m 17 to 18.5 kgf·m 123 to 133.8 lbf·ft

(1) Taper RY9212001GEG0044US0

G-19

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

[4] HOSE CLAMP SCREW TORQUE Type 1 36-

09318-89045

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.9 to 2.5 lbf·ft

42-

09318-89050

2.5 to 3.4 N·m 25 to 35 kgf·cm 3.0 to 3.6 lbf·ft

Tightening torque

RY9212332GEG0010US0

Type 2 19-

R1401-63210

3.9 to 4.9 N·m 40.0 to 50.0 kgf·cm 3.0 to 3.6 lbf·ft

32-

68311-72831

4.9 to 5.9 N·m 50.0 to 60.0 kgf·cm 3.7 to 4.4 lbf·ft

68-

RD401-63171

4.9 to 5.9 N·m 50.0 to 60.0 kgf·cm 3.7 to 4.4 lbf·ft

50-

RC401-63190

4.9 to 5.9 N·m 50.0 to 60.0 kgf·cm 3.7 to 4.4 lbf·ft

66-

3F740-04592

4.9 to 5.9 N·m 50.0 to 60.0 kgf·cm 3.7 to 4.4 lbf·ft

77-

69284-63170

4.9 to 5.9 N·m 50.0 to 60.0 kgf·cm 3.7 to 4.4 lbf·ft

Tightening torque

RY9212332GEG0011US0

G-20

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

6. LUBRICANTS, FUEL AND COOLANT Place

Capacity

Lubricants, fuel and coolant

SSV65

Engine oil (Include oil filter)

7.5 L (1.98 gal)

API classification CJ-4

Coolant (Include reserve tank)

9.0 L (2.38 gal)

LLC-N-50F 50 %; the mixing ratio of antifreeze solution

Fuel

96 L (25.4 gal)

Hydraulic oil tank

11.2 L (3.0 gal)

Kubota Hydraulic Fluid 46HD

Hydraulic oil system

35 L (9.25 gal)

Kubota Hydraulic Fluid 46HD

Travel motor

20.5 L (5.4 gal)

Kubota Hydraulic Fluid 46HD Each

Grease

–

EP2 RY9212332GEG0012US0

Hydraulic oil inspection and replenishment Machine orientation during inspection and replenishment Park the machine on flat ground, lower the lift arm fully to the ground and fully roll back in the front attachment. • Check the hydraulic fluid temperature (20 to 30 °C / 68 to 86 °F), and check that the level meter is central. • When fluid is low, supply more fluid through the hydraulic oil filling port. (1) Gauge RY9212332GEG0013US0

G-21

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

7. MAINTENANCE CAUTION • To avoid personal injury: Before doing maintenance work on the machine, place the machine on a firm, flat and level surface, lower the lift arms slowly to the ground, stop the engine. Whether the machine is properly lubricated and maintained directly determines the trouble frequency and service life of the machine. Periodically check and maintain your machine, and you will find in the long run that the jobs can be finished earlier and more economically. Shown in the Service Interval Chart below are the hours indicated on the hourmeter, practically, it will be convenient to schedule the time of inspection and maintenance according to the calender (day, week, month) on the basis of the chart. If the machine is used in harder-than-usual working conditions, it must be checked and maintained at shorter intervals. RY9212038GEG0009US0

[1] MAINTENANCE INTERVALS No.

Indication on hour meter

Item

50 check

250

500

1000

1500

2000

3000

every 2 years

change check

Daily check

(every 10 hrs)

check

Daily check

(every 10 hrs)

3 Engine oil change check

Important

(every 10 hrs)

Daily check

1 Coolant

2 Fuel

Interval



every 500 hrs (every 10 hrs)

Daily check

4 Hydraulic oil change



every 1000 hrs

5 Greasing

grease

Daily check

(every 10 hrs)

6 Radiator and oil cooler

check

Daily check

(every 10 hrs)

7 Engine and electrical wiring

check

Daily check

(every 10 hrs)

8 Water separator

drain

Daily check

(every 10 hrs)

9 Washer liquid

check

Daily check

(every 10 hrs)

10 Battery condition

check

Daily check

(every 10 hrs)

check

Daily check

(every 10 hrs)

11 V-belt tension adjust



every 250 hrs

12 Dust indicator

check

Daily check

(every 10 hrs)

13 Fuel tank cab

clean

Daily check

(every 10 hrs)

14 Wheel bolt torque

check



15 Tire pressure

check



every 50 hrs

16 Fuel tank

drain



every 50 hrs

17 Foot pedals

grease



every 50 hrs

clean



every 50 hrs



every 250 hrs



every 250 hrs

Outer element 18 Air cleaner element

replace

Inner element replace

 

G-22

 

every 50 hrs

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM No.

Indication on hour meter

Item

50 check

250

500

1000

1500

2000

3000



19 Radiator hoses and clamps

Interval

Important

every 250 hrs every 2 years

replace check



20 Fuel line and intake air line

every 250 hrs

every 2 years

replace 21 Drive chain tension

check



every 250 hrs

22 Inside of main frame

clean



every 250 hrs

23 Fuel filter cartridge

replace



every 500 hrs

24 Engine oil filter cartridge

replace



every 500 hrs



every 500 hrs



every 1000 hrs

check



25 Drive chain tank oil (each side) change

 



every 500 hrs



every 500 hrs



every 500 hrs



every 1000 hrs



every 1500 hrs

26 Breather filter

replace

27 Hydraulic return filter

replace

28 Hydraulic oil filter

replace

29 Hydraulic suction filter

replace

30 Injector tip

check

31 Alternator and starter motor

check

32 Oil separator element

replace



every 1500 hrs

33 PCV valve

check



every 1500 hrs

34 EGR cooler

check



every 1500 hrs

35 EGR system

check



every 3000 hrs

36 Turbo charger

check



every 3000 hrs

37 DPF

clean



every 3000 hrs

check

every 1 year

*3 *3

Exhaust manifold (crack, gas leakage and mounting screw)

39 Intake air line for air leaks

 

 

every 2000 hrs



check

every 1 year

40 Boost sensor and AFS (Air flow sensor) check

every 1 year

41 Condition of DPF muffler

check

every 1 year

check

every 1 year

43 DPF exhaust gas temperature sensor

check

every 1 year

44 EGR and piping for gas leak

check

every 1 year

45 Radiator system

rinse

every 2 years

46 Closed breather related rubber piping

replace

every 2 years

DPF differential pressure sensor rubber replace piping (Front and back)

every 2 years

Suction pipe downstream the AFS (Air flow sensor)

replace

every 2 years

49 Boost sensor pressure rubber piping

replace

every 2 years

DPF differential pressure sensor and piping for gas leak

G-23

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM No.

Indication on hour meter

Item

50 EGR cooler hose

250

500

1000

1500

2000

3000

replace

Interval

Important

every 2 years

Interval

Important

Air conditioner No.

1 Air-conditioner condenser Outer filter 2 Air-conditioner filter

3 Air-conditioner drain 4 Air-conditioner pipes and hose

250

check

Daily check

clean



500

1000

1500

2000

3000

(every 10 hrs) 

replace clean

Inner filter

5 Refrigerant (gas)

Indication on hour meter

Item



every 50 hrs

*2 *2



every 500 hrs



every 50 hrs

*2 *2

replace



every 500 hrs

check



every 500 hrs

check

every 1 year

replace

every 2 years

check

service as required

IMPORTANT •  : First operation • *1 : When using a hydraulic hammer, change hydraulic oil and return filter according to the table on "Hydraulic Oil Change (Including Replacing of the Suction Filter and Return Filter in the Hydraulic Tank) "EVERY 1000 SERVICE HOURS" in "REGULAR CHECKS AND MAINTENANCE WORK" section. *2 : Clean and replace the air cleaner element more frequently if used under dusty conditions. When the filter is very dirty from dusty conditions, replace the filter. *3 : Service in KUBOTA dealer. • The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction. Please see the warranty Statement in detail. RY9212332GEG0014US0

G-24

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

NOTE Engine Oil: • Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures. Above 25 °C (77 °F)

SAE30 or SAE 10W-30, SAE 15W-40

0 °C to 25 °C (32 °F to 77 °F)

SAE20 or SAE 10W-30, SAE 15W-40

Below 0 °C (32 °F)

SAE10W or SAE 10W-30, SAE 15W-40

• Refer to the following table for the suitable API classification engine oil and the fuel. Engine oil classification (API classification)

Fuel used

Oil class of engines except external DPF

Ultra Low Sulfur Fuel [< 0.0015 % (15 ppm)]

CJ-4

Fuel: • Use the ultra low sulfur diesel fuel only [below 0.0015 % (15 ppm)] for these engines. • Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20 °C (-4 °F) or elevations above 1500 m (5000 ft). • Diesel fuels specified to EN 590 or ASTM D975 are recommended. • No. 2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87) • Indicated capacities of water and oil are manufacture's estimate. IMPORTANT • If you use different fuel or engine oil, the cleaning interval of the DPF (3000 hours) can't be secured and the DPF will be clogged for a shorter time than expected. RY9212134GEG0062US0

[2] OTHER ADJUSTMENTS AND REPLACEMENTS (1) Fuses CAUTION • To avoid personal injury: – When changing fuse, stop the engine and turn the key in position "STOP". RY9212038GEG0077US0

Replacing fuses 1. Detach the cover and remove the cover of the fuse box. 2. Replace the burnt out fuse with a fuse having the same capacity. (1) Cover

(2) Fuse Box RY9212332GEG0016US0

G-25

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Fuse Capacities and Circuits

(A) Fuse Box

(a) Space Fuse

[Open cab model] Fuse

Relay

(1)

Engine elements [5A]

(27)

–

(2)

Alternator [5A]

(28)

–

(3)

Control elements [5A]

(29)

Arm lock

(4)

Fuel pump [5A]

(30)

Front work lights

(5)

–

(31)

–

(6)

CRS ECU (AC) [5A]

(32)

Glow

(7)

ECU main power [20A]

(33)

Electrical outlet

(8)

Air ride seat [15A]

(34)

(9)

Attachments-2 [20A]

(35)

CRS

–

(10)

Switch (starter) [5A]

(36)

Starter

(11)

Attachment (+B) [15A]

(37)

Rear work lights

(12)

Front work lights [30A]

(38)

Horn

(13)

Solenoid [10A]

(14)

Switch (AC) [5A]

(15)

–

(16)

–

(17)

ECU (+B) [5A]

(18)

AUX electrical power [15A]

(19)

Meter (+B) [5A]

(20)

–

(21)

Arm harness [20A]

(22)

Electrical outlet [15A]

(23)

Attachments-1 [20A]

(24)

Rear work lights [15A]

(25)

Horn [10A]

(26)

–

(To be continued) G-26

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

(Continued) [Closed cab model] Fuse

Relay

(1)

Engine elements [5A]

(27)

(2)

Alternator [5A]

(28)

(3)

Control elements [5A]

(29)

Arm lock

(4)

Fuel pump [5A]

(30)

Front work lights

(5) (6)

– CRS ECU (AC) [5A]

Compressor –

(31)

Wiper

(32)

Glow

(7)

ECU main power [20A]

(33)

Electrical outlet

(8)

Air ride seat [15A]

(34)

Blower

(9)

Attachments-2 [20A]

(35)

CRS

(10)

Switch (starter) [5A]

(36)

Starter

(11)

Attachment (+B) [15A]

(37)

Rear work lights

(12)

Front work lights [30A]

(38)

Horn

(13)

Solenoid [10A]

(14)

Switch (AC) [5A]

(15)

Compressor [10A]

(16)

Blower motor [30A]

(17)

ECU (+B) [5A]

(18)

AUX electrical power [15A]

(19)

Meter (+B) [5A]

(20)

–

(21)

Arm harness [20A]

(22)

Electrical outlet [15A]

(23)

Attachments-1 [20A]

(24)

Rear work lights [15A]

(25)

Horn [10A]

(26)

Wiper [15A] RY9212332GEG0017US0

Electrical Outlet Max power is less than 120 W. If you need another auxiliary electric, contact your KUBOTA dealer for details. (1) Electrical Outlet RY9212332GEG0018US0

G-27

KiSC issued 12, 2015 A

GENERAL

SSV65, WSM

Slow Blow Fuse Layout [Open cab model] (A)

Main [60A]

(B)

Alternator [80A]

(C)

CRS [30A]

(D)

Glow CAB [60A]

[Closed cab model] (A)

Main [60A]

(B)

Alternator [100A]

(C)

CRS [30A]

(D)

Glow CAB [60A]

(1) Slow Blow Fuse RY9212332GEG0019US0

G-28

KiSC issued 12, 2015 A

1 ENGINE

KiSC issued 12, 2015 A

GENERAL CONTENTS 1. SPECIFICATIONS...................................................................................................................... 1-G1 2. DIMENSIONS ............................................................................................................................. 1-G2 3. PERFORMANCE CURVE .......................................................................................................... 1-G3

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. SPECIFICATIONS SSV65 Model

V2607-CR-TE4-SL1-Q

No. of cylinders

Cylinder Bore × Stroke

87 × 110 mm (3.4 × 4.3 in.) 2615 cm3 (159.6 cu.in.)

Total displacement Idling RPM

1250 min-1

Rated RPM

2800 min-1

Rated output/RPM

Net (ISO 8178)

47.0 kW / 2800 min-1 (63.0 HP / 2800 min-1)

Gross (SAE J 1995)

47.7 kW / 2800 min-1 (64.0 HP / 2800 min-1)

Net (ISO 8178)

221.6 N·m / 1500 min-1 (22.6 kgf·m / 1500 min-1) (163.4 lbf·ft / 1500 min-1 )

Gross (SAE J 1995)

225.0 N·m / 1500 min-1 (22.9 kgf·m / 1500 min-1) (166 lbf·ft / 1500 min-1 )

Max torque/RPM

Machine dimensions (L × W × H)

859 × 552 × 716 mm (33.8 × 21.7 × 28.2 in.)

Dry weight

295 kg (650 lbs)

Combustion type

Reentrant type, Center direct injection type (E-CDIS)

Fuel injection pump type Governor type Nozzle type

Denso common rail system

Fuel injection timing Fuel injection pressure Rotation direction

Counterclockwise viewed from flywheel side

Firing order

1-3-4-2

Compression ratio

16.8

EGR

External EGR

Compression pressure

3.2 MPa (32.6 kgf/cm2, 464 psi)

Compression pressure (allowable limit)

2.2 MPa (22.4 kgf/cm2, 319 psi)

Fuel consumption (at rated RPM)

Net (ISO 8178)

247.7 g/kW·h (184.8 g/PS·h, 0.407 lb/HP·h)

Gross(SAE J 1995)

244.1 g/kW·h (182.1 g/PS·h, 0.401 lb/HP·h)

Engine oil consumption (at rated RPM)

0.54 g/kW·h (0.40 g/PS·h) or less

Alternator

12 V (960 W)

Starter motor

12 V (2 kW)

Battery

12 V (100 Ah) RY9212332END0001US0

1-G1

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

2. DIMENSIONS V2607-CR-TE4-SL1-Q

V2607-CR-TE4-SL1-Q A

859 mm (33.8 in.)

552 mm (21.7 in.)

716 mm (28.2 in.) RY9212332END0002US0

1-G2

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

3. PERFORMANCE CURVE

(a) Engine RPM (rpm) (b) Output (kW) (c) Torque (N·m)

(d) Fuel Consumption (g/kW·h) (f) Output (HP) (e) Fuel Consumption (g/HP·h) (g) Torque (ft·lb)

A : SI Unit B : Industrial Unit of the United States RY9212332END0003US0

1-G3

KiSC issued 12, 2015 A

SERVICING CONTENTS 1. ENGINE .......................................................................................................................................1-S1 [1] RADIATOR ............................................................................................................................1-S1 (1) Removal and Installation .................................................................................................1-S1 [2] DPF MUFFLER .....................................................................................................................1-S6 (1) Removal and Installation .................................................................................................1-S6 [3] ENGINE...............................................................................................................................1-S11 (1) Removal and Installation ...............................................................................................1-S11

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. ENGINE [1] RADIATOR (1) Removal and Installation [A] Disassembly Procedures 1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Put the jack stand under the center of the rear frame. 5. Open the hood. (1) Lift Arm (2) Rear Frame

(3) Jack Stands (4) Hood RY9212332ENS0001US0

1. After opening the hood, remove the pin. (1) Pin RY9212332ENS0002US0

1. Install the pin on the lock side, and lock the hood.

CAUTION • Check that the hood is securely locked. (1) Pin RY9212332ENS0003US0

1-S1

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Remove the cover. (1) Cover RY9212332ENS0035US0

1. Remove the radiator undercover. (1) Undercover RY9212332ENS0036US0

1. Remove the radiator top cover. (1) Top cover RY9212332ENS0037US0

1. Release the A/C gas. (See, "Collection, Vacuuming and Charging" page.) 2. Remove the bolts and then remove the frame. 3. Remove the bolts and then remove the frame. (1) Frame (2) Bolt

(3) Bolt (4) Cooler hose RY9212332ENS0004US0

1. Remove the A/C condenser. (1) A/C condenser RY9212332ENS0038US0

1-S2

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Drain the coolant. RY9212332ENS0005US0

1. Remove the lower radiator hose. (1) Lower Hose RY9212332ENS0006US0

1. Remove the upper radiator hose. (1) Upper Hose RY9212332ENS0007US0

1. Remove the radiator stay. (1) Stay RY9212332ENS0039US0

1. Remove the radiator. Radiator weight

Standard spec (reference value)

7.0 kg 15 Ibs

(1) Radiator RY9212332ENS0008US0

1-S3

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

[B] Assembly Procedures 1. Install the radiator. Standard spec (reference value)

Radiator weight

7.0 kg 15 Ibs

(1) Radiator RY9212332ENS0009US0

1. Install the radiator stay. Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.2 lbf·ft

Bolt

(1) Stay

(2) Bolt RY9212332ENS0040US0

1. Install the lower radiator hose. (1) Lower Hose RY9212332ENS0010US0

1. Install the upper radiator hose. (1) Upper Hose RY9212332ENS0011US0

1. Fill the radiator with coolant. Amount of coolant

9.0 L / 2.38 gal RY9212332ENS0012US0

1-S4

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Install the A/C condenser. (1) A/C condenser RY9212332ENS0041US0

1. Assemble the cooler hose. 2. Charge the A/C gas. 3. Install the frame. Bolt (2)

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.2 lbf·ft

Bolt (3)

3.9 to 6.9 N·m 0.4 to 0.7 kgf·m 2.88 to 5.09 lbf·ft

Tightening torque

(1) Frame (2) Bolt

(3) Bolt (4) Cooler hose RY9212332ENS0042US0

1. Install the radiator top cover. (1) Undercover RY9212332ENS0044US0

1. Install the cover. (1) Cover RY9212332ENS0045US0

1. Fill the reserve tank with coolant. Amount of coolant

2.0 L / 0.53 gal RY9212332ENS0013US0

1-S5

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

CAUTION • Make sure the coolant temperature has dropped sufficiently before opening the radiator cap. Also, since the inside of the radiator is pressurized, when removing the cap, first loosen it to release the pressure before removing the cap completely. 1. Close the radiator cap, and start the engine. Idle the engine for 5 minutes, and stop. 2. Open the radiator cap after 30 minutes, and make sure the coolant reaches the specified amount. If not, add some more coolant. RY9212332ENS0064US0

[2] DPF MUFFLER (1) Removal and Installation [A] Disassembly Procedures 1. Remove the cover and top cover. (1) Cover

(2) Top cover RY9212332ENS0046US0

1. Raise the lift arm. (See the "Raise Lift Arm Procedure" page.) RY9212332ENS0014US0

1. Raise the cab. (See the "Raise Cab Procedure" page.) RY9212332ENS0015US0

1. Remove the DPF exhaust pipe. (1) DPF Exhaust Pipe RY9212332ENS0016US0

1-S6

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Remove the stay on top of the DPF. 2. Remove the bolts. (1) Stay

(2) Bolt RY9212332ENS0047US0

1. Remove the differential pressure sensor connector. (1) Differential pressure sensor connector RY9212332ENS0017US0

1. Remove the clamp and temperature sensor. (1) Temperature sensor connector (DOC inlet exhaust temperature) (T0) (2) Temperature sensor connector (DOC outlet exhaust temperature) (T1)

(3) Temperature sensor connector (DPF outlet exhaust temperature) (T2) (4) Clamp

RY9212332ENS0018US0

1. Remove the bolts and nuts from the DPF muffler. IMPORTANT • Replace used nuts with new ones. (1) Bolt

(2) Nut RY9212332ENS0048US0

1-S7

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Remove the stud bolts and gasket. IMPORTANT • Replace used stud bolts and gasket with new ones. (1) Stud bolt

(2) Gasket RY9212332ENS0062US0

1. Remove the DPF muffler. CAUTION • It takes 2 people to remove the DPF muffler because it is heavy, and it should be removed with care. • If the temperature sensor collides with the frame, this may cause damage to parts. (1) DPF Muffler RY9212332ENS0019US0

[B] Assembly Procedures 1. Install the stud bolts and gasket. Tightening torque

(1) Stud bolt

25 to 31 N·m 2.5 to 3.2 kgf·m 18 to 23 lbf·ft

Stud bolt

(2) Gasket RY9212332ENS0063US0

1. Install the DPF muffler, and temporarily tighten with the nuts. CAUTION • It takes 2 people to install the DPF muffler because it is heavy. NOTE • Tighten the nuts until they touch the DPF muffler. (1) DPF Muffler

(2) Nut RY9212332ENS0049US0

1-S8

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Temporarily tighten the DPF stay using the bolts. (1) Bolt RY9212332ENS0050US0

NOTE • When putting bolts in place temporarily, tighten them until the head touches the washer. (1) Washer (a) Gap

A : NG B : OK RY9212213ENS0001US0

1. Install the clamp and temperature sensor. (1) Temperature sensor connector (DOC inlet exhaust temperature) (T0) (2) Temperature sensor connector (DOC outlet exhaust temperature) (T1)

(3) Temperature sensor connector (DPF outlet exhaust temperature) (T2) (4) Clamp

RY9212332ENS0020US0

1. Install the differential pressure sensor and differential sensor connector. Tightening torque

9.8 to 11.3 N·m 1.0 to 1.15 kgf·m 7.23 to 8.33 lbf·ft

Bolt

(1) Differential pressure sensor (2) Differential pressure sensor connector

(3) Bolt

RY9212332ENS0021US0

1. Install the stay on the DPF and temporarily tighten it with the bolts. (1) Stay RY9212332ENS0051US0

1-S9

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

NOTE • When putting bolts in place temporarily, tighten them until the head touches the washer. (1) Washer (a) Gap

A : NG B : OK RY9212213ENS0001US0

1. Tighten the flange nuts in the indicated order. 2. Tighten the flange bolts of the DPF bracket in the indicated order. 3. Tighten the bolts for the stay in the indicated order. Tightening torque

49.0 to 55.9 N·m 5.0 to 5.7 kgf·m 36.1 to 41.2 lbf·ft

Bolts, nuts

RY9212332ENS0052US0

1. Install the DPF pipe. Tightening torque

(1) DPF pipe

49.0 to 55.9 N·m 5.0 to 5.7 kgf·m 36.1 to 41.2 lbf·ft

Bolt

(2) Bolt RY9212332ENS0053US0

1. Install the cover and top cover. (1) Cover

(2) Top cover RY9212332ENS0054US0

1-S10

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

[3] ENGINE (1) Removal and Installation 1. Jack up the machine. (See, "Jack up" page.) (1) Jack Stands RY9212332MBS0150US0

1. Remove the cab. (See, "Cab Removal and Installation" page.) RY9212332ENS0024US0

1. Remove the lift arm. (See "Lift Arm Removal/Installation" page.) RY9212332ENS0025US0

1. Remove the radiator. (See, "Assembly/Disassembly of the radiator" page.) RY9212332ENS0055US0

1. Remove the HST pump. (See, "Assembly/Disassembly of the HST Pump" page.) RY9212332ENS0056US0

1-S11

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Remove the return filter line hose. (1) Return filter RY9212332ENS0057US0

1. Remove the lower oil cooler hose. (1) Lower Hose RY9212332ENS0026US0

1. Remove the fan motor hose. (1) Fan motor RY9212332ENS0058US0

1. Remove the fuel cooler hose. (1) Fuel cooler RY9212332ENS0059US0

1. Disconnect the fuel hoses on the supply pump side. IMPORTANT • Between the fuel filter and supply pump • Between the supply pump and fuel tank • Plug the disconnected hoses. • Remove the fuel hose mounting bracket if necessary. (1) Fuel Filter (2) Supply Pump

(3) Fuel Tank RY9212332ENS0061US0

1-S12

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Loosen the hose clamp on the air cleaner and detach the air intake hose from the intake manifold. (1) Air cleaner RY9212332ENS0060US0

1. Use a shackle to hook a nylon sling on the top side (left and right) of the upper frame. 2. Hang the nylon sling on the rear-side pin, and while supporting with a crane, remove the bolts, and lift the upper frame to remove. IMPORTANT • During installation, tighten the mounting bolts for the upper frame in the order indicated on the left. NOTE • If the nylon sling is in contact with other parts, use a rag to protect the parts while carrying out the work. • The task of disassembling and assembling the upper frame must be carried out by at least two persons. Factory specification (reference value)

Upper frame weight

Bolt (2)

259.9 to 304.0 N·m 26.5 to 31.0 kgf·m 191.7 to 224.2 lbf·ft

Bolt (6)

519.8 to 568.8 N·m 53.0 to 58.0 kgf·m 383.4 to 419.5 lbf·ft

Tightening torque

(1) (2) (3) (4) (5) (6)

350.5 kg 772.7 lbs

Upper frame Bolt Nylon sling Shackle Pin Bolt

(A) (B) (C) (D) (E)

Front Right side Left side Left bottom Right bottom RY9212332ENS0027US0

1. Remove the bolt and the cooler hose. Tightening torque

(1) Bolt

Bolt

7.9 to 11.8 N·m 0.8 to 1.2 kgf·m 5.8 to 8.7 lbf·ft (2) Cooler Hose RY9212332ENS0028US0

1-S13

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Remove the heater hose. (1) Heater Hose RY9212332ENS0029US0

1. Remove the connectors of the engine. (501) Intake Air Heater Connector (CN501) (502) Intake Air Temperature Sensor Connector (CN502) (503) EGR Valve Connector (CN503) (504) Camshaft Position Sensor Connector (CN504) (505) SCV (Suction Control Valve) Connector (CN505) (506) Fuel Temperature Sensor Connector (CN506) (507) Starter Motor Connector (CN507) (508) Starter Motor +B Terminal (CN508) (509) Engine Oil Pressure Sensor Connector (CN509) (510) Rail Pressure Sensor Connector (CN510) (511) Alternator Connector (CN511) (512) Alternator +B Terminal (CN512) (513) Crankshaft Position Sensor Connector (CN513) (514) Boost Pressure Sensor Connector (CN514) (515) Injector Connector (CN515) A : Engine Left Side B : Engine Back Side RY9212213ENS0136US0

1. Remove the bolt and disconnect the ground code. Ground Bolt (1)

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.2 lbf·ft

Bolt (3)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Tightening torque

(1) Ground Bolt (2) Ground Code

(3) Bolt RY9212332ENS0030US0

1-S14

KiSC issued 12, 2015 A

ENGINE

SSV65, WSM

1. Remove the front stopper bolts and nuts. 2. Remove rubber mount.

Tightening torque

Nut

166.7 to 191.2 N·m 17 to 19.5 kgf·m 123 to 141 Ibf·ft

Stud bolt

98 to 113 N·m 10 to 11.5 kgf·m 72.3 to 83.2 Ibf·ft

Stopper bolt

259.9 to 304.0 N·m 26.5 to 31.0 kgf·m 191.7 to 224.2 Ibf·ft

On assembly, apply adhesive (Loctite 263) to the bolts. (1) Nut (2) Stud Bolt

(3) Stopper Bolt (4) Rubber Mount RY9212332ENS0031US0

1. Remove the nuts of the rear-side stud bolts. 2. Remove the anti-vibration rubber. Nut

166.7 to 191.2 N·m 17 to 19.5 kgf·m 123 to 141 lbf·ft

Stud bolt

98 to 113 N·m 10 to 11.5 kgf·m 72.3 to 83.2 lbf·ft

Tightening torque

Apply a thread lock (Loctite® 263) to the bolts during assembly. IMPORTANT • Replace used nuts with new ones. (1) Nut (2) Stud bolt

(3) Anti-vibration rubber (4) Plate RY9212332ENS0032US0

1. Pull out the engine slowly and put the engine. NOTE • Adjust the nylon sling length to keep the engine level. Hoist the engine slowly by crane without any interference with other parts. • When pull out the engine, do not hit oil pan to any other parts. Engine weight (1) Engine (2) Bracket

Standard specification (reference value)

325 kg 716 lbs

(3) Nylon Sling RY9212332ENS0034US0

1-S15

KiSC issued 12, 2015 A

2 MACHINE BODY

KiSC issued 12, 2015 A

SERVICING CONTENTS 1. FRONT ........................................................................................................................................2-S1 [1] CAB TILT...............................................................................................................................2-S1 [2] LIFT ARM STOPPER ............................................................................................................2-S3 [3] JACK UP ...............................................................................................................................2-S5 [4] DISASSEMBLY AND ASSEMBLY OF LIFT ARM, LINK AND LINK (CONTROL) ................2-S7 [5] INSTALL THE VACUUM PUMP ..........................................................................................2-S10 [6] MECHANICAL QUICK HITCH.............................................................................................2-S11 [7] HYDRAULIC QUICK HITCH (OPTION) ..............................................................................2-S12 (1) Removal and Installation ...............................................................................................2-S13 [8] FRONT PINS AND BUSHES ..............................................................................................2-S15 (1) Assembling ....................................................................................................................2-S17 2. UPPER STRUCTURE ...............................................................................................................2-S18 [1] ROPS (CABIN) ....................................................................................................................2-S18 (1) Removal and Installation ...............................................................................................2-S18 [2] WINDSHIELD ......................................................................................................................2-S22 (1) Disassembly/Assembly..................................................................................................2-S22 [3] SEAT BAR ...........................................................................................................................2-S30 [4] SEAT AND SEATBELT .......................................................................................................2-S31 3. LOWER CHASSIS LAYOUT .....................................................................................................2-S32 [1] FUEL TANK.........................................................................................................................2-S32 (1) Removal and Installation ...............................................................................................2-S32 [2] REAR HOOD .......................................................................................................................2-S33 (1) Removal and Installation ...............................................................................................2-S33 [3] HYDRAULIC OIL TANK ......................................................................................................2-S35 (1) Removal and Installation ...............................................................................................2-S35 [4] AXLE SHAFT.......................................................................................................................2-S37 (1) Components ..................................................................................................................2-S37 (2) Disassembly/Assembly..................................................................................................2-S37 (3) Special Tools .................................................................................................................2-S41 [5] SPROCKET .........................................................................................................................2-S42 (1) Removal and Installation ...............................................................................................2-S42

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. FRONT [1] CAB TILT Tilting up the CAB For inspection and maintenance, the CAB is designed so that it can be tilted up. WARNING • To avoid personal injury or death: – Raising or lowering the cab while the engine is running may cause the machine to move, and cause serious injury or death. Place the machine on a firm, flat and level surface, lower the lift arms slowly to the ground and stop the engine before raising or lowering the cab. – When the cab is tilted up, support it firmly with the stopper to prevent it from falling. – Do not enter beneath the cab, while raising or lowering the cab. – More than one person may be needed to tilt the cab. Raising (Tilt up) 1. Select a firm, level surface, lower the lift arms fully to the ground, and stop the engine. 2. Set the armrest to the "RAISED" position. 3. Put the jack stands under the rear corners of the frame. 4. Remove the lock bolts from the front of the machine. (1) Lift Arm (2) Jack Stands

(3) Lock Bolt RY9212332MBS0137US0

5. Slowly raise the cab until the cab is all the way up and the latching mechanism engages. 6. Set the stopper lock to the lock position.

(1) Cab (2) Stopper (3) Stopper Lock

(a) RAISE (b) ENGAGE (c) LOCK RY9212332MBS0138US0

2-S1

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

Lowering (Tilt down) 1. Set the stopper lock to the release position. 2. Support the cab and release the latching mechanism. 3. Lower the cab slowly all the way down. 4. Tighten the lock bolts with correct tightening torque and reinsert. 5. Remove the jack stands under the rear corners of the frame, Tightening torque (1) Stopper Lock (2) Stopper (3) Lock Bolt

Lock bolt

77.5 to 90.2 N·m 57.2 to 66.5 lbf·ft (a) RELEASE

RY9212332MBS0139US0

2-S2

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[2] LIFT ARM STOPPER WARNING • To avoid personal injury or death: – Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm stopper. 1. You can perform machine maintenance with the lift arm in the lowered position. If the lift arm must be raised, use the following method. 2. Installing • Park the machine on level and firm ground and lower the lift arms fully to the ground. Remove the front attachment. • Stop the engine. • Put the jack stands under the rear corners of the frame. • The second person should remove the lift arm stopper from the storage position. • Start the engine and set the parking brake switch to the parking position. • Slowly raise the lift arms to the maximum height and stop the engine. Operator must stay in the operator seat with the seat belt fastened. • The second person must install the lift arm stopper. Place the top (dented) of lift arm stopper upward and cover the rod with the stopper from front. Using one of the knob bolts, secure the stopper in position. • Start the engine and set the parking brake switch to the parking position. • Slowly lower the lift arms against the lift arm stopper. (1) Lift Arm (2) Jack Stands

(3) Lift Arm Stopper (4) Knob Bolt RY9212332MBS0128US0

2-S3

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

IMPORTANT • Make sure that the dent on top the lift arm stopper fits the round part of the lift arm cylinder and that the bottom of lift arm stopper fits the flat top of arm cylinder tube. No gap is allowed in both locations. 3. Removing • The operator should be in the operator's seat with the seat belt fastened. • Start the engine and set the parking brake switch to the parking position. • Slowly raise the lift arms to the maximum height and stop the engine. • The second person must remove the lift arm stopper. • Start the engine and lower the lift arms fully to the ground and stop the engine. • Return the lift arm stopper to the storage position and secure with the a knob bolt. (1) Lift Arm Stopper

A : "FIT" RY9212332MBS0129US0

2-S4

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[3] JACK UP •

• • •

DANGER When you need to access the underside of the machine for maintenance purposes, but sure to support the machine with a safety stand. Getting under the machine while supporting the machine by machine's own hydraulic cylinder or using a hydraulic jack can be extremely dangerous in the event of a hydraulic fluid leakage or similar mishap. Before starting the engine, always sit in the driver's seat and make sure the area is safe and clear. As it is dangerous, never start the engine from anywhere but the driver's seat. Always check and make sure control lever(s) are not engaged before starting the engine. RY9212332MBS0126US0

2-S5

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

WARNING • Perform work with 2 or more people. • After lowering the machine onto the jack stands, ensure the machine is securely stationed on the jack stands. If the machine is not securely stationed, move to another location where you can ensure that the machine will be securely stationed on the jack stands. 1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Lift the front of the machine, station the jack stands in the front corners. 5. Lower the front of the machine on the jack stands. 6. Lift the back of the machine, station the jack stands in the rear corners. 7. Lower the back of the machine on the jack stands. (1) Jack stand RY9212332MBS0127US0

2-S6

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[4] DISASSEMBLY AND ASSEMBLY OF LIFT ARM, LINK AND LINK (CONTROL) 1. Jack up the machine. (See, "Jack up" page.) (1) Jack Stands RY9212332MBS0150US0

1. Remove the cab. (See, "Cab Removal and Installation" page.) RY9212332ENS0024US0

1. Remove the bolts from linkage (left and right), and remove the hose guides (left and right). Tightening torque

(1) Linkage (2) Bolt

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt

(3) Hose Guide RY9212332MBS0003US0

1. Remove the hose clamp. 2. Remove the hydraulic host and plug in. (1) Hose clamp

(2) Hose RY9212332MBS0004US0

2-S7

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the hydraulic host and plug in. (1) Hose RY9212332MBS0064US0

1. Remove the hydraulic host and plug in. (1) Hose RY9212332MBS0065US0

1. Remove the level valve and plug in. (1) Hose RY9212332MBS0005US0

1. Remove the connector. (1) Connector RY9212332MBS0105US0

1. Remove the self-locking nut on the lift arm cylinder (head side, left and right), and remove the bolt. (1) Bolt

(2) Self-Locking Nut RY9212332MBS0006US0

2-S8

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the internal circlips (left and right), and remove the control link pins (left and right). 2. Remove the lift arm cylinder pins (left and right). (1) Internal circlip (2) Pin

(3) Pin RY9212332MBS0007US0

1. Remove self-locking nut from link (left and right), and remove bolt (left and right). (1) Link (2) Self-Locking Nut

(3) Bolt RY9212332MBS0008US0

1. Hang the front-side nylon sling of the lift arm. 2. Hang the nylon sling on the rear-side bar, and while supporting with a crane, remove the pins (left and right), and lift the lift arm assembly to remove. NOTE • If the nylon sling is in contact with other parts, use a rag to protect the parts while carrying out the work. • The task of removing the right bonnet must be carried out by at least two persons. Lift arm weight (bucketless)

Factory spec (reference value)

(1) Lift arm (2) Nylon sling

302 kg 666 lbs

(3) Pin RY9212332MBS0009US0

1. Secure a nylon sling to linkage, and support with a crane. 2. Remove bolts and a bracket with air cleaner. (Right side only) 3. Remove self-locking nut (left and right) and bolt (left and right). 4. Remove pin (left and right), and gently hoist linkage. NOTE • The photograph shows removal of linkage (right side); linkage is removed from the left side by the same procedure. Linkage weight

Tightening torque

(1) (2) (3) (4)

Linkage Nylon Sling Bolt Bracket

Factory specification (reference value)

Bolt (3)

16.5 kg 36.4 lbs 48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

(5) Self-Locking Nut (6) Bolt (7) Pin RY9212332MBS0010US0

2-S9

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

Self-locking nut installation measurement NOTE • When installing the self-locking nut, you must assure a gap (a) with the boss. (a) Gap (1.0 to 3.0 mm, 0.04 to 0.12 in.) RY9212038MBS0012US0

[5] INSTALL THE VACUUM PUMP 1. Remove the front attachment. 2. Park the machine in a flat hard location. 3. Lower the lift arm all the way down. (1) Lift Arm RY9212332MBS0122US0

1. Remove the oil plug. 2. Install the vacuum pump plug. (1) Oil Plug RY9212332MBS0123US0

1. Open the cab. (See, "Cab Tilt" page.) 2. Remove the breather filter. 3. Put a cover on the block. (1) Breather Filter

(2) Block RY9212332MBS0124US0

1. Set the vacuum pump. RY9212332MBS0125US0

2-S10

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[6] MECHANICAL QUICK HITCH

No.

Parts Name

Q'ty

Hitch (quick)

(2)

Handle (LH)

Mechanical quick hitch version

(3)

Handle (RH)

Mechanical quick hitch version

(4)

Spring (handle)

(5)

Bolt

(6)

Nut

(7)

Plane washer

(8)

Pin (hitch)

(9)

Spring (link)

(10)

Linkage (hitch)

(11)

Stopper (hitch)

(12)

Snap nut

(13)

Plane washer

(14)

Nut

(15)

Reamer bolt (M10)

(16)

Snap nut

(17)

Grease nipple

• • • • •

Remarks

(1)

NOTE (a): Apply grease to the pin, for smoothness of assembly. (b): For protecting the bolt from rotation, bolt head should contact with the groove of the hitch. (c): Bolt head should be inside of the hitch. (d): Gap: 0.5 to 1.5 mm (0.02 to 0.059 in.) (e): Spring set length: 78.5 ± 0.5 mm (3.09 ± 0.02 in.) RY9212332MBS0130US0

2-S11

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[7] HYDRAULIC QUICK HITCH (OPTION)

No.

Parts Name

Q'ty

Remarks

(1)

Hitch (quick)

(2)

Arm (LH, hydraulic quick hitch)

Hydraulic quick hitch version only Hydraulic quick hitch version only

(3)

Arm (RH, hydraulic quick hitch)

(4)

Spring (handle)

(5)

Bolt

(6)

Nut

(7)

Plane washer

(8)

Pin (hitch)

(9)

Spring (link)

(10)

Linkage (hitch)

(11)

Stopper (hitch)

(12)

Snap nut

(13)

Plane washer

(14)

Nut

(15)

Reamer bolt (M10)

(16)

Snap nut

(17)

Grease nipple

(18)

Cylinder, assy (hitch)

Hydraulic quick hitch version only

(19)

Plane washer

Hydraulic quick hitch version only

(20)

Nut

Hydraulic quick hitch version only

• • • • •

2-S12

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

(1) Removal and Installation 1. Remove the front attachment. 2. Switch the quick hitch to the dump end. (1) Lift Arm

(2) Quick Hitch RY9212332HYS0016US0

1. Remove the quick hitch cylinder hose. (1) Quick hitch cylinder

(2) Hose RY9212332HYS0017US0

1. Remove the bucket cylinder bolts, and remove the guide. 2. Remove the pin. Tightening torque

(1) Bucket cylinder (2) Bolt

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Bolt

(3) Guides (4) Pin RY9212332HYS0027US0

2-S13

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the detent nuts and then remove the bolts.

NOTE • When assembling the detent nuts, ensure to maintain gap (a) with the boss. (1) Detent nut (2) Bolt

(a) 1 to 3 mm RY9212332MBS0107US0

1. Remove the pin. (1) Pin RY9212332MBS0106US0

1. Remove the quick hitch. Quick hitch weight

Factory specification (reference value)

74.9 kg 165 lbs

(1) Quick hitch RY9212332MBS0109US0

2-S14

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[8] FRONT PINS AND BUSHES

(a) Pin Diameter (b) Pin Length (c) Bush Internal Diameter

(d) Bush External Diameter (e) Bush Length (f) Bolt Diameter

(g) Bolt Length (h) 1 to 3 mm (0.04 to 0.12 in.) (i) Hitch Side

(j)

Pin Side

(A) Punch mark is positioned in the center.

Pin (diameter × length)

Bush (internal diameter × external diameter × length)

Bolt (diameter × length)

(1)

38 × 231 mm (1.5 × 9.09 in.)

38 × 47 × 74 mm (1.5 × 1.8 × 2.9 in.)

10 × 100 mm (0.39 × 3.94 in.)

(2)

38 × 131 mm (1.5 × 5.16 in.)

38 × 47 × 74 mm (1.5 × 1.8 × 2.9 in.)

10 × 90 mm (0.39 × 3.54 in.)

(3)

38 × 231 mm (1.5 × 9.09 in.)

38 × 47 × 50 mm (1.5 × 1.8 × 1.97 in.)

10 × 90 mm (0.39 × 3.54 in.)

(4)

38 × 135 mm (1.5 × 5.31 in.)

38 × 47 × 50 mm (1.5 × 1.8 × 1.97 in.)

10 × 100 mm (0.39 × 3.94 in.)

(5)

44.5 × 135 mm (1.75 × 5.31 in.)

44.5 × 54 × 25 mm (1.75 × 2.1 × 0.98 in.)

10 × 135 mm (0.39 × 5.31 in.)

(6)

44.4 × 62 mm (1.74 × 2.44 in.)

44.5 × 54 × 25 mm (1.75 × 2.1 × 0.98 in.)

–

(7)

44.4 × 242.5 mm (1.74 × 9.55 in.)

44.5 × 54 × 55 mm (1.75 × 2.1 × 2.17 in.)

12 × 80 mm (0.47 × 3.15 in.)

(8)

38 × 174 mm (1.5 × 6.85 in.)

38 × 47 × 50 mm (1.5 × 1.8 × 1.97 in.)

10 × 25 mm (0.39 × 0.98 in.)

(9)

38 × 100 mm (1.5 × 3.94 in.)

38 × 47 × 40 mm (1.5 × 1.8 × 5.06 in.)

12 × 25 mm (0.47 × 0.98 in.)

Remarks

With dust seal

RY9212332MBS0132US0

2-S15

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM (1) (2) (3) (4) (5) (6) (7) (8) (9)

Frame - Linkage Linkage - Lift Arm Frame - Lift Arm Cylinder (Bottom) Lift Arm - Lift Arm Cylinder (Rod) Frame - Control Link Lift Arm - Control Link Lift Arm - Quick Hitch Lift Arm - Bucket Cylinder (Bottom) Quick Hitch - Bucket Cylinder (Rod) RY9212332MBS0133US0

(a) Pin (b) Bushing (c) Bolt

(d) Snap Nut (e) Grease Nipple

(f) Internal Circlip (g) Shim

(h) Plate (i) Dust Seal RY9212332MBS0134US0

2-S16

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

(1) Assembling Use a patch to insert the bush. IMPORTANT • Always use a patch to cover the bush. • The bush must be lined with the both side. (a) Bush (b) Insert

Insert the dust seal. IMPORTANT Pay attention to the direction of the dust seal. RY9212332MBS0141US0

Dust seal enlarged view (a) (b) (c) (d)

Dust Seal (e) Inner Side Bush (f) Outer Side Bucket Cylinder (Rod) The dust seal must be lined with the boss edge face. RY9212332MBS0142US0

2-S17

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

2. UPPER STRUCTURE [1] ROPS (CABIN) (1) Removal and Installation 1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Put the jack stands under the rear corners of the frame. (1) Lift Arm

(2) Jack Stands RY9212332MBS0144US0

1. Remove the cover behind the seat. Tightening torque

1.47 to 1.96 N·m 0.15 to 0.20 kgf·m 1.08 to 1.45 lbf·ft

Bolt

(1) Cover

(2) Bolt RY9212332MBS0066US0

1. Remove the main harness connection connector. (1) Connector RY9212332MBS0013US0

1. Remove the cab mounting bolts. Tightening torque

(1) Cab

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Bolt

(2) Bolt RY9212332MBS0014US0

2-S18

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Put the eyebolts on the cab, and tighten them with the nuts. 2. Secure the nylon sling, slowly raise the cab until the cab is all the way up and the latching mechanism engages. CAUTION • Use the crane to lift the cab until the stopper lock of gas cylinder operates, and only begin work after first checking that the stopper lock is definitely operational. 3. Set the stopper lock to the lock position. (1) (2) (3) (4) (5) (6) (7)

Cab Eyebolt Nut Nylon Sling Gas Cylinder Stopper Stopper Lock

(a) LOCK

RY9212332MBS0145US0

[ Closed cab model ] 1. Release the A/C gas. (See, "Collection, Vacuuming and Charging" page.) 2. Before removing the heater hose, wait until the water temperature drops, and then drain the coolant. 3. Remove the cooler hose. 4. Remove the heater hose. 5. Pull the main harness out from the cab hole. (1) Cooler Hose (2) Heater Hose

(3) Main Harness RY9212332MBS0016US0

1. While supporting the cab with the crane, remove the split pin of the gas cylinder, and remove the pin. (1) Gas Cylinder (2) Split Pin

(3) Stopper Pin (4) Pin RY9212332MBS0017US0

2-S19

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the gas cylinder assy. (1) Gas Cylinder

(a) Raise RY9212332MBS0147US0

1. Gradually lower the cab with the crane. (1) Cab RY9212332MBS0018US0

1. Pass the nylon sling through the eyebolts, and put it to the crane hook. 2. Lift it with the crane until the nylon sling becomes straight. (1) Eyebolt (2) Nut (3) Nylon Sling

(4) Hook (5) Crane RY9212332MBS0148US0

2-S20

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the split pin. 2. Remove the pin. (1) Split Pin

(2) Pin RY9212332MBS0149US0

1. Gently raise the cab and remove. Cab weight (1) Cab

Factory specification (reference value) (2)

177 kg 390 lbs

Nylon Sling RY9212332MBS0019US0

2-S21

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[2] WINDSHIELD (1) Disassembly/Assembly [A] Assembly Procedures 1. Apply primer 69 of the frame. IMPORTANT • Take care to apply primer 69 in the correction locations. Primer 69 (Made by SUNRISE MSI Co. Ltd.)

Primer Application Location (1) Frame (a) 585 mm (23.0 in.) (b) 880 mm (34.6 in.) (c) 145 mm (5.71 in.)

A: B: C: D:

Right Bottom Left Top RY9212332MBS0020US0

1. Install the left and right handrails to the frame. (1) Handrail

(2) Frame RY9212332MBS0022US0

1. Assemble the lock assembly and lever assembly on the frame, and temporarily tighten the bolts. IMPORTANT • Install so the cable assembly wrapped with white tape is on the left. (1) Frame (2) Lock assembly (3) Lever assembly

(a) White tape

RY9212332MBS0023US0

2-S22

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Adjust and install the roller on the handle assembly. IMPORTANT • Adjust so the height (a) of the roller of the handle assembly is 21 ± 0.5 mm (0.827 ± 0.019 in.). Tightening torque

(1) Handle, ASSY (2) Roller

7.8 to 9.3 N·m 0.8 to 0.95 kgf·m 5.8 to 6.9 lbf·ft

Nut

(a) 21 ± 0.5 mm (0.827 ± 0.019 in.) RY9212332MBS0025US0

1. Assemble the packing, pad, and handrail on the glass. (1) Handrail (2) Glass

(3) Packing (4) Pad RY9212332MBS0028US0

1. Install the handle assembly on the glass. (1) Glass

(2) Handle, ASSY RY9212332MBS0029US0

1. Assemble the gasket and collars on the glass. (1) Glass (2) Gasket

(3) Collar (4) Collar RY9212332MBS0030US0

2-S23

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Install the plate and the handle on the glass. (1) Glass (2) Plate

(3) Handle RY9212332MBS0031US0

1. Affix seals to the top (A), right (B), left (C) and bottom (D) of the glass. IMPORTANT • Be careful to position seals correctly. (1) Glass

(2) Seal RY9212332MBS0032US0

Installation Positioning (1) Seal (2) Seal (3) Seal A: B: C: D:

Top Right Left Bottom

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

17 mm (0.67 in.) 585 mm (23.0 in.) 117.5 mm (4.626 in.) 110 mm (4.33 in.) 880 mm (34.6 in.) 13 mm (0.51 in.) 337.5 mm (13.29 in.) 145 mm (5.71 in.) 786 mm (30.9 in.) 30 mm (1.2 in.) RY9212332MBS0033US0

1. After installing them, apply primer 39 along the seals. IMPORTANT • Primer 39 runs easily, so do not apply too much. Primer 39 (Made by SUNRISE MSI Co. Ltd.)

Primer 39 Application Location (1) Seal (2) Seal

(a) (b) (c) (d)

Right Left Top Bottom RY9212332MBS0034US0

2-S24

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Apply SR sealant 99 to the primer 39. Sunrise MSI SR sealant U99 (1) Seal RY9212332MBS0035US0

1. Assemble the frame on the glass. IMPORTANT • Set a gap (a) of 5 mm (0.197 in.) between the frame and glass. (1) Glass (2) Frame

(a) 5 mm (0.197 in.) RY9212332MBS0036US0

1. Fit the rubber seal in the frame. 2. Assemble the lever assembly on the handle. (1) Lever assembly (2) Frame

(3) Rubber seal RY9212332MBS0037US0

Enlarged view (1) Glass (2) Frame

(3) Rubber Seal RY9212332MBS0062US0

1. Install the cover on the glass. Tightening torque

(1) Glass (2) Cover

1.47 to 1.96 N·m 0.15 to 0.20 kgf·m 1.09 to 1.44 Ibf·ft

Bolt

(3) Bolt RY9212332MBS0039US0

2-S25

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Install the motor ASSY on the glass. Tightening torque

2.94 to 3.92 N·m 0.3 to 0.4 kgf·m 2.17 to 2.89 lbf·ft

Nut

(1) Glass

(2) Motor ASSY RY9212332MBS0040US0

1. Install the blade ASSY and the arm ASSY to the motor ASSY. Tightening torque

6.37 to 9.32 N·m 0.65 to 0.95 kgf·m 4.70 to 6.87 lbf·ft

Nut

(1) Blade ASSY (2) Arm ASSY

(3) Motor ASSY RY9212332MBS0041US0

1. Install the bushing and brackets to the linkage. Tightening torque

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt

(1) Bushing (2) Bolt

(3) Linkage (4) Bracket RY9212332MBS0042US0

1. Install the damper to the linkage. IMPORTANT • The stud to the damper is fragile, so take care not to bend it. Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Stud

Enlarged view (1) Stud (2) Damper

(3) Linkage RY9212332MBS0043US0

2-S26

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Install the brackets and the damper to the linkage to the front of the cab. Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

(1) Stud (2) Damper (3) Bracket

(4) Bolt (5) Linkage RY9212332MBS0044US0

1. Install the left and right cushions and strikers to the front of the cab. Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

(1) Cushion (2) Striker

(3) Bolt RY9212332MBS0045US0

1. Assemble the striker on the rear of the cab, and temporarily tighten the bolts. (1) Striker

(2) Bolt RY9212332MBS0046US0

1. Install the linkage to the frame. Tightening torque

(1) Linkage

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt

(2) Frame RY9212332MBS0047US0

1. Install the brackets to the frame and screw the bolts in loosely. (1) Bolt (2) Frame

(3) Bracket RY9212332MBS0048US0

2-S27

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Install the left and right lock assemblies to the front of the cab. IMPORTANT • After installing them, check and make sure the locks engage securely with the lock assemblies when the windshield is opened. • When the windshield is open and in the locked position, check and make sure there is no rattling up and down. Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

(1) Lock ASSY

(2) Bolt RY9212332MBS0050US0

1. Install the brackets to the frame. IMPORTANT • After tightening the bolts, check and make sure the windshield opens and closes smoothly. Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

(1) Bolt (2) Frame

(3) Bracket

Checking the Windshield Opens and Closes RY9212332MBS0049US0

1. Install the lock assemblies to the frame. IMPORTANT • When tightening bolt, make sure the locks engage securely with the strikers. Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 Ibf·ft

Bolt

Enlarged View of Front (1) Bolt (2) Lock ASSY

(3) Frame (4) Striker RY9212332MBS0057US0

2-S28

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Tighten the striker to the rear of the cab. IMPORTANT • When tightening bolt, make sure the lock engages securely with the striker. Tightening torque

Bolt

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Enlarged View of Rear (1) Striker (2) Bolt

(3) Lock ASSY RY9212332MBS0059US0

1. Adjust, then tighten the lock assemblies to the frame. IMPORTANT • Make sure there is no slack in the cables (a) to the lock assemblies when the bolts are tightened. • After tightening bolt, check and make sure the lever of the lock is engaged in the notch in the stopper (b). Bolt

7.8 to 9.3 N·m 0.8 to 0.95 kgf·m 5.9 to 6.9 lbf·ft

Bolt

4.0 to 6.0 N·m 0.41 to 0.61 kgf·m 3.0 to 4.4 lbf·ft

Tightening torque

(1) Bolt (2) Bolt (3) Lock ASSY

(a) Cable (b) Stopper RY9212332MBS0061US0

2-S29

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[3] SEAT BAR

(a) Lock Release Range 20 ± 5 ° (c) 27 mm (1.06 in.) (Reference (d) Margin of the both R and L (b) Grease Application Value) height at the end. 0 ± 2 mm (0 ± 0.078 in.) No.

Parts Name

(e) Pay attention the direction.

Q'ty LH

Holder (guard, armrest LH)

–

(2)

Holder (guard, armrest RH)

–

(3)

Armrest (LH)

–

(4)

Armrest (RH)

–

(5)

Linkage (armrest LH)

–

(6)

Linkage (armrest RH)

–

(1)

(7)

Bushing

(8)

Magnet (brake linkage)

(9)

Bolt (with washer, M5)

(10)

Flange nut

(11)

Spring (armrest LH)

–

(12)

Spring (armrest RH)

–

(13)

Snap pin

(14)

Pin (armrest)

(15)

Snap pin

(16)

Switch (brake linkage)

(17)

Screw with washer

(18)

Bolt

(19)

Nut

(20)

Bolt

2-S30

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

Switch (brake linkage) mounting bolt (M5) (16)

2.4 to 3.0 N·m 0.24 to 0.31 kgf·m 1.8 to 2.2 lbf·ft

Bolt (18) (20)

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.2 lbf·ft

Tightening torque

RY9212332MBS0135US0

[4] SEAT AND SEATBELT Seat mounting bolt

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.2 lbf·ft

Seatbelt mounting bolt

34 to 41 N·m 3.5 to 4.1 kgf·m 25 to 30 lbf·ft

Tightening torque

Seatbelt mounting angle (a) (1) Seat (2) Seat Mounting Bolt (3) Seatbelt

Factory Specification

60 °

(a) Seatbelt Mounting Angle

RY9212332MBS0136US0

2-S31

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

3. LOWER CHASSIS LAYOUT [1] FUEL TANK (1) Removal and Installation 1. Lower the lift arm fully to the ground. 2. Put the jack stand under the center of the rear frame. 3. Open the hood. (1) Lift Arm (2) Rear Frame (3) Jack Stands

(4) Hood (5) Drain Hose (6) Plug RY9212332MBS0146US0

1. Remove the drain plug and release the fuel. RY9212332MBS0110US0

1. Remove all hoses from the fuel tank. 2. Remove the fuel sensor and backup buzzer connectors. (1) Fuel hose (2) Fuel sensor connector

(3) Backup buzzer connector RY9212332MBS0111US0

1. Remove the fuel tank stay and bracket. Bolt (1)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt (2)

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.4 to 20.2 lbf·ft

Tightening torque

(1) Bolt (2) Bolt

(3) Bracket (4) Stay RY9212332MBS0112US0

1. Remove the fuel tank. (1) Fuel tank RY9212332MBS0113US0

2-S32

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[2] REAR HOOD (1) Removal and Installation 1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Put the jack stand under the center of the rear frame. 5. Open the hood. (1) Lift Arm (2) Rear Frame

(3) Jack Stands (4) Hood RY9212332ENS0001US0

1. Remove the clamp. (1) Clamp RY9212332MBS0120US0

1. Remove the fuel tank. (See "Fuel Tank Removal and Installation" page.) RY9212332MBS0121US0

2-S33

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Secure a nylon sling to the hood, and support with a crane. 2. While supporting with the crane, remove the bolts and nuts, and remove the hood. Hood weight (1) Hood (2) Nylon Sling

Standard spec (reference value)

45.8 kg 101 lbs

(3) Bolt (4) Nut RY9212332MBS0119US0

2-S34

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[3] HYDRAULIC OIL TANK (1) Removal and Installation 1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Put the jack stand under the center of the rear frame. 5. Open the hood. (1) Lift Arm (2) Rear Frame

(3) Jack Stands (4) Hood RY9212332ENS0001US0

1. Remove the drain plug from the oil drain hose and drain all oil. (1) Plug

(2) Drain Hose RY9212332MBS0114US0

2-S35

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the return filter line hose and line. 2. Remove all hoses from the hydraulic oil tank. Tightening torque

62.8 to 72.6 N·m 6.4 to 7.4 kgf·m 46.4 to 53.5 lbf·ft

Bolt

(1) Return filter (2) Hydraulic oil tank

(3) Bolt RY9212332MBS0115US0

1. Remove the mounting bolts and stay from the hydraulic oil tank. Tightening torque

(1) Stay

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

(2) Bolt RY9212332MBS0117US0

1. Remove the hydraulic oil tank. (1) Hydraulic oil tank RY9212332MBS0116US0

2-S36

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[4] AXLE SHAFT (1) Components

No.

Part Name

Q'ty

(1)

O-Ring

Part Name

Q'ty 1

Remarks

(6)

Taper Roller Bearing

(2)

External Circlip

(7)

Internal Circlip

(3)

Shim

(8)

Oil Seal

(4)

UBS Nut

(9)

Shaft

(5)

Case

(10)

Bolt

Remarks

RY9212332MBS0143US0

(2) Disassembly/Assembly [A] Disassembly 1. Remove the external circlip. (1) External Circlip RY9212332MBS0067US0

1. Remove the shim. (1) Shim RY9212332MBS0068US0

2-S37

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the shaft from the case. (1) Case

(2) Shaft RY9212332MBS0069US0

1. Remove the clip. (1) Clip RY9212332MBS0070US0

1. Remove the bearing collar.

Enlarged view (1) Collar RY9212332MBS0071US0

1. Remove the bearing. (1) Bearing

(a) Gear puller GL-12 (b) Bearing separator BS-2 RY9212332MBS0073US0

2-S38

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the oil seal. (1) Oil Seal RY9212332MBS0074US0

[B] Assembly 1. Apply molybdenum to the bearing, and then install the bearing. (1) Bearing

(a) Bearing, oil seal press-fit tool RY9212332MBS0075US0

1. Install the clip. (1) Clip RY9212332MBS0076US0

1. Apply grease to the oil seal, and then install the oil seal. IMPORTANT • Make sure the oil seal is facing the right way when installing it. (1) Oil seal

(a) Bearing, oil seal press-fit tool RY9212332MBS0077US0

2-S39

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Apply molybdenum to the shaft, and then install it in the case. (1) Shaft (2) Case

(a) Bearing, shaft press-fit tool RY9212332MBS0078US0

1. Apply molybdenum to the bearing, and then install the bearing. (1) Bearing

(a) Bearing, shaft press-fit tool RY9212332MBS0079US0

1. Install the shim. (1) Shim RY9212332MBS0080US0

2-S40

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Assemble the external circlip. IMPORTANT • Install so that the gap between the external circlip and shim is 0.1 mm or less. (1) External circlip RY9212332MBS0081US0

(3) Special Tools No. in Figure

Name

(A)

Gear puller GL-12

(B)

Bearing separator BS-2

(C)

Bearing, shaft press-fit tool

(D)

Bearing, oil seal press-fit tool RY9212332MBS0082US0

75 mm (

3.0 in.)

70 mm (2.8 in.)

110 mm (4.33 in.)

6.0 mm (0.2 in.)

• Material: S45C • Surface treatment: Hard chrome plating on whole surface (hardness: HV800 above, thickness: 0.01 or more) R1: 1.0 mm (0.0394 in.) RY9212332MBS0083US0

(D) Bearing, oil seal press-fit tool A

50 mm (

2.0 in.)

130 mm (5.118 in.)

15 mm (0.59 in.)

85 mm (

3.3 in.)

• Material: S45C • Surface treatment: Hard chrome plating on whole surface (hardness: HV800 above, thickness: 0.01 or more) R1: 1.0 mm (0.0394 in.) RY9212332MBS0084US0

2-S41

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[5] SPROCKET (1) Removal and Installation [A] Disassembly Procedures 1. Jack up the machine. (See, "Jack up" page.) (1) Jack Stands RY9212332MBS0052US0

1. Remove the tires. RY9212332MBS0085US0

1. Set the vacuum pump. (See, "Install the Vacuum Pump" page.) RY9212332HYS0012US0

1. Drain the oil from the chain case. RY9212332MBS0086US0

1. Remove the chain case cover. (1) Cover RY9212332MBS0087US0

2-S42

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Remove the axle hub. IMPORTANT • Always add a matching mark on the frame before removing the axle hub. (1) Axle hub RY9212332MBS0088US0

Enlarged view RY9212332MBS0089US0

1. Remove the plate. (1) Plate RY9212332MBS0090US0

1. Remove the gear. (1) Gear RY9212332MBS0091US0

1. Remove the chain and the sprocket. (1) Chain

(2) Sprocket RY9212332MBS0092US0

2-S43

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

[B] Assembly Procedures 1. Install the chain and sprocket. IMPORTANT • Make sure the sprocket is facing the right way during installation. (1) Chain

(2) Sprocket RY9212332MBS0093US0

1. Install the gear. (1) Gear RY9212332MBS0094US0

1. Install the chain on the gear. 2. Install the plate and tighten the bolts. IMPORTANT • Use a tap before installing the bolts. (Because ThreeBond has been applied, forcibly installing the bolts may damage the thread holes.) • Apply ThreeBond 263 to the bolts before installing them.

Tightening torque

(1) Bolt

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Bolt

(2) Plate RY9212332MBS0053US0

1. Install the axle hub, and temporarily tighten with the nuts. (1) Axle hub RY9212332MBS0054US0

NOTE • When putting nuts in place temporarily, tighten them until the head touches the washer. (1) Washer (a) Gap

A : NG B : OK RY9212332MBS0055US0

2-S44

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Adjust the chain as far as the matching mark on the frame. RY9212332MBS0096US0

Enlarged view RY9212332MBS0089US0

1. Tighten the nuts. Tightening torque

Nut

166.7 to 196.1 N·m 17.0 to 20.0 kgf·m 123.0 to 144.6 lbf·ft

(1) Nut RY9212332MBS0098US0

1. Clean the cover seal, and apply Three Bond 1211 to the groove section. (1) Cover RY9212332MBS0099US0

1. Clean the frame seal, and install the cover. (1) Cover RY9212332MBS0100US0

2-S45

KiSC issued 12, 2015 A

MACHINE BODY

SSV65, WSM

1. Tighten the nuts. Tightening torque

62.8 to 72.6 N·m 6.4 to 7.4 kgf·m 46.4 to 53.5 lbf·ft

Nut

(1) Nut RY9212332MBS0101US0

1. After installing the cover, supply chain oil from the oil supply port. Fill with chain oil until the oil flows out of the oil inspection port, and then tighten the oil inspection port plug (b) and the oil supply port plug (a). Chain oil capacity

20.5 L (5.4 gal)

(a) Supply port

(b) Oil inspection port RY9212332MBS0056US0

1. Install the tires. IMPORTANT • Be careful that the tires face the right direction when installed. (1) Tire RY9212332MBS0102US0

Tire installation direction Because the tread shape of the tires is of a lag type (providing significant traction and buoyancy even in soft ground), please be aware of the tread pattern direction. (A) Correct (B) Incorrect

(a) Front RY9212067GEG0058US0

1. Tighten the nuts in the order according to the diagram on the left. Tightening torque

Nut

200 to 220 N·m 20.4 to 22.4 kgf·m 148 to 162 lbf·ft RY9212332MBS0103US0

2-S46

KiSC issued 12, 2015 A

3 HYDRAULIC SYSTEM

KiSC issued 12, 2015 A

MECHANISM CONTENTS 1. HYDRAULIC CIRCUIT DIAGRAM.............................................................................................. 3-M1 [1] HYDRAULIC HITCH + HIGH-FLOW + SELF LEVELING VALVE + RIDE CONTROL SPEC.................................................................................................................................... 3-M1 [2] MECHANICAL QUICK HITCH SPEC. .................................................................................. 3-M3 [3] MECHANICAL QUICK HITCH + HIGH-FLOW SPEC. ......................................................... 3-M5 [4] MECHANICAL QUICK HITCH + SELF LEVELING VALVE + RIDE CONTROL SPEC. ...... 3-M7 [5] MECHANICAL QUICK HITCH + HIGH-FLOW + SELF LEVELING VALVE + RIDE CONTROL SPEC. ................................................................................................................ 3-M9 [6] HYDRAULIC HITCH SPEC. ............................................................................................... 3-M11 [7] HYDRAULIC HITCH + HIGH-FLOW SPEC. ...................................................................... 3-M13 [8] HYDRAULIC HITCH + SELF LEVELING VALVE + RIDE CONTROL SPEC..................... 3-M15 2. HYDRAULIC EQUIPMENT LAYOUT ......................................................................................... 3-M1 3. HYDRAULIC SYSTEM ............................................................................................................... 3-M2 [1] OVERVIEW .......................................................................................................................... 3-M2 [2] FRONT OPERATION SYSTEM ........................................................................................... 3-M3 (1) Overview......................................................................................................................... 3-M3 (2) Flow of Oil when in Neutral............................................................................................. 3-M4 (3) Raising the Lift Arm Operation ....................................................................................... 3-M5 (4) Lift Arm Float Operation ................................................................................................. 3-M6 (5) Bucket Dump Operation ................................................................................................. 3-M7 (6) Lift Arm Raise + Self Leveler Switch ON Operation (without Bucket Operation) ........... 3-M8 (7) AUX Operation (Single Flow) ......................................................................................... 3-M9 (8) AUX Operation (High-Flow Flow) ................................................................................. 3-M11 (9) Ride Control Operation................................................................................................. 3-M13 (10)Hydraulic Hitch Operation (when Locked).................................................................... 3-M14 [3] TRAVEL SYSTEM .............................................................................................................. 3-M15 (1) Function........................................................................................................................ 3-M15 (2) Forward Driving Operation ........................................................................................... 3-M16 (3) Right Turn Operation (Spin Turn) ................................................................................. 3-M17 (4) Charge Circuit............................................................................................................... 3-M18 (5) Flushing Circuit............................................................................................................. 3-M19 (6) Travel High-Low Operation (Forward Driving).............................................................. 3-M20 (7) Parking Brake Operation ............................................................................................. 3-M21

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. HYDRAULIC CIRCUIT DIAGRAM [1] HYDRAULIC HITCH + HIGH-FLOW + SELF LEVELING VALVE + RIDE CONTROL SPEC.

3-M1

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Hydraulic Hitch + High-Flow + Self Leveling Valve + Ride Control Spec.) Part Name

Part Name

(1)

Engine

(35)

Accumulator

(2)

HST Pump Assy

(36)

Ride Control Solenoid Valve

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(9)

Charge Pump (P3)

(43)

Traveling Speed Pressure Sensor

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

High-Flow Valve Assy

(15)

Proportional Relief Valve

(49)

High-Flow Unload Spool

(16)

HST Motor Assy (Left)

(50)

High-Flow Spool

(17)

Parking Brake

(51)

High-Flow Relief Valve [18.0Mpa (184 kgf/cm2, 2610 psi)]

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

Self Leveling Valve Assy

(58)

AUX Spool

(25)

Self Leveling Valve Assy Solenoid

(59)

3 Spool Solenoid Valve

(26)

Flow Dividing Valve

(60)

Unload Solenoid

(27)

A Orifice

(61)

Orifice

(28)

Device Spool W Cell

(62)

Parking Brake Solenoid

(29)

Center Spool

(63)

By-pass Valve

(30)

Hydraulic Oil Filter

(64)

Travel high-low Solenoid

(31)

Hydraulic Quick-Hitch Cylinder

(65)

AUX Outlet Port Assy

(32)

Hydraulic Quick-Hitch Cylinder Solenoid Valve Assy

(66)

AUX Outlet Port (Male)

(33)

Hydraulic Quick-Hitch Solenoid (Lock)

(67)

AUX Outlet Port (Drain)

(34)

Hydraulic Quick-Hitch Solenoid (Release)

(68)

AUX Outlet Port (Female) 3-M2

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[2] MECHANICAL QUICK HITCH SPEC.

3-M3

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Mechanical Quick Hitch Spec.) Part Name

Part Name

(1)

Engine

(35)

–

(2)

HST Pump Assy

(36)

–

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(43)

Traveling Speed Pressure Sensor

(9)

–

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

–

(15)

Proportional Relief Valve

(49)

–

(16)

HST Motor Assy (Left)

(50)

–

(17)

Parking Brake

(51)

–

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

–

(58)

AUX Spool

(25)

–

(59)

3 Spool Solenoid Valve

(26)

–

(60)

Unload Solenoid

(27)

–

(61)

Orifice

(28)

–

(62)

Parking Brake Solenoid

(29)

–

(63)

By-pass Valve

(64)

Travel high-low Solenoid

(30)

Hydraulic Oil Filter

(31)

–

(65)

AUX Outlet Port Assy

(32)

–

(66)

AUX Outlet Port (Male)

(33)

–

(67)

AUX Outlet Port (Drain)

(34)

–

(68)

AUX Outlet Port (Female) 3-M4

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[3] MECHANICAL QUICK HITCH + HIGH-FLOW SPEC.

3-M5

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Mechanical Quick Hitch + High-Flow Spec.) Part Name

Part Name

(1)

Engine

(35)

–

(2)

HST Pump Assy

(36)

–

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(9)

Charge Pump (P3)

(43)

Traveling Speed Pressure Sensor

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

High-Flow Valve Assy

(15)

Proportional Relief Valve

(49)

High-Flow Unload Spool

(16)

HST Motor Assy (Left)

(50)

High-Flow Spool

(17)

Parking Brake

(51)

High-Flow Relief Valve [18.0Mpa (184 kgf/cm2, 2610 psi)]

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

–

(58)

AUX Spool

(25)

–

(59)

3 Spool Solenoid Valve

(26)

–

(60)

Unload Solenoid

(27)

–

(61)

Orifice

(28)

–

(62)

Parking Brake Solenoid

(29)

–

(63)

By-pass Valve

(64)

Travel high-low Solenoid

(30)

Hydraulic Oil Filter

(31)

–

(65)

AUX Outlet Port Assy

(32)

–

(66)

AUX Outlet Port (Male)

(33)

–

(67)

AUX Outlet Port (Drain)

(34)

–

(68)

AUX Outlet Port (Female) 3-M6

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[4] MECHANICAL QUICK HITCH + SELF LEVELING VALVE + RIDE CONTROL SPEC.

3-M7

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Mechanical Quick Hitch + Self Leveling Valve + Ride Control Spec.) Part Name

Part Name

(1)

Engine

(35)

Accumulator

(2)

HST Pump Assy

(36)

Ride Control Solenoid Valve

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(43)

Traveling Speed Pressure Sensor

(9)

–

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

–

(15)

Proportional Relief Valve

(49)

–

(16)

HST Motor Assy (Left)

(50)

–

(17)

Parking Brake

(51)

–

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

Self Leveling Valve Assy

(58)

AUX Spool

(25)

Self Leveling Valve Assy Solenoid

(59)

3 Spool Solenoid Valve

(26)

Flow Dividing Valve

(60)

Unload Solenoid

(27)

A Orifice

(61)

Orifice

(28)

Device Spool W Cell

(62)

Parking Brake Solenoid

(29)

Center Spool

(63)

By-pass Valve

(30)

Hydraulic Oil Filter

(64)

Travel high-low Solenoid

(31)

–

(65)

AUX Outlet Port Assy

(32)

–

(66)

AUX Outlet Port (Male)

(33)

–

(67)

AUX Outlet Port (Drain)

(34)

–

(68)

AUX Outlet Port (Female) 3-M8

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[5] MECHANICAL QUICK HITCH + HIGH-FLOW + SELF LEVELING VALVE + RIDE CONTROL SPEC.

3-M9

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Mechanical Quick Hitch + High-Flow + Self Leveling Valve + Ride Control Spec.) Part Name

Part Name

(1)

Engine

(35)

Accumulator

(2)

HST Pump Assy

(36)

Ride Control Solenoid Valve

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(9)

Charge Pump (P3)

(43)

Traveling Speed Pressure Sensor

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

High-Flow Valve Assy

(15)

Proportional Relief Valve

(49)

High-Flow Unload Spool

(16)

HST Motor Assy (Left)

(50)

High-Flow Spool

(17)

Parking Brake

(51)

High-Flow Relief Valve [18.0Mpa (184 kgf/cm2, 2610 psi)]

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

Self Leveling Valve Assy

(58)

AUX Spool

(25)

Self Leveling Valve Assy Solenoid

(59)

3 Spool Solenoid Valve

(26)

Flow Dividing Valve

(60)

Unload Solenoid

(27)

A Orifice

(61)

Orifice

(28)

Device Spool W Cell

(62)

Parking Brake Solenoid

(29)

Center Spool

(63)

By-pass Valve

(30)

Hydraulic Oil Filter

(64)

Travel high-low Solenoid

(31)

–

(65)

AUX Outlet Port Assy

(32)

–

(66)

AUX Outlet Port (Male)

(33)

–

(67)

AUX Outlet Port (Drain)

(34)

–

(68)

AUX Outlet Port (Female) 3-M10

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[6] HYDRAULIC HITCH SPEC.

3-M11

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Hydraulic Hitch Spec.) Part Name

Part Name

(1)

Engine

(35)

–

(2)

HST Pump Assy

(36)

–

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(43)

Traveling Speed Pressure Sensor

(9)

–

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

–

(15)

Proportional Relief Valve

(49)

–

(16)

HST Motor Assy (Left)

(50)

–

(17)

Parking Brake

(51)

–

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

–

(58)

AUX Spool

(25)

–

(59)

3 Spool Solenoid Valve

(26)

–

(60)

Unload Solenoid

(27)

–

(61)

Orifice

(28)

–

(62)

Parking Brake Solenoid

(29)

–

(63)

By-pass Valve

(30)

Hydraulic Oil Filter

(64)

Travel high-low Solenoid

(31)

Hydraulic Quick-Hitch Cylinder

(65)

AUX Outlet Port Assy

(32)

Hydraulic Quick-Hitch Cylinder Solenoid Valve Assy

(66)

AUX Outlet Port (Male)

(33)

Hydraulic Quick-Hitch Solenoid (Lock)

(67)

AUX Outlet Port (Drain)

(34)

Hydraulic Quick-Hitch Solenoid (Release)

(68)

AUX Outlet Port (Female) 3-M12

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[7] HYDRAULIC HITCH + HIGH-FLOW SPEC.

3-M13

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Hydraulic Hitch + High-Flow Spec.) Part Name

Part Name

(1)

Engine

(35)

–

(2)

HST Pump Assy

(36)

–

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(9)

Charge Pump (P3)

(43)

Traveling Speed Pressure Sensor

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

High-Flow Valve Assy

(15)

Proportional Relief Valve

(49)

High-Flow Unload Spool

(16)

HST Motor Assy (Left)

(50)

High-Flow Spool

(17)

Parking Brake

(51)

High-Flow Relief Valve [18.0Mpa (184 kgf/cm2, 2610 psi)]

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

–

(58)

AUX Spool

(25)

–

(59)

3 Spool Solenoid Valve

(26)

–

(60)

Unload Solenoid

(27)

–

(61)

Orifice

(28)

–

(62)

Parking Brake Solenoid

(29)

–

(63)

By-pass Valve

(30)

Hydraulic Oil Filter

(64)

Travel high-low Solenoid

(31)

Hydraulic Quick-Hitch Cylinder

(65)

AUX Outlet Port Assy

(32)

Hydraulic Quick-Hitch Cylinder Solenoid Valve Assy

(66)

AUX Outlet Port (Male)

(33)

Hydraulic Quick-Hitch Solenoid (Lock)

(67)

AUX Outlet Port (Drain)

(34)

Hydraulic Quick-Hitch Solenoid (Release)

(68)

AUX Outlet Port (Female) 3-M14

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[8] HYDRAULIC HITCH + SELF LEVELING VALVE + RIDE CONTROL SPEC.

3-M15

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Hydraulic Circuit Diagram (Hydraulic Hitch + Self Leveling Valve + Ride Control Spec.) Part Name

Part Name

(1)

Engine

(35)

Accumulator

(2)

HST Pump Assy

(36)

Ride Control Solenoid Valve

(3)

HST Pump (Right)

(37)

Lift Arm Cylinder

(4)

Charge Relief Valve [2.83 Mpa (28.9 kgf/cm2, 410 psi)]

(38)

HST Motor Assy (Right)

(5)

HST Pump Relief Valve [34.5 Mpa (352 kgf/cm2, 5000 psi)]

(39)

Oil Tank

(6)

HST Pump (Left)

(40)

Breather Filter

(7)

Hydraulic Pump (P1)

(41)

Suction Filter

(8)

High-Flow Pump (P2)

(42)

Return Filter

(43)

Traveling Speed Pressure Sensor

(9)

–

(10)

Charge Pump Relief Valve [17.5 Mpa (178 kgf/cm2, 2540 psi)]

(44)

Relief Valve

(11)

Oil Cooler

(45)

Load Check Valve

(12)

Hydraulic Fan Motor Assy

(46)

Lift Arms Lowering By-pass Valve

(13)

Hydraulic Fan Motor

(47)

Bucket Cylinder

(14)

Load Check Valve

(48)

–

(15)

Proportional Relief Valve

(49)

–

(16)

HST Motor Assy (Left)

(50)

–

(17)

Parking Brake

(51)

–

(18)

HST Motor

(52)

Control Valve

(19)

HST Motor (High-Low)

(53)

Maine Relief Valve [22.5 Mpa (230 kgf/cm2, 3270 psi)]

(20)

Travel High-Low Spool

(54)

Left Arm Spool

(21)

Flushing Spool

(55)

Over Lord Relief Valve [30.0 Mpa (310 kgf/cm2, 4400 psi)]

(22)

Flushing Relief Valve

(56)

Over Lord Relief Valve [24.5 Mpa (250 kgf/cm2, 3550 psi)]

(23)

Block Valve

(57)

Bucket Spool

(24)

Self Leveling Valve Assy

(58)

AUX Spool

(25)

Self Leveling Valve Assy Solenoid

(59)

3 Spool Solenoid Valve

(26)

Flow Dividing Valve

(60)

Unload Solenoid

(27)

A Orifice

(61)

Orifice

(28)

Device Spool W Cell

(62)

Parking Brake Solenoid

(29)

Center Spool

(63)

By-pass Valve

(30)

Hydraulic Oil Filter

(64)

Travel high-low Solenoid

(31)

Hydraulic Quick-Hitch Cylinder

(65)

AUX Outlet Port Assy

(32)

Hydraulic Quick-Hitch Cylinder Solenoid Valve Assy

(66)

AUX Outlet Port (Male)

(33)

Hydraulic Quick-Hitch Solenoid (Lock)

(67)

AUX Outlet Port (Drain)

(34)

Hydraulic Quick-Hitch Solenoid (Release)

(68)

AUX Outlet Port (Female) 3-M16

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

2. HYDRAULIC EQUIPMENT LAYOUT (1) (2) (3) (4) (5) (6) (7) (8)

HST Pump Hydraulic Pump (P1) High-Flow Pump (P2) Charge Pump (P3) HST Motor Assy (Right) Control Valve 3 Spool Solenoid Valve Quick Hitch Cylinder (Option) (9) Bucket Cylinder (10) AUX Hydraulic Outlet Port (11) High-Flow Valve (12) Block Valve (13) Lift Arm Cylinder (14) Oil Cooler (15) Self Leveling Valve (16) Hydraulic Fan Motor Assy (17) Hydraulic Oil Filter (18) Accumulator (19) Hydraulic Quick-Hitch Cylinder Solenoid Valve (20) Ride Control Solenoid Valve RY9212332HYM0042US0

3-M17

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

3. HYDRAULIC SYSTEM [1] OVERVIEW

(1) (2) (3) (4) (5) (6)

HST Pump P1 P2 P3 HST Motor (Right) HST Motor (Left)

(7) Hydraulic Fan Motor (8) Control Valve (9) 3 Spool Solenoid Valve (10) AUX Outlet Port (11) High-Flow Solenoid Valve (12) Block Valve

(13) Self Leveling Valve (14) Hydraulic Quick Hitch Solenoid Valve (15) Lift Arm Cylinder (16) Ride Control Valve (17) Accumulator

(18) Bucket Arm Cylinder (19) HST Filter (20) Oil Tank (21) Return Filter

KUBOTA Skid Steer Loader uses a hand-and-foot method. The hydraulic system consists of a travel system based on an HST pump motor and a front operation system based on a gear pump. While driving, the machine moves forward or backward and makes a turn by manipulating the left and right hand levers. During front operation, the lift arm and the bucket can be moved by manipulating the foot pedals. A travel high-low system and a float mechanism are equipped as a standard. Optionally, high-flow specifications, bucket leveling mechanism, hydraulic quick hitch, and ride control are available, enabling further enhanced functions based on needs. Pumps of the standard specification machine consist of an HST pump and two gear pumps. (Only the high-flow specification machine include three gear pumps.) The HST pump is used for driving, while the three gear pumps are respectively used for the following purposes: From the axis onward, the working machine pump ("P1"), the high-flow pump ("P2"), and the charging pump ("P3") are located. • P1 is used for lift arm, bucket, and AUX operations. • P2 is used for high-flow. (Optional) • P3 is used for the cooling hydraulic fan motor ("fan motor"), supply to the HST pump, the hydraulic quick hitch (optional), and the 3 spool solenoid valve. The 3 spool solenoid valve has the following functions: 1. Block solenoid valve ("block valve") 2. Travel high-low solenoid valve ("two-speed valve") 3. Parking solenoid valve ("parking valve") RY9212332HYM0003US0

3-M18

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[2] FRONT OPERATION SYSTEM CAUTION • These instructions are focused on the hydraulic system, and therefore detailed pre-driving instructions are omitted. Be sure to refer to the operating manual, and understand the safety precautions, how to wear the seatbelt, and operations of respective switches ("Checks before start") before driving. RY9212332HYM0012US0

(1) Overview

(1) Hydraulic Unlock Switch (2) 3 Spool Solenoid Valve

(3) Lift Arm Solenoid (4) Bucket Solenoid

(5) P3 (6) Block Valve

(7) P1

The bucket dump is indicated in the overview and the circuit diagrams above. (Explanation is provided based on circuit diagrams for the high-flow specification, self leveling specification, hydraulic quick hitch specification, and ride control specification.) Sit in the driver's seat, and start the engine. Press the hydraulic unlock switch (1) to excite the lift arm solenoid (3) and the bucket solenoid (4) of the 3 spool solenoid valve (2) and the control valve. Pressure oil from P3 (5) is supplied to Port P of the 3 spool solenoid valve. After being supplied to Port P, the pressure oil flows to the block valve (6), and presses the spool. After being discharged from P1 (7), the pressure oil passes through the control valve, flows to the actuator and activates it. RY9212332HYM0004US0

3-M19

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Flow of Oil when in Neutral

(1) Control Valve (2) Port P1

(3) Center Bypass Passage

(4) Port T

(5) Port T2

Oil from P1 enters Port P1 (2) of the control valve (1). It then passes through the center bypass passage (3), and returns to the operating oil tank through Port T (4) and Port T2 (5). RY9212332HYM0005US0

3-M20

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Raising the Lift Arm Operation

(1) (2) (3) (4) (5)

Pedal (Left) P1 Port P1 Load Check Valve Port A1

(6) Lift Arm Cylinder Bottom (7) Lift Arm Cylinder Rod (8) Self Leveling Valve (9) Solenoid Spool (10) Port B

(11) Port B1 (12) Bucket Section (13) AUX Section (14) Center Bypass Passage

Press

Step on Pedal (Left) (1) toward A, to move the lift arm spool rightward. Pressure oil from P1 (2) enters Port P1 (3), and pushes open the load check valve (4) in the lift arm section. It then passes through Port A1 (5) and flows toward the lift arm cylinder bottom (6) side. Return oil from the lift arm cylinder (7) rod side enters Port A of the self leveling valve (8). It then passes through the solenoid spool (9) and flows to B1 (11) through Port B (10). After entering B1, the oil flows through the bucket section (12) and the AUX section (13) in this order toward operation. If the bucket/AUX spool is not operating, the oil flows through the center bypass passage (14), and returns to the tank. RY9212332HYM0006US0

3-M21

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(4) Lift Arm Float Operation

(1) Pedal (Left) (2) Lift Arm Cylinder Bottom (3) Lift Arm Cylinder Rod

(4) Spool (5) P1

(6) Port P1 (7) Load Check Valve

A : Press B : Press

Step on Pedal (Left) (1) toward B. Another stepping causes the pedal to be locked in the float position. (The lift arm spool is locked by the detent mechanism.) In the float position, oil on the lift arm cylinder bottom (2) side and the lift arm cylinder rod (3) side is connected to the tank circuit through the spool (4), and the cylinder oil flows into the tank circuit. Because of the flow, cylinder oil can move freely, and flexible strokes become possible in accordance with the terrain. Consequently, the front attachment can move in line with the ground surface. Pressure oil from P1 (5) enters Port P1 (6), and flows to the arm section through the load check valve (7). It then flows into the tank, because the spool is connected to the tank circuit. To cancel the float, step on Pedal (Left) toward A and unlock the pedal. RY9212332HYM0013US0

3-M22

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(5) Bucket Dump Operation

(1) (2) (3) (4) (5)

Pedal (Right) Bucket Spool P1 Port P1 Center Bypass Passage

(6) Load Check Valve (7) Port B2 (8) Lift Arm Cylinder Bottom (9) Lift Arm Cylinder Rod (10) Self Leveling Valve

(11) Block Valve (12) Spool (13) Port A2 (14) AUX Section (15) P3

(16) 3 Spool Solenoid Valve (17) Port P A : Press

Step on Pedal (Right) (1) toward A, to press the bucket spool (2) leftward. Pressure oil from P1 (3) enters Port P1 (4), and pushes open the load check valve (6) in the bucket section through the center bypass (5) passage. It then passes through Port B2 (7) and flows toward the bucket cylinder bottom (8) side. Return oil from the bucket cylinder rod (9) side enters Port C of the self leveling valve (10), but, because the passage is closed, it flows to Port A2 (13) through the spool (12) of the block valve (11). After entering A2, the oil passes through toward the operation of the AUX section (14). If the AUX spool is not operating, the oil flows through the center bypass passage, and returns to the tank. Pressure oil from P3 (15) is supplied to Port P (17) of the 3 spool solenoid valve (16). After being supplied to Port P, the pressure oil flows to the block valve, and presses the spool. RY9212332HYM0014US0

3-M23

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(6) Lift Arm Raise + Self Leveler Switch ON Operation (without Bucket Operation)

(1) (2) (3) (4) (5) (6) (7)

Pedal (Left) P1 Port P1 Load Check Valve Port A1 Lift Arm Cylinder Bottom Lift Arm Cylinder Rod

(8) Self Leveling Valve (9) Port A1 (10) a Orifice (11) Port B (12) Port B1 (13) Flow Dividing Valve (14) Device Spool W Cell

(15) Device Spool Spring (16) Check Valve (17) Port D (18) Bucket Cylinder Bottom (19) Bucket Cylinder Rod (20) Port A2 (21) Bucket Spool

(22) Port C (23) Center Spool y Cell A : Press

Step on Pedal (Left) (1) toward A, to press the lift arm spool rightward. Pressure oil from P1 (2) enters Port P1 (3), and pushes open the load check valve (4) in the lift arm section. It then passes through Port A1 (5) and flows toward the lift arm cylinder bottom (6) side. Return oil from the lift arm cylinder (7) rod side enters Port A (9) of the self leveling valve (8). It then passes through Orifice (a) (10) and returns to the tank from Port B (11) through Port B1 (12). At the same time, oil that has passed through the flow dividing valve (13) flows to the device spool W cell (14). When the pressure exceeds the device spool spring (15) force, the spool is pressed downward. The oil then passes through the spool hole, presses the check valve (16), and flows from Port D (17) to the bucket cylinder bottom (18) side. Oil on the bucket cylinder rod (19) side flows to Port A2 (20), but the bucket spool (21) is not activated and is therefore closed. The oil has nowhere to go and therefore flows to Port C (22), but it cannot flow into the tank, because the center spool is also closed. Pressure rises gradually, and the oil flows to the center spool y cell (23). When the pressure exceeds the center spool spring force, the spool is pressed downward. The oil then passes through the spool hole, and returns to the tank from Port B through B1 of the control valve. RY9212332HYM0015US0

3-M24

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(7) AUX Operation (Single Flow)

(1) (2) (3) (4)

AUX Port Switch Knob Switch AUX Solenoid (Right) Port X1

(5) (6) (7) (8)

AUX Spool P3 P1 Port P1

(9) Center Bypass Passage (10) Load Check Valve (11) Port B3 (12) Quick Couple (Male)

(13) Quick Couple (Female) (14) Port A3

(To be continued) 3-M25

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued) Press the AUX port switch (1) toward A. Next, slide the knob switch (2) of the AUX travel lever (right) rightward, to excite the AUX solenoid (right) (3) and connect Port X (4) and the right cell of the AUX spool (5). Pressure oil from P3 (6) enters Port X and is guided to the right cell of the AUX spool, thereby moving the AUX spool leftward. Pressure oil from P1 (7) enters Port P1 (8), and pushes open the load check valve (10) in the AUX section through the center bypass (9) passage. It then passes through Port B3 (11) and flows toward the quick coupler (male) at the AUX outlet port. The return oil after activating the attachment flows toward the quick coupler (female) (13), enters Port A3 (14), and flows into the tank. (1) AUX Port Switch (2) Knob Switch

A : Press RY9212332HYM0007US0

3-M26

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(8) AUX Operation (High-Flow Flow)

(To be continued)

3-M27

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued) Press the AUX port switch (1) toward B. Next, slide the knob switch (2) of the AUX travel lever (right) rightward, to excite the AUX solenoid (right) (3) and consequently connect Port X (4) and the right cell of the AUX spool (5). Pressure oil from P3 (6) enters Port X and is guided to the right cell of the AUX spool, thereby moving the AUX spool leftward. Pressure oil from P1 (7) enters Port P1 (8), and pushes open the load check valve (10) in the AUX section through the center bypass (9) passage. It then passes through Port B3 (11) and flows toward the quick coupler (male) (12) at the AUX outlet port. At the same time, the solenoid (14) of the high-flow valve (13) is excited, and is consequently switched rightward. Pressure oil from P3 enters Port PP (15) of the high-flow valve, and presses the spool (16) upward. Pressure oil from P2 (17) enters Port P (18) of the high-flow valve, presses the check valve (19), and joins the quick coupler (male) at the AUX outlet port. The return oil after activating the attachment flows toward the quick coupler (female) (20), enters Port A3 (21), and flows into the tank. (1) AUX Port Switch (2) Knob Switch (3) AUX Solenoid (Right) (4) Port X1 (5) AUX Spool (6) P3 (7) P1 (8) Port P1 (9) Center Bypass Passage (10) Load Check Valve (11) Port B3 (12) Quick Couple (Male)

(13) High-Flow Valve (14) Solenoid (15) Port PP (16) Spool (17) P2 (18) Port P1 (19) Check Valve (20) Quick Couple (Female) (21) Port A3 A : Press RY9212332HYM0016US0

3-M28

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(9) Ride Control Operation

(1) Ride Control Switch

(2) Ride Control Solenoid

(3) Lift Arm Cylinder

(4) Accumulator

Press the ride control switch (1) to excite the ride control solenoid (2). When excited, the bottom side of the lift arm cylinder and the accumulator (4) are connected. When oil on the bottom side enters the accumulator, gas inside the accumulator is compressed, and oil is accumulated for the compressed volume. The accumulated oil is stored as energy. Using the stored energy, the lift arm cylinder is moved upward and downward to reduce load spills. Without the ride control function, gravel in the bucket is spilled during handling as the machine jolts vertically and horizontally on the uneven ground. By using this function, the drop of gravel inside the bucket is reduced by extending and retracting the lift arm cylinder, even when the machine jolts vertically and horizontally. RY9212332HYM0017US0

3-M29

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(10) Hydraulic Hitch Operation (when Locked)

(1) Hydraulic Hitch Switch (2) Hydraulic Hitch Solenoid A (3) P3

(4) Hydraulic Hitch Solenoid Valve (5) Hydraulic Hitch Cylinder

(6)

Hydraulic Hitch Solenoid B

A : Press B : Press

Press the hydraulic switch (1) toward A to excite the hydraulic hitch solenoid A (2). Oil from P3 (3) enters Port P of the hydraulic hitch solenoid valve (4), and flows to the bottom side of the hydraulic hitch cylinder (5) through the spool. It thus extends the cylinder and locks the attachment (6). To unlock the attachment, press the hydraulic switch toward B to excite the hydraulic hitch solenoid B (6). Oil in Port P, as described earlier, flows to the rod side of the hydraulic hitch cylinder through the spool. It thus retracts the cylinder and unlocks the attachment. RY9212332HYM0008US0

3-M30

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[3] TRAVEL SYSTEM (1) Function HST Motor Operating Principle Piston position A Drive cycle start position. Hydraulic fluid flows through the distributor valve (1) and raises the piston (2). Rollers (3) roll over the cam surface (4), and rotate the cylinder block (5). Piston position B As the piston rises, the degree of opening of the distributor valve reaches maximum, and eventually recedes. Piston position C When the piston reaches top dead center, the supply of hydraulic fluid stops. In this position, there is no driving force. This same operation repeats from when other pistons are in position A. Piston position D As the piston goes down, the degree of opening of the distributor valve reaches maximum, and recedes little by little. Piston position E After bottom dead center (neutral point) is reached, the cycle repeats again from piston position A. The motor rotation direction can be varied by switching the hydraulic fluid supply port. (1) Distributor Valve (2) Piston (3) Roller

(4) Cam Surface (5) Cylinder Block RY9212332HYM0001US0

Motor Capacity Conversion Principle High torque mode A When full capacity (A), the hydraulic fluid is exerted to all cams. High speed torque mode B When low capacity (B), hydraulic fluid is exerted to half of the cams. RY9212332HYM0002US0

3-M31

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Forward Driving Operation

(1) Travel Levers (2) HST Pump (3) HST Motor

(4) Port A (5) Port A (6) Port C

(7) Port A (8) Port B (9) Port R

(10) Port D (11) Port R

When the left and right travel levers (1) are pushed forward, oil in the HST pump (2) enters the left and right HST motors (3). The oil enters Port A (5) of the right HST motor from Port A (4) of the HST pump. At the same time, the oil enters Port A (7) of the HST motor on the left of the machine from Port C (6) of the HST pump. This causes the machine to drive forward. For backward driving, when the left and right travel levers are pushed backward, the oil enters Port R (9) of the right HST motor from Port B (8) of the HST pump. At the same time, the oil enters Port R (11) of the HST motor on the left of the machine from Port D (10) of the HST pump. This causes the machine to drive backward. RY9212332HYM0018US0

3-M32

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Right Turn Operation (Spin Turn)

(1) (2) (3) (4)

Travel Lever (Right) HST Pump HST Motor Travel Lever (Left)

(5) HST Motor (Left) (6) Port B (7) Port R

(8) Port C (9) Port A (10) Port A

(11) Port A (12) Port D (13) Port R

When the travel lever (right) (1) is pushed backward, oil in the HST pump (2) enters the right HST motor (3). When the travel lever (left) (4) is pushed forward, oil in the HST pump enters the left HST motor (5). The oil enters Port R (7) of the right HST motor from Port B (6) of the HST pump. At the same time, the oil enters Port A (9) of the HST motor on the left of the machine from Port C (8) of the HST pump. This causes the machine to make a right spin turn. To make a left spin turn, when the travel lever (right) is pushed forward, oil in the HST pump enters the right HST motor. When the travel lever (left) is pushed backward, oil in the HST pump enters the left HST motor. The oil enters Port A (10) of the right HST motor from Port A (11) of the HST pump. At the same time, the oil enters Port R (13) of the HST motor on the left of the machine from Port D (12) of the HST pump. This causes the machine to make a left spin turn. RY9212332HYM0019US0

3-M33

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(4) Charge Circuit

(1) HST Pump

(2) HST Motor

(3) P3

The HST pump (1) for HST and the HST motor (2) are in a closed circuit. The hydraulic oil discharged from the HST pump enters the HST motor and returns to the HST pump. That said, the oil that drains from the HST pump and the HST motor does return to the hydraulic oil tank, so the oil in the closed circuit is not sufficient by itself. To make up for the insufficient hydraulic oil, oil is supplied from the P3 (3) to the HST pump. RY9212332HYM0009US0

3-M34

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(5) Flushing Circuit

The HST pump for travel and the motor are in a closed circuit. The hydraulic oil discharged from the HST pump enters the HST motor and returns to the HST pump. For that reason, the oil between the HST pump and the motor gets hot. To prevent the oil from getting hot, the circuit is equipped with a flushing valve (1) for forcibly returning part of the oil back to the hydraulic oil tank. In order to make up for the deficiency in oil due to the drain from the HST pump and motor, and the oil returning to the hydraulic tank from this flushing valve, oil from the P3 (2) is supplied to the HST pump. Also, as hydraulic oil from the hydraulic oil tank is supplied to the closed circuit between the HST pump and the motor, contamination within the closed circuit can also be removed. (1) Flushing Valve

(2) Spool RY9212332HYM0010US0

3-M35

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(6) Travel High-Low Operation (Forward Driving)

Press the travel high-low switch (1) to excite the travel high-low solenoid (2). Pressure oil enters Port Y (3) of the HST motor, and presses the spool. Pressure oil from Port A (4) and Port C (5) of the HST pump enters the left and right HST motors, passes through the high-low spool, and is divided to the left and right of the motor (6) to stop the motor. When stopped, the motor volume is reduced, resulting in a higher rotation of the motor. However, because the torque force is reduced, the machine becomes more liable to engine stall when a spin turn is made during travel high-low operation. (1) Travel High-Low Switch (2) Travel High-Low Solenoid (3) Port Y

(4) Port A (5) Port C (6) Motor RY9212332HYM0020US0

3-M36

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(7) Parking Brake Operation

Press the parking brake switch (1) toward A to excite the parking brake solenoid (2). Pressure oil enters Port X (3) of the HST motor, and unlocks the brake. Pressure oil from Port A (4) and Port C (5) of the HST pump enters the left and right HST motors and drives the motor. For example, when the parking brake switch is pressed toward B, the brake is not unlocked. Therefore, the HST motor remains locked. Even if the travel lever is put into the forward driving position in this state, the machine cannot move forward because of the locked motor. If the travel lever is kept in this position, oil of the HST pump continues to flow, but the engine gets stalled because the brake force is stronger. (1) (2) (3) (4) (5) (6)

Parking Brake Switch Parking Brake Solenoid Port X Port A Port C HST Motor

A : Press B : Press

RY9212332HYM0011US0

3-M37

KiSC issued 12, 2015 A

SERVICING CONTENTS 1. SERVICE DATA ..........................................................................................................................3-S1 2. PERFORMANCE CHECKS AND ADJUSTMENT METHODS ....................................................3-S3 3. HYDRAULIC EQUIPMENT........................................................................................................3-S13 [1] HST PUMP ..........................................................................................................................3-S13 (1) Specifications ................................................................................................................3-S13 (2) Components ..................................................................................................................3-S14 (3) Joints Arrangement .......................................................................................................3-S16 (4) Assembly .......................................................................................................................3-S20 (5) Pump Coupling ..............................................................................................................3-S21 (6) Removal and Installation ...............................................................................................3-S22 (7) Disassembly/Assembly..................................................................................................3-S24 (8) Special Tools .................................................................................................................3-S36 (9) Neutral Adjustment ........................................................................................................3-S38 (10)Backup Buzzer Adjustment ...........................................................................................3-S39 [2] GEAR PUMP .......................................................................................................................3-S40 (1) Specifications ................................................................................................................3-S40 (2) Components ..................................................................................................................3-S40 (3) Joints Arrangement .......................................................................................................3-S41 [3] GEAR PUMP (HIGH-FLOW VERSION OPTION) ...............................................................3-S42 (1) Specifications ................................................................................................................3-S42 (2) Components ..................................................................................................................3-S43 (3) Joints Arrangement .......................................................................................................3-S44 [4] CONTROL VALVE ..............................................................................................................3-S45 (1) Specifications ................................................................................................................3-S45 (2) Joints Arrangement .......................................................................................................3-S46 (3) Assembly ......................................................................................................................3-S47 (4) Removal and Installation ...............................................................................................3-S50 (5) Disassembly/Assembly..................................................................................................3-S52 [5] TRAVEL MOTOR ................................................................................................................3-S57 (1) Specifications ................................................................................................................3-S57 (2) Components ..................................................................................................................3-S58 (3) Joints Arrangement .......................................................................................................3-S60 (4) Removal and Installation ...............................................................................................3-S62 (5) Disassembly/Assembly..................................................................................................3-S63 (6) Special Tools .................................................................................................................3-S77 [6] FAN MOTOR .......................................................................................................................3-S79 (1) Specifications ................................................................................................................3-S79 (2) Components ..................................................................................................................3-S80 (3) Joints Arrangement .......................................................................................................3-S81 (4) Removal and Installation ...............................................................................................3-S82 (5) Disassembly/Assembly..................................................................................................3-S83 [7] LIFT ARM CYLINDER .........................................................................................................3-S87 (1) Specifications ................................................................................................................3-S87 (2) Components ..................................................................................................................3-S87 (3) Removal and Installation ...............................................................................................3-S88 (4) Disassembly/Assembly..................................................................................................3-S90 (5) Special Tools .................................................................................................................3-S96 [8] BUCKET CYLINDER .........................................................................................................3-S100 (1) Specifications ..............................................................................................................3-S100 KiSC issued 12, 2015 A

(2) Components ................................................................................................................3-S100 (3) Removal and Installation .............................................................................................3-S101 [9] HYDRAULIC QUICK HITCH CYLINDER ..........................................................................3-S103 (1) Specifications...............................................................................................................3-S103 (2) Components ................................................................................................................3-S103 (3) Removal and Installation .............................................................................................3-S104 [10]3 SPOOL SOLENOID VALVE ...........................................................................................3-S105 (1) Specifications...............................................................................................................3-S105 (2) Components ................................................................................................................3-S106 (3) Joints Arrangement......................................................................................................3-S107 [11]QUICK HITCH SOLENOID VALVE (OPTION) ..................................................................3-S108 (1) Specifications...............................................................................................................3-S108 (2) Components ................................................................................................................3-S109 (3) Joints Arrangement......................................................................................................3-S110 [12]HIGH-FLOW SOLENOID VALVE (OPTION) .....................................................................3-S111 (1) Specifications...............................................................................................................3-S111 (2) Joints Arrangement......................................................................................................3-S112 (3) Disassembly/Assembly................................................................................................3-S112 [13]HORIZONTAL CONTROL VALVE (OPTION) ...................................................................3-S114 (1) Specifications...............................................................................................................3-S114 (2) Disassembly/Assembly................................................................................................3-S115 (3) Joints Arrangement......................................................................................................3-S117 [14]RIDE CONTROL SOLENOID VALVE (OPTION) ..............................................................3-S119 (1) Specifications...............................................................................................................3-S119 (2) Components ................................................................................................................3-S120 (3) Accumulator Assembly ................................................................................................3-S121 (4) Joints Arrangement......................................................................................................3-S122 [15]BLOCK VALVE (OPTION) .................................................................................................3-S123 (1) Specifications...............................................................................................................3-S123 (2) Components ................................................................................................................3-S124 (3) Joints Arrangement......................................................................................................3-S125

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. SERVICE DATA Item

SSV65

Engine • Idling RPM • MAX RPM

1250 ± 25 rpm 2800 ± 25 rpm

Front Speeds • To raise the lift arm • To lower the lift arm • To crowd the bucket • To dump the bucket

4.7 to 5.1 sec. 3.2 to 3.6 sec. 2.1 to 2.5 sec. 2.2 to 2.6 sec.

Cylinder drift • Lift arm cylinder drift distance (when loaded)

26.3 mm or less 1.04 in. or less

• Bucket cylinder drift distance (when loaded)

Reference Page –

3-S3 3-S3

3-S3

9.4 mm or less 0.37 in. or less

Gear pump flow volume • Front operation pump (P1)

At least 68 L/min At least 18 gal

• High flow spec (P2/optional)

At least 106 L/min At least 28.0 gal

• Charge pump (P3)

At least 45 L/min At least 11.9 gal

HST pump flow volume

At least 96 L/min At least 25.4 gal

Front relief valve (P1) • Main relief valve

3-S5

3-S8

22.5 to 24.0 MPa 230 to 244 kgf/cm2 3270 to 3480 psi

• Lift arm relief valve (overload) up

22.5 to 24.0 MPa 230 to 244 kgf/cm2 3270 to 3480 psi

• Lift arm relief valve (overload) down

30.0 to 31.5 MPa 306 to 321 kgf/cm2 4360 to 4560 psi

• Bucket relief valve (overload) crowd

30.0 to 31.5 MPa 306 to 321 kgf/cm2 4360 to 4560 psi

• Bucket relief valve (overload) dump

22.5 to 24.0 MPa 230 to 244 kgf/cm2 3270 to 3480 psi

• AUX relief valve (overload)

22.5 to 24.0 MPa 230 to 244 kgf/cm2 3270 to 3480 psi

High flow pump (P2) outlet pressure

22.5 to 24.0 MPa 230 to 244 kg/cm2 3270 to 3480 psi 3-S1

3-S8 3-S9

3-S10

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Item Charge pump (P3) outlet pressure

Travel pressure • Travel 1st speed (reference value)

SSV65

Reference Page

12.5 to 13.5 MPa 127.5 to 137.6 kg/cm2 1813 to 1958 psi

3-S11

4.0 MPa 41 kgf/cm2 580 psi

• Travel 2nd speed (reference value)

–

5.0 MPa 51 kgf/cm2 730 psi

Travel relief valve • Relief valve A (Left BWD)

34.5 to 36.0 MPa 352 to 367 kgf/cm2 5010 to 5220 psi

• Relief valve B (Left FWD)

34.5 to 36.0 MPa 352 to 367 kgf/cm2 5010 to 5220 psi

• Relief valve C (Right BWD)

34.5 to 36.0 MPa 352 to 367 kgf/cm2 5010 to 5220 psi

• Relief valve D (Left FWD)

34.5 to 36.0 MPa 352 to 367 kgf/cm2 5010 to 5220 psi

Travel speed • 1st speed

10.0 to 12.2 km/h 6.22 to 7.58 mph

• 2nd speed

3-S12

3-S4

16.6 to 19.6 km/h 10.4 to 12.1 mph

Travel performance • Ability to travel straight

600 mm or less 23.6 in. or less

Wheel speed test • 1st speed

81 ± 1 rpm

• 2nd speed

130 ± 1 rpm

3-S4

3-S5

RY9212332HYS0162US0

3-S2

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

2. PERFORMANCE CHECKS AND ADJUSTMENT METHODS Lift Arm Cylinder Speed 1. Park the machine in a flat, hard location. 2. Crowd the bucket cylinder to the end. 3. When timing the raising of the lift arm, time it from the lowered end to the raised end. 4. When timing the lowering of the lift arm, time it from the raised end to the lowered end. • • • •

Engine : Max RPM Bucket : Empty Hydraulic oil temperature : 50 ± 5 °C (122 ± 9 °F). Perform the measurement several times and performance based on the average.

judge

RY9212334HYS0001US0

Bucket Cylinder Speed 1. Park the machine in a flat, hard location. 2. Raise the lift arm to the end. 3. When timing the bucket crowd speed, time it from the dump end to the crowd end. 4. When timing the bucket dump speed, time it from the crowd end to the dump end. • • • •

Engine : Max RPM Bucket : Empty Hydraulic oil temperature : 50 ± 5 °C (122 ± 9 °F). Perform the measurement several times and performance based on the average.

judge

RY9212334HYS0002US0

Cylinder Drift 1. Park the machine in a flat, hard location. 2. Put the front attachments in the position shown in the figure at left and stop the engine. 3. Make a mark on each cylinder rod. 4. After 10 minutes, measure the extension of the lift arm and bucket cylinders. • • • •

Engine : Engine stopped Bucket : Empty and loaded with 1050 kg (2320 lbs) Hydraulic oil temperature : 50 ± 5 °C (122 ± 9 °F). Perform the measurement several times and performance based on the average.

judge

(a) 1500 mm (4.921 ft, 59.06 in.) RY9212334HYS0003US0

3-S3

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Travel Speed 1. Park the machine in a flat, hard location. 2. Put the front in its travel position and run it until it reaches its max speed for each speed (about 5 m). 3. Time how long it takes to cover 20 m in each speed. • • • •

Engine : Max RPM Bucket : Empty Hydraulic oil temperature : 50 ± 5 °C (122 ± 9 °F). Perform the measurement several times and performance based on the average.

judge

Travel Position : Bucket pin height : about 300 mm (11.8 in.) above the ground At bucket crowd end (1) 5 m (16 ft, 196.8 in.)

(2) 20 m (66 ft, 787.4 in.) RY9212334HYS0004US0

Ability to Travel Straight 1. Park the machine in a flat, hard location. 2. Put the front in its travel position and run the engine at max RPM. 3. Establish an approach section of 5 m. 4. Travel in each speed for 20 m and record measurement A in the figure. • • • •

Engine : Max RPM Bucket : Empty Hydraulic oil temperature : 50 ± 5 °C (122 ± 9 °F). Perform the measurement several times and performance based on the average.

(1) 20 m (66 ft, 787.4 in.) (2) 10 m (33 ft, 393.7 in.)

judge

(3) At Least 5 m (16 ft, 196.8 in.) RY9212334HYS0007US0

3-S4

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

AUX Flow Measurement CAUTION • Be sure to make the connections between the hose and the flow meter correctly. (If hoses are misconnected, the flow meter, pump and/or hoses will be damaged.) To Connect • Push the quick couplers tightly and hold for a few seconds, the pressure is relieved automatically. To Disconnect • Push the quick couplers tightly and hold for a few seconds, then retract the sleeves until the couplers disconnect. 1. 2. 3. 4. 5.

Remove front attachment. Park the machine in a flat, hard location. Lower the lift arm all the way down. See connection. Connect the AUX discharge (high-pressure side) and the IN side of the flow meter with a hose. 6. Connect the OUT side of the flow meter and the AUX discharge (high-pressure side) with a hose. 7. Open the valve of the flow meter all the way and start the engine. 8. Perform the measurement 3 times; take the average and use this as the measurement value. [High-flow version] 1. Push the AUX port switch (4) in direction B. 2. Slide the AUX port switch to the right. 3. Maximum discharge flow for port 1. Measurement Conditions • Engine RPM: Rated RPM • Oil Temperature: 50 ± 5 °C (122 ± 9 °F) • Parking brake: ON (1) Port 1 (Quick Connector, Female) (6) (2) Port 2 (Quick Connector, Male) (7) (3) Hose for Measuring (G3/4-G3/4, Pressure Rating: at Least 27.5 MPa, (A) 4000 psi) (B) (4) Quick Connector (Male) (5) Joint (G3/4)

Flow Meter Valve Male Port Female Port

RY9212334HYS0006US0

Wheel Speed Test 1. 2. 3. 4. 5. 6. 7. 8.

Remove the front attachment. Park the machine on level and firm ground. Put jack stands under the frame. See, jack up the machine. Install reflective tape. Engine at Max. rpm. Push front of control lever (left) down. Record tire speed using hand held digital tachometer. Compare tire speed specification.

• • • •

Engine : Max RPM Bucket : None Hydraulic oil temperature : 50 ± 5 °C (122 ± 9 °F) Perform the measurement several times and performance based on the average.

judge

(a) Reflective tape RY9212334HYS0005US0

3-S5

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

HST Pump Flow Measurement

(1) HST Pump (2) HST Motor (3) Flow Meter

(4) Valve (a) (5) Plug (b) (6) Test Hose [3 m (9.8 ft, 120 in.)] (c) (d)

Port A (Right Forward) Port B (Right Backward) Port C (Left Forward) Port D (Left Backward)

A : Motor (Right) B : Motor (Left)

(To be continued)

3-S6

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued) DANGER • Do not allow anyone to approach the machine during testing. CAUTION • Be careful not to make a mistake in the direction of hose connections or in the direction of travel of the loader. (If misconnected, the flow meter, HST pump and/or HST motor will be damaged.) 1. Remove front attachment. 2. Park the machine in a flat, hard location. 3. See connection. 4. Lower the lift arm all the way down. 5. The method for measuring when traveling right-forward is described as an example. 6. After disconnecting the hoses between the HST pump and the HST motor, attach hoses to the flow meter as shown in the figure at up. 7. Plug the (right) hydraulic hoses. 8. Completely open the flow meter valve. 9. Lower the cabin. When the cabin is lowered, check and make sure no hoses, such as those for measuring, get caught. 10. Start the engine and run it at max RPM. 11. Put the travel lever in forward and measure the flow and pressure in 1st and 2nd speeds. 12. When measuring the flow other than right-forward, refer to the table below to connect the flow meter and pressure gauge. Measurement Conditions • Engine RPM: rated RPM • Oil temperature: 50 ± 5 °C (122 ± 9 °F) • Parking brake: OFF Flow meter IN connection port

Flow meter OUT connection port

Right forward

Right backward

Left forward

Left backward

(3) Flow Meter (4) Valve (6) Test Hose [3 m (9.8 ft, 120 in.)]

(a) Port A (Right Forward) (b) Port B (Right Backward) RY9212334HYS0008US0

3-S7

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Joint A

32 mm (1.26 in.)

Material: S20C O-Ring: HNBR (Hg95)

(a) 15 ° (b) 45 ° (c) 30 ° RY9212334HYS0009US0

Measuring the Main Relief Valve Pressure

• 1. 2. 3. 4. 5. 6. 7. 8. 9.

DANGER Do not allow anyone to approach the machine during testing. Remove front attachment. Park the machine in a flat, hard location. Lower the lift arm all the way down. See connection. Remove the plug of the gear pump (front operation/P1) and attach a pressure port and pressure gauge. Lower the cabin. When the cabin is lowered, check and make sure no hoses, such as those for measuring, get caught. Start the engine and run it at max RPM. Operate the front control lever so the bucket crowds to the end and relieves the pressure. Perform the measurement 3 times; take the average and use this as the measurement value.

Measurement Conditions • Engine RPM: Rated RPM • Oil Temperature: 50 ± 5 °C (122 ± 9 °F) • Parking brake: ON (1) Plug (R1/8) (2) Pressure Gauge (3) Pressure Port

(a) Back of Machine

RY9212334HYS0010US0

3-S8

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Measuring the Over Load Relief Valve Pressure DANGER • Do not allow anyone to approach the machine during testing. 1. Remove front attachment. 2. Park the machine in a flat, hard location. 3. Lower the lift arm all the way down. 4. See connection. 5. Remove the plug of the gear pump (front operation/P1) and attach a pressure port and pressure gauge. 6. Lower the cabin. When the cabin is lowered, check and make sure no hoses, such as those for measuring, get caught. 7. Start the engine and run it at max RPM. 8. Raise and lower the lift arm, crowd and dump the bucket until pressure is relieved and record each of the pressures. 9. Compare the values recorded in step 6 to the pressure setting of the main relief valve and if the value for any operation is low, then the overload relief valve for that operation is judged to be no good. 10. Perform the measurement 3 times; take the average and use this as the measurement value. Measurement Conditions • Engine RPM: Rated RPM • Oil Temperature: 50 ± 5 °C (122 ± 9 °F) • Parking brake: ON (1) Plug (R1/8) (2) Pressure Gauge (3) Pressure Port

(a) Back of Machine

RY9212334HYS0011US0

3-S9

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Measuring the High Flow Valve Pressure DANGER • Do not allow anyone to approach the machine during testing. 1. Remove front attachment. 2. Park the machine in a flat, hard location. 3. Lower the lift arm all the way down. 4. See connection. 5. Remove the plug of the gear pump (high flow pump/P2) and attach a pressure port and pressure gauge. 6. Lower the cabin. When the cabin is lowered, check and make sure no hoses, such as those for measuring, get caught. 7. Start the engine and run it at max RPM. 8. Slide the AUX knob switch (4) to the right and relieves the pressure. 9. Perform the measurement 3 times; take the average and use this as the measurement value. Measurement Conditions • Engine RPM: Rated RPM • Oil Temperature: 50 ± 5 °C (122 ± 9 °F) • Parking brake: ON (1) (2) (3) (4)

Plug (R1/8) Pressure Gauge Pressure Port Knob Switch

(a) Back of Machine

RY9212334HYS0014US0

3-S10

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Measuring the Charge Pump Relief Valve Pressure DANGER • Do not allow anyone to approach the machine during testing. 1. Remove front attachment. 2. Park the machine in a flat, hard location. 3. Lower the lift arm all the way down. 4. See connection. 5. Remove the plug of the gear pump (charge pump/P3) and attach a pressure port and pressure gauge. 6. Lower the cabin. When the cabin is lowered, check and make sure no hoses, such as those for measuring, get caught. 7. Start the engine and run it at max RPM. 8. Disconnect the fan motor connector. 9. Perform the measurement 3 times; take the average and use this as the measurement value. Measurement Conditions • Engine RPM: Rated RPM • Oil Temperature: 50 ± 5 °C (122 ± 9 °F) • Parking brake: ON (1) Plug (R1/8) (2) Pressure Gauge (3) Pressure Port

(a) Back of Machine

RY9212334HYS0015US0

3-S11

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Measuring Travel Relief Valve Pressures

1. Select a hard, flat location, lower the lift arm all the way down, and put the machine up on jack stands. 2. Stop the engine and lift the cabin. 3. To measure the pressure for FWD, attach pressure gauges to the hydraulic outlet port (2) of Port B's joint and to pressure measurement port D (4). 4. To measure the pressure for BWD, attach pressure gauges to the pressure port (1) of Port A's joint and to pressure measurement port C (3). 5. Lower the cabin. When the cabin is lowered, check and make sure nothing, such as measurement hoses, gets caught. 6. Push the parking brake switch (5) in direction A and apply the parking brake. 7. Run the engine to max RPM and put the travel lever in FWD or BWD and move it to the end of its stroke. 8. Record the value on the pressure gauge. Port No. Right forward

Right backward

Left forward

Left backward

• Hydraulic oil temperature : 50 ± 5 °C (122 ± 9 °F). • Perform the measurement several times and performance based on the average. (1) (2) (3) (4) (5)

Pressure Port (Port A) Pressure Port (Port B) Port C Port D Parking Brake Switch

judge

(a) Back of Machine (A) Forward (B) Backward RY9212334HYS0016US0

3-S12

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

3. HYDRAULIC EQUIPMENT [1] HST PUMP (1) Specifications

(1) (2) (3) (4) (5)

Port A : Forward (Right) Port B: Backward (Right) Port C : Forward (Left) Port D: Backward (Left) Port M4 (Pressure Guage for Left Backward) (6) Port M1 (Pressure Guage for Right Forward)

(7) Charge Relief Valve (11) Port M3 (Pressure Guage for (a) Engine Side (8) Port M2 (Pressure Guage for Left Forward) (b) Machine Top Right Backward) (12) Port A (High Pressure Relief (9) Port B (High Pressure Relief Valve) Valve) (13) Port C (High Pressure Relief (10) Port D (High Pressure Relief Valve) Valve)

Item Direction of rotation

SSV65

Notes

Rotates right viewed from engine side

Rated RPM

2700 rpm

Max Displacement

35 cc/rev 2.1 in3/rev

High-pressure relief valve pressure setting

34.5 MPa 350 kgf/cm2 5000 psi

Charge relief valve pressure setting

2.83 MPa 28.9 kgf/cm2 410 psi RY9212332HYS0264US0

3-S13

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

(To be continued)

3-S14

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued) No.

Name of part

Quant ity

Notes

No.

Name of part

Quant ity

(1)

Internal circlip

(24)

O-ring

(2)

External circlip

(25)

O-ring

(3)

Ball bearing

(26)

Plug assembly

(4)

Shaft

(27)

O-ring

(5)

Bolt

(28)

Block

(6)

Cover assembly

(29)

Bolt

(7)

Oil seal

(30)

Coupling

(8)

O-ring

(31)

O-ring

(9)

Bearing assembly

(32)

O-ring

(10)

O-ring

(33)

O-ring

(11)

Plug assembly

(34)

Block

(12)

Housing

(35)

Plug assembly

(13)

(36)

O-ring

(14)

Cover

(37)

Shim

(15)

Swash-plate

(38)

Spring

(16)

Thrust plate

(39)

Poppet

(17)

Cylinder block kit

(40)

Valve plate

(18)

Valve plate

(41)

Housing

(19)

Needle bearing

(42)

Shaft

(20)

(43)

Key

(21)

Gasket

(44)

Axis seal

(45)

Plate

(22)

Bolt

(23)

Main relief valve assembly

Notes

RY9212332HYS0103US0

3-S15

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement STD version

(a) 30 °

(b) 35 °

No.

Parts Name

Q'ty

A : Clearance

No.

Parts Name

Q'ty

(1)

Pump assy

(10)

Joint (S, 105U, 105U)

(2)

Stud bolt

(11)

Joint (L, 105, 115, R1)

(3)

Spring washer

(12)

Joint (S, 1-1/16, 115)

(4)

Nut

(13)

Joint (S, 105U, 105U)

(5)

Joint (L, 105U, 105U)

(14)

Joint (S, 1-1/16, 105)

(6)

Joint (S, 105U, 105U)

(7)

Joint (L, 105, 115, R1)

A: 6.3 mm (0.25 in.) or less

(8)

Plug (seal)

PT1/8

(9)

Joint (S, 105U, 105U)

(15)

Joint (S, 1-1/16, 115)

(16)

Joint (T, 7/8U, 3/4U)

(17)

Joint (T, 3-9/16U)

(18)

Joint (T, 105U, 16-2)

Remarks

A: 3.3 mm (0.13 in.) or less

(To be continued)

3-S16

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued)

Tightening torque

Stud bolt (2)

39.2 to 45.1 N·m 4.0 to 4.6 kgf·m 29.0 to 33.2 lbf·ft

Joint (5) (6) (7) (9) (10) (11) (13) (14) (15)

130.0 to 144.0 N·m 13.3 to 14.7 kgf·m 95.9 to 106.2 lbf·ft

Plug (seal) (8)

19.6 to 29.4 N·m 2.0 to 3.0 kgf·m 14.5 to 21.6 lbf·ft

Nut (4)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Joint (14)

165.0 to 175.0 N·m 16.8 to 17.8 kgf·m 121.7 to 129.0 lbf·ft RY9212332HYS0273US0

3-S17

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

High-Flow version

(a) 30 °

(b) 35 °

No.

Parts Name

Q'ty

A : Clearance

No.

Parts Name

Q'ty

(1)

Pump assy

(11)

Joint (L, 105, 115, R1)

(2)

Stud bolt

(12)

Joint (S, 1-1/16, 115)

(3)

Spring washer

(13)

Joint (S, 105U, 105U)

(4)

Nut

(14)

Joint (S, 1-1/16, 105)

(5)

Joint (L, 105U, 105U)

(15)

Joint (S, 1-1/16, 115)

(6)

Joint (S, 105U, 105U)

(16)

Joint (T, 7/8U, 3/4U)

(7)

Joint (L, 105, 115, R1)

A: 6.3 mm (0.25 in.) or less

(17)

Joint (T, 3-9/16U)

(8)

Plug (seal)

PT1/8

(18)

Joint (T, 105U, 16-2)

(9)

Joint (S, 105U, 105U)

(19)

Joint (T, 3/4U, 9/16U)

(10)

Joint (S, 105U, 105U)

Remarks

A: 3.3 mm (0.13 in.) or less

(To be continued)

3-S18

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued)

Tightening torque

Stud bolt (2)

39.2 to 45.1 N·m 4.0 to 4.6 kgf·m 29.0 to 33.2 lbf·ft

Joint (5) (6) (7) (9) (10) (11) (13) (14) (15)

130.0 to 144.0 N·m 13.3 to 14.7 kgf·m 95.9 to 106.2 lbf·ft

Plug (seal) (8)

19.6 to 29.4 N·m 2.0 to 3.0 kgf·m 14.5 to 21.6 lbf·ft

Nut (4)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Joint (14)

165.0 to 175.0 N·m 16.8 to 17.8 kgf·m 121.7 to 129.0 lbf·ft RY9212332HYS0274US0

3-S19

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(4) Assembly

(a) Right Side

(b) Left Side

No.

Parts Name

Q'ty

(1)

Hose (1-3/16-12UN)

(2)

Hose (1-3/16-12UN)

Tightening torque

Hose

Remarks

No.

Parts Name

Q'ty

(3)

Hose (1-3/16-12UN)

(4)

Hose (1-3/16-12UN)

Remarks

157 to 165 N·m 16.0 to 16.8 kgf·m 116 to 121 lbf·ft RY9212332HYS0275US0

3-S20

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(5) Pump Coupling

(a) HST Pump Side No.

(b) Engine Side

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty

(1)

Housing (pump)

(7)

Hex socket bolt

(2)

Bolt

(8)

Spring washer

(3)

Parallel pin

(9)

Nut

(4)

Coupling

(10)

Stud

(5)

Coupling (hub)

(11)

Spring washer

(6)

Disk

(12)

Nut

Pump housing mounting stud (1), (10)

24.1 to 28 N·m 2.5 to 2.9 kgf·m 17.8 to 20.6 lbf·ft

Hex socket bolt (7)

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.4 to 20.2 lbf·ft

Nut (9)

259.9 to 304.0 N·m 26.5 to 31.0 kgf·m 191.7 to 224.2 lbf·ft

Nut (12)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Tightening torque

Remarks

3/4-16UNF

RY9212332HYS0241US0

3-S21

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(6) Removal and Installation CAUTION • When removing a hydraulic device after operating the machine, lower the lift arm and bucket to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the machine. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212079HYS0028US0

1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Put the jack stands under the rear corners of the frame. (1) Lift Arm

(2) Jack Stands RY9212332MBS0144US0

1. Remove the mat. (1) Mat RY9212332HYS0002US0

1. Remove the step. Tightening torque

Bolt

9.8 to 11.3 N·m 1.00 to 1.15 kgf·m 7.20 to 8.33 lbf·ft

(1) Step RY9212332HYS0003US0

3-S22

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the cover. Tightening torque

17.7 to 20.6 N·m 1.8 to 2.1 kgf·m 13.1 to 15.2 lbf·ft

Bolt

RY9212332HYS0032US0

1. Loosen the drain hose clamp, remove the plug, and drain out the hydraulic oil. 2. To make it easier to drain the hydraulic oil, remove the oil filler cap from the hydraulic oil tank. (1) Drain hose RY9212332HYS0005US0

1. Remove all hoses connected to the HST and gear pumps. 2. Remove the control link. (1) HST Pump (2) Gear Pump

(3) Control Link RY9212332HYS0006US0

1. Remove the gear pump. Tightening torque

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Bolt

RY9212332HYS0034US0

1. Remove the spring. CAUTION • If you suddenly loosen the bolt for a spring, the spring may fly out, so do not put your face near the spring. Also, do not place your body in front of the spring when loosening the bolt to remove it. (1) Spring

(2) Bolt RY9212332HYS0033US0

3-S23

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Attach a nylon sling to the HST pump and support with a crane. CAUTION • Take suitable care with the way of hooking the nylon sling when performing the task. 2. While supporting with a crane, remove the mounting nuts and bolts for the HST pump. 3. Detach the HST pump from the engine section, and lift it to remove. 77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Nut Tightening torque Bolt HST pump

Factory spec (reference value)

65.5 kg 144 lbs

NOTE • Lift the HST pump slowly and carefully so that it does not interfere with adjacent accessory parts. (1) HST pump

(2) Nylon sling RY9212332HYS0007US0

(7) Disassembly/Assembly [A] Disassembly Procedures 1. Remove the gear. (1) Gear RY9212332HYS0104US0

1. Remove the bolts and take out half. (1) Bolt RY9212332HYS0105US0

1. Remove the coupling. (1) Coupling RY9212332HYS0106US0

3-S24

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the internal circlip. (1) Internal circlip RY9212332HYS0107US0

1. Remove the plate. (1) Plate RY9212332HYS0108US0

1. Remove the carrier shaft seal. (1) Carrier Shaft Seal RY9212332HYS0091US0

1. Remove the internal circlip. (1) Internal circlip RY9212332HYS0109US0

3-S25

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the relief valve. (1) Relief valve RY9212332HYS0110US0

1. Remove the charge relief valve. (1) Poppet (2) Spring

(3) Plug assembly RY9212332HYS0111US0

1. Remove the block. (1) Block

(2) Bolt RY9212332HYS0112US0

1. Remove the valve plate. (1) Valve plate RY9212332HYS0113US0

3-S26

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the cylinder block kit. (1) Cylinder block kit RY9212332HYS0114US0

1. Remove the gasket. (1) Gasket RY9212332HYS0115US0

1. Remove the assy shaft. (1) Assy Shaft RY9212332HYS0092US0

3-S27

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the cover. (1) Cover RY9212332HYS0116US0

1. Remove the O-ring. (1) O-Ring RY9212332HYS0117US0

3-S28

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the bearing assy. (1) Bearing Assy RY9212332HYS0093US0

1. Remove the swash-plate. (1) Swash-Plate RY9212332HYS0094US0

1. Remove the oil seal. (1) Oil seal RY9212332HYS0118US0

1. Remove the needle bearing. IMPORTANT • The needle bearing is not to be reused. (1) Needle bearing RY9212332HYS0119US0

3-S29

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[B] Assembly Procedures Precautions on Assembly Replacing Seals All seals and gasket must be replaced when disassembling the HST pump. Replacing O-rings Thoroughly clean the mounting groove before fitting the O-ring. Apply hydraulic fluid to the O-ring, for smoothness of assembly. If not sufficiently lubricated, O-rings may become twisted during assembly, resulting in oil leakage. RY9212332HYS0232US0

1. Use a press to insert and install the needle bearing. (1) Needle bearing

(a) Needle bearing press-fit tool RY9212332HYS0120US0

1. Install the swash-plate. (1) Swash-plate RY9212332HYS0121US0

1. Install the bearing assembly. (1) Bearing assembly RY9212332HYS0122US0

3-S30

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the O-rings. (1) O-ring RY9212332HYS0123US0

1. Install the oil seal. (1) Oil seal RY9212332HYS0124US0

1. Install the cover. Tightening torque

(1) Cover

24 to 30 N·m 2.4 to 3.1 kgf·m 18 to 22 lbf·ft

Bolt

(2) Bolt RY9212332HYS0125US0

3-S31

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the assy shaft. (1) Assy Shaft RY9212332HYS0095US0

1. Assemble the internal circlip. (1) Internal circlip RY9212332HYS0126US0

1. Use a press to insert and install the shaft seal. IMPORTANT • Be careful that the shaft seal faces the right direction. (1) Shaft seal

(a) Shaft seal press-fit tool RY9212332HYS0127US0

1. Install the plate. (1) Plate RY9212332HYS0128US0

3-S32

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Assemble the internal circlip. (1) Internal circlip RY9212332HYS0129US0

1. Install the gasket. (1) Gasket RY9212332HYS0130US0

Cylinder Block Kit Components (a) Cylinder Block (b) Plate (Retainer) (c) Pin

(d) Holder (Retainer) (e) Piston Assy (f) Plate RY9212332HYS0096US0

1. Pins install them in the cylinder block. IMPORTANT • Apply a small amount of grease to the pin. (a) Cylinder Block

3-S33

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the plate on the holder (retainer). (d) Holder (retainer)

(f)

Plate RY9212332HYS0131US0

1. Install the holder (retainer). (d) Holder (Retainer) RY9212332HYS0098US0

1. Install the piston assemblies in the plate (retainer) and install them all into the cylinder block. IMPORTANT • Apply hydraulic oil to the piston assy. • Make sure the piston assys move smoothly. • Be careful to install the plate (retainer) facing the right direction. (a) Cylinder Block (b) Plate (Retainer)

(e) Piston Assy RY9212332HYS0099US0

1. Install the cylinder block kit. (1) Cylinder block kit RY9212332HYS0132US0

1. Install the valve plate. (1) Valve plate RY9212332HYS0133US0

3-S34

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the block. Tightening torque

47 to 61 N·m 4.8 to 6.2 kgf·m 35 to 45 lbf·ft

Bolt

(1) Block

(2) Bolt RY9212332HYS0134US0

1. Install the charge relief valve. Tightening torque

Plug assembly

(1) Poppet (2) Spring

54 to 135 N·m 5.5 to 13.8 kgf·m 40 to 100 lbf·ft (3) Plug assembly RY9212332HYS0135US0

Components (1) Poppet (2) Spring

(3) Shim (4) Plug assembly RY9212332HYS0136US0

1. Install the relief valve. Tightening torque

Relief valve

41 to 68 N·m 4.2 to 6.9 kgf·m 30 to 50 lbf·ft

(1) Relief valve RY9212332HYS0137US0

3-S35

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the coupling. (1) Coupling RY9212332HYS0138US0

1. Install the left and right pumps. Tightening torque

47 to 61 N·m 4.8 to 6.2 kgf·m 35 to 45 lbf·ft

Bolt

(1) HST pump

(2) Bolt RY9212332HYS0139US0

1. Install the key and then install the gear. (1) Key

(2) Gear RY9212332HYS0140US0

(8) Special Tools No.

Parts Name

(A)

Gear installation tool

(B)

Shaft seal mounting tool

(C)

Oil seal, needle bearing mounting tool RY9212332HYS0100US0

(A) Gear installation tool A

70 mm (

2.8 in.)

60 mm (

2.4in.)

90 mm (3.5in.)

5.0 mm (0.2 in.)

1.0 mm (0.0394 in.)

1.0 mm (0.0394 in.) Material: S45C RY9212332HYS0101US0

3-S36

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(B) Shaft seal mounting tool A B

72 mm ( (

2.835 in.)

35.5 mm +0.1, -0 1.398 in. +0.00394, -0)

107.5 mm (4.232 in.)

95 mm (3.740 in.)

15 mm (0.591 in.)

55 mm (2.165 in.)

80 mm (3.150 in.)

H I

5 mm (

0.197 in.)

50 mm (

1.968 in.)

1.0 mm (0.0394 in.)

(a)

5°

(b)

45 °

(c)

6.3S

Material: S55C RY9212038HYS0376US0

200 mm (7.874 in.)

182 mm (7.165 in.)

60.5 mm (2.382 in.)

D E F

25 mm (

0.984 in.)

18 mm (0.709 in.) 17 mm (

0.669 in.)

1.0 mm (0.0394 in.)

1.0 mm (0.0394 in.) RY9212332HYS0141US0

13 mm (0.512 in.)

6.0 mm (0.236 in.)

32 mm (

1.3 in.)

40 mm (

1.6in.)

E F R1

11.5 mm (0.45 in.) 17 mm (

0.669 in.)

1.0 mm (0.0394 in.) RY9212332HYS0142US0

13 mm (0.512 in.)

8.0 mm (0.315 in.)

19 mm (

0.748 in.)

24.5 mm (

0.965 in.)

E F R1

3.7 mm (0.146 in.) 17 mm (

0.669 in.)

1.0 mm (0.0394 in.) RY9212332HYS0102US0

3-S37

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(9) Neutral Adjustment 1. Loosen bolts (1) and (2). 2. Align the travel lever (right) with the position where the right tire does not rotate. 3. Temporarily fasten bolt (1). NOTE • When putting bolts in place temporarily, tighten them until the head touches the washer. 4. Align the travel lever (left) with the position where the left tire does not rotate. 5. Temporarily fasten bolt (2). NOTE • When putting bolts in place temporarily, tighten them until the head touches the washer. 6. Align the travel lever (right) with the position where the right tire does not rotate again, and then tighten bolt (1). 7. Align the travel lever (left) with the position where the left tire does not rotate again, and then tighten bolt (2). Tightening torque

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt

8. After adjustment, measure the RPM of the front and rear tires. Travel RPM (1) Bolt (2) Bolt

Factory spec (reference value)

130 +/- 1 rpm

(3) Travel lever (right) (4) Travel lever (left) RY9212332HYS0233US0

3-S38

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(10) Backup Buzzer Adjustment 1. Loosen bolts (1) and (2). 2. Align the travel lever (right) with the position where the right tire begins to shift backward. 3. Slide the stay (7) to align with the position where the backup buzzer sounds continuously, and then temporarily fasten bolt (1). NOTE • When putting bolts in place temporarily, tighten them until the head touches the washer. 4. Align the travel lever (left) with the position where the left tire begins to shift backward. 5. Slide the stay (8) to align with the position where the backup buzzer sounds continuously, and then temporarily fasten bolt (2). NOTE • When putting bolts in place temporarily, tighten them until the head touches the washer. 6. Align the travel lever (right) with the position where the right tire begins to shift backwards again, confirm that the backup buzzer sounds continuously, and then tighten bolt (1). 7. Align the travel lever (left) with the position where the left tire begins to shift backwards again, confirm that the backup buzzer sounds continuously, and then tighten bolt (2). Tightening torque

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

8. Align the travel lever (right)(left) with the position where the tire starts to shift backwards, and confirm that the backup buzzer sounds. (1) (2) (3) (4)

Bolt Bolt Backup buzzer connector (right) Backup buzzer connector (left)

(5) (6) (7) (8)

Travel lever (right) Travel lever (left) Stay Stay RY9212332HYS0234US0

3-S39

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[2] GEAR PUMP (1) Specifications

(1) Front Operation Pump (P1) Delivery Port 7/8-14UNF

(2) Charge Pump (P3) Delivery Port 7/8-14UNF

Item Direction of rotation

SSV65

Remarks

Rotates right viewed from the axle side

Rated RPM Theoretical discharge volume

(3) Suction Port

2700 rpm Front operation pump (P1)

24.7 cc/rev 1.51 in3/rev

Charge pump (P3)

18.1 cc/rev 1.10 in3/rev RY9212332HYS0242US0

(2) Components No.

Parts Name

Q'ty

(1)

Cover front

(2)

Cover rear

(3)

Body

(4)

Gear drive (1st)

(5)

Gear driven (1st)

(6)

Gear drive (2nd)

(7)

Gear driven (2nd)

(8)

Side plate

(9)

Bush

(10)

Gasket (3-shaped)

(11)

Back up

(12)

Gasket

(13)

Bolt

(14)

Washer

(15)

Oil seal

(16)

Retainer ring

Remarks

RY9212332HYS0243US0

3-S40

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement No.

Parts Name

Q'ty

Remarks

(1)

Pump assy

(2)

Joint (S, 7/8U, 7/8U)

(3)

Joint (L, 7/8U)

A: 3.1 mm (0.12 in.) or less

(4)

Plug (seal)

PT1/8

(5)

Joint (S, 7/8U, 3/4U)

A: 6.8 mm (0.27 in.) or less

(6)

Plug (seal)

PT1/8

(7)

Main relief valve

(8)

Joint (S, 3/4U, 7/8U)

(9)

Joint (L, 3/4U, 16)

(10)

Water temperature sensor

Joint (5)

61.6 to 75.6 N·m 6.3 to 7.7 kgf·m 13.9 to 16.9 lbf·ft

Main relief valve (7)

34.0 to 39.0 N·m 3.5 to 4.0 kgf·m 7.65 to 8.76 lbf·ft

Tightening torque

(a) 20 ° (b) 55 ° (c) 90 °

A : Clearance

RY9212332HYS0254US0

3-S41

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[3] GEAR PUMP (HIGH-FLOW VERSION OPTION) (1) Specifications

(1) Front Operation Pump (P1) (2) High-Flow Pump (P2)

(3) Charge Pump (P3) (4) First Suction Port

(5) Second Suction Port (6) Discharge Port (P1)

Item Direction of rotation

Remarks

Rotates right viewed from the axle side

Rated RPM

Theoretical discharge volume

SSV65

(7) Discharge Port (P2) (8) Discharge Port (P3)

2700 rpm Front operation pump (P1)

25.3 cc/rev 1.55 in3/rev

High-flow pump (P2)

14.0 cc/rev 0.85 in3/rev

Charge pump (P3)

17.1 cc/rev 1.05 in3/rev RY9212332HYS0244US0

3-S42

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

No.

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty

(1)

Cover front

(15)

Side plate

(2)

Body

(16)

Bush

(3)

Gear drive

(17)

Bush

(4)

Gear driven

(18)

Gasket (3-shaped)

(5)

Side plate

(19)

Gasket

(6)

Adapter plate

(20)

Back up strip

(7)

Body

(21)

Gasket (3-shaped)

(8)

Gear drive

(22)

Gasket

(9)

Gear driven

(23)

Oil seal

(10)

Side plate

(24)

Retainer ring

(11)

Adapter plate

(25)

Bolt

(12)

Body

(26)

Washer

(13)

Gear drive

(27)

Steel ball

(14)

Gear driven

Remarks

RY9212332HYS0245US0

3-S43

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement No.

Parts Name

Q'ty

Remarks

(1)

Pump assy

(2)

Flange bolt

(3)

Joint (S, 7/8U, 7/8U)

(4)

Joint (L, 7/8U)

(5)

Plug (seal)

PT1/8

(6)

Joint (L, 7/8U, 3/4U)

A: 6.8 mm (0.27 in.) or less

(7)

Joint (7/8U, 3/4U)

(8)

Main relief valve

(9)

Joint (S, 3/4U, 7/8U)

A: 3.1 mm (0.12 in.) or less

(10)

Joint (L, 3/4U, 16)

A: 6.8 mm (0.27 in.) or less

(11)

Water temperature sensor

A: 6.8 mm (0.27 in.) or less

Tightening torque

(a) (b) (c) (d)

20 ° 50 ° 65 ° Apply Grease

Flange bolt (2)

39.2 to 45.1 N·m 4.00 to 4.59 kgf·m 29.0 to 33.2 lbf·ft

Joint (7)

61.6 to 75.6 N·m 6.3 to 7.7 kgf·m 13.9 to 16.9 lbf·ft

Main relief valve (8)

34.0 to 39.0 N·m 3.5 to 4.0 kgf·m 7.65 to 8.76 lbf·ft

A : Clearance

RY9212332HYS0255US0

3-S44

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[4] CONTROL VALVE (1) Specifications

No.

Parts Name

Pressure

Remarks

SSV65

(1)

Main relief valve

22.5 + 0.49/0 MPa 230 + 5/0 kgf/cm2 3270 + 70/0 psi

(2)

Overload relief valve

24.5 + 0.49/0 MPa 250 + 5/0 kgf/cm2 3550 + 70/0 psi

A1 Lift arm up

(3)

Overload relief valve

30.0 + 0.49/0 MPa 306 + 5/0 kgf/cm2 4350 + 70/0 psi

B1 Lift arm up

(4)

Overload relief valve

30.0 + 0.49/0 MPa 306 + 5/0 kgf/cm2 4350 + 70/0 psi

A2 Bucket crowd

(5)

Overload relief valve

24.5 + 0.49/0 MPa 250 + 5/0 kgf/cm2 3550 + 70/0 psi

B2 Bucket dump

(6)

Overload relief valve

24.5 + 0.49/0 MPa 250 + 5/0 kgf/cm2 3550 + 70/0 psi

A3 AUX RY9212332HYS0236US0

3-S45

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Joints Arrangement

(a) 15 ° (b) 16 to 18 ° No.

Q'ty

Remarks

Clearance

Clearance 8 mm (0.3 in.) or Less

No.

Parts Name

Q'ty

(1)

Control valve assy

(6)

Joint (L, 105U, 105U)

(2)

Joint (S, 105U, 105U)

(7)

Filter assy (9/16, 9/16)

(3)

Joint (L, 105U, 105U)

(8)

Joint (L, 9/16, 9/16)

(4)

Joint (T, 105U, 3/4U)

(9)

Joint (L, 7/8U, 7/8U)

(5)

Joint assy

A: 5.7 mm (0.22 in.) or less

Remarks

A: 3.1 mm (0.12 in.) or less

RY9212332HYS0237US0

3-S46

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Assembly Assembly 1

(a) 20 °

No. (1) (2)

Parts Name Control valve assy Joint (arm rod)

Back of Machine Q'ty

Remarks

No.

Parts Name

Q'ty

Piping (AUX, high) (6)

Piping (AUX)

(3)

Joint (bucket rod)

(7)

Piping (AUX, low)

(4)

O-ring

(8)

O-ring

(5)

Joint bolt

(9)

Joint bolt

(10)

Joint (L, 3/4U, 3/4U)

Joint bolt (5)

58.8 to 63.7 N·m 6.0 to 6.5 kgf·m 44 to 46 lbf·ft

Joint bolt (9)

117.6 to 127.4 N·m 12.0 to 13.0 kgf·m 87 to 93 lbf·ft

Tightening torque

Remarks

High-flow version

RY9212332HYS0238US0

3-S47

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Assembly 2

(a) AUX Low No.

(b) AUX High Parts Name

Q'ty

A : Front of Machine Remarks

No.

Parts Name

Q'ty

(6)

Clamp (Pipe, AUX, 1)

(7)

Clamp (Pipe, AUX, 2)

(8)

Cushion (Pipe, AUX)

(1)

Piping (AUX, Low)

(2)

Piping (AUX, High)

(3)

Clamp (Pipe, AUX)

(9)

Collar (Pipe, AUX)

(4)

Collar (Clamp, Pipe, AUX)

(10)

Clamp (Pipe, CV, 1)

(5)

Bolt

(11)

Clamp (1, Front)

High-flow version

Remarks

1. Mount the clamp and hold it in place temporarily with the joint bolts. 2. Tighten the joint bolts. 3. Tighten the clamp bolts. Tightening torque

Bolt (5)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft RY9212332HYS0239US0

3-S48

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Assembly 3

(a) Apply Grease No.

(b) Apply Adhesive

Parts Name

Q'ty

Remarks

(d) Left Hand Screw

No.

Parts Name

Q'ty

(12)

Linkage (Pedal, Arm)

(1)

Bracket

(2)

Bolt

(13)

Linkage (Pedal, Bucket)

(3)

Pedal

(14)

Grease nipple

(4)

Shaft (Pedal)

(15)

Shaft (Linkage)

(5)

Bolt

(16)

Bolt

(6)

Rod (Pedal)

(17)

Linkage

(7)

Rod end (Right hand screw)

Right hand screw

(18)

Snap pin (

(8)

Rod end (Left hand screw)

Left hand screw

(19)

Snap pin (

10)

Apply adhesive

(9)

Snap nut

(20)

Boot

(10)

Nut

(21)

Bolt

(11)

Nut (Left hand screw)

(22)

Trim

Left hand screw

Bolt (2)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Bolt (21)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Tightening torque

Remarks

RY9212332HYS0240US0

3-S49

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(4) Removal and Installation 1. Raise the lift arm. (See the "Raise Lift Arm Procedure" page.) RY9212332ENS0014US0

1. Open the cab. (See, "Cab Tilt" page.) RY9212332HYS0011US0

1. Remove the mat. (1) Mat RY9212332HYS0002US0

1. Remove the step. Tightening torque

Bolt

9.8 to 11.3 N·m 1.00 to 1.15 kgf·m 7.20 to 8.33 lbf·ft

(1) Step RY9212332HYS0003US0

1. Remove the cover. Tightening torque

Bolt

17.7 to 20.6 N·m 1.8 to 2.1 kgf·m 13.1 to 15.2 lbf·ft RY9212332HYS0032US0

3-S50

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Set the vacuum pump. (See, "Install the Vacuum Pump" page.) RY9212332HYS0012US0

1. Remove all of the hoses connected to the control valve. (1) Control Valve RY9212332HYS0013US0

1. Remove the lines in the order shown in the photo on the right. 2. Remove the link and connector. RY9212332HYS0036US0

1. Remove the control valve. Tightening torque

Control Valve

48.1 to 55.9 N·m 4.90 to 5.70 kgf·m 35.5 to 41.2 lbf·ft

Bolt

Factory spec (reference value)

26.2 kg 57.8 lbs RY9212332HYS0037US0

3-S51

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(5) Disassembly/Assembly

(To be continued) 3-S52

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued) No.

Name of part

Quant ity

Notes

No.

Name of part

Quant ity

Notes

No.

Name of part

Quant ity

(1)

Bolt

(33)

Valve

(65)

Detent ball

(2)

Bolt

(34)

Plunger

(66)

Detent

(3)

Flat metal washer

(35)

Spring

(67)

Cap nut

(4)

Case

(36)

Plug

(68)

Actuator

(5)

Bolt

(37)

Packing

(69)

Spring

(6)

Solenoid valve

(38)

Solenoid valve

(70)

Housing

(7)

O-ring

(39)

Spring

(71)

Spring

(8)

Plunger

(40)

Bolt

(72)

Bolt

(9)

Spring

(41)

Bolt

(73)

Guides

(10)

Plug

(42)

Cap

(74)

Flat metal washer

(11)

Packing

(43)

Flat metal washer

(75)

(12)

O-ring

(44)

Guides

(76)

Case

(13)

Valve

(45)

Flat metal washer

(77)

Flat metal washer

(14)

O-ring

(46)

(78)

Backup ring

(15)

Bolt

(47)

Case

(79)

O-ring

(16)

Solenoid valve

(48)

Flat metal washer

(80)

O-ring

(17)

Case

(49)

Backup ring

(81)

Backup ring

(18)

Flat metal washer

(50)

O-ring

(82)

Guides

(19)

Bolt

(51)

O-ring

(83)

Bolt

(20)

Bolt

(52)

Backup ring

(84)

Spool

(21)

Guides

(53)

Guides

(85)

Socket

(22)

Spring

(54)

Bolt

(86)

Spool

(23)

Guides

(55)

Spool

(87)

Packing

(24)

O-ring

(56)

O-ring

(88)

Guides

(25)

Flat metal washer

(57)

Valve

(89)

Spring

(26)

Spool

(58)

Plunger

(90)

O-ring

(27)

O-ring

(59)

Spring

(91)

Guides

(28)

Flat metal washer

(60)

Plug

(92)

O-ring

(29)

Guides

(61)

Packing

(93)

Case

(30)

Spring

(62)

Cap

(94)

Adjustment screw

(31)

Guides

(63)

Guides

(95)

Nut

(32)

O-ring

(64)

Nut

(96)

Cap

Notes

RY9212332HYS0222US0

3-S53

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[A] AUX Section AUX section components No.

Name of part

Quantity

Tightening torque

(1)

Case

(2)

Solenoid valve

(3)

Bolt

5 to 7 N·m 0.5 to 0.7 kgf·m 4 to 5 lbf·ft

(4)

Bolt

5 to 7 N·m 0.5 to 0.7 kgf·m 4 to 5 lbf·ft

(5)

Flat metal washer

(6)

Guides

(7)

Shim

(8)

Spring

(9)

Flat metal washer

(10)

O-ring

(11)

Spool

1 RY9212332HYS0040US0

3-S54

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[B] Bucket Section Bucket section components No.

Name of part

Quantity

Tightening torque

(1)

Cap

(2)

Bolt

5 to 7 N·m 0.5 to 0.7 kgf·m 4 to 5 lbf·ft

(3)

Bolt

5 to 7 N·m 0.5 to 0.7 kgf·m 4 to 5 lbf·ft

(4)

Flat metal washer

(5)

Guides

(6)

Spring

(7)

O-ring

(8)

Backup ring

(9)

Flat metal washer

(10)

Spool

(11)

Guides

(12)

Bolt

(13)

Guides

(14)

Nut

(15)

Solenoid valve

(16)

Adjustment bolt

(17)

Spring

(18)

(19)

Case

5 to 7 N·m 0.5 to 0.7 kgf·m 4 to 5 lbf·ft

20 to 30 N·m 2.1 to 3.1 kgf·m 15 to 22 lbf·ft

RY9212332HYS0039US0

3-S55

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[C] Lift Arm Section Lift arm section components No.

Name of part

Quantity

(1)

Cap nut

(2)

Nut

(3)

Cap

(4)

Bolt

(5)

Guides

(6)

Spring

(7)

Flat metal washer

(8)

Backup ring

(9)

O-ring

(10)

Spool

(11)

Guides

(12)

Bolt

(13)

Guides

(14)

Nut

(15)

Solenoid valve

(16)

Adjustment bolt

(17)

Spring

(18)

(19)

Case

Tightening torque 5 to 7 N·m 0.5 to 0.7 kgf·m 4 to 5 lbf·ft

5 to 7 N·m 0.5 to 0.7 kgf·m 4 to 5 lbf·ft

20 to 30 N·m 2.1 to 3.1 kgf·m 15 to 22 lbf·ft

RY9212332HYS0038US0

[D] Main Relief Valve and Overload Relief Valve Main relief valve and overload relief valve components No.

Name of part

Quantity

(1)

Cap

(2)

Adjustment screw

(3)

Case

(4)

Guides

(5)

O-ring

(6)

Spring

(7)

Guides

(8)

Spool

(9)

Socket

(10)

Plug

(11)

Spring

(12)

Valve

Tightening torque

120 to 160 N·m 12.2 to 16.3 kgf·m 88.5 to 118.0 lbf·ft

RY9212332HYS0041US0

3-S56

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[E] Check Valve Check valve section components No.

Name of part

Quantity

(1)

Plug

(2)

Spring

(3)

Plunger

Tightening torque

RY9212332HYS0042US0

[5] TRAVEL MOTOR (1) Specifications

A : Right Side

B : Left Side

No.

Port symbol

Name

Screw size

(1)

Forward

1-1/16-12UNF

(2)

Drain port

7/8-14UNF

(3)

Travel 2-speed change port

3/4-16-UNF

(4)

Backward

1-1/16-12UNF

(5)

Parking brake port

3/4-16-UNF RY9212332HYS0265US0

Item Suction volume/1 revolution

SSV65

Slow

560 cm 34.2 in3

Fast

350 cm3 21.4 in3

Parking brake release pressure

Notes

1.2 MPa 12 kgf/cm2 170 psi RY9212332HYS0266US0

3-S57

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

(To be continued)

3-S58

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(Continued) No.

Name of part

Quant ity

Notes

No.

Name of part

Quant ity

(1)

Shaft

(24)

O-ring

(2)

Seal

(25)

Piston

(3)

Bearing assembly

(26)

(4)

Stud bolt

(27)

Spring

(5)

Body

(28)

Seal ring

(6)

Oil seal

(29)

Seal ring

(7)

Bearing assembly

(30)

Seal ring

(8)

Shim

(31)

Seal ring

(9)

External circlip

(32)

O-ring

(10)

Clip

(33)

O-ring

(11)

Plate

(34)

O-ring

(12)

Cylinder block

(35)

O-ring

(13)

Roller

(36)

O-ring

(14)

Bushing

(37)

(15)

Piston

(38)

Snap ring

(16)

Piston ring

(39)

O-ring

(17)

O-ring

(40)

Cover

(18)

Brake piston

(41)

Backup ring

(19)

O-ring

(42)

O-ring

(20)

Spring

(43)

Backup ring

(21)

Internal circlip

(44)

O-ring

(22)

Washer

(45)

Backup ring

(23)

Spool

(46)

Flushing relief valve

Notes

RY9212332HYS0164US0

3-S59

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement HST Motor Left Side No.

Parts Name

Q'ty

Remarks

(1)

Motor assy

(2)

Stud bolt

(3)

Flange

(4)

Bolt

(5)

O-ring

(6)

Joint (S, 105U, 105U)

(7)

Joint (L, 105U, 105U)

A: 5.1 mm (0.20 in.) or less

(8)

Joint (L, 1-1/16, 115)

A: 4.0 mm (0.16 in.) or less

(9)

Joint (S, 115U, 105U)

(10)

Joint (S, 3/4U, 9/16U)

(11)

Joint (S, 7/8U, 3/4U)

(12)

Joint (S, 1-1/16, 115)

Stud bolt (2)

83.3 to 98.0 N·m 8.5 to 10.0 kgf·m 61.5 to 72.2 lbf·ft

Joint (6) (7) (8) (9)

165.0 to 175.0 N·m 16.8 to 17.8 kgf·m 121.7 to 129.0 lbf·ft

Joint (10)

56.0 to 62.0 N·m 5.7 to 6.3 kgf·m 41.3to 45.7 lbf·ft

Joint (11)

74.0 to 82.0 N·m 7.6 to 8.4 kgf·m 54.6 to 60.4 lbf·ft

Tightening torque

(a) 10 ° (b) 40 ± 2 ° (c) 88 to 90 °

Apply adhesive (Loctite 263)

A : Clearance B : Apply Adhesive RY9212332HYS0276US0

3-S60

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

HST Motor Right Side No.

Parts Name

Q'ty

Remarks

(1)

Motor assy

(2)

Stud bolt

(3)

Flange

(4)

Bolt

(5)

O-ring

(6)

Joint (L, 105U, 105U)

A: 5.1 mm (0.20 in.) or less

(7)

Joint (S, 1-1/16, 115)

A: 3.3 mm (0.13 in.) or less

(8)

Joint (S, 105U, 105U)

(9)

Joint (L, 1-1/16, 115)

(10)

Joint (S, 3/4U, 9/16U)

(11)

Joint (S, 7/8, 3/4U)

Stud bolt (2)

83.3 to 98.0 N·m 8.5 to 10.0 kgf·m 61.5 to 72.2 lbf·ft

Joint (6) (7) (8) (9)

165.0 to 175.0 N·m 16.8 to 17.8 kgf·m 121.7 to 129.0 lbf·ft

Joint (10)

56.0 to 62.0 N·m 5.7 to 6.3 kgf·m 41.3to 45.7 lbf·ft

Joint (11)

74.0 to 82.0 N·m 7.6 to 8.4 kgf·m 54.6 to 60.4 lbf·ft

Tightening torque

(a) 10 °

Apply adhesive (Loctite 263)

A : Clearance B : Apply Adhesive RY9212332HYS0277US0

3-S61

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(4) Removal and Installation CAUTION • When removing a hydraulic device after operating the machine, lower the lift arm and bucket to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the machine. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212079HYS0028US0

1. Set the lift arm to the down end. 2. Remove the gear. (See, "Assembly/Disassembly of the Chain and Sprocket" page.) RY9212332HYS0014US0

1. Remove the gear pump. (See, "Assembly/Disassembly of the HST Pump" page.) RY9212332HYS0043US0

1. Disconnect all the hoses connected to the HST travel motor. (1) Travel motor RY9212332HYS0044US0

3-S62

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Attach a nylon sling to the HST motor and support with a crane, then remove the bolts and nuts, and remove the HST motor. Bolt Tightening torque

166.7 to 196.1 N·m 17.0 to 20.0 kgf·m 123.0 to 144.6 lbf·ft

Nut

Apply a thread lock(Loctite® 263) to the bolts during assembly. Travel motor

Factory spec (reference value)

(1) HST motor (2) Nylon sling (3) Bolt

57.7 kg 127 lbs

(4) Bolt (5 Nut RY9212332HYS0015US0

(5) Disassembly/Assembly [A] Disassembly Procedures 1. Use a press to insert and remove the snap ring. (1) Snap ring

(a) HST motor clamping tool RY9212332HYS0165US0

1. Remove the pin. (1) Pin RY9212332HYS0166US0

1. Remove the cover assembly. (1) Cover assembly

(a) HST motor clamping tool RY9212332HYS0167US0

3-S63

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the spring. (1) Spring RY9212332HYS0168US0

1. Align with the position where the pin is inserted, and add a mark. RY9212332HYS0169US0

1. Remove the o-ring. (1) O-Ring RY9212332HYS0170US0

1. Use a C-clamp to insert the piston assembly and remove the pin. (1) Pin

(a) Piston press-fit tool RY9212332HYS0171US0

1. Remove the piston assembly. (1) Piston assembly RY9212332HYS0172US0

3-S64

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the spring. (1) Spring RY9212332HYS0173US0

1. Remove the spool and spring. (1) Spool (2) Spring

(3) Spring RY9212332HYS0174US0

1. Remove the internal circlip. (1) Internal circlip RY9212332HYS0175US0

1. Remove the washer. (1) Washer RY9212332HYS0176US0

3-S65

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Split the seal ring, and remove. (1) Seal ring

1. Remove the O-ring. IMPORTANT • The O-ring is not to be reused. (1) O-ring RY9212332HYS0177US0

1. Remove the brake piston. (1) Brake piston RY9212332HYS0178US0

1. Remove the O-ring. IMPORTANT • The O-ring is not to be reused. (1) O-ring

(2) O-ring RY9212332HYS0179US0

3-S66

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the cylinder block assembly. (1) Cylinder block assembly RY9212332HYS0180US0

1. Remove the clip. (1) Clip RY9212332HYS0181US0

1. Remove the piston assembly. (1) Piston assembly RY9212332HYS0182US0

1. Remove the plate. (1) Plate RY9212332HYS0183US0

1. Remove the roller. (1) Roller RY9212332HYS0184US0

3-S67

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the bushing. (1) Bushing RY9212332HYS0185US0

1. Remove the piston ring. IMPORTANT • The piston ring is not to be reused. (1) Piston ring RY9212332HYS0186US0

1. Insert the bearing assembly and remove the external circlip. (1) External circlip

(a) Bearing press-fit tool RY9212332HYS0187US0

1. Remove the shim. (1) Shim RY9212332HYS0188US0

3-S68

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Use a press to insert and remove the shaft assembly. RY9212332HYS0189US0

1. Remove the bearing assembly. (1) Bearing assembly RY9212332HYS0190US0

1. Use a press to insert and remove the bearing assembly. (1) Bearing assembly (2) Shaft assy

(a) Bearing removing tool RY9212332HYS0191US0

1. Remove the bearing collar. (1) Bearing collar

(2) Bearing collar RY9212332HYS0192US0

3-S69

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the oil seal. IMPORTANT • The oil seal is not to be reused. (1) Oil seal RY9212332HYS0193US0

[B] Assembly Procedures Precautions on Assembly Replacing Seals All seals must be replaced when disassembling the HST motor. Replacing O-rings Thoroughly clean the mounting groove before fitting the backup ring and O-ring. Take care over the backup ring location. Apply grease or hydraulic fluid to the backup ring and O-ring, for smoothness of assembly. If not sufficiently lubricated, O-rings may become twisted during assembly, resulting in oil leakage. RY9212332HYS0224US0

1. Install the oil seal. IMPORTANT • Apply a small amount of grease to the outer circumferential surface of the oil seal. • Be careful that the oil seal faces the right direction. (1) Oil seal

(a) Oil seal press-fit tool RY9212332HYS0194US0

1. Use a press to insert and install the bearing assembly. (1) Bearing assembly (2) Shaft assy

(a) Bearing press-fit tool RY9212332HYS0195US0

3-S70

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Use a press to insert and install the bearing collar. (1) Bearing collar (2) Bearing collar

(a) Bearing collar press-fit tool RY9212332HYS0196US0

1. Use a press to insert and install the shaft assembly. RY9212332HYS0197US0

1. Use a press to insert and install the bearing assembly. (a) Bearing press-fit tool RY9212332HYS0198US0

1. Install the shim. (1) Shim RY9212332HYS0199US0

3-S71

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Assemble the external circlip. IMPORTANT • Install so that the gap between the external circlip and shim is 0.1 mm or less. (1) External circlip RY9212332HYS0221US0

1. Install the piston ring on the piston. NOTE • Apply a small amount of hydraulic oil to the piston ring. (1) Piston ring RY9212332HYS0200US0

1. Install the bush. (1) Bush RY9212332HYS0201US0

1. Install the roller. (1) Roller RY9212332HYS0202US0

1. Install the plate. IMPORTANT • Make sure the plate is facing the right way. (1) Plate RY9212332HYS0203US0

3-S72

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the piston assembly. (1) Piston assembly RY9212332HYS0204US0

1. Assemble the clip. (1) Clip RY9212332HYS0205US0

1. Install the cylinder block assembly. (1) Cylinder block assembly RY9212332HYS0206US0

1. Install the O-ring on the brake piston. IMPORTANT • Apply a small amount of hydraulic oil to the O-ring. (1) O-ring

(2) O-ring RY9212332HYS0207US0

3-S73

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the brake piston. (1) Brake piston RY9212332HYS0208US0

1. Install the O-ring on the piston assembly. IMPORTANT • Apply a small amount of hydraulic oil to the O-ring. (1) O-ring RY9212332HYS0209US0

1. Install the seal ring. IMPORTANT • Apply a small amount of hydraulic oil to the seal ring. (1) Seal ring RY9212332HYS0210US0

1. Install the washer. (1) Washer RY9212332HYS0211US0

1. Assemble the internal circlip. (1) Internal circlip RY9212332HYS0212US0

3-S74

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the spool and spring. (1) Spool (2) Spring

(3) Spring RY9212332HYS0213US0

1. Install the springs. (1) Spring RY9212332HYS0214US0

1. Install the piston assembly. IMPORTANT • When installing the piston assembly, align it with the matching mark. (1) Piston assembly RY9212332HYS0215US0

1. Use a C-clamp to insert the piston assembly and install the pin. (1) Pin

(a) Piston press-fit tool RY9212332HYS0216US0

1. Install the o-ring. (1) O-ring RY9212332HYS0217US0

3-S75

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the spring. (1) Spring RY9212332HYS0218US0

1. Install the cover assembly. (1) Cover assembly

(a) HST motor clamping tool RY9212332HYS0219US0

1. Use a press to insert and install the pin and snap ring. (1) Pin

(2) Snap ring RY9212332HYS0220US0

3-S76

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(6) Special Tools No. in Figure

Name of part

(A)

Bearing collar press-fit tool

(B)

Oil seal press-fit tool

(C)

Bearing removing tool

(D)

Bearing press-fit tool

(E)

Piston press-fit tool

(F)

HST motor clamping tool RY9212332HYS0225US0

Bearing collar press-fit tool A

200 mm (7.874 in.)

182 mm (7.165 in.)

60.5 mm (2.382 in.)

D E

25 mm (

0.984 in.)

18 mm (0.709 in.)

17 mm (

0.669 in.)

1.0 mm (0.0394 in.)

13 mm (0.512 in.)

6 mm (0.236 in.)

97 mm (

3.8 in.)

83 mm (

3.3 in.)

107 mm (

4.21 in.)

93 mm (

3.7 in.)

45 mm (1.8 in.)

17 mm (

38 mm (1.5 in.)

0.669 in.)

1.0 mm (0.0394 in.) RY9212332HYS0226US0

Oil seal press-fit tool A B

59 mm (

2.32 in.)

69 mm (

2.72 in.)

154 mm (6.063 in.)

35 mm (1.37 in.)

10 mm (0.394 in.)

20 mm (

M16 x P1.75

0.78 in.)

RY9212332HYS0227US0

3-S77

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Bearing removing tool A

86 mm (

3.4 in.)

76 mm (3.0 in.)

150 mm (5.91 in.)

10 mm (0.394 in.)

1.0 mm (0.0394 in.)

• Material: S45C • Surface treatment: Hard chrome plating on whole surface (hardness: HV800 above, thickness: 0.01 or more) RY9212332HYS0235US0

Bearing press-fit tool A

100 mm (3.94 in.)

50 mm (1.97 in.)

80 mm (

3.15 in.)

61.3 mm (

10 mm (0.394 in.)

2.41 in.)

RY9212332HYS0228US0

Piston press-fit tool A

60 mm (

2.36 in.)

40 mm (1.57 in.) RY9212332HYS0229US0

3-S78

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Travel motor clamping tool A

150 mm (5.90 in.)

215 mm (

8.46 in.)

180 mm (

7.10 in.) RY9212332HYS0230US0

[6] FAN MOTOR (1) Specifications

(1) Inlet Port

(2) Outlet Port

(3) Drain Port

Item Direction of rotation

SSV65

(4) Solenoid Valve Remarks

Rotates left viewed from the axle side

Rated RPM

2700 rpm

Theoretical discharge volume

16 cc/rev 0.98 in3/rev RY9212332HYS0256US0

3-S79

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

No.

Name of part

Qua ntity

Notes

No.

Name of part

Qua ntity

(1)

Nut

(12)

Seal

(2)

Washer

(13)

Body

(3)

Key

(14)

Driveshaft

(4)

Internal circlip

(15)

Seal

(5)

Plate

(16)

(6)

Oil seal

(17)

Backup ring

(7)

Driveshaft

(18)

Case

(8)

Bushing

(19)

Plug

(9)

Cover

(20)

Gasket

(10)

Washer

(21)

Check valve

(11)

Bolt

(22)

Solenoid valve

Notes

RY9212332HYS0143US0

3-S80

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement

(a) 20 °

(b) Direction of Rotation

No.

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty

(1)

Collar

(5)

Joint (L, 7/8U, 3/4U)

(2)

Fan

(6)

Joint (L, 9/16U, 13)

(3)

Flange bolt

(7)

Hose clamp (13-20)

(4)

Joint (S, 7/8U, 7/8U)

Tightening torque

Flange bolt (3)

Remarks

2.35 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft RY9212332HYS0257US0

3-S81

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(4) Removal and Installation 1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Put the jack stand under the center of the rear frame. 5. Open the hood. (1) Lift Arm (2) Rear Frame

(3) Jack Stands (4) Hood RY9212332ENS0001US0

1. Remove the radiator. (See, "Assembly/Disassembly of the radiator" page.) RY9212332ENS0055US0

1. Set the vacuum pump. (See, "Install the Vacuum Pump" page.) RY9212332HYS0012US0

1. Remove the fan. Tightening torque

(1) Fan

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

(2) Bolt RY9212332HYS0144US0

1. Remove the fan motor hose and connectors. (1) Fan motor RY9212332HYS0145US0

3-S82

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the fan motor. Tightening torque

Bolt

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 36.1 to 41.2 lbf·ft

(1) Fan motor RY9212332HYS0146US0

(5) Disassembly/Assembly Precautions on Assembly Replacing Seals All seals and gasket must be replaced when disassembling the fan motor. Replacing O-rings Thoroughly clean the mounting groove before fitting the backup ring and O-ring. Take care over the backup ring location. Apply grease or hydraulic fluid to the backup ring and O-ring, for smoothness of assembly. If not sufficiently lubricated, O-rings may become twisted during assembly, resulting in oil leakage. RY9212332HYS0231US0

[During disassembly] Remove the nut. [During assembly] Install the nut. Tightening torque

Nut

49 to 54 N·m 5.0 to 5.5 kgf·m 37 to 39 lbf·ft

(1) Nut RY9212332HYS0147US0

[During disassembly] Remove the washer. [During assembly] Install the washer. (1) Washer RY9212332HYS0148US0

[During disassembly] Remove the fan collar. [During assembly] Install the fan cover. (1) Fan collar RY9212332HYS0149US0

3-S83

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[During disassembly] Remove the key. [During assembly] Install the key. IMPORTANT • Make sure the key is facing the right way during installation. (1) Key RY9212332HYS0150US0

[During disassembly] Remove the solenoid valve. [During assembly] Install the solenoid valve. Nut (1)

34 N·m 3.5 kgf·m 25 lbf·ft

Nut (3)

12 N·m 1.2 kgf·m 8.8 lbf·ft

Tightening torque

(1) Nut (2) Solenoid valve

(3) Nut RY9212332HYS0151US0

[During disassembly] Remove the bolts and then the cover. [During assembly] Install the cover and tighten the bolts. Tightening torque

60 to 70 N·m 6.2 to 7.1 kgf·m 45 to 51 lbf·ft

Bolt

(1) Cover

(2) Bolt RY9212332HYS0152US0

[During disassembly] Remove the seal. IMPORTANT • Do not reuse seals once removed. [During assembly] Install the seal. IMPORTANT • Apply a small amount of hydraulic oil to the seal. (1) Seal RY9212332HYS0153US0

[During disassembly] Remove the bushing. [During assembly] Install the bushing. (1) Bushing RY9212332HYS0154US0

3-S84

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[During disassembly] Remove the backup ring, and then the seal. IMPORTANT • Do not reuse the backup ring and seal once removed. [During assembly] Install the seal, and then install the backup ring. IMPORTANT • Apply a small amount of hydraulic oil to the seal and backup ring.. (1) Backup ring

(2) Seal RY9212332HYS0155US0

[During disassembly] Remove the drive shaft. [During assembly] Install the drive shaft. (1) Driveshaft RY9212332HYS0156US0

[During disassembly] Remove the bushing. [During assembly] Install the bushing. (1) Bushing RY9212332HYS0157US0

(2) Seal RY9212332HYS0155US0

3-S85

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[During disassembly] Remove the internal circlip. [During assembly] Assemble the internal circlip. (1) Internal circlip RY9212332HYS0159US0

[During disassembly] Remove the plate. [During assembly] Install the plate. (1) Plate RY9212332HYS0160US0

[During disassembly] Remove the oil seal.

[During assembly] Install the oil seal. • Tool to use: Oil seal press-fit tool (1) Oil seal RY9212332HYS0161US0

3-S86

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[7] LIFT ARM CYLINDER (1) Specifications Item

SSV65

Tube O.D.

75 mm 3.0 in.

Tube I.D.

65 mm 2.56 in.

Rod diameter

40 mm 1.57 in.

Remarks

665 ± 2 mm 26.2 ± 0.08 in.

Stroke

1025 mm 40.35 in.

Max retracted length

RY9212332HYS0246US0

(2) Components

No.

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty

(1)

Cylinder rod

(7)

Spacer

(2)

Rod wiper

(8)

Guide ring

(3)

Cylinder head

(9)

Piston seal

(4)

Rod seal

(10)

O-ring

(5)

O-ring

(11)

Piston

(6)

Backup ring

(12)

Bolt

Cylinder head (3)

700 ± 10 N·m 71.4 ± 1 kgf·m 516 ± 7.4 lbf·ft

Bolt (12)

500 ± 10 N·m 51 ± 1 kgf·m 369 ± 7.4 lbf·ft

Tightening torque

Remarks

RY9212332HYS0258US0

3-S87

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Removal and Installation CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the lift arm and bucket to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. • The work should always be carried out by 2 persons. RY9212332HYS0019US0

1. Remove the front attachment. 2. Select a firm-solid, level surface, and stop the machine. 3. Lower the lift arm so it is fully extended to the ground, and stop the engine. 4. Put the jack stand under the center of the rear frame. 5. Open the hood. (1) Lift Arm (2) Rear Frame

(3) Jack Stands (4) Hood RY9212332ENS0001US0

1. Set the vacuum pump. (See, "Install the Vacuum Pump" page.) RY9212332HYS0012US0

1. Remove the detent nuts and then remove the bolts. 2. Raise the lift arm so that the lift arm boss is above the bonnet. (1) Bolt

(2) Detent nut RY9212332HYS0046US0

3-S88

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Use a crane to support the arm, and secure the end of the arm on the jack stands to prevent it from dropping. (1) Jack Stands RY9212332HYS0047US0

1. Remove the pin. (1) Pin RY9212332HYS0048US0

1. Remove the hose and plug it. 2. Remove the bolt and remove the hose clamp. Tightening torque

(1) Hose (2) Bolt

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Bolt

(3) Hose Clamp RY9212332HYS0021US0

1. Remove the nylon sling from the lift arm, and then hook the nylon sling on the lift arm cylinder to hold it. (1) Lift arm cylinder

(2) Nylon sling RY9212332HYS0022US0

1. While supporting with a crane, remove the detent nuts and bolts. 2. Slide the pin in to a position where it will not come into contact with the oil filter. (1) Detent nut (2) Bolt

(3) Pin RY9212332HYS0023US0

3-S89

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the lift arm cylinder. (1) Lift arm cylinder RY9212332HYS0049US0

NOTE • When assembling a stop nut, ensure there is a gap (a) between the nut and the hose. • Remove the lift arm cylinder (left) using the lift arm cylinder (right) operation procedure. Arm cylinder

Factory specification (reference value)

36.3 kg 80 lbs

(a) 1 to 3 mm RY9212332HYS0030US0

(4) Disassembly/Assembly 1. Drain the oil from the cylinder, fasten the tube on a vice and cylinder holder. IMPORTANT • Place the block on the cylinder holder to prevent it becoming scratched. (1) Tube RY9212332HYS0058US0

[During disassembly] 1. Loosen the cylinder head. CAUTION • Because loctite has been applied to the cylinder head, you can easily remove it by lightly heating it up with gas. [During assembly] 1. Tighten the cylinder head to the prescribed torque. IMPORTANT • Apply Loctite® to the threads of the cylinder head. (1) Cylinder head RY9212332HYS0081US0

3-S90

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[During disassembly] 1. Remove the cylinder head and piston rod. IMPORTANT • Check if the pipe cap has been removed. • Place an oil receptacle under the port on the cylinder head. • Draw the piston rod out, keeping it horizontal, to avoid dropping it and causing damage to parts immediately after it is withdrawn. [During assembly] 1. Fasten the tube on a vice and cylinder holder, and install the piston rod. IMPORTANT • Apply a small amount of hydraulic oil to the cylinder head and piston. (1) Cylinder head

(2) Piston rod RY9212332HYS0082US0

[During disassembly] 1. Fasten the piston rod on a vice and cylinder holder, and remove the bolts. CAUTION • Because loctite has been applied to the bolts, you can easily remove them by lightly heating them up with gas. [During assembly] 1. Tighten the bolts to the prescribed torque. IMPORTANT • Apply Loctite to the bolts. (1) Bolt RY9212332HYS0083US0

[During disassembly] 1. Remove the piston. [During assembly] 1. Install the pistons. (1) Piston RY9212332HYS0084US0

Replacing Seals • • • • •

CAUTION All seals must be replaced when disassembling the cylinder. Thoroughly clean the mounting groove before fitting the backup ring and O-ring. Take care over the backup ring location. Apply grease or hydraulic fluid to the backup ring and O-ring, for smoothness of assembly. If not sufficiently lubricated, O-rings may become twisted during assembly, resulting in oil leakage. RY9212332HYS0059US0

3-S91

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Remove the slide ring. IMPORTANT • Do not reuse the slide ring. (1) Slide Ring RY9212332HYS0060US0

1. Remove the O-ring. (1) O-ring RY9212332HYS0085US0

Cut off and remove the seal ring assembly. IMPORTANT • Do not reuse the seal ring assembly. • Mount a cushion plate in the vise to prevent damage to the piston. • Tool: Screwdriver (-) and hammer (1) Seal Ring ASSY RY9212332HYS0061US0

Remove the wiper ring. IMPORTANT • Do not reuse the wiper ring. • Tool: Screwdriver (-) and hammer (1) Wiper Ring RY9212332HYS0062US0

Remove the U-ring seal. IMPORTANT • Do not reuse the U-ring. • Tool: Screwdriver (-) (1) U-Ring RY9212332HYS0063US0

3-S92

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the backup ring. (1) Backup ring RY9212332HYS0087US0

Remove the O-rings and backup ring from the cylinder head. CAUTION • Take care not to gouge your finger with the tool. IMPORTANT • Do not reuse the O-rings or the backup ring after removing them. • Take care not to damage the cylinder head with the screwdriver. • Tool: Screwdriver (-) (1) Cylinder Head (2) O-Ring

(3) Backup Ring (4) O-Ring RY9212332HYS0064US0

1. Install the U-rings. IMPORTANT • Apply a small amount of hydraulic oil to the outer circumference of the U-ring. • Be careful that the U-ring faces the right direction. (1) U-ring RY9212332HYS0088US0

1. Install the backup ring. IMPORTANT • Apply a small amount of hydraulic oil to the outer circumference of the backup ring. (1) Backup ring RY9212332HYS0089US0

1. Install the wiper ring. IMPORTANT • Apply a small amount of hydraulic oil to the outer circumference of the wiper ring. (1) Wiper ring RY9212332HYS0090US0

3-S93

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Install the O-ring and backup ring. IMPORTANT • Apply a small amount of hydraulic oil to the O-ring and backup ring. (1) Backup ring

(2) O-ring RY9212332HYS0065US0

1. Install the O-ring. IMPORTANT • Apply a small amount of hydraulic oil to the O-ring. (1) O-ring RY9212332HYS0066US0

1. Install the seal ring insertion inner tool (B). • Tool to use: Seal ring insertion inner tool (B) RY9212332HYS0067US0

Install the seal ring assembly. • Tool: Inner part of seal ring inserting jig (B), seal ring inserting jig (C) (1) Seal Ring ASSY RY9212332HYS0068US0

Use a piston ring pressing jig (A) to seat the seal ring assembly. • Tool: Pressing jig (A) RY9212332HYS0069US0

3-S94

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Install the slide ring. (1) Slide Ring RY9212332HYS0070US0

Cylinder Inspection 1. Warping of the piston rod 1. Put the piston rod by itself on the V blocks. 2. Set a dial gauge on the center of the rod. 3. Rotate the piston rod and read the measurements on the dial gauge. Warpage equals 1/2 the difference in the readings. 4. Replace any rod that exceeds its usage limit. • Factory spec for warpage : 0.05 mm (0.002 in.) ≥ • Usage limit for warpage : 0.5 mm (0.02 in.) 2. Wear in the rod and bushings 1. Measure the diameter of the outside of the piston rod and that of the inside of the bushing in the cylinder head and calculate the gap.

Factory specification

Allowable limits

Rod size

Gap

25 to 40 mm 0.99 to 1.5 in.

0.25 mm ≥ 0.01 in. ≥

45 to 75mm 1.8 to 3.0 in.

0.30 mm ≥ 0.01 in. ≥

25 to 40 mm 0.99 to 1.5 in.

0.4 mm 0.02 in.

45 to 75mm 1.8 to 3.0 in.

0.5 mm 0.02 in.

3. Wear in the tube and piston ring 1. Measure the inside diameter of the cylinder tube. 2. Measure the outside diameter of the piston ring and calculate the clearance.

Factory specification

Allowable limits

Rod size

Gap

60 mm ≥ 2.4 in. ≥

0.05 to 0.30 mm 0.002 to 0.01 in.

65 to 115 mm 2.6 to 4.53 in.

0.05 to 0.35 mm 0.002 to 0.01 in.

120 mm ≤ 4.72 in. ≤

0.05 to 0.40 mm 0.002 to 0.02 in.

60 mm ≥ 2.4 in. ≥

0.60 mm 0.02 in.

65 to 115 mm 2.6 to 4.53 in.

0.70 mm 0.03 in.

120 mm ≤ 4.72 in. ≤

0.80 mm 0.03 in. RY9212001HYS0469US0

3-S95

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(5) Special Tools No.

Parts Name

(A)

Piston Ring Compression Tool

(B)

Seal ring inserting jig

(C)

Seal ring inserting jig RY9212332HYS0071US0

3-S96

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(A) Piston Ring Compression Tool Bucket cylinder A

78 mm (

3.1 in.)

77 mm (

3.0 in.)

C D

(

68 mm +0.1,-0 2.7 in. +0.00394, -0)

(

65 mm +0.05,-0 2.6 in. +0.00197, -0)

71.3 mm (

78 mm (3.1 in.)

2.81 in.)

30 mm (1.2 in.)

23 mm (0.91 in.)

Lift arm cylinder A

83 mm (

3.3 in.)

82 mm (

3.2 in.)

C D

73 mm +0.1,-0 ( 2.9 in. +0.00394, -0) (

70 mm +0.05,-0 2.8 in. +0.00197, -0)

76.3 mm (

78 mm (3.1 in.)

3.0 in.)

30 mm (1.2 in.)

23 mm (0.91 in.)

Quick hitch cylinder A

73 mm (

2.9 in.)

72 mm (

2.8 in.)

C D

63 mm +0.1,-0 ( 2.5 in. +0.00394, -0) (

60 mm +0.05,-0 2.4 in. +0.00197, -0)

66.3 mm (

78 mm (3.1 in.)

2.61 in.)

30 mm (1.2 in.)

23 mm (0.91 in.)

• Material quality: S45C • Surfacing: Hardened chrome plating on entire surface (Hardness HV800+, thickness 0.01 or more) C0.5 : 0.5 mm (0.0197 in.) R1 : 1.0 mm (0.0394 in.) R2 : 2.0 mm (0.0787 in.)

(a) (b) (c) (d)

R20 to 30 Cotton Buffed Finish 1.6 15 ° 6° RY9212332HYS0072US0

3-S97

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(B) Seal ring inserting jig Bucket cylinder A B

(

65.7 mm ± 0.25 2.59 in. ± 0.0098)

(

64.7 mm -0.3, -0 2.55 in. +0.0118, -0)

55.7 mm (

2.19 in.)

50 mm (

72 mm (2.8 in.)

47.6 mm (1.87 in.)

10 mm (0.39in.)

2.0 in.)

Lift arm cylinder A B

(

70.7 mm ± 0.25 2.78 in. ± 0.0098)

(

69.7 mm -0.3, -0 2.74 in. +0.0118, -0)

60.7 mm (

2.39 in.)

55 mm (

72 mm (2.8 in.)

2.2 in.)

47.6 mm (1.87 in.)

10 mm (0.39in.)

Quick hitch cylinder A B

(

60.7 mm ± 0.25 2.39 in. ± 0.0098)

(

59.7 mm -0.3, -0 2.35 in. +0.0118, -0)

50.7 mm (

2.0 in.)

45 mm (

72 mm (2.8 in.)

47.6 mm (1.87 in.)

10 mm (0.39in.)

1.8 in.)

• Material quality: S45C • Surfacing: Hardened chrome plating on entire surface (Hardness HV800+, thickness 0.01 or more) C0.5 : 0.5 mm (0.0197 in.) R0.2 : 0.2 mm (0.00787 in.) R0.3 : 0.3 mm (0.0118 in.) R1 : 1.0 mm (0.0394 in.) R1.5 : 1.5 mm (0.0591 in.)

(a) R20 to 30 (b) Cotton Buffed Finish 1.6 (c) 6 °

RY9212332HYS0073US0

3-S98

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

67 mm ± 0.2 (

2.6 in. ± 0.00787)

60 mm ± 0.2 (

2.4 in. ± 0.00787)

64 mm ± 0.2 (

2.5 in. ± 0.00787)

72 mm (2.8 in.)

10 mm (0.39 in.)

Lift arm cylinder A

72 mm ± 0.2 (

2.8 in. ± 0.00787)

65 mm ± 0.2 (

2.6 in. ± 0.00787)

69 mm ± 0.2 (

2.7 in. ± 0.00787)

72 mm (2.8 in.)

10 mm (0.39 in.)

Quick hitch cylinder A

62 mm ± 0.2 (

2.4 in. ± 0.00787)

55 mm ± 0.2 (

2.2 in. ± 0.00787)

59 mm ± 0.2 (

2.3 in. ± 0.00787)

72 mm (2.8 in.)

10 mm (0.39 in.)

• Material quality: Bakelite (fiber in crowded) • Completely deburred. R0.2 : 0.2 mm (0.00787 in.)

(a) 30 ° (b) 1 to 3 mm RY9212332HYS0074US0

3-S99

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[8] BUCKET CYLINDER (1) Specifications Item

SSV65

Tube O.D.

80 mm 3.1 in.

Tube I.D.

65 mm 2.6 in.

Rod diameter

35 mm 1.4 in.

Stroke

340 ± 2 mm 13.4 ± 0.08 in.

Max retracted length

601 ± 2 mm 23.7 ± 0.08 in.

Remarks

RY9212332HYS0247US0

(2) Components

No.

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty

(1)

Cylinder rod

(7)

Guide ring

(2)

Rod wiper

(8)

Piston seal

(3)

Cylinder head

(9)

O-ring

(4)

Rod seal

(10)

Piston

(5)

O-ring

(11)

Bolt

(6)

Backup ring

Cylinder head (3)

750 ± 10 N·m 76.5 ± 1 kgf·m 553 ± 7.4 lbf·ft

Bolt (11)

500 ± 10 N·m 51 ± 1 kgf·m 369 ± 7.4 lbf·ft

Tightening torque

Remarks

RY9212332HYS0259US0

3-S100

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the bolts and the cover. (1)

Bolt

(2) Cover RY9212332HYS0024US0

1. Remove the front attachment. 2. Switch the quick hitch to the dump end. (1) Lift Arm

(2) Quick Hitch RY9212332HYS0016US0

1. Remove the bucket cylinder hose. (1) Bucket cylinder

(2) Hose RY9212332HYS0026US0

3-S101

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the bucket cylinder bolts, and remove the guide. 2. Remove the pin. Tightening torque

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Bolt

(1) Bucket cylinder (2) Bolt

(3) Guides (4) Pin RY9212332HYS0027US0

1. Remove the bucket cylinder bolts, and remove the plate. Tightening torque

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt

(1) Bucket cylinder (2) Bolt

(3) Plate RY9212332HYS0028US0

1. Remove the bucket cylinder. Bucket cylinder

Factory specification (reference value)

14 kg 31 lbs

(1) Bucket Cylinder RY9212332HYS0029US0

3-S102

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[9] HYDRAULIC QUICK HITCH CYLINDER (1) Specifications Item

SSV65

Tube O.D.

70 mm 2.8 in.

Tube I.D.

60 mm 2.4 in.

Rod diameter

30 mm 1.2 in.

Stroke

232 ± 1.5 mm 9.13 ± 0.06 in.

Max retracted length

618 ± 1.5 mm 24.3 ± 0.06 in.

Remarks

RY9212332HYS0248US0

(2) Components

No.

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty

(1)

Cylinder rod

(4)

Bolt

(2)

Piston

(5)

Wire ring

(3)

Wiper ring

Tightening torque

Bolt (4)

Remarks

90 N·m 9.2 kgf·m 66 lbf·ft RY9212332HYS0260US0

3-S103

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

1. Remove the front attachment. 2. Switch the quick hitch to the dump end. (1) Lift Arm

(2) Quick Hitch RY9212332HYS0016US0

1. Remove the quick hitch cylinder hose. (1) Quick hitch cylinder

(2) Hose RY9212332HYS0017US0

1. Remove the quick hitch cylinder nuts. (1) Quick hitch cylinder

(2) Nut RY9212332HYS0018US0

1. Remove the quick hitch cylinder. (1) Quick hitch cylinder RY9212332HYS0045US0

3-S104

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[10] 3 SPOOL SOLENOID VALVE (1) Specifications

(1) P Port G1/4 (2) Port A1 (Unload) G1/4 Item Rated pressure

Leak volume (P→T)

(3) Port A3 (Travel Two-Speed Switch) G1/4

(4) Port A2 (Parking Brake) G1/4 (5) T Port G1/4

SSV65

Remarks

4.9 MPa 50.0 kgf/cm2 710 psi 300 ml/min or less 0.08 gal/min or less RY9212332HYS0249US0

3-S105

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

(A) Hydraulic Circuit Diagram No.

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty 6

Remarks

(1)

Plug

(7)

Collar plug

G1/4

(2)

Spring, compress

(8)

Hex socket bolt

(3)

Spool

(9)

Rivet screw

(4)

Plate, name

(10)

O-ring

(5)

Solenoid

(11)

O-ring

JISB2401 1B P10

(6)

Body

(12)

O-ring

JISB2401 1B P11

JISB2401 1A P16

RY9212332HYS0250US0

3-S106

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement

(a) 10 ° (b) 15 °

No.

Parts Name

Q'ty

(d) 30 °

Remarks

No.

A : Front of Machine

Parts Name

Q'ty

(1)

Valve, assy

(8)

Joint (S, G2-G2)

(2)

Bolt

(9)

Joint, assy (L, 1, 4)

(3)

Filter assy (G2, 9/16U)

(10)

Joint (L, 9/16U, 9/16U)

(4)

Joint (T, 3-916U)

(11)

Joint (S, G2, 9/16U)

(5)

Joint (L, G2-13)

(12)

Valve, assy (check valve)

(6)

Joint (L, G2, 9/16U)

(13)

Joint (T, G2, G2-G2)

(7)

Joint (L, G2-G2)

Tightening torque

Bolt (2)

Remarks

39.2 to 45.1 N·m 4.00 to 4.59 kgf·m 29.0 to 33.2 lbf·ft RY9212332HYS0261US0

3-S107

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[11] QUICK HITCH SOLENOID VALVE (OPTION) (1) Specifications

(1) P Port (G1/4)

(2) T Port (G1/4) Item

Rated pressure

Leak volume (P→T)

(3) A Port (G1/4) SSV65

(4) B Port (G1/4) Remarks

4.9 MPa 50.0 kgf/cm2 710 psi 220 ml/min or less 0.06 gal/min or less

at 4.9 MPa (50 kgf/cm2, 710 psi) RY9212332HYS0251US0

3-S108

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

(A) Hydraulic Circuit Diagram

No.

Parts Name

(B) Spool Opening Reference Diagram Q'ty

Remarks

(a) Opening Area (mm2)

No.

Parts Name

(b) Stroke (mm)

Q'ty

(1)

Spring, compress

(6)

Collar plug

(2)

Spool

(7)

Hex socket bolt

(3)

Body

(8)

Rivet screw

(4)

Plate, name

(9)

O-ring

(5)

Solenoid

(10)

O-ring

Remarks

RY9212332HYS0252US0

3-S109

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement

(a) 20 °

A : Front of Machine

No. (1)

Parts Name Valve, assy

Q'ty

Remarks

No.

(6)

Parts Name Joint (L, G2-G2)

Q'ty 1

(2)

Bolt

(7)

Joint (T, G2, 13, 13)

(3)

Joint (L, G2, 9/16U)

(8)

Hose (QH, T)

(4)

Filter assy (G2, 9/16U)

(9)

Hose Clamp (13-20)

(5)

Joint (L, 9/16U, 9/16)

Tightening torque

bolt (2)

Remarks

39.2 to 45.1 N·m 4.00 to 4.59 kgf·m 29.0 to 33.2 lbf·ft RY9212332HYS0262US0

3-S110

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[12] HIGH-FLOW SOLENOID VALVE (OPTION) (1) Specifications

(1) P Port (2) T Port (3) A Port

(4) PP Port (5) Drain Port

Item

SSV65

P, A

24.5 MPa 250.0 kgf/cm2 3553 psi

3.92 MPa 40.0 kgf/cm2 569 psi

40 L/min 10.6 gal/min

16 L/min 4.23 gal/min

Rated hydraulic oil pressure

Rated hydraulic oil flow

(A) Hydraulic Circuit Diagram (B) Spool Opening Diagram

Check cracking pressure

(a) Opening Area (mm2) (b) Stroke (mm)

Remarks

0.06 MPa 0.6 kgf/cm2 9 psi RY9212332HYS0253US0

3-S111

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Joints Arrangement No.

Parts Name

Q'ty

(1)

Valve assy

(2)

bolt

(3)

Flat metal washer

(4)

Joint (S, 3/4U, 3/4U)

(5)

Joint (L, 3/4U, 3/4U)

(6)

Filter assy (9/16U, 9/16)

(7)

Joint (L, 9/16U, 9/16)

Tightening torque

Remarks

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt (2)

RY9212332HYS0263US0

(3) Disassembly/Assembly Check valve components No.

Name of part

Quantity

(1)

Plug

(2)

Spring

(3)

Plunger

Tightening torque

RY9212332HYS0050US0

Spool Section Components No.

Name of part

Quantity

(1)

Plug

(2)

Spring

(3)

Spool

Tightening torque

RY9212332HYS0051US0

3-S112

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Solenoid valve components No.

Name of part

Quantity

(1)

Plug

(2)

Spring

(3)

Spool

(4)

Tightening torque

RY9212332HYS0052US0

3-S113

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[13] HORIZONTAL CONTROL VALVE (OPTION) (1) Specifications

(1) Port A (3/4-16UNF) (2) Port B (3/4-16UNF) Item

(3) Port C (9/16-18UNF) (4) Port D (9/16-18UNF)

(5) Flow Dividing Valve (6) Solenoid Valve SSV65

Rated Hydraulic Oil Pressure

30.0 MPa 310 kgf/cm2 4400 psi

Rated Hydraulic Oil Flow

70 L/min 18 gal/min

A : Hydraulic Circuit Diagram

Remarks

RY9212332HYS0267US0

3-S114

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Disassembly/Assembly

No.

Name of part

Quant ity

Notes

No.

Quant ity

Name of part

(1)

Case

(13)

Plug

(2)

O-ring

(14)

Spring

(3)

External circlip

(15)

Spool

(4)

Spring

(16)

Control spool

(5)

Ball stopper

(17)

O-ring

(6)

Ball

(18)

Backup ring

(7)

Spool

(19)

O-ring

(8)

Check valve

(20)

Plug

(9)

Spring

(21)

Nut

(10)

O-ring

(22)

Spring pin

(11)

Plug

(23)

Adjustment bolt

(12)

O-ring

(24)

Solenoid valve

Notes

RY9212332HYS0223US0

Flow divisor spool section components No.

Name of part

Quantity

(1)

Plug

(2)

Spool

Tightening torque

RY9212332HYS0053US0

3-S115

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Over center spool section components No.

Name of part

Quantity

(1)

Case

(2)

Spring

(3)

Spool

(4)

Check valve

(5)

Spring

(6)

Plug

Tightening torque 90 to 100 N·m 9.2 to 10.1 kgf·m 66.0 to 73.8 lbf·ft

RY9212332HYS0054US0

Solenoid valve section components No. (1)

Name of part Solenoid valve

Quantity

Tightening torque 7 to 8 N·m 0.7 to 0.8 kgf·m 5 to 6 lbf·ft

RY9212332HYS0055US0

Flow control section components No. (1)

Name of part Control spool

Quantity 1

Tightening torque 90 to 100 N·m 9.2 to 10.1 kgf·m 66.0 to 73.8 lbf·ft

RY9212332HYS0056US0

IMPORTANT • Always measure and record the external dimensions of the adjusting bolt before disassembling the control spool. RY9212332HYS0057US0

3-S116

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement STD version

(a) To Arm Cylinder Rod (Right) (c) To Bucket Cylinder Rod (e) To Control Valve A2 (b) To Arm Cylinder Rod (Left) (d) To Bucket Cylinder Bottom No.

Parts Name

Q'ty

Remarks

No.

Parts Name

A : Assembly Position B : Front of Machine Q'ty

(1)

Stay

(4)

Joint (S, 3/4U, 3/4U)

(2)

Bolt

(5)

Flange nut

(3)

Joint (T, 3/4, 2-9/16)

Bolt (2)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Joint (3) (4)

74.0 to 82.0 N·m 7.5 to 8.4 kgf·m 55 to 60 lbf·ft

Tightening torque

Remarks

RY9212332HYS0278US0

3-S117

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

Self Leveling Valve version

(a) 5 ° (d) To Control Valve B2 (g) To Block Valve A1 (b) 10 ° (e) To Arm Cylinder Rod (Left) (h) To Control Valve A2 (c) To Bucket Cylinder Bottom (f) To Arm Cylinder Rod (Right) (i) To Bucket Cylinder Rod No.

Parts Name

Q'ty

Remarks

A : Assembly Position B : Front of Machine

No.

Parts Name

Q'ty

(6)

Joint (S, 3/4U, 3/4U)

(7)

Joint (L, 3/4U, 3/4U)

(1)

Valve assy

(2)

Stud bolt

(3)

Flat metal washer

(8)

Joint (T, 9/16, 3/4U)

(4)

Flange nut

(9)

Joint (L, 3/4U, 3/4U)

(5)

Joint (T, 3/4, 2-9/16U)

Tightening torque

Apply adhesive (Loctite 263)

Stud bolt (2)

25.0 to 31.0 N·m 2.5 to 3.2 kgf·m 18.5 to 22.8 lbf·ft

Flange nut (4)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Joint (6)

43.0 to 47.0 N·m 4.4 to 4.8 kgf·m 31.8 to 34.6 lbf·ft

Remarks

RY9212332HYS0279US0

3-S118

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[14] RIDE CONTROL SOLENOID VALVE (OPTION) (1) Specifications

(1) Port A (9/16-18UNF) Item

(2) Port T (9/16-18UNF)

(3) Port B (9/16-18UNF) SSV65

Maximum usable pressure

24.5 MPa 250 kgf/cm2 3553 psi

Maximum flow volume

22.7 L/min 6.0 gal/min

Drain flow volume

(A) Hydraulic Circuit Diagram Notes

15 cc/min or less 0.92 gal/min or less RY9212332HYS0268US0

3-S119

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

No.

Parts Name

Q'ty

Remarks

No.

(6)

Parts Name

(1)

Valve assy

(2)

Spool

(7)

O-ring

(3)

Spring

(8)

Coil

(4)

Tube

(9)

Nut

(5)

O-ring

Tube (4)

42.5 ± 7.5 N·m 4.33 ± 0.76 kgf·m 31.3 ± 5.5 lbf·ft

Nut (9)

4.2 ± 0.8 N·m 0.43 ± 0.08 kgf·m 3.1 ± 0.6 lbf·ft

Tightening torque

Q'ty

Remarks

RY9212332HYS0270US0

3-S120

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Accumulator Assembly

(a) Label No.

Parts Name

Q'ty

(1)

Accumulator

(2)

Stay

Tightening torque

Accumulator (1)

Remarks

No.

(0.75L-30)

Parts Name

Q'ty

(3)

Bolt

(4)

Joint (S, 3/4U, 9/16)

Remarks

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.4 to 20.2 lbf·ft RY9212332HYS0271US0

3-S121

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(4) Joints Arrangement

(a) 45 ° (b) To Accumulator No.

No.

Parts Name

Q'ty

(4)

Joint (T, 9/16U, 9/16)

(2)

Hex socket bolt

(5)

Joint (L, 9/16U, 9/16)

(3)

Joint (S, 9/16U, 9/16)

(6)

Spring washer

Tightening torque

Q'ty

Hex socket bolt (2)

Remarks

A : Assembly Position B : Front of Machine

Valve assy

(1)

Parts Name

(d) To Oil Cool

Remarks

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.4 to 20.2 lbf·ft RY9212332HYS0272US0

3-S122

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

[15] BLOCK VALVE (OPTION) (1) Specifications

(a) PP Port (9/16-18UNF) (b) A2 Port (3/4-16UNF)

Item

Pilot pressure

Rated Hydraulic Oil Flow

(e) B1 Port (3/4-16UNF)

SSV65

A1, A2, B1, B2

24.5 MPa 250.0 kgf/cm2 3553 psi

2.5 MPa 25 kgf/cm2 360 psi

0.3 MPa 3 kgf/cm2 40 psi

135 L/min 35.7 gal/min

(f)

T Port (9/16-18UNF)

Remarks

RY9212332HYS0269US0

3-S123

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(2) Components

(A) Hydraulic Circuit Diagram No.

Parts Name

Q'ty

Remarks

No.

Parts Name

Q'ty

Remarks

(1)

Valve assy

(5)

Cover (T)

(2)

Spool

(6)

Spring

(3)

Cover (PP)

(7)

Hex socket bolt

M6 × 40

(4)

O-ring

(8)

Hex socket bolt

M6 × 60

Tightening torque

Hex socket bolt (7) (8)

12 ± 2.4 N·m 1.2 ± 0.24 kgf·m 8.8 ± 1.8 lbf·ft RY9212332HYS0280US0

3-S124

KiSC issued 12, 2015 A

HYDRAULIC SYSTEM

SSV65, WSM

(3) Joints Arrangement

(a) (b) (c) (d)

10 ° 60 ° To Drian To Control Valve A2

No.

Parts Name

(1)

Valve assy

(2)

Bolt

(3)

Joint (S, 3/4U, 3/4U)

Tightening torque

(e) To Control Valve B1 (f) To 3 Spool Solenoid Valve A1

Q'ty

Remarks

No.

Parts Name

Q'ty

(4)

Joint (L, 3/4U, 3/4U)

(5)

Joint (S, 3/4U, 3/4U)

(6)

Joint (S, 9/16U, 9/16)

Bolt (2)

(g) To Bucket Rod Position / A : Assembly Position To Self Leveling Valve Port B : Front of Machine C (h) To Arm Bottom Position Remarks

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft RY9212332HYS0281US0

3-S125

KiSC issued 12, 2015 A

4 ELECTRICAL SYSTEM

KiSC issued 12, 2015 A

SERVICING CONTENTS 1. DIAGNOSING MALFUNCTIONS ................................................................................................4-S1 [1] OVERVIEW OF MALFUNCTION DIAGNOSIS .....................................................................4-S1 [2] STEPS IN DIAGNOSING MALFUNCTIONS .........................................................................4-S1 [3] TESTING WITH A CIRCUIT TESTER...................................................................................4-S2 2. WIRING CIRCUIT........................................................................................................................4-S4 [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING ...................................4-S4 [2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS .........................................4-S4 3. ELECTRONIC EQUIPMENT LAYOUT........................................................................................4-S5 4. ELECTRICAL CONNECTOR LAYOUT .......................................................................................4-S6 [1] ROPS/CAB, A/C SPECIFICATION .......................................................................................4-S6 5. TERMINAL NAMES OF THE MAIN CONNECTOR ..................................................................4-S40 6. INSTRUMENT PANEL ..............................................................................................................4-S41 [1] PANEL FUNCTIONS ...........................................................................................................4-S41 (1) Lamp Displays ...............................................................................................................4-S41 (2) Warning Lamp ...............................................................................................................4-S41 (3) Alarm .............................................................................................................................4-S41 [2] USER MODE .......................................................................................................................4-S42 [3] SERVICE MODE .................................................................................................................4-S47 (1) What is the Service Mode?............................................................................................4-S47 (2) Entering the Service Mode ............................................................................................4-S48 (3) Using the Service Modes...............................................................................................4-S50 7. TROUBLESHOOTING...............................................................................................................4-S61 [1] No.3 HYDRAULIC OIL TEMPERATURE SENSOR ERRORS (E:005) ...............................4-S61 (1) Checking via the Panel Display .....................................................................................4-S61 (2) Inspecting each Device Visually and Physically ............................................................4-S61 (3) Testing with a Circuit Tester ..........................................................................................4-S63 (4) Testing the Equipment Itself ..........................................................................................4-S64 [2] No.4 FUEL SENSOR SYSTEM ERRORS (E:008)..............................................................4-S65 (1) Checking via the Panel Display .....................................................................................4-S65 (2) Inspecting each Device Visually and Physically ............................................................4-S66 (3) Testing with a Circuit Tester ..........................................................................................4-S67 (4) Testing the Equipment Itself ..........................................................................................4-S68 [3] No.5 ACCELERATION SYSTEM ERRORS (E:009) ...........................................................4-S69 (1) Checking via the Panel Display .....................................................................................4-S69 (2) Inspecting each Device Visually and Physically ............................................................4-S69 (3) Testing with a Circuit Tester ..........................................................................................4-S71 (4) Testing the Equipment Itself ..........................................................................................4-S73 [4] No.6 TWO-SPEED TRAVEL SOLENOID ERROR (E:010) .................................................4-S74 (1) Checking via the Panel Display .....................................................................................4-S74 (2) Inspecting each Device Visually and Physically ............................................................4-S75 (3) Testing with a Circuit Tester ..........................................................................................4-S76 (4) Testing the Equipment Itself ..........................................................................................4-S77 [5] No.7 PARKING BRAKE SOLENOID ERRORS (E:011) ......................................................4-S79 (1) Checking via the Panel Display .....................................................................................4-S79 (2) Inspecting each Device Visually and Physically ............................................................4-S80 (3) Testing with a Circuit Tester ..........................................................................................4-S82 (4) Testing the Equipment Itself ..........................................................................................4-S83 [6] No.8 HIGH-FLOW SOLENOID ERRORS (E:014)...............................................................4-S85 (1) Checking via the Panel Display .....................................................................................4-S85 KiSC issued 12, 2015 A

(2) Inspecting each Device Visually and Physically ............................................................4-S87 (3) Testing with a Circuit Tester ..........................................................................................4-S88 (4) Testing the Equipment Itself ..........................................................................................4-S89 [7] No.9 HYDRAULIC QUICK-HITCH LOCK SOLENOID (E:015)............................................4-S92 (1) Checking via the Panel Display .....................................................................................4-S92 (2) Inspecting each Device Visually and Physically ............................................................4-S93 (3) Testing with a Circuit Tester ..........................................................................................4-S94 (4) Testing the Equipment Itself ..........................................................................................4-S95 [8] No.10 AUX KNOB ERRORS (E:016) ..................................................................................4-S97 (1) Checking via the LCD Panel Display .............................................................................4-S97 (2) Inspecting each Device Visually and Physically ............................................................4-S98 (3) Testing with a Circuit Tester ..........................................................................................4-S99 (4) Testing the Equipment Itself ........................................................................................4-S100 [9] No.11 AUX RIGHT SOLENOID ERRORS (E:018) ............................................................4-S102 (1) Checking via the LCD Panel Display ...........................................................................4-S102 (2) Inspecting each Device Visually and Physically ..........................................................4-S104 (3) Testing with a Circuit Tester ........................................................................................4-S105 (4) Testing the Equipment Itself ........................................................................................4-S106 [10]No.12 AUX LEFT SOLENOID ERRORS (E:019) ..............................................................4-S108 (1) Checking via the LCD Panel Display ...........................................................................4-S108 (2) Inspecting each Device Visually and Physically ..........................................................4-S110 (3) Testing with a Circuit Tester ........................................................................................4-S111 (4) Testing the Equipment Itself ........................................................................................4-S112 [11]No.13 5V SHORT SYSTEM ERRORS (E:021) .................................................................4-S114 (1) Checking via the Panel Display ...................................................................................4-S114 (2) Inspecting each Device Visually and Physically ..........................................................4-S115 (3) Testing the Equipment Itself ........................................................................................4-S116 [12]No.14 OVER VOLTAGE ERRORS (E:023) .......................................................................4-S117 (1) Checking via the Panel Display ...................................................................................4-S117 (2) Testing with a Circuit Tester ........................................................................................4-S117 [13]No.16 CRS COMMUNICATION ERRORS (E:026) ...........................................................4-S118 (1) Checking via the Panel Display ...................................................................................4-S118 (2) Inspecting each Device Visually and Physically ..........................................................4-S118 (3) Testing with a Circuit Tester ........................................................................................4-S118 (4) Testing the Equipment Itself ........................................................................................4-S119 [14]No.17 RIDE CONTROL SOLENOID ERRORS (E:027) ....................................................4-S120 (1) Checking via the Panel Display ...................................................................................4-S120 (2) Inspecting each Device Visually and Physically ..........................................................4-S121 (3) Testing with a Circuit Tester ........................................................................................4-S123 (4) Testing the Equipment Itself ........................................................................................4-S124 [15]No.18 FAN SOLENOID ERRORS (E:028) ........................................................................4-S126 (1) Checking via the Panel Display ...................................................................................4-S126 (2) Inspecting each Device Visually and Physically ..........................................................4-S126 (3) Testing with a Circuit Tester ........................................................................................4-S127 (4) Testing the Equipment Itself ........................................................................................4-S128 [16]No.19 HYDRAULIC LOCK (LIFT ARM) ERRORS (E:029)................................................4-S129 (1) Checking via the Panel Display ...................................................................................4-S129 (2) Inspecting each Device Visually and Physically ..........................................................4-S129 (3) Testing with a Circuit Tester ........................................................................................4-S131 (4) Testing the Equipment Itself ........................................................................................4-S131 [17]No.20 HYDRAULIC LOCK (BUCKET) ERRORS (E:030) .................................................4-S133 (1) Checking via the Panel Display ...................................................................................4-S133 (2) Inspecting each Device Visually and Physically ..........................................................4-S133 (3) Testing with a Circuit Tester ........................................................................................4-S135 (4) Testing the Equipment Itself ........................................................................................4-S135 [18]No.21 TRAVEL PILOT PRESSURE SENSOR ERRORS (E:031).....................................4-S137 (1) Checking via the Panel Display ...................................................................................4-S137 (2) Inspecting each Device Visually and Physically ..........................................................4-S138 (3) Testing with a Circuit Tester ........................................................................................4-S139 KiSC issued 12, 2015 A

(4) Testing the Equipment Itself ........................................................................................4-S140 [19]No.29 WATER TEMPERATURE SENSOR OVERHEATING ERRORS (E:9104) ............4-S141 (1) Checking via the Panel Display ...................................................................................4-S141 (2) Inspecting each Device Visually and Physically ..........................................................4-S142 (3) Testing with a Circuit Tester ........................................................................................4-S143 (4) Testing the Equipment Itself ........................................................................................4-S144 [20]No.47 ENGINE OIL PRESSURE ERRORS (E:9118) .......................................................4-S145 (1) Checking via the Panel Display ...................................................................................4-S145 (2) Inspecting each Device Visually and Physically ..........................................................4-S145 (3) Testing with a Circuit Tester ........................................................................................4-S146 (4) Testing the Equipment Itself ........................................................................................4-S148 [21]No.48 CHARGE ERRORS (E:9119) .................................................................................4-S149 (1) Checking via the Panel Display ...................................................................................4-S149 (2) Inspecting each Device Visually and Physically ..........................................................4-S149 (3) Testing with a Circuit Tester ........................................................................................4-S150 [22]No.49 WATER SEPARATOR, WATER FULL ERRORS (E:9120) ....................................4-S152 (1) Checking via the Panel Display ...................................................................................4-S152 (2) Inspecting each Device Visually and Physically ..........................................................4-S152 8. FLOW CHART OF THE USER MODE AND SERVICE MODE SETTINGS................................4-S1

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

1. DIAGNOSING MALFUNCTIONS The most important thing in diagnosing a malfunction is inferring the cause of the problem. It is important because inferring the cause allows for a narrowing of the places that need to be inspected, and thus reducing wasted inspection work. And the inference has to be supported by theory and practice--relying on intuition does not work. RY9212038ELS0013US0

[1] OVERVIEW OF MALFUNCTION DIAGNOSIS When diagnosing errors if you fail to go through the proper procedures, it clouds the view of the actual problem and conversely, in the end you are liable to make an incorrect guess about the cause and repair. For that reason, it is necessary to think through the following 4 steps when diagnosing errors. Error Diagnosis Procedure

• Accurately observe what the problem is. Check whether that problem is the only one or whether there are other problems.

Infer the Cause of the Error

• When inferring the cause of an error, it is important to grasp the circuits in the wiring diagram as a system. Of course you have to know how switches, relays, etc. function, but having a broader view of the causes of errors, such as from experience of what caused past errors that you repaired, is necessary to making inferences.

Test Specified Locations and Find the Cause

• Error diagnosis is a matter of building up facts from tests and step by step getting closer to the real cause. While making checks, you always have to be thinking, which test can I make where to be more effective.

Check your Repairs

• After repairing a fault, always check and make sure the system is functioning normally. And make sure no new problem has arisen.

These materials provide information necessary for diagnosing errors and the overall wiring diagram and circuit diagrams for each system were compiled with a view to simplifying error diagnosis. 1. The circuit diagrams show the layout of connectors and wiring routing on the machine. 2. The circuit diagrams show the structure of circuits in the system and indicate the normal (not operating) state of all of the kinds of switches. 3. Troubleshooting tips are provided to help identify the causes of errors from multiple pieces of information and using common sense. If you cannot pinpoint the cause based on these tips, follow the circuit for each system to diagnose the error. RY9212332ELS0001US0

[2] STEPS IN DIAGNOSING MALFUNCTIONS All diagnoses of malfunctions should narrow down the cause via the following procedures and specify the faulty location. (Not following the procedures results in not knowing the cause of the fault.) 1

Observing the Malfunction

• Normal meter display • Abnormal meter display

Checking the Faulty Line

• Check in the meter's service mode. Checking for Breaks in Wiring

Specify the Faulty Circuit with a Circuit Tester

• Test related circuits with a circuit tester. Specify any faulty circuits in a harness.

Diagnose Sensors and Actuators with the Tester

• Judge sensors and actuators as normal or abnormal.

Final Operation Check

• Clear the history display after completing repairs. After clearing the history and thoroughly checking operations, check for a history display again. RY9212038ELS0015US0

4-S1

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[3] TESTING WITH A CIRCUIT TESTER Testing Voltage and Continuity at a Connector To prevent damage to the connector terminal contacts and/or reducing the water-proofing of the connector when testing a connector for voltage and/or continuity, follow the guidelines below. RY9212038ELS0016US0

1. General (not waterproof) connectors • Insert the test lead from the harness side. Female terminals are particularly prone to damage so always insert the test leads from the harness side. • ECU connector terminal pins are extremely small, so do not try and force a test lead in; use the special tool. 2. Waterproof connectors • If you try to test the circuit when it is in a closed state and force the test leads in from the harness side, it will reduce the effectiveness of its waterproofing, leading to corrosion, so never do this. • When testing a male pin, touch the test lead directly to the pin. In this situation, be very careful not to short circuit across connector terminals. 3. Special tools • When the connector pin holes are smaller than the test leads, use thin wires.

(A) Correct Example (B) Incorrect Example (C) Using a Special Tool

(a) (b) (c) (d) (e) (f)

Measuring Harness 600 to 700 mm (23.7 to 27.5 in.) 10 mm (0.39 in.) 0.6 mm (0.02 in.) Clip Tape RY9212038ELS0017US0

4-S2

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Testing the Voltage When testing the voltage, touch the point to test with the red test lead (+ side) and touch the body (earth) with the black test lead (- side). Ex.) 12.5 V (a) Pointer (b) Scale to use

A : Meter RY9212038ELS0020US0

Testing for Continuity Select the appropriate range with the rotary switch. Also, after changing the range, always zero out the pointer before taking measurements. Ex.) 2 Ω (a) Pointer (b) Scale to use (c) Rotary Switch

A : Meter

RY9212038ELS0018US0

When testing for resistance, there is no difference between the red (+ side) and black (- side) test leads. However, in the interest of preventing testing errors, in this manual we indicate (+ side) and (- side), so test the circuits based on the following tables. Measurement

(a)

Connector Name (+ terminal side) Engine oil pressure connector CN509

Pin No.

Connector Name (- terminal side)

Pin No.

<1>

Meter connector CN302

<9>

Assess ment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212213ELS0002US0 Measurement

(a)

Connector Name (+ terminal side) Engine oil pressure connector CN509

Pin No.

Connector Name (- terminal side)

<1>

Body GND

Pin No.

Assess ment Results

–

Regular: 5 V (OK) Irregular: Large discrepancy from 5 V (NG) RY9212213ELS0001US0

4-S3

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. WIRING CIRCUIT [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING 1. Do not touch the wiring or the area around it. Do not touch where uncovered. 2. Do not clamp to fuel hoses. 3. Connect connectors and terminals securely so they do not come unplugged when pulled on gently. 4. Be sure to clamp the harness at the clamp position. 5. Clamps for securing harnesses (1) Anchor Type (Insert Firmly Until it Catches.) (2) Screw Type (Insert to the End of the Screw.) (3) and (4) Insert Type : Insert Until it Locks.

(A) Harness (B) Clamp the Harness so It Stays in Position and Does Not Move. Insert the End of the Cable Tie Into the Hole on the Other Side to Clamp the Harness. RY9212001ELS0025US0

[2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS 1. When disconnecting connectors, grasp the body of the connector and pull it out; do not pull on the wiring harness. If the connector is the locking type, release the lock and then pull to disconnect. 2. When removing a connector's plastic cover (for water protection) to inspect it, be careful not to let any water get in the connector. If water does get in, dry it thoroughly before reassembling the connector and putting its plastic cover securely in place. 3. Straighten any bent connector terminals and make sure none are sticking out or missing. Also make sure there is no corrosion on the connector's terminals before connecting it. 4. When connecting a locking connector, be sure to press it in until you hear it click and then pull gently on the harness close to the connector and make sure the harness does not come out. RY9212001ELS0224US0

4-S4

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. ELECTRONIC EQUIPMENT LAYOUT (1) (2) (3) (4) (5)

Meter Accelerator Sensor Key Switch Wiper Motor DPF Regeneration Inhibitor Switch (6) Worklight Switch (7) AUX Lock Release Switch (8) Parking Brake Switch (9) Hydraulic Release Switch (10) Horn (11) Power Socket (12) Backup Buzzer Switch (13) Front Worklight (14) Speaker (15) Room Light (16) Rear Worklight (17) Speaker (18) A/C Switch (19) Air Conditioning Unit (20) Backup Buzzer Switch (21) Washer Motor (22) Hydraulic Quick Hitch Switch (23) Level Switch (24) Wiper Switch (25) Main ECU (26) Fuel Pump (27) Backup Buzzer (28) Fuel Sensor (29) Slow-Blow Fuse (30) Compressor (31) Alternator (32) Starter Motor (33) Fuse Box (34) Engine ECU (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Right AUX Hold Switch Left AUX Hold Switch AUX Knob Switch AUX Control Switch 3 AUX Hold Switch Horn Switch Ride Control Switch AUX Control Switch 1 Turn Signal Switch Travel High-Low Switch RY9212332ELS0343US0

4-S5

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

4. ELECTRICAL CONNECTOR LAYOUT [1] ROPS/CAB, A/C SPECIFICATION

(101) Level valve connector (105) Main fan connector (4P) (102) Slow-blow fuse connector (106) Fan connector (4P) (107) Fan motor connector (103)Compressor clutch diode connector (108) Air flow sensor connector (104) Compressor clutch connector (109) Backup buzzer connector (110) Fuel sensor connector

(111) Fuel pump connector (112) Water separator connector (113) Hydraulic quick hitch solenoid connector (lock)

(114) Hydraulic quick hitch solenoid connector (release) (115) Ride control valve connector

RY9212332ELS0158US0

(101) Level valve connector (CN101) (a) Press lock and unplug RY9212332ELS0159US0

4-S6

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(102) Slow-blow fuse connector (CN102) (a) Press lock and unplug RY9212332ELS0161US0

(103)Compressor clutch diode connector (CN103) (104)Compressor clutch connector (CN104) RY9212332ELS0163US0

4-S7

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(105) Main fan connector (4P) (CN105) (106) Fan connector (4P) (CN106) (a) Press lock and unplug

RY9212332ELS0167US0

(107) Fan motor connector (CN107) (a) Press lock and unplug RY9212332ELS0165US0

4-S8

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(108) Air flow sensor connector (CN108) (a) Press lock and unplug RY9212332ELS0170US0

(109) Backup buzzer connector (110) Fuel sensor connector (a) Press lock and unplug

RY9212332ELS0172US0

4-S9

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(111) Fuel pump connector (112) Water separator connector (a) Press lock and unplug

RY9212332ELS0175US0

(113) Hydraulic quick hitch solenoid connector (lock) (CN113) (114) Hydraulic quick hitch solenoid connector (release) (CN114) (a) Press lock and unplug RY9212332ELS0178US0

4-S10

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(115) Ride control valve connector (a) Press lock and unplug RY9212332ELS0180US0

4-S11

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(201) Wiper motor connector (207) Front worklight connector (214) Front worklight connector (202) Seat bar switch connector (right) (left) (right) (208) Horn connector (215) Front blinker connector (left) (203) Radio connector (209) Rear blinker connector (right) (216)Interior light connector (204) Speaker connector (right) (210) Rear worklight connector (217) Rear worklight connector (205) Front blinker connector (right) (right) (left) (206) Front worklight connector (211) Rear worklight connector (218) Rear worklight connector (right) (right) (left) (212) Beacon connector (219) Rear blinker connector (left) (213) Front worklight connector (220) Speaker connector (left) (left)

(221)A/C switch connector (222)Fan switch connector (223)Washer motor connector (224) Seat bar switch connector (right)

RY9212332ELS0182US0

4-S12

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(201)Wiper motor connector (CN201) (a) Press lock and unplug RY9212332ELS0183US0

(202) Seal bar switch connector (right) (CN202) (a) Press lock and unplug RY9212332ELS0185US0

4-S13

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(203) Radio connector (CN203) (204) Speaker connector (right) (CN204) (a) Press lock and unplug

RY9212332ELS0187US0

(205) Front blinker connector (right) (CN205) (a) Press lock and unplug RY9212332ELS0190US0

4-S14

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(206) Front worklight connector (right) (CN206) (207) Front worklight connector (right) (CN207)

RY9212332ELS0192US0

(208) Horn connector (CN208) (a) Squeeze the connector and pull RY9212332ELS0195US0

4-S15

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(209) Rear blinker connector (right) (CN209) (a) Press lock and unplug RY9212332ELS0197US0

(210) Rear worklight connector (right) (CN210) (211) Rear worklight connector (right) (CN211) (212) Beacon connector (CN212) (a) Press lock and unplug

RY9212332ELS0199US0

4-S16

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(213) Front worklight connector (left) (CN213) (214) Front worklight connector (left) (CN214) (a) Press lock and unplug

RY9212332ELS0203US0

(215) Front blinker connector (left) (CN215) (a) Press lock and unplug RY9212332ELS0206US0

4-S17

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(216)Interior light connector (CN216) RY9212332ELS0208US0

(217) Rear worklight connector (left) (CN217) (218) Rear worklight connector (left) (CN218) (a) Press lock and unplug

RY9212332ELS0210US0

4-S18

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(219) Rear blinker connector (left) (CN219) (a) Press lock and unplug RY9212332ELS0213US0

(220) Speaker connector (left) (CN220) (221)A/C switch connector (CN221) (222)Fan switch connector (CN222) (a) Press lock and unplug

RY9212332ELS0215US0

4-S19

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(223)Washer motor connector (CN223) (a) Press lock and unplug RY9212332ELS0219US0

(224) Seal bar switch connector (left) (CN224) (a) Press lock and unplug RY9212332ELS0221US0

4-S20

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(301) Key switch connector (308) Parking brake switch (302) Meter connector connector (303) Accelerator sensor connector (309) Hydraulic release switch (304) Power socket connector connector (305) DPF regeneration inhibitor (310) Main connector (6P) switch connector (311) Cab connector (6P) (306) Worklight switch connector (312) Main connector (8P) (307) AUX lock release switch (313) Cab connector (8P) connector (314) Main connector (16P) (315) Cab connector (16P)

(316) Main power connector (8P) (317) Cab power connector (8P) (318) Air suspension connector (319)Servo motor connector (320) Dual pressure switch connector (321)Blower motor connector (322) Thermistor connector (323)Blower resistor connector

(324) OPC switch connector (325) Hydraulic quick hitch switch connector (326) Level switch connector (327)Wiper switch connector (328) Hazard switch connector (329) Blinker panel connector (330) AUX power socket connector

RY9212332ELS0223US0

4-S21

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(301) Key switch connector (CN301) (302) Meter connector (CN302) (303) Accelerator sensor connector (CN303) (a) Press lock and unplug

RY9212332ELS0224US0

(304) Power socket connector (CN304) (a) Squeeze the connector and pull RY9212332ELS0228US0

4-S22

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(305) DPF regeneration inhibitor switch connector (CN305) (306) Worklight switch connector (CN306) (307) AUX lock release switch connector (CN307) (308) Parking brake switch connector (CN308) (309) Hydraulic release switch connector (CN309) (a) Squeeze the connector and pull

RY9212332ELS0230US0

4-S23

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(310) Main connector (6P) (CN310) (311) Cab connector (6P) (CN311) (312) Main connector (8P) (CN312) (313) Cab connector (8P) (CN313) (314) Main connector (16P) (CN314) (315) Cab connector (16P) (CN315) (316) Main power connector (8P) (CN316) (317) Cab power connector (8P) (CN317) (318) Air suspension connector (CN318) (a) Press lock and unplug

RY9212332ELS0233US0

4-S24

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(319)Servo motor connector (CN319) (320) Dual pressure switch connector (CN320) (321)Blower motor connector (CN321) (322) Thermistor connector (CN322) (323)Blower resistor connector (CN323) (a) Press lock and unplug

RY9212332ELS0243US0

(324) OPC switch connector (CN324) (a) Press lock and unplug RY9212332ELS0249US0

4-S25

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(325) Hydraulic quick hitch switch connector (CN325) (326) Level switch connector (CN326) (327)Wiper switch connector (CN327) (328)Hazard switch connector (CN328) (329) Blinker panel connector (CN329) (a) Squeeze the connector and pull

RY9212332ELS0251US0

(330) AUX power socket connector (CN330) RY9212332ELS0254US0

4-S26

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(401) Backup buzzer switch (410) Travel motor pressure switch connector (right) connector (402) Travel lever connector (right) (411) AUX relay connector (10P) (403)DM connector (412) AUX relay box connector (404) RS-232C connector (10P) (405)CAN connector (413) Backup buzzer switch (406)Settings connector connector (left) (407)Main ECU connector (414) Travel lever connector (left) (408) Buzzer connector (415) AUX relay connector (16P) (409) Hydraulic oil temp sensor (416) AUX relay box connector connector (16P)

(417) Engine ECU connector (96P) (422) AUX solenoid connector (418) Engine ECU connector (58P) (right) (419)High flow solenoid connector (423) AUX solenoid connector (left) (420)Lift lock solenoid connector (424) Parking brake solenoid (421)Bucket lock solenoid connector connector (425) Travel 2-speed solenoid connector (426) Hydraulic release solenoid connector

RY9212332ELS0256US0

4-S27

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(401) Backup buzzer switch connector (right) (CN401) (402) Travel lever connector (right) (CN402) (a) Press lock and unplug

RY9212332ELS0257US0

(403)DM connector (CN403) (404) RS-232C connector (CN404) (405)CAN connector (CN405) (406)Settings connector (CN406) (407)Main ECU connector (CN407) (408) Buzzer connector (CN408) (a) Press lock and unplug

(b) Release the lever and unplug

RY9212332ELS0260US0

4-S28

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(409) Hydraulic oil temp sensor connector (CN409) (a) Press lock and unplug RY9212332ELS0267US0

(410) Travel motor pressure switch connector (CN410) (a) Press lock and unplug RY9212332ELS0269US0

4-S29

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(411) AUX relay connector (10P) (CN411) (412) AUX relay box connector (10P) (CN412) (a) Press lock and unplug

RY9212332ELS0271US0

(413) Backup buzzer switch connector (left) (CN413) (414) Travel lever connector (left) (CN414) (a) Press lock and unplug

RY9212332ELS0274US0

4-S30

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(415) AUX relay connector (16P) (CN415) (416) AUX relay box connector (16P) (CN416) (a) Press lock and unplug

RY9212332ELS0277US0

(417) Engine ECU connector (96P) (CN417) (418) Engine ECU connector (58P) (CN418) (a) Release the lever and unplug

RY9212332ELS0280US0

4-S31

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(419) High flow solenoid connector (CN419) (a) Press lock and unplug RY9212332ELS0283US0

(420) Lift lock solenoid connector (CN420) (421) Bucket lock solenoid connector (CN421) (422) AUX solenoid connector (right) (CN422) (423) AUX solenoid connector (left) (CN423) (a) Press lock and unplug

RY9212332ELS0285US0

4-S32

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(424) Parking brake solenoid connector (CN424) (425) Travel 2-speed solenoid connector (CN425) (426) Hydraulic release solenoid connector (CN426) (a) Press lock and unplug RY9212332ELS0288US0

4-S33

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(501) Intake throttle valve connector (CN501) (502) Intake air temp sensor connector (CN502) (503) EGR valve connector (CN503) (504) Cam position sensor connector (CN504) (505) SCV (Suction control valve) connector (CN505) (506) Fuel temp sensor connector (CN506) (507) Starter motor connector (CN507) (508) Starter motor connector + B terminal (CN508) (509) Engine oil pressure switch connector (CN509) (510) Rail pressure sensor connector (CN510) (511) Alternator connector (CN511) (512) Alternator + B terminal (CN512) (513) Crank position sensor connector (CN513) (514) Boost pressure sensor connector (CN514) (515) Injector connector (CN515) (516) Water temperature sensor connector (CN516) (517) Temperature sensor connector (DOC inlet exhaust temperature) (T0) (CN517) (518) Temperature sensor connector (DPF inlet exhaust temperature) (T1) (CN518) (519) Temperature sensor connector (DPF outlet exhaust temperature) (T2) (CN519) (520) Differential pressure sensor connector (CN520) A: Engine left-side B: Engine rear-side C : Engine top-side RY9212332ELS0157US0

4-S34

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(501) Intake throttle valve connector (CN501) (502) Intake air temp sensor connector (CN502) (503) EGR valve connector (CN503) (a) Press lock and unplug

RY9212332ELS0290US0

(504) Cam position sensor connector (CN504) (a) Press lock and unplug RY9212332ELS0293US0

4-S35

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(505) SCV (Suction control valve) connector (CN505) (506) Fuel temp sensor connector (CN506) (507) Starter motor connector (CN507) (508) Starter motor + B terminal (CN508) (509) Engine oil pressure switch connector (CN509) (a) Press lock and unplug

RY9212332ELS0294US0

(510) Rail pressure sensor connector (CN510) (a) Press lock and unplug RY9212332ELS0299US0

4-S36

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(511) Alternator connector (CN511) (512) Alternator + B terminal (CN512) (a) Press lock and unplug

RY9212332ELS0300US0

(513) Crank position sensor connector (CN513) (a) Press lock and unplug RY9212332ELS0302US0

4-S37

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(514) Boost pressure sensor connector (CN514) (515) Injector connector (CN515) (a) Press lock and unplug

RY9212332ELS0303US0

(516) Water temperature sensor connector (CN516) (a) Press lock and unplug RY9212332ELS0310US0

4-S38

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(517) Temperature sensor connector (DOC inlet exhaust temperature) (T0) (CN517) (518) Temperature sensor connector (DPF inlet exhaust temperature) (T1) (CN518) (519) Temperature sensor connector (DPF outlet exhaust temperature) (T2) (CN519) (520) Differential pressure sensor connector (CN520) (a) Press lock and unplug

(b) Lift up the lock and then unplug

RY9212332ELS0311US0

4-S39

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

5. TERMINAL NAMES OF THE MAIN CONNECTOR Names of the Terminal Signals of the Main ECU Connector (Harness Side)

ECU Connector CN337 No.

Signal Name

No.

Signal Name

Back Buzzer Switch (Right)

Key Switch (RUN)

GND (Load line)

AUX Right / Clockwise Solenoid

AUX Left / Counterclockwise Solenoid

Key Switch (START)

+ 5 V (Sensor)

Seat Bar Switch (Left)

AUX Operating Lever Sensor 1

GND (Sensor)

Seat Bar Switch (Right)

7 8

– Accelerator Sensor 1

–

Accelerator Sensor 2

No.

–

Charge Input Power

–

Warning Buzzer

34 35

– DPF Inhibit LED

–

Ride Control Solenoid

Travel High-Low Solenoid

Engine Pressure Switch

DPF Inhibit Switch

–

5 V Output (Sensor)

–

Fan Reverse Switch

5 V Output (Sensor)

GND (Sensor)

– Fan Motor

–

Travel Pilot Pressure Sensor

OPC Switch

AUX Hold Switch (Left)

AUX Hold Switch (Right) Front Work Light Switch

GND (Sensor)

AUX Relay 2

12 V Outlet

+B Power (supplied directly)

Wake up Signal Output

AUX Solenoid Feedback

–

AUX Hold Switch

– AUX Port Switch

CAN (H)

Back Buzzer Switch (Left)

CAN (H)

Travel High-Low Switch

Fan Feedback

CAN (H)

Ride Control Switch

Hydraulic Hitch Solenoid

CAN (L)

RXD

Starter Auto Release Relay

CAN (L)

TXD

AUX Relay 1

CAN (L)

High Flow Solenoid

Hydraulic Lock (Lift Arm)

Setting Connector

Glow Relay

Hydraulic Oil Temperature

Hydraulic Unlock

Hydraulic Lock (Bucket)

AUX Operating Lever Sensor 2

High Flow Switch

Back Buzzer

Fuel Sensor

Parking Brake Switch

Parking Brake Solenoid

19 20

–

RY9212332ELS0002US0

4-S40

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

6. INSTRUMENT PANEL [1] PANEL FUNCTIONS (1) Lamp Displays No.

Name

Function

(1)

Speed indicator lamp

Speed indicator lamp light up

(2)

Parking brake lamp

Parking brake lamp light up

(3)

Hydraulic lock lamp

Hydraulic lock lamp light up

(4)

AUX operation lamp

AUX operation lamp light up High flow lamp blinking

(5)

Ride control lamp

Ride control lamp light up

(6)

Coolant temperature warning lamp

Overheats or higher Blink in the coolant temperature over 110 °C (230 °F)

(7)

Hydraulic oil temperature warning lamp

Blinks in the hydraulic oil temperature over 103 °C (217 °F)

(8)

Glow lamp

Light during glow operation

(9)

Remaining fuel warning lamp

Blinks when the fuel is low

(10)

DPF regeneration indicator

DPF raise the level 1 to 3 lamp light up.

(11)

Engine oil pressure warning lamp

Lights when the engine oil pressure switch is ON

(12)

Battery charge lamp

Lights when the battery is not charging

(13)

Warning lamp

Blinks to indicate a warning

(14)

Engine rev up warning lamp

(15)

Fuel gauge indicator

–

(16)

Coolant temperature gauge

–

(17)

LCD screen

Hour-meter, Error code numbers RY9212332ELS0003US0

(2) Warning Lamp (1) Off (2) On

(3) Blinking RY9212038ELS0166US0

(3) Alarm (1) Buzzer off (2) Pi

(3) Pi, Pi, Pi (4) Pi – RY9212038ELS0167US0

4-S41

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[2] USER MODE 1. Turn the starter key to the position "RUN". (1) Key Switch

(A) STOP (B) RUN (C) START RY9212332ELS0004US0

2. The hour meter (b) on the LCD panel (a) comes on when the key switch is in the [RUN] position or when the engine is started. (a) LCD Screen

(b) Hour Meter RY9212332ELS0005US0

3. If the warning lamp (a) blinks and an error code (c) is displayed on the LCD screen (b), something is wrong with the track loader, so immediately investigate what is causing the problem(s). • E:005 (hydraulic oil temperature sensor) The fault can be determined from the error code. → Refer to the Table of Error Codes. (a) Warning Lamp (b) LCD Screen

4-S42

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

List of Error Code Numbers CAUTION • First move the machine to a place suited for repair.  : Sure to happen : May happen Machine condition No.

Error Code Number

Problem or Failure

E:001

CAN communication

E:004

Engine performance

Hydraulic oil temperature over

Acceleration limited

Engine output limited

Engine stopped

Machine performance

–

Provisional measure and Correction

–

Stop the engine and check the level in the hydraulic oil tank and for a hydraulic oil leak. Fill to proper level. Cleaning the oil cooler. Stop the engine and check the level in the hydraulic oil tank and for a hydraulic oil leak. Fill to proper level. 4-S61

E:005

Hydraulic oil temperature sensor

–

E:008

Fuel sensor system

–

The fuel level indicator does not appear on the meter. The machine's other functions are still operative.

4-S65

–

The accelerator fails, but the machine's other functions are still operative. The machine is operative at the idling rpm.

4-S69

4-S74

E:009

Acceleration system

–

E:010

Travel high-low switch system

–

The machine still runs at low speed without switching to high speed. The machine's other functions are still operative.

E:011

Parking brake system

–

The machine fails to move.

4-S79

–

The high-flow system is not turned on. The machine's other functions are still operative.

4-S85

The hydraulic quick-hitch system is not turned on. The machine's other functions are still operative.

4-S92

E:014

High-flow system

E:015

Hydraulic quick-hitch system

–

E:016

Auxiliary hydraulic control system (Control switch on the knob)

–

E:018

Auxiliary hydraulic control system (Solenoid valve for Rightward SW)

–

E:019

Auxiliary hydraulic control system (Solenoid valve for Leftward SW)

–

E:021

The sensor's 5V power supply is short-circuited.

–

4-S43

4-S97

The auxiliary hydraulic control system is not turned on.The machine's other functions are still operative.

4-S102

4-S108

–

4-S114

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM Machine condition Engine performance

Error Code Number

Problem or Failure

E:023

This error code number appears if a jumper cable is connected to a 24V battery or improper device to jump start the engine

E:024

Hydraulic oil temperature sensor error

–

E:026

CRS communication

E:027

No.

Provisional measure and Correction

Acceleration limited

Engine output limited

Engine stopped

Machine performance

–

The machine still runs at low speed without switching to high speed. The machine's other functions are still operative.

–

4-S118

Ride control system

–

The ride control mode is not turned on. The machine's other functions are still operative.

4-S120

E:028

Fan solenoid

–

E:029

Hydraulic lock (lift arm)

–

The lift arm mode is not turned on. The machine's other functions are still operative.

4-S129

E:030

Hydraulic lock (bucket)

–

The lift arm mode is not turned on. The machine's other functions are still operative.

4-S133

E:031

Traveling speed pressure sensor

–

The machine still runs at low speed without switching to high speed. The machine's other functions are still operative.

4-S137

E:9000

Requirement for DPF regeneration.

–

DPF must be regenerated, but low engine rpm is unable to start DPF regeneration.

–

4-S117

Warm up the engine for few minutes. The warning lamp turns off the light.

Stop the engine and check the fan solenoid. 4-S126

E:9001

Requirement for DPF regeneration.

–





DPF must be regenerated, but low engine rpm is unable to start DPF regeneration. If you leave the machine with the hydraulic locked, the engine can stop automatically.

E:9002

DPF is regenerated.

–



–

E:9003

Requirement for DPF regeneration.

–





E:9004

Requirement for DPF regeneration.

Refer to engine DM.

–





DPF must be regenerated, but unable to start regeneration. DPF must be regenerated, but unable to start regeneration because the inhibit switch is activated.

Move the machine to a safe place and release the inhibit switch to start DPF regeneration. Refer to engine DM.

E:9006

Requirement for DPF regeneration.

–

4-S44

Rev up the engine rpm and start DPF regeneration. Refer to engine DM.

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM Machine condition No.

Error Code Number

Engine performance Problem or Failure

Acceleration limited

Engine output limited

Engine stopped

Machine performance

Provisional measure and Correction

E:9007

Requirement for DPF regeneration.

–





DPF must be regenerated, but unable to start regeneration because the inhibited switch is activated. If you leave the machine with the hydraulic locked, the engine can stop automatically.

E:9010

Requirement for DPF regeneration.

–

E:9100

Rpm sensor system



–

E:9101

Fuel or rail pressure system



–

E:9102

SCV system



–

E:9103

Intake air temperature sensor system

–

E:9104

Water temperature sensor system



–

E:9105

Fuel temperature sensor system

–

E:9106

Injector system





–

E:9107

Intake air pressure sensor system

–



–

E:9108

Battery voltage system





–

E:9109

Sensor voltage system





–

E:9110

Main relay system

–

E:9112

Atmospheric pressure sensor system

–



–

E:9113

EGR valve system

–



–

E:9114

Emission level warning

–

E:9115

Emission level caution



–

E:9116

Engine overheat warning



–

E:9117

Air heater system

–

Refer to engine DM.

E:9118

Engine oil pressure system

–

Stop the engine and check the engine oil level. 4-S145

E:9119

Charging system failure

–

Stop the engine and check the V-belt. Refer to engine DM. 4-S149

E:9120

Fuel filter mater warning

–

Stop the engine and check and drain the water. Refer to engine DM. 4-S152

Move the machine to a safe place and release the inhibit switch to start DPF regeneration. Refer to engine DM.

Refer to engine DM.

4-S141

Refer to engine DM.

–

4-S45

For correction, refer to the Water Temperature Gauge section. Refer to engine DM.

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM Machine condition Error Code Number

Problem or Failure

E:9121

No.

Engine performance

Provisional measure and Correction

Acceleration limited

Engine output limited

Engine stopped

Machine performance

Engine ECU



–

E:9122

ECU communication failure



–

E:9200

Mass air flow sensor system

–



–

E:9203

Intake air throttle

–

E:9204

Differential pressure sensor system

–

E9205

Exhaust temperature sensor (DOC inlet)

–

E:9206

Exhaust temperature sensor (DOC outlet)

–

E:9207

Exhaust temperature sensor (DPF outlet)

–

E:9208

All the exhaust temperature sensors break down at once.

–

E:9211

DOC response is unusual.



–

E:9212

DPF regeneration time up

–

Playback time over. Refer to engine DM.

E:9213

Low coolant temperature in parked regeneration

–

Water temperature is 65 °C (149 °F) or less. Refer to engine DM.

E:9214

DPF regeneration cycle occurs too often.

–



–

Refer to engine DM.

E:9300

Engine fuel system (P/L)



–

E:9301

Engine fuel system (rail pressure)



–

E:9302

Engine fuel system (leakage)



–

E:9303

Engine fuel system (SCV)



–

E:9304

Engine fuel system error (supply pump).



–

E:9305

Engine air intake system error (poor air intake)



–

E:9306

Engine air intake system error (boost pressure too low)



–

E:9307

Engine exhaust temperature (DOC inlet) is not as specified.

–



–

E:9308

Engine exhaust temperature (DOC outlet) is not as specified.

–



–

E:9309

Engine exhaust temperature (DPF outlet) is not as specified.

–



–

4-S46

Refer to engine DM.

Check the fuel level and see if the fuel filter is clogged. Refer to engine DM.

Check to see if any air-intake hose is disconnected and if the air cleaner element is clogged. Refer to engine DM.

Check the fuel level and see if the fuel filter is clogged. Check to see if any air-intake hose is disconnected and if the air cleaner element is clogged. Refer to engine DM.

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM Machine condition Error Code Number

Problem or Failure

E:9310

E:9400

No.

Engine performance Acceleration limited

Engine output limited

Engine stopped

Machine performance

Starter relay inhibit drive.

–

Other failures

–

Provisional measure and Correction

Refer to engine DM. RY9212332ELS0007US0

[3] SERVICE MODE (1) What is the Service Mode? Service modes allow problems to be diagnosed when they occur with the track loader. They also allow settings to be made to the operational feel when an attachment is changed or for making settings when the ECU is replaced. The loader has the following 9 service modes.

Mode

Item

Reference page

Description

No-01

Tester

The guide mode when checking the data of the different sensors and switches.

4-S51

No-02

AUX knob settings

Knob settings when the ECU and/or AUX knob are replaced

4-S54

No-03

AUX start-up point settings

Settings required when the ECU and/or proportional AUX valve are replaced

4-S55

No-04

Fine adjustment of AUX feel

When the feel of the AUX has changed

4-S56

No-07

Accelerator lever settings

Settings required when the accelerator lever, sensor or wire are adjusted or replaced

4-S57

No-08

Model settings

Setting required when the ECU is replaced

4-S57

No-09

Read error log

Guide when checking the log of errors that have occurred in the past

4-S58

No-10

Delete error log

Guide when deleting the log of errors that have occurred in the past

4-S59

No-11

Read all error logs

Guide when checking the log of errors that have occurred in the past

4-S59

RY9212332ELS0008US0

4-S47

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Entering the Service Mode Perform the steps according to the numbers in the figure.

(1) AUX Hold Switch (Right)

(To be continued)

4-S48

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(Continued)

Setup connector cap (CN406)

(a) Turn the key switch to the STOP position. (b) Remove the setting connector cap. (CN406) (c) Warning lamp: off (d) Buzzer: no sound

Key switch: RUN

(a) Turn the key switch to the RUN position. (b) Warning lamp: off (c) Buzzer: no sound

Setup connector cap (CN406)

(a) Attach the setup connector cap (CN406) within 10 seconds. (b) Warning lamp: off (c) Buzzer: no sound

Service mode start

(a) Enters the service mode. (b) Warning lamp: on (c) Buzzer: no sound

Selecting the service mode

(a) Moves in direction (b) each time the AUX hold switch (left) is pressed. You can tell how many times the AUX hold switch (left) is pressed by how many times the warning lamp (b) on. (c) Warning lamp: on (d) Buzzer sound: "pi"

Setting the service mode

(a) Once you press the AUX hold switch (right) once, it moves right to 7.

Service mode settings

(a) Tester (No-01) (b) AUX knob settings (No-02) (c) AUX start-up point settings (No-03) (d) Fine adjustment of AUX feel (No-04) (e) Accelerator lever settings (No-07) (f) Model settings (No-08) (g) Read error log (No-09) (h) Delete error log (No-10) (i) Read all error logs (No-11) (j) Warning lamp: on (k) Buzzer: no sound

RY9212332ELS0009US0

4-S49

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Using the Service Modes IMPORTANT • First read about and thoroughly understand the service modes before using them. The content in the table below explains how to use the service modes from this point on. Operation

Description of Operation

(a)

Right S/W: S

Press the right AUX hold switch for a short time (short push).

(b)

Left S/W: S

Press the left AUX hold switch for a short time (short push).

(c)

Right S/W: L

Press the right AUX hold switch for a long time (long push).

(d)

Left S/W: L

Press the left AUX hold switch for a long time (long push).

(1) Right AUX Hold Switch (2) Left AUX hold Switch

(a) (b) (c) (d)

Right S/W: S Left S/W: S Right S/W: L Left S/W: L RY9212332ELS0010US0

4-S50

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Service Mode No-01: Tester 1. Check that "no-01" is displayed on the LCD screen (2). 2. Pressing [Right S/W:L] (1) changes the display from "no-01" to "1: 1150" 3. Pressing [Right S/W:S] changes the item number.

Item No.

Item

Description

Engine RPM

Ex.: 1150 rpm When engine stopped: 0 rpm

Battery voltage

Ex.: 11.7 V

Oil

On: Before starting engine OFF: After starting engine

↓ 54

↓

↓ On: Has high-flow specification OFF: Does not have high-flow specification

High-flow setting

For example, with "3: On" displayed on the LCD screen, if the engine is started, the pressure of the engine oil breaks the contacts of the switch, which changes the display. If it differs from the following, it can be determined there is some kind of problem. 3: On

Before starting (normal)

3: OFF

After starting (normal)

NOTE • Refer to the List of Tester Codes 4. To return to the normal screen, return the key switch to its [STOP] position. (1) Right AUX Hold Switch (2) LCD Screen

(a) (b) (c) (d)

Right S/W: S Left S/W: S Right S/W: L Left S/W: L RY9212332ELS0011US0

4-S51

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Tester List Item

Problem

Display

Remarks

1

Engine RPM

1: OOOO

Ex.: 1250 rpm Engine stopped: 0 rpm

Battery voltage

2: OO.O

Ex.: 11.7 V

Oil

3: On OFF

On: Before starting engine OFF: After starting the engine

Charge

4: On OFF

On: Before starting engine OFF: After starting the engine

Start position

5: On OFF

On: Ket at START position OFF: Any other position

Work light switch

6: On OFF

On: Switch OK OFF: NG

Water temperature

7: OOO.O

Ex.: 26 °C (78.8 °F)

Hydraulic oil temp

8: OOO.O

Ex.: 26 °C (78.8 °F)

Main accel. sensor

9: O.OO

Ex.: Min. 0.64 V Max. 4.25 V

Aux. accel. sensor

10: O.OO

Ex.: Min. 4.37 V Max. 0.78 V

Main accel. sensor (setting value min.)

11: O.OO

Ex.: 0.63 V

Sub accel. sensor (setting value max.)

12: O.OO

Ex.: 4.25 V

Fuel voltage

13: O.OO

Ex.: 1.87 V E: High, F: Low

Fuel resistance

14: O.OO

Ex.: 57 Ω Full tank (F): 3 ± 1 Ω Remain. amt.: 56.5 ± 1 Ω Empty (E): 110 ± 1 Ω

Water separator, water full switch

15: On OFF

On: As water is collected, the float goes up OFF: Other than above

Travel high-low switch

16: On OFF

On: Switch OK OFF: NG

17 

Travel high-low solenoid

17: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

Hydraulic unlock

18: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

19 

Hydraulic lock (lift arm)

19: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

20 

Hydraulic lock (bucket)

20: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

AUX port switch

21: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

22 

AUX relay 1

22: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

23 

AUX relay 2

23: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

High flow switch

24: On OFF

On: Switch OK OFF: NG

25 

High flow solenoid

25: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

Seat bar switch (right)

26: On OFF

On: Switch OK OFF: NG

Seat bar switch (left)

27: On OFF

On: Switch OK OFF: NG

No-01

4-S52

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM Item

No-01

Problem

Display

Remarks

Parking brake switch

28: On OFF

On: Switch OK OFF: NG

29 

Parking brake solenoid

29: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

Ride control switch

30: On OFF

On: Switch OK OFF: NG

31 

Ride control solenoid

31: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

Settings connector

32: On OFF

On: Switch OK OFF: NG

Backup buzzer switch (right)

33: On OFF

On: Switch OK OFF: NG

Backup buzzer switch (left)

34: On OFF

On: Switch OK OFF: NG

Backup buzzer output

35: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

OPC switch

36: On OFF

On: Switch OK OFF: NG

DPF inhibit switch lamp

37: On OFF

On: Switch OK OFF: NG

DPF disable switch

38: On OFF

On: Switch OK OFF: NG

39 

DPF manual regeneration switch

39: On OFF

On: Switch OK OFF: NG

AUX knob (current value)

40: O.OO

Ex.: Left slide 0.48 V Neutral 2.51 V Right slide 4.5 V

AUX knob (setting value left)

41: O.OO

Ex.: Left slide 0.48 V

AUX knob (setting value neutral)

42: O.OO

Ex.: Neutral 2.51 V

AUX knob (setting value right)

43: O.OO

Ex.: Right slide 4.49 V

44 

AUX Amperage

44: O.O

Ex.: Neutral 0.0 A

45 

AUX Amperage (Left)

45: O.O

Ex.: Left slide 1.2 A

46 

AUX Amperage (Right)

46: O.O

Ex.: Right slide 0.8 A

47 

Hydraulic quick hitch solenoid

47: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

48 

Fan reverse switch

48: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

49 

Fan motor

49: O.O

Ex.: Min. 1.0 A Max. 1.5 A

50 

Alarm

50: On OFF

On: Normal OFF: NG (Incl. breaks, shorts)

Travel pilot pressure sensor

51: O.OO

Ex.: 1.0 MPa

Travel pilot pressure sensor (current value)

52: O.OO

Ex.: 2.50 V

Model Setup

53: O

1: SSV65 2: SSV75

High flow selector

54: On OFF

On: High flow specification OFF: Not high flow specification

Ride control selector

55: On OFF

On: Ride control specification OFF: Not ride control specification

: Active after engine starts. RY9212332ELS0012US0

4-S53

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Service Mode No-02: AUX knob settings [Setting Conditions] • Oil temperature 50 ± 5 °C 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-02". 3. Pressing [Right S/W:L] displays "nob-R," so with the AUX knob switch (3) slid to the right, press [Right S/W:L]. 4. This displays "nob-L," so with the AUX knob switch (3) slid to the left, press [Right S/W:L]. 5. This displays "nob-n," so release the AUX knob switch (3) and when it is in the center, press [Right S/W:L]. 6. The buzzer beeps several times and the display returns to "no-02." 7. Returning the key switch to its [STOP] position completes the setting. (1) Right AUX Hold Switch (2) LCD Screen (3) AUX knob Switch

RY9212332ELS0013US0

If an error occurs making AUX knob settings If the display fails to change from "no-02" to "nob-R," the following problems may exist. • AUX knob wiring break/disconnected (c) Right S/W: L RY9212134ELS0105US0

4-S54

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Service Mode No-03: AUX start-up point settings [Setting Conditions] • Oil temperature 50 ± 5 °C 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-03". 3. Pressing [Right S/W:L] displays "3:– – – –". 4. Start the engine. 5. Lower the seat bar. 6. Adjust the accelerator dial at max position. 7. Push the hydraulic unlock switch (3). 8. Press the AUX port switch (4). The AUX operating lamp (5) lights on the meter at the same time as "set. ." is displayed. 9. Slide the AUX knob switch (6) left and right, and after adjusting the position of the attachment cylinder (7) roughly midway between max compressed and max extended, pressing [Right S/W:S] sets the neutral position and a buzzer starts beeping.

10. After "set-L" is displayed, the cylinder automatically moves toward the compressed side or the extended side. Once it moves, press [Right S/W:S]. (Buzzer is beeping)

11. After "set-R" is displayed, the cylinder automatically moves in the opposite direction from step 10. Once it moves, press [Right S/W:S]. (Buzzer is beeping)

12. It returns to "no-03". 13. Returning the key switch to its [STOP] position completes the setting. (1) (2) (3) (4) (5)

Right AUX Hold Switch LCD Screen Hydraulic Release Switch AUX Port Switch AUX Operating Lamp

(6) AUX Knob Switch (7) Attachment Cylinder (a) Right S/W: S (c) Right S/W: L

(To be continued)

4-S55

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(Continued) CAUTION • This setting determines the origin for operations of equipment, such as the cylinder. Consequently, watch the cylinder carefully for when it starts to move and press [Right S/W:L]. To change the origin, go through the "no-04" fine adjustment of AUX feel. • This setting applies to attachments that use actuators, such as cylinders, whose motion is linear. For attachments that use actuators for rotary motion, this setting is unnecessary as a neutral position cannot be specified. RY9212332ELS0014US0

Service Mode No-04: Fine adjustment of AUX feel [Setting Conditions] • Oil temperature 50 ± 5 °C 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-04". 3. Pressing [Right S/W:L] displays "4: – – – –". 4. Start the engine 5. Lower the seat bar. 6. Adjust the accelerator dial at max position. 7. Push the hydraulic unlock switch (3). 8. Press the AUX port switch (4). The AUX operating lamp (5) lights on the meter at the same time as "L: 0" is displayed. 9. The "L: 0" displayed is the current setting value. Press the switch as indicated in the table below to adjust it and then press [Right S/W:L] to set it.  The "R: " works in the same way as the foregoing. Feel fine adjustment value Right S/W: S

0 to 20 to 40

Left S/W: S

0 to -20 to -40

Remarks Once a value is set, it is stored in the meter.

10. The buzzer beeps several times and the display returns to "no-04." 11. Returning the key switch to its [STOP] position completes the setting. CAUTION • This setting adjust the feel of operations. With "0" as the baseline, adjust the feel by changing the numerical value to the (+) or (-) side. • The feel adjustment has a limited range, so if the feel still isn't right, redo the AUX start-up point setting. (1) (2) (3) (4) (5)

Right AUX Hold Switch LCD Screen Hydraulic Release Switch AUX port Switch AUX operating lamp

RY9212332ELS0015US0

4-S56

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Service Mode No-07: Accelerator dial settings 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-07". 3. Pressing [Right S/W:L] displays "set-H". 4. Put the accelerator dial in the Max position and press [Right S/W:L]. 5. Once "set –L" is displayed, put the accelerator dial in the idling position and press [Right S/W:L]. 6. The buzzer beeps several times and the display returns to "no-07." 7. Returning the key switch to its [STOP] position completes the setting. (1) Right AUX Hold Switch (2) LCD Screen (3) Accelerator Dial

RY9212332ELS0016US0

Service Mode No-08: Model settings 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-08". 3. Pressing [Right S/W:L] displays "81: 001". 4. Pressing [Left S/W:S] displays "81: 002" and pressing [Right S/W: S] again displays "81: 001," so after selecting the model press [Right S/W:L] to set it. • 001: SSV65 • 002: SSV75 5. "82: y n" is displayed. Pressing [Right S/W:S] makes the display blink "y" →"n". Pressing [Right S/W:S] again makes it blink "n" → "y", so after selecting the specification, press [Right S/W: L] to set it. • y: High-flow specification model • n: Not high-flow specification model 6. The buzzer beeps several times and the display returns to "no-08." 7. Returning the key switch to its [STOP] position completes the setting. (1) Right AUX Hold Switch (2) LCD Screen

(a) Right S/W: S (c) Right S/W: L RY9212332ELS0017US0

4-S57

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Service Mode No-09: Read error log [Setting Conditions] 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-09". 3. Pressing [Right S/W:L] displays error codes on the LCD screen. Item

Description

Error code

Ex.) E: 008 Fuel sensor

Times error occurred

Ex.) 2 times (After clearing the log, the times errors occurred are also cleared and it displays 0 times.)

Hour meter at most recent error

Ex.) 310 (h)

After clearing the error log, hour meter at first error

Ex.) 130 (h)

NOTE • Refer to the Table of Error Codes. 4. Check the hour meter and the number of times. Pressing [Right S/W:S] on the LCD screen. 5. To return to the normal screen, return the key switch to its [STOP] position. (1) Right AUX Hold Switch (2) LCD Screen

(a) Right S/W: S (c) Right S/W: L RY9212332ELS0018US0

If there are multiple error codes: 1. "E: 008" is displayed first, but pressing [Right S/W: L] displays "E: 012". Pressing [Right S/W:L] again displays the 3rd and 4th in order. Item

Description

Error code

Ex.) E: 008 Fuel sensor

Ex.) E: 016 AUX knob

Times error occurred

Ex.) 2 times (After clearing the log, the times errors occurred are also cleared and it displays 0 times.)

Ex.) 5 times (After clearing the log, the times errors occurred are also cleared and it displays 0 times.)

Hour meter at most recent error

Ex.) 310 (h)

Ex.) 250 (h)

After clearing the error log, hour meter at first error

Ex.) 130 (h)

Ex.) 100 (h)

(a) Right S/W: S

If no error codes are displayed: • If it will not switch from "no-09", there are no errors in the log. (c) Right S/W: L RY9212332ELS0020US0

4-S58

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Service Mode No-10: Clear error log settings 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-10". 3. Pressing [Right S/W:L] displays "0: y n". 4. Pressing [Right S/W:S] selects between "y" → "n" and the choice that is selected blinks. Pressing [Right S/W:L] while the text blinks sets it and the buzzer beeps. • y: Clear error log (Yes) (Beeps several times) • n: Do not clear the log (No) (Beeps once) 5. Returning the key switch to its [STOP] position completes clearing of the log. (1) Right AUX Hold Switch (2) LCD Screen

(a) Right S/W: S (c) Right S/W: L RY9212332ELS0021US0

Service Mode No-11: Read all error logs 1. Check that "no-01" is displayed on the LCD screen (2). 2. Press [Right S/W: S] (1) until the display changes from "no-01" to "no-11". 3. Pressing [Right S/W:L] displays error codes on the LCD screen. Item

Description

Error code

Ex.) E: 008 Fuel sensor

Times error occurred (cannot be cleared)

Ex.) 2 times (Displays times error occurred even after clearing the log)

Hour meter at most recent error

Ex.) 310 (h)

After clearing the error log, hour meter at first error

Ex.) 130 (h)

Hour meter at first error 

Ex.) 130 (h)

:Content added to No-09: Read error log

NOTE • Refer to the Table of Error Codes. 4. To return to the normal screen, return the key switch to its [STOP] position. (1) Right AUX Hold Switch (2) LCD Screen

(a) Right S/W: S (c) Right S/W: L RY9212332ELS0022US0

4-S59

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

If there are multiple error codes: 1. "E: 008" is displayed first, but pressing [Right S/W: L] displays "E: 016". Pressing [Right S/W:L] again displays the 3rd and 4th in order. Item Error code

Description Ex.) E: 008 Fuel sensor

Ex.) E: 016 AUX knob

Times error occurred

Ex.) 2 times (Displays times error occurred even after clearing the log)

Ex.) 5 times (After clearing the log, the times errors occurred are also cleared and it displays 0 times.)

Hour meter at most recent error

Ex.) 310 (h)

Ex.) 250 (h)

First hour meter after clearing the error log

Ex.) 130 (h)

Ex.) 100 (h)

Hour meter at first error

Ex.) 130 (h)

Ex.) 100 (h)

(a) Right S/W: S

4-S60

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

7. TROUBLESHOOTING [1] No.3 HYDRAULIC OIL TEMPERATURE SENSOR ERRORS (E:005) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the hydraulic oil temperature warning lamp (1) on the panel is blinking red or not. (1) Hydraulic Oil Temperature Warning (2) Error Code E:005 Lamp RY9212332ELS0025US0

2. Service Mode 1. Select the tester mode (No-01). 2. Check the hydraulic oil temperature according to the table below. Oil Temperature

Assessment

50 °C (122 °F)

When cut off

-30 °C (-22 °F)

When shorted

140 °C (284 °F)

Regular

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Hydraulic Oil Temperature

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0026US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. 2. Checking relays

RY9212038ELS0153US0

Checking relays is not necessary. RY9212038ELS0154US0

4-S61

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. The hydraulic oil temperature sensor connector CN410 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the hydraulic oil temperature sensor again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Hydraulic Oil Temperature Sensor Connector CN410 RY9212332ELS0027US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The hydraulic oil temperature sensor connector CN410 (a) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the hydraulic oil temperature sensor again in the tester mode No-01. Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Hydraulic Oil Temperature Sensor Connector CN410 RY9212332ELS0028US0

4-S62

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0029US0

1. Voltage check [Measurement Conditions] 1. Disconnect hydraulic oil temperature sensor connector CN410. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Hydraulic oil temperature sensor connector CN410

<1>

Hydraulic oil temperature sensor connector CN410

<2>

(2)

Hydraulic oil temperature sensor connector CN410

<1>

Body GND

–

Assessment Results

Regular: 5 V (OK) Irregular: Large discrepancy from 5 V (NG) RY9212332ELS0030US0

2. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the main ECU CN407. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Hydraulic oil temperature sensor connector CN410

<1>

Main ECU connector CN407

<25>

(2)

Hydraulic oil temperature sensor connector CN410

<2>

Main ECU connector CN407

<14>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0031US0

4-S63

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Testing the Hydraulic Oil Temperature Sensor [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect hydraulic oil temperature sensor connector CN410 and test it. 3. Refer to the following table for the resistance at different temperatures. 4. Refer to the graph at left on the relationship between oil temperature and resistance. Oil Temperature (°C / °F)

Resistance

– 20 / –4.0

15.04 kΩ

20 / 68.0

2.45 kΩ

30 / 86.0

1.66 kΩ

40 / 104.0

1.15 kΩ

50 / 122.0

811 Ω

60 / 140.0

584 Ω

80 / 176.0

240 Ω

110 / 230.0

142 Ω

130 / 266.0

88 Ω Assessment Results

Criteria Regular: Within standards (OK) Irregular: Outside standards (NG) (A) Oil Temperature and Resistance

(a) Hydraulic Oil Temperature Sensor CN410 (b) Oil Temperature (°C / °F) (c) Resistance (Ω)

2. Settings after replacing device

RY9212332ELS0032US0

1. No settings required. RY9212001ELS0013US0

3. Erasing error logs 1. After completing repairs, select Erase Error Log and erase the records. 2. After erasing the records, read the error log again and make sure there are no errors. If no error codes are displayed: • If it will not switch from "no-09", there are no errors in the log. Criteria

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0171US0

4-S64

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[2] No.4 FUEL SENSOR SYSTEM ERRORS (E:008) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp

(2) Error Code E:008 RY9212332ELS0033US0

[Inspection Conditions]] 1. Key switch: RUN Assessment Criteria

Assessment Results

Normal: Not disconnected (OK) Error: Disconnected (NG) Error: Shorted (NG) (a) If the needle is pegged on the full (b) If the needle is pegged on the fuel fuel level side: the cause is a level empty side: the cause is a short disconnect RY9212332ELS0034US0

2. Service Mode 1. Select the tester mode (No-01). 2. Check the display of fuel resistance values as per the following table. Voltage (Reference Value)

Resistance Value (Reference Value)

1.87 V

57 Ω

Disconnected

5.00 V

135 Ω or more

Shorted

0.00 V

0Ω

Normal

Assessment Criteria

Assessment Results

Normal: Not disconnected (OK) Error: Disconnected (NG) Error: Shorted (NG) (1) (2) (3) (4)

Engine RPM Battery Voltage Fuel Voltage Fuel Resistance

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0035US0

4-S65

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. RY9212038ELS0153US0

2. Checking relays Checking relays is not necessary.

RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. The fuel sensor connector CN108 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the fuel sensor connector CN417 again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Fuel Sensor Connector CN108 RY9212332ELS0036US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The fuel sensor connector CN108 (a) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the fuel sensor again in the tester mode No-01. Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Fuel Sensor Connector CN108 RY9212332ELS0037US0

4-S66

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0038US0

1. Voltage check [Measurement Conditions] 1. Disconnect fuel sensor connector CN108. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Fuel Sensor Connector CN108

<1>

Fuel Sensor Connector CN108

<2>

(2)

Fuel Sensor Connector CN108

<1>

Body GND

–

Assessment Results

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0039US0

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

(1)

Fuel Sensor Connector CN108

<2>

Main ECU connector CN407

(2)

Fuel Sensor Connector CN108

<1>

Body GND

Pin No.

Assessment Results

<27> –

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0040US0

4-S67

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Inspecting the Fuel Sensor [Test Conditions] 1. Key switch: STOP 2. Disconnect connector CN108 from the fuel sensor and test the sensor. 3. Refer to the table below for the resistance at given float positions. F (a) (b)

Float position

(c)

10 Ω ± 3 % Standard value (resistance)

E (d)

55.8 Ω ± 3 % 110 Ω ± 3 % 150 Ω ± 3 %

Assessment Results

Assessment Criteria Normal: Within standard range (OK) Error: Outside standard range (NG) (a) Full Tank

(d) Empty

2. Settings after replacing device

RY9212332ELS0041US0

1. No settings required. RY9212001ELS0013US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0171US0

4-S68

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[3] No.5 ACCELERATION SYSTEM ERRORS (E:009) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp

(2) Error Code E:009 RY9212332ELS0042US0

2. Service Mode 1. Select the tester mode (No-01). 2. Start the engine. 3. Check the display of the main accelerator sensor and sub accelerator sensor as per the following table. (Ex.) Value Displayed No.9 Main accelerator sensor No.10 Sub accelerator sensor

(Ex.) Setting Values Min.

Max.

0.64 V

4.25 V

4.37 V

0.78 V

Assessment Results

0.5 - 4.49

Assessment Criteria

Assessment Results

Normal: Not disconnected (OK) Error: Disconnected 0.15 V (NG) (1) (2) (3) (4)

Engine RPM Battery Voltage Main Accelerator Sensor Sub Accelerator Sensor

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0043US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. 2. Checking relays

RY9212038ELS0153US0

Checking relays is not necessary. RY9212038ELS0154US0

4-S69

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. The accelerator sensor connector CN303 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the accelerator sensor again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Accelerator Sensor Connector CN303 RY9212332ELS0044US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The accelerator sensor connector CN303 (a) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the accelerator sensor again in the tester mode No-01. Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Accelerator Sensor Connector CN303 RY9212332ELS0045US0

4-S70

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0046US0

1. Voltage check [Measurement Conditions] 1. Disconnect accelerator sensor connector CN303. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Accelerator sensor connector CN303

<4>

Accelerator sensor connector CN303

<3>

(2)

Accelerator sensor connector CN303

<4>

Body GND

–

Assessment Results

Regular: 5 V (OK) Irregular: Large discrepancy from 5 V (NG) RY9212332ELS0047US0

4-S71

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the main ECU CN407, main (8P) CN312 and cab (8P) CN313. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Accelerator sensor connector CN303

<1>

Cab connector (8P) CN313

<5>

(2)

Accelerator sensor connector CN303

<2>

Cab connector (8P) CN313

<2>

(3)

Accelerator sensor connector CN303

<3>

Cab connector (8P) CN313

<1>

(4)

Accelerator sensor connector CN303

<4>

Cab connector (8P) CN313

<3>

(5)

Main ECU connector CN407

<8>

Main connector (8P) CN312

<2>

(6)

Main ECU connector CN407

<12>

Main connector (8P) CN312

<3>

(7)

Main ECU connector CN407

<15>

Main connector (8P) CN312

<1>

(8)

Main ECU connector CN407

<28>

Main connector (8P) CN312

<5>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0048US0

4-S72

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Testing the Accelerator Sensor [Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect accelerator sensor connector CN418 and test it. Measurements (a) <3> - <4>

Factory specification

Criteria

1 kΩ ± 20% (at 25 °C, 77 °F)

Assessment Results

Normal: Within standard range (OK) Error: Outside standard range (NG) (a) Accelerator Sensor Connector

2. Settings after replacing device

RY9212332ELS0049US0

1. Make the setting again in service mode No-07 (Accelerator for settings). RY9212332ELS0050US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0171US0

4-S73

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[4] No.6 TWO-SPEED TRAVEL SOLENOID ERROR (E:010) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Press the travel high-low switch (4) to operate the high travel speed. 5. The speed indicator lamp (5) lights up on the meter panel. Check the speed indicator lamp according to the table below. Speed Indicator Lamp

During Travel High-Low

Assessment Results

Regular

Operating

Break in wiring

OFF

Not operating

Short

OFF

Not operating

Normal: OK Abnormal: NG (1) Warning Lamp (2) Error Code E:010 (3) Hydraulic Release Switch

(4) Travel High-Low Switch (5) Speed Indicator Lamp ON (6) Speed Indicator Lamp OFF RY9212332ELS0051US0

4-S74

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the travel high-low switch. Check the "14: On" and "15: On" to switch correctly. 6. Check the travel high-low switch and travel high-low solenoid operating, followed by the table below. No.16 Travel High-Low Switch

Press

Release

Assessment Results

Regular

OFF

Break in wiring

OFF

OFF

Short

On

No.17 Travel High-Low Solenoid

Travel High-Low Operating

Travel High-Low Not Operating

Assessment Results

Regular

OFF

Break in wiring

OFF

OFF

Short

OFF

 : Irregular

Normal: OK Abnormal: NG (1) (2) (3) (4)

Engine RPM Battery Voltage Travel High-Low Switch Travel High-Low Solenoid

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0052US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses 1. Check whether the control elements fuse 5 A is blown. Criteria

Assessment Results

Normal: no brake (OK) Error: has a brake (NG) RY9212038ELS0194US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

4-S75

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Travel high-low solenoid connector CN426 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the travel high-low again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Travel High-Low Solenoid CN426 RY9212332ELS0053US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the travel high-low solenoid connector CN426 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the travel high-low again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Travel High-Low Solenoid CN426 RY9212332ELS0054US0

(3) Testing with a Circuit Tester

RY9212332ELS0055US0

4-S76

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

1. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the connectors of the travel high-low solenoid CN426, main ECU CN407 and travel lever (left) CN412. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Travel high-low solenoid connector CN426

<1>

Main ECU connector CN407

(2)

Travel high-low solenoid connector CN426

<2>

Body GND

–

(3)

Main ECU connector CN407

<16>

Travel lever (left) connector CN412

<2>

(4)

Main ECU connector CN407

<73>

Travel lever (left) connector CN412

<1>

Assessment Results

<62>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0056US0

(4) Testing the Equipment Itself 1. Testing the Switch of the Control Lever (Left) (1) (2) (3) (4)

Travel High-Low Switch Travel High-Low Switch Line Ground Travel Lever (Left) Connector

[Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the travel lever (left) connector CN412 from the machine. 3. Press the travel high-low switch and check for continuity. Measurement Location (a)

Connector Name (+ terminal) Travel lever connector

Pin No. <1>

Connector Name (- terminal) Travel lever connector

Pin No.

Assessment Results

<2>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0057US0

4-S77

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Testing the Travel High-Low Solenoid [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the travel high-low solenoid connector CN426 and test the solenoid. (A) Travel high-low solenoid terminals (a)

Factory Specification

12 Ω ± 10 %

Assessment Results

Criteria Regular: Within standards (OK) Irregular: Outside standards (NG) (A) Diagram of Test

(a) Travel High-Low Solenoid Terminals

3. Settings after replacing device

RY9212332ELS0058US0

1. No settings required. RY9212001ELS0020US0

4. Erasing error logs 1. After completing repairs, select Erase Error Log and erase the records. 2. After erasing the records, read the error log again and make sure there are no errors. If no error codes are displayed: • If it will not switch from "no-09", there are no errors in the log. Criteria

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0170US0

4-S78

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[5] No.7 PARKING BRAKE SOLENOID ERRORS (E:011) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Push the parking brake switch (4) in direction A and apply the parking brake. Pressing the switch again in direction B releases the parking brake. 5. The parking brake lamp (5) lights up on the meter panel. Check the parking brake lamp, followed by the table below.

Regular

Break in wiring

Short

Press A

→

Press B

Parking Brake Lamp

→

OFF

Travel

Stop

→

Travel

Parking Brake Lamp

→

OFF

Travel

Stop

→

Stop

Parking Brake Lamp

→

Travel

Stop

→

Stop

Assessment Results OK

Normal: OK Abnormal: NG (1) Warning Lamp (2) Error Code E:011 (3) Hydraulic Release Switch

(4) Parking Brake Switch (5) Parking Brake Lamp ON (6) Parking Brake Lamp OFF RY9212332ELS0059US0

4-S79

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the parking brake switch. Check the "24: On" and "25: On" to switch correctly. 6. Check the parking brake switch and parking brake solenoid operating, followed by the table below. No.28 Parking Brake Switch

Press

Release

Assessment Results

Regular

OFF

Break in wiring

OFF

OFF

Short

On

No. 29 Parking Brake Solenoid

Travel Operating

Travel Not Operating

Assessment Results

Regular

OFF

Break in wiring

OFF

OFF

Short

OFF

OFF

Normal: OK Abnormal: NG

 : Irregular

Normal: OK Abnormal: NG (1) (2) (3) (4)

Engine RPM Battery Voltage Parking Brake Switch Parking Brake Solenoid

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0060US0

(2) Inspecting each Device Visually and Physically 1. Checking Fuses 1. Check whether the switch's 5A fuse is blown. Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) RY9212134ELS0151US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

4-S80

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Parking brake solenoid connector CN425 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the parking brake again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Parking Brake Solenoid Connector CN425 RY9212332ELS0061US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the parking brake solenoid connector CN425 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the parking brake again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Parking Brake Solenoid Connector CN425 RY9212332ELS0062US0

4-S81

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

(a) SW (AC) 5A RY9212332ELS0063US0

1. Voltage check [Measurement Conditions] 1. Disconnect parking brake switch connector CN308. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Parking brake switch connector CN308

<2>

Parking brake switch connector CN308

<3>

(2)

Parking brake switch connector CN308

<2>

Body GND

–

Assessment Results

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0064US0

4-S82

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the connectors of the main ECU CN407, main harness (32P) CN406, engine harness (32P) CN407 and switch (AC) 5A fuse. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

(1)

Parking brake switch connector CN308

<2>

Cab connector (16P) CN315

<8>

(2)

Parking brake switch connector CN308

<3>

Cab connector (16P) CN315

<16>

(3)

Main connector (16P) CN314

<8>

Switch (AC) 5A fuse

(4)

Parking brake solenoid connector CN425

<2>

Body GND

(5)

Parking brake solenoid connector CN425

<1>

Main ECU connector CN407

<81>

(6)

Main connector (16P) CN314

<16>

Main ECU connector CN407

<54>

Connector Name (- terminal)

Pin No.

Assessment Results

– –

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0065US0

(4) Testing the Equipment Itself 1. Testing the parking brake switch [Test Conditions] 1. Turn the key switch to STOP. 2. Disconnect the parking brake switch connector from the machine, press the switch and measure it separately. Point to Measure

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(a)

Parking brake switch connector

<2>

Parking brake switch connector

<3>

(b)

Parking brake switch connector

<2>

Parking brake switch connector

<1>

Assess ment Results

Regular: Continuity (OK) Irregular: No continuity (NG) A : Press RY9212332ELS0066US0

2. Testing the Parking Brake Solenoid [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the parking brake solenoid CN425 from the loader and test the solenoid. (A) Parking brake solenoid terminals (a)

Factory Specification

12 Ω ± 10 %

Assessment Results

Criteria Regular: no break (OK) Irregular: has a break (NG) (A) Diagram of Test

(a) Parking Brake Solenoid Terminals

3. Settings after replacing device

RY9212332ELS0067US0

1. No settings required. RY9212001ELS0020US0

4-S83

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0170US0

4-S84

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[6] No.8 HIGH-FLOW SOLENOID ERRORS (E:014) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Push the AUX port switch (4). 5. Slide the AUX knob switch (5) to the right. 6. The AUX operating lamp (6) lights up on the meter panel. Check operation of the AUX operating lamp as per the table blow. AUX Operating Lamp

AUX Operating

Assessment Results

Regular

Operating

Break in wiring

OFF

Not operating

Short

OFF

Not operating

Normal: OK Abnormal: NG (1) (2) (3) (4)

Warning Lamp Error code E:016 Hydraulic Release Switch AUX Port Switch

(5) AUX Knob Switch (6) AUX Operating Lamp ON (7) AUX Operating Lamp OFF RY9212332ELS0312US0

4-S85

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5. 6. 7.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the AUX port switch. Slide the AUX knob switch to the right. Check the AUX operating relay, AUX knob (setting value right) and AUX current value (right) operating, followed by the table below.

No.21 AUX Release Switch

Press

Release

Assessment Results

Regular

OFF

Break in wiring

OFF

Short

No.22 AUX Relay

AUX Operating

AUX Not Operating

Assessment Results

Regular

OFF

Break in wiring

OFF

Short

OFF

No.43 AUX Knob (Right Settings)

(Ex.) Value Displayed

AUX Knob Switch

0.48 - 4.49

No.46 AUX Amperage (Right)

(Ex.) Value Displayed

AUX Amperage (Right)

1.2

(Ex.) Setting Values No.41 Left

No.42 Neutral

No.43 Right

0.48 V

4.49 V

(Ex.) Setting Values No.45 Left

Neutral

No.46 Right

1.2 A

0.8 A

Assessment Results

Normal: OK Abnormal: NG (1) (2) (3) (4) (5)

Engine RPM AUX Release Switch AUX Relay 1 AUX Knob (Right Settings) AUX Amperage (Right)

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L

RY9212332ELS0142US0

4-S86

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Inspecting each Device Visually and Physically 1. Checking Fuses 1. Check whether the switch's 5A fuse is blown. Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) RY9212134ELS0151US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. High-flow solenoid connector CN419 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the high-flow solenoid again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) High-Flow Solenoid Connector CN419 RY9212332ELS0143US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The high-flow solenoid connector CN419 (a) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the high-flow solenoid again in the tester mode No-01. Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) High-Flow Solenoid Connector CN419 RY9212332ELS0144US0

4-S87

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0145US0

1. Voltage check [Measurement Conditions] 1. Disconnect the travel lever (right) connector CN402. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location (1)

Connector Name (+ terminal) Travel lever (right) connector CN402

Pin No. <6>

Connector Name (- terminal) Body GND

Pin No.

Assessment Results

–

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0146US0

2. Continuity check

[Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the travel lever (right) CN402, main ECU CN407 and AUX solenoid (right) CN422. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Travel lever (right) connector CN402

<4>

Main ECU connector CN407

<13>

(2)

Travel lever (right) connector CN402

<5>

Main ECU connector CN407

<6>

(3)

Travel lever (right) connector CN402

<6>

Main ECU connector CN407

<33> <77>

(4)

AUX solenoid (right) connector CN422

<1>

Main ECU connector CN407

(5)

AUX solenoid (right) connector CN422

<2>

Body GND

Assessment Results

–

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0147US0

4-S88

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Testing the Switch of the Control Lever (Right) (1) Out Line (ECU 64) (2) 12 V Input (3) – (4) Ground (5) Out Line (ECU 6) (6) 5 V Input (7) – (8) Out Line (ECU 23) (9) Out Line (ECU 23) (10) AUX Relay (ECU 42) (11) AUX Relay (ECU 23) (12) 12 V Input (13) Travel Lever (Right) Connector A: B: C: D: E:

AUX Hold Switch (Right) (SW1) AUX Hold Switch (Left) (SW2) AUX Knob Switch Switch (SW3) Trig Switch

[Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the travel lever (right) connector CN402 from the machine. 3. Slide the C to the right and check for continuity. Measurement Location (a)

Connector Name (+ terminal) Travel lever (right) connector CN402

Pin No. <1>

Connector Name (-terminal) Travel lever (right) connector CN402

Pin No.

Assessment Results

<2>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0148US0

4-S89

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Testing the AUX port switch [Test Conditions] 1. Turn the key switch to STOP. 2. Disconnect the AUX lock release switch connector CN39 from the machine, press the switch and measure it separately. Point to Measure

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(a)

AUX lock release switch

<3>

AUX lock release switch

<8>

(b)

AUX lock release switch

<2>

AUX lock release switch

<8>

Point to Measure

Connector Name

Pin No.

(c)

AUX lock release switch

<4> – <10>

620 Ω ± 10 %

(d)

AUX lock release switch

<1> – <5>

620 Ω ± 10 %

Factory specification

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) A : Press

B : Press RY9212134ELS0248US0

3. Testing the high-flow solenoid [Test Conditions] 1. Turn the key switch to STOP. 2. Disconnect the high-flow solenoid connector CN419 from the machine and test the solenoids. High-flow solenoid

Factory Specification

Criteria

12 Ω ± 10 %

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) High-Flow Solenoid Terminal

4. Settings after replacing device

RY9212332ELS0149US0

1. Make the settings again in service mode No-02 (AUX knob settings). 2. Make the settings again in service mode No-03 (AUX start-up point settings). RY9212332ELS0329US0

4-S90

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

5. Erasing error logs 1. After completing repairs, select Erase Error Log and erase the records. 2. After erasing the records, read the error log again and make sure there are no errors. If no error codes are displayed: • If it will not switch from "no-09", there are no errors in the log. Criteria

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212332ELS0313US0

4-S91

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[7] No.9 HYDRAULIC QUICK-HITCH LOCK SOLENOID (E:015) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Push the hydraulic hitch switch (4) in direction A and apply the hydraulic hitch. Pressing the switch again in direction B releases the hydraulic hitch. (1) (2) (3) (4)

Warning Lamp Error Code E:015 Hydraulic Release Switch Hydraulic Hitch Switch

A : Press B : Press

RY9212332ELS0068US0

2. Service Mode 1. 2. 3. 4. 5.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the hydraulic hitch switch. Check the "44: On" to switch correctly. 6. Check the operation of the hydraulic hitch solenoid as per the tables below. No.47 Hydraulic Hitch

Operating Lock

Operating Unlock

Assessment Results

Regular

OFF

Break in wiring

OFF

OFF

Short

OFF

OFF

: Irregular

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Hydraulic Hitch Solenoid

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0069US0

3. Checking relays 1. Replace either the left or the right hydraulic hitch relay. After replacing it, check for normal operation. Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Hydraulic Hitch Relay RY9212332ELS0070US0

4-S92

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Inspecting each Device Visually and Physically 1. Checking Fuses 1. Check whether the solenoid 10A fuse is blown. Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) RY9212332ELS0071US0

2. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. The hydraulic hitch solenoid release connector CN114 (a), the hydraulic hitch solenoid lock connector CN113 (b) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the hydraulic hitch solenoid again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Hydraulic Hitch Solenoid Release (b) Hydraulic Hitch Solenoid Lock Connector CN114 Connector CN113 RY9212332ELS0072US0

3. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The hydraulic hitch solenoid release connector CN114 (a) and the hydraulic hitch solenoid lock connector CN113 (b) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the hydraulic hitch solenoid again in the tester mode No-01. Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Hydraulic Hitch Solenoid Release (b) Hydraulic Hitch Solenoid Lock Connector CN114 Connector CN113 RY9212332ELS0073US0

4-S93

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0074US0

1. Voltage check [Measurement Conditions] 1. Disconnect hydraulic hitch switch connector CN325. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Hydraulic hitch switch connector CN325

<2>

Hydraulic hitch switch connector CN325

<1>

(2)

Hydraulic hitch switch connector CN325

<2>

Hydraulic hitch switch connector CN325

<3>

(3)

Hydraulic hitch switch connector CN325

<2>

Body GND

–

Assessment Results

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0075US0

4-S94

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the hydraulic hitch solenoid release CN114, hydraulic hitch solenoid lock CN113, main ECU CN407, main (16P) CN314 and cab (16P) CN315. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Hydraulic hitch solenoid release connector CN114

<1>

Cab connector (16P) CN315

<1>

(2)

Hydraulic hitch solenoid lock connector CN113

<1>

Cab connector (16P) CN315

<2>

(3)

Hydraulic hitch solenoid release connector CN114

<2>

Body GND

–

(4)

Hydraulic hitch solenoid lock connector CN113

<2>

Body GND

–

(5)

Hydraulic hitch switch connector CN325

<3>

Main connector (16P) CN314

<2>

(6)

Hydraulic hitch switch connector CN325

<1>

Main connector (16P) CN314

<1>

(7)

Hydraulic hitch relay

–

Main ECU connector CN407

<4>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0076US0

(4) Testing the Equipment Itself 1. Testing the hydraulic quick-hitch switch [Test Conditions] 1. Turn the key switch to STOP. 2. Disconnect the hydraulic hitch switch connector from the machine, press the switch and measure it separately. Point to Measure

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(a)

Hydraulic hitch switch connector

<2>

Hydraulic hitch switch connector

<1>

(b)

Hydraulic hitch switch connector

<2>

Hydraulic hitch switch connector

<3>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) A : Press

B : Press RY9212332ELS0077US0

4-S95

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Testing the hydraulic quick-hitch solenoid [Test Conditions] 1. Turn the key switch to STOP. 2. Disconnect the hydraulic hitch solenoid lock connector CN113 and hydraulic hitch solenoid release connector CN114 from the machine and test the two solenoids. Hydraulic hitch solenoid lock Hydraulic hitch solenoid release

Factory Specification.

Criteria

12 Ω ± 10 %

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Hydraulic Hitch Solenoid Terminal

3. Settings after replacing device

RY9212332ELS0078US0

1. No settings required. RY9212001ELS0020US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0170US0

4-S96

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[8] No.10 AUX KNOB ERRORS (E:016) (1) Checking via the LCD Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Push the AUX port switch (4). 5. Slide the AUX knob switch (5) to the right. 6. The AUX operating lamp (6) lights up on the meter panel. Check operation of the AUX operating lamp as per the table blow. AUX Operating Lamp

AUX Operating

Assessment Results

Regular

Operating

Break in wiring

OFF

Not operating

Short

OFF

Not operating

Normal: OK Abnormal: NG (1) (2) (3) (4)

Warning Lamp Error code E:016 Hydraulic Release Switch AUX Port Switch

(5) AUX Knob Switch (6) AUX Operating Lamp ON (7) AUX Operating Lamp OFF RY9212332ELS0342US0

4-S97

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5. 6.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the AUX port switch. Check the AUX operating relay and AUX current value operating, followed by the table below. No.22 AUX Relay

AUX Operating

AUX Not Operating

Assessment Results

Regular

OFF

Break in wiring

OFF

Short

OFF

No.44 AUX Amperage

(Ex.) Value Displayed

AUX Amperage

1.2

(Ex.) Setting Values No.44 Left

Neutral

No.44 Right

1.2 A

0.8 A

Assessment Results

Normal: OK Abnormal: NG (1) Engine RPM (2) AUX Relay 1 (3) AUX Amperage

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0080US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. RY9212038ELS0153US0

2. Checking relays Checking relays is not necessary.

RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. The travel lever (right) connector CN402 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the travel lever (right) connector CN402 again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Travel Lever (Right) Connector CN402 RY9212332ELS0081US0

4-S98

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the travel lever (right) connector CN402 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the travel lever (right) connector CN402 again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Travel Lever (Right) Connector CN402 RY9212332ELS0082US0

(3) Testing with a Circuit Tester

RY9212332ELS0083US0

1. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the main ECU CN407 and travel lever (right) connector CN402. Test for continuity based on the table below. Measurement Location (1)

Connector Name (+ terminal) Main ECU connector CN407

Pin No. <6>

Connector Name (- terminal) Travel lever (right) connector CN402

Pin No.

Assessment Results

<5>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0084US0

4-S99

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

AUX Hold Switch (Right) (SW1) AUX Hold Switch (Left) (SW2) AUX Knob Switch Switch (SW3) Trig Switch

[Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the travel lever (right) connector CN402 from the machine. 3. Press switch A and check for continuity. Measurement Location (a)

Connector Name (+ terminal) Travel lever (right) connector CN402

Pin No. <4>

Connector Name (-terminal) Travel lever (right) connector CN402

Pin No.

Assessment Results

<7>

Regular: Continuity (OK) Irregular: No continuity (NG) 2. Settings after replacing device.

RY9212332ELS0314US0

1. Make the setting again in service mode No-02 (AUX knob settings). 2. Make the setting again in service mode No-03 (AUX stuart-up point settings). RY9212332ELS0330US0

4-S100

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0171US0

4-S101

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[9] No.11 AUX RIGHT SOLENOID ERRORS (E:018) (1) Checking via the LCD Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Push the AUX port switch (4). 5. Slide the AUX knob switch (5) to the right. 6. The AUX operating lamp (6) lights up on the meter panel. Check operation of the AUX operating lamp as per the table blow. AUX Operating Lamp

AUX Operating

Assessment Results

Regular

Operating

Break in wiring

OFF

Not operating

Short

OFF

Not operating

Normal: OK Abnormal: NG (1) (2) (3) (4)

Warning Lamp Error code E:018 Hydraulic Release Switch AUX Port Switch

(5) AUX Knob Switch (6) AUX Operating Lamp ON (7) AUX Operating Lamp OFF RY9212332ELS0131US0

4-S102

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5. 6. 7.

No.21 AUX Port Switch

Press

Release

Assessment Results

Regular

OFF

Break in wiring

OFF

Short

No.43 AUX Knob (Right Settings)

(Ex.) Value Displayed

AUX Knob Switch

0.48 - 4.49

No.46 AUX Amperage (Right)

(Ex.) Value Displayed

AUX Amperage (Right)

1.2

(Ex.) Setting Values No.41 Left

No.42 Neutral

No.43 Right

0.48 V

4.49 V

(Ex.) Setting Values No.45 Left

Neutral

No.46 Right

1.2 A

0.8 A

Assessment Results

Normal: OK Abnormal: NG (1) (2) (3) (4)

Engine RPM AUX Port Switch AUX Knob (Right Settings) AUX Amperage (Right)

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0132US0

4-S103

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Inspecting each Device Visually and Physically 1. Checking fuses 1. Check whether the control elements fuse 5 A is blown. Criteria

Assessment Results

Normal: no brake (OK) Error: has a brake (NG) RY9212038ELS0194US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. AUX solenoid (right) connector CN422 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the AUX solenoid (right) again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) AUX Solenoid (Right) Connector CN422 RY9212332ELS0134US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the AUX solenoid (right) connector CN422 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the AUX solenoid (right) again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) AUX Solenoid (Right) Connector CN422 RY9212332ELS0135US0

4-S104

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0136US0

Connector Name (+ terminal) Travel lever (right) connector CN402

Pin No. <6>

Connector Name (- terminal) Body GND

Pin No.

Assessment Results

–

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0137US0

2. Continuity check

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Travel lever (right) connector CN402

<4>

Main ECU connector CN407

<33>

(2)

Travel lever (right) connector CN402

<5>

Main ECU connector CN407

<6>

(3)

Travel lever (right) connector CN402

<6>

Main ECU connector CN407

<13>

(4)

AUX solenoid (right) connector CN422

<1>

Main ECU connector CN407

<3>

(5)

AUX solenoid (right) connector CN422

<2>

Main ECU connector CN407

<18>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0138US0

4-S105

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

AUX Hold Switch (Right) (SW1) AUX Hold Switch (Left) (SW2) AUX Knob Switch Switch (SW3) Trig Switch

Connector Name (+ terminal) Travel lever (right) connector CN402

Pin No. <4>

Connector Name (-terminal)

Pin No.

Travel lever (right) connector CN402

Assessment Results

<7>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0314US0

2. Testing the AUX Solenoid (Right) [Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the AUX solenoid connector (right) CN422 and test the resistance. Right AUX solenoid terminal

Factory Specification

Criteria

3.2 ± 0.5 Ω (at 20 °C, 68 °F)

Assessment Results

Regular: Within standards (OK) Irregular: Outside standards (NG) (A) Diagram of Test

(a) AUX Solenoid (Right) Terminals RY9212332ELS0140US0

4-S106

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Settings after replacing device 1. Make the settings again in service mode No-02 (AUX knob settings). 2. Make the settings again in service mode No-03 (AUX start-up settings). RY9212332ELS0331US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0170US0

4-S107

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[10] No.12 AUX LEFT SOLENOID ERRORS (E:019) (1) Checking via the LCD Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Push the AUX port switch (4). 5. Slide the AUX knob switch (5) to the left. 6. The AUX operating lamp (6) lights up on the meter panel. Check operation of the AUX operating lamp as per the table blow. AUX Operating Lamp

AUX Operating

Assessment Results

Regular

AUX operating

Break in wiring

OFF

AUX not operating

Short

OFF

AUX not operating

Normal: OK Abnormal: NG (1) (2) (3) (4)

Warning Lamp Error Code E:019 Hydraulic Release Switch AUX Port Switch

(5) AUX Knob Switch (6) AUX Operating Lamp ON (7) AUX Operating Lamp OFF RY9212332ELS0315US0

4-S108

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5. 6. 7.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the AUX port switch. Slide the AUX knob switch to the left. Check the AUX operating relay, AUX knob (setting value left) and AUX current value (left) operating, followed by the table below.

No.21 AUX Port Switch

Press

Release

Assessment Results

Regular

OFF

Break in wiring

OFF

Short

No.41 AUX Knob (Left Settings)

(Ex.) Value Displayed

AUX Knob Switch

0.48 - 4.49

No.45 AUX Amperage (Left)

(Ex.) Value Displayed

AUX Amperage (Left)

1.2

(Ex.) Setting Values No.41 Left

No.42 Neutral

No.43 Right

0.48 V

4.49 V

(Ex.) Setting Values No.45 Left

Neutral

No.46 Right

1.2 A

0.8 A

Assessment Results

Normal: OK Abnormal: NG (1) (2) (3) (4)

Engine RPM AUX Port Switch AUX Knob (Left Settings) AUX Amperage (Left)

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0316US0

4-S109

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Inspecting each Device Visually and Physically 1. Checking fuses 1. Check whether the control elements fuse 5 A is blown. Criteria

Assessment Results

Normal: no brake (OK) Error: has a brake (NG) RY9212038ELS0194US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. AUX solenoid (left) connector CN423 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the AUX solenoid (left) again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) AUX Solenoid (Left) Connector CN423 RY9212332ELS0317US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the AUX solenoid (left) connector CN423 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the AUX solenoid (left) again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) AUX Solenoid (Left) Connector CN423 RY9212332ELS0318US0

4-S110

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0319US0

Connector Name (+ terminal) Travel lever (right) connector CN402

Pin No. <6>

Connector Name (- terminal) Body GND

Pin No.

Assessment Results

–

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0137US0

2. Continuity check

[Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the travel lever (right) CN402, main ECU CN407 and AUX solenoid (left) CN423. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Travel lever (right) connector CN402

<4>

Main ECU connector CN407

<33>

(2)

Travel lever (right) connector CN402

<5>

Main ECU connector CN407

<6>

(3)

Travel lever (right) connector CN402

<6>

Main ECU connector CN407

<13>

(4)

AUX solenoid (left) connector CN423

<1>

Main ECU connector CN407

<4>

(5)

AUX solenoid (left) connector CN423

<2>

Main ECU connector CN407

<18>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0320US0

4-S111

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

AUX Hold Switch (Right) (SW1) AUX Hold Switch (Left) (SW2) AUX Knob Switch Switch (SW3) Trig Switch

[Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the travel lever (right) connector CN402 from the machine. 3. Slide the C to the left and check for continuity. nt Location Measureme (a)

Connector Name (+ terminal) Travel lever (right) connector CN402

Pin No. <4>

Connector Name (-terminal)

Pin No.

Travel lever (right) connector CN402

Assessment Results

<8>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0321US0

2. Testing the AUX Solenoid (Left) [Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the AUX solenoid connector (left) CN423 and test the resistance. Left AUX solenoid terminal

Factory Specification

Criteria

3.2 ± 0.5 Ω (at 20 °C, 68 °F)

Assessment Results

Regular: Within standards (OK) Irregular: Outside standards (NG) (A) Diagram of Test

(a) AUX Solenoid (Left) Terminals RY9212332ELS0322US0

4-S112

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Settings after replacing device 1. Make the settings again in service mode No-02 (AUX knob settings). 2. Make the settings again in service mode No-03 (AUX start-up settings). RY9212332ELS0331US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0170US0

4-S113

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[11] No.13 5V SHORT SYSTEM ERRORS (E:021) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp

(2) Error Code E:021 RY9212134ELS0183US0

2. Service Mode No-09 (Read error log) 1. Select the error log read mode. 2. Check the hour meter when the first error occurred. (1) (2) (3) (4)

Error Code Times Error Occurred Hour Meter at Most Recent Error Hour Meter at First Error after Clearing the Error Log

(a) Right S/W: S (c) Right S/W: L

RY9212332ELS0332US0

4-S114

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Inspecting each Device Visually and Physically 1. Checking Fuses 1. Check whether the switch's 5A fuse is blown. Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) RY9212134ELS0151US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

3. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The travel lever (left) connector CN414 (a) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation again in the tester mode No-01. Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Travel Lever (Left) Connector CN414 RY9212332ELS0323US0

4-S115

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

4. Example base

[Test Conditions] Put the key switch in the STOP position. [Method of Checking] Check the travel lever (left) connector CN412 wire is pinching 5 V route. (a) 5 V Wire is Pinching Place RY9212332ELS0324US0

(3) Testing the Equipment Itself 1. Erasing error logs 1. After completing repairs, select Erase Error Log and erase the records. 2. After erasing the records, read the error log again and make sure there are no errors. If no error codes are displayed: • If it will not switch from "no-09", there are no errors in the log. Criteria

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0172US0

4-S116

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[12] No.14 OVER VOLTAGE ERRORS (E:023) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp

(2) Error Code E:023 RY9212332ELS0086US0

[Inspection point] 1. Check whether the machine has been jump started with a 24 V battery. Ex.) Whether switched to 24V (a) 12 V (b) 24 V

(2) Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Start and maximum engine speed. Measure the voltage based on the table below. Point to Measure (a)

Connector Name (+ terminal) Alternator terminal B

Pin No.

–

Connector Name (– terminal) Body GND

Pin No.

Assessment Results

–

Regular: 12 to 14 V (OK) Irregular: Over 18 V (NG) (a) Terminal B RY9212038ELS0202US0

4-S117

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[13] No.16 CRS COMMUNICATION ERRORS (E:026) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp

(2) Error Code E:026 RY9212332ELS0152US0

(2) Inspecting each Device Visually and Physically 1. Checking Fuses 1. Check whether the CRS ECU 5A fuse is blown. Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) RY9212332ELS0326US0

(3) Testing with a Circuit Tester

RY9212332ELS0153US0

4-S118

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

1. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the main ECU CN407 and engine ECU (58P) CN418. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Main ECU connector CN407

<49>

Engine ECU connector (58P) CN418

<39>

(2)

Main ECU connector CN407

<45>

Engine ECU connector (58P) CN418

<38>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0154US0

(4) Testing the Equipment Itself 1. Erasing error logs 1. After completing repairs, select Erase Error Log and erase the records. 2. After erasing the records, read the error log again and make sure there are no errors. If no error codes are displayed: • If it will not switch from "no-09", there are no errors in the log. Criteria

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0172US0

4-S119

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[14] No.17 RIDE CONTROL SOLENOID ERRORS (E:027) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Push the ride control switch (4). 5. The ride control lamp (5) lights up on the meter panel. Check the ride control operating lamp, followed by the table below. Ride Control Lamp

During Ride Control

Assessment Results

Regular

Operating

Break in wiring

OFF

Not operating

Short

OFF

Not operating

Normal: OK Abnormal: NG (1) Warning Lamp (2) Error Code E:027 (3) Hydraulic Release Switch

(4) Ride Control Switch (5) Ride Control Lamp ON (6) Ride Control Lamp OFF RY9212332ELS0087US0

4-S120

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the ride control switch. Check the "30: On" and "31: On" to switch correctly. 6. Check the ride control switch and ride control solenoid operating, followed by the table below. No.30 Ride Control Switch

Press

Release

Assessment Results

Regular

OFF

Break in wiring

OFF

OFF

Short

On

No.31 Ride Control Solenoid

Ride Control Operating

Ride Control Not Operating

Assessment Results

Regular

OFF

Break in wiring

OFF

OFF

Short

OFF

 : Irregular

Normal: OK Abnormal: NG (1) (2) (3) (4)

Engine RPM Battery Voltage Ride Control Switch Ride Control Solenoid

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0088US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses 1. Check whether the control elements fuse 5 A is blown. Criteria

Assessment Results

Normal: no brake (OK) Error: has a brake (NG) RY9212038ELS0194US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

4-S121

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Ride control solenoid connector CN115 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the ride control again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Ride Control Solenoid CN115 RY9212332ELS0089US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the ride control solenoid connector CN115 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the ride control again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Ride Control Solenoid CN115 RY9212332ELS0090US0

4-S122

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0091US0

1. Voltage check [Measurement Conditions] 1. Disconnect ride control solenoid connector CN115. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Ride control solenoid connector CN115

<2>

Ride control solenoid connector CN115

<1>

(2)

Ride control solenoid connector CN115

<2>

Body GND

–

Assessment Results

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0327US0

2. Continuity check

[Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the connectors of the ride control solenoid CN115, main ECU CN407 and travel lever (left) CN412. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

(1)

Ride control solenoid connector CN115

<2>

Main ECU connector CN407

(2)

Ride control solenoid connector CN115

<1>

Body GND

Connector Name (- terminal)

Pin No.

Assessment Results

<61> –

(3)

Main ECU connector CN407

<16>

Travel lever (left) connector CN412

<2>

(4)

Main ECU connector CN407

<74>

Travel lever (left) connector CN412

<3>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0092US0

4-S123

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Testing the Switch of the Control Lever (Left) (1) Out Line (ECU 73) (2) 12 V Input (3) Out Line (ECU 74) (4) Ground (5) 12 V Input (6) – (7) 12 V Input (8) Out Line (ECU 42) (9) Out Line (ECU 42) (10) Out Line (ECU 23) (11) Blinker (12) – (13) Travel Lever (Left) Connector A: B: C: D: E:

Horn Switch Ride Control Switch Switch (SW3) Switch (SW4) High-Low Switch

[Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the travel lever (left) connector CN414 from the machine. 3. Press switch B and check for continuity. Measurem ent Location (a)

Connector Name (+ terminal) Travel lever (left) connector CN414

Pin No. <2>

Connector Name (- terminal)

Pin No.

Travel lever (left) connector CN414

Assessment Results

<3>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0093US0

2. Testing the Ride Control Solenoid [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the ride control solenoid connector CN115 and test the solenoid. (A) Ride control solenoid terminals (a)

Factory Specification

12 Ω ± 10 %

Assessment Results

Criteria Regular: Within standards (OK) Irregular: Outside standards (NG) (A) Diagram of Test

(a) Ride Control Solenoid Terminals

3. Settings after replacing device

RY9212332ELS0094US0

1. No settings required. RY9212001ELS0020US0

4-S124

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0170US0

4-S125

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[15] No.18 FAN SOLENOID ERRORS (E:028) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp

(2) Error Code E:028 RY9212332ELS0095US0

2. Service Mode 1. Select the tester mode (No-01). 2. Start the engine. 3. Check the fan amperage, followed by the table below. Oil Temperature

Assessment

Regular

1.2

When cut off

0.0

When shorted

0.0

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Fan Amperage

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0096US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. RY9212038ELS0153US0

2. Checking relays Checking relays is not necessary.

RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Fan motor connector CN107 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the fan motor again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Fan Motor Connector CN107 RY9212332ELS0097US0

4-S126

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the fan motor connector CN107 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the fan motor again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Fan Motor Connector CN107 RY9212332ELS0098US0

(3) Testing with a Circuit Tester

RY9212332ELS0099US0

1. Continuity check

[Measurement Conditions] 1. Put the key switch in the STOP position. 2. Remove the connectors of the fan motor CN107, main ECU CN407, fan (4P) CN106 and main fan (4P) CN105. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No. <1>

Connector Name (-terminal) Fan connector (4P) CN106

Pin No.

(1)

Fan motor connector CN107

(2)

Fan motor connector CN107

<2>

Fan connector (4P) CN106

<2>

(3)

Main fan connector (4P) CN105

<1>

Main ECU connector CN407

<41>

(4)

Main fan connector (4P) CN105

<2>

Main ECU connector CN407

<20>

Assessment Results

<1>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0100US0

4-S127

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Testing the Fan Motor [Test Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the fan motor connector CN107 and test the resistance. Fan motor connector CN105

Factory Specification

Criteria

13 ± 1 Ω (at 20 °C, 68 °F)

Assessment Results

Regular: Within standards (OK) Irregular: Outside standards (NG) (a) Fan Motor Terminal

2. Settings after replacing device

RY9212332ELS0101US0

1. No settings required. RY9212001ELS0013US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0171US0

4-S128

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[16] No.19 HYDRAULIC LOCK (LIFT ARM) ERRORS (E:029) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). (1) Warning Lamp (2) Error Code E:029

(3) Hydraulic Release Switch RY9212332ELS0102US0

2. Service Mode 1. 2. 3. 4. 5.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Check the hydraulic lock (lift arm) solenoid operating, followed by the table below.

No.19 Hydraulic Lock (Lift Arm)

Press

Assessment Results

Release

Regular

OFF

Break in wiring

OFF

Short

On

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Hydraulic Lock (lift Arm)

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0103US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. 2. Checking relays

RY9212038ELS0153US0

Checking relays is not necessary. RY9212038ELS0154US0

4-S129

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Hydraulic lock (lift arm) connector CN420 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the hydraulic lock (lift arm) solenoid again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Hydraulic Lock (Lift Arm) Connector CN420 RY9212332ELS0104US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] A wire of the hydraulic lock (lift arm) connector CN420 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the hydraulic lock (lift arm) solenoid again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Hydraulic Lock (Lift Arm) Connector CN420 RY9212332ELS0105US0

4-S130

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0106US0

1. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the connectors of the hydraulic lock (lift arm) CN420 and main ECU CN407. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

(1)

Hydraulic lock (lift arm) connector CN420

<1>

Main ECU connector CN407

(2)

Hydraulic lock (lift arm) connector CN420

<2>

Body GND

Connector Name (- terminal)

Pin No.

Assessment Results

<24> –

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0107US0

(4) Testing the Equipment Itself 1. Testing the Hydraulic Lock (Lift Arm) Solenoid [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Test the solenoid. (A) Front control lock solenoid terminals (a)

Factory specification

12 Ω ± 10 %

Assessment Results

Criteria Regular: no break (OK) Irregular: has a break (NG) (A) Diagram of Test

(a) Hydraulic Lock (Lift Arm) Solenoid Terminals

2. Settings after replacing device

RY9212332ELS0108US0

1. No settings required. RY9212332ELS0109US0

4-S131

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212332ELS0110US0

4-S132

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[17] No.20 HYDRAULIC LOCK (BUCKET) ERRORS (E:030) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). (1) Warning Lamp (2) Error Code E:030

(3) Hydraulic Release Switch RY9212332ELS0334US0

2. Service Mode 1. 2. 3. 4. 5.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Check the hydraulic lock (bucket) operating, followed by the table below.

No.20 Hydraulic Lock (Bucket)

Press

Assessment Results

Release

Regular

OFF

Break in wiring

OFF

Short

On

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Hydraulic Lock (Bucket)

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0111US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. 2. Checking relays

RY9212038ELS0153US0

Checking relays is not necessary. RY9212038ELS0154US0

4-S133

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Hydraulic lock (bucket) connector CN421 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the hydraulic lock (bucket) solenoid again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Hydraulic Lock (Bucket) Connector CN421 RY9212332ELS0112US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] A wire of the hydraulic lock (bucket) connector CN421 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the hydraulic lock (bucket) solenoid again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Hydraulic Lock (Bucket) Connector CN421 RY9212332ELS0113US0

4-S134

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212332ELS0114US0

1. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the connectors of the hydraulic lock (bucket) CN421 and main ECU CN407. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

(1)

Hydraulic lock (bucket) connector CN421

<1>

Main ECU connector CN407

(2)

Hydraulic lock (bucket) connector CN421

<2>

Body GND

Connector Name (- terminal)

Pin No.

Assessment Results

<79> –

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0115US0

(4) Testing the Equipment Itself 2. Testing the Hydraulic Lock (Bucket) Solenoid [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Test the solenoid. (A) Hydraulic lock (bucket) solenoid terminals (a)

Factory specification

12 Ω ± 10 %

Assessment Results

Criteria Regular: no break (OK) Irregular: has a break (NG) (A) Diagram of Test

(a) Hydraulic Lock (Bucket) Solenoid Terminals

2. Settings after replacing device

RY9212332ELS0116US0

1. No settings required. RY9212332ELS0109US0

4-S135

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212332ELS0110US0

4-S136

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[18] No.21 TRAVEL PILOT PRESSURE SENSOR ERRORS (E:031) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. [Test Conditions] 1. Start the engine. 2. Lower the seat bar. 3. Push the hydraulic unlock switch (3). 4. Press the travel high-low switch (4) to operate the high travel speed. 5. The speed indicator lamp (5) lights up on the meter panel. Check the speed indicator lamp according to the table below. Speed Indicator Lamp

During Travel High-Low

Assessment Results

Regular

Operating

Break in wiring

OFF

Not operating

Short

OFF

Not operating

Normal: OK Abnormal: NG (1) Warning Lamp (2) Error Code E:031 (3) Hydraulic Release Switch

(4) Travel High-Low Switch (5) Speed Indicator Lamp ON (6) Speed Indicator Lamp OFF RY9212334ELS0006US0

4-S137

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

2. Service Mode 1. 2. 3. 4. 5. 6.

Select the tester mode (No-01). Start the engine. Lower the seat bar. Push the hydraulic unlock switch. Push the travel high-low switch. Check the travel pilot pressure sensor (MPa) and travel pilot pressure sensor (V) operating, followed by the table below.

No.51 Travel pilot pressure sensor (MPa)

No.52 Travel pilot pressure sensor (V)

Regular (Example) display value

Disconnection (Example) display value

Short (Example) display value

0.01 - 4.49

1.00

4.49

Regular (Example) display value

Disconnection (Example) display value

Short (Example) display value

4.49

1.00

4.49

Normal: OK Abnormal: NG (1) (2) (3) (4)

Engine RPM Battery Voltage Travel Pilot Pressure Sensor Travel pilot Pressure Sensor

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212334ELS0007US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. RY9212038ELS0153US0

2. Checking relays Checking relays is not necessary.

RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Travel pilot pressure sensor CN410 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the travel pilot pressure again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Travel Pilot Pressure CN410 RY9212334ELS0008US0

4-S138

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the travel pilot pressure connector CN410 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the travel pilot pressure again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Travel Pilot Pressure CN410 RY9212334ELS0009US0

(3) Testing with a Circuit Tester

RY9212334ELS0010US0

1. Voltage check [Measurement Conditions] 1. Disconnect travel pilot pressure connector CN410. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Travel pilot pressure connector CN410

<1>

Travel pilot pressure connector CN410

<3>

(2)

Travel pilot pressure connector CN410

<3>

Body GND

–

Assessment Results

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212334ELS0003US0

4-S139

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

1. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the connectors of the travel pilot pressure CN410. Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

(1)

Travel pilot pressure connector CN410

<1>

Main ECU connector CN407

<15>

(2)

Travel pilot pressure connector CN410

<2>

Main ECU connector CN407

<37>

(3)

Travel pilot pressure connector CN410

<3>

Main ECU connector CN407

<37>

Connector Name (- terminal)

Pin No.

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212334ELS0011US0

(4) Testing the Equipment Itself 1. Settings after replacing device 1. No settings required. RY9212334ELS0004US0

2. Erasing error logs 1. After completing repairs, select Erase Error Log and erase the records. 2. After erasing the records, read the error log again and make sure there are no errors. If no error codes are displayed: • If it will not switch from "no-09", there are no errors in the log. Criteria

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212334ELS0005US0

4-S140

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[19] No.29 WATER TEMPERATURE SENSOR OVERHEATING ERRORS (E:9104) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp (3) Error Code E:9104 (2) Coolant temperature Warning Lamp RY9212134ELS0135US0

2. Service Mode NO-09 (Read error log) 1. Select the error log read mode. 2. Check the hour meter when the first error occurred. (1) (2) (3) (4)

Error Code Times Error Occurred Hour Meter at Most Recent Error Hour Meter at First Error after Clearing the Error Log

(a) Right S/W: S (c) Right S/W: L

RY9212134ELS0136US0

3. Service Mode NO-01 (Tester) 1. Select the tester mode. 2. Check the water temperature as per the table below. Water Temperature

Assessment

Regular

50 °C (122 °F)

When cut off

80 °C (176 °F)

When shorted

80 °C (176 °F)

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Water Temperature

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212134ELS0137US0

4-S141

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. RY9212038ELS0153US0

2. Checking relays Checking relays is not necessary.

RY9212038ELS0154US0

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Water temperature sensor connector disconnected. 2. A break somewhere in the wiring.

CN516

(a)

[Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the water temperature sensor again in service mode NO-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Water Temperature Sensor Connector CN516 RY9212332ELS0336US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The water temperature sensor connector CN516 (a) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the water temperature sensor again in the service mode NO-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Water Temperature Sensor Connector CN516 RY9212332ELS0337US0

4-S142

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(3) Testing with a Circuit Tester

RY9212213ELS0085US0

1. Voltage check [Measurement Conditions] 1. Disconnect the water temperature sensor connector CN516. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Water temperature sensor connector CN516

<1>

Water temperature sensor connector CN516

<2>

(2)

Water temperature sensor connector CN516

<1>

Body GND

–

Assessment Results

Regular: 5 V (OK) Irregular: Large discrepancy from 5 V (NG) RY9212213ELS0086US0

2. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the ECU connector CN104 (96P). Test for continuity based on the table below. Measurement Location

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

Pin No.

(1)

Engine ECU connector CN104 (96P)

<39>

Water temperature sensor connector CN516

<1>

(2)

Engine ECU connector CN104 (96P)

<15>

Water temperature sensor connector CN516

<2>

Assessment Results

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212213ELS0087US0

4-S143

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Inspecting the water temperature sensor [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the connector CN516 from the water temperature sensor and take measurements. 3. Refer to the following table for the resistance at different temperatures. 4. Refer to the graph at left on the relationship between water temperature and resistance. Water Temperature (°C / °F)

Resistance

– 20 / –4.0

15.04 kΩ

20 / 68.0

2.45 kΩ

30 / 86.0

1.66 kΩ

40 / 104.0

1.15 kΩ

50 / 122.0

811 Ω

60 / 140.0

584 Ω

80 / 176.0

240 Ω

110 / 230.0

142 Ω

130 / 266.0

88 Ω Assessment Results

Criteria Regular: Within standards (OK) Irregular: Outside standards (NG) (A) Water Temperature and Resistance

(a) Water Temperature (°C / °F) (b) Resistance (Ω)

2. Settings after replacing device

RY9212213ELS0088US0

1. No settings required. RY9212001ELS0013US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0171US0

4-S144

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[20] No.47 ENGINE OIL PRESSURE ERRORS (E:9118) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp (2) Engine Oil Lamp

(3) Error Code E:9118 RY9212332ELS0117US0

2. Service Mode 1. Select the tester mode (No-01). 2. Check the operation of the engine oil pressure switch according to the table below. Key Switch

STOP Position

→

RUN Position

→

START Position

Assessment Results

Regular

OFF

→

OFF

Short

OFF

→

ON

Break in wiring

OFF

→

OFF

→

OFF

 : Irregular

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Engine Oil Pressure Switch

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0118US0

(2) Inspecting each Device Visually and Physically 1. Checking fuses Checking fuses is not necessary. 2. Checking relays

RY9212038ELS0153US0

Checking relays is not necessary. RY9212038ELS0154US0

4-S145

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes of a break in wiring [Test Conditions] Put the key switch in the STOP position. [Inspection Point] 1. Engine oil pressure connector CN509 (a) is disconnected. 2. A break somewhere in the wiring. [Method of Checking] Pull on the wiring harness and see if any connectors and/or wires come off. [Pull with 3 kgf (30 N, 7 lbf) or less of force] If any come off, plug the connector in securely and check the operation of the engine oil pressure sensor again in service mode No-01 (tester). Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) (a) Engine Oil Pressure Connector CN509 RY9212213ELS0089US0

4. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The wire of the engine oil pressure connector CN509 (a) is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the engine oil pressure again in the service mode No-01 (tester). Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Engine Oil Pressure Connector CN509 RY9212332ELS0119US0

(3) Testing with a Circuit Tester

RY9212332ELS0120US0

4-S146

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

1. Voltage check [Measurement Conditions] 1. Disconnect the engine oil pressure connector CN509. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location (1)

Connector Name (+ terminal) Engine oil pressure connector CN509

Pin No. <1>

Connector Name (- terminal) Body GND

Pin No.

Assessment Results

–

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212213ELS0092US0

2. Continuity check [Measurement Conditions] 1. Put the key switch in the STOP position. 2. Disconnect the main ECU connector CN407. Test for continuity based on the table below. Measurement Location (1)

Connector Name (+ terminal) Engine oil pressure switch connector CN509

Pin No.

<1>

Connector Name (- terminal)

Main ECU connector CN407

Pin No.

Assessment Results

<10>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0121US0

Connector Connections (When removing) • While pressing the lock button, release the lever and unplug the connector. (When connecting) • Press the connector all the way in, close the lever and make sure it is securely locked. (a) Lever (b) Lock Button

4-S147

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

(4) Testing the Equipment Itself 1. Measuring engine pressure [Measurement Conditions] Remove the engine oil pressure switch, attach a pressure gauge and measure the pressure. When Idling

Engine Oil Pressure At Rated RPM

Tightening torque

Usable Limit

0.098 MPa 1.0 kgf/cm2 14 psi

Factory Specification

0.20 to 0.39 MPa 2.0 to 4.0 kgf/cm2 28 to 57 psi

Usable Limit

0.15 MPa 1.50 kgf/cm2 21 psi

Oil switch tapering screw R1/8

Criteria

15 to 19 N·m 1.5 to 1.9 kgf·m 11 to 14 lbf·ft

Assessment Results

Regular: Within factory spec (OK) Irregular: Outside factory spec (NG)

2. Settings after replacing device

RY9212038ELS0164US0

1. No settings required. RY9212001ELS0013US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212213ELS0171US0

4-S148

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[21] No.48 CHARGE ERRORS (E:9119) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking red or not. (1) Warning Lamp (2) Charge Lamp

(3) Error Code E:9119 RY9212332ELS0123US0

2. Service Mode 1. Select the tester mode (No-01). 2. Check the battery voltage as per the table below. Assessment Regular

50 °C (122 °F)

When cut off

80 °C (176 °F)

When shorted

80 °C (176 °F)

Normal: OK Abnormal: NG (1) Engine RPM (2) Battery Voltage (3) Water Temperature

(a) Right S/W: S (b) Left S/W: S (c) Right S/W: L RY9212332ELS0124US0

(2) Inspecting each Device Visually and Physically 1. Checking Fuses 1. Check whether the alternator's 5A fuse is blown. Criteria

Assessment Results

Regular: no break (OK) Irregular: has a break (NG) RY9212332ELS0125US0

2. Checking relays Checking relays is not necessary. RY9212038ELS0154US0

4-S149

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

3. Causes when a short [Test Conditions] Put the key switch in the STOP position. [Method of Checking] The alternator connector CN511 (a) wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation again in the tester mode No-01. Criteria

Assessment Results

Regular: no short (OK) Irregular: shorted (NG) (a) Alternator Connector CN511 RY9212332ELS0126US0

(3) Testing with a Circuit Tester

(a) Alternator 5A Fuse RY9212332ELS0127US0

1. Voltage check [Measurement Conditions] 1. Disconnect the alternator connector CN511. 2. Put the key switch in the RUN position. Measure the voltage based on the table below. Measurement Location (1)

Connector Name (+ terminal) Alternator connector CN511

Pin No. <1>

Connector Name (- terminal) Body GND

Pin No.

Assessment Results

–

Regular: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) RY9212332ELS0128US0

4-S150

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

Connector Name (+ terminal)

Pin No.

Connector Name (- terminal)

(1)

Alternator connector CN511

<1>

Alternator 5A fuse

(2)

Alternator connector CN511

<2>

Main ECU connector CN407

Pin No.

Assessment Results

– <30>

Regular: Continuity (OK) Irregular: No continuity (NG) RY9212332ELS0129US0

Assessment Results

Regular: Error log erased (OK) Irregular: Error log not erased (NG) (c) Right S/W: L RY9212332ELS0130US0

4-S151

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

[22] No.49 WATER SEPARATOR, WATER FULL ERRORS (E:9120) (1) Checking via the Panel Display 1. Meter Panel Display (User Mode) Check whether or not the warning lamp (1) on the panel is blinking orange or not. (1) Warning Lamp

(2) Error Code E:9120 RY9212332ELS0122US0

(2) Inspecting each Device Visually and Physically 1. Checking Water Separator 1. When there is water in the water separator, it lifts the float. (a) Float

(b) Water RY9212332ELS0155US0

2. Draining the Water Separator CAUTION • To prevent accidents: – Stop the engine and remove the key prior to draining the water separator. IMPORTANT • If debris has accumulated inside the water separator, remove the water separator from the machine and clean out the cup. After cleaning it, put it back in place and be sure to purge the air from the fuel system prior to operating the machine. • If the water separator is completely full of water, the water may have gotten into the fuel filter as well, so replace the fuel filter too. 1. Close the cock. 2. Loosen the screw bolt. 3. Loosen the drain plug on the bottom and drain out the water. 4. It goes back up according to procedure. 5. Be sure to purge the air from the fuel system. 6. Start the engine. Next, check the engine stall. (1) (2) (3) (4) (5)

Water Separator Float Handle Screw Bolt Drain Plug

(A) Close (B) Open

RY9212332ELS0156US0

4-S152

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

7. FLOW CHART OF THE USER MODE AND SERVICE MODE SETTINGS

4-S153

KiSC issued 12, 2015 A

ELECTRICAL SYSTEM

SSV65, WSM

4-S154

KiSC issued 12, 2015 A

5 CABIN

KiSC issued 12, 2015 A

MECHANISM CONTENTS 1. AIR CONDITIONING SYSTEM .................................................................................................. 5-M1 [1] STRUCTURE ....................................................................................................................... 5-M1 [2] HOW THE MECHANISMS OF THE SYSTEM WORK ......................................................... 5-M3 [3] COMPRESSOR.................................................................................................................... 5-M4 [4] AIR CONDITIONING UNIT................................................................................................... 5-M7 [5] CONDENSER..................................................................................................................... 5-M12 [6] RECEIVER ......................................................................................................................... 5-M13 [7] PRESSURE SWITCH......................................................................................................... 5-M14 [8] SYSTEM CONTROLS ........................................................................................................ 5-M15 [9] ADJUSTING THE AIR FLOW AND DIRECTION ............................................................... 5-M16 [10]ELECTRICAL SYSTEM...................................................................................................... 5-M17 (1) Electrical Circuits .......................................................................................................... 5-M17 (2) Relays........................................................................................................................... 5-M18 2. WIPER ...................................................................................................................................... 5-M19 [1] WIPER SWITCH................................................................................................................. 5-M19 [2] WIPER MOTOR ................................................................................................................. 5-M19

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

1. AIR CONDITIONING SYSTEM [1] STRUCTURE

(1) Air Conditioning Unit (2) Heater Core

(3) Compressor (4) Condenser

(5) Pressure Switch (6) Receiver

(7) Control Panel (8) Outside Air Inlet

The cabin is equipped with a high-capacity, low-profile air conditioner that can circulate cabin air or bring in fresh air from outside. Cabin air is sucked into the cabin air inlet (9), which is located behind the seat, it then passes through thein/outside air duct to the air conditioning unit (1) (cabin air circulation). Fresh air is taken in via the outside air inlet (8) and passes through the in/outside air duct and enters the air conditioning unit (1) (fresh air intake). The inside or outside air that is sucked into the air conditioning unit (1) is cooled and dehumidified by the cooler of the air conditioning unit (1). When the system is used for heating, the air is heated by the heater core (2) and then expelled from the air duct ASSY. The vents installed inside the cabin can be opened and closed as well as adjusted to blow in different directions. (To be continued)

5-M1

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(Continued) Cooling Capacity

3.8 kW ± 10 %

Heating Capacity

4.3 kW ± 10 %

Type of Refrigerant (charge capacity)

R134a 900 ± 50 g 1.98 ± 0.11 lbs

Pressure Sensor (Low)

Factory specification

Pressure Sensor (High) (1) Air Conditioning Unit

0.196 MPa 2.0 kgf/cm2 28.4 psi 3.14 MPa 32 kgf/cm2 455 psi

(9) Cabin Air Inlet RY9212332CAM0001US0

5-M2

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[2] HOW THE MECHANISMS OF THE SYSTEM WORK

(1) Capillary Tube (Heat Sensitive (7) Condenser Capillary Tube) (8) Receiver (2) Expansion Valve (9) Dryer (3) Evaporator (10) Pressure Switch (4) Blower Motor (11) Heater Core (5) Compressor (12) Hot Water Valve (6) Engine Cooling Fan

A : Cooled Air B : Low Pressure and Temperature Vapor C, D : Air Passes Through In / Outside Air Filter

E : High Pressure/Temperature Gas F : Hot Air G : Liquid

This air conditioning system works as follows. 1. Refrigerant passes through the evaporator (3), is vaporized and then is compressed by the compressor (5) to approximately 1.47 MPa (15 kgf/cm2, 210 psi) and raised to a temperature of approximately 70 °C (158 °F) the refrigerant is then sent in this state to the condenser (7). 2. The vaporized refrigerant passes through the condenser (7), where it is cooled down to approximately 50 °C (122 °F) and the refrigerant changes back from a vapor to a liquid; it is then sent on to the receiver (8). Then the heat from inside the cabin that is captured by the condenser (7) is released outside the cabin. 3. The liquid refrigerant collects in the receiver (8) and any moisture is removed from the refrigerant by the dryer (9). 4. The liquid refrigerant then passes on to the expansion valve (2), where it is sprayed through the small holes in the valve into the evaporator (3), which produces a mist of the refrigerant; its pressure and temperature drop and the refrigerant evaporates. 5. The refrigerant simultaneously captures heat from the surface of the evaporator's (3) pipes and evaporates vigorously at 0 °C (32 °F). 6. As this happens, warm air from inside the cabin is drawn into the evaporator (3) by the blower motor (4) and the refrigerant captures the heat and evaporates. In this way the air in the cabin is cooled. [NOTE] • Because the warm air inside the cabin is cooled quickly, the moisture in the air condenses. In other words, the air in the cabin can be dehumidified. 7. The refrigerant vaporized in the evaporator (3) is returned to the compressor (5) and compressed, changing it back into a liquid. In doing so, the refrigerant is put under high pressure and temperature. 8. The air that passed through the evaporator (3) can be adjusted to the desired temperature by then passing it through the heater core (11). Engine coolant is heated by the engine and the amount of the coolant that flows into the heater core (11) is controlled by the hot water valve (12), and this adjusts the temperature of the air that flows through the heater core (11). RY9212001CAM0002US0

5-M3

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[3] COMPRESSOR The vane type of compressor installed in this system is composed of a cylinder (1) that is elliptical in cross-section, along with five vanes (3) attached to the rotor (2). This vane compressor has two each of intake and discharge ports. The five vanes (3) are attached to the rotor (2) and as it rotates, the tips of the vanes come in contact with the walls of the cylinder (1) and an airtight compression space is maintained both by the centrifugal force exerted by the rotor (2) along with the back pressure on the vanes (3), which is in proportion to the rpms of the rotor (2). As a result, the volume changes in each of the five segments of the cylinder, which are divided by the five vanes (3) in the cylinder (1). Each time that the rotor (2) rotates, each of the five segments of the cylinder goes through two cycles of intake, compression and discharge. (1) Cylinder (2) Rotor

(3) Vane RY9212001CAM0003US0

How it Works As the rotor (3) turns, the volume of space in a segment, as divided by the cylinder (1) and vanes (4), increases, sucking refrigerant gas from the intake port (2) into the cylinder space. As the rotor (3) turns further, the volume of the space created between the cylinder (1) and vanes (4) decreases, compressing the refrigerant gas. As the rotor (3) continues to turn, the refrigerant gas is compressed further, putting it under a great deal of pressure, pressing on the discharge valve and opening it. The refrigerant gas is then expelled via the discharge port (5). (1) (2) (3) (4) (5)

Cylinder Intake Port Rotor Vane Discharge Port

(A) Compression Cycle (B) Discharge Cycle (C) Intake Cycle

RY9212001CAM0004US0

Compressor Oil The compressor oil is dissolved in the refrigerant and circulates throughout the entire cooling system acting as the lubricating oil for the compressor. However, because the previously used R12 compressor oil does not dissolve in R134a, it does not circulate through the cooling cycle. So it drastically reduces the working life of the compressor. As a result, it is imperative that the right compressor oil is always used. The mineral oil that is used in an R12 cooling system cannot be used in an R134a cooling system. A synthetic PAG oil has to be used in an R134a cooling system. This oil mixes extremely well with refrigerant gas and provides the entire system with the optimum lubrication. Volume of Oil 100 to 120 cc 0.106 to 0.127 U.S.qts

Product Name ND–OIL8 <PAG* oil>

*PAG : Polyalkylene glycol (synthetic oil) RY9212213CAM0005US0

5-M4

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Magnetic Clutch A magnetic clutch is a device that governs the mechanical linkage between the engine and the compressor. When the engine is rotating and the A/C switch is on, air at cabin temperature comes out and when the temperature reaches the temperature set with the temperature control switch, or when the cabin gets hot, the clutch works to stop or to drive the compressor, respectively. The hub of the magnetic clutch is attached to the compressor shaft and when it is not driving the compressor, it is separate from the rotor and just the pulley turns. When the A/C switch is turned on, current flows into the stator coil, making the stator into a magnet, which then holds onto the hub and the pulley turns along with the compressor. (1) Hub Plate (2) Ball Bearing (3) Snap Ring

(4) Magnetic Clutch (5) Rotor RY9212134CAM0006US0

Safety Valve The valve opens when the refrigerant pressure reaches the specified pressure, thus relieving the pressure. When the pressure becomes abnormally high, it overcomes the force of the spring, allowing refrigerant to leak out of the relief port; when the pressure drops the reverse happens--the spring overcomes the pressure and the safety valve closes. When an error occurs, this also keeps the discharge of refrigerant to a minimum. (1) Safety Valve

a : 113 L/min (29.9 U.S.gals./min) (A) Refrigerant Leak Route b : 2.75 MPa (B) Functional Characteristics (28 kgf/cm2, 399 psi) c : 3.43 MPa (C) Amount of Refrigerant (35 kgf/cm2, 497.8 psi) Leaked d : 4.12 MPa (D) Pressure (42 kgf/cm2, 598 psi) RY9212079CAM0009US0

5-M5

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Temperature Sensor A temperature sensor is installed on the head of the vane type of compressor. This sensor detects the temperature of the refrigerant and when the refrigerant becomes unusually hot, it cuts off the magnetic clutch, stopping the compressor. The temperature sensor is composed of a bimetallic strip and contacts. A bimetallic strip is a sandwich of two metals with different rates of expansion and it bends when heated due to these different rates of expansion. This characteristic is exploited when there is an excessive temperature via the rod, which breaks the contact and switches the magnetic clutch off. OFF

153 to 163 °C 307 to 325 °F

120 ± 5 °C 248 ± 41 °F

Temperature Sensor

11.8 ± 1.47 N·m 1.2 ± 0.15 kg·fm 8.7 ± 1.08 lbf·ft

Operating Ranges

Tightening torque

(1) Temperature Sensor (2) Compressor

A : Contact B : Bimetallic Strip C : Rod

(a) To battery + Terminal RY9212001CAM0008US0

5-M6

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[4] AIR CONDITIONING UNIT

(A) Diagram of Linkages and Electrical Parts No.

Parts Name

Q'ty

No.

Parts Name

Q'ty

(1)

Case (Low Side)

(10)

Hose

(2)

Evaporator, Assy

(11)

Clamp

(3)

Thermistor

(12)

Servo

(4)

Clamp

(13)

Linkage lever

(5)

Case (Up Side)

(14)

Resistor

(6)

Screw

(15)

Fan motor

(7)

Heater core

(16)

Screw

(8)

Clamp

(17)

Expansion valve

(9)

Water valve Assy

(18)

Bolt

2 RY9212332CAM0002US0

5-M7

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Evaporator The evaporator takes the refrigerant, which has been made liquid by the condenser and cooled and put under low-pressure by the expansion valve, and by evaporating it, the heat and humidity of the air passing through the evaporator is removed, thus producing cool, dehumidified air. (a) Fins (b) Tubes

(A) Inlet (B) Outlet RY9212001CAM0010US0

Heater Core The heater core dissipates the heat of the heated engine coolant. So, the air that is blown through it by the blower motor passes through the fins of the heater core and the air takes on the heat of the coolant. (1) Heater Core

(A) Inlet (B) Outlet RY9212079CAM0010US0

Blower The blower is built into the right side of the A/C unit. The blower forces cool, warm or fresh outside air through the vents into the cabin. The rpm of the blower motor can be adjusted to three levels with the blower resistor. The blower fan is the type that uses centrifugal force and it sucks in air parallel to its axis of rotation and blows it out perpendicular to the centrifugal force, or in other words, perpendicular to the axis of rotation. Specifications (at 20 °C) Model

T70

Rated Voltage

12 V

No load rpm

4300 ± 400 rpm

Amperage

18.3 ± 1.8 A

(1) Blower

(A) Circuit Diagram (a) (+) Terminal (b) (–) Terminal RY9212332CAM0003US0

5-M8

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Blower resistor Acts as the blower switch and controls the rpm of the blower motor by switching the degree of resistance. The fan speed can be switched to three levels, 1, 2 and 3, with 3 being the fastest. (1) (2) (3) (4)

MI Blank HI LO

(A) Blower Resistor (B) Wiring Diagram

RY9212332CAM0004US0

5-M9

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Expansion Valve [Functions] The expansion valve works in the following two ways. 1. By spraying the liquid refrigerant, which is hot and under high pressure, it makes it expand rapidly, producing a low-temp, low-pressure refrigerant vapor. 2. It adjusts the amount of refrigerant according to the vaporized state of the refrigerant in the evaporator. In order to take full advantage of the capabilities of the evaporator, a state must always be maintained in which the liquid refrigerant takes on the ambient heat, then it is completely vaporized at the outlet of the evaporator. In order to do so, the expansion valve automatically adjusts the volume of refrigerant in response to changes in the cabin temperature (cooling load) and changes in the compressor RPM. [Structure (box type)] • The expansion valve is composed of a diaphragm, heat-sensing rod, and a needle valve (ball) and the refrigerant gas is enclosed upstream of the diaphragm. The downstream side of the diaphragm is pressurized by the evaporator outlet pressure. [How it Works] • The heat-sensitive rod senses the temperature of the refrigerant passing to the evaporator and the temperature at that point is communicated to the refrigerant gas on the upstream side of the diaphragm via the heat-sensitive rod. As such, the pressure of the gas varies with the temperature, thus moving the heat-sensitive rod directly connected to the diaphragm and adjusting the opening of the needle valve. Evaporator outlet temperature

Operation

When low (when cooling load is low)

The pressure of the gas in the diaphragm chamber drops, reducing the volume and moving the heat-sensitive rod to the right, which constricts the needle valve and reduces the flow of refrigerant to the evaporator.

When high (when cooling load is high)

The pressure of the gas in the diaphragm chamber rises, increasing the volume and moving the heat-sensitive rod to the left, which opens the needle valve and supplies more refrigerant to the evaporator.

(1) Evaporator

A : Diaphragm B : Heat-Sensitive Rod C : Spring

D : Body E : Needle Valve

(a) From Receiver (Hi-Pressure) (b) To Compressor (Lo-Pressure) (c) To Evaporator (d) From Evaporator RY9212001CAM0014US0

5-M10

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Fin Thermistor (for frost control) [Function] Senses the temperature of the fins of the evaporator and when they are too cold, it stops the compressor and prevents frost from forming before it happens. [How it Works] The sensor of the fin thermistor senses the evaporator's fin temperature and if the resistance inside the sensor exceeds the thermo-amp resistance setting, its internal circuit shuts off the power to the compressor clutch. Specifications Rated Voltage

DC12 V

Measurement Conditions

DC13 ±0.2 V at 25 ± 5 °C (77 ± 9 °F)

Temperature Detection

OFF R1

4383 ±131 Ω (2 °C, 36 °F)

ON R2

(4095 Ω) (3.35 °C, 38 °F)

Hysteresis

215 ±5.0 Ω (1 °C, 34 °F)

Usage Conditions Temperature Range

–30 to 80 °C (–22 to 176 °F)

Voltage Range

DC10 to 16 V

Operating Voltage Range

DC8 to 16 V (at 25 °C, 77 °F)

Temperature Detection

0 °C / 32 °F

15 °C / 59 °F

Resistance Value

4.852 kΩ

2.34 kΩ

(1) Thermistor (2) Thermo-Amp

(a) Evaporator Fin Temperature Detector RY9212332CAM0005US0

Hot Water Valve The hot water valve is the valve that adjusts the volume of engine coolant that flows into the heater core, and this adjustment changes the temperature of the heater core and thus controls the temperature of air flowing through it. (a) Open (MAX Hot) (b) Closed (MAX Cool)

5-M11

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[5] CONDENSER The hot, compressed refrigerant is under high pressure and in a gaseous state; the condenser cools it and returns it to a liquid state. In the interval between entering and passing through the condenser, the refrigerant is cooled and becomes liquid refrigerant again. At this point, it is necessary to be sure the refrigerant is liquid at the outlet of the condenser. If the refrigerant is not condensed enough in the condenser some refrigerant would be in a gaseous state and that would reduce the AC's cooling efficiency. (1) (2) (3) (4) (5)

Tubes Fins Vapor Vapor/Liquid Mix Liquid

(a) (b) (c) (d)

Gaseous Refrigerant Liquid Refrigerant Inlet Outlet RY9212004CAM0009US0

5-M12

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[6] RECEIVER The receiver is composed of a receiver tank, dryer, strainer and a receiver tube. [Receiver Tank] In the A/C system, the rpm of the compressor changes in response to changes in the engine rpm, so the appropriate amount of refrigerant in the cooling circuit also changes. The receiver tank is the part that reacts to those changes; when a lot of refrigerant is not required in the cooling circuit, excess refrigerant is stored temporarily in the tank and when more coolant is needed, it is supplied to the circuit via the receiver tube. It also acts to store the balance of refrigerant charges and for extra refrigerant to counteract the leak of small amounts of refrigerant, such as via permeation of rubber hoses. [Dryer] If any moisture exists in the cooling circuit, it damages the system by deteriorating the valves of the compressor, its oil, by corroding metal parts in the circuit, and/or freezes in the expansion valve and blocks the circuit. The A/C system uses synthetic zeolite as a dryer that is compatible with the circuit, and it absorbs any moisture that gets mixed into the circuit during installation or charging of refrigerant. If the expansion valve freezes up frequently due to moisture (icing), it means the dryer has lost its ability to absorb it, so the receiver has to be replaced. [Strainer] If dirt gets into the cooling circuit, it blocks the expansion valve, damages the compressor and otherwise hampers its cooling function. The strainer works to prevent any dirt flowing in the refrigerant from going any further. The strainer cannot be cleaned, so when it becomes severely clogged up, (in which case the high pressure gets high, low pressure gets low), the receiver has to be changed. [Sight Glass] The sight glass is mounted at the receiver joint on top of the receiver and it is the only place in the circuit where the amount of refrigerant can be visually inspected. (1) (2) (3) (4)

Dryer Receiver Tube Strainer Receiver Tank

(A) Refrigerant Inlet (B) Refrigerant Outlet

RY9212079CAM0004US0

5-M13

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[7] PRESSURE SWITCH This dual type of switch detects unusually high and low pressures in the cooling cycle. If the pressure gets abnormally high or, due to a leak, abnormally low, it may damage the equipment or deteriorate the lubricating ability of the compressor oil, leading to scorching and breakdown. To prevent these kind of problems from occurring, the switch cuts the power to the compressor clutch and stops the compressor. Refrigerant pressure

Operation

(A)

No increase in pressure state (when abnormally low)

The refrigerant pressure becomes less than the force of the spring, so the spring presses the plate up and the upper contact opens (OFF).

(B)

Contact ON (normal operation)

The refrigerant pressure is greater than the force of the spring, so the pressure plate is pressed down, which presses the upper contact down, closing the contact (ON).

(C)

Contact OFF (abnormally high pressure)

The refrigerant pressure becomes greater than the force of the plate spring and the plate spring pushes down on the pin, which press on the lower contact, opening it (OFF).

(1) (2) (3) (4) (5) (6) (7)

Diaphragm Plate Spring Pin Plate Contact Spring Terminal

a : 0.19 MPa (2.0 kgf/cm2, 28.4 psi) b : 3.14 MPa (32 kgf/cm2, 455 psi) D : OFF E : ON P : Pressure PS : Pressure Switch RY9212001CAM0020US0

5-M14

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[8] SYSTEM CONTROLS Control Panel  A/C Switch (A/C specification) Press A/C switch (2) [ON] to use the AC. When the A/C is [ON], the indicator lamp lights up. Press the switch again to turn it [OFF].  Temperature Control Dial Slide the temperature control lever to the left for heat, to the right to cool.  Fan Switch The fan can be switched to 3 different speeds. The strongest speed is [3]. [Operating the A/C]  Heating 1. Adjust the fan switch and the temperature control lever to the desired temperature. NOTE • When not using the heater in the summer, slide the temperature control lever all the way to the right (cool air side) so hot air does not raise the cabin temperature. Dry Heat Press the A/C switch to operate the A/C. Turn the fan switch to operate the fan. Slide the temperature control lever to the left (warm air) for adjusting the air temperature. NOTE • Keep the door closed while operating the A/C.

 1. 2. 3.

Cooling Press the A/C switch to operate the A/C. Turn the fan switch to operate the fan. Slide the temperature control lever to the right (cool air) for adjusting the air temperature. NOTE • The moisture from dehumidifying the cabin collects in the A/C unit and is expelled outside the machine. • The idle boost function operates when the compressor is operating.

 1. 2. 3.

 Defrost To eliminate fog or frost from the front window, 1. Open the front vents and point them toward the front window. 2. Turn the fan switch to [3] and slide the temperature control lever to the left (warm air). (1) Fan Switch (2) AC Switch

(3) Indicator Lamp (4) Temperature Control Lever RY9212332CAM0007US0

5-M15

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[9] ADJUSTING THE AIR FLOW AND DIRECTION Air Flow The air flows inside the cab as in the photo. The ideal condition can be achieved by adjusting the five vents. A : Chest B : Foot C : Front Window

D : Rear E : Side RY9212332CAM0008US0

5-M16

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[10] ELECTRICAL SYSTEM (1) Electrical Circuits

(1) (2) (3) (4) (5) (6)

Battery Slow-Blow Fuse (100A) Main Slow-Blow Fuse (60A) Key Switch Control Elements Fuse (5A) Glow Relay

(7) Glow Slow-Blow Fuse (60A) (8) Blower Motor Fuse (30A) (9) Blower Motor Relay (10) Blower Motor (11) Blower Resistor (12) Compressor Fuse (10A)

(13) A/C Switch (14) Refigerant Pressure Switch (15) Control Amp (Frost) (16) Control Amp (A/C) (17) Temperature Control Servo Motor

(18) Temperature Sensor (19) Magnetic Clutch (20) Compressor Clutch Relay (21) Diode

RY9212332CAM0009US0

5-M17

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(2) Relays Current flows in the components of the A/C system to the blower motor and compressor's magnetic clutch. If all of the current were supplied via the main switch, the current would be too much for the switch, so the contacts of the main switch would be in danger of burning out. Similarly, if this current flowed directly from the battery and the operator forget to turn the blower motor off, the battery would discharge. The system is equipped with relays in order to prevent these kind of problems. When the current flows through the coils of these relays, their contacts close, allowing electricity to be supplied from the battery. By adopting these relays, only a tiny amount of current is needed to operate the relays, so very little current flows through the main switch. As a result, the concern over its contacts burning out is eliminated and when the main switch is open, the relays' contacts open at the same time. When this occurs, the flow of electricity in the A/C circuit ceases and the possibility of the battery discharging is also eliminated. (1) (2) (3) (5)

Relay Terminal 1 Relay Terminal 2 Relay Terminal 3 Relay Terminal 5

(A) Connection Diagram

RY9212134CAM0008US0 (1) Compressor Relay

(2) Blower Motor Relay RY9212332CAM0013US0

5-M18

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

2. WIPER [1] WIPER SWITCH This switch has three positions, namely (a), (b) and (c) as indicated in the figure. When the starter key is in its [RUN] position and the switch is pressed to its (b) position, the wiper motor operates; pressing it in further to its (a) position operates the window washer. When the operator releases the switch, it automatically returns to position (b). (1) Knob

(a) Wash 1 Position (Both Wiper Motor and Window Washer Operate) (b) ON (Only for Wiper Motor) (c) OFF RY9212332CAM0011US0

[2] WIPER MOTOR A cylindrical ferrite magnet and an armature are assembled inside the housing of the wiper motor. A worm gear and a helical gear are attached to the end of the armature and act as reduction gears and the rod and a segmented arm provide reciprocating motion, which is communicated to the wiper arm via the arms axis. (1) Breaker (2) Motor (3) Switch

(A) Wiring Diagram (Motor Stop Position) RY9212332CAM0012US0

5-M19

KiSC issued 12, 2015 A

SERVICING CONTENTS 1. TROUBLESHOOTING.................................................................................................................5-S1 2. MAINTENANCE AND SERVICE RELATED SPECIFICATIONS.................................................5-S4 3. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM .......................................5-S5 [1] USE OF SERVICE TOOLS ...................................................................................................5-S5 (1) Manifold Gauge Set.........................................................................................................5-S5 (2) Refrigerant Charging Hoses ............................................................................................5-S7 (3) Vacuum Pump Adapter ...................................................................................................5-S8 (4) Electric Gas Leak Tester .................................................................................................5-S8 (5) Canister Tap Valve ..........................................................................................................5-S8 (6) T-Joint..............................................................................................................................5-S9 (7) R134a Refrigerant Collection/Recycling Device..............................................................5-S9 4. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM .............................................5-S10 [1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE...................................................5-S10 [2] COLLECTION, VACUUMING AND CHARGING.................................................................5-S15 (1) Collecting Refrigerant ....................................................................................................5-S15 (2) Vacuuming Out the System...........................................................................................5-S16 [3] CHARGING FROM THE HIGH-PRESSURE SIDE .............................................................5-S17 [4] CHARGING FROM THE LOW-PRESSURE SIDE ..............................................................5-S18 5. INSPECTION AND DISASSEMBLY..........................................................................................5-S19 [1] CHECKS AND ADJUSTMENTS .........................................................................................5-S19 (1) Compressor ...................................................................................................................5-S19 (2) Relays............................................................................................................................5-S21 (3) Blower Motor .................................................................................................................5-S23 (4) Blower Resistor .............................................................................................................5-S24 (5) A/C Switch .....................................................................................................................5-S24 (6) Fan Switch.....................................................................................................................5-S25 (7) Pressure Switch.............................................................................................................5-S26 [2] DISASSEMBLY AND ASSEMBLY ......................................................................................5-S28 (1) Removal and Installation of the A/C Unit.......................................................................5-S28 (2) Mounting and Removing the Compressor .....................................................................5-S29 (3) Connecting/Disconnecting A/C Hoses...........................................................................5-S32 (4) Removal and Installation of Heater Hoses ....................................................................5-S35 (5) Heater Hose Routing .....................................................................................................5-S37

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

1. TROUBLESHOOTING Compressor Problem and/or Situation

Noise (compressor on)

Noise (compressor off)

Possible Cause Wearing of or damage to the compressor's bearings

Replace

Compressor valve damaged

Replace

Belt slipping

Adjust or replace

Compressor bracket mounting bolt(s) loose

Tighten

Lines vibrating

Tighten and/or add clamp(s)

Blower damaged

Repair or replace

Magnetic clutch, idler pulley and/or crank pulley bearings damaged or wearing

Replace

Air Conditioning System Problem and/or Situation

Cooling not working (air not blowing)

Cooling not working (compressor not turning)

Cooling not working (other)

Cooling not working effectively (not enough air blowing)

Not cooling effectively (lots of foam visible in sight glass) Too much refrigerant (no foam in sight glass) Not cooling effectively (compressor not rotating properly)

Solution

Possible Cause

Solution

Blown fuse

Replace

Main A/C relay defective

Replace

A/C's blower motor damaged

Replace

A/C's blower switch broken

Replace

Wiring harness unplugged or poor contact

Fix

Blown fuse

Replace

Magnetic clutch broken

Repair or replace

A/C switch broken

Replace

Pressure switch broken

Replace

Belt slipping

Adjust or replace

Not enough refrigerant

Check with a manifold gauge

Expansion valve broken

Replace

Compressor broken

Replace

Filter clogged

Clean or replace

Frost on the evaporator

Clean or replace the temperature switch

A/C's blower motor damaged

Replace

A/C blower resistor broken

Replace

Not enough refrigerant

Check with a manifold gauge

Refrigerant gas leaking from the cooling circuit

Repair and/or recharge refrigerant

Air got in

Check with a manifold gauge

Refrigerant overcharged

Check with a manifold gauge

Belt slipping

Adjust or replace

Magnetic clutch broken

Repair or replace

Compressor broken

Replace

5-S1

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Problem and/or Situation Not cooling effectively (other) Not heating effectively Not enough air flow (blower motor not turning) Not enough air flow (air flow does not change to speed 3)

Not enough air flow (other)

Not cooling effectively (compressor clutch not working)

Not cooling effectively (high-pressure level too high)

Not cooling effectively (high-pressure level too low) Not cooling effectively (low-pressure level too high) Not cooling effectively (low-pressure level too low)

Possible Cause

Solution

Thermistor broken

Replace

Hot water valve damaged

Replace

Condenser clogged with dirt or debris

Clean

Expansion valve broken

Replace

Hot water valve damaged

Replace

Blower fan switch broken

Check and repair

A/C main relay broken

Replace

Blown fuse

Replace

Miswiring or poor connections

Check and repair

Blower resistor damaged

Replace

Relay damaged

Replace

Blower fan switch broken

Replace

Blower not tight enough

Check and repair

Blower deformed

Replace

Blower hitting its casing

Check and repair

Something blocking the inlet

Check and repair

Frost on the evaporator

Clean or replace

Filter clogged

Clean or replace

Vent ducts clogged or detached

Check and repair

Battery voltage too low

Charge the battery

Rotor is hitting the stator

Replace

Miswiring or loose connectors

Check and repair

Relay damaged

Replace

Coil shorted

Replace

Ground defective

Check and repair

Coil burned out

Replace

Refrigerant overcharged

Check with a manifold gauge

Condenser clogged with dirt or debris

Clean

Air got in

Check with a manifold gauge

Not enough refrigerant

Check with a manifold gauge

Compressor discharge valve damaged

Replace

Compressor gasket damaged

Replace

Error in the low-pressure line (cracked or clogged)

Replace

Refrigerant overcharged

Check with a manifold gauge

Expansion valve too far open

Replace

Not enough refrigerant

Check with a manifold gauge

Frost on the evaporator

Clean or replace

Error in the low-pressure line (cracked or clogged)

Replace

Expansion valve clogged

Replace

5-S2

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Problem and/or Situation

Possible Cause

Solution

Not cooling effectively (both low and high pressure levels too high)

Refrigerant overcharged

Check with a manifold gauge

Not cooling effectively (both low and high pressure levels too low)

Not enough refrigerant

Check with a manifold gauge

Temperature control lever broken

Replace

Cable is off

Repair or replace

Cannot control the temperature (hot water valve does not open normally)

Servo motor broken

Replace

Hot water valve damaged

Replace

Cannot control the temperature (poor heater hose layout)

Heater hose is pinched

Fix

Heater hose is bent or broken

Repair or replace

Water leak (water leak inside the cab)

Drain hose bent or broken

Check and repair

Drain hose clogged

Clean

Cannot control temperature (temperature control lever defective)

Wiper Problem and/or Situation

Wiper doesn't work

Wiper moves too slowly

Wiper fails to stop in the correct position

Possible Cause

Solution

Fuse blown (a part inside the wiper motor or some other moving part is shorted or burned out)

Pinpoint the cause of the damage and replace

Wiper motor faulty (damaged armature, worn motor brushes, motor shaft locked)

Replace

Wiper switch faulty

Replace

Faulty operation of linkage mechanism due to foreign matter

Fix

Wiper arm locked or rusted together

Grease up or replace

Wiper motor faulty (damaged armature, poor contact due to worn motor brushes, faulty operation of motor shaft)

Replace

Battery voltage low

Recharge or replace

Wiper arm shaft rusty, foreign matter stuck in it

Grease up or replace

Poor contact in wiper switch

Replace

Wiper motor faulty (Dirty or poor contact of the contacts at the auto-stop position due to foreign matter)

Replace RY9212079CAS0042US0

5-S3

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

2. MAINTENANCE AND SERVICE RELATED SPECIFICATIONS Factory Specification

Allowable Limit Value

0.30 to 0.65 mm 0.0118 to 0.0255 in.

–

3.0 to 5.0 Ω

–

Pressure (low-pressure side)

0.15 to 0.20 MPa 1.5 to 2.0 kgf/cm2 21 to 28 psi

–

Pressure (high-pressure side)

1.27 to 1.66 MPa 13 to 17 kgf/cm2 185 to 242 psi

–

Pressure setting (low-pressure side)

Lower than the values below About 0.196 MPa 2.0 kgf/cm2 28.4 psi

–

Pressure setting (high-pressure side)

Higher than the values below About 3.14 MPa 32 kgf/cm2 455 psi

–

A/C drive belt

Tension

Deflects 11 to 12 mm (0.44 to 0.47 in.) when 265 to 441 N (27.1 to 44.9 kgf, 59.6 to 99.1 lbf) of forced is applied

–

Refrigerant

Type (HFC134a)

900 ± 50 g 1.98 ± 0.11 lbs

–

Compressor Oil

Type (usage volume)

ND-OIL8 <PAG* oil> 100 to 120 cc 0.106 to 0.127 U.S.qts

–

Item A/C Compressor Magnetic Clutch

Air Gap

Magnetic Clutch Stator Coil

Electrical Resistance

Cooling Cycle (cooling cycle when operating normally)

Pressure switch (dual type) (when pressure switch is off)

*PAG: Polyalkylene glycol (synthetic oil) RY9212332CAS0001US0

5-S4

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

3. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM [1] USE OF SERVICE TOOLS (1) Manifold Gauge Set Always follow the warnings and regulations below when inspecting or repairing the air conditioning system. It is also extremely important that no one other than specially trained service personnel handles refrigerants. CAUTION • If the liquid refrigerant comes in contact with skin, it results in frostbite, so always be careful when handling refrigerants. Always wear goggles when working on this system in order to protect your eyes. • Refrigerant service containers are made very sturdy for safety. However, they can explode if handled improperly. Always follow the instructions printed on their labels. In particular, never heat a refrigerant container above 40 °C (104 °F). Also, never drop one from any height. • Do not steam clean this system. In particular, this system is under extremely high pressure, so do not steam clean the condenser as it may cause the system to explode. • If an error is made in handling the service valve or in connecting a hose between the compressor's service valve and a manifold gauge, it may cause the refrigerant service container or the charging hose to explode. When connecting hoses or handling service valves, always check the pressure on the high-pressure side or on the low-pressure side. • When recharging refrigerant with the compressor operating, do not open the high-pressure valve of the manifold gauge. • Be careful of gas toxicity. The refrigerant gas in its natural state is harmless and is not toxic. However, when it comes in contact with very hot parts, it can break down chemically, producing hazardous materials. • Do not heat service canisters unless absolutely necessary. When necessary to heat a canister, use water at or below 40 °C (104 °F). Never use boiling water to heat a canister. • Take care with the following points on storing and handling service canisters. • Store in a cool, dry place. • Never drop or strike a canister. • Do not use service canisters that are deformed, have unusable screws or are otherwise damaged. • Never heat a service canister unless necessary. If one must be heated for some reason, use water at or below 40 °C (In such cases, never warm the canister while heating the water.) Do not immerse the valve of the service canister in water. Do not turn the service canister upside down. Turning it upside down allows liquid refrigerant into the compressor, which damages the valve. • Do not shake hard. (If the mounting of the valve is not secure, it may come off.) • Use ND-OIL8 (made by DENSO (Co. Ltd.)) compressor oil. (ND-OIL6 is designated for use with R12, so do not mistakenly use ND-OIL6.) • Precautions on Inspecting and Charging A/C Gas • Perform all work in a well-ventilated location. • Be careful when handling high-pressure valves. When recharging refrigerant with the engine running, do not open the high-pressure valve (HI) of the manifold gauge. Overcharging refrigerant may cause problems such as poor cooling and overheating. IMPORTANT • Using R12 refrigerant in an R134a A/C system may cause problems to result, such as leaks of refrigerant at O-rings and fogging of the sight glass. Consequently, the shapes of line joints, service valves and service tools are different in order to prevent mistakes in connecting or recharging the wrong system. • Always keep the work area clean, dry and free of any dirt or dust. Always wipe off any water from line fittings with a clean cloth before opening the fitting. • Only use R134a refrigerant service tools. • When discharging refrigerant, use an R134a refrigerant collection/recycling machine. • Prior to connecting a charging hose to the tap valve of a refrigerant canister, check each seal and make sure it is not clogged up. • When disconnecting charging hoses from compressor and receiver valves, do so as quickly as possible to minimize the leakage of gas. • Be careful to only charge with the specified amount of refrigerant; never overcharge the system. This is important because overcharging the refrigerant can cause poor cooling performance among other things. 5-S5

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

• Hand tighten when connecting the charging hose to the canister's tap valve. Do not use pliers to tighten the charging hose. • Store refrigerant containers in a cool, dark place and never leave them in direct sunlight or in a hot place. • R134a compressor oil readily absorbs moisture, so always seal any parts after disconnecting them. • Do not use any of the old style R12 refrigerant or previous kinds of refrigerant compressor oil. RY9212079CAS0001US0

The manifold gauge set has a valve handle for opening and closing valves. The valve handle marked LO is for use on the low-pressure valve (5) and the valve handle marked HI is for use on the high-pressure valve (3). The following circuits can be achieved by variously opening and closing the high and low pressure valves. (1) Low-Pressure Gauge (2) High-Pressure Gauge (3) High-Pressure Valve

(4) Valve Core (5) Low-Pressure Valve RY9212001CAS0005US0

When low and high pressure valves are closed The following 2 circuits are formed. Port (C) → Low-pressure gauge (1) Port (A) → High-pressure gauge (2) CAUTION • Be sure to open the valve core (d). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0006US0

With the low-pressure valve open and the high-pressure valve closed The following circuits are formed. Port (C) → Low-pressure gauge (1) Port (C) → Port (B) Port (C) → Port (D) Port (A) → High-pressure gauge (2) CAUTION • Be sure to open the valve core (D). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0007US0

With the low-pressure valve closed and the high-pressure valve open The following circuits are formed. Port (C) → Low-pressure gauge (1) Port (A) → Port (B) Port (A) → Port (D) (Be sure to open the valve core.) Port (A) → High-pressure gauge (2) CAUTION • Be sure to open the valve core (D). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0008US0

5-S6

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

With low and high pressure valves open The following circuits are formed. Port (A) → High-pressure gauge (2) Port (A) → Low-pressure gauge (1) Port (A) → Port (B) Port (A) → Port (C) Port (A) → Port (D) (Be sure to open the valve core.) CAUTION • Be sure to open the valve core (D). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0009US0

(2) Refrigerant Charging Hoses The three kinds of refrigerant charging hoses are distinguishable by color. Each of the refrigerant charging hoses is to be used as follows. • In line with the A/C manufacturer's recommendation, the blue hose (6) is to be used on the low-pressure side (intake side), the green hose (5) on the cooling side (center connection port) and the red hose (3) on the high-pressure side (discharge side). (When connecting) • Press the quick-disconnect adapter (4) into the recharge valve and press part A in until you hear it catch. CAUTION • While pressing in to make a connection, be careful not to bend any lines. • When connecting a quick-disconnect adapter, if you move the sleeve (7) before the quick-link connector is connected to the charge valve, move the sleeve back to its original position and then try making the connection again. • If there is any refrigerant left in the refrigerant charging hose, it can be difficult to connect the quick-link connector. In this case, make the connection after relieving the pressure remaining in the refrigerant charging hose. (Pressing on the pusher (8) eliminates any remaining pressure.) (When disconnecting) • With part A of the quick-disconnect adaptor held in place, slide part B up. CAUTION • After removing the quick-disconnect adaptor, be sure to put a cap on the service valve of the adaptor. (1) (2) (3) (4) (5) (6)

Low-Pressure Valve High-Pressure Valve Red Hose Quick-Disconnect Adapter Green Hose Blue Hose

(7) Sleeve (8) Pusher (9) Sleeve a : Makes a Catching Sound RY9212001CAS0010US0

5-S7

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(3) Vacuum Pump Adapter Purpose of the Vacuum Pump Adapter 1. After the A/C cooling system is vacuumed, when the vacuum pump is stopped, there is a vacuum inside the hoses of the manifold gauge, so the oil of the vacuum pump flows back into the refrigerant charging hose. If the refrigerant system is charged in this state, the vacuum pump oil remaining in the refrigerant charging hose will go into the A/C refrigerant system along with the refrigerant. A vacuum pump adaptor equipped with a solenoid valve is used to prevent this backflow of oil from the vacuum pump. The role of the solenoid valve is to close when electricity is flowing to the solenoid valve, cutting it off from outside air and maintaining the vacuum; when the electricity is cut off, the valve opens, bringing in outside air and relieving the vacuum. 2. If this adapter is connected to the currently used R12 vacuum pump, it enables the vacuum pump to be used for both R134a and R12. (1) (2) (3) (4)

Vacuum Pump Adapter Vacuum Pump For R134a Solenoid Valve

(5) Air (6) For R12 (7) Plug Cap RY9212079CAS0002US0

(4) Electric Gas Leak Tester The old style R12 gas leak tester are not sensitive enough for R134a and cannot be used. Consequently a new and very sensitive electrical gas leak tester has been designed that can be used with both R134a and R12. [NOTE] Halogenated Torch Gas Leak Testers • Because this tester detects gas leaks based on the reaction of chlorine in the refrigerant, it cannot detect R134a because it does not contain chlorine. (1) Electrical Gas Leak Tester RY9212001CAS0012US0

(5) Canister Tap Valve The canister tap valve used in recharging the refrigerant of the A/C system has to be used as follows. 1. Before attaching the canister tap valve to the refrigerant container, rotate the handle (1) counterclockwise until the needle of the valve is completely retracted. 2. Rotate the plate nut (3) counterclockwise to its highest position and then screw the canister tap valve into the sealed tap. 3. Rotate the plate nut clockwise as far as you can and fasten the center charging hose to the canister tap valve. 4. Tighten the plate nut securely by hand. 5. Rotate the handle (1) clockwise to open a hole in the sealed tap. 6. To charge the system with refrigerant, turn the handle (1) counterclockwise. To stop charging, turn the handle clockwise. (1) Butterfly Handle (2) Connector

(3) Plate Nut (4) Needle RY9212004CAS0033US0

5-S8

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(6) T-Joint A T-joint (2) is used when using two refrigerant canisters (4) at the same time to make gas recharging more efficient. 1. Attach a refrigerant canister service valve on each side of the T-joint (2) and connect a refrigerant charging hose (1) to the T-joint. (1) Refrigerant Charging Hose (Green) (3) Canister Tap Valve (2) T-Joint (4) Refrigerant Canister RY9212001CAS0014US0

(7) R134a Refrigerant Collection/Recycling Device When it is necessary to discharge the refrigerant in order to work on the machine, a collection / recycling device must be used. (Never release refrigerant into the atmosphere.) IMPORTANT • Use a dedicated R134a refrigerant collection/recycling device. • To prevent any damage to the compressor, use neither R12 system refrigerant nor cooling system oil in R134a equipment. RY9212001CAS0015US0

5-S9

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

4. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM [1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE IMPORTANT • Be aware that the gauge pressure values noted in the following test are measured under identical conditions and they may vary somewhat from your gauge pressure values, depending on the prevailing conditions. Conditions Ambient temperature

30 to 35 °C (86 to 95 °F)

Engine rpm

Approx. 1,500

Temperature control lever

Max cooling position

Blower switch

HI Position RY9212079CAS0003US0

Manifold gauge connections and test preparations 1. Close the manifold gauge's high (2) and low (3) pressure valves tightly. 2. Connect the red (4) refrigerant charging hose to the high-pressure charge valve (6) and the yellow (5) refrigerant charging hose to the low-pressure charge valve (7). 3. For releasing air in the hose, press the valve on the manifold gauge 3 to 5 seconds. CAUTION • Use the refrigerant pressure in the refrigerant cycle to completely flush out the air in the refrigerant charging hose from the end of the manifold gauge's connection. 4. Start up the engine and set it at approximately 1,500 rpm. 5. Turn the A/C switch on and set the temperature control lever to the max cooling position. 6. Set the blower switch to its HI position. (1) (2) (3) (4) (5)

Manifold Gauge (6) High-Pressure Valve (7) Low-Pressure Valve Refrigerant Charging Hose (Red) (a) Refrigerant Charging Hose (Yellow)

High-Pressure Side Charge Valve Low-Pressure Side Charge Valve Press the Valve Core for Releasing Air. RY9212332CAS0002US0

When operating normally If the refrigerant cycle is operating normally, readings will be around the factory specifications in the table below.

Gas Pressure

(1) Low Pressure Side

Factory specification

Low pressure side

0.15 to 0.20 MPa 1.5 to 2.0 kgf/cm2 21 to 28 psi

High pressure side

1.27 to 1.66 MPa 13 to 17 kgf/cm2 185 to 242 psi

(2) High Pressure Side RY9212001CAS0018US0

5-S10

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Without enough refrigerant 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too low. Low-pressure side (1) : 0.05 to 0.10 MPa (0.5 to 1.0 kgf/cm2, 7.1 to 14.2 psi) High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2, 99.6 to 142.2 psi) • Foam visible in the sight glass. • Air output by the A/C appears to be cooled. 2. Possible Cause • Gas leaking from the circuit of the refrigerant cycle. 3. Solution Methods • Use an electric gas leak tester to check for leaks and repair any found. • Recharge the system with an appropriate amount of refrigerant. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0019US0

Excess refrigerant or insufficient condenser cooling 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too high. Low-pressure side (1) : 0.20 to 0.35 MPa (2.0 to 3.5 kgf/cm2, 28.4 to 49.8 psi) High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2, 284.5 to 355.6 psi) 2. Possible Causes • Cycle charged with too much refrigerant. • Poor condenser cooling. 3. Solution Methods • Clean the condenser. • Adjust the tension of the A/C drive belt to the appropriate tension. • If the 2nd item above is normal, check the amount of refrigerant. CAUTION • To discharge excess refrigerant, loosen the manifold's gauge's low-pressure valve and slow discharge it. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0020US0

5-S11

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Air mixed into the cycle 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too high. Low-pressure side (1) : 0.20 to 0.35 MPa (2.0 to 3.5 kgf/cm2, 28.4 to 49.8 psi) High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2, 284.5 to 355.6 psi) • The line on the low-pressure side (1) feels cold to the touch. 2. Possible Causes • Air is mixed in the refrigerant cycle 3. Solution Methods • Replace the receiver. • Check the amount of compressor oil and whether it is contaminated. • Vacuum it out and charge the cycle again with fresh refrigerant. CAUTION • If you fail to vacuum out a refrigerant cycle like that mentioned above and simply charge the cycle with refrigerant, the problem may recur. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0021US0

Moisture mixed into the cycle 1. Symptoms that appear in the refrigerant cycle • At first the A/C works normally, but after some time, the pressure on the low-pressure side (1) becomes a vacuum and the high-pressure side (2) is at a low pressure. Low-pressure side (1) : Vacuum; High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2, 99.6 to 142.2 psi) 2. Possible Causes • Moisture in the refrigerant cycle freezes up in the expansion valve orifice, creating a temporary blockage. As time elapses, the ice thaws and it returns to normal. 3. Solution Methods • Replace the receiver. • Eliminate the moisture in the refrigerant cycle by repeatedly vacuuming it out. • Recharge the system with an appropriate amount of refrigerant. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0022US0

5-S12

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Refrigerant fails to circulate 1. Symptoms that appear in the refrigerant cycle • Low-pressure side (1) becomes a vacuum and the high-pressure side (2) is at low pressure. Low-pressure side (1) : Vacuum; High-pressure side (2) : 0.49 to 0.59 MPa (5 to 6 kgf/cm2, 71.2 to 85.3 psi) 2. Possible Causes • The line above the expansion valve orifice is frozen up and the refrigerant cannot flow due to moisture and/or dirt stuck in the refrigerant cycle. 3. Solution Methods Wait for some time to elapse and determine whether it is dirt or moisture blocking the line by whether A/C operation recovers or not. • If the problem is moisture, the problem resolves itself, as indicated in the previous section. • If the cause is dirt, remove the expansion valve and blow out any dirt with compressed air. • If the dirt cannot be eliminated, replace the expansion valve and the receiver. Vacuum out the line and charge the cycle with an appropriate amount of fresh refrigerant. • If the problem is caused by a gas leak in the heat-sensitive tube, replace the expansion valve. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0023US0

Expansion valve too far open 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too high. Low-pressure side (1) : 0.29 to 0.39 MPa (3 to 4 kgf/cm2, 42.7 to 56.9 psi) High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2, 284.5 to 355.6 psi) • Either frost or heavy condensation on the low-pressure side line 2. Possible Causes • Problem with the expansion valve. • The flow volume adjustment is set improperly. 3. Solution Methods • Replace the expansion valve. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0024US0

Faulty compression from compressor 1. Symptoms that appear in the refrigerant cycle • Low-pressure side (1) : 0.39 to 0.59 MPa (4 to 6 kgf/cm2, 56.9 to 85.3 psi) High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2, 99.6 to 142.2 psi) 2. Possible Causes • Compressor is leaking. 3. Solution Methods • Replace the compressor. CAUTION • When the compressor is producing a faulty compression, it can be detected with a manifold gauge (figure at left). (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0025US0

5-S13

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Checking with the sight glass Conditions Doors

All open

Inside/outside air switch

Inside

Ambient air temperature

30 to 35 °C (86 to 95 °F)

Engine rpm

About 1500 rpm

Temperature control

Max cooling position

Blower switch

Position (HI)

Criteria (a)

Overcharged

No air bubbles at all in the flow. In this case, both high and low-pressure sides are at high pressure and the cooling is ineffective.

(b)

Normal amount

Almost no air bubbles in the flow. If the engine rpm is raised gradually from idle to 1500 rpm, the air bubbles disappear and the flow becomes transparent.

(c)

Undercharged

Air bubbles flow past constantly.

(1) Sight Glass RY9212079CAS0044US0

5-S14

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[2] COLLECTION, VACUUMING AND CHARGING IMPORTANT • Follow 4. Precautions when Repairing the Refrigerant Cycle when discharging, vacuuming and charging the refrigerant system. RY9212001CAS0026US0

(1) Collecting Refrigerant CAUTION • Follow the instructions of the manufacturer and discharge the refrigerant from the cooling system. • When removing the charge valve hose, cover it with a rag to protect your fingers and eyes from frost bite from the refrigerant. IMPORTANT • Do not use any device except an R134a refrigerant collection and recycling machine. In order to prevent damage to the compressor, do not mix R134a equipment, refrigerant or compressor oil into an R12 system. [NOTE] 1. Get the R134a collector (9) ready. 2. Close the high-pressure (HI) (2) and low-pressure (LO) (3) valves of the manifold gauge. 3. Connect the red charge hose (4) to the high-pressure side (H mark) (7) and the green charge hose (6) to the low side (L mark) (8). 4. Connect the yellow charge hose (5) to the collector. 5. Open the inlet valve (11) of the collector (9) and the blue valve (13) on the collection tank (12). 6. Turn the collector on and collect the refrigerant. 7. Continue collecting refrigerant until the pressure on the low-pressure gauge reaches -0.1 MPa and then turn the collector off. Wait five minutes to make sure the pressure on the gauge does not go back up. If the pressure on the gauge does rise, some refrigerant may be remaining in the circuit, so run the collector again. 8. Close the blue valve on the collection tank and then remove all the charge hoses. (1) (2) (3) (4) (5) (6) (7)

Manifold High-Pressure Valve (HI) Low-Pressure Valve (LO) Red Charge Hose Yellow Charge Hose Green Charge Hose High-Pressure Side (H Mark)

(8) Low-Pressure Side (L Mark) (9) Collector (10) Low-Pressure Gauge (11) Inlet Valve (12) Collection Tank (13) Blue Valve RY9212332CAS0003US0

5-S15

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(2) Vacuuming Out the System No.

Description of Work

Remarks

(1)

Check the connected parts and correct any problems

(2)

Start vacuuming

Approx 15 minutes, 750 mmHg (229 in.Hg) or greater

(3)

Stop vacuuming

Leave for five minutes

(4)

Check the concentration

If the gauge indicates abnormally, return to (1)

(5)

Charge with refrigerant

98 kPa (1.0 kgf/cm2, 14 psi)

(6)

Check for gas leaks

(7)

Charge with refrigerant RY9212001CAS0028US0

Manifold gauge connections and vacuuming 1. Close the high-pressure (HI) and low-pressure (LO) valves of the manifold gauge. 2. Connect the L-shaped side of 2 charging hoses to quick joints and connect them to the compressor and receiver service valves. Yellow hose

Low-pressure side (L mark)

Red hose

High-pressure side (H mark)

3. Connect the charging hose (yellow) in the middle of the manifold gauge to the vacuum pump. 4. Open the high and low pressure valves of the manifold gauge. 5. Turn the vacuum pump switch on and vacuum the line until the low-pressure gauge reaches a reading of approximately -0.1 MPa (-750 mmHg). (approx 15 minutes) 6. Once approx -0.1 MPa (-750 mmHg) is reached, close the high and low pressure valves of the manifold gauge and stop the vacuum pump. 7. Let it set for at least five minutes and check to make sure the indicator needle of the load pressure gauge does not approach 0. 8. If the needle of the gauge does approach 0, the system's airtightness is compromised somewhere, so after inspecting and repairing the line connections, run the vacuum again and check to make sure there are not any places that are not airtight. (1) (2) (3) (4) (5) (6)

Manifold High-Pressure Valve Low-Pressure Valve Red Charge Hose Yellow Charge Hose Vacuum Pump

(A) Inspection Line Connections (B) Low-Pressure Gauge (a) Valve Settings (L : Closed, H : Closed) (b) Leave for at Least Five Minutes (c) Check RY9212332CAS0004US0

5-S16

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Connections with a refrigerant collector or service canister 1. Close the high-pressure (HI) and low-pressure (LO) valves of the manifold gauge. 2. Connect the charging hose (green) connected to the vacuum pump to the collector or service canister. (Air is in the charging hose, so do not open the high or low pressure valves.) 3. Discharge from the collector or open the service canister's valve. 4. Press on the valve core of the manifold gauge for three to five seconds to discharge any air from the hose. (1) (2) (3) (4) (5) (6)

Manifold High-Pressure Gauge Low-Pressure Gauge Red Charge Hose Yellow Charge Hose Service Canister Valve

(a) Press Valve Core to Expel Air

RY9212332CAS0005US0

[3] CHARGING FROM THE HIGH-PRESSURE SIDE Charging from the High-pressure Side CAUTION • Important: do not start the engine. If the engine is running, the gas will flow back and burst either the service canister or a hose. IMPORTANT • Do not open the low-pressure valve of the manifold gauge. • If the service canister has been changed, be sure to expel any air out of the charging hose (yellow). 1. Without starting the engine, open the high-pressure valve and charge with approx 600 ± 50 g (1.43 ± 0.11 lbs) of gas. 2. While charging, once the low-pressure gauge indicates approx 0.10 MPa (approx 1.0 kgf/cm2), close the high-pressure valve and the service canister valve for the time being. 3. Use a gas detector to check the hoses and pipe connections for gas leaks; if any exist, repair them. If there are no leaks, continue charging the refrigerant. 4. When charging on the high-pressure side stops, close the high-pressure valve on the manifold gauge and the service canister valve, and then charge from the low-pressure side. (1) (2) (3) (4) (5)

High-Pressure Gauge Low-Pressure Gauge High-Pressure Valve (HI) Open Low-Pressure Valve (LO) Closed Service Canister Valve

(a) Press Valve Core to Expel Air

RY9212213CAS0075US0

5-S17

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[4] CHARGING FROM THE LOW-PRESSURE SIDE Charging from the Low-Pressure Side

CAUTION Never open the manifold gauge's high-pressure valve when charging refrigerant while the engine is running. (If the high-pressure valve is opened, high-pressure gas will flow back up the line and rupture the service canister or a charging hose.) Always keep the service canister upright when charging. IMPORTANT If the service canister has been changed, be sure to expel any air out of the charging hose (yellow). Check and make sure the manifold gauge's high-pressure valve is closed. After starting the engine, set it to approx 1500 rpms and open all of the doors. Turn the A/C switch on and set the temperature control to maximum cooling. Open the manifold gauge's low-pressure valve and the service canister valve and charge with the specified amount of gas. After completing refrigerant charging, close the manifold gauge's low-pressure valve and the service canister valve and stop the engine. Check for any gas leaks with the gas leak tester.

(1) (2) (3) (4) (5)

High-Pressure Gauge Low-Pressure Gauge High-Pressure Valve (HI) Closed Low-Pressure Valve (LO) Open Service Canister Valve

•

• • 1. 2. 3. 4. 5.

(a) Press Valve Core to Expel Air

RY9212079CAS0009US0

5-S18

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

5. INSPECTION AND DISASSEMBLY [1] CHECKS AND ADJUSTMENTS (1) Compressor Magnetic clutch 1. Start the engine. 2. With the A/C switch on the A/C control panel off, check and make sure that no scraping sounds or other noise comes from the pulley as it turns. 3. Turn the A/C switch and the fan switch on to make the A/C system operate. With the A/C working, check and make sure the magnetic clutch is not slipping. 4. If there is any noise, repair or replace it. (1) Magnetic Clutch

(2) Compressor Clutch Connector (CN104) RY9212332CAS0006US0

Stator coil

1. Remove the magnetic clutch's 1P connector. 2. Measure the resistance between the 1P connector on the magnetic clutch side and the body of the stator. 3. If the measurement falls outside of the factory specification, replace the stator coil. Between stator body and harness side of stator coil

Factory specification

3 to 5 Ω RY9212332CAS0007US0

5-S19

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Adjusting the Clearance 1. Use a feeler gauge (9) to check the clearance. 2. If the measurement is outside the factory specification, adjust the clearance. Clearance

Factory specification

0.30 to 0.65 mm 0.0118 to 0.0255 in.

[NOTE] Shim Thickness

Part number

0.1 mm (0.0039 in.)

T1065-87340

0.15 mm (0.0059 in.)

T1065-87350

0.4 mm (0.016 in.)

T1065-87360

0.6 mm (0.024 in.)

T1065-87370

1.0 mm (0.0394 in.)

T1065-87380

(1) (2) (3) (4) (5) (6)

Washer Head Hub Plate Shim Snap Ring Rotor Snap Ring

(7) Stator (8) Compressor Body (9) Feeler Gauge L : Clearance RY9212213CAS0003US0

5-S20

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(2) Relays Inspecting the Blower Motor 1. Key switch: STOP 2. Check whether the blower motor fuse (30A) is broken. Assessment Results

Criteria Regular: No brake (OK) Irregular: Has a brake (NG)

3. To replace the horn relay and blower motor relay. 4. After starting the engine, set the fan switch on [3]. Assessment Results

Criteria Regular: Operating (OK) Irregular: Not operating (NG) (1) Blower Motor Fuse (30 A) (2) Blower Motor Relay

(3) Horn Relay (4) Fan Switch RY9212332CAS0008US0

Testing the Blower Motor Relay Voltage 1. Remove the blower motor relay. 2. Key switch: RUN 3. Measure the voltage based on the table below. Measurement

Connector Name (+terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Blower motor relay

<2>

Body GND

–

(b)

Blower motor relay

<3>

Body GND

–

Assessment Results

Factory specification: 11 to 14 V (battery voltage) OK Outside factory specification: NG RY9212134CAS0018US0

5-S21

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Inspecting the Blower Motor Relay 1. Key switch: STOP 2. Remove the blower motor relay. 3. Measure the resistance based on the table below. Measurement

Relay terminal (+ terminal side)

Relay terminal (- terminal side)

(a)

(3)

(5)

Assessment Results

Factory specification:72 to 88 Ω, OK Outside factory specification: NG 4. Test the continuity based on the table below. Measurement

Relay terminal (+ terminal side)

Relay terminal (- terminal side)

(a)

(1)

(2)

Assessment Results

Factory specification: No continuity, OK Outside factory specification: Continuity, NG RY9212134CAS0019US0

5-S22

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(3) Blower Motor Checking the Voltage 1. Remove the blower motor connector CN323. 2. After starting the engine, set the fan switch off. 3. Measure the voltage based on the table below. Measurement

Connector Name (+terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Blower resistor motor connector CN323

<3>

Body GND

–

Assessment Results

Normal: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) (1) Blower Resistor (2) Blower Resistor Motor Connector CN323

(3) Fan Switch

RY9212332CAS0011US0

Blower motor test 1. Remove the blower resistor. 2. Turn the blower motor by hand and check whether it turns smoothly. 3. If the blower motor fails to turn, check the motor. (1) Blower Motor

(A) Circuit Diagram (a) (+) Terminal (b) (–) Terminal RY9212332CAS0010US0

5-S23

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(4) Blower Resistor Inspecting the Blower Resistor 1. Put the key switch in its STOP position. 2. Disconnect the blower resistor connector CN323 from the machine and test the resistor on its own. 3. Measure the resistance based on the table below. Measurement

Between terminals

Factory specification

(a)

1–4

Approx. 1.0 Ω

(b)

1–3

Approx. 2.0 Ω

(c)

3–4

Approx. 3.0 Ω

Assessment Results

Regular: Within factory specification (OK) Irregular: Outside factory specification (NG) (1) (2) (3) (4)

MI Blank HI LO

(A) Blower Resistor (B) Wiring Diagram

RY9212332CAS0012US0

(5) A/C Switch Inspecting the Fan Switch [Test Conditions] 1. Put the key switch in its STOP position. 2. Disconnect the fan switch from the machine and test the switch on its own. Resistance of the fan switch when ON Resistance of the fan switch when OFF

0Ω Factory Specification Ω

RY9212332CAS0026US0

5-S24

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(6) Fan Switch Checking the Voltage 1. Remove the fan switch connector CN222. 2. After starting the engine, set the fan switch on [3]. Measure the voltage based on the table below. Measurement

Connector Name (+terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Fan switch connector CN222

<6>

Fan switch connector CN222

<4>

(b)

Fan switch connector CN222

<6>

Body GND

–

Assessment Results

Normal: 12 V (OK) Irregular: Large discrepancy from 12 V (NG) (1) Control Panel (2) Fan Switch Connector CN222

(A) 6P Connector (Harness Side) RY9212332CAS0024US0

Fan switch test 1. Check the continuity between each of the terminals according to the table below. 2. If continuity exists, it is normal.

(A) 6P connector (Switch side) RY9212332CAS0028US0

5-S25

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(7) Pressure Switch When a dual pressure switch (inside the high-pressure / low-pressure switch) is operating normally, electricity is conducted (ON) and when an abnormal pressure occurs, it trips the switch, blocking the electricity (OFF). RY9212134CAS0047US0

Manifold Gauge Connections 1. Close the high-pressure (HI) (4) and low-pressure (LO) (5) valves of the manifold gauge. 2. Connect the red charge hose (6) to the high-pressure side (H mark) and the yellow charge hose (7) to the low side (L mark). 3. Open the high-pressure (HI) valve (4) slightly and press the valve core, purging air from inside the red (6) charge hose; then close the high-pressure (HI) valve. 4. Open the low-pressure (LO) valve (5) slightly and press the valve core, purging air from inside the yellow (7) charge hose; then close the low-pressure (LO) valve. (1) (2) (3) (4) (5)

Manifold Gauge High-Pressure Gauge Low-Pressure Gauge Hi-Pressure Valve (HI) Low-Pressure Valve (LO)

(6) Red Charge Hose (7) Yellow Charge Hose (a) Press the Valve Core to Purge Air RY9212332CAS0015US0

1. Remove the cab. (See, "Cab Removal and Installation" page.) RY9212332ENS0024US0

5-S26

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

1. Remove the cover. Tightening torque

1.47 to 1.96 N·m 0.15 to 0.20 kgf·m 1.08 to 1.45 lbf·ft

Bolt (2)

(1) Cover

(2) Bolt RY9212332CAS0027US0

When refrigerant pressure is rising (OFF) 1. Start the engine and set it at 1500 rpms. Turn the A/C switch on the control panel on, set the fan switch to HI and set the temperature control lever to the max cool position. 2. Cover the front of the condenser with cardboard or the like and raise the pressure on the high-pressure side of the A/C cycle. 3. Once the pressure on the high-pressure side rises, the high-pressure switch operates, turning the magnetic clutch of the compressor off. When it does so, read the high-pressure gauge of the manifold gauge and if it reads higher than the pressure setting, replace the dual pressure switch (1). • Pressure setting on the high-pressure side of the switch: Switches off at approximately 3.14 MPa (32 kgf/cm2) or higher (1) Dual Pressure Switch RY9212213CAS0009US0

When refrigerant pressure is dropping (OFF)

1. Remove the connector of the dual pressure switch (1). 2. Measure the resistance between the terminals of the dual pressure switch with a circuit tester. It should register 0 Ω unless there is insufficient gas due to a leak or unless the dual pressure switch is faulty. • Pressure setting on the low-pressure side of the switch : Switches off at approximately 0.196 MPa (2.0 kgf/cm2, 28 psi) RY9212134CAS0046US0

5-S27

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

[2] DISASSEMBLY AND ASSEMBLY (1) Removal and Installation of the A/C Unit

(a) Apply Threadlock to the Stud Bolt Side. No.

Parts Name

Q'ty

(1)

A/C (unit)

(2)

Collar (A/C)

(3)

Bolt

(4)

Stud

(5)

Nut

(6)

Spring washer

(7)

Plain washer

Remarks

Loctite 263

Tightening torque

Bolt (3)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Stud (4) 

25.0 to 31.0 N·m 2.5 to 3.2 kgf·m 18.5 to 22.8 lbf·ft

Nut (5)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

: Bolt threadlock (Loctite 263) RY9212332CAS0016US0

5-S28

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(2) Mounting and Removing the Compressor Cab and Air conditioner Version

(a) Point to Measure Compressor Belt Tension No. (1)

Parts Name Support (compressor)

(b) Bushing Flange Q'ty

No.

(9)

Parts Name

Q'ty

Tensioner pulley (1)

(2)

Bolt

(10)

Bolt

(3)

Bolt

(11)

V-belt (A56)

(4)

Bolt

(12)

Flat metal washer

(5)

Compressor, assy

(13)

Flat metal washer

(6)

Bushing (compressor)

(14)

Guide assy (oil gauge)

(7)

Flange bolt

(15)

Engine oil gauge

(8)

Bolt

(16)

Bolt

• Bolts (8) and tighten its bolts (7).

Tightening torque

Bolt (2) (3) (7) (8) (16)

16.7 to 19.6 N·m 1.7 to 2.0 kgf·m 12.3 to 14.5 lbf·ft

Bolt (4)

39.2 to 45.1 N·m 4.0 to 4.6 kgf·m 29.0 to 33.2 lbf·ft

Tensioner pulley (9)

37 to 41 N·m 3.7 to 4.2 kgf·m 27 to 30 lbf·ft RY9212332CAS0017US0

5-S29

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Removal 1. Collect the refrigerant from the A/C system. 2. Disconnect the negative (–) cable from the battery and the 1P connector of the magnetic clutch. 3. Remove the low-pressure pipe and the high-pressure pipe from the compressor, then immediately cap them so no water or moisture gets into the A/C system. 4. Remove the A/C drive belt and then the compressor. Tightening torque

7.9 to 11.8 N·m 0.8 to 1.2 kgf·m 5.8 to 8.7 lbf·ft

Bolt (3)

(1) Hose (Discharge) (2) Hose (Suction)

(3) M6 Bolt (6T) (4) O-Ring RY9212079CAS0039US0

Installation • Mount the compressor. IMPORTANT • Be careful that the bushing faces the right direction. • Press on part (a) to adjust the tension of the compressor drive belt Early time

451 to 667 N·m 46 to 68 kgf·m 102 to 149 lbf·ft

Engine running

265 to 441 N·m 27.1 to 44.9 kgf·m 59.6 to 99.1 lbf·ft

Belt Tension (a)

• Attach each bolt and tighten to its specified torque. • Apply compressor oil to the O-rings. • Connect the low-pressure hose to the side of the compressor marked "S" (suction). • Connect the high-pressure hose to the side of the compressor marked "D" (discharge). (a) Point to Measure Compressor Belt Tension

5-S30

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Filling the Compressor with Oil When replacing the compressor • The amount of oil required by the new compressor is enclosed within the A/C cycle. A certain amount of compressor oil circulates along with the gas in the A/C system. • When replacing the compressor, remove the excess oil from the new compressor. • Compressor oil (ND-OIL8) readily absorbs moisture, so seal it immediately. Compressor Oil

Type: ND-OIL8

(1) New Compressor (2) Compressor Being Replaced

Capacity (reference value): 60 cc

A : Amount of Oil for New Compressor B : Amount of Oil from Old Compressor (a) Remove Excess Oil (A-B) RY9212332CAS0025US0

5-S31

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(3) Connecting/Disconnecting A/C Hoses Cab and Air conditioner Version

(a) Clamp Position

(b) Up Side

No.

Parts Name

Q'ty

Remarks

No.

(1)

Joint (suction, liquid)

(9)

Bolt

(2)

Flange bolt

(10)

Stay (A/C Hose, 2)

(3)

Hose (suction)

(4)

Flange bolt

(5)

Hose (pressure)

Blue

Parts Name

Q'ty

(11)

Stay (A/C Hose, 3)

(12)

Bolt

Orange

(13)

Stay (A/C Hose, 4)

(6)

Hose (discharge)

Red

(14)

Stay (A/C Hose, 5)

(7)

Hose (liquid)

Green

(15)

Band, cord

(8)

Stay (fuel hose)

Tightening torque

Bolt (2) (4)

Remarks

7.9 to 11.8 N·m 0.8 to 1.2 kgf·m 5.8 to 8.7 lbf·ft RY9212332CAS0019US0

5-S32

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

Removal 1. Collect the refrigerant from the A/C system. 2. Disconnect the negative (–) cable from the battery and the 1P connector of the magnetic clutch. 3. Remove the A/C hose(s). CAUTION • After removing hose(s), immediately seal the A/C system so no moisture or water gets into it. Installation • • • •

Pay attention to whether each hose is for high or low pressure. Pay attention to whether each hose is for intake or output. Attach each bolt and tighten to its specified torque. Tighten the nuts for aluminum pipe with two wrenches, holding one side from turning and tightening the nut to it. (The mating side is soft, so be careful when tightening.) • Tighten carefully so the pipe does not turn. • Apply some compressor oil (ND-OIL8) to pipes that have O-rings and press the tip into the stepped surface. RY9212079CAS0053US0 (1) (2) (3) (4)

Parts Name

SSV65

Hose (suction)

(a) Overall length 1700 mm 66.93 in. 5.577 ft

Compressor Side Air Conditioning Unit Side M6 Bolt M10 Bolt

Tightening torque M6 bolt (3)

M10 bolt (4)

7.9 to 11.8 N·m 0.8 to 1.2 kgf·m 5.8 to 8.7 Ibf·ft

19.6 to 24.5 N·m 2.00 to 2.49 kgf·m 14.5 to 18.0 Ibf·ft RY9212332CAS0020US0 (1) (2) (3) (4)

Parts Name

SSV65

Hose (pressure)

(a) Overall length 1900 mm 74.8 in. 6.234 ft

Receiver-Drier Side Air Conditioning Unit Side M16 × 1.5 M10 Bolt

Tightening torque Nut M16 x 1.5 (3) 11.8 to 14.7 N·m 1.2 to 1.5 kgf·m 8.7 to 11 Ibf·ft

M10 bolt (4) 19.6 to 24.5 N·m 2.00 to 2.49 kgf·m 14.5 to 18.0 Ibf·ft RY9212332CAS0021US0

5-S33

KiSC issued 12, 2015 A

CABIN

SSV65, WSM (1) (2) (3) (4)

Parts Name

SSV65

Hose (discharge)

(a) Overall length 1300 mm 51.18 in. 4.265 ft

Condenser Side Compressor Side M6 Bolt M6 Bolt

Tightening torque M6 bolt (3) 7.9 to 11.8 N·m 0.8 to 1.2 kgf·m 5.8 to 8.7 Ibf·ft

M6 bolt (4) 3.9 to 6.9 N·m 0.4 to 0.7 kgf·m 2.9 to 5.1 Ibf·ft RY9212332CAS0022US0 (1) Condenser Side (2) Receiver-Drier Side (3) M6 Bolt

Parts Name

SSV65

Hose (liquid)

Tightening torque

(a) Overall length 1500 mm 59.06 in. 4.921 ft

M6 bolt (3) 3.9 to 6.9 N·m 0.4 to 0.7 kgf·m 2.9 to 5.1 Ibf·ft RY9212332CAS0023US0

5-S34

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(4) Removal and Installation of Heater Hoses Cab and Air conditioner Version

(a) Hot Water IN (b) Hot Water OUT

No.

Parts Name

(e) Black Tape

Q'ty

Joint (water)

(2)

Hose, assy (heater, OUT)

(3)

Hose (heater, 1)

Blue tape

(4)

Hose (heater, 2)

Black tape

(5)

Hose clamp (with screw)

Clamp (heater hose)

(7)

Hose assy (heater, IN)

(8)

Plate (heater hose)

(9)

Bolt

Tightening torque

Joint (water)

Blue Tape

Remarks

(1)

(6)

(f)

17.7 to 22.6 N·m 1.8 to 2.3 kgf·m 13.1 to 16.7 lbf·ft RY9212332CAS0029US0

5-S35

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(a) Overall Length (e) Black tape (f) Blue Tape Parts Name

(A) Pipe (Heater) Up Side (B) Pipe (Heater) Down Side

(E) Engine Side

Length (a)

(b)

(c)

(d)

Remarks

(1)

Hose (heater, 2) Black tape

1615 to 1655 mm 63.58 to 65.18 in. 5.299 to 5.429 ft

1110 ± 7.5 mm 43.70 ± 0.3 in. 3.642 ± 0.025 ft

585 ± 7.5 mm 23.0 ± 0.3 in. 1.92 ± 0.025 ft

205 ± 7.5 mm 8.07 ± 0.3 in. 0.673 ± 0.025 ft

(2)

Hose (heater, 1) Blue tape

1630 to 1670 mm 64.17 to 65.77 in. 5.348 to 5.478 ft

1135 ± 7.5 mm 44.68 ± 0.3 in. 3.724 ± 0.025 ft

630 ± 7.5 mm 24.8 ± 0.3 in. 2.07 ± 0.025 ft

225 ± 7.5 mm 8.86 ± 0.3 in. 0.738 ± 0.025 ft

24.5 to 29.4 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 Ibf·ft

RY9212332CAS0030US0

5-S36

KiSC issued 12, 2015 A

CABIN

SSV65, WSM

(5) Heater Hose Routing

(1) Hose (heater, 2) (2) Hose (heater, 1)

(a) Hot Water IN (b) Hot Water OUT RY9212332CAS0031US0

5-S37

KiSC issued 12, 2015 A

B/W

8.00

40.0 f f B/R

40.0

FRAME

B/Y

A-1

C-1

8.0

BATTERY

RELAY RD451-54381 3.0

R/W 0.3

W/B

40.0

B/Y

40.0

B/Y

GND_CAB

B-1

H-1

3.0

5.0

8.00

PLUG,GLOW 1J705-65511

R 0.5

CN301-1

3 R/W

3 B/W

CN301-2

3 B/W

3.0

CN301-3

3 R

3.0

METER(+B) 5A MiniFuses AUX_Electrical_Power1 15A MiniFuses ECU_+B 5A MiniFuses R&FBOX

R/W

3.0

0.5

8.0

B/W

CN511-1

0.5

CN511-2

0.75

f f

B/W

R f

A-1

W/G

A-2

B-1

R f

ASSY_ALTERNATOR (CN511) 3R600-64012 B-1

A-1

W/G

A-2

ALTERNATOR (CN511) 1J730-64011

MIC

OFF

1 2 3

Y/R

0.5

CN315-8 0.5

Y/R

0.5

CN315-14 0.3

1.25

0.5

B/R 1.25

0.85

B/R

METER (CN302) V0621-53112

Y/R

CN314-8

B/R

Y/B

RELAY RD451-54381

R/B

CN302-7

0.30

R/B

CN314-14

CN302-8

0.5

Y/R

0.5

CN314-8 CN315-8 f R

CN302-10

0.50

0.5

CN302-11

0.50

L CN312-6 CN313-6

5 6

ALTERNATOR 5A MiniFuses FUEL_PUMP 5A MiniFuses Control_Element 5A MiniFuses R&FBOX

R/W

B-1

STARTER (CN507) 1J755-63012

START

5.0

R/W

SSV65, SSV75 Electrical Circuit Diagram

A-1

B/R

F_GND(L)2

STARTER-SW (CN301) RC461-53962

3.0

GND(L)1

RELAY RD451-54211

R/W

Y/R

40.0

R&FBOX

3.0

CN508-1

F_GND(L)1

CN511-1 0.5

W/B

CN-507-1

GND_CAB2

CN511-2 0.75

B-1

CN512

0.3

A-1

B/R

STARTER (CN507) 1J730-63011

CN512-1

Y/R

0.3

R&FBOX

5.0

Y/R

40.0

GND_CAB2 3 B

ENGINE

3.0

CN508-1

Y/R

3.0

SBF_BOX2

3.0

CN507-1

F_GND(L)1

G-1

R/W

F_GND(L)2

F-1

BATTERY

5.0

E-1

3 R/W

3.0 3.0

F_GND(R)

D-1

B/R

0.5

L/R

CN111-1

0.5

CN111-2

0.5

F_GND(R) 0.5

B/W

0.5

CN415-1 CN416-1 O 0.5

0.5

B/R

0.5

CN414-3

P/L

10 CN414-12 0.5

B/W

0.3

B/W

9 CN414-5

0.3

P/L

0.5

B/L

CN302-6

1.25

F_GND(L)1

CN412-4 CN411-4 B

0.85

0.5

Y/B B/L

6 4

V1311-3647F (CN402) GRIP

0.3

CN414-10 0.5

CN414-11 0.5

CN414-8

0.5

Y/G

CN414-9

0.5

B/O

CN414-6

0.3

CN414-4

0.30

CN402-1

Y/G

W/R f

0.3

CN402-7

0.5

B/W

CN402-5

0.3

P/L

8 9

BR/B

CN402-3

0.3

R/G

CN402-2

0.3

CN402-10

0.5

G/W

CN402-11

0.5

Y/L

CN402-8

0.5

R/Y

CN402-9

0.5

CN402-6

0.3

L/W

0.85

B/R

0.5

R/Y

0.85

B/R

0.5

B/L

1.25

0.50

GND_CAB2 POWER_SOCKET (CN330)

RELAY RD451-54381

1 f

L/R

4 0.85

V1311-3642F (CN414) GRIP

B/G

0.85

RELAY RD451-54381

CN415-2 CN416-2

B/R

B/W

CN414-2

0.5

FUEL_PUMP (CN111) RC601-51351

L/R f

0.5

0.85

CN411-1

0.85

CN411-2

0.85

L/R

CN330-2

0.75

L/R

CN411-3

0.85

Y/B

CN330-3

0.75

Y/B

CN411-4

0.85

B/R

CN330-4

0.75

B/R

CN411-5

0.85

W/Y

CN330-5

0.75

W/Y

CN411--6

0.85

R/L

CN330-6

0.75

R/L

CN411-7

0.85

B/Y

CN330-7

0.75

B/Y

CN411-8

0.85

CN330-8

0.75

CN411-9

0.85

CN330-9

0.75

CN330-1

0.75

2 3 4 5 6 7 8

BR f

CN412-6 CN411-6

11 12

RELAY RD451-54381

13 14 4

0.85

B/R

0.5

RELAYBOX2

0.85

W/Y

0.5

B/L

B/W

8.0

8.0 5.0

RELAY RD451-54381

0.5

8.00

GLOW_CAB/SBF 60A Plug-in_type CRS/SBF 30A Bolt-on_type Main/SBF 60A Bolt-on_type ALTERNATOR 100.80A Bolt-on_type

4 B/O

0.5

Y/G

0.50

B/O

RELAY RD451-54381 4 0.3

0.5

LG 0.3

0.5

Y/L

CN415-7

0.5

R/Y

CN416-7

0.5

R/Y

CN415-8

0.5

CN416-8

0.5

B/O

0.5

F_GND(R)

0.50

G/W

0.85 0.5

R/L L

RELAY RD451-54381 4

B/O

0.85

B/R

0.5

Y/L

0.85

B/Y

0.5

CN404-4

RELAY RD451-54381

0.5

R&FBOX

0.5

CN416-3

0.5

B/G

CN416-14

Y/L

R/Y

0.5

G/W

B/G

0.5

G/W

0.5

CN415-3

B/R

0.5

CN415-14

0.85

B/L

CN404-3

F_GND(R)

0.5 0.5

DIODE 7321-9822

G/B f

CN311-6 0.5

Y/R

CN310-6

0.5

CN203-1 1.25

GND_CAB2

DIODE(HORN) 0.5

RELAYBOX1

B/O

B-1

CN309-3

3 7

CN314-6 Y/R

0.50

0.3

Y/B

CN404-2

0.5

B/L

CN404-1

0.5

B/W

2 1

SWITCH(HYD,UNLOCK) (CN309) V1311-5381B

ON OFF 0.50

HORN (CN203)

A-1

0.5

CN309-2

5K126-42511

0.85

Y/R

CN315-6

CN422-1

0.5

W/R

CN423-1

0.5

R/W

CN405-1

0.5

BR/W

CN405-2

0.5

CAN_TOOL (CN404) 7234-2601-40

CAN_TOOL VALVE,CONTROL,ASSY V1311-6311B

R/W

1.25

0.5

3.0

WIPER 15A MiniFuses FUSE(ECU(AC,SIGNAL)) 5A MiniFuses CRS_ECU(AC) 5A MiniFuses R&FBOX

B/R

0.3 0.5

4 0.85

232C (CN404)

0.5

B3-1

B3-2

A3-1

A3-2

CN422-2

0.5

G/W

CN423-2

0.5

G/W

1.25

CN307-2

0.50

CN315-5

1 3

LIGHT,ROOM (CN216) 3C581-54211_2 CN216-2

0.5

OFF

W 2

12V,5W

CN216-3

GND_CAB

3 CN401-3

0.3

0.50

2 1

CN401-2

0.3

B/W

CN401-1

0.3

CN308-2

0.50

CN413-1

CN406-1

0.5

CN406-2

0.5

L W/R

0.3

W/R

0.3

L/B

0.3

0.50

0.3

Y/R

HYD-Unlock-SW 52

TxD

CN407-53

0.3

W/G

Hi-Flow-SW 53

RxD

76 75

CN407-54

0.3

Parking-SW 54

CAN-H

CN407-55

0.3

B/W

Buzzer-Back-SW(RH) 55

CAN-H

CN407-72

0.3

L/B

Buzzer-Back-SW(LH) * 72

CAN-H

Setup-Connector 51

CAN-L

W/R

Trabel-Speed-SW 73

CAN-L

BR/B

RIDE-CONTROL-SW 74

CAN-L

L/W

AUX-Hold-SW 64

Front-Work-SW_LH 69

CN407-51

0.5

CN407-73

0.3

CN407-74

0.30

CN407-64

0.3

CN407-69

0.3

CN407-71

0.3

45 46 47 48 49

NULL

CN223-3

0.3

CN223-1

0.30

CN202-2

CN202-1

Y/B

0.30

CN407-67

0.5

CN407-68 0.3

0.3

F_GND(R)

G/W

CN314-9 1

0.30

0.75

CN315-9 0.3

GND_CAB2

CN407-66

RESISTOR(OPC) CN315-11

0.3

CN314-11

0.3

CN315-10

0.30

G/W

CN314-10

0.3

G/W

CN407-59

0.3

CN305-2

0.5

SWITCH(DPF,INHIBIT) (CN305) V1311-5384C

0.4A

T1850-39011

CN313-2 1

CN305-7

0.5

W 7

CN305-3

0.5

Y/B

CN305-9

0.5

L/R CN410-1

0.3

0.30

B/Y

W/L

CN312-2

0.3

W/L

OIL_TEMP_SENSOR (CN410) 5H601-41941

R/Y

CN410-2

0.3

CN315-16 CN314-16 Y/B 0.3

Y/B

0.5

L/R

0.3

CN110-2

0.3

FUEL_SENSOR (CN110) V1311-5114A

W/R

R/W

AUX-SOL-FeedBack 18

CN407-18

0.5

G/W

W/B

CN315-15 CN314-15

CN407-41

0.5

Y/L

0.5

Fan-FeedBack 20

CN407-20

0.5

L/Y

0.5

L/Y

CN110-1

0.3

0.5

L/Y

Travel-Speed-Sol 62

CN407-62

0.3

Park-Brake-Sol 81

CN407-81

0.3

R/Y

Seat-Bar-SW(RH) 60

HYD_HITCH-RELAY 21

CN407-21

0.3

AUX-Relay 23

CN407-23

0.5

AUX-Relay 42

CN407-42

0.5

B/L

Starter-Relay 22

CN407-22

0.3

W/B

Glow-Relay 78

CN407-78

0.3

W/B

Back-Buzzer 80

CN407-80

0.3

BUZZER 31

CN407-31

0.3

Wakeup-Signal-OUTPUT 17

CN407-17

0.3

R/B

DPF-Inhibit-LED 35

CN407-35

0.3

L/R

Charge-Input 30 OIL-SW 10

R/B

+5V-OUT 32

W/L

+5V-OUT 12

CN407-13

0.3

Y/G

+5V-OUT 13

GND(Sensor-Use) 14

Y/R

GND(Sensor-Use) 15

CN407-33

0.3

R/G

GND(Sensor-Use) 33

CN407-27

0.3

W/B

FUEL-SENS 27

NULL

R/Y

Oil-Temp-Sensor 25

NULL

AUX-Control1 6

NULL

3 2 1

0.30

Y/R

CN303-2

0.30

LG/R

CN303-1

0.30

Y/R

1 2 3

1.25

G/L

A-2

B-1

B-2

0.3

Y/R

0.3

L/B

CN409-3

0.3

R/B

CN105-1 f

0.5

L/Y

0.5

LG/W

ACCEL-SENS1 8

CN407-28

0.3

ACCEL_SENS2 28

L/B

B2-1

0.3

CN420-1

0.5

L/W

0.5

L/Y

CN426-1

0.3

CN425-1

0.3

F_GND(R)

0.3

R/Y

CN424-1

0.5

P/L

L/R

Starter-SW(Run) 1

Y/B

+B(Direct) 43

f Y/B

P/W

GND(Power) 2

0.3

1.25

SWITCH(WIPER) (CN327) V1311-5484B

1.25

0.5

CN306-3

0.5

CN311-3 CN310-3

B/W

0.3

CN306-6

0.5

1.25

CN327-6

1.25

CN327-4

1.25

G W

B/W

0.5

0.75

CN201-1

1.25

CN201-4

0.75

1.25

CN201-3

0.75

5.0

W/R

0.3

1.25 0.3

F_GND(L)2

3.0

W/G

0.5

R&FBOX

3.0

CN217-1

1.25

CN218-1

2 f

L/Y

3.0 0.3

F_GND(L)2

1.25

2.0

B/R

L/Y

R/W

0.5

1.25

3.0

BOX(RELAY&FUSE) 3 B/R 0.5

1.25

CN304-1

1.25

CN304-2

1.25

GND_CAB2

RADIO_CONVERT(CN204) 1 2

1 2

CN318-1

1.25

CN205-1

0.5

Y/R

CN205-2

0.5

CN220-1

0.50

W/B

CN220-2

0.50

CN204-7

1.25

CN318-2

3.0

0.75

BR/W

0.75

CN214-1

2.0

CN207-1

2 f

L/Y

CN208-1

2.0

CN503-1

0.75

1.25

3.0

CN503-2

0.75

CN503-3

2.0

CN503-4

2.0

B/R

BR/W

0.5

BR/W

0.5

BR/W

0.5

B/O

0.5

Y/G

1.25

B-1

B-2

CN418-5

2.0

B/R

CN418-6

2.0

B/R

1.25

0.5

CN213-2

0.5

CN214-2

0.5

CN207-2

0.5

CN208-2

0.5

P/L

CN325-1

0.50

CN325-3

0.50

R/B

CN315-3 CN316-3 R/B 0.50

f O CN315-4

R/B

0.50 O CN316-4

CN113-2

0.3

F_GND(R)

CN114-2

SOLENOID(UNLOCK) SWITCH(SELF_LEVEL) (CN326) V1311-5483C

0.5

P/W

3 0.5

GND_CAB GND_CAB

0.5

R/B

CN326-1

RESISTOR

0.5

BR/W

1 1

0.3

F_GND(R)

3.0

2.0

R/W

2.0

3.0

B/Y

3.0

1.25

CN108-1 0.5

Y/G

CN108-2 0.5

R/L

CN108-3 0.5

L/B

CN108-4 0.5

G/B

CN108-5 0.5

0.5

BR/W

0.5

CN418-33

0.5

CN418-51

0.5

CN418-52

0.5

BR/W

CN418-38

0.5

BR/W

CN418-39

0.5

AIR_FLOW_SENSOR (CN108) 1J520-10701

B-6

R/B

CN421-2

CN109-1

0.5

B/W

0.3

CN408-1

0.3

3 4 5

0.5

BR/W

0.5

Y/R f

2.0

R/W

2.0

R/W

1 1

2 f

CN417-30

0.5

L/B

CN417-7

0.5

G/B

CN417-34

0.5

R/L

CN417-10

0.5

Y/G

CN418-57

0.75

R/B

CN418-44

0.75

B/R

CN418-29

0.75

CN418-16

0.75

CN418-9

0.75

INTAKE_THROTTLE_VALVE (CN501) 1J770-10601

CN501-1

0.75

B/R

CN501-2

0.75

R/B

CN501-3

0.75

CN501-4

0.75

CN501-5

0.75

0.5

CN418-54

0.5

Y/B

CN418-47

0.5

Y/R

CN418-48

0.5

Y/R

B-49 MainRelay B-33

B-14 CAN1-H B-51 CAN1-L B-52

BUZZER (CN408) 53660-53811

1 2

0.85

CN215-1

CN328-3

1.25

CN219-1

0.85

LAMP,FLASHER (CN215) T1060-30032

0.85

LAMP,FLASHER (CN209) T1060-30032

LAMP,FLASHER (CN219) T1060-30032

CN206-2 0.50

CN515-1

CN209-2 0.50

2.0

CN215-2 0.50

2.0

CN219-2 0.50

CN515-1

2.0

CN515-1

FLASHER_UNIT 3F240-75432

CN329-7

0.85

CN329-10

0.5

0.50

0.5

O 0.5

CN329-9

0.5

CN329-8

0.5

0.75

2.0

CN515-2

INJECTOR_3 (CN515) 1J705-53052 1J770-53051

PANNEL(INDICATOR) (CN329) V1311-5487A 2

INJECTOR_2 (CN515) 1J705-53052 1J770-53051

B CN515-1

CN515-2

INJECTOR_4 (CN515) 1J705-53052 1J770-53051

2.0

CN418-3

CN515-2

2.0

F_GND(L)2 CN418-4 F_GND(L)2 CN418-18 F_GND(L)2

CN417-49

1.25

CN417-73

1.25

R/W

CN417-1

1.25

L/R

CN417-25

1.25

B/R

CN417-74

1.25

* B-37 CAN2-H B-38 CAN2-L B-39

A-65 B-54 B-47

Y/B

A-52 INJ2_DRV_TWV2 A-26

0.75

B f

CN513-1

0.5

CN417-18

0.5

CN513-2

0.5

CN417-42

0.5

CN513-3

0.5

G_SENSOR (CN513) 1J574-59711

0.5

B 0.5

0.5

2 3 4 5 6

7182-9631-40

CN520-3

0.75

CN520-2

0.75

L/R

CN520-1

0.75

CN417-66

0.75

CN417-59

0.75

L/R

DIFF_PRESSURE_SENSOR (CN520) 1J520-18601 3 2 1

CN417-23

0.75

CN418-20

0.75

R/B

CN418-7

0.75

Y/R

0.75

R/B

CN505-2

0.75

Y/R

CN506-1

0.75

B/Y

CN506-2

0.75

G/W

B-1 B-2

0.75

B/Y

0.75

G/W

CN417-39

0.75

CN417-15

0.75

L/R

CN510-1

0.75

CN417-40

0.5

CN510-2

0.75

CN417-41

0.5

CN510-3

0.75

CN417-24

0.75

CN417-16

0.75

CN417-46

0.75

CN514-1

0.75

CN417-61

0.75

L/B

CN514-2

0.75

L/B

CN417-57

0.75

Y/R

CN514-3

0.75

Y/R

CN418-28

0.75

CN418-15

0.75

CN516-1

0.5

WATER_TEMP_SENSOR (CN516) 5H601-41941

0.75

CN516-2

0.75

L/R

RAIL_PRESSURE_SENSOR (CN510) 1 2 3

1J770-50601 BOOST_SENSOR (CN514) 1 2 3

1J500-59671

CN502-1

INTAKE_AIR_TEMP_SENSOR (CN502) 1J574-59681

CN502-2

0.75

WATER_SEPARATOR (CN112) V0521-51861 CN417-85

A-60 Inlet_DOC_Temp A-38 Inlet_DOC_Temp_GND A-14 Outlet_DOC_Temp A-36 Outlet_DOC_Temp_GND A-12 Outlet_DPF_Temp A-62 Outlet_DPF_Temp_GND A-58

A-48 POWER_GND B-3 POWER_GND B-4 CASE_GND B-18

A-2

CN417-8

A-72

A-50 INJ3_DRV_TWV3 A-51

A-1

CN417-31

B-21 STOP_SW B-55 Parking_SW B-42 ForceRegen_SW A-83 Regenlnhibit_SW A-84 WaterLevel_SW A-85 FilterPlugged_SW B-41 CAN_SEL_SW A-78 BGmode_SW A-82 RatedSpeedSel_SW(BG) A-81 Neutral_SW B-53 OIL_SW A-80

PUMP_ASSY_SUPPLY (CN505) 1J770-50501

CN505-1

0.5

A-37 ExtAirTempSEN_SIG B-28 ExtAirTempSEN_GND B-15

A-5 INJ_Common1 A-49 INJ_Common1 A-73 INJ-Common2 A-1 INJ-Common2 A-25 INJ_DRV_TWV1 A-74

1.25

F_GND(L)2

A-35 PFuel_SIG A-40 PFuel_SIG A-41 PFuel_Vcc A-24 PFuel_GND A-16 BoostSEN_Vcc A-46 BoostSEN_SIG A-61 BoostSEN_GND A-57

IG_SW

1.25

A-32 SLD_GND A-6

B-48

CN417-26

0.5

JOINT_CONNECTOR2

A-29 FuelTemp_SIG A-31 FuelTemp_GND A-8 CoolantTemp_SIG A-39 CoolantTemp_GND A-15

IG_SW

A-53 INJ4_DRV_TWV4 A-3

1.25

CN417-44

A-28 SCV(+) B-20 SCV(-) B-7

ST_SW

W/R

L/B

0.5

B-13 PressDiffSensor_SIG A-66 PressDiffSensor_GND A-59 PressDiffSensor_Vcc A-23

A-79 IntakeThrottleSensor_SIG B-29 IntakeThrottleSensor_GND B-16 IntakeThrottleSensor_Vcc B-9

CN504-3

NE_SENSOR (CN504) 1J770-59661

B-8 VehicleSpeed B-30

B-26 IntakeThrottleMotor(+) B-57 IntakeThrottleMotor(-) B-44

1.25

0.5

A-21 AccelSensor2_Vcc B-10 AccelSensor2_SIG B-11 AccelSensor2_GND B-12

B-34 MAF_SEN_SIG A-30 MAF_GND A-7 IntakeAirTemp(AFS) A-34 IntakeAirTemp(AFS)_GND A-10

CN417-3

CN417-51

CN417-43

A-55

A-90

LAMP,FLASHER (CN206) T1060-30032

G Y

A-20 AccelSensor1_Vcc B-23 AccelSensor1_SIG B-24 AccelSensor1_GND B-25

A-54

INJECTOR_1 (CN515) 1J705-53052 1J770-53051

f f

A-63

A-56

R/W

0.5 0.5

A-11 EngineWarning_Lamp A-70 EngineStop_Lamp A-95 OIL_Lamp A-94 Heater_Lamp A-68 OverHeat_Lamp A-93 ForceRegenReq_Lamp A-91 Regen_Lamp A-67

A-4 Starter_Relay A-92

CN504-1 CN504-2

A-17

A-75 ExtShutterPull_Relay A-69 ExtShutterHold_Relay A-71

G Y

A-87

B-31

f f

A-13

A-76

0.5 0.5

A-86

A-77

CN417-22 CN417-19

B-17

TAC B-35 EGR_Lft_SEN_Vcc A-45 EGR_Lft_SEN_GND A-9 EGR_lIFT_SEN A-33 EGR_Motor(-) B-45 EGR_Motor(+) B-58

A-47 SIGNAL_GND B-1 SIGNAL_GND B-2

0.5

W/B

CN417-38

0.75

W/B

CN417-14

0.75

CN417-36

0.75

B/R

CN417-12

0.75

CN417-62

0.75

R/B

CN417-58

0.75

Y/B

CN418-1

1.25

CN418-2

1.25

CN517-1

0.75

CN518-1

0.75

CN519-1

0.75

Y/B

F_GND(L)2 F_GND(L)2

1H993-60201

CN112-2

0.5

DOC_INLET_SENSOR (CN517) 1J770-18501 1

CN517-2

DOC_OUTLET_SENSOR (CN518) 1J770-18511 1

CN518-2

DPF_OUTLET_SENSOR (CN519) 1J770-18521 1

CN519-2

0.75

W/B

0.75

B/R

0.75

R/B

0.50

B 1.25

F_GND(R)

0.5

CN103-1

1.25

B/W

RELAY RD451-54381

CN104-1

1.25

0.5

5.0

f f

R/B B/W

R&FBOX

R/B

0.75 0.5

f f

CN320-1

0.50

3.0

0.5

B/W

F_GND(L)1

BR/W

CN320-2

RELAY RD451-54381

R&FBOX

0.50

R/B

CN322-2

0.50

R/B

CN322-3

0.50

B/L

CN322-1

0.50

B/Y

3.0

A-2

B-1

A-3

B-2 A-4

0.5

3.0

B/Y

CN321-1

R CN316-3

0.5

B/Y CN312-2

CN311-2 0.50

3.0

B/L

CN321-2

3.0

CN319-7 CN221-16

0.5

Y/R

CN221-8

0.50

R/B

A-5

A-1

V1311-3911A BLOWER_MOTOR (CN321)

CN317-3

ASSY_SWITCH,AIR-CON (CN221) RD451-53832

THERMOSTAT(CN322) 3C581-72161

CN312-1

4 3.0

0.50 0.5

COMPRESSOR_CLUTCH (CN104) 3C581-50062 Dual_Pressure_SW (CN320) V0511-39334

CN313-1

BR/W

R/B

4 0.75

0.50

DIODE_A/C (CN103) 7321-9822

DIODE(A/C)

BACK_BUZZER (CN109) V0511-53924

CN408-2

0.5

F_GND(R)

GND_CAB GND_CAB

A-2 G_Vcc A-44 G_GND A-18 G_SIG A-42

B-32

E-OUT(ROOF)

F_GND(L)1

3.0

GND_CAB

SWITCH(HAZARD) (CN328) V1311-5485A

+BP

A-96

ROOF_GND

CN206-1

+BP

A-89

SWITCH(SELF_LEVEL) V1311-5483C

0.75

GND_CAB GND_CAB

A-88

E-OUT(ROOM)

B-5

A-27

COMPRESSOR_FUSE 10A MiniFuses BlowerMotor 30A MiniFuses R&FBOX

R/B 0.5

GND_CAB

CN314-1 CN315-1 R/B 0.5

0.5

CN326-6

CN109-2

GND_CAB GND_CAB

NE_Vcc A-22 NE_GND A-19 NE_SIG A-43

B-36

B-50

A-64

BR 1.25 1

A-2

0.5

CN211-2

B-40

1.25

A-1

SIGNAL_BLINKER

L/Y

LAMP(WORKING,RH) (CN207) V1311-5352C

ON OFF

1.25

B-2

A-2

B-1

CN210-2

B-19

1.25

L/Y

CN209-1

CN328-2

LAMP(WORKING,LH) (CN213) V1311-5351C A-1

2.0 2.0

1.25

R/B

ENGINE-ECU (CN417)(CN418)

R/W

3.0 2

ON OFF

B-2

B-43

SWITCH(SELF_LEVEL) V1311-5483C 1

1.25

B-1

Y/R

1.25

B/Y

A-2

0.5

B-56

F_GND(R)

3.0

A-1

0.5

CN218-2

B-46

0.5

L/Y

CN217-2

B-27

3.0

ON OFF

CN211-1 2 f

L/Y

F_GND(L)1

B/Y

3.0

LAMP(TAIL,RH) (CN210) V1311-5354C

J/C(CAN,EGR,SERVICE)

3.0

R/W

2 f

AIR_RIDE_SEAT (CN318)

B/Y

2.0

SOLENOID(BK_POSITION)

B-22

B-2

B/Y

3.0

0.85

GND_CAB

A-2

EGR_VALVE (CN503)

TO_E-OUT(ROOM)

2.0

B-1

BR 1.25

CN210-1 1.25

CN213-1

BONDER_A

E-OUT(SWITCH)

A-1

F_GND(L)2

AirRideSeat 15A MiniFuses ATTACHMENT2 20A MiniFuses R&FBOX

3.0

MiniFuses

7382-5053-3R

0.75

LAMP(TAIL,LH) (CN217) V1311-5353C

R&FBOX

GND_CAB

CN201-2

R&FBOX 4

CN204-9 0.50

0.5

Engine_Elements 3.0

3 R/W

SPEAKER(CN220) 3C581-54131

CN326-2

W/R

F_GND(L)2

SPEAKER(CN205) 3C581-54131

W/R

ASSY_SOCKET(CN304) RC418-53451

5.0

0.50

1J770-62701

ArmHarness 20A MiniFuses ElectricalOutlet-1 15A MiniFuses ATTACHMENT1 20A MiniFuses R&FBOX

Motor_Wiper (CN201) V0511-35801

RELAY RD451-54381

CN311-1 CN310-1

1.25

RELAY RD451-54381

1.25

W/L

1.25

W/R

CN222-2

GND_CAB2

0.5

f 0.5

0.5

R&FBOX

5.0

B/W

W/R

W/G

RELAY RD451-54211

R/W

B/W

f 0.5

B/W

f 0.5

B/W

0.5

3.0

W/R

SWITCH(WORKING_LIGHT,MULTI) (CN306) V1311-5383A

5.0

0.85

CN222-1

0.5

0.3

CN306-5

R/W

W/R

0.3

W/R

FRONT&SIDE_LAMP 30A MiniFuses FUSE(SOLENOID) 10A MiniFuses ATTACHMENT(+B) 15A MiniFuses R&FBOX

0.3

F_GND(R)

RELAY RD451-54381

OFF

0.3

ON OFF

4 1.25

P/L

SOL_BK_POSITION (CN421) V1311-6431B

CN306-2

5.0

0.85

CN327-3

Motor_Washer (CN222) 6A671-74231

0.5

SOLENOID (CN114) RD451-96261 CN114-1

0.5

2.0

SWITCH(HITCH) (CN325) V1311-5482A

CN421-1

REAR

R/W

0.3

CN424-2

CN315-2 CN316-2 P/W 0.5

B/W

FRONT

5.0

B/G

CN425-2

F_GND(R)

SOLENOID(LOCK)

0.5

SOLENOID (CN113) RD451-96261

CN327-5 1.25

HORN 10A MiniFuses FUSE(ECU_MAIN(POWER)) 20A MiniFuses REAR_LAMP 15A MiniFuses R&FBOX

0.3

0.5

SOLENOID (CN424) RD451-96261

P/W

2.0

0.5

CN113-1

CN426-2

R&FBOX

CN327-2 1.25

0.5

F_GND(R)

0.3

OFF

0.5

F_GND(R)

SOLENOID (CN425) RD451-96261

L/R

WASHER

1.25

CN317-1 1.25

F_GND(L)1

1 CN316-1 G/B

CN115-1

SOLENOID (CN426) RD451-96261

W/L

0.3 2

RELAY RD451-54381

CN325-2

0.5

F_GND(R)

+12V-OUT 16

0.5

L/R 1

R&FBOX

0.5

CN407-1

0.3

F_GND(R)

SOLENOID(RIDE_CONTROL)

0.3

CN407-43 2.0

F_GND(L)1

CN420-2

B1-2

NULL

CN407-2

L/Y

0.5

CN419-2

B1-1

P/L

F_GND(R)

SOLENOID(HF_VALVE) VALVE,CONTROL,ASSY (CN420) V1311-6311B

VALVE,ASSY(ACC) (CN115) V1311-6581D CN115-2

TRAVEL_PILOT_PRESS_SSR 37

f P

CN421-2

B2-2

NULL

0.3

0.5

0.3

HF_VALVE (CN419) V0611-64712 CN419-1

0.5

0.3

CN407-37

0.5

VALVE,CONTROL,ASSY (CN421) V1311-6311B

G/Y

0.3 2.0

CN105-2

NULL

2.0 f

4 0.5

L/Y

RELAY RD451-54381 3

L/Y

MOTOR,ASSY (CN105) V1311-6231A

Y/L

NULL

0.5

F_GND(L)1

Y/L

0.5

CN105-2

CN407-8

CN407-16

2.0

CN105-2

DIODE 7321-9822

G/L

NULL

CN409-1

G/L

A-1

CN409-2

G/L

MOTOR,ASSY (CN105) V9993-2239A

Y/L

CN421-1

0.3

RB257-53821 SENSOR(PRESSURE,5MPA) (CN409)

CN105-1

f 1.25

UNLOCK

DIAL_ACCEL (CN303) V1311-5388C

0.3

CN303-3

Y/R

CCW

W/L

0.5

NULL CN303-4 0.30

0.5

NULL

AUX-Control2 26

F_GND(R)

CN407-61

CN105-1

0.5

Motor-Fan 41

RIDE-CONTROL-SOL 61

0.3

G/L

DIODE(2WAY_FAN)

CN107-2 CN106-2 Y/L

OPC-SW

0.3

1.25

L/W

CN407-12

CN407-6

CN407-32

CN407-25 0.5

0.5

Starter-SW(Start) 5

CN407-24

DPF-Inhibit-SW 11

0.3

LIFT-Lock-Sol 24

Y/B

CN407-15

0.5

NULL

CN407-49

NULL

0.3

CN407-11

CN407-14

0.5

Seat-Bar-SW(LH) 59

B/Y

0.5

W/G

CN407-48

0.3

Y/B

BR/W

CN407-77

G/W

Hi-Flow-SOL 77

1.25

0.75 1.25

CN107-1 CN106-1

0.75

0.5

G/Y

0.5

CN407-10

CN407-47

0.3

0.75 W/G

0.5

CN407-5

BR/W

CN407-79

CN407-60

0.75

0.5

TILTLOCK_SOL 79

f 0.5

ON OFF

0.75

SETTING_RH 68

0.3

CN407-30 CN509-1

SETTING_LH 67

CN407-58

0.5

CN407-46

0.5

CN407-30

R/Y

GND_CAB2

OIL_SW (CN509)

CN407-45

CN407-4

FAN-REVERSE-SW 66

B/W

G/L

NULL

0.5

B/L

CN407-3

63 CN324-1 0.5

Y/B

0.5

CN223-2

SEAT_BAR_R_SW (CN202) T1060-33751

STARTER_SW 5A MiniFuses R&FBOX

3 B/W

0.30

0.5

AUX-SOL(RH) 3

NULL

RESISTOR 7321-9981

SEAT_BAR_L_SW (CN223) T1060-33751 CN202-3

0.5

CN407-75

AUX-SOL(LH) 4

SEAT,ASSY (CN324) V1311-3810B

CN407-76

CN407-50

AUX-PORT-SW 71

W/R

G/L 1.25

CN407-52

CN314-13

CN324-2

CN308-3

1.25

CN315-13 GR

ECU(MAIN) (CN407) V1311-5371A

CAP

2 1

F_GND(L)1

0.5

SETTING (CN406) 0.5

0.50

W/G

SWITCH(PARKING) (CN308) V1311-5382A

F_GND(R)

CN413-2

BUZZER_BACK_SW_LH (CN413) T1060-33751

CN307-3

1.25

CN315-9 CN314-9

3 CN413-3

0.50

4 ON OFF

BUZZER_BACK_SW_RH (CN401) T1060-33751

CN307-1

CN313-7 CN312-7 W/G 0.3

SWITCH(FAN_REVERSE(HYD,UNLOCK)) V1311-5381B

ON OFF

NON

LOCK

0.5

0.50

NON

CN314-5 W

HI_FLOW

AUX 0.5 W

0.3

0.5

0.3

R&FBOX

SW(AC) 5A MiniFuses

0.3

L/R

2.0

1.25

SWITCH(HI_FLOW) (CN307) V1311-5486A

CN221-11

0.50

B/Y

CN221-10

0.5

B/Y

0.50

R/W

CN221-1

0.50

CN319-3

0.50

CN221-3

0.50

CN319-2

0.50

G/W

CN221-6

0.50

G/W

CN221-5

0.50

CN221-4

0.5

GND_CAB2

OFF 0.5

B/Y

GND_CAB2

CN222-3

3.0

CN222-6

0.50

B/Y

CN222-2

0.50

B/Y

CN222-1

0.85

L/Y

CN222-4

3.0

6 2 1 4 5

FAN_SW (CN222) RD451-53832

CN319-5

0.50

R/W

CN319-1

0.50

3 2

T1275-72191

CN323-1

0.85

L/Y

CN323-2

1.25

CN323-3

B/Y

SERVOMOTOR_ASSY (CN319)

CN221-2

R 1.25

0.50

1.25

GND_CAB2

RESISTOR,BLOWER (CN323) 1 2 3 4

3A851-72181

8.00

8.0

B/W

GLOW_CAB/SBF 60A Plug-in_type CRS/SBF 30A Bolt-on_type Main/SBF 60A Bolt-on_type ALTERNATOR 100.80A Bolt-on_type

8.0 5.0

8.00

R 40.0

40.0 f f B/R

40.0

FRAME

B/Y

A-1

C-1

F-1

R/W

8.0

40.0

BATTERY

40.0

RELAY RD451-54381 3.0

R/W 0.3

W/B

3.0

B/Y

B-1

GND_CAB

3.0 0.3

GND(L)1

8.00

CN511-1 0.5 CN511-2 0.75

W/B

RELAY RD451-54211 3

5.0

3.0

R/W

CN301-1

3 R/W

3 B/W

CN301-2

3 B/W

3.0

CN301-3

3 R

METER(+B) 5A MiniFuses AUX_Electrical_Power1 15A MiniFuses ECU_+B 5A MiniFuses R&FBOX

R/W

3.0

R/W

ALTERNATOR 5A MiniFuses FUEL_PUMP 5A MiniFuses Control_Element 5A MiniFuses R&FBOX

0.5

1.25

0.5

W/G

B-1 A-1 A-2

ALTERNATOR (CN511) 1J730-64011

OFF

1 2 3

B/R

Y/B

0.5

L/R

CN111-1 CN111-2

F_GND(R) 0.5

B/W

0.5

0.5 0.5

L/R f

FUEL_PUMP (CN111) RC601-51351

1 2

B/W

CN414-2

0.5

B/G

V1311-3642F (CN414) GRIP 2

CN414-3

B/W

P/L

0.3

0.5

10 CN414-12 0.5

B/W

8 9

V1311-3647F (CN402) GRIP

0.3

CN414-10 0.5

CN414-11 0.5

CN414-8

0.5

Y/G

CN414-9

0.5

B/O

CN414-6

0.3

W/R

1/10

Y/R

R/W

B/W R

START

5.0

3.0

f f

F_GND(L)2

STARTER-SW (CN301) RC461-53962 R/W

PLUG,GLOW 1J705-65511 0.5

R&FBOX

3.0

CN512

5.0

3.0

GND_CAB2

Y/R f

R&FBOX

0.3

GND_CAB2 3 B

H-1

ENGINE

B/Y

F_GND(L)2 F_GND(L)1

Y/R

3.0

SBF_BOX2

G-1

5.0

3.0

F_GND(L)2

E-1

BATTERY

3 R/W

3.0

F_GND(R)

D-1

B/R

CN402-1

0.3

Y/G

12 CN402-7

0.5

B/W

11 7

CN507-1

3.0

Y/R

CN508-1

40.0

A-1

B/R

B-1

STARTER (CN507) 1J730-63011

CN-507-1

3.0

Y/R

CN508-1

40.0

B/R

SSV65, SSV75 Electrical Circuit Diagram

A-1 B-1

STARTER (CN507) 1J755-63012

F_GND(L)1

CN512-1

8.0

B/W

CN511-1

0.5

CN511-2

0.75

ASSY_ALTERNATOR (CN511) 3R600-64012 B-1

R f

W/G

A-1 A-2

MIC

0.5

Y/R

CN315-8 0.5

Y/R

0.5

CN315-14 0.3

1.25 f

B/R

0.85

METER (CN302) V0621-53112

Y/R

CN314-8

B/R

RELAY RD451-54381

0.5

R/B

CN302-7

0.30

R/B

CN314-14

CN302-8

0.5

Y/R

CN314-8 CN315-8 R

CN302-10

0.50

CN302-11

0.50

L CN312-6 CN313-6

5 6

4 0.5

0.5

0.85

CN415-1 CN416-1 0.5 O

0.5

B/R O

0.85

L/R

0.5

B/L

RELAY RD451-54381

CN415-2 CN416-2

CN302-6

F_GND(L)1

1.25

CN412-4 CN411-4 B

4 0.85 0.5

B/R V

0.85 0.5

Y/B B/L

RELAY RD451-54381 4 0.85 CN402-3

0.3

R/G

CN402-2

0.3

CN402-10

0.5

G/W

CN402-11

0.5

Y/L

CN402-8

0.5

R/Y

0.5

B/R R/Y

0.85 0.5

B/R B/L

1.25

W CN412-6 CN411-6

0.50

GND_CAB2 POWER_SOCKET (CN330) CN330-1

0.75

CN411-1

0.85

CN411-2

0.85

L/R

CN330-2

0.75

L/R

CN411-3

0.85

Y/B

CN330-3

0.75

Y/B

CN411-4

0.85

B/R

CN330-4

0.75

B/R

CN411-5

0.85

W/Y

CN330-5

0.75

W/Y

CN411--6

0.85

R/L

CN330-6

0.75

R/L

CN411-7

0.85

B/Y

CN330-7

0.75

B/Y

CN411-8

0.85

CN330-8

0.75

CN411-9

0.85

CN330-9

0.75

BR f

1 2 3 4 5 6 7 8 9

10 11 12

RELAY RD451-54381

13 14 4

0.85

B/R

0.85

W/Y

2/10

CN414-5

0.3

P/L

CN414-6

0.3

CN414-4

0.30

W/R

6 4

BR/B

CN402-5

0.3

P/L

0.5

B/O

0.5

Y/G

0.50

B/O

RELAY RD451-54381 4 B/G

3 1

3.0

R/W

1.25

0.5

Y/R

R/Y

0.5

0.50

G/W

O B/O

0.5 0.5

CN203-1 1.25

CN310-6

CN203-1 1.25

GND_CAB2

DIODE(HORN) CN311-6

F_GND(R)

0.5 0.5

0.3

DIODE 7321-9822

G/B 0.5

0.5

CN415-8

R&FBOX

WIPER 15A MiniFuses FUSE(ECU(AC,SIGNAL)) 5A MiniFuses CRS_ECU(AC) 5A MiniFuses R&FBOX

0.5

Y/L

CN415-7

R/Y

0.3

0.5

B/G

0.5

CN415-3

0.5

CN415-14

B ON OFF CN309-2

5K126-42511

0.50

HORN (CN203)

A-1 B-1

SWITCH(HYD,UNLOCK) (CN309) V1311-5381B 1

CN309-3

3 7

0.50

NON

AUX W

0.5

CN314-5 W

0.50

CN307-2

0.50

1 3

LIGHT,ROOM (CN216) 3C581-54211_2 CN216-2

0.5

OFF

W 2

12V,5W

CN216-3

0.3

0.50

GND_CAB

3 CN401-3

BUZZER_BACK_SW_RH (CN401) T1060-33751

2 1

CN401-2

0.3

B/W

CN401-1

0.3

CN308-2

0.50

0.3

BUZZER_BACK_SW_LH (CN413) T1060-33751

F_GND(R)

CN406-1

0.5

CN406-2

0.5

CN308-3

0.3

L/B

0.3

CN202-3

0.30

2 1

SEAT_BAR_R_SW (CN202) T1060-33751

0.5

SEAT,ASSY (CN324) V1311-3810B

CN324-1 0.5 L

2 1

CN223-2

0.3

CN223-1

0.30

1 2

GND_CAB2

CN202-2

0.30

G/W

CN202-1

0.30

CN315-11

0.3

CN315-10

0.30

G/W

0.3

G/W

GND_CAB2

Y/B

RESISTOR(OPC)

0.5

RESISTOR 7321-9981

SEAT_BAR_L_SW (CN223) T1060-33751

0.5

0.50

CN223-3

STARTER_SW 5A MiniFuses R&FBOX

0.3

CN324-2

3 B/W

7 CN413-2

F_GND(L)1

W/G W/R

SWITCH(PARKING) (CN308) V1311-5382A

CN413-1

0.5

SETTING (CN406) 0.5

0.50 0.50

3 CN413-3

CN307-1 CN307-3

4 ON OFF

SWITCH(HI_FLOW) (CN307) V1311-5486A

CN315-5

0.3

0.5

0.3

R&FBOX

SW(AC) 5A MiniFuses

0.3

L/R

2.0

HI_FLOW

OIL_SW (CN509) ON OFF CN305-2

0.5

SWITCH(DPF,INHIBIT) (CN305) V1311-5384C

0.4A

T1850-39011

CN313-2 1

3/10

CN305-7

0.5

CN509-1

W 7

9 10

CN305-3

0.5

Y/B

CN305-9

0.5

L/R CN410-1

0.3

R/Y

0.30

0.75

W/L

B/Y

CN312-2

0.3

OIL_TEMP_SENSOR (CN410) 5H601-41941

W/L

0.5

0.3

L/W

0.5

RELAYBOX2

B/L

CN402-9 CN402-6

0.5

RELAY RD451-54381 4

G/W

0.5

Y/L

CN416-7

0.5

R/Y

CN416-8

0.5

0.85 0.5

R/L L

RELAY RD451-54381 4

B/O

0.85

B/R

0.5

Y/L

0.85

B/Y

0.5

CN404-4

0.5

G/W

B/L

0.5

CN416-3

B/R

0.5

RELAY RD451-54381

CN404-3

F_GND(R) 4

0.85

B/R

0.5

B/O

0.5

0.3

Y/B

CN404-2

0.5

B/L

CN404-1

0.5

B/W

3 2 1

Y/R

CN315-6

CN422-1

0.5

W/R

CN423-1

0.5

R/W

CN405-1

0.5

BR/W

CN405-2

0.5

CAN_TOOL (CN404) 7234-2601-40

CAN_TOOL VALVE,CONTROL,ASSY V1311-6311B

0.5

CN314-6 Y/R

0.3 0.5

RELAYBOX1

0.85

232C (CN404)

CN416-14

0.85

B3-1

B3-2

A3-1

A3-2

CN422-2

0.5

G/W

CN423-2

0.5

G/W

1.25

f f

W/G

0.3

W/R

SWITCH(FAN_REVERSE(HYD,UNLOCK)) V1311-5381B

ON OFF

0.5

CN313-7 CN312-7 0.3

1.25

7 *

0.3

Y/R

HYD-Unlock-SW 52

TxD

CN407-53

0.3

W/G

Hi-Flow-SW 53

RxD

0.5

BR/W

CN407-48

0.5

CN407-49

0.5

CN407-50

0.5

AUX-SOL(RH) 3

CN407-3

0.5

W/R

AUX-SOL(LH) 4

CN407-4

0.5

R/W

AUX-SOL-FeedBack 18

CN407-18

0.5

G/W

L/B

Buzzer-Back-SW(LH) * 72

CAN-H

Setup-Connector 51

CAN-L CAN-L

BR/B

RIDE-CONTROL-SW 74

CAN-L

L/W

AUX-Hold-SW 64

Front-Work-SW_LH 69

W/R

0.3 0.3

0.75

CN407-67

0.5

CN407-68

CN314-9

f 0.5

G/L

AUX-PORT-SW 71

FAN-REVERSE-SW 66

R/Y

SETTING_LH 67

SETTING_RH 68

0.3

0.5

L/Y

0.3

Park-Brake-Sol 81

CN407-81

0.3

R/Y

Charge-Input 30 OIL-SW 10

0.3

R/B

+5V-OUT 32

0.3

W/L

+5V-OUT 12

CN407-13

0.3

Y/G

+5V-OUT 13

GND(Sensor-Use) 14

CN407-15

0.3

Y/R

GND(Sensor-Use)

CN105-1

1.25

HYD_HITCH-RELAY 21

CN407-21

0.3

AUX-Relay 23

CN407-23

0.5

AUX-Relay 42

CN407-42

0.5

B/L

Starter-Relay 22

CN407-22

0.3

W/B

Glow-Relay 78

CN407-78

0.3

W/B

Back-Buzzer 80

CN407-80

0.3

BUZZER 31

CN407-31

0.3

Wakeup-Signal-OUTPUT 17

CN407-17

0.3

R/B

G/L G/L

MOTOR,ASSY (CN105) V9993-2239A

Y/L f

G/L

A-1

A-2

B-1

B-2

CN105-2

0.5

L/Y

CN105-2

0.5

DIODE 7321-9822

G/L

0.5

F_GND(L)1

Y/L

CN105-1

0.5

CN107-1 CN106-1

CN407-62

CN407-12

0.3

L/Y

CN407-61

CN407-32

CN407-14

Travel-Speed-Sol 62

Starter-SW(Start) 5

B/Y

0.5

RIDE-CONTROL-SOL 61

DPF-Inhibit-SW 11

W/G

L/Y

OPC-SW

Y/B

L/W

Y/B

0.75

0.5

CN407-10

CN407-20

0.5

Fan-FeedBack 20

CN407-24

0.3

0.75 W/G

CN107-2 CN106-2 Y/L

LIFT-Lock-Sol 24

0.5

NULL

CN407-11

0.75

0.5

NULL

CN407-5

CN407-30

Y/L

Seat-Bar-SW(RH) 60

CN407-30

Seat-Bar-SW(LH) 59

0.5

0.3

CN105-1

f 1.25

0.5

L/Y

DIODE(2WAY_FAN)

CN407-41

CN407-77

G/W

G/L

1.25

Hi-Flow-SOL 77

f 0.5

0.5

MOTOR,ASSY (CN105) V1311-6231A

NULL

G/Y

G/L

0.75 1.25

Motor-Fan 41

0.3

0.5

CN407-60

CN407-59

CN407-79

57 CN407-58

TILTLOCK_SOL 79

F_GND(R)

Trabel-Speed-SW 73

0.3

f f

0.30

W/R

0.5 0.3

CN407-66

CN407-47

0.3

NULL

CN407-72

NULL

0.3

BR/W

CAN-H

CN410-2

0.5

CAN-H

0.5

CN407-46

Parking-SW 54 Buzzer-Back-SW(RH) 55

CN407-69

0.3

CN407-45

GR B/W

CN407-71

0.3 f

B/W

CN407-64

B/L

0.3

CN407-74

0.5

0.3

CN407-51

0.3

0.5

CN407-75

CN407-54

CN407-73

CN315-9

CN407-76

CN407-55

1.25

G/L

CN407-52

CN314-13

CN315-13

1.25

G/L

1.25

CN315-9 CN314-9

0.3

ECU(MAIN) (CN407) V1311-5371A

CAP

Y/L

CN105-2

0.5

L/Y f

L/Y

CN421-1

0.5

G/Y

VALVE,CONTROL,ASSY (CN421) V1311-6311B B2-1

CN421-2

0.5

F_GND(R)

B2-2

HF_VALVE (CN419) V0611-64712 CN419-1

0.3

CN420-1

0.5

CN419-2

L/W

B1-1

B1-2

0.3

F_GND(L)1

SOLENOID(HF_VALVE) VALVE,CONTROL,ASSY (CN420) V1311-6311B

CN420-2

0.5

F_GND(R)

VALVE,ASSY(ACC) (CN115) V1311-6581D CN115-2

0.5

L/Y

CN115-1

CN426-1

0.3

SOLENOID (CN426) RD451-96261 1

0.5

F_GND(L)1

SOLENOID(RIDE_CONTROL)

CN426-2

0.3

F_GND(R)

4/10

1 6

0.5

CN315-16 CN314-16 Y/B 0.3

Y/B

0.5

L/R

0.3

CN110-2

0.3

FUEL_SENSOR (CN110) V1311-5114A

W/B

CN315-15 CN314-15 CN303-4 0.30

W/L

CN110-1

CCW

DIAL_ACCEL (CN303) V1311-5388C

2 1

RB257-53821 SENSOR(PRESSURE,5MPA) (CN409)

CN409-1

CN409-2

CN409-3

2.0

L/R

RELAY RD451-54381 4 G P

R&FBOX f

CN316-1 G/B

CN317-1 1.25

L/R

G 1.25

1.25

WASHER

1.25

2.0 0.3

F_GND(R)

CN327-2 1.25

f f

OFF

2.0 0.5

SWITCH(WIPER) (CN327) V1311-5484B

2 3

CN327-5 1.25

5 6 4

B/G

2.0

W/R

1.25

CN306-3

0.5

B/W

CN306-6

0.5

CN311-3 CN310-3

3 5

5/10

0.5

FRONT&SIDE_LAMP 30A MiniFuses FUSE(SOLENOID) 10A MiniFuses ATTACHMENT(+B) 15A MiniFuses R&FBOX

W/G

0.5

1.25

RELAY RD451-54211 3

3.0

W/L

5.0

W/R

0.3

CN311-1 CN310-1

f f

W/R B/W

1.25

0.3

B/W

0.5

RELAY RD451-54381

R/W B/W

1.25

CN327-4

0.3

SWITCH(WORKING_LIGHT,MULTI) (CN306) V1311-5383A

0.3

0.5

OFF

5.0

CN327-6

4 1.25

CN306-5

R/W

W/R

RELAY RD451-54381

CN306-2

5.0

0.85

B/W

REAR

R/W

0.5 0.5

FRONT

5.0

HORN 10A MiniFuses FUSE(ECU_MAIN(POWER)) 20A MiniFuses REAR_LAMP 15A MiniFuses R&FBOX

CN327-3

4 3.0

W/G

0.5

R&FBOX

DPF-Inhibit-LED 35

15 CN407-33

0.3

R/G

GND(Sensor-Use) 33

NULL

0.3

W/B

CN407-25

0.3

R/Y

Oil-Temp-Sensor 25

NULL

AUX-Control1 6

NULL

F_GND(R) CN303-3

CN425-1

0.3

Y/R

0.30

LG/R

CN303-1

0.30

R/Y

LG/W

ACCEL-SENS1 8

CN407-28

0.3

ACCEL_SENS2 28

W/L

0.3

R/B

L/B

TRAVEL_PILOT_PRESS_SSR 37

CN424-1

0.5

P/L

1 0.5

NULL 39 NULL 40 CN407-16

0.3

P/L

+12V-OUT 16

CN407-1

2.0

L/R

Starter-SW(Run) 1

CN407-43

0.5

Y/B

+B(Direct) 43

f Y/B

2.0

P/W

GND(Power) 2

CN315-2 CN316-2 0.5 P/W

P/L 0.3

0.5

P/L

0.3

F_GND(R) f

P/L

SWITCH(HITCH) (CN325) V1311-5482A

2 1 3 7

0.3

F_GND(R)

0.5

CN407-2

CN325-2

CN424-2

NULL 38

LOCK

0.3

CN407-37

UNLOCK

L/B

F_GND(R)

SOLENOID (CN424) RD451-96261

NON

Y/R

NULL

0.3 f

0.5

R&FBOX

NULL

0.3

F_GND(R)

0.3

29 0.3

CN425-2

RELAY RD451-54381 0.5

CN407-8

Y/R

CN303-2

0.3

NULL

0.30

SOLENOID (CN425) RD451-96261

L/R

AUX-Control2 26

0.3

CN407-27

0.3

CN407-35

NULL

FUEL-SENS 27

CN407-6 0.3

CN325-1

0.50

CN325-3

0.50

R/B

4 0.3 0.3

CN315-3 CN316-3 0.50 R/B

R/B

0.50 O CN316-4

f O CN315-4

SOLENOID (CN113) RD451-96261 CN113-1

0.3

O 1

CN113-2

0.3

F_GND(R)

SOLENOID(LOCK)

SOLENOID (CN114) RD451-96261 CN114-1

CN222-1

0.85

W/R

Motor_Washer (CN222) 6A671-74231 M

CN222-2

0.50

GND_CAB2

0.3

CN326-2

R/B

0.5

P/W

CN326-1

1 1.25

CN201-1

0.75

1.25

CN201-4

0.75

1.25

CN201-3

0.75

Motor_Wiper (CN201) V0511-35801

1 4

CN201-2

0.75

0.85

GND_CAB

CN114-2

SOLENOID(UNLOCK) ON OFF SWITCH(SELF_LEVEL) (CN326) V1311-5483C

0.5

CN314-1 CN315-1 R/B 0.5

0.5

CN326-6

0.3

F_GND(R)

R/B 0.5

GND_CAB

R/B

SOL_BK_POSITION (CN421) V1311-6431B CN421-1

1.25

Y 0.3

F_GND(L)2

3.0

F_GND(L)2

Y L/Y

CN211-1 2 f

3.0 0.3

1.25 2 f

CN210-1 1.25

W/R

CN217-1 CN218-1

L/Y

Y L/Y

CN213-1

2 f

L/Y

CN214-1

2.0

CN207-1

2 f

L/Y

CN208-1

2.0

L/Y

LAMP(TAIL,LH) (CN217) V1311-5353C A-1

A-2

B-1

B-2

LAMP(TAIL,RH) (CN210) V1311-5354C A-1 B-1

A-2

A-1

A-2

B-1

B-2

LAMP(WORKING,RH) (CN207) V1311-5352C A-1

A-2

B-1

B-2

R/B

SOLENOID(BK_POSITION) CN217-2

0.5

CN218-2

0.5

CN210-2

0.5

CN211-2

0.5

CN213-2

0.5

CN214-2

0.5

CN207-2

0.5

CN208-2

0.5

B-2

LAMP(WORKING,LH) (CN213) V1311-5351C

0.5

GND_CAB GND_CAB GND_CAB GND_CAB

CN109-1

0.5

B/W

CN109-2

0.3

1 2

CN408-1

0.3

CN408-2

0.3

1 2

CN421-2

0.5

F_GND(R)

BACK_BUZZER (CN109) V0511-53924 BUZZER (CN408) 53660-53811

GND_CAB GND_CAB GND_CAB GND_CAB

6/10

f 0.5

B/W

f 0.5

B/W

f 0.5

B/W

F_GND(L)2

R&FBOX

RELAY RD451-54381

5.0

ArmHarness 20A MiniFuses ElectricalOutlet-1 15A MiniFuses ATTACHMENT1 20A MiniFuses R&FBOX

W/R

3 R/W 1.25

2.0

R/W

G 1.25

1.25

0.5

BONDER_A

R&FBOX 1.25

3.0

B/Y

ASSY_SOCKET(CN304) RC418-53451 1.25

BOX(RELAY&FUSE) 3 B/R

CN304-1

1.25

CN304-2

1.25

1 2

GND_CAB2

RADIO_CONVERT(CN204) SPEAKER(CN205) 3C581-54131

1 2

SPEAKER(CN220) 3C581-54131

1 2

CN205-1

0.5

Y/R

CN205-2

0.5

CN220-1

0.50

W/B

CN220-2

0.50

CN204-7

1.25

0.75

BR/W BR

0.5

BR/W

0.5

BR/W

0.5

J/C(CAN,EGR,SERVICE)

2 3

CN204-9 0.50

4 5 6 7 8

GND_CAB

RESISTOR

0.5

BR/W

1 2

7382-5053-3R

1.25

5.0

AirRideSeat 15A MiniFuses ATTACHMENT2 20A MiniFuses R&FBOX

W/R

CN318-1

1.25

AIR_RIDE_SEAT (CN318)

V CN318-2

3.0

TO_E-OUT(ROOM) B/Y

3.0

B/Y

3.0

1.25

3.0

2.0

R/W

3.0

2.0

R/W

3.0 3.0

3.0

2.0

1.25

2.0

1.25

Y/R f

G BR

E-OUT(ROOF)

F_GND(L)1

3.0

2.0

R/W

2.0

R/W

1 1

GND_CAB

2 f

R/W

SWITCH(HAZARD) (CN328) V1311-5485A 1 3

7/10

BR/W

0.5

1.25

ROOF_GND

CN206-1

0.85

CN209-1

0.85

CN215-1

0.85

ON OFF CN328-2

SWITCH(SELF_LEVEL) V1311-5483C 1

0.5

3 ON OFF

1.25

0.5

BR/W

B/Y

SWITCH(SELF_LEVEL) V1311-5483C

3.0

0.5

B/Y

1.25

2.0 ON OFF

0.5

E-OUT(ROOM)

R/W

2.0

3.0

0.5

3.0

F_GND(R)

B/Y

F_GND(L)1

E-OUT(SWITCH) 1

1.25

CN328-3

1.25

CN219-1

0.85

LAMP,FLASHER (CN206) T1060-30032 1

LAMP,FLASHER (CN209) T1060-30032 LAMP,FLASHER (CN215) T1060-30032

5 4

CN209-2 0.50

CN215-2 0.50

CN219-2 0.50

CN515-1

2.0

CN515-1

2.0

CN515-1

2.0

PANNEL(INDICATOR) (CN329) V1311-5487A

LAMP,FLASHER (CN219) T1060-30032

CN206-2 0.50

INJECTOR_1 (CN515) 1J705-53052 1J770-53051 1

INJECTOR_2 (CN515) 1J705-53052 1J770-53051 1

INJECTOR_3 (CN515) 1J705-53052 1J770-53051 1

INJECTOR_4 (CN515) 1J705-53052 1J770-53051

CN515-2

2.0

CN515-2

2.0

CN515-2

2.0

CN515-2

2.0

ENGINE-ECU (CN417)(CN418)

CN418-5

2.0

B/R

CN418-6

2.0

B/R

B-50 B-5

+BP +BP

B-6

EGR_VALVE (CN503) F_GND(L)2

CN503-2

0.75

BR/W

CN503-3

2.0

CN503-4

2.0

B/R

1 M

CN418-33

0.5

B-49 MainRelay B-33

B-19 f

CN418-52

0.5

BR/W

B-14 CAN1-H B-51 CAN1-L B-52 B-40

CN418-38

0.5

BR/W

CN418-39

0.5

B-37 CAN2-H B-38 CAN2-L B-39

CN108-1 0.5

Y/G

CN108-2 0.5

R/L

CN108-3 0.5

L/B

CN108-4 0.5

G/B

CN108-5 0.5

B-32

TAC B-35 EGR_Lft_SEN_Vcc A-45 EGR_Lft_SEN_GND A-9 EGR_lIFT_SEN A-33 EGR_Motor(-) B-45 EGR_Motor(+) B-58

1 2 3 4 5 CN417-30

0.5

L/B

CN417-7

0.5

G/B

CN417-34

0.5

R/L

CN417-10

0.5

Y/G

CN418-57

0.75

R/B

CN418-44

0.75

B/R

CN418-29

0.75

CN418-16

0.75

CN418-9

0.75

INTAKE_THROTTLE_VALVE (CN501) 1J770-10601

CN501-1

0.75

B/R

CN501-2

0.75

R/B

CN501-3

0.75

CN501-4

0.75

CN501-5

0.75

B-26 IntakeThrottleMotor(+) B-57 IntakeThrottleMotor(-) B-44 A-79 IntakeThrottleSensor_SIG B-29 IntakeThrottleSensor_GND B-16 IntakeThrottleSensor_Vcc B-9 A-77

B-34 MAF_SEN_SIG A-30 MAF_GND A-7 IntakeAirTemp(AFS) A-34 IntakeAirTemp(AFS)_GND A-10

A-76 B-31

A-75 ExtShutterPull_Relay A-69 ExtShutterHold_Relay A-71

3 4 5

A-4 Starter_Relay A-92

0.5

Y/R

B-36

AIR_FLOW_SENSOR (CN108) 1J520-10701

CN418-54

0.5

Y/B

CN418-47

0.5

Y/R

CN418-48

0.5

Y/R

A-65 B-54 B-47

ST_SW IG_SW IG_SW

B-48 A-64 A-27 A-56 A-90 A-54

CN417-49

1.25

CN417-73

1.25

R/W

CN417-1

1.25

L/R

CN417-25

1.25

B/R

CN417-74

1.25

F_GND(L)2

CN418-3 CN418-4

A-5 INJ_Common1 A-49 INJ_Common1 A-73 INJ-Common2 A-1 INJ-Common2 A-25 INJ_DRV_TWV1 A-74

CN417-3

1.25

W/R

A-53 INJ4_DRV_TWV4 A-3

CN417-26

1.25

Y/B

A-52 INJ2_DRV_TWV2 A-26

CN417-51

1.25 1.25

1.25

B f

L/B

CN417-43

0.5

CN417-44

0.5

CN513-1

0.5

CN417-18

0.5

CN513-2

0.5

CN417-42

0.5

A-50 INJ3_DRV_TWV3 A-51 A-48 POWER_GND B-3 POWER_GND B-4

CN504-3

0.5

NE_SENSOR (CN504) 1J770-59661

A-63

B-43

0.5

0.5 0.5

A-17

B-46

CN418-51

CN504-1 CN504-2

A-87

A-96

1J770-62701

G Y

A-13

A-89

f f

A-86

A-88

0.5 0.5

B-17

B-22

0.75

CN417-22 CN417-19

A-2 G_Vcc A-44 G_GND A-18 G_SIG A-42

B-27

CN503-1

NE_Vcc A-22 NE_GND A-19 NE_SIG A-43

0.5

B-56

0.5

R&FBOX

0.5

MiniFuses

0.5

Engine_Elements

B/R

3.0

CN513-3

G_SENSOR (CN513) 1J574-59711

JOINT_CONNECTOR2

A-11 EngineWarning_Lamp A-70 EngineStop_Lamp A-95 OIL_Lamp A-94 Heater_Lamp A-68 OverHeat_Lamp A-93 ForceRegenReq_Lamp A-91 Regen_Lamp A-67

F_GND(L)2

0.5

B 0.5

0.5

2 3 4 5 6

7182-9631-40

A-55 A-20 AccelSensor1_Vcc B-23 AccelSensor1_SIG B-24 AccelSensor1_GND B-25 A-21 AccelSensor2_Vcc B-10 AccelSensor2_SIG B-11 AccelSensor2_GND B-12

0.75

CN520-3

DIFF_PRESSURE_SENSOR (CN520) 1J520-18601

CN520-2

0.75

L/R

CN520-1

0.75

3 2 1

B-8 VehicleSpeed B-30 B-13 PressDiffSensor_SIG A-66 PressDiffSensor_GND A-59 PressDiffSensor_Vcc A-23 A-28 SCV(+) B-20 SCV(-) B-7 A-29 FuelTemp_SIG A-31 FuelTemp_GND A-8 CoolantTemp_SIG A-39 CoolantTemp_GND A-15

CN417-66

0.75

CN417-59

0.75

L/R

CN417-23

0.75

CN418-20

0.75

R/B

CN418-7

0.75

Y/R

CN417-31

0.75

B/Y

CN417-8

0.75

G/W

CN417-39

0.75

CN417-15

0.75

L/R

A-35 PFuel_SIG A-40 PFuel_SIG A-41 PFuel_Vcc A-24 PFuel_GND A-16 BoostSEN_Vcc A-46 BoostSEN_SIG A-61 BoostSEN_GND A-57 A-37 ExtAirTempSEN_SIG B-28 ExtAirTempSEN_GND B-15

CN505-1

0.75

R/B

CN505-2

0.75

Y/R

CN506-1

0.75

B/Y

CN506-2

0.75

G/W

CN516-1

A-32 SLD_GND A-6

0.5

A-60 Inlet_DOC_Temp A-38 Inlet_DOC_Temp_GND A-14 Outlet_DOC_Temp A-36 Outlet_DOC_Temp_GND A-12 Outlet_DPF_Temp A-62 Outlet_DPF_Temp_GND A-58 A-47 SIGNAL_GND B-1

0.75

A-1 A-2

B-1 B-2

WATER_TEMP_SENSOR (CN516) 5H601-41941

CN510-1

0.75

0.5

CN510-2

0.75

CN417-41

0.5

CN510-3

0.75

CN417-24

0.75

CN417-16

0.75

CN417-46

0.75

CN514-1

0.75

L/B

CN514-2

0.75

L/B

0.75

Y/R

CN514-3

0.75

Y/R

CN418-28

0.75

CN418-15

0.75

L 0.75

L/R

RAIL_PRESSURE_SENSOR (CN510) 1 2 3

2 3

1J500-59671

CN502-1

CN417-61

0.5

0.75

1J770-50601 BOOST_SENSOR (CN514)

CN417-57

CN516-2

CN417-40

A-72 B-21 STOP_SW B-55 Parking_SW B-42 ForceRegen_SW A-83 Regenlnhibit_SW A-84 WaterLevel_SW A-85 FilterPlugged_SW B-41 CAN_SEL_SW A-78 BGmode_SW A-82 RatedSpeedSel_SW(BG) A-81 Neutral_SW B-53 OIL_SW A-80

PUMP_ASSY_SUPPLY (CN505) 1J770-50501

INTAKE_AIR_TEMP_SENSOR (CN502) 1J574-59681

CN502-2

0.75

WATER_SEPARATOR (CN112) V0521-51861 CN417-85

0.5

W/B

CN417-38

0.75

W/B

CN417-14

0.75

CN417-36

0.75

B/R

CN417-12

0.75

CN417-62

0.75

R/B

CN417-58

0.75

Y/B

CN418-1

1.25

CN517-1

0.75

CN518-1

0.75

CN519-1

0.75

Y/B

CN112-2

0.5

DOC_INLET_SENSOR (CN517) 1J770-18501 1

CN517-2

DOC_OUTLET_SENSOR (CN518) 1J770-18511 1

CN518-2

DPF_OUTLET_SENSOR (CN519) 1J770-18521 1

CN519-2

0.75

W/B

0.75

B/R

0.75

R/B

8/10

SIGNAL_BLINKER 1 2

1.25

0.5

B/O

0.5

Y/G

1.25

FLASHER_UNIT 3F240-75432 5

CN329-7

0.85

CN329-10

0.5

O 0.5

CN329-9

0.5

CN329-8

0.5

0.75

0.50

B 1.25

F_GND(R)

0.5

CN103-1

1.25

B/W

CN104-1

1.25

COMPRESSOR_CLUTCH (CN104) 3C581-50062 Dual_Pressure_SW (CN320) V0511-39334

4 0.75 0.5

5.0

COMPRESSOR_FUSE 10A MiniFuses BlowerMotor 30A MiniFuses R&FBOX

0.75

f f

R/B B/W

R&FBOX

R/B

0.75 0.5

f f

CN313-1 CN320-1

BR/W

0.50

BR/W

3.0

0.5

B/W

RELAY RD451-54381

R&FBOX

3.0

0.5

CN317-3 3.0

B/Y

CN321-1

R CN316-3

0.5

B/Y CN312-2

9/10

CN312-1

4 3.0

R/B

DIODE_A/C (CN103) 7321-9822

DIODE(A/C) RELAY RD451-54381

0.50

CN311-2 0.50

B/Y

3.0

F_GND(L)2 F_GND(L)2

0.50 0.5

CN320-2 0.50

CN322-2

0.50

R/B

CN322-3

0.50

B/L

CASE_GND B-18

SIGNAL_GND B-2

CN322-1

0.50

B/Y

CN321-2

A-3

B-2 A-4

3.0

1.25

F_GND(L)2

ASSY_SWITCH,AIR-CON (CN221) RD451-53832 B-1

A-1

CN418-2

1H993-60201

A-2

CN319-7 CN221-16

0.5

Y/R

CN221-8

0.50

R/B

A-5

B/L

THERMOSTAT(CN322) 3C581-72161

V1311-3911A BLOWER_MOTOR (CN321) 1

0.75

R/B

F_GND(L)1

CN418-18

CN221-11

0.50

B/Y

CN221-10

0.5

B/Y

CN221-2

0.50

CN221-1

0.50

CN319-3

0.50

CN319-2

0.50

G/W

CN221-6

0.50

G/W

CN221-5

0.50

CN221-4

0.5

GND_CAB2

B/Y

GND_CAB2

CN222-3

3.0

CN222-6

0.50

B/Y

CN222-2

0.50

B/Y

CN222-1

0.85

L/Y

CN222-4

3.0

FAN_SW (CN222) RD451-53832

CN319-5

0.50

R/W

CN319-1

0.50

3 2

T1275-72191

CN323-1

0.85

L/Y

CN323-2

1.25

CN323-3 OFF 0.5

SERVOMOTOR_ASSY (CN319)

CN221-3

R 1.25

0.50

R/W

1.25

GND_CAB2

RESISTOR,BLOWER (CN323) 1 2 3 4

3A851-72181

6 2 1 4 5

10/10

EDITOR:

KUBOTA CORPORATION CONSTRUCTION MACHINERY SERVICE TECHNICAL SUPPORT DEPARTMENT 1-1 NAKAMIYA-OHIKE 1-CHOME, HIRAKATA-CITY, OSAKA, 573-8573, JAPAN PHONE : (81)72-840-1195 FAX : (81)72-890-2883 E-mail : kbt_g.ce-sv@kubota.com

KUBOTA Corporation

Printed in Japan 2015. 12, H, EI, EI, engusa Printed in Japan 2015. 05, H, EI, EI, engusa

Code No. RY911-23332 Code No. RY911-23330